Emerson Global | EmersonVilter | Refrigeration, Oil & Gas Industry Compressors | Copeland US
Vilter.comInstruction Manual for EMERSON models including: VSS, VSM, VSH, VSSH, Compressor Unit, VSS Compressor Unit, VSM Compressor Unit, VSH Compressor Unit, VSSH Compressor Unit
VSS/VSM/VSH/VSSH Compressor Unit
Installation, Operation & Maintenance Manual
FOR UNITS BUILT AFTER JANUARY 1, 2015
Standard VILTERTM Warranty Statement
What is covered & how long it is covered: Subject to the other terms of this Warranty Statement, Seller warrants to its direct purchasers (and to no others) that the Products it manufactures will be free from defects in material and workmanship under normal use, regular service and maintenance. This warranty only applies when such defect appears in the Products within 12 months ("m") from the date such Products are placed in service and when such Products are returned to and received by Seller within 18m from the date of manufacture by Seller ("12m/18m"), except that defects in the following Products different than 12m/18m are covered by the number of months indicated below if returned to Seller within the following number of months ("m Ship") from shipment by Seller--
Compressor Type
Product
Reciprocating VSS / VSM Refrigeration VSG / VSSG Gas
Compressors
Compressors
Compressors
New Unit
24m Ship
24m Ship
12m/18m
Compressor (New Unit Only)
24m Ship
60m Ship
12m/18m
New Bareshaft Compressor
24m Ship
24m Ship
12m/18m
Remanufactured Compressor
12m/18m
12m/18m
12m/18m
Any Engineered to Order (ETO) packaged system (including Heat Pumps and Process Chillers) not described above carry the 12m/18m warranty.
VSS / VSM single screw compressors installed and shipped on New Units carry an internal Product component warranty of 5 years from shipment date and a warranty of 15 years from shipment date for compressor bearings only. Does not include actuator motors and shaft seals.
VilterTM Genuine OEM Parts, retrofit Vission 20/20 panels, retrofit PLC panels and any other supplied equipment not described above carry a 12m warranty from shipment date.
New Vapor Recovery Units ("VRU Units") and its Compressors carry the standard 12m/18m warranty--all other VRU parts carry a 6 m warranty from shipment date.
What is not covered: This warranty does not extend to any losses or damages due to misuse; corrosion; accident; abuse; neglect; normal wear and tear; negligence (other than Seller's); unauthorized alteration; use beyond rated capacity; acts of God; war or terrorism; unsuitable power sources or environmental conditions; operation with refrigeration or lubricants which are not suitable for use with the Product; improper installation, repair, handling, maintenance or application; substitution of parts not approved by Seller; or any other cause not the fault of Seller. This warranty is only applicable to Products properly maintained and used according to Seller's instructions, the use of genuine VilterTM replacement parts and recommended oil in all repairs, and when Buyer has demonstrated adherence to a scheduled maintenance program as detailed in the applicable operating manual. The Buyer must use Vilter approved oil only and provide oil analysis results to Vilter. To the extent the Buyer has supplied specifications, information, representation of operating conditions or other data to Seller in the selection or design of the Products and the preparation of Seller's quotation, and in the event that actual operating conditions or other conditions differ from those represented by Buyer, any warranties or other provisions contained herein which are affected by such conditions will be null and void. Seller does not warrant that the Products comply with any particular law or regulation not explicitly provided in the Product specifications, and Buyer is responsible for ensuring that the Products contain all features necessary to safely perform in Buyer's and its customers' plants and operations. If the Products are for a gas compression application, this warranty does not apply if the Products are operated in conjunction with a gas with an H2S level above 100 PPM.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Standard VILTERTM Warranty Statement
Third Party Motors & Starters: Motors and starters or Motor & Starter Parts purchased by Seller from a third party for resale to Buyer or for incorporation into Seller's Product will carry only the warranty extended by the original manufacturer ("OEM"). Motor manufacturer warranties cover only the repair or replacement of the motor, and do not cover removal and installation charges, incidental charges associated with the removal and installation process, loss of product, or shipping to and from the manufacturer or approved shop. The individual motor manufacturer warranty terms can be found on the manufacturer's associated websites.
Other limitations: Seller will not be liable under the above warranty if Buyer is in default of its payment obligations to Seller under any purchase order or credit agreement. Except with Seller's written permission given after receipt of Buyer's request within 60 days of an event, Seller will not be responsible for costs of dismantling, lost refrigerant, reassembling, repair labor and expenses, travel cost or transporting the Product. Products repaired or replaced under this warranty will be warranted for the unexpired portion of the warranty applying to the original Products. Buyer agrees that all instructions and warnings supplied by Seller will be passed on to those persons who use the Products. Products are to be used in their recommended applications and all warning labels adhered to the Products by Seller must be left intact. Any technical advice furnished by Seller before or after delivery in regard to the use, application or suitability of the Products may not be construed as an express warranty unless confirmed by Seller in writing, and Seller assumes no obligation or liability for the advice given or results obtained--all advice given and accepted at Buyer's sole risk.
Exclusive Remedy: Within (10) ten days after Buyer's discovery of any warranty defects within the warranty period, Buyer will notify Seller of such defect in writing. Seller will, at its option and as Buyer's exclusive remedy, repair, correct, or replace F.O.B. point of manufacture, or issue credit or refund the purchase price for, that portion of the Products found by Seller to be defective. Failure by Buyer to give such written notice within the applicable time period will be deemed an absolute and unconditional waiver of Buyer's claim for such defects. Buyer assumes all other responsibility for any loss, damage, or injury to persons or property arising out of, connected with, or resulting from the use of the Products, either alone or in combination with other products/components. If so required, Products or parts for which a warranty claim is made are to be returned transportation prepaid to Seller's factory. THE FOREGOING CONSTITUTES THE SOLE AND EXCLUSIVE REMEDY FOR BREACH OF ANY WARRANTY HEREUNDER.
SOLE WARRANTY: THE WARRANTIES ABOVE CONSTITUTE SELLER'S SOLE AND EXCLUSIVE WARRANTIES WITH RESPECT TO THE PRODUCTS AND ARE IN LIEU OF AND EXCLUDE ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHETHER OR NOT THE PURPOSE OR USE HAS BEEN DISCLOSED TO SELLER IN SPECIFICATIONS, DRAWINGS OR OTHERWISE, AND WHETHER OR NOT SELLER'S PRODUCTS ARE SPECIFICALLY DESIGNED AND/OR MANUFACTURED BY SELLER FOR BUYER'S USE OR PURPOSE.
LIMITATION OF LIABILITY: SELLER SHALL NOT BE LIABLE FOR DAMAGES CAUSED BY DELAY IN PERFORMANCE AND THE REMEDIES OF BUYER HEREIN ARE EXCLUSIVE. IN NO EVENT, REGARDLESS OF THE FORM OF THE CLAIM OR CAUSE OF ACTION (WHETHER BASED IN CONTRACT, INFRINGEMENT, NEGLIGENCE, STRICT LIABILITY, OTHER TORT OR OTHERWISE) SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXCEED THE PRICE PAID BY BUYER FOR THE SPECIFIC PRODUCTS OR PORTION OF THE PRODUCTS PROVIDED BY SELLER GIVING RISE TO THE CLAIM OR CAUSE OF ACTION, AND BUYER SHALL INDEMNIFY AND HOLD HARMLESS SELLER FOR ANY DAMAGES INCURRED BY SELLER IN EXCESS THEREOF. BUYER AGREES THAT IN NO EVENT SHALL SELLER'S LIABILITY TO BUYER AND/OR ITS CUSTOMERS EXTEND TO INCLUDE INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES. The term "consequential damages" includes loss of anticipated profits, business interruption, loss of use, revenue, reputation and data, costs incurred, including for capital, fuel, power and loss or damage to capital or equipment. Buyer agrees that all instructions and warnings supplied by Seller will be passed on to those persons who use the Products. Seller's Products are to be used in their recommended applications and all warning labels adhered to the Products by Seller are to be left intact.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Important Message
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.
The following instructions have been prepared to assist in installation, operation and removal of VilterTM 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.
Only qualified personnel shall operate, install and maintain the equipment.
Qualified personnel shall be accredited by a local regulatory agency, which requires that they are continually scrutinized by an organization whose sole mission is to establish, maintain and assure that the highest industry standards are set and met in a continuous and ongoing basis. The credentials shall address topics ranging from plant safety, operating concepts and principles and operations through the basics of refrigeration compliance and PSM (Process Safety Management) requirements.
Follow local workplace occupational safety and health regulations.
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.
VilterTM 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 VilterTM 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
5555 South Packard Ave Cudahy, WI 53110 USA Telephone: 1-414-744-011; Fax:1-414-744-3483 E-mail: info.vilter@emerson.com; Web: Emerson.com/Vilter Equipment Identification Numbers:
Vilter Order Number: _______________________Compressor Serial Number: _________________ Vilter Order Number: _______________________Compressor Serial Number: _________________
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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EC Declaration of Incorporation
We hereby declare that the following machinery is intended to be incorporated into other machinery, and must not be put into service until the relevant machinery into which it is to be incorporated has been declared in conformity with the essential requirements of the Machinery Directive 2006/42/EC.
Machine Description: Industrial Compressor
Make:
Vilter
Type:
VSM / VSS / VSH / VSSH / VSG & VSSG Single Screw Compressor
Model Size:
97, 113, 127, 128, 145, 160, 180, 204, 222, 243, 152, 182, 202, 301, 361, 401, 501, 601, 701, 291, 341, 451, 601, 751, 901, 791, 891, 1051, 1201, 1301, 1551, 1851, 2101, 2401, 2601, 2801, 3001
Manufactured by:
Vilter Manufacturing, LLC.
The following transposed harmonised European Standards have been used:
EN ISO 12100-1: 2010
- Safety of Machinery - General principles for design-Risk assessment and risk reduction.
EN ISO 13857: 2008
- Safety of Machinery - Safety distances to prevent danger zones being reached by the upper and lower limbs.
EN349: 1993 + A1: 2008
- Safety of Machinery - Minimum gaps to avoid crushing hazards.
EN ISO 13850: 2015
- Safety of Machinery - Emergency stop equipment - Principles for design.
IEC/EN60204-1 (2016) - Safety of Machinery - Electrical equipment of machines - Specification for general requirements
A technical construction file for this machinery is retained at the following address:
Vilter Manufacturing, LLC. 5555 South Packard Avenue P.O. Box 8904, Cudahy Wisconsin 53110-8904
Signed for and on behalf of Vilter Manufacturing, LLC.:
Last update: May 2019
Vilter Manufacturing, LLC. 5555 South Packard Avenue t P.O. Box 8904 t Cudahy, Wisconsin 53110-8904
001-414- 744-0111 t FAX: 001-414-744-3483
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Table of Contents
Section Title
Page Number
Standard VilterTM Warranty Statement ............................................................................................................i
Important Message....................................................................................................................................... iii
EC Declaration of Incorporation .................................................................................................................... iv
Section 1 · General Information
How To Use This Manual............................................................................................................................. 1-1 Additional Important Notes ....................................................................................................................... 1-1 Refrigeration Compressor Unit Model Designations ................................................................................... 1-2 System Unit Identification ......................................................................................................................... 1-3 Compressor Unit Component Identification ............................................................................................... 1-4 Instrument Identification Letters................................................................................................................ 1-7 Symbols Identification ............................................................................................................................... 1-9 Major Component Identification ................................................................................................................ 1-9 Control and Instrument Identification ...................................................................................................... 1-10 Line Type Designations ............................................................................................................................ 1-10 Valve and Instrument Tagging.................................................................................................................. 1-11 Equipment Number Identification............................................................................................................ 1-11 Pipe Line Data Identification..................................................................................................................... 1-12
Section 2 · Theory Of Operation
Refrigerant Flow ........................................................................................................................................ 2-1 Oil Life and Oil Flow.................................................................................................................................... 2-1 Oil Cooling................................................................................................................................................. 2-2
Water Cooled Oil Cooling ............................................................................................................... 2-2 Liquid Injection Oil Cooling............................................................................................................. 2-2 V-Plus Oil Cooling........................................................................................................................... 2-2 Thermosyphon Oil Cooling............................................................................................................. 2-2 Control System .......................................................................................................................................... 2-3 Temperature Elements, Pressure Transmitters and Indicators ......................................................... 2-3
Section 3 · Installation
Delivery Inspection .................................................................................................................................... 3-1
Rigging and Lifting of Compressor Unit...................................................................................................... 3-1
Compressor Unit Inspections Prior To Installation ...................................................................................... 3-2
Recommended On-Site Tools..................................................................................................................... 3-2
Long Term Storage Recommendations....................................................................................................... 3-3
Compressor Motor ......................................................................................................................... 3-3
Long Term Storage Log................................................................................................................... 3-4
Foundation ................................................................................................................................................ 3-5
Considerations Prior To Starting ..................................................................................................... 3-5
Foundation Materials...................................................................................................................... 3-5
Building The Foundation ................................................................................................................ 3-5
Compressor Unit Installation .......................................................................................................... 3-6
Leveling and Grouting .................................................................................................................... 3-7
Additional Information ................................................................................................................... 3-8
Operation and Performance ........................................................................................................... 3-8
General Design Requirements ........................................................................................................ 3-8
Stop/Check Valve Installation................................................................................................................... 3-11
Piping .................................................................................................................................................... 3-12
Flange Loads.. .......................................................................................................................................... 3-13
Remote Air-Cooled Oil Cooler Piping ........................................................................................................ 3-14
Electrical Connections ............................................................................................................................. 3-15
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Table of Contents
Section Title
Page Number
Field Wiring Instructions .............................................................................................................. 3-15 Testing Refrigeration System For Leaks .................................................................................................... 3-18
Ammonia Systems ....................................................................................................................... 3-18 Halocarbon Refrigerant Systems .................................................................................................. 3-18 CO2 Systems ................................................................................................................................ 3-19 Evacuating The System ............................................................................................................................ 3-19 Notice on Using Non-Vilter Oils ................................................................................................................ 3-20 Unit Oil Charging and Priming.................................................................................................................. 3-20 Unit Initial Oil Charging ................................................................................................................ 3-21 Priming Oil Lines and Compressor ................................................................................................ 3-21 System Refrigerant Charging ................................................................................................................... 3-22 Low Side Equipment..................................................................................................................... 3-22 Compressors ................................................................................................................................ 3-22 Condensers .................................................................................................................................. 3-22 Controls ....................................................................................................................................... 3-22 Initial High Side Charging ............................................................................................................. 3-22
Section 4 · Operation
Notice on Using Non-Vilter Oils .................................................................................................................. 4-1 Operation .................................................................................................................................................. 4-1 Oil Inspection ............................................................................................................................................ 4-1 Dual Oil Filters............................................................................................................................................ 4-2 Control System ......................................................................................................................................... 4-2
Calibration ..................................................................................................................................... 4-2 Starting, Stopping and Restarting The Compressor ........................................................................ 4-2 Emergency Shutdown .................................................................................................................... 4-3 Slide Valve Actuator Operation .................................................................................................................. 4-3 Calibrate Slide Valve Actuators (For Units Using Vission20/20TM) ................................................................ 4-4 Calibrate Slide Valve Actuators (For Units Using Compact Logix PLC)........................................................ 4-10 Compressor Control with Vission20/20TM Micro-Controller (No Slide Operation)...................................... 4-15 Coalescing Oil Return Line Setup.............................................................................................................. 4-16 Suction Equalizing Line Setup - For VSS/VSM Compressors....................................................................... 4-17 Dual Oil Filter Setup For Oil Filters With Filter Head Assemblies ................................................................ 4-18 Stop/Check Valve Operation .................................................................................................................... 4-19
Section 5 · Maintenance/Service
Maintenance and Service Schedule - For VSS/VSM Unit Only ...................................................................... 5-1 Maintenance and Service Schedule - For VSH/VSSH Unit Only..................................................................... 5-2 Preventive Maintenance, Checks and Services ............................................................................................ 5-4
Daily............................................................................................................................................... 5-4 Weekly........................................................................................................................................... 5-4 Monthly ......................................................................................................................................... 5-4 Trimonthly ..................................................................................................................................... 5-4 Annually......................................................................................................................................... 5-4 Compressor Unit Isolation For Maintenance/Service (Compressors With Slide Valves)................................ 5-5 Recommendations When Servicing (Compressors Without Slide Valves) ................................................... 5-6 Preparation of Unit For Servicing................................................................................................................ 5-6 Compressor Unit Leak Check After Servicing .............................................................................................. 5-7 Oil System Components............................................................................................................................. 5-7 Oil Sampling................................................................................................................................... 5-7
Recommendations ............................................................................................................. 5-7 Installation of The Oil Sampler Valve ................................................................................... 5-8
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Table of Contents
Section Title
Page Number
Pre-Sampling...................................................................................................................... 5-8 Sampling Procedure ........................................................................................................... 5-8 Oil Sample Analysis Report ............................................................................................... 5-10 Oil Draining.................................................................................................................................. 5-11 Oil Charging ................................................................................................................................. 5-12 Tool Required ................................................................................................................... 5-12 Charging During Operation .............................................................................................. 5-12 Charging During Shutdown .............................................................................................. 5-12 Filter Element Replacement (Single Oil Filter Assembly) and Oil Pump Strainer Servicing .............. 5-13 Drain Oil From Isolated Oil Line ......................................................................................... 5-13 Oil Filter Element Removal (For 3111A Oil Filter Housing) ................................................. 5-14 Oil Filter Element Removal (For 3110A or 3112A Oil Filter Housing) .................................. 5-14 Oil Pump Strainer Screen Removal and Service.................................................................. 5-14 Oil Pump Strainer Screen Installation ................................................................................ 5-15 Oil Filter Element Installation (For 3111A Oil Filter Housing) ............................................. 5-15 Oil Filter Element Installation (For 3110A or 3112A Oil Filter Housing) .............................. 5-15 Filter Element Replacement (Duplex Oil Filter Assembly) .............................................................. 5-16 Removal ........................................................................................................................... 5-16 Installation ....................................................................................................................... 5-17 Filter Element Replacement (Dual Oil Filter Assembly) .................................................................. 5-17 Switching Oil Filters For Maintenance................................................................................ 5-18 Drain Oil From Isolated Oil Filter........................................................................................ 5-19 Oil Filter Element Removal (For 3111A Oil Filter Housing) ................................................. 5-19 Oil Filter Element Removal (For 3110A or 3112A Oil Filter Housing) .................................. 5-20 Oil Filter Element Installation (For 3111A Oil Filter Housing) ............................................. 5-20 Oil Filter Element Installation (For 3110A or 3112A Oil Filter Housing) .............................. 5-20 Oil Separator Coalescing Filter Replacement................................................................................. 5-21 Removal ........................................................................................................................... 5-21 Installation ....................................................................................................................... 5-21 Oil Separator Heater Cartridge Replacement ................................................................................ 5-23 Parts Required .................................................................................................................. 5-23 Removal ........................................................................................................................... 5-23 Installation ....................................................................................................................... 5-23 Drive Coupling Hub (Form-Flex BPU) Installation...................................................................................... 5-24 Straight Bore Hubs ....................................................................................................................... 5-24 Tapered Bore Hubs ....................................................................................................................... 5-24 Drive Center Member Installation and Alignment..................................................................................... 5-25 Drive Coupling Hub (Form-Flex BPU) and Center Member Removal .......................................................... 5-27 Drive Coupling (Type C Sure-Flex) Replacement ....................................................................................... 5-27 Removal ....................................................................................................................................... 5-27 Installation ................................................................................................................................... 5-28 Coupling Guard Replacement................................................................................................................... 5-29 Removal ....................................................................................................................................... 5-29 Installation ................................................................................................................................... 5-29 Compressor Replacement ........................................................................................................................ 5-30 Removal ....................................................................................................................................... 5-30 Installation ................................................................................................................................... 5-31 Bare Shaft Compressor Lifting Points and Weights ................................................................................... 5-31 Bare Shaft Compressor Center of Gravity (Models 291-2101) ................................................................... 5-33 Bare Shaft Compressor Center of Gravity (Models 2401-3001) ................................................................. 5-34 Compressor Inspection ............................................................................................................................ 5-35 Compressor Shaft Bearing Clearance Inspections ......................................................................... 5-35 Determine Maximum Applied Force.................................................................................. 5-35 Main Rotor Bearing Axial Clearance Inspection.................................................................. 5-35 Main Rotor Bearing Radial Clearance Inspection................................................................ 5-36
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Table of Contents
Section Title
Page Number
Gaterotor Bearing Inspection ....................................................................................................... 5-37 Gaterotor Inspection .................................................................................................................... 5-38
A) Gaterotor - Main Housing Shelf Clearance..................................................................... 5-38 B) Gaterotor Float Measurement....................................................................................... 5-39 C) Gaterotor Backlash Inspection ...................................................................................... 5-40 Important Notes............................................................................................................... 5-42 Additional Inspections.................................................................................................................. 5-42 Post Inspection............................................................................................................................. 5-42 Gaterotor Assembly Replacement (All Compressors Except VSM 301-701 & VSM 97-127 Compressors) ... 5-42 Removal ....................................................................................................................................... 5-42 Installation ................................................................................................................................... 5-43 Gaterotor Assembly Replacement (VSM 301-701 Compressors Only)....................................................... 5-46 Removal ....................................................................................................................................... 5-46 Installation ................................................................................................................................... 5-46 Gaterotor Assembly Replacement (VSM 97-127 Compressors Only)......................................................... 5-48 Removal ....................................................................................................................................... 5-48 Installation ................................................................................................................................... 5-48 Gaterotor Disassembly (All Compressors Except VSM 97-127 Compressors)............................................. 5-50 Gaterotor Blade Removal.............................................................................................................. 5-50 Gaterotor Blade Installation.......................................................................................................... 5-51 Gaterotor Thrust Bearing Removal................................................................................................ 5-51 Gaterotor Thrust Bearing Installation............................................................................................ 5-51 Gaterotor Roller Bearing Removal................................................................................................. 5-52 Gaterotor Roller Bearing Installation............................................................................................. 5-52 Gaterotor Disassembly (VSM 97-127 Compressors Only) ......................................................................... 5-53 Gaterotor Blade Removal.............................................................................................................. 5-53 Gaterotor Blade Installation.......................................................................................................... 5-53 Gaterotor Thrust Bearing Removal................................................................................................ 5-54 Gaterotor Thrust Bearing Installation............................................................................................ 5-54 Gaterotor Roller Bearing Removal................................................................................................. 5-54 Gaterotor Roller Bearing Installation............................................................................................. 5-54 Compressor Shaft Seal Replacement ........................................................................................................ 5-55 Shaft Seal Assembly ..................................................................................................................... 5-55 Handling Seal Face with Care ........................................................................................................ 5-55 Compressor Shaft Seal Replacement - For VSS/VSM Units ............................................................. 5-56 Tools ................................................................................................................................ 5-56 Removal ........................................................................................................................... 5-56 Installation ....................................................................................................................... 5-56 Compressor Shaft Seal Replacement - For VSH/VSSH Units ........................................................... 5-58 Shaft Seal Removal -For Part# 25985Y and 25985YA ......................................................... 5-58 Shaft Seal Removal For Part# 28985W and 28985WA .................................................... 5-59 Prior to Shaft Seal Installation ........................................................................................... 5-60 Shaft Seal Installation For Part# 25985Y and 25985YA ...................................................... 5-61 Shaft Seal Installation For Part# 28985W and 28985WA ................................................ 5-61 Slide Valve Actuator Assembly Replacement ............................................................................................ 5-63 Removal ....................................................................................................................................... 5-63 Installation ................................................................................................................................... 5-63 Actuator Installation Using Anti-Rotation Bolts............................................................................. 5-64 Slide Valve Command Shaft Assembly Replacement................................................................................. 5-65 Removal ....................................................................................................................................... 5-65 Installation ................................................................................................................................... 5-65 Liquid Injection Control Valve Station....................................................................................................... 5-66 Main Rotor Assembly ............................................................................................................................... 5-68 Torque Specifications............................................................................................................................... 5-68 Using A Torque Wrench Correctly............................................................................................................. 5-69
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Table of Contents
Section Title
Page Number
Nord-Lock® Washers ................................................................................................................................ 5-69
Section 6 · Troubleshooting
Slide Valve Actuator Troubleshooting Guide............................................................................................... 6-1 Slide Valve Actuator LED Blink Codes.......................................................................................................... 6-4 Troubleshooting Guide - General Problems & Solutions .............................................................................. 6-6
Section 7 · Warranty And Parts
Warranty Claim Processing ........................................................................................................................ 7-1 Motor Warranty Procedure ........................................................................................................................ 7-2 On-Site Service Support............................................................................................................................. 7-3 Remanufactured Bare Shaft Single Screw Compressor Process................................................................... 7-3
Explanation of Rebuild Levels.......................................................................................................... 7-3 Bare Shaft Compressor Description ................................................................................................ 7-3
Section 8 · Spare Parts List
VSH/VSSH Recommended Spare Parts List ................................................................................................. 8-1 VSS Recommended Spare Parts List ........................................................................................................... 8-3
Gaterotor ....................................................................................................................................... 8-5 Shaft Seal ..................................................................................................................................... 8-11 Main Rotor ................................................................................................................................... 8-13 Slide Valve Cross Shafts and End Plate........................................................................................... 8-14 End Plate (VSS 2401 - VSS 3001 Only) ........................................................................................... 8-16 Slide Valve Carriage Assembly ...................................................................................................... 8-18 Actuator and Command Shaft ...................................................................................................... 8-21 Miscellaneous Frame Components ............................................................................................... 8-22 Miscellaneous Frame Components Tubing and Fittings................................................................. 8-25 Replacement Tools ....................................................................................................................... 8-25 Replacement Parts ....................................................................................................................... 8-28 VSM 301-701 Recommended Spare Parts List .......................................................................................... 8-31 Gaterotor Assembly ..................................................................................................................... 8-31 Shaft Seal ..................................................................................................................................... 8-34 Main Rotor ................................................................................................................................... 8-35 Slide Valve Cross Shafts and End Plate........................................................................................... 8-36 Slide Valve Carriage Assembly ...................................................................................................... 8-38 Actuator and Command Shaft ...................................................................................................... 8-40 Miscellaneous Frame Components ............................................................................................... 8-41 Housing Accessories..................................................................................................................... 8-43 Replacement Tools ....................................................................................................................... 8-44 VSM 97-127 Recommended Spare Parts List ............................................................................................ 8-46 Kits................................................................................................................................................ 8-47
Appendices
Appendix A Torque Specifications.............................................................................................................. A-1 Appendix B Vilter Oil.................................................................................................................................B -1 Appendix C Vibration Measurements - Single Screw Compressor ...............................................................C-1 Appendix D Liquid Injection Valve Setup Instructions & ICM/ICAD Motorized Valve Quick Start Guide .......D-1 Appendix E Liquid Injection Valve Station ICF 20-40 Installation Guide .......................................................E-1 Appendix F Hand-Held Slide Valve Calibration Tool ....................................................................................F-1 Appendix G Pre Start Up for Remote Oil Coolers ........................................................................................G-1
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Table / Figure
Table of Contents
List of Tables and Figures
Page Number
Tables
Table 3-1. Maximum Allowable Flange Loads ........................................................................................... 3-14
Table 4-1. Command Shaft Rotation Specifications .................................................................................... 4-8 Table 4-2. Stop/Check Valve Open Positions ............................................................................................. 4-19
Table 5-1. Maintenance/Service Schedule - For VSS/VSM Unit Only............................................................. 5-1 Table 5-2a. Maintenance/Service Schedule (For VSH/VSSH Unit Only) ........................................................ 5-2 Table 5-2b. Maintenance/Service Schedule (For VSH/VSSH Compressor Only) ............................................ 5-3 Table 5-3. Oil Filter Replacement Parts Required....................................................................................... 5-13 Table 5-4. Shaft And Hub Distances.......................................................................................................... 5-24 Table 5-5. Hub Clamp Bolt and Set Screw Torque Specifications ............................................................... 5-25 Table 5-6. Disc Pack Installation Torque Specifications.............................................................................. 5-25 Table 5-7. Clamping Bolts and Set Screw Torque Specifications ................................................................ 5-28 Table 5-8. Bare Shaft Compressor Component Weights............................................................................ 5-31 Table 5-9. Bare Shaft Compressor Component Lifting Hole Sizes .............................................................. 5-31 Table 5-10. Maximum Main Rotor Bearing Clearance ............................................................................... 5-36 Table 5-11. Maximum Gaterotor Bearing Clearance.................................................................................. 5-37 Table 5-12. Gaterotor Float ...................................................................................................................... 5-39 Table 5-13. Backlash Range ...................................................................................................................... 5-41 Table 5-14. Gaterotor Tool Kits ................................................................................................................. 5-42 Table 5-15. Shaft Seal Tool Kits................................................................................................................. 5-56 Table 5-16. VSH/VSSH Shaft Seals ............................................................................................................ 5-58 Table 5-17. Coils For Solenoid Valves (ICFE) .............................................................................................. 5-67 Table 5-18. Parts For Motorized Valve Station (ICF)................................................................................... 5-67 Table 5-19. Torque Specifications (ft-lbs).................................................................................................. 5-68
Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 3) ................................................................... 6-1 Table 6-2. Slide Valve Actuator LED Blink Codes (1 of 2) .............................................................................. 6-3 Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3) .................................................. 6-5
Figures
Figure 1-1. Refrigeration Compressor Unit Components ............................................................................ 1-4
Figure 2-1. Figure 2-1. Refrigeration Compressor Unit P&ID (Thermosyphon Oil Cooling with Single Oil Filter Shown)........................................................................... 2-1
Figure 3-1. Rigging and Lifting Points (VSS-2101 Compressor Unit Shown) ................................................ 3-1 Figure 3-2. Concrete Pad With Compressor Unit Dimensions - Side View.................................................... 3-6 Figure 3-3. Concrete Pad With Compressor Unit Dimensions - Front View .................................................. 3-7 Figure 3-4. Interior Foundation Isolation .................................................................................................... 3-7 Figure 3-5. Foundation With Housekeeping Pads Dimensions - Top View ................................................... 3-8 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. Stop/Check Valve Orientation................................................................................................. 3-11 Figure 3-10. Maximum Allowable Flange Loads........................................................................................ 3-13 Figure 3-11. Recommended Remote Air Cooled Oil Cooler Piping ............................................................ 3-14 Figure 3-12. Example - Vission 20/20 Wiring Diagram .............................................................................. 3-16
TOC - 6
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Table of Contents
Table / Figure
Page Number
Figure 3-13. Example - Interconnect Wiring Diagram ............................................................................... 3-17 Figure 3-14. Example - V-Plus Wiring Diagram ......................................................................................... 3-17 Figure 3-15. Oil Operating Levels ............................................................................................................. 3-20 Figure 3-16. Oil Drain Valve...................................................................................................................... 3-21 Figure 3-17. Priming Oil Lines and Compressor ........................................................................................ 3-21
Figure 4-1. Oil Operating Levels ................................................................................................................. 4-1 Figure 4-2. Actuator Assembly ................................................................................................................... 4-4 Figure 4-3. Slide Valve Calibration Screen (Vission 20/20) .......................................................................... 4-5 Figure 4-4. Menu Screen and Slide Calibration Button (Vission 20/20)........................................................ 4-6 Figure 4-5. Wire Connections For Capacity and Volume Actuators ............................................................. 4-7 Figure 4-6. Photo-Chopper ........................................................................................................................ 4-9 Figure 4-7. Actuator Assembly ................................................................................................................. 4-10 Figure 4-8. Overview, Main Menu and Instrument Calibration Screens (Compact Logix PLC)..................... 4-12 Figure 4-9. Slide Calibration Screen (Compact Logix PLC) ......................................................................... 4-13 Figure 4-10. Photo-chopper ..................................................................................................................... 4-13 Figure 4-11. Vission 20/20 Configuration Screen - I/O Configuration (Page 8) .......................................... 4-15 FIgure 4-12. Compressor and Model Setup with Vission 20/20 ................................................................. 4-15 Figure 4-13. Coalescing Oil Return Line .................................................................................................... 4-16 Figure 4-14. Suction Equalizing Line and Valve ......................................................................................... 4-17 Figure 4-15. Dual Oil Filter Setup For Oil Filters With Manifold Heads........................................................ 4-18
Figure 5-1. Discharge Bleed Valve, Suction Equalizing Line and Valve ......................................................... 5-5 Figure 5-2. Oil Analysis Kit (VPN 3097A) ..................................................................................................... 5-8 Figure 5-3. Oil Sampler Valve (VPN #3708A) For Gas Compression Applications ......................................... 5-8 Figure 5-4. Oil Sampling Valve (VPN #3709A) For Ammonia and Refrigerant Compressors ......................... 5-9 Figure 5-5. Operating the Oil Sampling Valve ............................................................................................. 5-9 Figure 5-6. Stages of the Oil Sample Taking Process ................................................................................. 5-10 Figure 5-7. Oil Strainer Drain Valve and Oil Separator Drain Valve ............................................................. 5-11 Figure 5-8. Suction Oil Charging Valve ..................................................................................................... 5-12 Figure 5-9. Filter Assembly and Oil Strainer Drain Valve (VPN 3111A Oil Filter Housing Shown) ................ 5-14 Figure 5-10. Filter Assembly (Vpn 3112A Oil Filter Housing Shown).......................................................... 5-15 Figure 5-11. Duplex Oil Filter Assembly (VPN 3110A Double Oil Filter Housing Shown) ............................ 5-16 Figure 5-12. Dual Oil Filter (3111A Oil Filter Housings Shown).................................................................. 5-18 Figure 5-13. Filter Assembly and Oil Strainer Drain Valve (VPN 3111A Oil Filter Housing Shown) .............. 5-19 Figure 5-14. Filter Assembly (VPN 3112A Oil Filter Housing Shown) ......................................................... 5-20 Figure 5-15. Oil Separators, Manhole Covers and Coalescing Filter Assemblies ......................................... 5-22 Figure 5-16. Heater Cartridges................................................................................................................. 5-23 Figure 5-17. Hub Distance (Axial Spacing) ................................................................................................ 5-25 Figure 5-18. Angular Alignment and Parallel Offset .................................................................................. 5-26 Figure 5-19. Coupling Guard Assembly (VPN A27435C shown) ................................................................ 5-29 Figure 5-20. Compressor Replacement and Hardware Assembly (VSS 2401-3001 Shown)........................ 5-30 Figure 5-21. Bareshaft Compressor Lifting Points and Component Weights ............................................. 5-32 Figure 5-22. Bareshaft Compressor Assembly Center of Gravity (Models 97-127) ..................................... 5-32 Figure 5-23. Bareshaft Compressor Assembly Center of Gravity (Models 291-2101) ................................. 5-33 Figure 5-24. Bareshaft Compressor Center of Gravity - Discharge Manifold and Main Compressor Assembly (Models 291-2101) .................................................................................................................................. 5-33 Figure 5-25. Bareshaft Compressor Assembly Center of Gravity (Models 2401-3001) ............................... 5-34 Figure 5-26. Bareshaft Compressor Center of Gravity - Discharge Manifold and Main Compressor Assembly (Models 2401-3001) ................................................................................................................................ 5-34 Figure 5-27. Bearing Axial Clearance Inspection ....................................................................................... 5-35 Figure 5-28. Bearing Radial Clearance Inspection ..................................................................................... 5-36 Figure 5-29. Gaterotor Bearing Clearance................................................................................................. 5-37 Figure 5-30. Gaterotor and Shelf Clearance .............................................................................................. 5-38
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
TOC - 7
Table of Contents
Table / Figure
Page Number
Figure 5-31. Gaterotor and Shelf Clearance Measurement Steps............................................................... 5-38 Figure 5-32. Visual Inspection Between Gaterotor and Bushing................................................................ 5-39 Figure 5-33. Gaterotor Float Dial Location ................................................................................................ 5-39 Figure 5-34. Gaterotor Float..................................................................................................................... 5-40 Figure 5-35. Alignment of Gaterotor ........................................................................................................ 5-40 Figure 5-36. Location of Dial Indicator Magnetic Base............................................................................... 5-40 Figure 5-37. Placement of Dial Indicator................................................................................................... 5-41 Figure 5-38. Measuring Backlash.............................................................................................................. 5-41 Figure 5-39. Chipped Edge of Gaterotor ................................................................................................... 5-42 Figure 5-40. Gaterotor Assembly Removal and Tools ................................................................................ 5-43 Figure 5-41. Gaterotor Assembly Removal ............................................................................................... 5-44 Figure 5-42. Gaterotor Assembly and Tools .............................................................................................. 5-45 Figure 5-43. Gaterotor and Shelf Clearance .............................................................................................. 5-45 Figure 5-44. Gaterotor Assembly Breakdown ........................................................................................... 5-46 Figure 5-45. Gaterotor Thrust Bearing...................................................................................................... 5-47 Figure 5-46. Gaterotor and Shelf Clearance .............................................................................................. 5-47 Figure 5-47. Gaterotor Assembly Removal ............................................................................................... 5-48 Figure 5-48. Gaterotor Assembly (VSM 97-127 Compressors ONLY) ......................................................... 5-49 Figure 5-49. Gaterotor and Shelf Clearance .............................................................................................. 5-50 Figure 5-50. Gaterotor Blade Assembly .................................................................................................... 5-50 Figure 5-51. Gaterotor Blade Installation.................................................................................................. 5-51 Figure 5-52. Gaterotor Thrust Bearing...................................................................................................... 5-51 Figure 5-53. Thrust Bearing Installation.................................................................................................... 5-51 Figure 5-54. Roller Bearing Assembly ....................................................................................................... 5-52 Figure 5-55. Gaterotor Support (VSM 97-127).......................................................................................... 5-53 Figure 5-56. Gaterotor Blade Installation.................................................................................................. 5-53 Figure 5-57. Gaterotor Thrust Bearing (VSM 97-127)................................................................................ 5-54 Figure 5-58. Shaft Seal Assembly.............................................................................................................. 5-55 Figure 5-59. Handling Seal Face with Care ................................................................................................ 5-55 Figure 5-60. Compressor Shaft Seal Assembly .......................................................................................... 5-56 Figure 5-61. Compressor Shaft Seal Installation: Tapered and Straight Shafts ........................................... 5-57 Figure 5-62. Shaft Seal Breakdown (28985Y & 28985YA).................................................................. 5-58,5-61 Figure 5-63. Shaft Seal Breakdown (28985W and 28985WA Only) .................................................. 5-59, 5-62 Figure 5-64. Shaft with Pin ....................................................................................................................... 5-60 Figure 5-65. Shaft Seal Housing................................................................................................................ 5-60 Figure 5-66. The Alignment of Compressor Shaft and Mating Ring ........................................................... 5-60 Figure 5-67. Actuator Installation Using Anti-Rotation Bolts..................................................................... 5-64 Figure 5-68. Command Shaft Assembly Replacement .............................................................................. 5-65 Figure 5-69. Danfoss ICF 20-40 Valve Station (Liquid Injection Control) .................................................... 5-66
Figure C-1. Compressor Bearing Vibration Measurement Location...............................................................C-1 Figure C-2. Main Rotor Cross-Section VSS/VSM Compressors ......................................................................C-2 Figure C-3. Gaterotor Cross-Section VSS/VSR/VSM Compressors .................................................................C-3
TOC - 8
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 1 · General Information
How To Use This Manual
This manual contains instructions for refrigeration compressor units. It has been divided into eight sections and Appendices:
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 Section 8: Spare Parts List
Appendices Appendix A: Torque Specifications Appendix B: Vilter Oil Appendix C: Vibration Measurements - Single Screw Compressor Appendix D: Liquid Injection Valve Setup Instructions and ICM/ICAD Motorized Valve Quick Start Guide Appendix E: Liquid Injection Valve Station ICF 20-40 Installation Guide Appendix F: Hand-Held Slide Valve Calibration Tool Appendix G: Pre Start Up for Remote Oil Coolers
WARNING - Warning statements are shown when there are hazardous situations, if not avoided, will result in serious 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 additional information pertaining to the instructions explained.
Additional Important Notes
· Additional installation, operation and maintenance instructions can be found in the Vission 20/20 manual (35391SC) or Compact Logix PLC Software Manual (35391CM).
· Due to continuing changes and unit updates, always refer to the website www.Vilter.com to make sure you have the latest manual.
· Any suggestions of manual improvements can be made to VilterTM Manufacturing at the contact information on page iii.
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 defined as the following:
NOTICE - Notice statements are shown when there are important information that shall be followed. Not following such notices may result in void of warranty, serious fines, serious injury and/or death.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
1 1
Section 1 · General Information
Refrigeration Compressor Unit Model Designations
The compressor unit model designation can be found on the nameplate. For nameplate location, see Component Identification section on page 1-4.
Separator Type
16= 16-inch diameter
20= 20-inch diameter
24= 24-inch diameter
30= 30-inch diameter
Compressor Model
VSM/VSMC = VilterTM Single Mini-Screw
VSS/VSSC= VilterTM Single Screw
VRS= VilterTM Twin Screw
VSH /VSSH= VilterTM Single Screw Heat Pump
Compressor Size
CFM- Nominal CFM displacement of the compressor at 3600
rpm
Application
HP=High Stage, with Oil Pump
HN=High Stage, No Oil Pump (SOI
= Suction Oil Injection)
B = Booster
S = Swing
36= 36-inch diameter
42= 42-inch diameter
48= 48-inch diameter
54= 54-inch diameter
60= 60-inch diameter
*H=Horizontal V=Vertical SH=Special Horizontal SV=Special Vertical
Oil Cooling Medium
R = Refrigerant W =Water G =Glycol A=Air
VSM - 301 - A - HP - E - 16H - N - PL - R - S - 3 - XCHR
* **
Refrigerant Service
A = R-717 (Ammonia) B = R-407A
C = R-744 (CO2) E = R-134a F=R-407F H = R-404A J = R-410A K=R-407C
Driver
V =Variable Frequency Drive E =Electric Motor
Drive
G =Engine Drive
Economizer
N= No Economizer, Economizer Ports
Plugged
E= Economizer Connection, Ports Piped
to Single Flange
F= Economizer Flanges, Flanged Port Covers (piping by others)
Oil Cooler PL=Plate
ST=Shell and Tube Liquid Injection Cooling & Port:
LH = High Port LM = Medium Port LL = Low Port L2 = High and Medium Ports
Oil Filter S=Single Filter D=Dual Filter
M = R-22
L1 = Medium and Low Ports
P = R-290 (Propane)
VP= V-Plus Pumped Liquid
R = R-1270 (Propylene)
R= Remote
Z = R-507
* Suction Connection
**
Blank
Custom Features X[letter(s)] = Special Feature(s):
3, 4, 6, 8 = 3", 4", 6", 8"
C=Cartridge-Style Reliefs
L=Dual coolers (LI or PL)
A = 10" B = 12"
No special features
E=Special Electrical Codes F=Fixed Slide
R=CRN Units S=Special Separator Features
C = 14"
H=Hazardous Area Req.
V=Specific Vendor
1 2
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 1 · General Information System Unit Identification
To keep definitions of units simple and consistent, VilterTM has defined 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-controller 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.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
1 3
Section 1 · General Information Compressor Unit Component Identification
Each refrigeration compressor unit may differ, but below are typical components that can be found on each unit.
1 - Motor 2 - Motor Conduit Box 3 - Coupling and Guard 4 - Suction Oil Charging Valve 5 - Thermometer 6 - Suction Strainer 7 - Suction Check Valve 8 - Suction Stop Valve 9 - Compressor 10 - Discharge Pipe 11 - Vission 20/20 HMI 12 - Block & Bleed Assembly
13 - Oil Drain/Fill Valve 14 - Oil Pressure Regulator 15 - Oil Heater 16 - Frame
17a - Oil Filter, Single (Vertical) 17b - Oil Filter, Dual (Horizontal) 18 - Oil Pump Motor 19 - Oil Pump 20 - Oil Sight Glass 21 - Oil Pump Strainer 22 - Oil Pressure Relief Valve
23 - Oil Temperature Control Valve (Oil Mixing Valve)
24 - Oil Cooler (Plate Heat Exchanger) 25 - Oil Separator 26 - Discharge Connection 27 - Coalescing Oil Return Line
28 - Heater Wiring Panel
29 - Economizer Connection Flange 30 - Nameplate 31 - Suction Equalizing Line 32 - Oil Separator Certification Plate
7
6
1
2
3
45
8 9 10
25
11
12
24
23
22
15 21 20 19 18 17a 16 15 14 13
Figure 1-1. Refrigeration Compressor Unit Components (1 of 3)
1 4
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 1 · General Information
7
5
2
1
30
29
26
28 18 19 21
30
27 31
17b 32
Figure 1-1. Refrigeration Compressor Unit Components (2 of 3)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
1 5
Section 1 · General Information
Compressor Unit Component Identification (Continued)
33 - Temperature Element (Suction)
34 - Pressure Transducer (Filter Inlet)
35 - Pressure Transducer (Oil Pressure)
36 - Pressure Transducer (Suction Pressure)
37 - Pressure Transducer (Discharge Pressure)
38 - Temperature Element (Oil Separator)
39 - Temperature Element (Oil Injection)
40 - Capacity Slide Valve Actuator
41 - Volume Slide Valve Actuator
42 - Temperature Element (Discharge)
36
33
34 35 36 37
42
40
41
38
39
Figure 1-1. Refrigeration Compressor Unit Components (3 of 3)
1 6
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 1 · General Information
Instrument Identification Letters
Use this list to identify components shown in the Piping & Identification Diagram.
A
Analysis
AAH Concentration High
AAHH Concentration/Detection High High
AI Analysis/Moisture Indicator
AIT Analysis/Detection Indicating Transmitter
AT Analysis/Detection (Blind)
AU Analysis/Detection Monitor
BFV Butterfly Valve
CV Check Valve
E
Voltage
EAH Voltage High
EAHH Voltage High High (Shutdown)
EI Voltage Indication
F
Flow
FAH Flow High
FAHH Flow High High (Shutdown)
FAL Flow Low
FALL Flow Low Low
FC Flow Controller/Fail Close
FG Flow Gauge
FI Flow Indication (Soft)/ Flow Sight Indicator (Glass)
FIC Flow Indicating Controller
FIT Flow Indicating Transmitter
FOP Orifice Plate
FT Flow Transmitter (Blind) FV Flow Control Valve FY Flow/Relay/Convertor G Gas GIT Gas Detecting Indicating
Transmitter
GAH Gas Detected Concentration Level High
GAHH Gas Detected Concentration Level High High (Shutdown)
H Hand
HH Hand Hole
HO Held Open (Solenoid Valve Only)
HV Hand Valve
I
Current
IAH Amperage High
IAHH Amperage High High (Shutdown)
II
Current Indication
IT Current Transmitter (Blind)
J
Power
JB Junction Box (Wire Termination)
JI
Power Indication
JIT Power Indicating Transmitter
JT Power Transmitter (Blind)
K
Time Schedule
KC Time Controller (Blind)
KI Time Indication
KIC Time Indication Controller
KR Time Recorder
KY Time/Relay/Convertor
L
Level
LAH Liquid Level High
LAHH Liquid Level High High (Shutdown)
LAL Liquid Level Low
LALL Liquid Level Low Low (Shutdown)
LC Level Controller
LE Level Probe (Element)
LG Level Gauge
LI Indication (Soft)/Level Sight Indicator (Glass)
LIT Level Indicating Transmitter
LO Lock Open
LSH Level Switch High
LSHH Level Switch High High (Shutdown)
LSL Level Switch Low
LSLL Level Switch Low Low (Shutdown)
LT Level Transmitter (Blind)
LV Level Control Valve
LY Level/Relay/Convertor
MCC Motor Control Center
MGV Manifold Gauge Valve
NC Normally Closed
NO Normally Open
NV Needle Valve
P
Pressure
PAH Pressure High
PAHH Pressure High High (Shutdown)
PAL Pressure Low
PALL Pressure Low Low
PC Pressure Control
PDAH Pressure Differential High
PDAHH Pressure Differential High High (Shutdown)
PDAL Pressure Differential Low
PDALL Pressure Differential Low Low (Shutdown)
PDC Pressure Differential Control
PDI Differential Pressure Indication
PDIC Pressure Differential Indicating Controller
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
1 7
Section 1 · General Information
PDIT Pressure Differential Indicating Transmitter
PDSH Pressure Differential Switch High
PDSHH Pressure Differential Switch High High (Shutdown)
PDSL Pressure Differential Switch Low
PDSLL Pressure Differential Switch Low Low (Shutdown)
PDT Differential Pressure Transmitter (Blind)
PDV Pressure Differential Control Valve (Pneumatic Actuator)
PFY Pressure Ratio Convertor/ Relay
PFC Pressure Ratio Controller
PG Pressure Gauge
PI Pressure Indication (Soft)
PIC Pressure Indicating Controller
PIT Pressure Indicating Transmitter
PSE Pressure Rupture Disk
PSH Pressure Switch High
PSHH Pressure Switch High High (Shutdown)
PSL Pressure Switch Low
PSLL Pressure Switch Low Low (Shutdown)
PSV Pressure Safety Relief Valve
PT Pressure Transmitter (Blind)
PV Pressure Control Valve
Q Quantity and Heat
QE Heater Element, Immersion, Tracing
R
Radiation
S
Speed, Frequency
SC Speed Control
SD Shutdown
SIC Speed Indicating Controller
T
Temperature
TC Temperature Controller
TAH Temperature High
TAHH Temperature High High (Shutdown)
TAL Temperature Low
TALL Temperature Low Low (Shutdown)
TE Temperature Element (RTD, Thermocouple, etc.)
TG Temperature Gauge
TI Temperature Indication (Soft)
TIC Temperature Indicating Controller
TIT Temperature Indicating Transmitter
TRV Transfer Valve 3-Way
TSH Temperature Switch High
TSHH Temperature Switch High High (Shutdown)
TTSL Temperature Switch Low
TSLL Temperature Switch Low Low (Shutdown)
TT Temperature Transmitter (Blind)
TV Temperature Control Valve
TW Temperature Thermowell
TY Temperature/Relay/ Convertor
U Multi Variable
V Vibration, Mechanical Analysis
VE Vibration Probe
VFD Variable Frequency Drive
VG Block/Bleed, Gauge Valve
VSH Vibration Switch High
VSHH Vibration Switch High High (Shutdown)
VT Vibration Transmitter (Blind)
VU Vibration Monitoring System
W Weight
XA Status (Stopping/Not Running) Alarm/Common Alarm
XC State Controller
XI Running Indication
XV Solenoid Valve
XY State Relay/Convertor
Y
Event, State, Presence
YAH Fire Alarm
YE Fire Detecting Sensor
YIT Fire Indicate and Transmit
YK Fire Control Station
Z
Position, Dimension
ZC Position Controller
ZE Position Element
ZI Position Indicator
ZIT Position Indicating Transmitter
ZT Position Transmitter (Blind)
ZY Position Transmitter (Blind)
ZZ Position Actuator (Capacity or Volume)
1 8
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 1 · General Information
Symbol Identification
Use this list to identify symbols shown in the Piping & Identification Diagram.
3-Way Valve
S
3-Way Solenoid Valve Angle Valve
Ball Valve Basket Strainer Block/Bleed Gauge Valve Butterfly Valve Check Valve
Diaphragm Actuator
Diaphragm Spring-Opposed
Diaphragm Pressure-Balanced Differential Pressure Regulating Valve
Drive Coupling
Flange Set FG Flow/Sight Glass
Gate Valve Globe Valve Hand Expansion Valve
QE Heater Heat Trace Insulation
MW Man-Way Cover
Manifold Gauge Valve
M
Motorized Ball Valve
Needle Valve Orifice Plate G Pilot Light Pipe Plug Pipe Reducer Pneumatic Actuator Control Valve Relief Valve
Regulating Valve Inlet Pressure Regulating Valve Outlet Pressure
Rotary Valve
Rupture Disc Schroder Valve
S
Solenoid Valve Spring-Closing Drain Valve Stop/Check Valve
Strainer T
Thermostatic Valve 3-Way Thermowell (SW or NPT) Thermowell (SW or NPT) Venturi Injector Nozzle Vibration Absorber
BY VILTER BY OTHERS
Scope of Supply
Major Component Identification
Use this list to identify major components shown in the Piping & Identification Diagram.
A
Air Drive
Compressor
Damper or Louver
Filter
Finned Tube Heat Exchanger
Heat Exchanger
Shell and Tube Heat Exchanger Fan
Tank/Drum Vessel
Engine Drive
Motor
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Positive Displacement Pump
1 9
Section 1 · General Information Major Component Identification (Continued)
Centrifugal Pump Rotary Pump
Plate & Frame Heat Exchanger
Turbine
Control and Instrument Identification
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 SD Safety Instrumented System, Field Mounted Programmable Logic Control, DCS or Remote Control Panel, Normally Accessible to Operator SD Safety Instrumented System Main Control Panel or DCS Programmable Logic Control, Auxiliary (Local) Control Panel, Normally Accessible to Operator SD Safety Instrumented System Auxiliary (Local) Control Panel Computer Function, Field Mounted Computer Function, DCS or Remote Control Panel, Normally Accessible to Operator Computer Function, Local Operator Panel, Normally Accessible to Operator I Interlock P Permissive
Line Type Designations
XXXXX LLLLL
1 10
Pneumatic Signal Capillary Tube Electrical Signal Internal System Link (Software or Data Link) Mechanical Link Hydraulic Signal Customer Field Piping Insulation
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 1 · General Information
Valve and Instrument Tagging
a-bc-yz = ABC-DEFGH-IJKL a = ABC, b = DE, c = FGH, y = IJK, z = L
A - Process cell or stage of compressor B - Unit number in process cell or stage of compression C - Service in process cell or stage of compression
1 - Gas lines 2 - Coolant lines 3 - Oil lube lines 4 - Refrigerant lines 5 - Condensate lines 6 - Air lines
D - Measured variable E - Variable Modifiers F - Readout or passive function G - Output or active function H - Function modifier I - Loop number or sequential number J - Loop number or sequential number K - Loop number or sequential number L - Suffix
Sample Tag 105-LSH-300-A
1 - First process cell or stage of compression 0 - First unit number in process cell or stage of
compression 5 - Condensate service
L - Level S - Switch H - High
3 - Loop number or sequential number 0 - Loop number or sequential number 0 - Loop number or sequential number
A - Another exactly the same device in the same loop as 105-LSH-300
Equipment Number Identification
Process Cell/Compression Stage Number
Equipment Type
101-V-300
Series Number
Equipment Type A - Agitator, Mechanical Mixers, Aerators B - Blowers C - Compressors D - Drivers E - Heat Exchangers
F - Fans P - Pumps R - Reactors U - Filters, Strainers V - Vessels, Tanks, Separators, Scrubbers
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
1 11
Section 1 · General Information
Pipe Line Data Identification
AB - C - D - E - F X - Y - Z
20-LFG-001-10-STD PS-1-ET
A - Process cell or stage of compression 1 - Process cell first stage of compression 2 - Process cell first stage of compression 3 - Process cell first stage of compression 4 - Process cell first stage of compression 5 - Process cell low pressure refrigeration (booster) 6 - Process cell high pressure refrigeration (high stage) 7 - Open 8 - Open
9 - Open
B - Unit number in process cell or stage of compression
C - Service AR - Process Air BD - Blowdown BRR - Brine CHWS - Chilled Water Supply CHWR - Chilled Water Return CWR - Cooling Water Return CWS - Cooling Water Supply DR - Drain ER - Ethylene Refrigerant GLR - Glycol Return GLS - Glycol Supply H - Hydrogen HR - Hydrocarbon Refrigerant
IAS - Instrument Air Supply LFG - Land Fill Gas LO - Lube Oil N - Nitrogen NG - Natural Gas NH - Ammonia PC - Process Condensate PG - Process Gas PR - Propylene Refrigerant/Propane SV - Safety Relief SO - Seal Oil VC - Vacuum Condensate
X - Insulation AC -Acoustic Control CC - Cold Service CP - Condensation Control N - Not Required PP - Personnel Protection PS - Process Stability TR - Traced (See Tracing Type)
Y - Insulation Thickness BO - By Others #" - Nominal Thickness (Inches) 0 - Insulation Not Required
Z - Heat Tracing ET - Electrical Heat Trace N - None
D - Numerical Sequence Number
E - Size #" - Nominal Pipe Size (Inches)
F - Standard/Other Standard STD -VilterTM 0 - Other Standard (Not VilterTM)
1 12
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 2 · Theory of Operation
R717 VAPOR TO ATMOSPHERE
1
250#
PI
002
PT
002
BLEED
V100
DRAIN
LG 001 LG
002
TW
TW
TW
TW
750W
750W
750W
QE
QE
QE
TE
001
002
003
005
2 DISCHARGE CHECK VALVE DISCHARGE STOP VALVE
HIGH PRESSURE R717 VAPOR OUTLET
100 PSID
OIL SEPARATOR
MW
OPTIONAL
(STANDARD FOR BOOSTER &
SWING COMPRESSORS ONLY)
MOTOR AND
3
OIL PUMP
COALESCING OIL RETURN LINE FILTER
D101
12
LOW PRESSURE R717 VAPOR INLET
PT
PI
001 001
BLEED
SUCTION STOP VALVE
11 10
SUCTION CHECK VALVE
TE TW 004
FG 001
TE TW 001
OIL CHARGE
9
8
PT 003 PI
BLEED 003
76
D100
MOTOR
D102 CAPACITY
C100
COMPRESSOR
D103 VOLUME
P100
4
TE TW 002
5
DRAIN
T
PT 004
PI
BLEED
004
R717 LIQUID/VAPOR OUTLET
E100
R717 LIQUID INLET
Figure 2-1. Refrigeration Compressor Unit P&ID (Thermosyphon Oil Cooling with Single Oil Filter Shown)
The refrigeration and oil systems work in unison, but
each one will be explained separately. Reference Figure 2-1 for refrigerant and oil flow descriptions. This is a typi-
cal refrigeration system with thermosyphon oil cooling.
Moreover, suction stop/check valve (11) and discharge
check valve (2) are provided between the oil separator to prevent refrigerant vapor or liquid from flowing back
to the compressor during shutdown periods.
Refrigerant Flow
Oil Life and Oil Flow
The refrigeration compression process begins as refrigerant vapor enters the suction inlet (12). The refrigerant vapor flows through a suction stop/check valve (11), then through a strainer (10) to the compressor (9). The refrigerant is then pressurized through the compressor and discharged as high pressure refrigerant vapor into the oil separator (1). In the oil separator, the oil is then separated from the discharged refrigerant by impingement separation. The high pressure refrigerant flows out to the condenser for cooling while the oil is pumped or siphoned back to the compressor.
Oil in the refrigeration system serves three primary purposes. They are compressor lubrication, sealing clearances between moving parts, and heat removal resulting from heat of compression and friction. Initially, oil flow is driven by a mechanical gear pump (3). Once the system reaches design conditions, the oil pump is shut off and oil flow is maintained by differential pressure.
As the oil is separated from the refrigerant in the oil separator (1), it is pumped or siphoned through an oil cooler (5), then through an oil filter (4) and back to the injection port (6) of the compressor (9). For additional
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Section 2 · Theory of Operation
information on thermosyphon oil cooling, refer to Oil Cooling - Thermosyphon Oil Cooling.
Furthermore, to collect oil from the coalescing side of the oil separator (1), an oil return line (8) is installed between the oil separator and the compressor (9). By opening the needle valve (7), this will allow oil dripping off the coalescing filters to be fed back to the compressor.
This is a continuous cycle.
Oil Cooling
There are different methods of oil cooling for VilterTM refrigeration compressor units. Oil cooling will depend on the type of application, below is an explanation of each method.
Water Cooled Oil Cooling
· In lieu of the three way oil temperature valve to control the temperature of the oil used for lubrication and cooling of the compressor, it is required to install a water regulating valve and solenoid valve combination to control the water supply to the oil cooler. The water inlet connection should be made on the bottom and the outlet connection on the top. The water supply is controlled by the water regulating valve to maintain the oil temperature at approximately 120°F. The solenoid valve provides positive water shutoff when the compressor is not in operation. A temperature of 150°F is considered high in most circumstances and the compressor is protected by a safety control to prevent operation of the compressor above this temperature. Unless otherwise specified, the oil cooler is sized for an 85°F water inlet temperature and 10°F temperature rise.
Liquid Injection Oil Cooling
· This type of oil cooling system is designed to maintain compressor discharge gas temperature within acceptable limits. Cooling is accomplished via injection of the liquid refrigerant into the compressor. For this purpose, a liquid injection control valve station is supplied and installed on the compressor unit. On this valve station is an electronically controlled motorized actuator valve assembly that controls the flow of liquid refrigerant being injected into the compressor.
· For additional information, refer to Section 5.
· Liquid injection cooling on booster compressors is handled in the following manner. Using high pressure
liquid, the point of injection can be the discharge line and no horsepower penalty is paid by injecting liquid into the compressor discharge line. The high pressure gas source normally used for the pressure regulator would be compressor discharge pressure. Since, on a booster unit, this intermediate pressure is very rarely as high as the nominal setting of 70 psig, high stage discharge gas is used. On high stage compressors, the liquid is injected directly into the compressor. However, there is a horsepower penalty when the liquid is injected into the compressor. This will vary with refrigerant and operating condition. The liquid is injected into the compressor at a point in the compressor cycle that minimizes the brake horsepower penalty.
V-Plus Oil Cooling
· This system consists of a liquid pump, shut-off valves, motor, solid state variable speed controller and solid state temperature controller. This method of oil cooling is not available on the VSM compressor units. The pump and solenoid valve cycle on and off in parallel with the compressor drive motor. The temperature controller receives a temperature signal from the sensor located in the discharge and oil lines and in turn, sends a signal to the motor speed controller.
· As the oil and de-superheating load varies, the temperature controller adjusts the speed of the pump/ motor combination to maintain a constant oil temperature.
· For additional V-Plus information, refer to V-Plus AC Drive manual (35391XA).
Thermosyphon Oil Cooling
· Using a brazed plate or one pass shell and tube type vessel, similar to the water cooled oil cooler, oil is circulated on the shell side and liquid refrigerant from the receiver is circulated through the tubes. Thermosyphon systems use a 3-way temperature sensing control valve to regulate oil at 120°F. Oil is bypassed around the thermosyphon oil cooler. When oil is higher than 120°F, the oil is passed through the thermosyphon oil cooler. A 1/4" tubing line with valve adds high pressure gas to the oil to quiet the sound of injection. Open this valve in small amounts, until noise subsides. The closed type cooling circuit is free from the fouling problems associated with open circuit water cooling. Since the oil cooling load is rejected in the condenser, this type of cooling is practical. The temperature limits here are the same as those regarding the water cooled oil coolers.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 2 · Theory of Operation
Control System
The compressor unit is controlled by the micro-processor, i.e. microVission 20/20 panel or PLC panel. This panel's main function is to control the refrigeration system from the data that it receives from the sensors around the unit. For additional information, refer to micro-processor manual (35391SC for Vission 20/20 Operating Manual or 35391CM for Compact Logix PLC Software Manual).
WARNING
Software programming credentials shall only be made available by the supplier. The user will only have access to operational features established by the supplier. Failure to comply may result in serious injury
or death.
Temperature Elements, Pressure Transmitters and Indicators
Temperature elements (TE), pressure transmitters (PT) and pressure indicators (PI) are instruments used to measure temperatures and pressures at specific locations on the compressor unit. Temperature elements are typically mounted on the compressor, suction pipe, discharge pipe, oil separator, oil filter inlet and outlet pipe. Pressure transmitters are typically mounted on the block and bleed assembly. The pressure transmitters measure suction pressure, inlet and outlet oil pressure, and discharge pressure in the oil separator. Typically, pressure indicators are not mounted from the factory, except for a pressure indicator to show the nitrogen holding charge for shipping and storage purposes. If required, end users have the ability to mount pressure indicators at the block and bleed assembly.
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Section 3 · Installation
NOTICE
Vilter compressors are to be installed and connected to the customer-provided piping. Vilter expects this piping to be designed and built following ASME B31.3 Process Piping Guide, plus any other local applicable codes, and that the installation will be performed by
qualified personnel only.
Delivery Inspection
All equipment supplied by Vilter are thoroughly inspected at the factory. However, damage can occur in shipment. For this reason, the units should be thoroughly inspected upon arrival, prior to off-loading. Any damage noted should be photographed and 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 claims made within ten (10) days after its discovery. Refer to Compressor Unit Inspections Prior To Installation for additional recommendations.
Lifting Point
Lifting Point
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 qualified 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.
Only qualified personnel shall operate rigging and lifting 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 compressor 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 compressor unit and a clear path to its location.
Use lifting chains/straps and spreader bar. Evenly distribute weight. Keep lifting chains and spreader bar clear of components to prevent damage.
Figure 3-1. Rigging and Lifting Points (VSS-2101 Compressor Unit Shown)
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Section 3 · Installation
Compressor Unit Inspections Prior To Installation
The compressor unit must be inspected prior to installation 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 compressor unit should have also been inspected prior to off-loading, see Delivery Inspection.
· Check that the nitrogen pressure is still holding pressure. The pressure gauge is located at the discharge bleed valve on the block and bleed assembly. Any leaks must be fixed and the system purged and recharged with dry nitrogen.
· Look into the suction and discharge connections and inspect for any signs of corrosion on parts.
· Prelube the compressor with the main oil pump and rotate by hand several revolutions prior to start.
· Notify VilterTM Service and Warranty Department when the compressor is started.
NOTE For Pre Start-Up and Start-Up checklists, please
contact Vilter Service and Warranty Department.
CAUTION
Before installation, follow the proper procedures to depressurize the compressor.
Recommended On-site 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 approved for Division 1 or Division 2 and with ability to overcome suction pressure) (VPN A40849A)
· 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
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
Long Term Storage Recommendations
The procedure described is a general recommendation for long term storage (over one month of no operation) of Vilter compressor units. It is the responsibility of the installation firm and end user to address any unusual conditions. Use the supplied long term storage log sheet to help with record keeping, see page 3-4.
Warranty of the system remains in effect as described at the beginning of this manual, section page i.
The following are recommendations regarding long term storage:
· If the unit is designed for indoor duty, it must be stored in a heated building.
· If the unit is designed for outdoor duty and is to be stored outdoors, a canvas tarp is recommended 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 atmospheric pressure. It is essential that the nitrogen holding 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 monitor 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 (Main rotor shaft, coupling, flange faces, etc.) with rust inhibitor.
· The volume and capacity slide valve motor enclosures should have corrosion inhibitors installed in them and the enclosures should be sealed. On a six month basis (depending on relative humidity), check and replace inhibitors as necessary, and check for signs of corrosion.
· Desiccant is to be placed in the control panel. If the panel is equipped with a space heater, it is to be energized. 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.
· Manually rotate the compressor shaft 6 ½ revolutions every month to prevent flat spots on the bearing surfaces. 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 cool compression, there is no pre-lube pump, so the driveshaft must be turned by hand.
· Long Term storage log sheet to be kept with documenting dates to show all the procedures have been completed.
· Notify Vilter Service and Warranty Department when the compressor is started.
Compressor Motor
The following are general recommendations. Refer to specific 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 silicagel (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 plastic bag. Before sealing this bag, a moisture indicator should be attached to the side of the motor and several 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, replace desiccants.
· Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F above the ambient temperature.
· Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate flat 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-lubricated at 2-year intervals using the grease specified on the motor lubrication nameplate.
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Long Term Storage Log
Company: Serial Number:
Sales Order Number:
Name (Please Print): Date (M/D/Y):
Initial:
PSI Nitrogen Pressure - Current
PSI Nitrogen Pressure - Recharged (If pressure is low, identify and fix leak prior to recharging, see Compressor Unit Leak Check procedure in Section 5)
Nitrogen Leak Location (Briefly explain nature of leak):
Compressor Shaft (Rotate shafts at least 6 revolutions) Motor Shaft (Rotate shafts at least 6 revolutions) Motor Bearings Greased Air Cooled Oil Cooler Rotated (If equipped) Bare Metal Surfaces (Check all bare metal surfaces for rust and ensure they are covered with rust inhibitor) Desiccants (Are desiccants still effective? If not, replace. Check control panel, motor, pneumatic controllers and valves) Cover Bags/Tarp (Ensure bags and tarps are not torn and are sealed over components correctly, replace if damaged) Valves (Stop valves are in closed position so the compressor unit is isolated. All other valves, except those venting and draining to atmosphere are to be open)
Space Heater & Panel Components (Ensure space heater is energized and panel components are rust-free)
Name (Please Print): Date (M/D/Y):
Initial:
PSI Nitrogen Pressure - Current
PSI Nitrogen Pressure - Recharged (If pressure is low, identify and fix leak prior to recharging, see Compressor Unit Leak Check procedure in Section 5)
Nitrogen Leak Location (Briefly explain nature of leak):
Compressor Shaft (Rotate shafts at least 6 revolutions) Motor Shaft (Rotate shafts at least 6 revolutions) Motor Bearings Greased Air Cooled Oil Cooler Rotated (If equipped) Bare Metal Surfaces (Check all bare metal surfaces for rust and ensure they are covered with rust inhibitor) Desiccants (Are desiccants still effective? If not, replace. Check control panel, motor, pneumatic controllers and valves) Cover Bags/Tarp (Ensure bags and tarps are not torn and are sealed over components correctly, replace if damaged) Valves (Stop valves are in closed position so the compressor unit is isolated. All other valves, except those venting and draining to atmosphere are to be open) Space Heater & Panel Components (Ensure space heater is energized and panel components are rust-free)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
Foundation
VilterTM Single Screw compressor units are low vibration 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 VilterTM foundation supports the entire operating weight of the unit and is suitable for years of continuous duty. Included are specifications for concrete, rebar, aggregate, 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
· 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, expansion 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 - Concrete Pad with Compressor Unit Dimensions - Side View. The rebar required is ASTM 615, grade 60, sizes #4 and #6. Wires will also be needed to tie the rebar together. The recommended grout is Masterflow 648CP high performance non-shrink grout to provide at least a 1" thick pad under each foot. The recommended anchors are 5/8" Diameter HILTI HAS SS threaded rod for outdoor installations or HAS-E rods for indoor installations. Anchor bolts shall have a five 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 compressor unit.
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
· Follow the local building codes to establish proper ventilation
· Make all valves and devices safely accessible · Use special bright primary color schemes to differen-
tiate service lines
Building The Foundation
Use the VilterTM General Arrangement (GA) and foundation drawings to help secure a building permit and foundation construction. The VilterTM 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 VilterTM 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 specifications. Using the VilterTM GA drawing, Vilter foundation drawing and the information from site characteristics, site layout and safety studies will provide enough data to allow building the foundation to proceed.
The foundation is to be cast and permanently exposed against the earth. Therefore, if constructing on an existing floor, typically indoors, the floor will need to be broken 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 foun-
dation extends below it
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Section 3 · Installation
· Ensure the foundation rests entirely on natural rock or entirely on solid earth, but never on a combination 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.
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 foundation will rest. The sand must be compacted before placing the forms and rebar. After the sand is compacted, use the VilterTM 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
VilterTM foundation drawing. When all rebars are in place the concrete can be poured. The concrete must then be trolled level and a surface texture etched in place. Leave the concrete to cure for at least 28 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 VilterTM GA drawing and slowly place it on the foundation housekeeping piers. As per the VilterTM GA drawing, ensure the compressor unit is correctly placed on the foundation. Once placed, use the spherical washers 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 TM 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 finger tight and prepare to grout.
G.A. G.A.
COMPRESSOR UNIT
CLEARANCE FOR REPLACING ELEMENTS
G.A.
CENTER LINE OF GAS COMPRESSION SYSTEM
2" (TYP.) 2" (TYP.)
2" CLR.
EL. TOP OF GRADE
4" COMPACTED SAND
1'-0" 6"
3" CLR.
# 6 @ 12" EACH WAY TOP & BOTTOM
EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL WITH CLSM OR NON-FROST SUSCEPTIBLE FILL
Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
Leveling and Grouting
The unit should be level in all directions. Wet the concrete pad according to the grout manufacturer's directions. Mix a sufficient amount of grout. The grout must be an expanding grout rather than shrinking to provide
CLEARANCE FROM OBSTRUCTIONS AND ELECTRICAL CONTROLLER
EQUIPMENT
G.A.
a tighter bond. Follow the manufacturer's recommendations for setting, precautions, mixing, and grout placement, finishing and curing. The grout must be worked under all areas of the feet with no bubbles or voids. If the grout is settled with a slight outside slope, oil and water can run off of the base. Once the grout has cured, torque the anchor bolts as per HILTI instructions.
G.A.
G.A.
COMPRESSOR UNIT
CENTER LINE OF GAS COMPRESSION SYSTEM
6"
EL. TOP OF GRADE
# 6 @ 12" EACH WAY TOP & BOTTOM
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
COMPRESSOR UNIT FOUNDATION
CHAMFER EDGE
ISOLATION JOINT, 1" MINIMUM THICKNESS
CONCRETE
SLAB IN
6"
BUILDING
Figure 3-4. Interior Foundation Isolation
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Section 3 · Installation
Additional Information
Codes and Standards VilterTM 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 sufficient depth to dampen vibrations.
OVER ALL G.A. LENGTH + 4'-0"
10'-0" 5'-0"
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CENTER LINE GAS COMPRESSION SYSTEM
Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
1" (TYP.)
G.A. G.A.
(2) - # 4 CLOSED TIES
CENTER LINE
G.A. + 2" G.A. G.A. G.A. G.A.
(5) - # 6 VERT. WITH STD. 90° HOOK AT BOTTOM EACH FACE
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.)
Figure 3-6. Housekeeping Pad Dimension Detail - Top View
COMPRESSOR UNIT
LEVEL
HOUSEKEEPING PADS SPHERICAL WASHERS
Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers
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Section 3 · Installation
Figure 3-8. Concrete Pad Housekeeping Detail
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
Stop/Check Valve Installation1
The new design will apply only to the 2" thru 4" stop valves. Retrofitting a field installation will require replacing the bonnet assembly.
The bonnet must be installed with the spring towards the bottom, see Figure. The drill fixture is designed so that the hole for the spring will always be drilled on the opposite side from the cast-in Vilter name on the bonnet. From the outside of the valve, the casting numbers must always be towards the top of the valve.
For Stop/Check Valve Operation, refer to Section 4.
Correct Wrong
Correct Wrong
Verify the location of the Spring and note the VilterTM name.
Figure 3-9. Stop/Check Valve Orientation
1
For VSM-97, VSM-113 and VSM-127 this is just
a Stop Valve
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Section 3 · Installation
Piping
Refer to the ANSI/ASME B31.5 Code for Refrigeration Piping. All compressor oil supply and oil return piping has been completed at the factory. The necessary connections to be made to the screw compressor unit will vary depending on the type of oil cooling method purchased. Main line refrigerant suction and discharge connections are always necessary.
· Before installing piping, the compressor inlet and outlet ports should be inspected to ensure no dirt is present.
· Piping should be supported so that no piping loads are transmitted to the compressor casings.
· All piping should be inspected for cleanliness before installation. As each pipe is connected to the compressor, the coupling alignment should be checked to ensure that no alteration has taken place.
· If alignment has altered, the compressor is being strained and the piping supports must be adjusted.
· It is not sufficient merely to re-align the drive coupling, as this will not correct the cause of the strain.
· Care must be taken to avoid trapping the lines except for specific purposes. When traps are used, the horizontal dimensions should be as short as possible to avoid excessive oil trapping.
· Lines for ammonia systems must be of steel pipe with specially designed ammonia service fittings. Common pipe fittings must NEVER be used as they will not provide the same service. Steel pipe is generally used in large installations when joints are welded.
In making up joints for steel pipe, the following procedures should be followed:
· For threaded connections, all threads on the pipe and fitting should be carefully cleaned to remove all traces of grease or oil. Threads should then be wiped dry with a lintless cloth. Only thread filling compounds suitable for service should be used for making steel pipe joints. These compounds should be used sparingly, and on the pipe only. Do not put any on the first two threads to prevent any of the thread sealing compound from entering the piping system. Acetylene or arc welding is frequently used in making steel pipe joints, however, only a skilled welder should attempt this kind of work. Take care to see no foreign materials are left in the pipes and remove all burrs formed when cutting pipe.
· It is important to avoid short, rigid pipe lines that do not allow any degree of flexibility. This must be done to prevent vibration being transmitted through the pipe lines to the buildings. One method of providing the needed flexibility to absorb the vibration is to
provide long lines that are broken by 90° Ells in three directions.
· A second method would be to install flexible pipe couplings as close to the compressor unit as possible with connections run in two different directions, 90° apart. These flexible connections should be installed on both the high and low side lines of the compressor unit.
· Hangers and supports for coils and pipe lines should receive careful attention. During prolonged operation of the coils, they may become coated with ice and frost, adding extra weight to the coil The hangers must have ample strength and be securely anchored to withstand the vibration from the compressor and adequately support the pipe lines.
·
aFonrdCtOhe2ypwipiilnl rge,qtuhierepaipgersecaatenrhtahviceksnmesasllteor
diameters withstand
the higher pressures.
· Smaller Halocarbon and Hydroflourocarbon installations use copper pipes with solder type fittings where possible. The use of screw type fittings in Halocarbon systems should be held to an absolute minimum, as these refrigerants, due to their physical properties, will leak through screw type joints.
· When drawn copper tubing is used for Halocarbon lines, type "K" or "L" conforming to ASTM B88 should be used. Soft annealed copper tubing conforming to ASTM B280 can also be used for tube sizes not larger than 1-3/8" in outside diameter. These requirements are in accordance with the mechanical code for refrigeration ANSI B9.1-1971. The type of copper tubing to be used for a given pressure is dependent on the strength of the copper at the design temperature. Some local codes forbid the use of Type "L". Therefore, before installation, be sure to check local requirements. Never use type "M" as it does not have adequate wall thickness to withstand the operating pressures.
· For halocarbon piping, only wrought copper fittings should be used. Cast fittings as used for water service are porous and will allow the refrigerant to escape. Note this exception: In larger pipe sizes, wrought fittings are not available. However, specially tested cast fittings are available and these may be used with complete safety.
· When soldering copper tubing joints, only silver solder should be used for Refrigerant-22 service. Soft solder such as "50-50" should never be used, as its melting point is too low, lacks mechanical strength, and tends to break down chemically in the presence of moisture.
· Water supply and drain connections, and equipment using water, should be installed so all the water
3 12
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
may be drained from the system after the plant has been shut down in cold weather. These precautions will avoid costly damage to the equipment due to freezing.
This information is taken from ASHRAE 15-89 and ANSI/ ASME B31.5. The installing contractor should be thoroughly familiar with these codes, as well as any local codes.
CAUTION
Accumulated liquid in the suction header can damage the compressor if not drained. Always drain headers (suction and discharge headers) prior to start-ups. Failure to comply may result in damage to equipment.
Flange Loads
The ideal load applied to flanges 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 tolerated. Well supported external piping connected to the compressor will still result in some loads applying forces and moments in three axes to unit flanges.
The most important issue is the motor-compressor misalignment caused by external forces (F in lbf) and moments (M in ft-lbf) imposed by plant piping. In Figure 3-10 and Table 3-1, are the maximum allowable forces and moments that can be applied to compressor flanges when the compressor is mounted on an oil separator.
It must be noted that it is necessary to check for compressor shaft movement when the job is complete. In no case shall the attached piping be allowed to cause
Nozzle Dia. (in.)
4 6 8 10 12 14
Table 3-1. Maximum Allowable Flange Loads
Fz (lbf)
400 600 900 1200 1500 2000
Fy (lbf)
400 600 900 1200 1500 2000
Fx (ft-lbf)
400 600 900 1200 1500 2000
Mzz (ft-lbf)
300 500 1000 1200 1500 2000
Myy (ft-lbf)
300 500 1000 1200 1500 2000
Mxx (ft-lbf)
300 500 1000 1200 1500 2000
CUSTOMER SUPPORTS WHEN CHECK VALVE
IS MOUNTED HERE
5-6 PIPE DIAMETERS
CHECK VALVE
DISCHARGE
LINE HANGER
3-4 PIPE DIAMETERS
SUCTION LINE
CHECK VALVE
Y
Z
X
X Y
Z
CUSTOMER SUPPORT
CUSTOMER SUPPORTS WHEN CHECK VALVE IS MOUNTED HERE
5 PIPE DIAMETERS
5 PIPE DIAMETERS
5 PIPE DIAMETERS
HANGER
DISCHARGE LINE
3-4 PIPE DIAMETERS
CHECK VALVE
CUSTOMER SUPPORT Y
SUCTION LINE
Z
X
X Y
Z
CUSTOMER SUPPORT
Figure 3-10. Maximum Allowable Flange Loads
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
3 13
Section 3 · Installation
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 movement 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 or other local codes as applicable. See guidelines below, particularly with concern to minimize loads on check valves.
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 important that the piping be installed correctly to and from the compressor unit and remote air cooled oil cooler:
· Outlet must be on top, inlet on bottom.
· Vertical drops should be no higher than 8 to 10 feet.
· If there is no choice 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.
OUTLET ON TOP
INLET ON BOTTOM
Recommended location of drain connections as required.
3 14
Figure 3-11. Recommended Remote Air Cooled Oil Cooler Piping
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
Electrical Connections
Single screw compressor units are shipped with all package mounted controls wired. The standard control power is 115 volts 60 Hertz, single phase. If a 115 volt supply is not available, a control transformer may be required. The power source must be connected to the control panel according to the electrical diagrams.
The units are shipped without the compressor motor starter. Field wiring is required between the field mounted starters and package mounted motors, see Field Wiring Instructions.
Additional control wiring in the field is also required. Dry contacts are provided in the control panel for starting the screw compressor motor. These contacts are to be wired in series with the starter coils. A current transformer is supplied along with the compressor unit, and is located in the motor junction box. This transformer is to be installed around one phase of the compressor motor starter. A normally open auxiliary contact from the compressor motor starter is also required.
Terminal locations for this wiring can be found on the wiring diagram supplied with this unit. Additional aspects of the electrical operation of the single screw units are covered in the start up and operation section of this manual.
Field Wiring Instructions
NOTE This procedure defines steps required to wire Vission 20/20 micro-controller for the following items: Compressor Motor Starter Auxiliary Contact, High Level Shutdown, Oil Separator Heater(s), Oil Pump
Start and Compressor Starter.
Follow supplied wiring diagram for detailed wiring.
Refer to Figure 3-12
1. Control power of 115 VAC 50/60 HZ must be wired to left side of terminal blocks inside the Vission 20/20 cabinet. Line power (1B) shall be connected to 15-amp circuit breaker, CB1. Neutral (1N) is connected to any N terminal blocks. Number of line power feeds required to panel is dependent upon number supplied on compressor, see Figure 3-12.
2. An auxiliary contact from compressor motor starter is required. Connect isolated contact to terminal blocks 1 and 31.
3. A dry contact from control relay CR11 must be wired to compressor motor starter coil. This dry contact is wired to terminal blocks according to supplied drawing. Control power for this coil should come from a source, which will be de-energized with compressor disconnect.
4. A dry contact from control relay CR12 must be wired to oil pump motor starter coil. This dry contact is wired to two terminal blocks according to supplied drawing. Control power for this coil should come from a source, which will be de-energized with compressor disconnect.
5. An auxiliary safety cutout is available to shut down compressor package. A dry contact must be supplied and wired to terminal blocks 1 and 32. The jumper installed on terminal blocks must be removed to use this cutout. If contact is closed, it will allow compressor to run. If contact opens at any time, compressor will shut down.
6. Indication of compressor shutdown status is also available. There is an output on terminal blocks 18 and N where a relay coil can be wired. For output, an energized state represents a "safe" condition. A deenergized state indicates a loss of voltage to relay coil or a "failure" has occurred.
7. Line power for oil separator heaters are required to be wired from the starter panel, see Figure 3-13.
8. Units with V-PLUSTM oil cooling, L1 must connected to a fuse in V-PLUS panel, and L2 must be connected to a neutral terminal block, see Figure 3-14.
NOTE There is a dot on one side of the current transformer.
This dot must face away from the motor.
9. Current transformer supplied in compressor motor conduit box should be checked to ensure that motor leads of one leg are pulled through the transformer. Typically, a wye delta started motor should have leads 1 and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as different motors and starting methods will require different leads to be used.
NOTE
For Compressor unit using PLC micro-controller,
please refer to the Single Screw Compressor PLC
Operation Manual (35391CM) for details.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
3 15
3 16
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
CONTROL POWER DISCONNECT AND BRANCH CIRCUIT PROTECTION TO BE SIZED PER THE NATIONAL
ELECTRIC CODE. INCOMING POWER SUPPLIED FROM REMOTE
CUSTOMER SUPPLIED UL LISTED FUSED DISCONNECT OR BREAKER
1A
N
GND
FLA = X.X AMPS
115VAC / 60HZ
FROM LINE 31
1
2
CB 1 15 AMPS
1
3
1
SW 1
E-STOP
1B
GND
32
DOOR
2
N
GND LUG
33
GND
N
1
34
AUX MS1
31
4
EMI FILTER
LINE LOAD
1C
2
HL
1
35
SHUTDOWN AUX
32
OUTPUT
5
INPUT
RD35-A
+5VDC +12VDC 5/12 COM
DC POWER SUPPLIES
1
36
LOW OIL LEVEL LS1
33
TO CPU BASEBOARD
OUTPUT
6
INPUT
RS50-24
+24VDC -24 COM
+24VDC
TO DC TERMINAL -24 COM SUBPLATE
1
37
LOW OIL LEVEL LS2
34
HP1
7
3&4
1H THERMOSTAT
150 WATT
HEATER
PANEL HEATER OPTION
38
5
ON 40 / OFF 60
8
OUTPUTS
39
9
1
11 TO STARTER
N COMPRESSOR STARTER
40
DIGITAL OUTPUT: BOARD #1 PLUG X1
10
2
12 TO STARTER
N OIL PUMP STARTER
1
41
CAP. CTRL SELECT
35
11
3
12
4
13
1
H
13
BLUE
1
REMOTE START/STOP
A1 *SEE NOTE 10
BLACK
N
CAPACITY INCREASE/DECREASE
42
36
14
ACTUATOR
1
43
REM. CAP. INCREASE
37
BROWN
1
REM. CAP. DECREASE
44
38
14
OUTPUTS
6
15
1
H
45
OUTPUTS
46
1
41
DIGITAL INPUT/OUTPUT: BOARD #4 PLUG 1
DIGITAL OUTPUT: BOARD #1 PLUG X2
16
5
15
BLUE
A2 *SEE NOTE 10
BLACK
N
VOLUME INCREASE/DECREASE
47
2
42
17
6
16
ACTUATOR 48
3
43
BROWN
18
7
17
TO STARTER
N OIL SEPARATOR HEATER START
49
4
44
19
8
18
TO CUSTOMER CONTROL
IF REQUIRED
N
TRIP ANNUNCIATION
(OUTPUT DE-ENERGIZES ON
50
1
H
A TRIP CONDITION)
INTERNAL PANEL WIRING (FACTORY) VILTER SHOP WIRING FIELD WIRING (BY OTHERS)
FROM LINE 31
63
INPUTS
1 2 3 4 N
DIGITAL INPUT: BOARD #3 PLUG X1
64
COMPRESSOR MOTOR
STARTER AUXILIARY
65
CONTACT
HIGH LEVEL SHUTDOWN
66
OIL LEVEL FLOAT SWITCH#1
/ LOW LEVEL TRIP (COOL
67
COMPRESSION)
OIL LEVEL FLOAT SWITCH#2
/ OIL FILL LEVEL (COOL
68
COMPRESSION)
N
69
INPUTS
70
N
N
71
DIGITAL INPUT: BOARD #3 PLUG X2
5
CAPACITY CONTROL SELECT 1/2
72
6
REMOTE START/STOP
73
7
REMOTE CAPACITY INCREASE
74
8
REMOTE CAPAPCITY DECREASE
75
76
CDR 1
N CONDENSER STEP #1
77
CDR
N CONDENSER
2
STEP #2
78
CDR
N CONDENSER
3
STEP #3
79
CDR
N CONDENSER
4
STEP #4
80
81
Figure 3-12. Example - Vission 20/20 Wiring Diagram
Section 3 · Installation
EQUIPMENT GROUND
GND
T1
OIL PUMP MOTOR FEED
T2
480 VAC
T3
7
52
OIL SEPARATOR HEATER
FEED 120VAC
N
54
OIL SEPARATOR HEATER
FEED 120VAC
N
56
OIL SEPARATOR HEATER
FEED 120VAC
N
JUNCTION BOX (COMPRESSOR SKID) GND
1T1 1T2 1T3
GND
52 N
54 N
56 N
INTERNAL PANEL WIRING (FACTORY) VILTER SHOP WIRING FIELD WIRING (BY OTHERS)
OIL PUMP MOTOR
OIL PUMP MOTOR 480 VAC
OIL SEPARATOR
HEATER
OIL SEPARATOR HEATER 120 VAC 1000 WATT = 8.7 AMPS 750 WATT = 6.5 AMPS
OIL SEPARATOR
HEATER
OIL SEPARATOR HEATER 120 VAC 1000 WATT = 8.7 AMPS 750 WATT = 6.5 AMPS
OIL SEPARATOR
HEATER
OIL SEPARATOR HEATER 120 VAC 1000 WATT = 8.7 AMPS 750 WATT = 6.5 AMPS
Figure 3-13. Example - Interconnect Wiring Diagram
8
Figure 3-14. Example - V-PLUS Wiring Diagram
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
3 17
Section 3 · Installation
Testing Refrigeration System For Leaks
CAUTION
Do not hydro test compressor 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 relief valve having a higher pressure setting, all system
components must be evaluated for acceptability.
Vilter equipment is tested for leaks at the factory. One the most important steps in putting a refrigeration system into operation is field testing for leaks. This must be done to assure a tight system that will operate without any appreciable loss of refrigerant. To test for leaks, the system pressure must be built up. Test pressures for various refrigerants are listed in ANSI B9.1-1971 code brochure entitle "Safety Code for Mechanical Refrigeration". These pressures will usually suffice, however, it is advisable to check local codes as they may differ. Before testing may proceed, several things must be done.
First, if test pressures exceed the settings of the system, relief valves or safety devices, they must be removed and the connection plugged during the test. Secondly, all valves should be opened except those leading to the atmosphere. Then, open all solenoids and pressure regulators by the manual lifting stems. All bypass arrangements must also be opened. Because of differences in characteristics of the various refrigerants, two different testing methods are necessary.
Ammonia Systems
Dry nitrogen may be used to raise the pressure in an ammonia system to the proper level for the test. The gas may be put into the system through the charging valve or any other suitable opening. Adjust the pressure regulator on the bottle to prevent over-pressurization. Do not exceed the pressure rating on the vessel with the lowest pressure rating.
Carbon Dioxide should NOT be used as a testing gas in a
system where ammonia is already dissolved in any mois-
ture remaining. This will cause ammonium carbonate to
precipitate precipitate
wmhaeynctahuesCeOth2 ies
added. If machine
heavy enough, this to freeze and clog
the strainer.
A mixture of four parts water to one part liquid soap,
with a few drops of glycerin added, makes a good solution. Apply this mixture with a one inch round brush at all flanges, threaded joints, and welds. Repair all visible leaks. If possible, leave the pressure on over night. A small pressure drop of 5 lbs. Over this period indicates a very tight system.
Remember to note the ambient temperature, as a change in temperature will cause a change in pressure.
After the system is thoroughly tested, open all valves on the lowest part of the system so the gas will float away from the compressor. This prevents any dirt or foreign particles from entering the compressor and contaminating the working parts. The oil should then be charged into the compressor.
Charge a small amount of ammonia into the system and pressurize the system to its respective design pressure. Pass a lit sulfur stick around all joints and connections. Any leaks will be indicated by a heavy cloud of smoke. If any leaks are observed during this test, they must be repaired and rechecked before the system can be considered tight and ready for evacuation.
Halocarbon Refrigerant Systems
"Oil der
pumped" dry of preference
mnitaryogbeenu,soerdatnohyradirsoeutshCeOp2riensstuhriseotro-
the proper level for testing.
When the proper pressure is attained, test for leaks with the soap mixture previously described. After all leaks are found and marked, relieve the system pressure and repair the leaks. Never attempt to repair soldered or welded joints while the system is under pressure. Soldered joints should be opened and re soldered.
Do not simply add more solder to the leaking joint. After all the joints have been repaired and the system is considered "tight" the system may be tested with refrigerant.
Attach a drum of the refrigerant to be used in the system and allow the gas to enter until a pressure of 5 psig is reached.
Remove the refrigerant drum and bring the pressure
to the recommended test level with oil pumped dry ni-
lteroakgse,nuosirnCgOa2.haTlhideen
check torch
the entire system or electronic leak
again for detector.
Be sure to check all flanged, welded, screwed and sol-
dered joints, all gasketed joints, and all parting lines on
castings. If any leaks are found, they must be repaired
and rechecked before the system can be considered
tight again, remembering that no repair should be made
to welded or soldered joins while the system is under
pressure.
3 18
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
CO2 Systems
A CO2 system will tend to be more prone to leaks due to the higher working pressures and the smaller molecule size, and therefore its leak detection should become a regular maintenance procedure. For a charge size of above 661 lbs, for example, the recommendation would be to perform the leak detection procedure about 4 times a year.
An oil stain will be a visual indicator of a CO2 leak, but there are also leak detection sprays available in the market (such as Weicon´s or Bulleye´s), infrared hand held leak detectors (such as D-TEK CO2), and ultrasonic leak detectors of several brands2.
Evacuating The System
A refrigeration system operates best when only refrigerant is present. Steps must be taken to remove all air, water, vapor, and all other non-condensables from the system before charging it with refrigerant. A combination of moisture and refrigerant, along with any oxygen in the system, can form acids or other corrosive compounds that corrode internal parts of the system.
To properly evacuate the system, and to remove all noncondensables, air and water vapor, use a high vacuum pump capable of attaining a blanked off pressure of 50 microns or less. Attach this pump to the system and allow it to operate until system pressure is reduced somewhere below 1000 microns. Evacuation should not be done unless the room temperature is 60°F or higher.
Attach vacuum gauge(s), reading in the 20 to 20,000 micron gauge range, to the refrigerant system. These gauge(s) should be used in conjunction with the high vacuum pump. The reading from the gauge(s) indicates when the system has reached the low absolute pressure required for complete system evacuation.
Connect the high vacuum pump into the refrigeration system by using the manufacturer's instructions. Connect the pump both to the high side and low side of the system, to insure system evacuation. Attach the vacuum gauge to the system in accordance with the manufacturer's instructions.
A single evacuation of the system does not satisfactorily remove all of the non-condensable, air and water vapor. To do a complete job, a triple evacuation is recommended.
When the pump is first turned on, bring system pressure to as low a vacuum level as possible, and continue operation for 5 to 6 hours.
Stop the pump and isolate the system. Allow the unit to stand at this vacuum for another 5 to 6 hours. After this time, break, the vacuum and bring the system pressure up to 0 psig with dry nitrogen.
To begin the second evacuation, allow the pump to operate and reduce the pressure again to within 50 to 1000 microns. After this reading is reached, allow the pump to operate 2 or 3 hours. Stop the pump and let the system stand with this vacuum. Again using dry nitrogen, raise the system pressure to zero.
For the third evacuation, follow the previous procedure with the pump operating until system pressure is reduced below the 1000 micron level. Run the pump an additional 6 hours and hold the system for approximately 12 hours at low pressure. After this, again break the vacuum with dry nitrogen and allow the pressure in the system to rise slightly above zero pounds (psig). Install new drier cartridges and moisture indicators. Charge the system once more below the 1000 micron level and use the refrigerant designed for the system.
When properly evacuating the system as outlined above, the system is dry, oxygen-free and free of noncondensables. The piping should not be insulated before the evacuation process is started. If moisture is in the system before evacuating, it condenses in low places and freezes. If this happens, it can be removed by gently heating the trap farthest away from the vacuum pump. This causes the ice to melt and water to boil. Water vapor collects in the next trap towards the vacuum pump. This process should be repeated until all pockets of water have been boiled off, and the vacuum pump has had a chance to remove all the water vapor from the system.
2
Information taken from Commercial CO2
Refrigeration Systems Guide for Subcritical and
Transcritical CO2 Applications, by Emerson.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
3 19
Section 3 · Installation
Notice on 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 specified or supplied by Vilter will void the compressor warranty.
Due to the need for adequate lubrication, Vilter recommends only the use of Vilter lubricants, designed specifically for Vilter compressors. Use of oil not specified or supplied by Vilter will void the compressor warranty. Please contact your local Vilter representative or the Home Office for further information.
Unit Initial 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.
NOTICE
Do not put oil under vacuum. Use an oil pump to charge oil.
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 specific 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 overcome suction pressure (VPN A40849A).
Normal Operating Level
Maximum NON-Operating Level
3 20
Minimum Operating Level
Figure 3-15. Oil Operating Levels
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
Unit Initial Oil Charging
(Reference Figure 3-17) 10. At initial start up, compressor unit must be off and
depressurized prior to initial oil charging. 11. Using a properly selected oil pump, connect oil
pump to oil separator drain valve (10) (for oil separator drain valve location, see Figure 3-16). 12. Open oil separator drain valve (10) and fill oil separator (1) to Maximum NON-Operating Level. 13. Once Maximum NON-Operating Level has been reached, shut off oil pump, close oil separator drain valve (10) and remove oil pump. 14. If equipped with remote oil cooler, refer to Priming Compressor Units Equipped with Remote Oil Cooler procedure (see Appendix G).
Priming Oil Lines and Compressor
Continue with the following steps to prime the oil lines and compressor:
15. Make sure valves on oil circuit are in the open position. In this case, make sure valves (2), (3), (5), (6) and (7) are in the open position.
16. Energize compressor unit. Vission 20/20 will energize oil heaters.
17. Run oil pump (4) for 15 seconds only. 18. Wait minimum of 30 minutes to allow oil to drain
from compressor (8). 19. If compressor unit is not being started right away,
repeat steps 6 to 9 prior to starting.
R717 VAPOR TO ATMOSPHERE
1 10
Figure 3-16. Oil Drain Valve
Oil Drain Valve (Oil Separator)
250#
PI 002 PT
002 BLEED
DISCHARGE CHECK VALVE DISCHARGE STOP VALVE
HIGH PRESSURE R717 VAPOR OUTLET
100 PSID
V100
LG 001 LG
002
OIL SEPARATOR
DRAIN
TW 750W QE
001
TW 750W QE
002
TW 750W QE
003
TW
TE 005
MW
OPTIONAL
(STANDARD FOR BOOSTER &
SWING COMPRESSORS ONLY)
MOTOR AND OIL PUMP
4
COALESCING OIL RETURN LINE FILTER
D101
PT
PI
001 001
LOW PRESSURE R717 VAPOR INLET
BLEED
SUCTION CHECK VALVE
TE TW 004
SUCTION
FG
STOP VALVE
001
TE TW 001
9
OIL CHARGE
8
2 3
PT 003
PI
003
BLEED
7
P100
5
TE TW 002
DRAIN
T
D100
MOTOR
D102 CAPACITY
C100
COMPRESSOR
D103 VOLUME
PT
6
004
PI
BLEED
004
Figure 3-17. Priming Oil Lines and Compressor
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
R717 LIQUID/VAPOR OUTLET
E100
R717 LIQUID INLET
3 21
Section 3 · Installation
System Refrigerant Charging
After the system is leak-free and evacuation has been completed, the entire operation of the refrigeration system should be inspected before charging.
A. Low Side Equipment
1. Fans on air handling equipment running. 2. Pumps on water cooling equipment running. 3. Proper location and attachment of thermostatic ex-
pansion valve bulb to suction line. 4. Correct fan and pump rotation. 5. Evaporator pressure regulators and solenoid valves
open. 6. Water pumps and motors correctly aligned. 7. Belt drives correctly aligned and tensioned. 8. Proper voltage to motors.
B. Compressors
1. Proper oil level. 2. Voltage agrees with motor characteristics. 3. Properly sized motor fuses and heaters. 4. Direct drivers aligned and couplings tight. 5. All suction and discharge valves open. 6. All transducers and RTDs calibrated and reading
correctly.
C. Condensers
1. Water available at water cooled condensers and supply line valve open.
2. Water in receiver of evaporative condenser and makeup water available.
3. Correct rotation of pump and fan motors. 4. Belt drives aligned and tensioned correctly. 5. Pump, fans and motors lubricated.
D. Controls
Controls should be at the initial set points. See microprocessor manual for further information.
Initial High Side Charging
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. Failure to comply may
result in serious injury or death.
WARNING
Avoid skin contact with any liquid refrigerant or oil. Wear rubber gloves and a face shield when working with liquid refrigerant or oil. Failure to comply may
result in serious injury or death.
CAUTION
Ensure compressor unit has been charged with the correct amount of oil prior to initial refrigerant charging. Failure to comply may result in damage to
equipment.
CAUTION
Do not apply flame or steam directly to drum, as this can produce dangerously high pressures inside drum. Failure to comply may result in damage to equipment.
There are two methods of charging refrigerant into the system, through the "high side" or through the "low side". High side charging is usually used for initial charging as filling of the system is much faster. Low side charging is usually reserved for adding only small amounts of refrigerant after the system is in operation.
High side charging of refrigerant into the system is accomplished as follows:
1. Connect a full drum of refrigerant to the liquid charging valve. This valve is generally located in the liquid line immediately after the king or liquid line valve. Purge the air from the charging line.
2. Close the liquid line or king valve, if it is not already closed. Open the "Liquid" charging valve slowly to allow refrigerant to enter the system. The vacuum in the system will draw in the refrigerant.
3. It is important that during this operation air handling units be running and water is circulating through the chillers. The low pressures on the system can cause the refrigerant to boil at low temperature and possibly freeze the water if it is not kept circulating. Water freezing in a chiller can rupture the tubes and cause extensive damage to the system. It would be desirable to charge the initial amount of refrigerant without water in the shell and tube equipment to eliminate the possibility of freeze up.
3 22
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 3 · Installation
4. After some refrigerant has entered the system, the compressor unit starting procedure may be followed, see Starting procedure in Section 4.
5. Continue charging refrigerant into the system until the proper operating requirements are satisfied. Then, close the liquid charging connection and open the liquid line valve allowing the system to operate normally. To check that enough refrigerant has been added, the liquid sight glass should show no bubbles, and there will be a liquid seal in the receiver. If these two conditions are not satisfied, additional refrigerant must be added.
6. When sufficient refrigerant has been charged into the system, close the charging and drum valves. Then remove the drum from the system.
7. During the charging period, observe the gauge carefully to insure no operating difficulties. Watch head pressures closely to make sure the condensers are functioning properly.
8. Since it is usually necessary to use several drums when charging a system, follow the procedures in steps 1 and 2 when attaching a new drum. After charging, the refrigerant drums should be kept nearby for several days as it is sometimes necessary to add more refrigerant as the system settles down.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
Notice on 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 specified or supplied by Vilter will void the compressor warranty.
Due to the need for adequate lubrication, Vilter recommends only the use of Vilter lubricants, designed specifically for Vilter compressors. Use of oil not specified or supplied by Vilter will void the compressor warranty.
Please contact your local Vilter representative or the Home Office for further information.
Operation
All operation (set-point adjustments, calibrations, monitoring) of the compressor unit is done through the micro-processor. For additional procedural information, refer to micro-processor manual (35391SC for Vission 20/20 Operating Manual or 35391CM for Compact Logix PLC Software Manual).
WARNING
Software programming credentials shall only be made available by the supplier. The user will only have access to operational features established by the supplier. Failure to comply may result in serious injury
or death.
Oil Inspection
WARNING
Avoid skin contact with any liquid refrigerant or oil. Wear rubber gloves and a face shield when working with liquid refrigerant or oil. Failure to comply may
result in serious injury or death.
WARNING
Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply
may result in serious injury or death.
Inspect oil level through sight glasses on the oil separator, see Figure 4-1. Oil Operating Levels. Drain or fill oil as required. For oil draining and filling procedure, see Oil Charging and Oil Draining in Section 5.
Normal Operating Level
Maximum NON-Operating Level
Minimum Operating Level
Figure 4-1. Oil Operating Levels
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 4 · Operation
Dual Oil Filters
On compressor units equipped with dual oil filters, only one filter should be in operation at a time.
NOTE During operation, both oil filter outlet shut-off valves should be open. This will help minimize the sudden loss of oil pressure when switching between oil filters for
servicing.
Refer to Oil Filter Replacement in Section 5 for further details.
Starting, Stopping and Restarting The Compressor
For additional control information, refer to micro-processor manual ( 35391SC for Vission20/20 Operating Manual or 35391CM for Compact Logix PLC Software Manual).
WARNING
Software programming credentials shall only be made available by the supplier. The user will only have access to operational features established by the supplier. Failure to comply may result in serious injury
or death.
Control System
Calibration
Equipped for automatic operation, the screw compressor unit has safety controls to protect it from irregular operating conditions, an automatic starting and stopping sequence, capacity and volume ratio control systems.
Check all pressure controls with a remote pressure source, to assure that all safety and operating control limits 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 transducer 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.
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 "ManualAuto" button is pressed, the oil pump will start. When sufficient 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.
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 calibration, refer to maintenance/service interval table in Section 5.
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 compressor 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 respective 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, restarting from this condition is accomplished by pushing the reset button to ensure positive operator control. If the auto start on power failure option is selected, 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.
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Section 4 · Operation
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.
Emergency Shutdown
Emergency shutdown is initiated by the following:
1. A shutdown or trip condition of a process variable while the system is in operation. If a process variable reaches a high-high or low-low shutdown setpoint, the compressor unit will automatically stop. A shutdown alarm is also generated on the control panel HMI screen annunciating the specific process variable trip condition.
2. The Local Emergency Shutdown push button located on the side of the control panel enclosure. When the Local Emergency Shutdown push button is activated, the entire unit powers down. Also, the compressor capacity and volume slide valve will stay in their last position until the unit is powered up. Once recovery has been accomplished and the unit is to be re-powered, the Local Emergency Shutdown push button must be pulled out to power up the unit and controls.
Slide Valve Actuator Operation
The slide valve actuator is a gear-motor with a position sensor. The motor is powered in the forward and reverse directions from the main computer in the control panel. The position sensor tells the main computer the position of the slide valve. The main computer uses the position and process information to decide where to move the slide valve next.
The position sensors works by optically counting motor turns. On the shaft of the motor is a small aluminum "photochopper". It has a 180 degree fence that passes through the slots of two slotted optocouplers. The optocouplers have an infrared light emitting diode (LED) on one side of the slot and a phototransistor on the other. The phototransistor behaves as a light controlled switch. When the photochopper fence is blocking the slot, light from the LED is prevented from reaching the phototransistor and the switch is open. When photochopper fence is not blocking the slot, the switch is closed.
As the motor turns, the photochopper fence alternately blocks and opens the optocoupler slots, generating a sequence that the position sensor microcontroller can use to determine motor position by counting. Because the motor is connected to the slide valve by gears, knowing the motor position means knowing the slide valve position.
During calibration, the position sensor records the high and low count of motor turns. The operator tells the position sensor when the actuator is at the high or low position with the push button. Refer to the calibration instructions for the detailed calibration procedure.
The position sensor can get "lost" if the motor is moved while the position sensor is not powered. To prevent this, the motor can only be moved electrically while the position sensor is powered. When the position sensor loses power, power is cut to the motor. A capacitor stores enough energy to keep the position sensor circuitry alive long enough for the motor to come to a complete stop and then save the motor position to nonvolatile EEPROM memory. When power is restored, the saved motor position is read from EEPROM memory and the actuators resumes normal function
This scheme is not foolproof. If the motor is moved manually while the power is off or the motor brake has failed, allowing the motor to free wheel for too long after the position sensor looses power, the actuator will become lost.
A brake failure can sometimes be detected by the position sensor. If the motor never stops turning after a power loss, the position sensor detects this, knows it will be lost, and goes immediately into calibrate mode when power is restored.
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Section 4 · Operation
Calibrate Slide Valve Actuators (For Units Using Vission20/20TM)1
Slide valve actuators must be installed prior to calibration. Refer to Slide Valve Actuator Installation procedure. 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 first time.
· A new actuator motor has been installed. · There is an error code flashing on the actuator's
circuit board - an attempt to recalibrate should be made.
· The range of travel is not correct and the command shaft travel is physically correct.
· The compressor is pulling high amperage, the calibration of the volume slide should be checked.
· An actuator does not unload below 5%, or an actuator that doesn't move.
· Something is not working properly such as the actuators, RTDs or transducers.
To calibrate optical actuators, continue with the following steps:
NOTE If the compressor unit is starting up for the first time or a new actuator motor has been installed, leave the power cable and position transmitter cable
disconnected until step 6.
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.
Actuator Assembly
View Rotate 180°
Actuator Plastic Cover
Red LED
Blue Calibrate Button
Figure 4-2. Actuator Assembly
1
Does not apply to compressors that operate
without slides (VSM-97, VSM-113, VSM-127).
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
3. Carefully lift actuator cover from actuator assembly and tilt towards connectors. Raise cover high enough to be able to press the blue calibration button and be able to see the red LED on the top of assembly.
4. Logging on into the Vission20/20TM with high-level access will prompt the Calibration buttons to appear, see Figure 4-3.
Calibration Buttons
Figure 4-3. Slide Valve Calibration Screen (Vission 20/20)
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Section 4 · Operation
5. On the main screen, press "Menu" then press the "Slide Calibration" button to enter the slide calibration screen, see Figure 4-4.
6. If the compressor unit is starting for the first time or a new actuator was installed, connect connectors of power cable and position transmitter cable to new actuator.
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Figure 4-4. Menu Screen and Slide Calibration Button (Vission 20/20)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
NOTE If the "+" (increase) and "-" (decrease) buttons do not
correspond to increase or decrease shaft rotation, swap the blue and brown wires of the "power cable" in the control panel. This will reverse the rotation of the
actuator/command shaft, see Figure 4-5.
Capacity actuator wires are connected on terminals 13 & 14. Volume actuator wires are connected on
terminals 15 & 16.
7. Press "+" or "-" 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 0 V when the actuator is running and 5 V when it is still. Thus, as stated earlier, the actuator voltage will fluctuate during calibration. After the actuator has been calibrated, 0 V output will correspond to the minimum
position and 5 V to the maximum position.
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 flashing rapidly.
CAUTION
DO NOT CONTINUE TO ENERGIZE THE ACTUATOR MOTOR AFTER THE SLIDE HAS REACHED THE MECHANICAL STOP. Doing so may cause mechanical damage to the motor or shear the motor shaft key. When the slide has reached the mechanical stop position, press the button in the center 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 the actuator output voltage. These values, (the % volume and the % capacity) displayed in the window are meaningless until
calibration has been completed.
9. Use the "-" button on the Control panel to drive the slide valve to its minimum "mechanical stop" position. Release the "-" button when the slowing of the motor rotation and a winding sound from the actuator motor is noted.
Capacity Actuator Wire connections (13, 14)
Volume Actuator Wire connections (15, 16)
Figure 4-5. Wire Connections for Capacity and Volume Actuators
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 4 · Operation
Compressor Model
Table 4-1. Command Shaft Rotation Specifications*
Command Shaft Rotation
Capacity
Volume
No. of Turns/Rotation Capacity
Angle/Slide Travel Volume
INC DEC INC DEC Turns Degrees Travel Turns Degrees Travel
VSM 71 VSM 91 VSM 101
VSM 151
VSM 181
CW CCW CW CCW 0.80
VSM 201
VSM 301
VSM 361
VSM 401
VSM 501
VSM 601 CCW CW CCW CW 0.91
VSM 701
VSS 451 VSS 601
CW CCW CW CCW 0.91
VSS 751 CCW CW CCW CW 1.09
VSS 901
VSS 1051
VSS 1201 CCW CW CCW CW 1.22
VSS 1301
VSSC 1501 CCW CW CCW CW 1.36
VSS 1551 CCW CW CCW CW 1.48
VSS 1801 CCW CW CCW CW 1.36
VSS 1851 CCW CW CCW CW 1.48
VSS 2101
VSS 2401
VSS 2601 CCW CW CCW CW 1.80
VSS 2801
VSS 3001
288 3.141" 0.45
328 3.568" 0.52 328 3.568" 0.52 392 4.283" 0.63 439 4.777" 0.74 490 5.325" 0.82 533 5.823" 0.87 490 5.325" 0.82 533 5.823" 0.87
648 7.072" 1.36
162 1.767"
187 2.045" 187 2.045" 227 2.473" 266 2.889" 295 3.200" 313 3.433" 295 3.200" 313 3.433"
490 5.341"
*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.
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Section 4 · Operation
10. Press and hold down on the photo-chopper shaft to disengage the brake slowly, releasing tension from the motor mount, see Figure 4-6. Use the "+" 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.
11. Quickly press and release the blue button on the actuator again. The red LED will now flash at a slower rate, indication that the minimum slide valve position (zero position) has been set.
12. Use the "+" button on the Control panel to drive the slide to its maximum "mechanical stop" position. Release the "+" button when the slowing of the motor rotation and a winding sound from the actuator motor is noted.
NOTE If the photo-chopper spins faster than 4800 rpm, the actuator will go into an over speed fault and
recalibration will be required.
13. Press and hold down on the photo-chopper shaft to disengage the brake slowly, releasing tension from the motor mount. Use the "-" button to pulse the actuator to where the slide is just off of its mechanical stop and there is no tension on the motor shaft.
NOTE After the blue button is pressed for the third time, an mV reading will be displayed in the Current field. Make sure the mV value is at least 150 to 200 mV higher than
the max setpoint on the screen.
14. Quickly press and release the blue button on the actuator one more time. The red LED will stop flashing. The actuator is now calibrated and knows the minimum and maximum positions of the slide valve it controls.
Now the Capacity Channel is automatically calibrated based on the calibration settings made to the actuator.
CAUTION
Do not over tighten screws. Failure to comply may result in damage to equipment.
15. 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 properly, gently tighten the four #10 screws.
16. Repeat procedure to calibrate other slide valve actuator.
Figure 4-6. Photo-chopper
Press down on Photo-chopper to release tension from motor mount.
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Section 4 · Operation
Calibrate Slide Valve Actuators (For Units Using Compact Logix PLC)
Slide valve actuators must be installed prior to calibration. Refer to Slide Valve Actuator Installation procedure. 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 first time.
· A new actuator motor has been installed. · There is an error code flashing on the actuator's
circuit board - an attempt to recalibrate should be made.
· The range of travel is not correct and the command shaft travel is physically correct.
· The compressor is pulling high amperage, the calibration of the volume slide should be checked.
· An actuator does not unload below 5%, or an actuator that doesn't move.
· Something is not working properly such as the actuators, RTDs or transducers.
To calibrate optical actuators, continue with the following steps:
NOTE If the compressor unit is starting up for the first time or a new actuator motor has been installed, leave the power cable and position transmitter cable
disconnected until step 7.
1. Stop compressor unit and allow to cool.
2. Remove screws securing actuator cover to actuator assembly. As a reference see Figure 4-7.
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.
View Rotate 180°
Actuator Assembly
Actuator Plastic Cover
Red LED
4 10
Blue Calibrate Button
Figure 4-7. Actuator Assembly
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
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 button and be able to see the red LED on the top of assembly.
4. On the main screen of the PLC, press "Menu", then "Instrument Calibration" button to enter the instrument calibration overview screen, then press "Calibrate Slides" button to enter the slide calibration screen, see Figure 4-8.
5. Logging on with high-level access will prompt the "Enter Slide Calibration Mode" button to appear.
6. Press "Enter Slide Calibration Mode" button to initiate calibration mode. The Slide Calibration button turns green and Set Max and Set Min buttons appear, see Figure 4-9.
7. If the compressor unit is starting for the first time or a new actuator was installed, connect connectors of power cable and position transmitter cable to new actuator.
NOTE If the UP (increase) and DOWN (decrease) buttons do
not correspond to increase (INC) or decrease (DEC) shaft rotation, swap the blue and brown wires of the "power cable" in the control panel. This will reverse the
rotation of the actuator/command shaft.
8. Press UP or DOWN 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 fluctuate during calibration. After the actuator has been calibrated, 0V output will correspond to the minimum
position and 5V to the maximum position.
9. Quickly press and release the blue push button on the actuator one time. This places the actuator in calibration mode. The red LED will begin flashing rapidly.
CAUTION
DO NOT CONTINUE TO ENERGIZE THE ACTUATOR MOTOR AFTER THE SLIDE HAS REACHED THE MECHANICAL STOP. Doing so may cause mechanical damage to the motor or shear the motor shaft key. When the slide has reached the mechanical stop position, press the button in the center 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.
10. Use the DOWN button on the Control panel to drive the slide valve to its minimum "mechanical stop" position. Release the DOWN button when the slowing of the motor rotation and a winding sound from the actuator motor is noted.
11. Press down on the photo-chopper shaft to disengage the brake, releasing tension from the motor mount, see Figure 4-10. Use the UP 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.
12. Quickly press and release the blue button on the actuator again. The red LED will now flash at a slower rate, indication that the minimum slide valve position (zero position) has been set.
13. Use the UP button on the Control panel to drive the slide to its maximum "mechanical stop" position. Release the UP button when the slowing of the motor rotation and a winding sound from the actuator motor is noted.
14. Press down on the photo-chopper shaft to disengage the brake, releasing tension from the motor mount. Use the DOWN button to pulse the actuator to where the slide is just off of its mechanical stop and there is no tension on the motor shaft.
15. Quickly press and release the blue button on the actuator one more time. The red LED will stop flashing. The actuator is now calibrated and knows the minimum and maximum positions of the slide valve it controls. Now the capacity or volume channel of the PLC can be calibrated.
16. Use the DOWN button to move the actuator towards its minimum position while watching the mV readout on the Control Panel screen. Discontinue pressing the DOWN button when the mV reading the "Current" window above the "Set Min" button is approximately 500 mV.
17. Now use the DOWN or UP 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 capacity or volume slide valve window to tell the controller that this is the minimum mV position. Note: The value in the "Current Cap" or "Current Vol" window has no meaning right now.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 4 · Operation
Figure 4-8. Overview, Main Menu and Instrument Calibration Screens (Compact Logix PLC)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
Figure 4-9. Slide Calibration Screen (Compact Logix PLC)
Screen colors inverted for ease of reading.
Figure 4-10. Photo-chopper
Press down on Photo-chopper to release tension from motor shaft.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 4 · Operation
18. Use the UP button to rotate the actuator towards its maximum position while watching the mV readout on the controller screen. Discontinue pressing the UP button when the mV reading in the "Current" window is approximately 4800 mV. You are nearing the mechanical stop position.
19. Pulse the UP button to carefully move the slide valve until the mV readout "saturates", or stops increasing. This is around 4800 mV Record mV maximum reading.
20. Pulse the DOWN button until the mV just start to decrease. (This is the point where the channel drops out of saturation). Adjust mV value to 300 mV below recorded maximum mV.
21. Press the "Set Max" button.
22. Press the "Main" button to complete calibration and exit the "Slide Calibration" screen. The controller 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.
23. Gently lower the plastic cover over the top of the actuator to where it contacts the base and O-ring seal.
CAUTION
Do not over tighten screws. Failure to comply may result in damage to equipment.
24. Check and make sure the cover is seated properly, then gently tighten the four #10 screws.
25. Enable the "Slide Non-Movement Alarm" by going to the "Setup" menu and choosing "Alarm Enable" for the "Slide Non-Movement Option".
26. Repeat procedure to calibrate other slide valve actuator.
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Section 4 · Operation
Compressor Control with Vission20/20TM Micro-controller (No Slide Operation)
The Vission20/20TM panel can provide control for a single screw compressor without slides as long as Analog Output Board #10 is present and selected in the Configuration screen, see FIgure 4-11.
The "No Slide" operation will become active once the correct type of compressor and model has been chosen, see Figure 4-12.
The user must select either VSG/VSH or VSM from the Compressor combo box in page 2 of the Configuration Menu, and then the Model from the next box. The choice of this type of compressor will cause the refrigerant combo box to be grayed out.
Once the compressor has been selected, the Vission 20/20TM panel touchscreen will show an indicator of VFD speed percentage, and buttons to increase and decrease it.
For more information on VFD capacity control, please check the Vission20/20TM manual (35391SC).
WARNING
Software programming credentials shall only be made available by the supplier. The user will only have access to operational features established by the supplier. Failure to comply may result in serious injury
or death.
Figure 4-11. Vission 20/20 Configuration Screen - I/O
Configuration (Page 8)
FIgure 4-12. Compressor and Model Setup with Vission 20/20
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 4 · Operation
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 compressor to return this oil back to the compressor. To adjust the return flow, proceed with the follow procedure:
NOTE Do not fully open the needle valve unless directed by VilterTM Technical Support. Leaving the needle valve fully open will reduce efficiency of the compressor unit.
1. Open shut-off valve on coalescing side of oil separator, see Figure 4-13.
2. While the unit is in operation, crack open needle valve and observe oil flow 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 flow.
Coalescing Oil Return Line
Needle Valve
Check Valve
SightGlass
4 16
Figure 4-13. Coalescing Oil Return Line
Shut-Off Valve
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
Suction Equalizing Line Setup - For VSS/VSM Compressors
The suction equalizing line allows system pressure to equalize to suction pressure during shutdown periods. The line is connected before the suction stop/check valve to after the suction strainer, see Figure 4-14.
NOTE Valve adjustment depends on size of oil separator and how quickly system pressure should equalize to suction pressure. The larger the oil separator the longer system
pressure will take to equalize to suction pressure.
1. To open valve, turn counterclockwise. To close valve, turn clockwise.
2. Fully close valve to a stop.
3. Turn valve to fully open position while counting number of turns to fully open. Note total number of turns.
4. Adjust valve to be half open. Close valve to half of the number of total turns.
5. If suction pressure needs to equalize slower, turn valve towards closed position.
6. If suction pressure needs to equalize faster, turn valve towards open position.
Suction Equalizing Valve
Suction Equalizing Line
Figure 4-14. Suction Equalizing Line and Valve
NOTE For VSH/VSSH compressors, suction equalizing is automatically controlled.
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Section 4 · Operation
Dual Oil Filter Setup For Oil Filters with Filter Head Assemblies
It is very important to correctly setup units equipped with dual oil filters, especially for oil filters that have filter head assemblies. Otherwise, oil pressure readings will show incorrectly. To setup dual oil filters, proceed with the following steps:
NOTE Inlet Oil Pressure Transducer should only read oil
pressure from active oil filter.
1. Decide which oil filter will be active/in use.
2. Open inlet and outlet oil filter shut-off valves to active oil filter.
3. Open inlet oil pressure shut-off valve for active oil filter.
4. Close outlet oil filter shut-off valve to inactive oil filter.
5. Close inlet oil pressure shut-off valve for inactive oil filter.
Outlet Oil Filter Shut-Off Valves
Inlet Oil Pressure Shut-Off Valves
Inlet Oil Filter Shut-Off Valves
Figure 4-15. Dual Oil Filter Setup for Oil Filters with Manifold Heads
4 18
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 4 · Operation
Stop/Check Valve Operation1
Valve Size
Table 4-2. Stop/Check Valve Open Positions
1.5"
2"
2.5"
3"
4"
5"
6"
8"
Number of Turns Open (From Closed Position)
2
2.25 2.75 3.25
4.5
3.75 5.75 7.75
Auto:
In the "Auto Position", the stop valve is operating as a check valve, allowing flow in the directions of the arrows.
To set the valve to the automatic position, fully close the valve, and turn the stem out as indicated by the chart below.
Closed:
In the manually "Closed Position", the stop check is operating as a conventional stop valve, not allowing flow in either direction.
Open:
In the manually " Open Position", with the valve stem fully back seated, the valve disc is lifted slightly, allowing flow in either direction.
1
Doesn´t apply to: VSM-97, VSM-113, VSM-127
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
4 19
4 20 / Blank
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
200 5,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 110,000 120,000
Section 5 · Maintenance/Service
Maintenance and Service Schedule - For VSS/VSM Unit Only
Follow this table for maintaining and servicing the compressor unit at hourly intervals.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Group
Table 5-1. Maintenance/Service Schedule - For VSS/VSM Unit Only
Service Interval (Hours)
Inspection/ Maintenance
Oil Circuit
Compressor Unit
Control Calibration
Compressor
Oil Change (1)
-
R
-
R
-
R
-
R
-
R
-
R
-
R
Oil Analysis (2)
-
S
S
S
S
S
S
S
S
S
S
S
S
S
Oil Filters (3)
RRRRRRRRRRRRRR
Oil Strainers
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Coalescing Filter
-
-
-
-
R
-
-
R
-
-
R
-
-
R
Coalescing Drain Line
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Suction Screen
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Liquid Line Strainers
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Coupling Alignment and Integrity
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Motor (Compressor)
See Motor Manual for proper lubrication procedures and service intervals.
Transducers
I
I
I
I
I
I
I
I
I
I
I
I
I
I
RTDs/ TTs
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Slide Valve Motors
Slide valve calibration should be inspected monthly. Inspections can be performed through the control panel. If a Non-Movement Alarm appears, calibrate immediately.
Compressor w Slides (4)
-
I
-
I
-
I
-
I
-
I
-
I
-
I
Compressor w/o Slides (5) -
-
I
I
I
I
I
I
I
I
I
I
I
I
Inspect for Back Spin
Inspect Every 5,000 Hours or As Needed
Inspect for Leak
Check Monthly
Bearings
-
-
-
-
-
-
-
-
-
-
-
-
-
I
I = Inspect S = Sampling R = Replace (1) The oil should be changed at these intervals, unless oil analysis results exceed the allowable limits. The frequency of changes will depend on the system cleanliness.
(2) Oil analysis should be done at these intervals as a minimum; the frequency of analysis will depend on system cleanliness. (3) The oil filter(s) on a minimum must be changed at these intervals or annually if not run continuously. However, the oil filter(s) must be changed if the oil filter differential
exceeds 12 psi or oil analysis requires it. (4) Inspection includes - Gaterotor Inspection (backlash measurement, shelf clearance and gaterotor float), End Play Measurement (main rotor & gaterotor), Slide Valve
Inspection (if applicable).
(5) For compressors with no slides (VSM-97, VSM-113, VSM-127)
5 1
200 5,000 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 110,000 120,000
Section 5 · Maintenance/Service
Maintenance and Service Schedule - For VSH/VSSH Unit Only
Follow this table for maintaining and servicing the heat pump at hourly intervals.
5 2
Group
Inspection/ Maintenance
Table 5-2a. Maintenance/Service Schedule (For VSH/VSSH Unit Only) Service Interval (Hours)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Oil Circuit
Compressor Unit
Control Calibration Compressor
Oil Change (1) Oil Analysis (2) Oil Filters (3) Oil Strainers Coalescing Filter Coalescing Drain Line Suction Screen Liquid Line Strainers Coupling Alignment and Integrity Motor (Compressor) Transducers RTDs/ TTs
Slide Valve Motors
Compressor Inspect for Back Spin Inspect for Leak
-
R
-
R
-
R
-
R
-
R
-
R
-
R
-
S
S
S
S
S
S
S
S
S
S
S
S
S
RRRRRRRRRRRRRR
I
I
I
I
I
I
I
I
I
I
I
I
I
I
-
-
-
-
R
-
-
R
-
-
R
-
-
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
See Motor Manual for proper lubrication procedures and service intervals.
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Slide valve calibration should be inspected monthly. Inspections can be performed through the control panel. If a Non-Movement Alarm appears, calibrate immediately.
See Table 5-2b for Service Schedule Timeline details
Inspect Every 5,000 Hours or As Needed
Check Monthly
I = Inspect S = Sampling R = Replace (1) The oil should be changed at these intervals, unless oil analysis results exceed the allowable limits. The frequency of changes will depend on the system cleanliness.
(2) Oil analysis should be done at these intervals as a minimum; the frequency of analysis will depend on system cleanliness. (3) The oil filter(s) on a minimum must be changed at these intervals or annually if not run continuously. However, the oil filter(s) must be changed if the oil filter dif-
ferential exceeds 12 psi or oil analysis requires it.
5,000 7500 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 55,000 60,000 65,000 70,000 75,000 80,000 85,000 90,000 95,000 100,000
Section 5 · Maintenance/Service
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Discharge Pressure (PSIG)
Differentinal Pressure (PSIG)
Table 5-2b. Maintenance/Service Schedule (For VSH/VSSH Compressor Only)
Service Interval (Hours)
200- 300 - - - I - - - I - - - I - - I - - I - - R
300(1) - 800
300 - 400 400- 500
- I - I - I -R- I - I - I - I - IRI I - I - I -R- I - I -R- I - I -R- I
500- 600
I - I - IRI - I -R- I - IRI - I -R I = Inspect* R = Replace Bearings & Inspect per Chart
Notes: *: Inspection includes - Gaterotor Inspection (backlash measurement, shelf clearance and gaterotor float), End Play Measurement (main rotor & gaterotor), Slide Valve Inspection (if applicable).
(1): For Discharge pressure under 300 PSIG, please use Table 5-1a for maintenance and service schedule.
NOTE
Upon Inspection, if any component shows wear beyond what is allowed in the Service section of this document, the component(s)
must be replaced.
5 3
Section 5 · Maintenance/Service
Preventive Maintenance, Checks and Services
Careful checking of a refrigeration system for leaks and proper operation of all components upon installation will start the system on its way to a long life of satisfactory service. To ensure the desired trouble-free operation, however, a systematic maintenance program is a prerequisite. The following PMCS is suggested in addition to the Maintenance/Service Schedule.
13. Operate compressor capacity and volume ratio controls through their range both automatically and manually.
Trimonthly
(Approximately 2000 operating hours) A. Check movement of compressor rotor at drive cou-
pling end to determine bearing float, see Compressor Shaft Bearing Float Inspections.
NOTE After any maintenance work, the workplace should be cleaned and free from any hazards.
Daily
Annually
(Items 1 thru 13 and "A" above plus 14 thru 31) 14. Check entire system thoroughly for leaks. 15. Remove all rust from equipment, clean and paint.
1. Check oil levels.
16. Grease valve stems and threads for the valve caps.
2. Check all pressure and temperature readings.
3. Check micronic oil filter inlet and outlet pressures for excessive pressure drop. Change filter when pressure drop exceeds 45 psi or every six months, whichever occurs first. For proper procedure for changing micronic oil filter and for charging oil into the system, see Operation Section.
4. Clean strainers each time filter cartridge if replaced.
5. Check compressor sound for abnormal noises.
6. Check shaft seals for excessive oil leakage. A small amount of oil leakage (approximately 6 to 15 drops per hour) is normal. This allows lubrication of the seal faces.
17. Flush out sediment, etc. from water circuits.
18. Clean all oil strainers.
19. Clean suction strainer compressors.
20. Check motors and fans for shaft wear and end play.
21. Check operation and general condition of microprocessor and other electrical controls.
· Check fuses in the Vission20/20 or PLC panel.
· Check for loose wiring connections in the Vission 20/20 or PLC panel.
· Check relay and contact operation for relays in the Vission20/20 or PLC panel.
· Verify set points in the Vission20/20 or PLC.
Weekly
(Items 1 thru 6 above plus 7 thru 9)
22. Clean all water strainers.
23. Check drains to make sure water will flow away from equipment.
7. Check the refrigeration system for leaks with a suitable leak detector.
8. Check oil pressures and review microprocessor log and log sheets.
9. Check refrigerant levels in vessels.
24. Drain and clean entire oil system at receiver drain. Recharge with new clean moisture free oil. For proper procedure for changing micronic oil filter and charging oil into the system, see Start-Up and Operation section.
25. Check compressor coupling. For integrity and alignment.
Monthly
26. Check oil pump for wear.
(Items 1 thru 8 above plus 9 thru 13)
10. Oil all motors and bearings. Follow manufacturer's instructions on lubrication.
27. Check the calibration of the microprocessor pressure transducers and RTD's for accuracy.
28. Check mounting bolts for compressor and motor.
11. Check calibration and operation of all controls, particularly safety controls.
29. Verify the operation of the suction and discharge check valves.
12. Check oil cooler for any evidence of corrosion, scaling or other fouling.
30. Check setup of soft starts and VFDs. 31. Check oil heater operation.
5 4
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Compressor Unit Isolation For Maintenance/Service (Compressors with Slide Valves)
WARNING
Avoid skin contact with any liquid refrigerant or oil. Wear rubber gloves and a face shield when working with liquid refrigerant or oil. Failure to comply may
result in serious injury or death.
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. 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 lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
NOTICE
Recover or transfer all refrigerant vapor in accordance with local ordinances before opening any part of the
package unit to atmosphere.
1. Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.
2. Turn motor and oil pump starter disconnect switches into the OFF position. Lock-out/tag-out disconnect switches.
3. If suction equalizing valve is not open, open it to allow oil separator pressure to vent to low-side system pressure, see Figure 5-1. Close valve when complete.
4. Isolate the compressor unit by closing all valves to the house system. Lock-out/tag-out 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.
5. Open any other valves that may trap gas or liquid. Lock-out/tag-out valves.
6. Recover and/or transfer all vapors per local/state codes and policies.
7. Servicing the compressor unit can proceed at this point. After servicing, ensure to perform a leak check, see Compressor Unit Leak Check procedure.
The compressor unit must be isolated and depressurized to atmosphere prior to servicing.
Suction Equalizing Valve
Suction Equalizing Line
Discharge Bleed Valve
Figure 5-1. Discharge Bleed Valve, Suction Equalizing Line and Valve
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 5
Section 5 · Maintenance/Service
Recommendations when Servicing (Compressors Without Slide Valves)
When working on the compressor, care must be taken to ensure that contaminants (i.e. water from melting ice, dirt and dust) do not enter the compressor while it is being serviced. It is essential that all dust, oil or ice that has accumulated on the outside of the compressor be removed before servicing the compressor.
After servicing the compressor, all gaskets, O-rings, roll pins and lock washers must be replaced when reassembling the compressor.
Preparation of Unit For Servicing
WARNING
Follow local lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
A) Shut down the unit, open the electrical disconnect switch and pull the fuses for the compressor motor to prevent the unit from starting. Put a lock on the disconnect switch and tag the switch to indicate that maintenance is being performed.
WARNING
Be cautious when isolating sections of CO2 piping. CO2 has a very steep pressure curve, and as sections containing CO2 warm up, pressures can rise
dramatically & well beyond system design.
WARNING
When working with LFG, NG or other dangerous or flammable gases, ensure there are adequate ventilation and vapor detectors. Refer to national fire and building codes. Failure to comply may result in
serious injury or 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.
B) Isolate the unit by manually closing the discharge Stop valve. Allow the unit to equalize to suction pressure before closing the Suction Bypass. After the unit has equalized to suction pressure and suction valve closed, use an acceptable means to depressurize the unit that complies with all Local, State and Federal Ordinances.
WARNING
At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to
equipment.
NOTICE
Recover or transfer all gas vapor in accordance with local ordinances before opening the compressor unit
to the atmosphere.
C) Remove drain plugs from the bottom of compressor housing and the discharge manifold. Drain the oil into appropriate containers.
5 6
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Compressor Unit Leak Check After Servicing
The compressor unit must be checked for leaks after servicing to ensure a tight system. For additional leak testing information, refer to Chapter VI of ASME B31.3 Process Piping Code.
CAUTION
Do not hydro test compressor 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 compressor unit from the house system, see Compressor Unit Isolation procedure.
2. Open all shut-off valves, check valves, control valves and solenoid valves in the system to be tested.
3. Slowly pressurize compressor unit through suction oil charging port with dry nitrogen.
4. Using appropriate soap solution, check for leaks on joints and connections of the serviced component.
5. If leaks are found, depressurize system and fix leaks. Repeat steps 3 and 4 until all leaks are fixed.
6. Evacuate from suction oil charging port.
7. Close all valves previously opened in the system. Remove tags as per the local lock-out/tag-out procedure.
8. Turn the motor and oil pump disconnect switches to the ON position.
9. Return compressor unit to service. Oil System Components
Oil System Components
Oil Sampling
WARNING
When working with LFG, NG or other dangerous or flammable gases, ensure there are adequate ventilation and vapor detectors. Refer to national fire and building codes. Failure to comply may result in
serious injury or death.
WARNING
Improper selection or application of fluid diagnostic products can cause serious injury or damage. The user is solely responsible for making the final selection of products to ensure that the overall system performance and safety requirements are met. These include reviewing fluid compatibility with materials
and seals.
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.
DANGER
Sampling often releases hot fluid under high velocity/pressure.
1. Hot fluid can cause severe burn injuries. 2. Skin penetration from high-pressure fluid
can occur, causing severe injury, gangrene and/or death. If this happens, immediately contact an experienced medical practitioner. 3. Hot fluid escaping to the atmosphere can ignite if it comes into contact with an ignition source. This can lead to severe property damage.
Recommendations:
1. Make sure you´re aware of the risks associated with the fluid being sampled or worked with. Check with the manufacturer.
2. If you have not been trained to sample, service, repair, or troubleshoot a pressurized fluid system, especially a hydraulic system, you are at risk of suffering an accident. Seek the proper training before proceeding.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 7
Section 5 · Maintenance/Service
Installation of The Oil Sampler Valve: 1. Lubricate the threads (1/4"-18 NPT) with Teflon
tape.
2. Tighten to the max. torque 25 ft-lbs (34 N-m). Use 11/16" open wrench. Avoid over tightening.
Pre-Sampling:
Use the Vilter Oil Analysis Kit (VPN 3097A) to collect an oil sample for analysis, see Figure 5-2.
Once the sample has been taken, the label must be filled out and pasted on the bottle, and both must be placed inside the mailing tube and sealed with the preaddressed mailing label.
Below are a few points to remember when taking a sample:
· Sample running compressor units, not cold units. Sample after minimum 30 minutes of compressor operating time.
· Sample after the oil filter.
· Sample according to the sampling procedure below.
· Ensure sampling valves and devices are thoroughly flushed prior to taking a sample.
· Ensure samples are taken as scheduled in the Maintenance and Service Schedule.
· Send samples to the oil analysis lab immediately after sampling, do not wait 24 hours.
Sampling Procedure
THE SAMPLING PRESSURE RANGE IS LIMITED BETWEEN 5 TO 750 PSI (0.03 5.17 MPa). IF THE OPERATING PRESSURE IS ABOVE 750 PSI (5.17 MPa), THE OIL SAMPLING MUST BE DONE WHEN THE COMPRESSOR IS NOT RUNNING AND ENSURE THE SYSTEM PRESSURE IS WITHIN THE 5 TO 750 PSI (0.03 5.17 MPa) SAMPLING RANGE.
A 1/4" NPT oil sampling valve is provided either in the oil filter canister cover or in the piping after the filter (See Figure 5-3 or 5-4(a) according to application).
1. Unthread the oil sampling valve cap. For valve #3709A, you also need to turn the knurled locknut clockwise, see Figure 5-4 (b).
NOTE DO NOT remove the valve from the piping or filter
housing.
2. Remove the cap of the oil analysis bottle and position it carefully under the valve spout. (Make sure the valve spout is rotated to the downward position) SLOWLY AND VERY CAREFULLY press the "PUSH BUTTON" with your finger to open the valve, and release the button to close it, see Figure 5-5.
WARNING
If the valve is opened too rapidly, a foamy pressurized jet of oil will gush out and splash outside the container.
Figure 5-2. Oil Analysis Kit (VPN 3097A)
Figure 5-3. Oil Sampler Valve (VPN #3708A) For Gas Compression Applications
5 8
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
(a) Oil Sampler Valve for Ammonia and Other Refrigerants Applications
(b) Valve shown ready for oil sampling
(c) Valve shown in lockout position
Figure 5-4. Oil Sampling Valve (VPN #3709A) For Ammonia and Refrigerant Compressors
Button being pressed, valve open
Button released, valve closed
Figure 5-5. Operating the Oil Sampling Valve
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 9
Section 5 · Maintenance/Service
3. In most cases there will be foam in the oil, so you must fill the bottle up to the top and then wait for the foam to dissipate. Repeat this step as many times as necessary (around 4 to 6 times) until the clear oil level reaches ¾ full, see sequence in Figure 5-6.
4. After all the foam dissipates, tighten the sample bottle cap.
5. Tighten the oil sampling valve cap.
6. For valve #3709A only: back seat the knurled locknut by turning it counter-clockwise. This is to prevent any accidental release, see Figure 5-4 (c).
7. Attach the filled sampling information label to the bottle and mail the sample out to the oil analysis lab immediately.
NOTE
Missing information from the sampling label may result in longer turnaround time as the laboratory will need to request the info before the sample can be tested.
Oil Sample Analysis Report
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 · Contaminating/additive metals
Figure 5-6. Stages of the Oil Sample Taking Process
5 10
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Oil Draining
WARNING
Avoid skin contact with any liquid refrigerant or oil. Wear rubber gloves and a face shield when working with liquid refrigerant or oil. Failure to comply may
result in serious injury or death.
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. Failure to comply may
result in serious injury or death.
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 located underneath the oil separator, see Figure 5-7.
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.
Oil Separator Drain Valve
Figure 5-7. Oil Strainer Drain Valve and Oil Separator Drain Valve
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 11
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 equipment. See Figure 4-1 for normal operating levels. There are a couple of ways to maintain oil, while the compressor 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 overcome suction pressure.
1. Using a properly selected oil pump, connect oil pump to suction oil charging valve.
2. Open suction oil charging valve and fill oil separator to Normal Operating 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 5-7. 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 fill 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.
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 5-8. 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 efficiency.
Suction Oil Charging Valve
5 12
Figure 5-8. Suction Oil Charging Valve
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Filter Element Replacement (Single Oil Filter Assembly) and Oil Pump Strainer Servicing
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. Failure to comply may
result in serious injury or death.
WARNING
Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply
may result in serious injury or death.
Change the oil filter as outlined in the Maintenance and Service Interval, see Table 5-1. Maintenance & Service Interval.
NOTE
Ensure to check the oil pressure drop and record it daily.
This procedure is for a compressor unit equipped with a single oil filter assembly only, but can be used for units equipped with dual oil filters. The compressor unit must be shut down prior to servicing, see Stopping/Restarting procedure in Section 4.
See Table 5-3 for the parts required for an oil filter replacement, with their part numbers.
NOTE
For filter housings with drain plugs only, replace with O-ring (VPN 3111AB) after removing drain plug. Drain plug and O-ring are not shown in this
procedure.
Drain Oil From Isolated Oil Line
1. Isolate the compressor unit, see Compressor Unit Isolation procedure.
2. Close oil supply valve and oil filter outlet valve to isolate oil filter assembly and oil pump strainer for servicing.
3. Remove plug from drain valve on oil pump strainer.
4. If needed, attach a hose with 1/4" male adapter to drain valve to aid in controlling discharged oil.
5. Using a drain pan, slowly open drain valve to reduce pressure and allow oil to completely drain from oil lines and oil pump strainer.
6. Remove plug from bleed valve on oil filter housing.
7. If needed, attach a hose with 1/4" male adapter to bleed port to aid in controlling discharged oil.
8. Using a drain pan, slowly open bleed valve and allow oil to completely drain from filter housing. Remove plug from oil filter head assembly to aid in oil removal.
Table 5-3. Oil Filter Replacement Parts Required, with their numbers
KIT
Oil Filter
Oil Filter Element
O-Ring and Drain Plug
Filter Type
KT773B 3111A
3109B
2176BZ
Single
KT773A 3109A
3109B
2176BY
Dual*
KT774** 3112A
3110B
2176BY
Single
KT721 3007A
3007B
2176BU
Single
KT722 3039A
3039B
2176AJ
Single
*2 Kits required **Supplied on VSS 1501-1801 Single Screw compressor units
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 13
Section 5 · Maintenance/Service
Oil Filter Element Removal (For 3111A Oil Filter Housing - See Figure 5-9)
NOTICE
Dispose of used oil in an appropriate manner following all Local, State and Federal laws and ordinances.
9. Remove locking ring and filter housing from head assembly.
10. Remove filter element from internal port of head assembly.
11. Clean filter element connection area of head assembly and interior of filter housing.
12. Remove (head-to-housing) O-ring from inside of filter head. Discard O-ring.
Oil Filter Element Removal (For 3110A OR 3112A Oil Filter Housing - See Figure 5-10) 13. Remove oil filter housing cover and O-ring from oil
filter housing. Discard O-ring. 14. Remove filter element from internal port of head
assembly. 15. Clean filter element connection area of head as-
sembly and interior of filter housing and cover.
Oil Pump Strainer Screen Removal and Service 16. Remove four bolts and strainer cover from strainer
body.
17. Remove screen from strainer body.
18. Clean screen and interior of strainer body
19. Inspect screen for damage, replace if required.
OIL OUTLET TO COMPRESSOR
View Rotated 180°
Oil Filter Outlet Valve
Temperature Gauge
OIL INLET FROM OIL COOLER
Oil Inlet Connection Temperature
Element
Oil Outlet Connection Oil Filter Head Assembly
Plug Oil Filter Mounting Bracket Locking Ring
Oil Filter Housing Oil Filter Element
Oil Strainer Drain Valve
Oil Filter Drain Valve
Figure 5-9. Filter Assembly and Oil Strainer Drain Valve (VPN 3111A Oil Filter Housing Shown)
5 14
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Oil Pump Strainer Screen Installation
20. Install screen in strainer body.
21. Install four bolts to secure strainer cover on strainer body.
22. Tighten bolts, see Appendix A.
23. Close drain valve on oil pump strainer.
24. Install plug on drain valve.
Oil Filter Element Installation (For 3111A Oil Filter Housing - See Figure 5-9)
25. Lubricate new O-ring with clean system oil. 26. Install O-ring on inside of filter head. 27. Install new filter element on internal port of head
assembly. Make sure filter element is fully seated.
28. Lubricate threads of locking ring with clean system oil.
29. Hand tighten locking ring only. Install locking ring and filter housing on head assembly until filter housing bottoms. Do not overtighten locking ring.
30. Using dry nitrogen gas, pressurize isolated oil line through bleed valve of filter housing. Check for leaks on replaced components.
31. Evacuate isolated oil line to 29.88" Hg (1000 microns) and close bleed valve.
32. Install plug on bleed valve of filter housing. 33. Slowly open oil supply valve and allow oil to fill oil
line. 34. Open filter outlet valve. 35. Check oil level and fill oil separator to non-operat-
ing level, see Oil Charging procedure.
Oil Filter Element Installation (For 3110A OR 3112A Oil Filter Housing - See Figure 5-10)
36. Install new filter element on internal port of head assembly. Make sure filter element is fully seated.
37. Lubricate new O-ring with clean system oil.
38. Hand tighten oil filter housing cover only. Install O-ring and oil filter housing cover on oil filter housing.
39. Using dry nitrogen gas, pressurize isolated oil line through bleed valve of filter housing. Check for
leaks on replaced components.
40. Evacuate isolated oil line to 29.88" Hg (1000 microns) and close bleed valve.
41. Install plug on bleed valve of filter housing.
42. Slowly open oil supply valve and allow oil to fill oil line.
43. Open filter outlet valve.
44. Check oil level and fill oil separator to non-operating level, see Oil Charging procedure.
Oil Outlet Connection
Oil Inlet Connection
Plug
Oil Filter Head Assembly
Oil Filter Housing
Oil Filter Element
O-ring
Oil Filter Drain Valve with Plug
Oil Filter Housing Cover
Figure 5-10. Filter Assembly (VPN 3112A Oil Filter Housing Shown)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 15
Section 5 · Maintenance/Service
Filter Element Replacement (Duplex Oil Filter Assembly)
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. Failure to comply may
result in serious injury or death.
WARNING
Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply
may result in serious injury or death.
Change the oil filter as outlined in the Maintenance and Service Interval, see Table 5-1. Maintenance & Service Interval.
NOTE
Ensure to check the oil pressure drop and record it daily.
This procedure is for a compressor unit equipped with a duplex oil filter assembly only (VPN 3109A and 3110A oil filter housings). One oil filter can be isolated and serviced one at a time during operation. Note that there is one oil filter head assembly for both oil filters. This is different from dual oil filters, where each oil filter has its own oil filter head assembly.
See Table 5-3 for the parts required for an oil filter replacement, with their part numbers.
To replace an oil filter element, continue with the following steps:
NOTE For filter housings with drain plugs only, replace with O-ring (VPN 3111AB) after removing drain plug. Drain plug and O-ring are not shown in this
procedure.
Removal
(Reference Figure 5-11)
NOTICE
Dispose of used oil in an appropriate manner following all Local, State and Federal laws and ordinances.
1. Pull switch lever and switch over to second filter.
2. Remove plug from bleed valve.
3. If needed, attach a hose with 1/4" male adapter to bleed port to aid in controlling the flow of discharged oil.
4. Using a drain pan, slowly open bleed valve to reduce pressure and allow oil to completely drain from filter housing.
5. Remove oil filter housing cover and O-ring from oil filter housing. Discard O-ring.
6. Remove filter element from internal port of head assembly.
7. Clean filter element connection area of head assembly and interior of filter housing.
Oil Filter Duplex Head Assembly
Oil Filter Switch Lever
Oil Filter Element
Oil Filter Housing
O-ring Oil Filter Housing Cover
Oil Filter Drain Valve
5 16
Figure 5-11. Duplex Oil Filter Assembly (VPN 3110A Double Oil Filter Housing Shown)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Installation
8. Before reassembling, clean all parts thoroughly.
9. Install new filter element on internal port of head assembly. Make sure filter element is fully seated.
10. Lightly lubricate new O-ring with clean system oil.
11. Install O-ring and replace the oil filter housing (canister) on oil filter Duplex head Assembly. Hand-tighten only the oil filter housing cover.
12. Using dry nitrogen gas, pressurize filter housing through bleed valve and check for leaks.
13. Evacuate filter housing to 29.88" Hg (1000 microns) and close bleed valve.
14. Install plug on bleed valve.
15. Pull switch lever and slowly rotate lever to middle position to allow oil to fill filter housing. Allow a minimum of 5 seconds to fill housing, then rotate lever back to second filter.
16. Repeat for second oil filter, as required.
Filter Element Replacement (Dual Oil Filter Assembly)
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. Failure to comply may
result in serious injury or death.
WARNING
Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply
may result in serious injury or death.
Change the oil filter as outlined in the Maintenance and Service Interval, see Table 5-1. Maintenance & Service Interval.
NOTE
Ensure to check the oil pressure drop and record it daily.
This procedure is for a compressor unit equipped with a dual oil filter assembly only. One oil filter can be isolated and serviced one at a time during operation. Note that there is one oil filter head assembly for each oil filter. This is different from duplex oil filters, where there is only one oil filter head assembly for both oil filters.
See Table 5-3 for the parts required for an oil filter replacement, with their part numbers.
To replace an oil filter element, continue with the following steps:
NOTE
For filter housings with drain plugs only, replace with O-ring (VPN 3111AB) after removing drain plug. Drain plug and O-ring are not shown in this
procedure.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 17
Section 5 · Maintenance/Service
Switching Oil Filters For Maintenance (Reference Figure 5-12)
When switching oil flow from one filter to the other for maintenance, proceed with the following steps:
1. Slowly open inlet oil filter shut-off valve to oil filter that will be active.
2. Slowly open inlet oil pressure shut-off valve for oil filter to allow oil pressure to be read from oil filter that is now active.
3. Slowly open outlet oil filter shut-off valve to oil filter that is now active.
4. Slowly close inlet and outlet oil filter shut-off valves for oil filter that is to be serviced.
5. Slowly close oil pressure shut-off valve for oil filter that is to be serviced. Remove plug from oil filter head assembly to aid in oil removal.
Outlet Oil Filter Shut-Off Valves
Inlet Oil Pressure Shut-Off Valves
Inlet Oil Filter Shut-Off Valves
Plug
Oil Filters
Plugs and Bleed Valves
Figure 5-12. Dual Oil Filter (3111A Oil Filter Housings Shown)
5 18
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Drain Oil From Isolated Oil Filter (Reference Figure 5-13) 6. Remove plug from bleed valve on oil filter housing.
7. If needed, attach a hose with 1/4" male adapter to bleed port to aid in controlling discharged oil.
8. Using a drain pan, slowly open bleed valve and allow oil to completely drain from filter housing.
Oil Filter Element Removal (For 3111A Oil Filter Housing - See Figure 5-13)
NOTICE
Dispose of used oil in an appropriate manner following all Local, State and Federal laws and ordinances.
9. Remove locking ring and filter housing from head assembly.
10. Remove filter element from internal port of head assembly.
11. Clean filter element connection area of head assembly and interior of filter housing.
12. Remove (head-to-housing) O-ring from inside of filter head. Discard O-ring.
OIL OUTLET TO COMPRESSOR
View Rotated 180°
Oil Filter Outlet Valve
Temperature Gauge
OIL INLET FROM OIL COOLER Oil Inlet Connection
Temperature Element
Oil Outlet Connection Oil Filter Head Assembly
Oil Filter Mounting Bracket
Locking Ring
Oil Filter Housing
Oil Filter Element
Oil Strainer Drain Valve
Figure 5-13. Filter Assembly and Oil Strainer Drain Valve (VPN 3111A Oil Filter Housing Shown)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Oil Filter Drain Valve
5 19
Section 5 · Maintenance/Service
Oil Filter Element Removal (For 3110A OR 3112A Oil Filter Housing - See Figure 5-14)
13. Remove oil filter housing cover and O-ring from oil filter housing. Discard O-ring.
14. Remove filter element from internal port of head assembly.
15. Clean filter element connection area of head assembly and interior of filter housing and cover.
Oil Filter Element Installation (For 3111A Oil Filter Housing - See Figure 5-9)
16. Lubricate new O-ring with clean system oil.
17. Install O-ring on inside of filter head.
18. Install new filter element on internal port of head assembly. Make sure filter element is fully seated.
19. Lubricate threads of locking ring with clean system oil.
Oil Outlet Connection
Oil Inlet Connection
Plug
Oil Filter Head Assembly
Oil Filter Housing
Oil Filter Element
20. Hand tighten locking ring only. Install locking ring and filter housing on head assembly until filter housing bottoms. Do not overtighten locking ring.
21. Using dry nitrogen gas, pressurize isolated oil line through bleed valve of filter housing. Check for leaks on replaced components.
22. Evacuate isolated oil line to 29.88" Hg (1000 microns) and close bleed valve.
23. Install plug on bleed valve of filter housing. 24. Slowly open oil supply valve and allow oil to fill oil
line. 25. Open filter outlet valve. 26. Check oil level and fill oil separator to non-operat-
ing level, see Oil Charging procedure.
Oil Filter Element Installation (For 3110A OR 3112A Oil Filter Housing - See Figure 5-14) 27. Install new filter element on internal port of head
assembly. Make sure filter element is fully seated.
28. Lubricate new O-ring with clean system oil. 29. Hand tighten oil filter housing cover only. Install
O-ring and oil filter housing cover on oil filter housing.
30. Using dry nitrogen gas, pressurize isolated oil line through bleed valve of filter housing. Check for leaks on replaced components.
31. Evacuate isolated oil line to 29.88" Hg (1000 microns) and close bleed valve.
32. Install plug on bleed valve of filter housing. 33. Slowly open oil supply valve and allow oil to fill oil
line. 34. Open filter outlet valve. 35. Check oil level and fill oil separator to non-operat-
ing level, see Oil Charging procedure.
O-ring
Oil Filter Housing Cover
Oil Filter Drain Valve with Plug
Figure 5-14. Filter Assembly (VPN 3112A Oil Filter Housing Shown)
5 20
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Oil Separator Coalescing Filter Replacement
WARNING
When working with refrigerants, ensure there is adequate ventilation and refrigerant vapor detectors as per ASHRAE standards. Failure to comply may
result in serious injury or death.
WARNING
Avoid skin contact with 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
Use appropriate lifting devices and additional personnel when lifting heavy components. Ensure lifting devices are capable of lifting the weight of 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.
NOTE For coalescing oil filters (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.
Installation 10. Install tubing over hold-down rod. Position tubing
as far back as possible.
11. With assistance of second person, position coalescing element over tubing and through hole of centering strap.
12. Push coalescing filter into vessel until fully seated on pipe stub.
13. Remove tubing.
14. Position cover plate and flat washer on hold-down rod on end of the coalescing filter.
15. Install nut to secure flat washer and cover plate to coalescing filter. Tighten nut to 25 ft-lbs.
16. Install second nut to prevent first nut from moving.
17. Repeat steps 10 to 16 for installing additional coalescing filters.
18. Position oil separator manhole cover on oil separator 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.
Removal
1. Isolate the compressor unit, see Compressor Unit Isolation procedure.
2. If required, install lifting eyes on oil separator manhole cover, see Figure 5-15.
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, flat washer and cover plate securing coalescing oil filter to hold-down rod.
8. With assistance of second person, remove coalescing filter from oil separator vessel.
9. Repeat steps 7 and 8 to remove additional coalescing filters, as required.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 21
Section 5 · Maintenance/Service
Horizontal Oil Separator
Oil Separator Vessel (Horizontal)
Oil Separator Manhole Cover Coalescing Filter
Centering Strap Flat Washer Nuts
Flat Washers Centering Strap
Coalescing Filter
Gasket Nuts
Pipe Stub Hold-Down Rod
3/4 in. O.D. Tubing, 6 ft. long
Oil Separator Manhole Cover Gasket Oil Separator Vessel (Vertical)
Hold-Down Rod
Pipe Stub
Vertical Oil Separator
5 22
Figure 5-15. Oil Separators, Manhole Covers and Coalescing Filter Assemblies
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Oil Separator Heater Cartridge Replacement Parts Required
· Heater Cartridges with loose wires · Heater Cartridge, 500W, 120V (VPN 3116A) · Heater Cartridge, 1000W, 120V (VPN 3116B) · Heater Cartridge, 750W, 120V (VPN 3116E) · Heater Cartridge, 1250W, 120V (VPN 3116J) · Heater Cartridge, 1000W, 220V (VPN 3116K)
· Heater Cartridges with Turck connectors · Heater Cartridge, 750W, 120V (VPN 3116C) · Heater Cartridge, 500W, 120V (VPN 3116D) · Heater Cartridge, 1250W, 120V (VPN 3116F)
· Anti-Seize, High Temperature (-65°F to 2400°F) Removal 1. Isolate the compressor unit, see Compressor Unit
Isolation procedure. 2. Drain oil from oil separator, see Oil Draining
procedure. 3. For heater cartridges with Turck connectors, see
step 4. For heater cartridges with loose wires, see steps 5 to 9.
Heater Cartridges with Turck connectors: 4. Disconnect Turck connector.
Heater Cartridge WITHOUT Turck Connector
Heater Cartridges with loose wires: 5. Remove junction cover to gain access to heater car-
tridge wires. NOTE
Note location of wires to aid in installation. 6. Disconnect wires. 7. Remove cable connector. 8. Remove cable and wires from junction. 9. Remove junction from heater cartridge. 10. Remove heater cartridge from thermowell.
Installation 11. Apply anti-seize to threads of heater cartridge. 12. Install heater cartridge in thermowell. 13. For heater cartridges with Turck connectors, see
step 14. For heater cartridges without Turck connectors, see steps 15 to 19.
Heater Cartridges with Turck connectors: 14. Connect Turck connector.
Heater Cartridges with loose wires: 15. Install junction on heater cartridge. 16. Route cable and wires through junction. 17. Connect wires as noted during removal. 18. Install cable connector. 19. Install junction cover.
Heater Cartridge WITH Turck Connector
Thermowell Heater Cartridge
Junction
Cable Cable Connector
Thermowell
Figure 5-16. Heater Cartridges
Heater Cartridge
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Turck Connector
5 23
Section 5 · Maintenance/Service
Drive Coupling Hub (Form-Flex BPU) 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 phasing 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 lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. 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 starter, 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 contact pattern. If bore is straight, measure bore and shaft diameters to ensure proper fitting. The keys should have a snug side-to-side fit in the keyway 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 5-4.
7. Install clamping bolts in hub.
8. Tighten clamping bolts, see Table 5-5.
9. Install set screw in hub to secure key.
10. Tighten set screw, see Table 5-5. Repeat steps for second straight bore hub.
Tapered Bore Hubs
11. For taper bore hubs, do not use Anti-seize because this will allow the hub to slide on farther than without, and you may not be able to get it removed. 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.
Coupling Size
BP38U BP41U BP47U BP54U BP54U BP56U
Shaft Gap for Tapered Compressor &
Straight Motor Shaft Combination
6.25" (158.75 mm)
Shaft Gap for Straight Compressor &
Straight Motor Shaft Combination
5.125" (130.18 mm)
Distance Between Hub
Faces
5.00" (127 mm)
Table 5-4. Shaft and Hub Distances
5 24
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Table 5-5. Hub Clamp Bolt and Set Screw Torque Specifications
Coupling Series/Size
BH38U BH41U BH47U BH54U BH56U DP42
# Bolts
4 4 4 4 4 4
Clamping Bolt
Size-Pitch
1/4-28 5/16-24
3/8-24 7/16-20
1/2-20 1/2-20
Torque ft-lbs (Nm)
12 (16) 23 (31) 49 (66) 78 (106) 120 (163) 120 (163)
Set Screw
Size
Torque ft-lbs (Nm)
3/8
10 (13)
3/8
10 (13)
1/2
20 (27)
1/2
20 (27)
5/8
40 (54)
1/2
20 (27)
15. Tighten bolt and draw hub up shaft to a stop. 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 5-5.
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 distance of 5" between both hub faces.
20. Soft Foot. The motor must sit flat on its base (+/- 0.002"). Any soft foot must be corrected prior to center member installation.
NOTE
If the driver or driven equipment alignment specification is tighter than these recommendations, the specification 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 flex disc pack is designed to an optimal thickness and is
not to be used for axial adjustments.
21. Axial Spacing. The axial spacing of the shafts should be positioned so that the flex disc packs are flat when the equipment is running under normal operating conditions. This means there is a minimal amount of waviness in the flex disc pack when viewed from the side. This will result in a flex disc pack that is centered and parallel to its mating flange faces. Move the motor to obtain the correct axial spacing, see Table 5-6 and Figure 5-17.
Table 5-6. Disc Pack Installation Torque Specifications
Coupling Size
BP38U BP41U BP47U BP54U BP56U
Lock Nut Size
5/16-24 7/16-20 9/16-18 9/16-18 9/16-18
Tightening Torque
ft-lbs (Nm) 22 (30) 55 (75)
120 (163) 120 (163) 120 (163)
Figure 5-17. Hub Distance (Axial Spacing)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 25
Section 5 · Maintenance/Service
Angular Alignment
Parallel Offset
Figure 5-18. Angular Alignment and Parallel Offset
22. Angular Alignment. Rigidly mount a dial indicator on one hub or shaft, reading the face of the other hub flange. Rotate both shafts together, making sure the shaft axial spacing remains constant. Adjust the motor by shimming and/or moving so that the indicator reading is within 0.002" per inch of coupling flange, see Figure 5-18.
23. Parallel Offset. Rigidly mount a dial indicator on one hub or shaft, reading the other hub flange outside diameter. Indicator set-up sag must be compensated 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 flex disc packs, see Figure 5-18.
With the coupling in good alignment the bolts will fit through the holes in the flanges 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 first. 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 the disc
pack.
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 member. 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 5-5. 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.
24. Install bolts and locking nuts to secure both disc packs to center member.
25. Tighten locking nuts.
5 26
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Drive Coupling Hub (Form-Flex BPU) and Center Member Removal
To remove coupling assembly, 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 lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. 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 components 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 allow 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-flange between the compressor 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 lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. 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 components to cool prior to servicing.
4. Remove C-flange 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.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 27
Section 5 · Maintenance/Service
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 compres-
sor 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 5-7.
15. Install clamping bolts to secure hub on compressor shaft. Tighten clamping bolts, see Table 5-7.
16. Install key and hub on motor shaft as noted during removal. Allow gap to install coupling sleeve.
17. Install coupling sleeve on hubs. Position hub on motor shaft on coupling sleeve as noted during removal.
18. Install set screw in compressor hub to secure key in keyway. Tighten set screw, see Table 5-7.
19. Install clamping bolts to secure hub to motor shaft. Tighten clamping bolts, see Table 5-7.
Table 5-7. Clamping Bolts and Set Screw Torque Specifications
Coupling Size
6 7 8 9 10 11
Type C ft-lbs (Nm)
Clamping Bolts
Key Set Screw
13 (18)
13 (18)
23 (31) 23 (31)
13 (18)
50 (68)
50 (68)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Coupling Guard Replacement
NOTE Coupling guards may differ slightly but this replacement procedure can be used to remove and install them. The coupling guard assembly described
in this procedure is VPN A27435C.
WARNING
The design, construction, mounting and opening of coupling guards should be performed following proper local codes. Failure to comply may result in
serious injury or death.
Removal
Reference Figure 5-19.
1. Shut down compressor unit, see Compressor Unit Isolation for Maintenance/Service procedure.
2. Remove eight screws (1) and flat washers (2) securing upper guard (7) to lower guard (8).
3. Remove three screws (1) and flat washers (2) securing upper guard (7) to ring mounting guard (5). Remove upper guard.
4. Remove two screws (1) and flat washers (2) securing lower guard (8) to ring mounting guard (5). Remove lower guard.
5. Remove eight fasteners (6) from lower guard (8).
1 2
7
6. Remove four nuts (4), screws (1) and flat washers (2) securing ring mounting guard (5) to four support brackets (3). Remove ring mounting guard.
7. Remove five fasteners (6) from ring mounting guard (5).
8. Remove four screws (9), lock washers (10) and flat washers (11) securing support brackets (3) from compressor. Remove support brackets. Discard lock washers.
Installation
9. Install four flat washers (11), new lock washers (10) and screws (9) to secure support brackets (3) to compressor. Do not fully tighten.
10. Install five fasteners (6) to ring mounting guard (5). 11. Install four screws (1), flat washers (2) and nuts (4)
to secure ring mounting guard (5) to four support brackets (3).
12. Tighten nuts (4) and screws (9).
13. Install eight fasteners (6) to lower guard (8). 14. Install two flat washers (2) and screws (1) to secure
lower guard (8) to ring mounting guard (5). 15. Install three flat washers (2) and screws (1) to se-
cure upper guard (7) to ring mounting guard (5). 16. Install eight flat washers (2) and screws (1) to se-
cure upper guard (7) to lower guard (8).
17. Return compressor unit to service.
1 2 6
5
12
8
34
9 1110
12
Figure 5-19. Coupling Guard Assembly (VPN A27435C shown)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 29
Section 5 · Maintenance/Service
Compressor Replacement
Notify VilterTM prior to performing a compressor replacement. See Warranty instructions in Section 7.
Removal
To replace a compressor on a unit, proceed with the following steps:
NOTICE
Dispose of used oil in an appropriate manner following all Local, State and Federal laws and ordinances.
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 coupling guard, see Coupling Guard Replacement procedure.
4. Remove drive coupling, see appropriate Drive Coupling Replacement procedure.
5. Remove center member, see Drive Coupling Removal procedure. NOTE
Use appropriate supporting equipment to support and keep motor, C-flange and compressor leveled.
6. If equipped with C-flange, remove bolts securing C-flange to compressor.
7. Using appropriate drain pan, drain oil by removing drain plugs from under compressor housing and discharge manifold. Allow oil to completely drain.
8. Remove all oil lines from the compressor. 9. Support suction line with appropriate supporting
equipment. 10. Remove nuts and bolts securing suction strainer/
check valve assembly to suction stop valve and compressor. 11. Using appropriate lifting device, remove suction strainer/check valve assembly from compressor. 12. Remove nuts and bolts securing discharge pipe to compressor and oil separator, see Figure 5-20. 13. Remove discharge pipe and gaskets from compressor and oil separator. 14. Remove nuts, flat washers, lock washers and studs securing compressor to frame. 15. Remove any additional lines and/or components to allow removal of compressor as required.
NOTE Refer to Bareshaft Compressor Lifting Points and Weights section for appropriate lifting hole sizes,
weights and lifting points.
16. Install appropriate lifting eyes on top of compressor. 17. Using appropriate lifting device and additional per-
sonnel, remove compressor from frame.
Compressor
Figure 5-20. Compressor Replacement and Hardware Assembly (VSS 2401-3001 Shown)
Nut Lock Washer
Flat Washer
5 30
Frame
Shim Stud
Spherical Washer Assembly
Flat Washer Lock Washer
Nut
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
18. Remove shims and spherical washers from com- 27. Install drive coupling, see appropriate Drive
pressor mounting locations.
Coupling Replacement procedure.
19. Inspect shims and spherical washers for damage, 28. Install center member, see Drive Center Member
replace as required.
Installation and Alignment procedure.
Installation
20. Install shims and spherical washers on compressor mounting locations, see Figure 5-20.
21. Install appropriate lifting eyes on top of compressor.
22. Using appropriate lifting device, position compressor on compressor mounting locations on frame.
23. Loosely install studs, lock washers, flat washers and nuts to secure compressor to frame until alignment is correct.
24. Check compressor for soft foot. Add or remove shims as required until measurements are within +/- 0.002".
25. Tighten nuts to secure compressor to frame, refer to Appendix A.
26. If equipped with C-flange, install bolts to secure C-flange to compressor. Tighten bolts, see Appendix A.
29. Install coupling guard, see Coupling Guard Replacement procedure.
30. Install nuts and bolts to secure discharge pipe to oil separator and compressor.
31. Tighten nuts on `discharge pipe-to-compressor flange' first, then tighten nuts on `discharge pipeto-oil separator flange', see Appendix A.
32. Install nuts to secure suction strainer/check valve assembly to compressor and suction stop valve.
33. Tighten nuts on `suction strainer/check valve assembly-to-compressor' first, then tighten nuts on `suction strainer/check valve assembly-to-suction stop valve', refer to Appendix A.
34. Install all lines to compressor.
35. Install all cables to sensors on compressor and actuator.
36. Perform leak check, see Compressor Unit Leak Check procedure.
Bareshaft Compressor Lifting Points and Weights
Table 5-8. Bareshaft Compressor Component Weights
Models
Gaterotor Bearing Housing
Component Weights
Gaterotor Bearing Housing Cover
Discharge Manifold
Main Compressor Assembly ONLY
Gaterotor Cover
97-127
3.3 lbs (1.6 kg)
8 lbs (4 kg)
N/A
249 lbs (113 kg)
10 lbs (5 kg)
291-601
19 lbs (9 kg)
11 lbs (5 kg)
125 lbs (57 kg)
1105 lbs (502 kg)
46 lbs (21 kg)
751-901
28 lbs (13 kg)
11 lbs (5 kg)
177 lbs (80 kg)
1450 lbs (658 kg)
33 lbs (15 kg)
1051-1301 37 lbs (17 kg)
13 lbs (6 kg)
274 lbs (125 kg)
2006 lbs (910 kg)
42 lbs (19 kg)
1551-2101 54 lbs (24 kg)
19 lbs (9 kg)
349 lbs (158 kg)
3151 lbs (1429 kg)
70 lbs (32 kg)
2401-3001 58 lbs (27 kg)
32 lbs (15 kg)
788 lbs (358 kg)
4152 lbs (1883 kg)
150 lbs (68 kg)
Table 5-9. Bareshaft Compressor Component Lifting Hole Sizes
Component Lifting Hole Sizes
Models
97-127
A
B
Discharge
Discharge
Manifold (Side) Manifold (Top)
A & B Lifting Points: 1/2 - 13 UNC -2B
C
Main Compressor Assembly ONLY
(Discharge)
-
D
Main Compressor Assembly ONLY
(Suction)
-
E
Gaterotor
Cover -
291-601
5/8-11 UNC -2B 5/8-11 UNC -2B
5/8-11 UNC -2B
5/8-11 UNC -2B
3/8-16 UNC-2B
751-901
5/8-11 UNC -2B 5/8-11 UNC -2B
5/8-11 UNC -2B
5/8-11 UNC -2B
-
1051-1301 5/8-11 UNC-2B 5/8-11 UNC -2B
3/4-10 UNC -2B
5/8-11 UNC -2B 3/8-16 UNC -2B
1551-2101 5/8-11 UNC -2B 5/8-11 UNC -2B
5/8-11 UNC -2B
5/8-11 UNC -2B 3/8-16 UNC -2B
2401-3001 5/8-11 UNC -2B 5/8-11 UNC -2B
5/8-11 UNC -2B
3/4-10 UNC -2B 5/8-11 UNC -2B
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5 31
Section 5 · Maintenance/Service
E C B
A
D Main Compressor Assembly E
Gaterotor Cover
Model 1551-2101 Shown
Discharge Manifold
MAIN HOUSING LIFTING POINT 1/2-13 UNC
Gaterotor Bearing Housing
Gaterotor Bearing Housing Cover
Figure 5-21. Bareshaft Compressor Lifting Points and Component Weights
Lifting Eye
Main Lift Point Lifting Eye
Lifting Point B 1/2-13 UNC
GATEROTOR COVER
Center of Gravity
Lifting Point A 1/2-13 UNC
ROLLER BEARING HOUSING
GATEROTOR BALL BEARING SUPPORT
Figure 5-22. Bareshaft Compressor Assembly Center of Gravity (Models 97-127)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service Bareshaft Compressor Center of Gravity (Models 291-2101)
Main Lift Point Lifting Eyes
Center of Gravity
Center of Gravity Range
Model 1551-2101 Shown
Figure 5-23. Bareshaft Compressor Assembly Center of Gravity (Models 291-2101)
Center of gravity may differ slightly between models 291-2101. Adjust main lift point within the range to keep bareshaft compressor as leveled as possible when lifting.
Main Lift Point
Lifting Eyes
Discharge Manifold
Center of Gravity Range
Main Compressor Assembly
Figure 5-24. Bareshaft Compressor Center of Gravity - Discharge Manifold and Main Compressor Assembly (Models 291-2101)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 33
Section 5 · Maintenance/Service Bareshaft Compressor Center of Gravity (Models 2401-3001)
Main Lift Point Lifting Eyes
Center of Gravity
Figure 5-25. Bareshaft Compressor Assembly Center of Gravity (Models 2401-3001)
Main Lift Point
Lifting Eyes Center of Gravity
Discharge Manifold
Main Compressor Assembly
Figure 5-26. Bareshaft Compressor Center of Gravity - Discharge Manifold and Main Compressor Assembly (Models 2401-3001)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Compressor Inspection
Compressor Shaft Bearing Clearance Inspections
If clearance measurements are out of tolerance, contact Vilter Technical Support for further assistance.
CAUTION
When taking the measurements, do not exceed 300 to 500 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)
Main Rotor Bearing Axial Clearance Inspection
To inspect bearing axial clearance, 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 5-27.
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 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 5-10, the bearing may need to be replaced. Contact VilterTM Technical Support.
Top View
Shaft being pushed by use of lever.
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:
Direction of shaft movement.
(300 lbf x 6")/30" = 60 lbf (Max. Applied Force) (1335 N x 15 cm)/85 cm = 235 N (Max. Applied Force)
Applied Force
Force at Hub/Shaft
A B
Pivot Point
Lever
Wooden Block or Fulcrum
Rigidly attach dial indicator. Position on axis of compressor.
Applied Force
Small wooden block or fulcrum.
Top View
Shaft being pushed by use of lever.
Rigidly attach dial indicator. Position on axis of compressor.
Direction of shaft movement.
As a quick reference, Table 5-10 shows maximum applied forces for 36" lever with 6" pivot for all compressor models.
Wooden block or fulcrum
Applied Force
Figure 5-27. Bearing Axial Clearance Inspection
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 5 · Maintenance/Service
Main Rotor Bearing Radial Clearance Inspection 6. Install dial indicator to the compressor frame and
zero indicator, see Figure 5-28.
NOTE Do not exceed maximum applied force. For maximum applied forces of all compressor models,
see Table 5-10.
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 5-10, the bearing may need to be replaced. Contact VilterTM Technical Support.
Side View
Shaft being pushed by use of lever. Rigidly attach dial indicator.
Direction of shaft movement. Applied Force
Figure 5-28. Bearing Radial Clearance Inspection
Table 5-10. Maximum Main Rotor Bearing Clearance
Max. Axial
Compressor Clearance
Model
in. (mm)
Max. Radial
Clearance
in. (mm)
Max. Force at
Hub/Shaft
lbf (N)
97-127
151, 181, 201, 152, 182, 202, 301, 361, 401
501, 601, 701
291, 341, 451, 601
751, 901
791, 891, 1051, 1201,
1301 1501, 1551, 1801, 1851,
2101
2401, 2601, 2801, 3001
0.002 (0.051)
0.004 (0.102)
0.006 (0.152)
0.007 (0.178) 0.007 (0.178) 0.006 (0.152)
0.006 (0.152)
0.007 (0.178)
0.006 (0.152)
100 (444)
100 (444)
150 (667) 150 (667) 200 (890)
300 (1335)
400 (1780)
600 (2670)
Max. Applied Force
(36" Lever, 6" Pivot)
lbf (N)
20 (89)
20 (89)
30 (133)
30 (133)
40 (178)
60 (267)
80 (356)
120 (534)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Gaterotor Bearing Inspection
1. Position a one gallon (at least) plastic oil collection bin beneath the side cover. Carefully pry open the side cover to allow the oil to drain before finally removing the side cover.
2. To measure the gaterotor radial bearing clearance, position a dial indicator to the gaterotor shaft as shown in Figure 5-29 (a) and zero the indicator. Put a hand as shown and firmly move the shaft in the direction shown in Figure 5-29 (a). Record the measurement. See table 5-11 for the maximum radial clearance value.
3. To measure the gaterotor axial bearing clearance, position a dial indicator on the gaterotor, as shown in Figure 5-29 (b).
4. To check axial bearing clearance use a lever arm pivoting on a bolt with a small block of wood against the gaterotor to protect it, as shown in Figure 5-29 (b). Record the measurement. See table 5-11 for the maximum axial clearance value.
Table 5-11. Maximum Gaterotor Bearing Clearance
Compressor Models
Max. Axial Clearance in (mm)
Max. Radial Clearance in (mm)
All Sizes
0.002"
0.004"
(0.051 mm) (0.102 mm)
Figure 5-29 (a): Radial
Figure 5-29 (b): Axial
Side V iew
Showing gaterotor bearing clearance being measured. Wooden block to prevent damage to gaterotor blade.
Direction of gaterotor movement. Axial force at gaterotor to not exceed 100 lbs.
Rigidly at tach
Force to be determined
dial indicator.
by length of lever arm.
Use bolt for fulcrum.
Figure 5-29. Gaterotor Bearing Clearance
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 5 · Maintenance/Service
Gaterotor Inspection A) Gaterotor - Main Housing Shelf Clearance
Follow these steps to check the clearance between the gaterotor and the shelf, which should be between 0.003" 0.004", see Figure 5-30. 1. Place a 0.003" feeler gauge between the gaterotor teeth, as shown in Figure 5-31 (a) and (b).
NOTE
Make sure the feeler gauge stays in the opening between the two teeth until it is on top of the shelf.
2. Without moving the feeler gauge, slowly rotate the gaterotor so that the feeler gauge tip stays between the gaterotor and the shelf. See Figure 5-31 (c).
Check for 0.003-0.004" (0.076- 0.102 mm) clearance between gaterotor blade and shelf.
CAUTION
Do not over rotate. If the rotor catches the feeler gauge, a piece can break and fall into the rotor groove.
Figure 5-30. Gaterotor and Shelf Clearance
3. Gently pull the feeler gauge out in the direction shown in Figure 5-31 (d).
(a) Feeler Gauge Placement (Side View)
(b) Feeler Gauge Placement
(Top View)
(c) Tip Of The Feeler Gauge Stays Between Gaterotor
And Shelf While Rotating
(d) Feeler Gauge Must Be Pulled
Out In This Direc-
tion
5 38
Figure 5-31. Gaterotor and Shelf Clearance Measurement Steps
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
4. If it is easy to pull out the feeler gauge, then increase the feeler gauge thickness by 0.001" and repeat above steps 1-3. If it is slightly tight to pull it out, then the clearance corresponds to the feeler gauge thickness.
NOTE
Replacement gaterotors are the same dimensionally as the gaterotors installed at the factory. Therefore, the same shims can be reused when replacement is needed
to preserve the 0.003" 0.004" clearance.
Clearance and Shims
Under 0.003" 0.003" 0.004" Over 0.004"
Remove shims (103 in Figure 5-48, 106 in Figure 5-42 & 5-44) to achieve 0.003" 0.004"
Perfect!
Add shims (103 in Figure 5-48, 106 in Figure 5-42 & 5-44) to achieve 0.003"
0.004"
B) Gaterotor Float Measurement
1. Before doing any measurements, first conduct a visual check to see if there is any noticeable clearance between the gaterotor and its bushing, see Figure 5-32. If there is noticeable clearance, please contact Vilter Service Department.
NOTE
The number of bushings on a gaterotor can be anywhere from one to three.
2. To measure the float between the gaterotor bushing and the support damper pin (see Figure 5-34), position a dial indicator at the tip of the support as shown in Figure 5-33. Hold the gaterotor in place, then gently move the support teeth back and forth with two fingers (and record measurement). Refer to Table 5-12 to find the maximum float value.
NOTICE
If clearance measurements are out of tolerance, contact Vilter Service Department for further
assistance.
Table 5-12. Gaterotor Float
Model
Float in. (mm)
VSM-97 - VSM127
0.045 (1.143)
VSM 71 - VSM 401
0.045 (1.143)
VSM 501 - 701
0.045 (1.143)
VSS/VSSH 291 - 601 0.045 (1.143)
VSS 751 - 901
0.055 (1.397)
VSS/VSH 791 - 1301 0.060 (1.524)
VSS 1501 - 2101
0.060 (1.524)
VSS 2401-3001
0.060 (1.524)
Figure 5-32. Visual Inspection Between Gaterotor and Bushing
Dial Indicator Gaterotor Blade
Gaterotor Support
Damper Pin and Bushing
Main Rotor
Figure 5-33. Gaterotor Float Dial Location
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Section 5 · Maintenance/Service
Figure 5-34. Gaterotor Float
C) Gaterotor Backlash Inspection
Gaterotor Backlash is the clearance between the gaterotor teeth width and the main rotor groove.
Follow these steps to perform the gaterotor backlash inspection:
1. The Gaterotor should be aligned so that a tooth in the rotor is perpendicular to the Main Axis as shown in Figure 5-35. The tooth should be in the center axis of the housing.
2. A dial indicator with magnetic base can be used (Vilter part numbers 9994ARE or 9994ARJ for the dial indicator, and 9994ARD for the magnetic base). See Figure 5-36 for location.
Inside Tooth is Perpendicular to the Rotor
Figure 5-35. Alignment of Gaterotor
Gaterotor Support
Gaterotor Shelf
Location for Dial Indicator Magnetic Base
5 40
Figure 5-36. Location of Dial Indicator Magnetic Base
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
3. Place the Dial Indicator as square as possible on the Gaterotor tooth as shown on Figure 5-37.
Dial Indicator
Figure 5-37. Placement of Dial Indicator
4. To measure the backlash (see Figure 5-38), move the gaterotor with two fingers back and forth rapidly several times while reading the dial indicator to see what the displacement range is. This displacement range will be the total backlash.
Contact Vilter Service Department if the measurement is above the ranges shown on Table 5-13.
Table 5-13. Backlash Range
Compressor Model
Normal backlash
VSM-97 thru VSS/VSH-1301 0.008" to 0.012"
VSS-1501 thru VSS-3001 0.008" to 0.015"
Fingers Positioning to Move the Gaterotor Back and Forth
Displacement Range
Figure 5-38. Measuring Backlash
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 5 · Maintenance/Service
Important Notes 1. Backlash cannot be checked if:
· The gaterotor is damaged in any way.
· The clearance between the gaterotor and the shelf is too tight.
2. Make sure you check the backlash, not the float:
· The backlash is the clearance between the gaterotor teeth width and the rotor groove.
· The float is the amount of play between the gaterotor bushing and the damper pins.
Additional Inspections In addition, visually inspect the main rotor and gaterotors for signs of abnormal wear due to dirt or other contaminants.
If some chipping is present on the edges of the gaterotor, this will not influence the compressor performance. If chipping is more than what´s shown on Figure 5-39, take pictures and contact Vilter Service Department.
Post Inspection After all the inspections are complete, the gaterotor cover, suction tee, coupling center member and coupling guard can be reinstalled and the unit can be evacuated and leak checked before starting.
Gaterotor Assembly Replacement (All Compressors Except VSM 301-701 and VSM 97-127 Compressors)
Table 5-14 lists the gaterotor tool sets needed to remove and install gaterotor assemblies.
Table 5-14. Gaterotor Tool Kits
Model
Tool Set VPN
VSM 97- VSM 127 VSM 71-VSM 401
VSM 501-701 VSS/VSSH 291-601 VSS/VSH 751-1301
VSS 1551-2101 VSS 2401-3001
N/A N/A A25205B A25205B A25205C A25205E 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 gaterotor support.
NOTE
The gaterotor stabilizer is designed to hold the gaterotor support in place and prevent damage to the gaterotor blade as the thrust bearings and
housing is being removed.
6. Insert gaterotor stabilizer. The side rails are not
Figure 5-39. Chipped Edge of Gaterotor
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
required on VSS 451 thru 601. For the VSS 751 thru 901 and VSS 1051 thru 1301 compressors, use the side rails and assemble to the gaterotor stabilizer as stamped. For the VSS 1551 thru 2101, use the side rails and assemble to the gaterotor stabilizer. Refer to Figure 5-40.
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 gaterotor support with a suitable wrench on the flats 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 gaterotor 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 gaterotor support. On dual gate compressor units, repeat the procedure for the remaining gaterotor support assembly.
Installation
15. Install gaterotor support by carefully tilting the roller bearing end of the gaterotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gaterotor support. Install gaterotor stabilizer. The gaterotor stabilizer (901) will hold the gaterotor support in place as the thrust bearing housing is being installed. If the gaterotor support is not restricted from moving, the gaterotor blade may be damaged. See Figure 5-41.
16. Install the roller bearing housing (112) with a new O-ring (141). See Figure 5-42.
17. Tighten bolts (152), see Appendix A.
18. When installing the thrust bearing housing (113), a
For VSS 451-601 compressors, do not use side rails.
90 1A
For VSS 751/901 and 10511301 compressors, use side rails and assemble gaterotor stabilizer as stamped.
90 1B 90 1C
Position leading edge of main rotor groove flush with or slightly below back of gaterotor
support.
! WARNING
Blades on gaterotor are sharp.
Figure 5-40. Gaterotor Assembly Removal and Tools
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 5 · Maintenance/Service
new O-ring (142) must be used when the housing is installed, see Figure 5-42. Lubricate the outside of the housing and bearings with clean compressor oil to aid in the installation. Due to the fit of the bearings on the gaterotor 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) using Loctite® 242 thread locker. Tighten bolts, see Appendix A. 19. Set clearance between gaterotor blade and shelf. 20. Place a piece of 0.003"-0.004" shim stock between gaterotor blade and shelf.
NOTE This measurement determines the amount of shims
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.
Use flats provided on gaterotor support to prevent rotation when removing bearing retainer.
Figure 5-41. Gaterotor Assembly Removal
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
23. Check the clearance between the entire gaterotor blade and the shelf, rotate the gaterotor to find the tightest spot. It should be between 0.003-0.004" (0.076-0.102 mm). Make adjustments, if necessary. It is preferable to shim the gaterotor blade looser rather than tighter against the shelf, see Figure 5-43.
24. After clearance has been set install a new O-ring (143) on bearing housing cover, install cover and tighten the bolts to the recommended torque value.
25. Install side cover with a new gasket. Tighten the bolts to the recommended torque value. The unit can then be evacuated and leak checked.
Check for 0.003-0.004" (0.076- 0.102 mm) clearance between gaterotor blade and partition.
Figure 5-42. Gaterotor Assembly and Tools Figure 5-43. Gaterotor and Shelf Clearance
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Section 5 · Maintenance/Service
Gaterotor Assembly Replacement (VSM 301-701 Compressors ONLY)
Removal
The removal of the gaterotor assembly for the VSM 301-701 compressors is similar for the VSS 751-3001 compressors 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 install 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 as described above.
5. Turn the main rotor so the driving edge of the groove is between the top of the shelf or slightly below the back of the gaterotor support. At this point install the gaterotor stabilizing tool.
6. Remove plug on the thrust bearing housing. Loosen the socket head cap screw that is located underneath 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 gaterotor 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 gaterotor 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 gaterotor support. On dual gate versions, repeat the procedure for the remaining gaterotor support assembly.
Installation
10. Install the gaterotor support. Carefully tilt the roller bearing end of the gaterotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gaterotor support.
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 between the shelf and blade.
Figure 5-44. Gaterotor Assembly Breakdown
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Section 5 · Maintenance/Service
13. Check the clearance between the entire gaterotor blade and the shelf, rotate the gaterotor to find the tightest spot. It should be between 0.003-0.004" (0.076-0.102 mm). Make adjustments, if necessary. It is preferable to shim the gaterotor blade looser rather than tighter against the shelf.
14. Once the clearance is set remove the spindle. Install new O-ring, apply Loctite 242 thread locker to the socket head cap screw clamping the thrust bearings to the spindle. Torque all bolts, see Appendix A.
15. Install side covers with new gaskets. Tighten bolts, see Appendix A. The unit can now be evacuated and leak checked.
Check for 0.003-0.004" (0.076- 0.102 mm) clearance between gaterotor blade and partition.
Figure 5-46. Gaterotor and Shelf Clearance
Figure 5-45. Gaterotor Thrust Bearing
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Section 5 · Maintenance/Service
Gaterotor Assembly Replacement (VSM 97-127 Compressors ONLY)
Removal
1. Remove center member.
NOTE All parts must be kept with their appropriate side and not mixed when the compressor is reassembled.
2. Remove bolts from side cover.
NOTE There will be some oil drainage when the cover is
removed.
3. Turn main rotor so a driving edge of any one of the main rotor grooves is even with the back of the gaterotor support.
4. Remove the three screws (item 107 in Figure 5-48) that hold the housing in place.
5. Remove the gaterotor roller bearing housing (item 105 in Figure 5-48).
6. Remove O-ring (102-2), bearing and retainer ring (106).
7. Remove the 8 screws (107) that hold the ball bearing support (104) and the O-Ring (102-1).
8. To remove the gaterotor support (101), carefully move support in the opposite 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 gaterotor support.
9. On dual gate compressor units, repeat the procedure for the remaining gaterotor support assembly.
Installation
1. Install gaterotor support by carefully tilting the roller bearing end of the gaterotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gaterotor support. Install gaterotor stabilizer. The gaterotor stabilizer (901) will hold the gaterotor support in place as the thrust bearing housing is being installed. If the gaterotor support is not restricted from moving, the gaterotor blade may be damaged.
2. Install the roller bearing housing (105) with a new O-ring (102-2), and make sure the O-Ring is installed in the proper groove.
3. Tighten bolts (107), see Appendix A.
4. Install thrust bearing support. Lubricate the outside of the support and bearings with clean compressor oil to aid in the installation. Tighten bolts, see appendix A.
5. Measure clearance between gaterotor blade and shelf by placing shim stock between gaterotor blade and shelf until snug. Subtract .003"-.004" from total amount of shim stock used.
NOTE
This measurement determines the amount of shims needed for the correct clearance.
6. Use factory installed shim pack (103) and bearing housing cover without the O-ring.
Figure 5-47. Gaterotor Assembly Removal
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.
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Section 5 · Maintenance/Service
Figure 5-48. Gaterotor Assembly (VSM 97-127 Compressors ONLY)
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Section 5 · Maintenance/Service
7. Check the clearance between the entire gaterotor blade and the shelf, rotate the gaterotor to find the tightest spot. It should be between 0.003-0.004" (0.076-0.102 mm). Make adjustments, if necessary. It is preferable to shim the gaterotor blade looser rather than tighter against the shelf, see Figure 5-49.
8. After clearance has been set install a new O-ring on bearing housing cover, install cover and tighten the bolts to the recommended torque value.
9. Install side cover with a new gasket. Tighten the bolts to the recommended torque value. The unit can then be evacuated and leak checked.
Check for 0.003-0.004" (0.076- 0.102 mm) clearance between gaterotor blade and partition.
Gaterotor Disassembly (All VSS & VSM Compressors Except VSM 97-127 Compressors)
10. To perform gaterotor disassembly, remove gaterotor from compressor, see Gaterotor Assembly Replacement procedure (All VSS-VSM Compressors Except VSM 301-701 Compressors) or Gaterotor Assembly procedure (VSM 301-701 Compressors ONLY).
Gaterotor Blade Removal
11. Remove the snap ring and washer from the gaterotor assembly. Lift gaterotor blade assembly off the gaterotor support, see Figure 5-50.
12. Check damper pin and bushing for excessive wear. Replace if required.
Figure 5-49. Gaterotor and Shelf Clearance
Figure 5-50. Gaterotor Blade Assembly
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Section 5 · Maintenance/Service
Gaterotor Blade Installation
13. Install damper pin bushing (120) in gaterotor blade (111) from the back side of the blade. Be sure bushing is fully seated.
14. Place blade assembly on gaterotor support. Locating damper over pin.
15. Install washer (119) and snap ring (130) on gaterotor assembly. The bevel on the snap ring must face away from the gaterotor blade. After the gaterotor blade and support are assembled, there should be a small amount of rotational movement between the gaterotor and support.
Gaterotor Thrust Bearing Installation
For installation of thrust bearings on VSS units
22. Install thrust bearings (126) in the housing so the bearings are face to face. 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 bearings into the housing.
23. Center the bearing retainer ring on housing, use Loctite® 242-thread locker and evenly tighten the bolts to the recommended torque value, see Figure 5-53.
Gaterotor Thrust Bearing Removal
For removal of thrust bearings on VSM units: 16. Remove bolts (150) from the clamping ring (114),
see Figure 5-52. 17. Remove thrust bearing clamping ring. 18. Remove thrust bearings (126) from housing (113).
For removal of thrust bearings on VSS units: 19. Remove retaining ring from gaterotor support. 20. Remove bearings from support. 21. Remove bearing retainer from inner race.
Figure 5-52. Gaterotor Thrust Bearing
Figure 5-51. Gaterotor Blade Installation
Figure 5-53. Thrust Bearing Installation
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Section 5 · Maintenance/Service
For installation of thrust bearings on VSM 301701 units
24. 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.
25. The bearing with the retainer should be placed in the housing first, retainer towards the support. Install the second bearing. The bearings should be positioned face to face. This means that the larger sides of the inner races are placed together. A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the gaterotor support.
26. Install the bearing retaining snap ring.
Gaterotor Roller Bearing Removal
27. Remove the snap ring (131), which retains the roller bearing in the bearing housing, see Figure 5-54.
28. Remove the roller bearing (125) from the bearing housing (112).
29. Use a bearing puller to remove the roller bearing race (125) from the gaterotor support (110).
Gaterotor Roller Bearing Installation
30. Match up the part numbers on the inner race to the part numbers outer race. Press the bearing race (numbers visible) onto the gaterotor support.
31. Install the outer bearing into the bearing housing so the numbers match the numbers on the inner race. Install the snap ring retainer in the housing. The bevel on the snap ring must face away from the roller bearing.
Figure 5-54. Roller Bearing Assembly
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Section 5 · Maintenance/Service
Gaterotor Disassembly (VSM 97-127 Compressors ONLY)
1. To perform gaterotor disassembly, remove gaterotor from compressor.
Gaterotor Blade Removal
2. Lift gaterotor blade assembly off the gaterotor support, see Figure 5-55.
3. Check damper pin and bushing for excessive wear. Replace if required.
Gaterotor Blade Installation
4. Install damper pin bushing (120) in gaterotor blade (111) from the back side of the blade. Be sure bushing is fully seated, see Figure 5-56.
5. Place blade assembly on gaterotor support. Locating damper over pin, see Figure 5-55.
6. After the gaterotor blade and support are assembled, there should be a small amount of rotational movement between the gaterotor and support.
GATEROTOR DAMPER
102
102
SUPPORT PIN
Figure 5-55. Gaterotor Support (VSM 97-127)
Figure 5-56. Gaterotor Blade Installation
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Section 5 · Maintenance/Service
Gaterotor Thrust Bearing Removal
(See Figure 5-57)
7. Remove retaining ring from gaterotor support. 8. Remove bearings from support. 9. Remove bearing retainer from inner race.
Gaterotor Roller Bearing Removal
11. Remove the snap ring, which retains the roller bearing in the bearing housing.
12. Remove the roller bearing from the bearing housing.
13. Use a bearing puller to remove the roller bearing race from the gaterotor support.
Gaterotor Thrust Bearing Installation
10. Install thrust bearings in the housing so the bearing is face out (face is visible when installed). A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the housing, see Figure 5-57.
Gaterotor Roller Bearing Installation
14. Match up the part numbers on the inner race to the part numbers outer race. Press the bearing race (numbers visible) onto the gaterotor support.
15. Install the outer bearing into the bearing housing so the numbers match the numbers on the inner race. Install the snap ring retainer in the housing. The bevel on the snap ring must face away from the roller bearing.
101
Install Retainer Ring
104
With Beveled Facing
Away From Gaterotor
103
Figure 5-57. Gaterotor Thrust Bearing (VSM 97-127)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Compressor Shaft Seal Replacement
Shaft Seal Assembly
The shaft seal is made up of a mating ring and a carbon or silicon carbide (SC) component.
The mating ring is the rotating part of the seal and is installed against the shaft shoulder. It has a drive notch on one end which aligns with the drive pin inserted in the shaft.
Carbon or SC component is the stationary part of the seal and is installed into the shaft seal housing using an O-ring.
The shaft seal housing with the stationary part is assembled in the compressor main housing using an O-ring, see Figure 5-58.
The shaft seal needs to be carefully handled and installed to function properly. Please see Figure 5-59 for details.
Figure 5-58. Shaft Seal Assembly
Handling Seal Face with Care
· Avoid touching seal faces as much as possible during installation.
· Be sure to always keep seal faces face-up, rather than face-down, see image on the right.
Figure 5-59. Handling Seal Face with Care
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Section 5 · Maintenance/Service
Compressor Shaft Seal Replacement - For VSS/VSM Units
Tools Table 5-15. Shaft Seal Tool Kits
Model
(VPN) for the Shaft Seal Tool Kits
VSM 97 - VSM 127 VSM 152 - VSM 401
VSM 501 - 701 VSS 291 - 601 VSS 751 - 1301 VSS 1551 - 2101
N/A 25455A 25455B 25455B 25455C 25455D
Removal
1. Remove bolts (281) securing shaft seal housing (218). to compressor.
NOTE
There will be a small amount of oil drainage as the shaft seal housing is removed.
2. Insert two of bolts (281) into threaded jacking holes to assist in removing shaft seal housing (218).
3. Remove mating ring (219C) from compressor shaft.
4. Remove oil seal (230) from shaft seal housing (218).
5. Using a brass drift and hammer, tap out cup assembly (219B) from the back side of shaft seal housing (218).
6. Remove O-ring (260).
Suggestion
A spray bottle filled with clean compressor oil may be used to lubricate the faces of the seals without touching the seal.
7. Install a new oil seal (230) in seal housing (218).
8. To install the carbon cartridge part of the seal in the seal housing: clean inside shaft seal housing (218) where cup assembly (219B) meets inside shaft seal housing.
9. If applicable, remove protective plastic from cup assembly (219B). DO NOT wipe or touch carbon component of cup assembly.
10. If carbon component of cup assembly (219B) needs cleaning, use alcohol and a lint-free cloth to clean.
11. Apply clean compressor lubricating oil to O-ring on cup assembly (219B).
12. Using shaft seal tool or similar, install cup assembly (219B) in shaft seal housing (218). If applicable, align the hole on the back of the carbon cartridge with the Anti-rotation pin in the seal housing. See Figure 5-61.
13. Clean compressor shaft and shaft seal cavity in compressor housing.
14. Apply clean compressor lubricating oil to mating ring (219C) seating area on compressor shaft. See Figure 5-61.
15. Apply clean compressor lubricating oil to inside area of mating ring (219C).
IMPORTANT
DO NOT wipe or touch the face of the mating ring (219C) where face meets the carbon component of the cup assembly (219B).
Installation
CAUTION
Care must be taken when handling the cup assembly and mating ring when installing. See Figure 5-59 for handling seal faces with care. Do not touch the carbon component of the cup assembly or mirror face on the mating ring as body oil and sweat will cause
corrosion.
281
218
260
219
219B 219C
NOTE
On VSS 291 - 601 compressors equipped with an Anti-rotation pin in the shaft seal housing, when replacing the cup assembly (219B) the Anti-rotation pin in the housing must be removed. See Figure
5-61.
Mirror Face
230
Carbon Component
Figure 5-60. Compressor Shaft Seal Assembly
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Section 5 · Maintenance/Service
CAUTION
Ensure the mating ring (219C) is fully seated against the shoulder of the compressor shaft. If the mating ring is not fully seated against the shoulder, the carbon component of the cup assembly (219B) will be damaged when the shaft seal housing (218) is
installed. See Figure 5-59.
16. Align slot in mating ring (219C) with drive pin on compressor shaft. Carefully push mating ring on while holding onto outside area of mating ring until mating ring is fully seated against shoulder on compressor shaft. See Figure 5-61.
17. Install a new O-ring (260) on the seal housing (218), making sure the O-ring is placed in the O-ring groove and not the oil gallery groove. See Figure 5-61.
18. Lubricate both seal faces with clean compressor lubricating oil.
19. Carefully install the seal housing (218) on the compressor shaft, evenly tightening the bolts (281) to the recommended torque values (36 ft-lbs).
20. Install the coupling and coupling guard. The unit can then be evacuated and leak checked.
218
Remove Anti-rotation Pin (If Installed)
218
Remove Anti-rotation Pin (if installed)
O-ring (260)
219C
O-ring
O-ring (260)
219C
O-ring
Align slot in mating ring (219C) with drive pin on compressor shaft.
Align slot in mating ring (219C) with drive pin on compressor shaft
Shoulder on Compressor Shaft
Shoulder on Compressor Shaft
Figure 5-61. Compressor Shaft Seal Installation: Tapered and Straight Shafts
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Section 5 · Maintenance/Service
Compressor Shaft Seal Replacement - For VSH/ VSSH Units
Shaft Seal Removal - For Part# 25985Y and 25985YA (see Table 5-16 and Figure 5-62)
WARNING
Follow local lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
NOTE
There will be a small amount of oil drainage as the shaft seal housing is removed.
1. Remove bolts (281) securing shaft seal housing (218) to compressor.
2. Insert two bolts (281) into threaded jacking holes to assist in removing shaft seal housing (218).
3. Remove silicon carbide rotating face (219.6) & O-ring (219.7) from shaft.
4. Remove spring holder (219.8) from shaft.
5. Remove oil seal (230) from shaft seal housing (218).
6. Remove retaining ring (219.5) from seal housing.
7. Flip the seal housing over and carefully tap the stationary silicon carbide piece (219.3), retainer (219.4), and O-ring (219.2) out of the seal housing using brass drift and hammer.
8. Remove O-ring (260).
NOTE
VSH/VSSH compressors are designed using the following shaft seals, see Table 5-16 for their VPN
and pressure ranges.
Table 5-16. VSH/VSSH Shaft Seals
Shaft Seal
25985Y 25985YA 25985W 25985WA
Pressure (PSI) O-Ring Material
Static Dynamic
1800 1800
1350 Fluoroelastomer
1350
EPDM
1800 1800
1350 Fluoroelastomer
1350
EPDM
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Figure 5-62. Shaft Seal Breakdown (28985Y & 28985YA)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Shaft Seal Removal For Part# 28985W and 28985WA
(see Table 5-16 and Figure 5-63)
WARNING
Follow local lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
7. Remove the O-ring (260) from the shaft seal housing (218).
8. The rotating assembly (219C) can be firmly pulled off the compressor shaft as one assembly. Be sure to note the location of the drive pin in the main compressor shaft for re-assembly. See Figure 5-61.
NOTE
There will be a small amount of oil drainage as the shaft seal housing is removed.
1. Prepare compressor for disassembly (standard nomenclature from other area of manual.
2. Loosen and remove screws (281) mounting shaft seal housing (218) to main compressor housing.
3. Carefully thread three screws (281) into the jacking holes in the shaft seal housing (218) to push it out of the main compressor housing. Do not go more than one-half turn on any screw at a time.
4. Once the shaft seal housing (218) has been removed from the compressor housing, loosen the 4 small socket cap screws (303) holding the shaft seal retainer (304) to the shaft seal housing (218).
5. Using a hammer and punch, carefully tap the seal cartridge (305) out of the shaft seal housing (218).
6. Remove oil seal (230) from shaft seal housing (218).
281
218
219B
219C
306 305 304 303 260 301A 301B 301C
Shaft
230
Stationary
Rotating
Face
Face
Figure 5-63. Shaft Seal Breakdown (28985W and 28985WA Only)
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Section 5 · Maintenance/Service
Prior to Shaft Seal Installation
WARNING
Follow local lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
NOTE
Care must be taken when handling the cup assembly and mating ring when installing. See Figure 5-59 for
Handling Seal Face with Care.
Suggestion A spray bottle filled with clean compressor oil may be used to lubricate the faces of the seals without touching the seal.
Notch in shaft seal for alignment with drive pin on
the shaft
Anti-rotation pin
Shaft Seal See Table 5-16
Lead chamfer on
inner diameter of
housing
Back wall of housing to
which shaft seal/shim
will bottom on
Figure 5-65. Shaft Seal Housing
Follow these steps to verify the integrity of a shaft seal:
1. Check lead chamfer and outer diameter of shaft for deep scratches that may potentially damage the O-ring on the inner diameter of the shaft seal, see Figure 5-64:
219C
O-ring
Drive Pin on Shaft
Lead Chamfer on Outer Diameter of Shaft
Shoulder to Which Seal Will Bottom on
Figure 5-64. Shaft with Pin
Align slot in mating ring (219C) with drive
pin on compressor shaft
Shoulder on Compressor Shaft
Figure 5-66. The Alignment of Compressor Shaft and Mating Ring
2. Check lead chamfer and inner diameter of shaft seal housing for burrs and/or deep scratches that may potentially damage the O-ring on the outer diameter of the shaft seal, see Figure 5-65.
3. Clean compressor shaft and shaft seal cavity in compressor housing.
4. Apply clean compressor lubricating oil to the compressor shaft in mating ring seating area, see Figure 5-66.
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Section 5 · Maintenance/Service
Shaft Seal Installation - For Part# 25985Y and 25985YA (see Table 5-16 and Figure 5-62)
NOTE Follow the "Prior to Shaft Seal Installation" steps
before starting this procedure.
WARNING
Follow local lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
NOTE
Care must be taken when handling the cup assembly and mating ring when installing. See Figure 5-59 for
Handling Seal Face with Care.
Suggestion A spray bottle filled with clean compressor oil may be used to lubricate the faces of the seals without touching the seal.
CAUTION
Do not wipe or touch the face of the mating ring (219C) where the face meets the carbon component
of the stationary assembly (219B).
1. Apply clean compressor lubricating oil to inside area of spring holder (219.8), rotating Silicon carbide piece (219.6) and o-ring (219.7).
2. Carefully fit spring holder (219.8) onto shaft until it is fully seated against shoulder on compressor shaft. Be sure to align slot in spring holder (219.8) with drive pin on compressor shaft, see Figure 5-66.
CAUTION
Ensure the spring holder (219.8) is fully seated against the shoulder of the compressor shaft. If the spring holder (219.8) is not fully seated against the shoulder, the carbon component of the stationary assembly (219B) will be damaged when the shaft seal housing
(218) is installed. 3. Place O-ring (219.7) inside rotating silicon carbide
piece (219.6) and carefully assemble onto shaft. You should feel some resistance in sliding this onto the shaft shoulder.
4. Install a new oil seal (230) in seal housing (218).
5. If necessary, Install anti-rotation pin (219.1a) in hole in shaft seal housing (218).
6. Install O-ring (219.2) into shaft seal housing.
7. Install stationary silicon carbide piece (219.3) in shaft seal housing with anti-rotation pin (219.1b) aligned 180 degrees away from the pin (219.1a) in step 4. You should feel some resistance to fit the stationary piece into the O-ring.
8. Fit the retainer (219.4) over the stationary piece while aligning the slots on the anti-rotation pins.
9. Install retaining ring (219.5) into groove in shaft seal housing.
10. Install a new O-ring (260) on the seal housing (218), making sure the O-ring is placed in the O-ring groove and not the oil gallery groove. Lubricate both seal faces with clean compressor lubricating oil.
11. Carefully install the seal housing (218) on the compressor shaft, evenly tightening the bolts (281) to the recommended torque values (36 ft-lbs).
12. Install the coupling and coupling guard. The unit can then be evacuated and leak checked.
Figure 5-62. Shaft Seal Breakdown (28985Y & 28985YA)
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Section 5 · Maintenance/Service
Shaft Seal Installation For Part# 28985W and 28985WA (see Table 5-16 and Figure 5-63)
NOTE Follow the "Prior to Shaft Seal Installation" steps
before starting this procedure.
WARNING
Follow local lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. Failure to comply may result in serious
injury, death and/or damage to equipment.
NOTE
Care must be taken when handling the cup assembly and mating ring when installing. See Figure 5-59 for
Handling Seal Face with Care.
Suggestion A spray bottle filled with clean compressor oil may be used to lubricate the faces of the seals without touching the seal.
CAUTION
Do not wipe or touch the face of the mating ring (219C) where the face meets the carbon component
of the stationary assembly (219B).
1. Install a new oil seal (230) in seal housing (218).
2. Ensure compressor shaft is clean and free from marks and scratches.
3. Remove seal rotating face (301A) and O-ring (301B) from rotating assembly portion of the seal (assembly 219C).
4. Apply clean compressor lubricating oil to seal
seating area on the compressor shaft and inside area of rotating face support (301C).
5. Gently assemble the rotating face support (301C) onto main compressor shaft, taking care to align the drive pin in the main shaft with the keyway on the rotating face support (301C).
6. Using a small amount of Flowserve supplied grease, carefully re-assemble O-ring (301B) and rotating face (301A) over the compressor shaft, onto the rotating face support (301C).
7. Moving onto the stationary portion of the seal (219B), gently press the stationary face (305), into the seal housing (218) ensuring it is fully seated. Make sure to align the hole on the back of the stationary face (305) with the Anti-rotation pin (306) in the seal housing (218). See Figure 5-65.
8. Assemble retaining ring (304) over the seal into the shaft seal housing (218), aligning the mounting holes with the threaded holes in the shaft seal housing.
9. Apply blue Loctite 242 to the bolts (303) and tighten them down evenly in a star pattern until snug, then torqueing each to 48 in-lbs (6 N-m).
10. Apply clean compressor lubricating oil to both seal faces (305 and 219C).
11. Ensure a new O-ring (260) is installed in proper groove of shaft seal housing (218).
12. Carefully assemble shaft seal housing (218) onto main compressor shaft into main compressor housing, evenly tightening the bolts (281) and torqueing to their appropriate value as specified by compressor specific drawing.
13. Install the coupling and coupling guard. The unit can then be evacuated and leak checked.
219B
219C
281
218
306 305 304 303 260 301A 301B 301C
Shaft
230
5 62
Stationary Face
Rotating Face
Figure 5-63. Shaft Seal Breakdown (28985W and 28985WA Only)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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 lock-out/tag-out procedure. Compressors must be depressurized before attempting to do any work on them. 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 components to cool prior to servicing. 4. Disconnect connectors from actuator.
NOTE Note orientation of components to aid in installation. 5. First remove E-clips, then remove Locking
Retainers, next loosen and remove Grooved Bolts and Washes that securing actuator assembly to actuator mount. See Figure 5-67 for parts details. 6. Remove actuator assembly from actuator mount.
Installation
CAUTION
When installing the slide valve actuator assembly, loosen locking collar down the shaft. Do not use a
screwdriver to pry locking collar into position.
7. Position actuator assembly on mount as noted in removal.
8. Install washers and grooved bolts to secure actuator assembly to actuator mount, torque them to 6 lb-ft. Then install locking retainers. Last push E-clips into grooved bolt heads. Refer to Actuator Installation Using Anti-Rotation Bolts (see next page) for details.
9. Tighten screws, see Appendix A.
CAUTION
If installing new actuator, do not connect connectors of power cable or position transmitter cable to new actuator once installed. Connecting connectors to new actuator will occur during calibration procedure. Failure to comply may result in damage to equipment.
10. Leave connectors disconnected to actuator assembly.
11. Calibrate actuator assembly, see Slide Valve Calibration procedure in Section 4 or Appendix F.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Section 5 · Maintenance/Service
Actuator Installation Using Anti-Rotation Bolts
Tools Needed: A 7/16" open wrench or torque wrench with 7/16" crowfoot wrench adapter.
Part #: The parts come with the actuator. Retrofit kit # is 25972R (Includes 4 sets of bolts, washers, retainers & E-clips).
1. Install the Grooved Bolt and Washer and torque them to 6 lb-ft. See figure 5-67 (a).
NOTE
It may be necessary to adjust the bolt position so that one of the bolt edges is parallel to line A and B, then the retainer will drop-on easily. If required,
tighten bolt further for this alignment.
A
B
E-clip
2. Position Locking Retainer over Grooved Bolt, with the shallow curved edge toward the center of the command shaft housing. See figure 5-67 (b). NOTE
The locking retainer hex hole is offset 3° so flipping it over gives it new positioning.
3. Push E-Clip into Grooved Bolt Head. Once E-clip is on make sure it rotates back and forth freely. This will ensure E-Clip is completely seated. See figure 5-67 (c).
GrooveLokTM Bolt
Retainer (Many Shapes
Available)
Assembled
Groove Bolt Washer
Locking Retainer
(a) Groove bolt and washer
(b) Locking Retainer
Complete Assembly
E- clip
5 64
(C) E-clip
Figure 5-67. Actuator Installation Using Anti-Rotation Bolts
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Slide Valve 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 the command shaft assembly to the discharge manifold.
4. The command shaft and mounting plate may now be removed from the compressor.
Installation
5. Install a new o-ring (446) into the groove on the compressor discharge manifold. You may use clean compressor lubricating oil on the o-ring.
6. Install the command shaft onto the compressor discharge manifold. Ensure that the command shaft tongue is engaged in the cross-shaft slot inside the compressor discharge manifold. Rotate the command shaft assembly so that the vent holes point downward. This will prevent water and dust from entering the vent.
7. Secure the command shaft assembly to the discharge manifold using the four socket head cap screws and Nord-Lock washers and apply the proper torque.
8. Perform leak check, see Compressor Unit Leak Check Procedure.
Command shaft assembly
457 477
Rotate bearing housing so vent hole points down
Align the tongue of the
446
command shaft with the
groove in the cross shaft
Figure 5-68. Command Shaft Assembly Replacement
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 65
Section 5 · Maintenance/Service
Liquid Injection Control Valve Station (Danfoss ICF 20-40 Valve Station)
For liquid injection control operation, refer to Section 2. For additional information regarding setup, installation, programming and troubleshooting, refer to Appendices.
The liquid injection control valve station (ICF) consists of these parts (Danfoss part acronyms are shown in parentheses):
· Shut-off Valves (ICFS), Inlet and Outlet · Solenoid Valve (ICFE) with Manual Stem (ICFO) · Motorized Valve Assembly (ICM valve assembly with
ICAD motor actuator) · Strainer (ICFF) with Drain Valve
For parts and service kits, refer to Tables 5-17 and 5-18.
Shut-off Valve (ICFS)
Solenoid Valve (ICFE)
Motorized Valve Assembly (ICM/ICAD)
Inlet Connection
Liquid Injection Control Valve Station (ICF)
Sight Glass (Shown with Covers)
Strainer (ICFF)
Drain Valve
Solenoid Manual Stem
(ICFO)
Shut-off Valve (ICFS)
Figure 5-69. Danfoss ICF 20-40 Valve Station (Liquid Injection Control)
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service
Table 5-17. Coils for Solenoid Valves (ICFE)
VILTERTM PART NO 3389DA 3389DB 3389DC 3389DD 3389DD1
VOLTAGE
110-120VAC 110-120VAC 110VAC 220VAC 220VAC W/110VAC LED BOX
Hz HOLDING CONNECTION PILOT LIGHT
60 14W 60 14W 60 12W 60 12W 60 12W
DIN DIN TERMINAL BOX TERMINAL BOX -
GREEN GREEN GREEN LED
Table 5-18. Parts for Motorized Valve Station (ICF)
VILTERTM PART NO 3389EA 3389EE
3389AE1 3389AE2 3389EB 3389FD 3389FA 3389FC 3389FB 3389FE 3389FF
DESCRIPTION
ICAD 600 MOTOR ACTUATOR W/10M CABLES ICAD 900 MOTOR ACTUATOR W/10M CABLES
CABLES, 10M FOR ICAD ACTUATOR TOP COVER FOR ICAD ACTUATOR CONTROLLER EKC 347, LIQUID LEVEL MODULE B66 FUNCTION (FOR ICF VALVE STATION) MAGNETIC TOOL FOR ICM VALVE MANUAL OPERATION 20,25, AND 32 MAGNETIC TOOL FOR ICM VALVE MANUAL OPERATION 40, 50, AND 65 ICM 20 SERVICE KIT (VALVE SEAT) ICM 25 SERVICE KIT (VALVE SEAT) ICM 32 SERVICE KIT (VALVE SEAT)
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
5 67
Section 5 · Maintenance/Service
Main Rotor Assembly
Due to the procedures and tools involved in the disassembly and reassembly, the main rotor assembly must be performed by qualified individuals. Please consult the factory if maintenance is required.
Torque Specifications
Refer to the following table for torque specifications.
Table 5-19. 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 FINE (UNF)
16
SAE GRADE 8 COARSE (UNC)
11 22 39 63 96 138 191 338 546
SOCKET HEAD CAP SCREW
(ASTM A574)
COARSE (UNC)
5 13 26 46 73 112 155 215 380 614
NOTES:
1) Torque values on this sheet are not to override those given on the individual drawings.
2) When using loctite, the torque value on this sheet are only 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.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 5 · Maintenance/Service Using A Torque Wrench Correctly
Torque Wrenches
USING A TORQUE WRENCH CORRECTLY INVOLVES FOUR PRIMARY CONCERNS:
A. A smooth even pull to the break point is required. Jerking the wrench can cause the pivot point to break early leaving the bolt at a torque value lower then required. Not stopping when the break point is reached results in an over torque condition.
B. When more than one bolt holds two surfaces together there is normally a sequence that should be used to
bring the surfaces together in an even manner. Generally bolting is tightened incrementally in a diametrically
staggered pattern. Some maintenance manuals specify a tightening scheme. If so, the manual scheme shall be followed. Just starting on one side and tightening in a circle can cause the part to warp, crack, or leak.
C. In some cases threads are required to be lubricated prior to tightening the bolt/nut. Whether a lubricant is used
or not has considerable impact on the amount of torque required to achieve the proper preload in the bolt/stud. Use a lubricant, if required, or not if so specified.
D. Unlike a ratchet wrench a torque wrench is a calibrated instrument that requires care. Recalibration is required periodically to maintain accuracy. If you need to remove a bolt/nut do not use the torque wrench. The clockwise/counterclockwise switch is for tightening right hand or left hand threads not for loosening a fastener. Store the torque wrench in a location where it will not be bumped around.
Fine Serration Face Out
Nord-Lock® Washers
A. The Nord-Lock® lock washer sets are used in many areas in the single screw compressors that require a vibration proof lock washer.
Coarse Serration Mate Together
B. The lock washer set is assembled so the coarse serrations that resemble ramps are mated together.
C. Once the lock washer set is tightened down, it takes more force to loosen the bolt that it did to tighten it. This is caused by the washers riding up the opposing ramps.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 6 · Troubleshooting
Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 3)
Problem
Reason
Solution
Dirt or debris is blocking one or both optocoupler slots.
Clean the optocoupler slots with a cotton swab and rubbing alcohol.
The photo-chopper fence extends less than about half way
into the optocoupler slots.
Adjust the photo-chopper so that the fence extends further into the optocou-
pler slots. Make sure the motor brake operates freely and the photo-chopper will not contact the optocouplers when
the shaft is pressed down.
The white calibrate wire in the grey Turck cable is grounded.
Tape the end of the white wire in the panel and make sure that it cannot
touch metal.
The actuator cannot be calibrated.
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.
The position sensor has failed.
Try to free the stuck button. Replace the actuator.
Push button is being held down for more that ¾ second when going through the cali-
bration procedure.
Depress the button quickly and then let go. Each ¾ second the button is held down counts as another press.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
6 1
Section 6 · Troubleshooting
Table 6-1. Slide Valve Actuator Troubleshooting Guide (2 of 3)
Problem
Reason
Solution
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.
The actuator goes into calibration mode spontaneously.
A very strong source of electromagnetic interference (EMI), such as a contactor, is in the vicinity of the actuator or
grey cable.
Increase the distance between the EMI source and the actuator. Install additional metal shielding material 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 properly.
The position sensor's EEPROM memory has failed
Get the motor brake to where it operates freely and recalibrate.
Replace the actuator.
The actuator does not transmit the correct position after a power loss.
The motor was manually moved while the position sen-
sor was not powered.
Recalibrate.
The motor brake is not working properly.
Get the motor brake to where it operates freely and recalibrate.
The position sensor's EEPROM memory has failed
Replace the actuator.
There is a rapid clicking noise when the motor is operating.
The photo-chopper is misaligned with the slotted optocouplers.
The photo-chopper is positioned too low on the motor
shaft.
A motor bearing has failed
Try to realign or replace the actuator.
Adjust the photo-chopper so that the fence extends further
into the optocoupler slots.
Replace the actuator.
There is a loose connection in the screw terminal blocks.
Tighten
The motor operates in one direction only
There is a loose or dirty connection in the yellow Turck
cable.
The position sensor has failed.
There is a broken motor lead or winding
Clean an tighten
Replace the actuator. Replace the actuator.
6 2
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 6 · Troubleshooting
Table 6-1. Slide Valve Actuator Troubleshooting Guide (3 of 3)
Problem
Reason
The thermal switch has tripped because the motor is overheated
Solution
The motor will resume operation when it cools. This could be caused by a malfunctioning control panel. Consult the factory.
The motor will not move in either direction
Any of the reasons listed in "The motor operates in one direction only"
The command shaft is jammed.
See above. Free the command shaft.
Broken gears in the gear-motor.
Replace the actuator.
Blown relays or fuses.
Check and replace blown relays and/or fuse
The motor operates intermittently, several Motor is overheating and the
minutes on, several minutes off.
thermal switch is tripping.
The motor runs sporadically
Bad thermal switch.
Any of the reasons listed in "The motor operates in one direction only"
This could be caused by a malfunctioning control panel. Consult the factory.
Replace the actuator.
See above.
The motor runs but output shaft will not turn.
Stripped gears inside the gear rotor, or the armature has come unpressed from the armature shaft.
Replace the actuator.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
6 3
Section 6 · Troubleshooting
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.
Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2)
Flash Pattern * = ON - = OFF
*-*-*-*-*-*-*-*-*-*-*-*-
*---*---*---*---*---*---
Meaning
Calibration step 1. Calibration step 2.
*--*--------------------
This indicates a zero span. This error can only occur during calibration. The typical 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 procedure. 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 can be tested as follows:
1. Manually rotate the motor shaft until the aluminum photo-chopper fence is not blocking either of the optocoupler slots.
2. Using a digital multimeter, measure the DC voltage between terminal 3 of the small terminal block and TP1 on the circuit board (see Note
1). The measurement should be between 0.1 and 0.2 Volts.
3. Next, measure the DC voltage between terminal 3 and TP2 on the circuit board. You should measure be- tween 0.1 and 0.2 Volts.
*-----------------------
This error means that the slide valve actuator is no longer transmitting accurate position information. The actuator should be recalibrated as soon as possible, after the cause of the over-speed is identified and cor-
rected. This error will not clear until the actuator is re-calibrated.
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.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 6 · Troubleshooting
Table 6-2. Slide Valve Actuator LED Blink Codes (2 of 2)
Flash Pattern * = ON - = OFF
Meaning
*--*--*-----------------
The motor is 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 humid environments when process conditions demand that the slide valve actuators reposition often. Solutions are available; consult your VilterTM
authorized distributor for details.
Another possible cause for this error is a stuck motor thermal switch. The thermal switch can be tested by measuring the DC voltage with a digital multimeter be- tween the two TS1 wire pads (see Note 2). If
the switch is closed (normal operation) you will measure 0 Volts.
*********************
The 24V supply voltage is low. This will occur momentarily when the actuator is powered up and on power down.
If the problem persists, measure the voltage using a digital multimeter between terminals 3 and 4 of the small terminal block. If the voltage is less than 24V, the problem is in the supply to the board.
If the voltage is >= 24V, replace the actuator.
-******************** *****----*--------------
The EEPROM data is bad. This is usually caused by loss of 24V power before the calibration procedure was completed. The actuator will not move while this error code is being displayed. To clear the error, calibrate the actuator. If this error has occurred and the cause was not
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. Please notify your VilterTM authorized distributor.
*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.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
6 5
Section 6 · Troubleshooting
Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3)
Problem
Solution
Low Oil Pressure at Start
· After failing to start compressor with "Prelube Oil Pump Inhibit", first 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, continue 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 fill the lines and oil cooler.
· Check oil strainer for dirt. · Check oil filter pressure drop. · Check "Prelube Oil Pressure Safety Changeover" setpoint is sufficient in Timers Screen.
· Prelube Oil Pressure is Manifold Pressure minus Discharge Pressure.
Low Run Oil Pressure
· Check solutions in "Low Oil Pressure at Start".
· Check that there is proper discharge pressure ratio to create differential pressure, otherwise oil pressure can't be maintained. Oil pressure is manifold oil pressure minus the suction pressure. It is a net pressure.
Oil flow or oil pressure problems
· Clean oil strainer screen. · Change oil filter, 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.
6 6
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 6 · Troubleshooting
Table 6-3. Troubleshooting Guide - General Problems & Solutions (2 of 3)
Problem
Solution
Oil Loss Issues
· Oil return line from coalescing side of oil separator to suction is closed, not open enough (3/4 turns should be sufficient), or plugged with debris · The check valve in the oil return line could be stuck closed or the flow 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 flow 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 3-way oil mixing valve.
· If you are controlling a step type oil cooler or a VFD oil cooler, verify the correct one is selected in the Configuration Screen and the amount of steps are entered in the Remote Oil Cooler Control Screen.
· Check the oil cooler and associated piping to make sure it is full of oil before starting.
· Check the oil strainer for debris and clean if necessary.
· Verify that the volume slide actuator is functioning correctly and that the correct compressor size (type) is selected.
· 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
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
6 7
Section 6 · Troubleshooting
Table 6-3. Troubleshooting Guide - General Problems & Solutions (3 of 3)
Problem
Solution
High Amp Draw
· Check calibration at full load. · Check CT ratio entered in Vission 20/20. · Check slide valve calibration, especially volume slide.
Vibration
· Check that unit is leveled and secured to mounting pad or floor. · Check supported pipes (i.e. suction and discharge pipe) and make sure they are adequately supported. · Check for loose bolts and nuts. · Check condition of compressor and motor (i.e. alignments)
Excessive Motor Backspin
· If there is more than normal motor backspin at shutdown, check suction check valve for proper operation.
6 8
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 7 · Warranty and Parts
Warranty Claim Processing
This section explains how the warranty claim is processed and to help clear any questions that may arise prior to contacting customer service. For additional warranty information, refer to the Terms and Conditions of your order. VilterTM contact information can be found on page iii.
1. The warranty process starts with contacting a Vilter Service and Warranty (S&W) department representative. Ensure to have the original Vilter sales order number for the equipment available to better assist you.
2. Our Vilter S&W representative will confirm if the equipment is within the warranty time frame as described in the warranty statement.
If the equipment (Part/Compressor/Compressor Motor) is within the warranty time frame, proceed to the following section regarding the type of equipment:
Process for returning Products covered by the warranty:
STEP 1. To return a defective Product or part under this warranty, you will need to provide the VilterTM compressor order number on all submitted documents.
For a parts warranty request, you will also need to provide:
· The VilterTM serial number of the compressor;
· A detailed and accurate description of the issue;
· A valid purchase order for the new part(s)-- you must pay the freight;
· One copy of Return Merchandise Authorization (RMA) sent to you for your records;
· One copy of RMA sent to you to include in the return shipment of parts back to VilterTM for warranty consideration.
STEP 3. Upon receipt of the returned part(s), VilterTM will complete a timely evaluation of the part(s). STEP 4. You will be contacted with Vilter's decision once the final report is completed. STEP 5. If approved, the approved warranty will be credited (excluding freight) to your account. VilterTM will retain the returned part(s) for final disposition. If a warranty request is not approved, you will be provided with a written response and the parts will be held for 30 days. After such time, VilterTM will dispose of the parts. If you wish to have the part(s) returned, you will need to contact VilterTM and the part(s) will be returned freight collect.
Procedure for parts not manufactured by VilterTM: Although VilterTM does not provide any warranty for parts and products that are not manufactured by VilterTM, VilterTM does pass through any manufacturer's warranty to you (to the maximum extent permitted by the manufacturer). VilterTM will work with you in facilitating your warranty claim with the manufacturer. To facilitate your warranty claim, please follow the following four steps:
STEP 1. Determine if the part or product is within the OEM's warranty.
STEP 2. If the defective part or product is not a motor, send a description containing the specifications of the part/product and the defect to:
Service.Vilter@Emerson.com
If the defective part or product is a motor or starter, please complete the form on the next page and return it to:
Service.Vilter@Emerson.com.
STEP 2. Return the parts (freight prepaid) to:
VILTER MANUFACTURING CORPORATION 5555 South Packard Avenue Cudahy, WI 53110-8904
STEP 3. VilterTM will communicate with you, if necessary, to ascertain additional information and will reasonably assist with the OEM to determine the part/product's warranty status.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
7 1
Motor Warranty Procedure
To facilitate your warranty claim, please follow the steps outlined below: 1. Determination if motor is within the OEM warranty. 2. Please complete the following and return to Service.Vilter@Emerson.com, along with a picture of the motor's nameplate. 3. Vilter will assist with the motor OEM to determine the motor's warranty status.
Model:
____________
Serial Number: ____________
Manufacturer: ____________
Run Hours: ____________
Grease Type: ____________
Start Date: ______/_____/____ Month Day Year
Starter Type:
Soft Start Across the Line VFD
Alignment Data Available:
Yes, please include with information
No
Lubrication Records Available: Yes, please include with information
No
Vibration Report:
Yes, please include with information
No
Describe Motor Symptoms:
4. If the motor falls within the OEM's warranty time frame: · The motor will need to be taken to a manufacturer approved shop for diagnosis. Vilter can help with locating motor shops that are manufacturer
approved in your area. The shop will diagnose the root cause, submit a report to the OEM, and the motor OEM will make the determination of warranty coverage. · If warranty is approved, the OEM will either have the motor repaired by the motor shop or send a new replacement motor to the site.
Note: Motor warranty is a "pass thru warranty" as stated in Vilter Manufacturing's standard warranty statement which means that the original motor OEM is the provider of the warranty. Vilter does assist with the expediting of the claim but any dispensation of warranty is provided solely by the motor OEM. Motor manufacturer warranty covers only repair or replacement of the motor. It does not cover removal and installation charges, incidental charges associated with the removal and installation process, loss of product or shipping to and from the manufacturer or approved shop. This is standard motor manufacturer warranty policy regardless of brand or application. If the end user requires additional information regarding warranty coverage, the individual motor manufacturer warranty terms can be found on their associated websites.
Section 7 · Warranty and Parts
STEP 4. For defective motor or starter claims, if the motor or starter falls within the OEM's warranty time frame: · The motor or starter will need to be taken to a man-
ufacturer approved shop for diagnosis. VilterTM can help you locate motor shops in your area that are manufacturer approved. The shop will diagnose the root cause, submit a report to the OEM, and the motor OEM will make the determination of warranty coverage. · If a warranty claim is approved, the OEM will either have the motor or starter repaired by the motor shop or send a new replacement motor to the site.
On-Site Service Support
If on site support is required, contact a Vilter S&W department representative to start this process. Warranty does not cover labor or 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.
Remanufactured Bare Shaft Single Screw 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 iii.
· Request a "VSS/VSM Single Screw Compressor Rebuild Form".
· Submit the Rebuild Form and a Purchase Order (PO) for the inspection. A fee is required for the initial inspection and tear down 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 compressor). 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, gaskets, 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 connection horizontal. · Standard drive shaft is tapered. · Standard slide assembly. · Viton shaft seal O-rings. · Crating with Purge & Gauge. · Does not include hand wheels or slide valve motors.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
7 3
7 4 / Blank
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
VSH/VSSH Recommended Spare Parts List
For VSH/VSSH compressor spare parts, please contact Vilter Engineering Service for the list.
Note Please have your Model # and Sales Order # available when ordering.
These are found on the compressor's Name Plate.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 1
8 - 2 / Blank
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
VSS Recommended Spare Parts List
Refer to the Custom Manual Spare Parts Section for Specific Applications
Please have your Model # and Sales Order # available when ordering. These are found on the compressor's Name Plate.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 3
Section 8 · Spare Parts List
Gaterotor
*For VSS Models from 451 to 2101
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 4
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Gaterotor
MODEL NUMBER
ITEM
DESCRIPTION
VSS 451
VSS 601
VSS 751
QTY VPN QTY VPN QTY VPN
Gaterotor BLADE AND BEARING REPLACEMENT KIT (111, 118,
-
120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 141,
142, 143)
KT712A
KT712B
KT712C
-
Gaterotor BLADE REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 130, 141, 142, 143)
KT713A
KT713B
KT713C
100
SUPPORT ASSEMBLY 110 & 135B.
2 A25159BB 2 A25159BA 2 A25159CB
102 Gaterotor SUPPORT ASSEMBLY (100, 111, 120B, 119, 130) 2 A25161BB 2 A25161BA 2 A25161CB
105
Gaterotor GASKET SET (118, 141, 142, 143)
2 A25164B 2 A25164B 2 A25164C
106
SHIM PACK SET ((2) 121, (2) 122, (1) 123, (1) 124)
2 A25165B 2 A25165B 2 A25165C
110
SUPPORT
2 25606A 2 25520A 2 25612A
111
Gaterotor
2 25557A 2 25534A 2 25608A
112
SMALL BEARING HOUSING
2 25518D 2 25518D -
N/A
113
LARGE BEARING HOUSING
2 25517A 2 25517A -
N/A
114
RETAINER
2 25008A 2 25008A -
N/A
115
RETAINER
2 25009A 2 25009A -
N/A
116
BALL BEARING COVER
2 25258A 2 25258A -
N/A
117
Gaterotor COVER
2 25519A 2 25519A -
N/A
118
Gaterotor COVER GASKET
2 25259A 2 25259A 2 25088A
119
WASHER
2 25007A 2 25007A 2 25086A
120A
BUSHING, SMALL DOWEL PIN
2 25006A 2 25006A 2 25087A
120B
BUSHING, LARGE DOWEL PIN
2 25760A 2 25760A 2 25760B
121
SHIM 0.002"
AR 25010AA AR 25010AA AR 25089AA
122
SHIM 0.003"
AR 25010AB AR 25010AB AR 25089AB
123
SHIM 0.005"
AR 25010AC AR 25010AC AR 25089AC
124
SHIM 0.010"
AR 25010AD AR 25010AD AR 25089AD
125
ROLLER BEARING
2
2864B
2
2864B
2
2864C
126
BALL BEARING
4 2865BP 4 2865BP 4 2865A
130
RETAINING RING
2 2866A 2 2866A 2 2866B
131
RETAINING RING
2 2867A 2 2867A 2 2867E
135A
DOWEL PIN, SM, 0.250" O.D.
2
2868B
2
2868B
2
2868F
135B
DOWEL PIN, LG, 0.4375" O.D.
2 25910A 2 25910A 2 25910B
141
O-RING ROLLER BEARING HOUSING
2 2176M 2 2176M 2 2176N
142
O-RING BALL BEARING HOUSING
2
2176R
2
2176R
2 2176CQ
143
O-RING BRG HSG COVER
2 2176N 2 2176N 2 2176U
150
HEX HEAD CAP SCREW (1/4-20 NC X 1-1/4)
12 2796AJ 12 2796AJ -
N/A
151
HEX HEAD CAP SCREW (5/16-18 NC X 1-1/4)
6
2796B
6
2796B
-
N/A
152
HEX HEAD CAP SCREW (3/8-16 NC X 1-1/4)
40 2796CJ 40 2796CJ -
N/A
153
HEX HEAD CAP SCREW (1/4-20 NC X 1)
32 2795E 32 2795E
-
N/A
160
SOCKET HEAD CAP SCREW
12 2795E 12 2795E
-
N/A
AR = As required
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 5
Section 8 · Spare Parts List
Gaterotor
ITEM
DESCRIPTION
Gaterotor BLADE AND BEARING
-
REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 125, 126,
130, 131, 141, 142, 143)
Gaterotor BLADE REPLACEMENT KIT - (111, 118, 120A, 120B, 121, 122, 123,
124, 130, 141, 142, 143)
100 SUPPORT ASSEMBLY 110 & 135B.
102
Gaterotor SUPPORT ASSEMBLY (100, 111, 120B, 119, 130)
105
Gaterotor GASKET SET (118, 141, 142, 143)
106
SHIM PACK SET ((2) 121, (2) 122, (1) 123, (1) 124)
110
SUPPORT
111
Gaterotor
118
Gaterotor COVER GASKET
119
WASHER
120A
BUSHING, SMALL DOWEL PIN
120B
BUSHING, LARGE DOWEL PIN
121
SHIM 0.002"
122
SHIM 0.003"
123
SHIM 0.005"
124
SHIM 0.010"
125
ROLLER BEARING
126
BALL BEARING
130
RETAINING RING
131
RETAINING RING
135A
DOWEL PIN, SM, 0.250" O.D.
135B
DOWEL PIN, LG, 0.4375" O.D.
141 O-RING ROLLER BEARING HOUSING
142 O-RING BALL BEARING HOUSING
143
O-RING BRG HSG COVER
VSS 901 QTY VPN
KT712D
KT713D
2 A25159CA 2 A25161CA
2 A25164C
2 A25165C
2 25553A
2 25554A
2 25088A
2 25086A
2 25087A
2 25760B
AR 25089AA
AR 25089AB
AR 25089AC
AR 25089AD
2
2864C
4
2865A
2
2866B
2
2867E
2
2868F
2 25910B
2
2176N
2 2176CQ
2
2176U
VSS 1051
QTY
VPN
KT712E
KT713E
2 A25159DB 2 A25161DB
2 A25164D
2 A25165C
2 25614A
2 25610A
2 25132A
2 25086A
2 25104A
2 25760B
AR 25089AA
AR 25089AB
AR 25089AC
AR 25089AD
2
2864G
4
2865A
2
2866B
2
2867L
2
2868H
2 25910B
2
2176AJ
2 2176AM
2
2176U
VSS 1201 QTY VPN
KT712F
KT713F
2 A25159DA 2 A25161DA
2 A25164D
2 A25165C
2 25587A
2 25588A
2 25132A
2 25086A
2 25104A
2 25760B
AR 25089AA
AR 25089AB
AR 25089AC
AR 25089AD
2
2864G
4
2865A
2
2866B
2
2867L
2
2868H
2 25910B
2 2176AJ
2 2176AM
2
2176U
VSS 1301
QTY
VPN
KT712Y
KT713Y
2 A25161DH
2 A25164D
2 A25165C
2 25587A
2 25588F
2 25132A
2 25086A
2 25104A
2 25760B
AR 25089AA
AR 25089AB
AR 25089AC
AR 25089AD
2
2864G
4
2865A
2
2866B
2
2867L
2
2868H
2 25910B
2
2176AJ
2 2176AM
2
2176U
AR = As required
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 6
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Gaterotor
MODEL NUMBER
ITEM
DESCRIPTION
VSS 1551
VSS 1501
VSS 1801
QTY VPN QTY VPN QTY VPN
Gaterotor BLADE AND BEARING REPLACEMENT KIT (111,
-
118, 120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 1 KT712L 1 KT712G 1 KT712H*
141, 142, 143)
-
Gaterotor BLADE REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 130, 141, 142, 143)
1
KT713G
1
KT713G
1 KT713H*
101
Gaterotor ASSEMBLY (111, 120)
2 A25160EB 2 A25160EB 2 A25160EA
102 Gaterotor SUPPORT ASSEMBLY (100, 111, 120B, 119, 130) 2 A25161EB 2 A25161EB 2 A25161EA
104
SHIM 350MM GATEROTOR BALL BRG VSS
2 25977U
105
Gaterotor GASKET SET (118, 141, 142, 143)
2 A25164E 2 A25164E 2 A25164E
106
SHIM PACK SET ((2) 121, (2) 122, (1) 123, (1) 124)
2 A25165E 2 A25165E 2 A25165E
110
SUPPORT
2 25665C 2 25087A 2 25665E
111
Gaterotor
2 25647A 2 25647A 2 25645A
112
SMALL BEARING HOUSING
2 26507A 2 25667A 2 25667A
113
LARGE BEARING HOUSING
2 26506A 2 25669A 2 25669A
114
RETAINER
2 25141A 2 25141A 2 25141A
115
RETAINER
2 25789A 2 25789A 2 25789A
116
BALL BEARING COVER
2 25351A 2 25351A 2 25351A
117
Gaterotor COVER
2 26508B 2 25354A 2 25354A
118
Gaterotor COVER GASKET
2 26509A 2 25790A 2 25790A
119
WASHER
2 25788A 2 25788A 2 25788A
120A
BUSHING, SMALL DOWEL PIN
-
N/A
2 25104A 2 25104A
120B
BUSHING, LARGE DOWEL PIN
2 25760C 2 25104A 2 25104A
121
SHIM 0.002"
AR 25791AA AR 25791AA AR 25791AA
122
SHIM 0.003"
AR 25791AB AR 25791AB AR 25791AB
123
SHIM 0.005"
AR 25791AC AR 25791AC AR 25791AC
124
SHIM 0.010"
AR 25791AD AR 25791AD AR 25791AD
125
ROLLER BEARING
2
2864K
2
2864K
2
2864K
126
BALL BEARING
4
2865K
4
2865K
4
2865K
130
RETAINING RING
2
2866G
2
2866G
2
2866G
131
RETAINING RING
2
2867R
2
2867R
2 2867R
135A
DOWEL PIN, SM, 0.250" O.D.
-
N/A
2 2868H 2 2868H
135B
DOWEL PIN, LG, 0.4375" O.D.
2 25910C 2 2868H 2 2868H
141
O-RING ROLLER BEARING HOUSING
2
2176U
2
2176U
2
2176U
142
O-RING BALL BEARING HOUSING
2 2176BD 2 2176BD 2 2176BD
143
O-RING BRG HSG COVER
2
2176P
2
2176P
2
2176P
150
HEX HEAD CAP SCREW ( 1/4-20 NC X 1-1/4 )
12 2796CJ 12 2796CJ 12 2796CJ
151
HEX HEAD CAP SCREW (5/16-18 NC X 1-1/4)
8 2796N 8 2796N 8 2796N
152
HEX HEAD CAP SCREW ( 3/8-16 NC X 1-1/4)
32 2796CJ 32 2796CJ 32 2796CJ
153
HEX HEAD CAP SCREW (1/4-20 NC X 1)
44 2796R 44 2796R 44 2796R
160
SOCKET HEAD CAP SCREW
16 2795G 16 2795G 16 2795G
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. PAaRrt=s Athsarteaqpupireeadr on diagrams might be shown separatel*yFfoorr rseeferiraelnncuem, bbuetrasrebesfooldrea5s5a8n0asse*m* Fbolyr osrekriat lonnulym. bers after 5580
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 7
Section 8 · Spare Parts List
Gaterotor
MODEL NUMBER
ITEM
DESCRIPTION
VSS 1851
VSS 2101
QTY VPN QTY
VPN
-
Gaterotor BLADE AND BEARING REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 141, 142, 143)
2
KT712M*
2
KT712K* KT712KN**
-
Gaterotor BLADE REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 130, 141, 142, 143)
2
KT713H*
2
KT713L
101
Gaterotor ASSEMBLY (111, 120)
2 A25160EA 2 A25160EA
102
Gaterotor SUPPORT ASSEMBLY (100, 111, 120B, 119, 130)
2 A25161EA 2 A25161EC
104
SHIM 350MM GATEROTOR BALL BRG VSS
2 25977U 2
25977U
105
Gaterotor GASKET SET (118, 141, 142, 143)
2 A25164E 2 A25164E
106
SHIM PACK SET ((2) 121, (2) 122, (1) 123, (1) 124)
2 A25165E 2 A25165E
110
SUPPORT
2 25665E 2
25665D
111
Gaterotor
2 25645A 2
25744D
112
SMALL BEARING HOUSING
2 26507A 2
26507A
113
LARGE BEARING HOUSING
2 26506A 2
26506A
114
RETAINER
2 25141A 2
25141A
115
RETAINER
2 25789A 2
25789A
116
BALL BEARING COVER
2 25351A 2
25351A
117
Gaterotor COVER
2 26508B 2
26508B
118
Gaterotor COVER GASKET
2 26509A 2
26509A
119
WASHER
2 25788A 2
25788A
120A
BUSHING, SMALL DOWEL PIN
-
N/A
-
N/A
120B
BUSHING, LARGE DOWEL PIN
2 25760C 2
25760C
121
SHIM 0.002"
AR 25791AA AR 25791AA
122
SHIM 0.003"
AR 25791AB AR 25791AB
123
SHIM 0.005"
AR 25791AC AR 25791AC
124
SHIM 0.010"
AR 25791AD AR 25791AD
125
ROLLER BEARING
2
2864K
2
2864K
126
BALL BEARING
4
2865K
4
2865K
130
RETAINING RING
2
2866G
2
2866G
131
RETAINING RING
2
2867R
2
2867R
135A
DOWEL PIN, SM, 0.250" O.D.
-
N/A
-
N/A
135B
DOWEL PIN, LG, 0.4375" O.D.
2 25910C 2
25910C
141
O-RING ROLLER BEARING HOUSING
2
2176U
2
2176U
142
O-RING BALL BEARING HOUSING
2 2176BD 2
2176BD
143
O-RING BRG HSG COVER
2
2176P
2
2176P
150
HEX HEAD CAP SCREW ( 1/4-20 NC X 1-1/4 )
12 2796CJ 12
2796CJ
151
HEX HEAD CAP SCREW (5/16-18 NC X 1-1/4)
8
2796N
8
2796N
152
HEX HEAD CAP SCREW ( 3/8-16 NC X 1-1/4)
32 2796CJ 32
2796CJ
153
HEX HEAD CAP SCREW (1/4-20 NC X 1)
44 2796R 44
2796R
160
SOCKET HEAD CAP SCREW
16 2795G 16
2795G
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor.
APRart=s Athsarteaqpupireeadr on diagrams might b* eFsohroswenriaslenpuarmatbeelyrsfobrerfeofreere5n5c8e0, but are sold as an asse**mFbolyr soer rkiiatlonnulym. bers after 5580
8 - 8
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Gaterotor
TIGHTEN TO 33 FT-LBS 14 5
INSTALL RETAINER WITH BEVEL FACING GATEROTOR 9
2 8 TIGHTEN TO 154 FT-LBS 12
TIGHTEN TO 78 FT-LBS 11 TIGHTEN TO 54 FT-LBS 13
15 CHECK GATEROTOR FLOAT
4 AFTER ASSEMBLY
1 6
TIGHTEN TO 19 FT-LBS 10
USE BLUE LOCTITE USE SHIMS TO ACHIEVE 3 0.003"- 0.004" SHELF CLEARANCE 7
*VSS 2401 thru VSS 3001 Only
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 9
Section 8 · Spare Parts List
Gaterotor
ITEM
-
-
001 002 003 004 005 006 007 008 009 010 011 012 013 014 015
DESCRIPTION
Gaterotor BLADE AND BEARING REPLACEMENT KIT
Gaterotor BLADE REPLACEMENT KIT
BALL BEARING SEAL GATEROTOR
SHIM SUPPORT BEARING HOUSING GATEROTOR BEARING HOUSING COVER GATEROTOR COVER RETAINING RING (3.346 X 0.109) BEVELED HEX HEAD CAP SCREW (5/16 -18 NC X 1-1/4) HEX HEAD CAP SCREW (1/2-13 NC X1-3/4) HEX HEAD CAP SCREW (5/8-11 NC X 2-3/4) HEX HEAD CAP SCREW (3/8-16 NC X 1-3/4) HEX HEAD CAP SCREW (3/8-16 NC X 1-1/4) ROLLER BEARING SHIM BEARING RETAINER
QTY
2.00
2.00
1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 1.00 4.00 10.00 24.00 10.00 6.00 1.00
VSS 2401 VPN
KT712N
KT713P
A25163G A25164F A25165F A25222FH 26089B 25789B 26087B 26132C
2867R 2796B 2796EL 2796GQ 2795AH 2796CJ 25977Z
VSS 2601 VSS 2801 VSS 3001
VPN
VPN
VPN
KT712P
KT712Q KT712QAF*
KT712R
KT713Q
KT713R KT713RAF*
KT713S
A25163G A25163G A25163G
A25164F A25164F A25164F
A25165F A25165F A25165F
A25222FG A25222FF A25222FE
26089B 26089B 26089B
25789B 25789B 25789B
26087B 26087B 26087B
26132C 26132C 26132C
2867R
2867R
2867R
2796B
2796B
2796B
2796EL
2796EL
2796EL
2796GQ 2796GQ 2796GQ
2795AH 2795AH 2795AH
2796CJ
2796CJ
2796CJ
25977Z 25977Z 25977Z
* AFLAS
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 10
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Shaft Seal
Shaft Seal With Stationary Carbon Face
230
260
219
ITEM
230 260
DESCRIPTION
MODEL NUMBER
QTY
VSS 291 thru VSS 601
VSS 751 thru VSS 1301
VSS 1551 thru VSS 2101
SHAFT SEAL AMM KIT (219, 230, 260) 1
KT709A
KT709B
KT709E
SHAFT SEAL R22 KIT (219, 230, 260) 1
KT781A
KT781B
KT781C
OIL SEAL
1
25040A
2930F
2930B
O-RING
1
2176F
2176AC
2176BH
VSS 2401 thru VSS 3001 KT709F KT781F 2930G 2176BD
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 11
Section 8 · Spare Parts List
ITEM
MODEL NUMBER
QTY
207
201
DESCRIPTION
SHIM PACK
ROTOR ASSEMBLY
VSS 451 1 A25177B A25226BB
VSS 601 1 A25177B A25226BA
VSS 751 1 A25177C A25226CB
VSS 901 1 A25177C A25226CA
VSS 1051 1 A25177D A25226DB
VSS 1201 1 A25177D A25226DA
VSS 1301 1 A25177D A25752HA
VSS 1501 1 A25177E A25226EB
VSS 1551 1 A25177E A25226EC
VSS 1801 1 A25177E A25226EA
VSS 1851 1 A25177E A25226ED
VSS 2101 1 A25177E A25226EE
Main Rotor
*For VSS Models from 451 to 2101
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 12
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Main Rotor
*VSS 2401 thru VSS 3001 Only
ITEM 102
DESCRIPTION
ROTOR ASSEMBLY SHIM PACK
MODEL NUMBER QTY VSS 2401 VSS 2601 VSS 2801 VSS 3001
1 A25226AN A25226AM A25226AL A25226AK 1 A25177G A25177G A25177G A25177G
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 13
Section 8 · Spare Parts List Slide Valve Cross Shafts and End Plate
*For VSS Models from 451 to 2101
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 14
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Slide Valve Cross Shafts and End Plate
MODEL NUMBER
ITEM
DESCRIPTION
QTY
VSS 291 thru
VSS 601
QTY
VSS 751 thru
VSS 901
QTY
VSS 1051 thru
VSS 1301
QTY
VSS 1501 VSS 1801
QTY
VSS 1551 thru
VSS 2101
221
SHAFT
2 25843A 2 25844A 2 25845A 2 25793A 2 25793A
222
GEAR
4 25027A 4 25027A 4 25027A 4 25027A 4 25027A
226
RACK CLAMP
2 25913A 4 25913C 4 25913C
4 25913C
227
RACK CLAMP
2 25913B -
N/A
-
N/A
-
-
N/A
228
SPACER
2 25847A 4 25033C 4 25033C 4 25033C 4 25033C
267
DOWEL PIN
-
N/A
2
2868B
2
2868B
2
2868B
2
2868B
268 EXPANSION PIN
4 1193D
4
1193D 4 1193D
2
1193D 4 1193D
269 EXPANSION PIN
4 2981AA 4 2981AA 4 2981AA 2 2981AA 4 2981AA
270
PIPE PLUG
-
N/A
2
2606E
2
2606E
2
2606E
2
2606A
286
SOCKET HEAD CAP SCREW
8
2795F
8
2795F
8
2795F
8
2795F
8
2795F
297
SET SCREW
2
2060J
2
2060J
2
2060J
2
2060J
298
SET SCREW
2 2060H 2 2060H 2 2060H
2 2060H
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 15
Section 8 · Spare Parts List End Plate (VSS 2401 - VSS 3001 Only)
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 16
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
End Plate (VSS 2401 - VSS 3001 Only)
ITEM
VSS 2401 thru VSS 3001
Quantity
018
PIPE PLUG SOCKET HEX
2
019
O-RING (1.609 X 1.887) NEOPRENE
2
270
FLUSH SEAL PLUG 3/4-14 NPTF SOCKET HEAD
2
269
ROLL PIN (M2.5 X 26) STEEL
4
286 SCREW (1/4-20 NC X 2) CAP SOCKET HEAD ASTM A574
8
226
RACK CLAMP
4
298
SET SCREW (10-32 NF X 3/16) CUP PNT HEX
4
222
GEAR
4
220
END PLATE ASSEMBLY
1
221
COMMAND SHAFT
1
268
ROLL PIN (.187 X 1)
4
267
DOWEL PIN (1/4 X 1) STEEL
2
DESCRIPTION 13163F 2176X 2606A 2981AA 2795Q 25913E 2060H 25027A
A25849FA A25849FAAF* A25849FAV**
A25994F A25994FAF* A25994FV**
1193D 2868B
* AFLAS ** VITON
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 17
Section 8 · Spare Parts List
Volume Slide
Slide Valve Carriage Assembly
Capacity Slide
Carriage Assembly
*For VSS Models from 451 to 2101
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 18
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Slide Valve Carriage Assembly
MODEL NUMBER
ITEM
DESCRIPTION
QTY
VSS 291 thru
VSS 601
QTY
VSS 751 thru
VSS 901
QTY
VSS 1051 VSS 1201
QTY
VSS 1501 thru
VSS 2101
300
CARRIAGE ASSEMBLY
2 A25179B 2 A25179C 2 A25179D 2 A25179E
304 CAPACITY PISTON (340, 341, 350, 355)
2 A25183B 2 A25183C 2 A25183D 2 A25183E
305
VOLUME PISTON (340, 342, 350, 355)
2 A25184B 2 A25184C 2 A25184D 2 A25184E
307A
GASKET (345)
2 25900A -
N/A
-
N/A
2 A25200E
307B
GASKET SET (345, 378)
-
N/A
2 A25200C 2 A25200D -
N/A
316
RACK
2 25024AH 2 25080AH 2 25080CH 2 25779AH
323
RACK
2 25023AH 2 25080BH 2 25080DH 2 25080DH
325
SHAFT
-
N/A
-
N/A
-
N/A
2 25778A
340
PISTON
-
N/A
4 25076A 4 25138A 4 25782A
341
CAPACITY PISTON SHAFT
-
N/A
2 25078A 2 25078E 2 25784A
342
VOLUME PISTON SHAFT
-
N/A
2 25078B 2 25078F 2 25783A
343A
COVER, SEPARATE VOL. & CAP.
4 25022A 2 25123B 4 25123D -
N/A
343B
COVER, ONE PIECE CAST
2 25399D 2 25279A 2 25401A 2 25690A
344
COVER, SEPARATE VOL. & CAP.
-
N/A
2 25123A -
N/A
-
N/A
345A GASKET, SEPARATE VOL. & n/a CAP COVERS. 4 25021A 2 25124B 4 25124C -
N/A
345B
GASKET, ONE PIECE CAST COVER
2 25900A 2 25902A 2 25901A 2 25384A
346
GASKET, ONE PIECE CAST COVER
-
N/A
2 25124A -
N/A
-
N/A
347
PISTON SLEEVE
-
N/A
2 25079A -
N/A
4 25786A
350
PISTON RING SET
4 2953AA 4 2953AB 4 2953AC 4 2953AD
355
EXPANSION PIN
4 1193PP 4 1193PP 4 1193PP 4 1193PP
359
PIPE PLUG
6 2606D 6 2606D 6 2606D 6 2606E
360
LOCK WASHER (PAIR)
4 3004C 4 3004C 4 3004C 4 3004C
361
WASHER
4 13265B 4 13265B 4 13265B 4 13265B
363
NUT
8 2797A 8 2797A 8 2797A 8 2797A
366A
HEX HEAD CAP SCREW, SEPARATE VOL. & CAP COVERS.
24
2796N
12
2796B
24
2796B
-
N/A
366B
HEX HEAD CAP SCREW, ONE PIECE CAST COVER.
24 2796B 12 2796P 24 2796P 28 3796BL
367
HEX HEAD CAP SCREW
-
N/A
12 2796BN -
N/A
-
N/A
373
SOCKET HEAD CAP SCREW
-
N/A
6 2795N 6 2795P 6 2795AG
374
LOCK WASHER (PAIR)
-
N/A
6 3004C 6 3004D 6 3004D
378
O-RING
-
N/A
2 2176Y -
N/A
4 2176AG
380
RETAINER RING
-
N/A
2 2866C -
N/A
4 2866G
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 19
Section 8 · Spare Parts List Slide Valve Carriage Assembly
*VSS 2401 thru VSS 3001 Only
ITEM
101 102 103 104 105 106 107 108 109 110
111
112
113 114 115
DESCRIPTION
CARRIAGE ASSEMBLY CAPACITY PISTON VOLUME PISTON SMALL PISTON SEAL PISTON COVER
SMALL CAPACITY PISTON SLEEVE PISTON SHAFT GUIDE WASHER
CAP SM PIPE NIPPLE (1/2 X 2-1/2) PIPE SOCKET PLUG HEX SCREW (5/8-16 NC X 4) CAP
SOCKET NORD LOCK WASHER (.625) PER-
MANENTLY TIGHT RETAINING RING (2.875 X 0.093)
INT BEVELED RETAINING RING (3.500) EXTER-
NAL BASIC VOLUME PISTON SLEEVE PISTON SHAFT GUIDE WASHER
MODEL NUMBER VSS 2401
QTY thru VSS 3001
1 A25179K 1 A25183GS 1 A25184GS 1 A25200FS 1 A25220F 1 26113E
1 26115D
1 13189D 3 13163F
3 2795BE
3 3004H
2 2867AQ
2 2866AC
1 26114E 1 26115C
8 - 20
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Actuator & Command Shaft
MODEL NUMBER
ITEM
DESCRIPTION
VSS 291 QTY thru
VSS 601
VSS 751 VSS 1051 VSS 1551 VSS 2401
thru VSS 1201 thru
thru
VSS 901 VSS 1301 VSS 2101 VSS 3001
400 COMMAND SHAFT ASSEMBLY 2 A25994B A25994C A25994D A25994E A25994F
401
SLIDE VALVE ACTUATOR
2 25972D 25972D 25972D 25972D 25972D
446
O-RING SEAL
2 2176X 2176X 2176X 2176X 2176X
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 21
Section 8 · Spare Parts List Miscellaneous Frame Components VSS Screw Compressor
*
* *For VSS Models from 451 to 2101
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 22
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Miscellaneous Frame Components
MODEL NUMBER
ITEM
DESCRIPTION
QTY
VSS 291 thru VSS
601
QTY
VSS 751 VSS 901
QTY
VSS 1051 VSS 1201
QTY
VSS 1301
-
GASKET & O-RING KIT
1 KT710AN 1 KT710B 1 KT710C 1
KT710J
504A FLANGE SET (513A, 514A, 545A) 1 A25190A 1 A25190A 1 A25190B 1 A25190A
504B* FLANGE SET (513B, 514B, 545B) 2 A25190B -
N/A
2 A25190B 2 A25190B
504C* FLANGE SET (513B, 514C, 545C) -
N/A
2 A25190A -
N/A
-
N/A
506A
PLUG SET, ECONOMIZER (514C, 528, 545B)
1
A25243BE
1
A25243CC
1
A25243DC 1
A25243DD
506B
PLUG SET, ECONOMIZER (514A, 514C, 528, 545C)
-
N/A
-
N/A
-
N/A
-
N/A
511
DISCHARGE MANIFOLD
1 25502A 1 25540A 1 25597A
512
MANIFOLD GASKET
1 25503A 1 25541A
1
25324A 1
25324A
513A
FLANGE
1 25058ASW 1 25058ASW 1 25058B 1 25058ASW
513B
FLANGE
2 25058B 2 25058ASW 2
25058B 2
25058B
514A
GASKET
1 11323D 1 11323D
1
11323E 1
11323D
514B
GASKET
2 11323E -
N/A
2
11323E 2
11323E
514C
GASKET
2 11323D 2 11323S
2
11323E 2
11323E
518
GASKET, SUCTION
1 25199C 1 25199C
1
25199D 1
25199D
519
GASKET, DISCHARGE
1 25199B 1 25199B
1
25199C 1
25199C
528
ECONOMIZER PLUG
2 25397G 2 25397A
2
25391D 2
25391A
530
O-RING
2 2176AB 2
2176J
2
2176J
2
2176AB
536
PIPE PLUG 3/4" MPT
-
N/A
-
N/A
6
2606A
6
2606A
540
DOWEL PIN
2
2868B
2
2868B
2
2868B
2
2868B
542
PIPE PLUG 3/4" MPT
-
N/A
-
N/A
-
N/A
-
N/A
545A
HEX HEAD CAP SCREW
2 2796GP 2 2796GP 2
2796C
2
2796GP
545B
HEX HEAD CAP SCREW
4
2796C
4
2796C
4
2796C
4
2796C
545C
HEX HEAD CAP SCREW
-
N/A
4 2796GP -
N/A
-
N/A
547
HEX HEAD CAP SCREW
8
2796C 24 2796GP 24 2796GP 24
2796F
QTY
1 1 2
1 1 1 1 1 1 1
3 2 1 4 -
VSS 1501 VSS 1801 KT710D A25190C A25190A
25663A 25676A 12477C
N/A 11323F
N/A N/A 25199D 25199C 25393A
2606E 2868K 13163F 11397E N/A N/A N/A
QTY
1 1 2 -
-
1
1 1 2 1 2 2 1 1 2 2 3 2 1 4 4 12 -
VSS 1551 thru VSS
2101 KT710D A25190C A25190D
N/A
N/A
A25243ED
25676A 12477C 25058ASW 11323F 11323S 11323G 25199D 25199C 25393A 2176J 2606A 2868K 13163F 11397E 2796GP 11397E
N/A
8 - 23
Section 8 · Spare Parts List Miscellaneous Frame Components
*VSS 2401 thru VSS 3001 Only
ITEM
DESCRIPTION
QTY
VSS 2401 thru VSS 3001
504
FLANGE SET 1.250 VSS 401MM
1
A25190EA
505
TUBING VSS2401-3001
1
A25201F
536 PLUG 1/2-14NPTF FLUSH SEAL SOC HD 2
2606E
538 PLUG 3/4-14NPTF FLUSH SEAL SOC HD 3
2606A
539
PLUG, LIQUID INJECTION
4
26293A
540
O-RING 0.171X0.499 NEOPRENE
4
2176DD
*
GASKET & O-RING KIT
1
KT710E
*
FLANGE
1
12478G
*
PLUG SET, ECONOMIZER
1
A25243BB
NOTES * Not Shown
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 24
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Miscellaneous Frame Components (Tubing and Fittings)
Gaterotor BEARING SUPPLY LINES
VSS 451 THRU VSS 1801
SEAL CHAMBER OIL LINE
VSS 451 THRU VSS 1201
VSS 1501 & VSS 1801
SLIDE VALVE BALANCE PISTON EQUALIZING LINE
VSS 451 & VSS 601
VSS 751 & VSS 901
VSS 1051 & VSS 1201
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 25
Section 8 · Spare Parts List
Miscellaneous Frame Components (Tubing and Fittings)
ITEM
555 556 557 558 559 560 561 562
563
564 565 566 567 568
DESCRIPTION
ELBOW 1/4 ODT X 1/4 MPT 90° MALE STRAIGHT 1/4 ODT X 1/4 MPT
TEE, RUNNING 1/4 OD X 1/4 MPT MALE HEX BUSHING HEX BUSHING
ELBOW 3/8 ODT X 1/2 MPT 90° MALE ELBOW 3/8 OD X 1/4 MPT 90° MALE
PLUG TEE 1/4 ODT X 1/4 ODT X 1/4 MPT
BRANCH TEE 1/4 TEE 1/4T X 1/4T X 1/4 FPT FEMALE NIPPLE 1/4 X 2-1/2 PIPE CONNECTOR 1/2-13 NC-2 X 1 SET REDUCING BUSHING 1 X 1/4
MODEL NUMBER
QTY
VSS 451 VSS 601
QTY
VSS 751 VSS 901
QTY
VSS 1051 VSS 1201
QTY
VSS 1501 VSS 1801
5 13375D 5 13375D 3 13375D 2 13375D
1 13229D 1 13229D 2 13229D -
N/A
1 1509A 1 1509A 1 1509A 1 13376D
1 13231AA 1 13231AA 1 1101H 1 13231AA
-
N/A
-
N/A
1 1101K 1 1101K
1 13375Z 1 13375Z 1 13375Z 1 13375Z
1 13375F 1 13375F 1 13375F -
N/A
1 2606E 1 2606E 1 2606A -
N/A
-
N/A
-
N/A
2 13376D -
N/A
-
N/A
-
N/A
1 13239C -
N/A
-
N/A
2 1884A -
N/A
-
N/A
-
N/A
2 13181D -
N/A
-
N/A
-
N/A
-
N/A
-
N/A
1 13299C
-
N/A
-
N/A
-
N/A
1 1101M
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 26
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Miscellaneous Frame Components (Tubing and Fittings) (VSS 2401 - VSS 3001)
ITEM
DESCRIPTION
555
MALE ELBOW (3/8 ODX 1/4MPT) 90°
557 BRANCH MLE TEE (1/4ODTX1/4ODTX1/4MPT)
560
MALE ELBOW (1/4ODTX1/4MPT) 90°
567 COMPRESSION CONNECTOR (3/8 ODT X 1/8MPT)
568
BUSHING (1 X 1/4) HEXAGON
570
UNION TUBE TEE (3/8)
573
BRANCH MALE TEE (3/80 DT X 1/4MPT)
571
STEEL TUBING (1/4 X .035) SMLS
572
STEEL TUBING (3/8 X .035) SMLS
QTY
2.00 1.00 2.00 1.00 2.00 1.00 1.00 2.00 4.00
VSS 2401VSS 3001 13375F 13376D 13375D 13229W 1101M 13239E
2084A 3509A 3509B
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 27
Section 8 · Spare Parts List Replacement Tools
291 1551
ITEM
900 901A 901B
8 - 28
DESCRIPTION
Gaterotor TOOLS Gaterotor STABILIZER SET (901A,
901B, 901C) Gaterotor STABILIZER SET (901A,
901B, 901C, 901D)
VSS 291 QTY thru VSS
601 1 A25205B
1 A25698A
MODEL NUMBER
VSS 751 VSS 901
VSS 1051 VSS 1201 VSS 1301
VSS 1551 thru VSS
2101
A25205C A25205C A25205E
A25698A A25698A
N/A
VSS 2401 thru VSS 3001
A25205F
N/A
1
N/A
N/A
N/A
A25699A
N/A
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Replacement Parts
COMPONENT
DESCRIPTION
VPN QTY
WHERE USED
1
20" Oil Separator
2
24" Oil Separator
Oil Separator Defogger Element
2879A 3
30" Oil Separator
VSS Units Horizontal Oil
Separator
Cover Gasket, 13"x12"
4 5 1 93559A 1
36" Oil Separator 42" Oil Separator 20" Oil Separator 24" Oil Separator
1
30" Oil Separator
Cover Gasket, 16"x15"
93560A 1
36" Oil Separator
1
42" Oil Separator
VSS Units Oil Filter
Oil Filter Element Filter Tank Cover Gasket (Included with 1833C)
1 1833C
2 35197A 1
Single Element Filter Tank Dual Element Filter Tank Single or Dual Element Filter Tank
Strainer Screen, 4" & 5"
2881A 1
4" & 5" Suction Strainer
VSS Units Suction Strainer
Strainer Screen, 6" Strainer Screen, 8" Strainer Cover Gasket Strainer Cover Gasket
2881B 1 2881C 1 2555E 1 2555F 1
6" Suction Strainer 8" Suction Strainer 4" & 5" Suction Strainer 6" Suction Strainer
Strainer Cover Gasket
2555G 1
8" Suction Strainer
300 Psig R-717 Relief Valve
1498GG 2
300 Psig R-717 Dual Relief Valve
250 Psig R-717 Relief Valve
1498EE 2
250 Psig R-717 Dual Relief Valve
Safety Relief Valves
300 Psig Halocarbon Relief Valve, 1/2"x 5/8" 300 Psig Halocarbon Relief Valve, 3/4"x 1"
1498GA 2 300 Psig Halocarbon Dual Relief Valve
1498GJ, 1498GK, 2 300 Psig Halocarbon Dual Relief Valve 1498GKA
300 Psig Halocarbon Relief Valve, 1"x 1"
1498GN 2 300 Psig Halocarbon Dual Relief Valve
Solenoid Coil, 115V/50 Hz., Yellow and Blue Leads 2650W
1
2650 Series Solenoid Valve, 115V/50 Hz.
Replacement Solenoid Valve Coils
Solenoid Coil, 230V/50 Hz., Yellow Leads Solenoid Coil, 120V/60 Hz., Blue Leads
2650X 2650Y
1
2650 Series Solenoid Valve, 230V/50 Hz.
1
2650 Series Solenoid Valve, 120V/60 Hz.
Solenoid Coil, 240V/60 Hz., Red Leads
2650Z 1 2650 Series Solenoid Valve, 240/60 Hz.
Bare 11 GPM Oil Pump
2954B 1
11 GPM Oil Pump
Replacement Shaft Seal for 11 GPM Oil Pump
KT718A 2
12 GPM Oil Pump
Viking Oil Pump
Bare 22 GPM Oil Pump Bare 31 GPM Oil Pump
2954E 1 2954H 1
22 GPM Oil Pump 31 GPM Oil Pump
Replacement Shaft Seal for 22 and 31 GPM Oil Pumps
KT718C 1
22 and 31 GPM Oil Pumps
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 29
Section 8 · Spare Parts List
Replacement Parts
COMPONENT
DESCRIPTION
VPN QTY
WHERE USED
Haight Oil Pump
Liquid Injection
Bare 10 GPM Oil Pump
3022AU & 2913N
1
10 GPM Oil Pump
Bare 20 GPM Oil Pump
3022DU & 2913E
1
20 GPM Oil Pump
Bare 30 GPM Oil Pump
3022GU & 2913E
1
30 GPM Oil Pump
Replacement Shaft Seal
3022C 1 10, 20, and 30 GPM Haight Oil Pumps
2 Ton R-717 Thermostatic Expansion Valve *
2629J
1 2 Ton R-717 Liquid Injection System *
5 Ton R-717 Thermostatic Expansion Valve **
2629A 1 5 Ton R-717 Liquid Injection System **
10 Ton R-717 Thermostatic Expansion Valve **
2629B
1
10 Ton R-717 Liquid Injection System **
15 Ton R-717 Thermostatic Expansion Valve **
2629C
1
15 Ton R-717 Liquid Injection System **
20 Ton R-717 Thermostatic Expansion Valve ***
2629D
1
20 Ton R-717 Liquid Injection System ***
30 Ton R-717 Thermostatic Expansion Valve ***
2629E
1
30 Ton R-717 Liquid Injection System ***
50 Ton R-717 Thermostatic Expansion Valve ***
2629F
1
50 Ton R-717 Liquid Injection System ***
75 Ton R-717 Thermostatic Expansion Valve ***
2629G
1
75 Ton R-717 Liquid Injection System ***
100 Ton R-717 Thermostatic Expansion Valve *** 2629H
1
100 Ton R-717 Liquid Injection System ***
Power Head Assembly
2637A
1
2 thru 15 Ton Thermostatic Expansion Valve
Power Head Assembly
2637B
1
20 thru 100 Ton Thermostatic Expansion Valve
120V R-717 Solenoid Valve
2562E
1
5 thru 15 Ton R-717 Liquid Injection System
120V R-717 Solenoid Valve
2875F
1
20 thru 100 Ton R-717 Liquid Injection System
Solenoid Valve Coil
2650VA 1 KIT REPLACEMENT W/S8F W/STRAINER
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 30
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
VSM 301-701 Recommended Spare Parts List
Refer to the Custom Manual Spare Parts Section for Specific Applications
Please have your Model # and Sales Order # available when ordering. These are found on the compressor's Name Plate.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 31
Section 8 · Spare Parts List Gaterotor Assembly
8 - 32
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Gaterotor Assembly
Part totals indicated are for one Gaterotor assembly, machines with two Gaterotors will require double the components listed below.
ITEM
DESCRIPTION
QTY VSM 301
VSM 361
MODEL NUMBER VSM 401 QTY VSM 501
VSM 601
VSM 701
Gaterotor BLADE REPLACEMENT KITS
1
KT1098A KT1098B KT1098C
1 KT1098D KT1098E KT1098F
Gaterotor BEARING REPLACEMENT KITS
1
KT759F
KT759G
KT759H
1
KT759BG KT759BH KT759BJ (REMAN) (REMAN) (REMAN)
105
SEAL GATEROTOR
1
A25164A A25164A A25164A A25164AV* A25164AV* A25164AV*
1
A25164B A25164B A25164B
105.1
O-RING
1
2176L
2176L
2176L
1 2176M 2176M 2176M
105.2
O-RING
1
2176F
2176F
2176F
1 2176R
2176R
2176R
106 SHIM GATEROTOR
1 A25165A A25165A A25165A 1 A25165B A25165B A25165B
108 SUPPORT GATEROTOR 1 A25222AB A25222AA A25222AC 1 A25222BB A25222BA A25222BC
108.1 SUPPORT GATEROTOR 1 A25161AB A25161AA A25161AC 1 A25161BB A25161BA A25161BC
108.2
BALL BEARING
1 A25163A A25163A A25163A 1 A25163B A25163B A25163B
108.3 ROLLER BEARING
1
2864F
2864F
2864F
1 2864B
2864B
2864B
108.4
RETAINING RING 0.781 ID X .065 X .031
1
2928Y
2928Y
2928Y
1 2928W 2928W 2928W
112
HOUSING GATEROTOR ROLLER BEARING
1
25407B
25407B
25407B 1 25407C 25407C 25407C
116
SUPPORT Gaterotor BALL BEARING
1
25408B
25408B
25408B 1 25408C 25408C 25408C
131
RETAINING RING
1
2867S
2867S
2867S
1 2867A
2867A
2867A
RETAINING RING 1.875
132 x 0.062 EXTERNAL
1
BEVELED
2866J
2866J
2866J
1 2866K
2866K
2866K
151
SCREW
1
2795AP
2795AP
2795AP 1 2795AAA 2795AAA 2795AAA
152 SCREW 3/8-16 NC X 1 11 2796CG
2796CG
2796CG 12 2796CG 2796CG 2796CG
155
SHIM
AR 25977D
25977D
25977D AR 25977G 25977G 25977G
156
SHIM
AR 25977C
25977C
25977C AR 25977H 25977H 25977H
170
WASHER .312
1
3004C
3004C
3004C
1 3004C
3004C
3004C
176
PLUG 3/8-18NPTF FLUSH SEAL SOC HD
1
2606D
2606D
2606D
1 2606D
2606D
2606D
NOTES AR = As Required * Viton
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 33
Section 8 · Spare Parts List Shaft Seal
ITEM
* * 219 230 244 252 260 261
DESCRIPTION
SHAFT SEAL KIT (AMM) 219, 230, & 260 SHAFT SEAL KIT (HALO) 219, 230, & 260
SHAFT SEAL. OIL SEAL.
TEFLON SEAL RETAINER RING
O-RING O-RING (205 Only)
NOTES
*
Not pictured.
A
Sold only as kit.
MODEL NUMBER
QTY VSM 301-401 VSM 501-701
1
KT709D
KT709A
1
KT781D
KT781A
1
A
A
1
2930C
25040A
1
25939A
25939A
1
2928M
2928M
1
2176U
2176F
1
2176AE
N/A
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 34
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Main Rotor
Models VSM 301-401 Counter Clockwise ONLY Models VSM 501-701 Clockwise ONLY
ITEM
DESCRIPTION
QTY VSM 301
VSM 361
MODEL NUMBER VSM 401 QTY VSM 501
VSM 601
VSM 701
MAIN ROTOR ASSEMBLY. 1 A25226AB A25226AA A25226AC 1 A26010BB A26010BA A26010BC
201
ROTOR
1 A25716AB A25716AA A25716AC 1 A26007BB A26007BA A26007BC
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 35
Section 8 · Spare Parts List Slide Valve Cross Shafts & End Plate
Models VSM 301-401 Counter Clockwise ONLY
Models VSM 501-701 Clockwise ONLY
8 - 36
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Slide Valve Cross Shafts & End Plate
ITEM
DESCRIPTION
MODEL NUMBER QTY VSM 301 VSM 361 VSM 401 QTY VSM 501 VSM 601 VSM 701
OIL BAFFLE ASSEMBLY (1)
-
217, (1) 244, (1) 248, (1)
1 A25942AA A25942AA A25942AA 1 A26034B A26034B A26034B
249, (1) 252
SHIM ASSORTMENT (2) 240, (2) 241, (1) 242, (1) 243
1
A25177A A25177A A25177A 1 A26035B A26035B A26035B
217
OIL BAFFLE PLATE
1 25938A 25938A 25938A
26045A 26045A 26045A
220
END PLATE.
1 25719D 25719D 25719D 1 26025B 26025B 26025B
221
SHAFT
2 25941A 25941A 25941A 2 25843A 25843A 25843A
222
GEAR.
4 25027A 25027A 25027A 4 25027A 25027A 25027A
227
CLAMP.
4 25913A 25913A 25913A -
N/A
N/A
N/A
228
SPACER.
4 25847A 25847A 25847A 4 25847A 25847A 25847A
293
SHIM 0.002"
AR 25409AA 25409AA 25409AA 2 26027BA 26027BA 26027BA
294
SHIM 0.003"
AR 25409AB 25409AB 25409AB 2 26027BB 26027BB 26027BB
295
SHIM 0.005"
AR 25409AC 25409AC 25409AC 1 26027BC 26027BC 26027BC
296
SHIM 0.010"
AR 25409AD 25409AD 25409AD 1 26027BD 26027BD 26027BD
244
TEFLON RING
1 25939A 25939A 25939A 1 25929B 25929B 25929B
248
CHECK VALVE
1
3120A
3120A
3120A 1 3120A 3120A 3120A
249
CHECK VALVE
1
3120B
3120B
3120B
1 3120B 3120B 3120B
252
RETAINING RING
1
2829M
2829M
2829M 1 2928N 2928N 2928N
255
WASHER
-
N/A
N/A
N/A
2 25977E 25977E 25977E
256
WASHER
-
N/A
N/A
N/A
2 25977F 25977F 25977F
268
EXPANSION PIN.
4
1193D
1193D
1193D 4 1193D 1193D 1193D
269
EXPANSION PIN.
4 2981AA 2981AA 2981AA 4 2981AA 2981AA 2981AA
271**
PLUG SOLID
1 25422A 25422A 25422A -
N/A
N/A
N/A
281
HEX HEAD CAP SCREW.
6
2796N
2796N
2796N 8 2796B 2796B 2796B
N2O8T6E: SOCKET HEAD CAP SCREW. 8
2795F
**29R7equired at toSpETloScCaRtEeWs.ingle gaterot2or only.2060J
298
SET SCREW.
2
2060H
2795F 2060J 2060H
2795F 2060J 2060H
2 2795D 2795D 2795D 2 2060J 2060J 2060J 2 2060H 2060H 2060H
NOTE: ** Required at top located single gaterotor only.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 37
Section 8 · Spare Parts List Slide Valve Carriage Assembly
Volume Ratio Capacity Slide Carriage Assembly
Assembly Includes Carriage and Slides.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 38
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Slide Valve Carriage Assembly
ITEM
300 304 305 316 318 323 325 350 360 361 363 372*
DESCRIPTION
CARRIAGE ASSEMBLY. CAPACITY PISTON 340, 341, 350 & 355. VOLUME PISTON 340, 342, 350 & 355.
CAPACITY RACK. CAPACITY RACK SHAFT. VOLUME RATIO RACK. VOLUME RATIO RACK SHAFT.
PISTON RING SET. LOCK WASHER (PAIR).
WASHER. NUT.
SOCKET HEAD CAP SCREW.
MODEL NUMBER
QTY VSM 301-401 VSM 501-701
1 A25179A
A26012B
1 A25183A
A25183B
1 A25184A
A25184B
1 25023BH
25024AH
1
25772C
25772A
1 25023CH
25023AH
1
25772D
25772B
2
2953AE
2953AA
2
3004C
3004C
2
13265B
13265B
4
2797A
2797A
1
N/A
2795M
NOTES: There are two slide valve carriages per compressor. Each one each has its own Volume Ratio and Capacity slide valves. The above totals are per side of the compressor, double the quantities if both slide valve carriages are being worked on. * = Not Pictured.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 39
Section 8 · Spare Parts List Actuator & Command Shaft
ITEM
DESCRIPTION
MODEL NUMBER QTY VSM 301-401 VSM 501-701
400 COMMAND SHAFT ASSEMBLY 2
A25994A
A25994B
401 SLIDEVALVE ACTUATOR
2
25972D
25972D
446
O-RING SEAL
2
2176X
2176X
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 40
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Miscellaneous Frame Components
VSM 301-401
VSM 501-701
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 41
Section 8 · Spare Parts List
Miscellaneous Frame Components
ITEM
512 514 522 523 528 530 540 542 551 570 571 572
*
DESCRIPTION
MANIFOLD GASKET. ECON-O-MIZER GASKET. COUPLING LOCK PLATE
LOCK WASHER ECON-O-MIZER PLUG.
O-RING DOWEL PIN PIPE PLUG HEX HEAD CAP SCREW BEARING OIL PLUG
PLUG SPRING GASKET / O-RING SET
MODEL NUMBER
QTY VSM 301-401 QTY VSM 501-701
1
25737A
1
26037A
2
11323G
2
11323D
-
N/A
1
25004D
-
N/A
1
3004H
2
25419A
2
25397K
-
N/A
2
2176BF
2
2868B
2
2868B
3
2606C
10
2606B
-
N/A
2
2796C
1
25978A
-
N/A
1
25979A
-
N/A
1
3148A
-
N/A
1
KT1075A
1
KT1075B
NOTES. * Not Pictured.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 42
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List
Housing Accessories
Housing Accessories
ITEM
DESCRIPTION
117 Gaterotor COVER.
118 COVER GASKET.
129
GASKET.
180
INLET SCREEN.
343 PISTON COVER. *
NOTES. * Not Pictured.
MODEL NUMBER
QTY VSM 301-701
1
25416B
2
25259B
1
11323T
1
25920A
1
25724B
ITEM
345 346
DESCRIPTION
O-RING. O-RING.
MODEL NUMBER
QTY VSM 301-401 VSM 501-701
4
2176BX
2176CA
2
2176BG
2176BG
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 43
Section 8 · Spare Parts List Replacement Tools
ITEM
DESCRIPTION
QTY
900
GATEROTOR TOOLS
1
901 GATEROTOR STABILIZER. 1
902 SEAL INSTALLATION TOOL 1
MODEL NUMBER
VSM 301-401 VSM 501-701
A25205B
A25205B
25742A
25742B
25455A
25455B
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 44
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Replacement Tools
ITEM
DESCRIPTION
QTY
PART NUMBER
-
GATEROTOR TOOL SET
1 A25205B*
1 STABILIZER GATEROTOR ASSEMBLY 1 A25698A
2
BAR BEARING PULLER
1 25204A
3
SHOE PULLER 1.875
1 25157A
4
SHOE PULLER 2.500
1 25157B
5
JACKSCREW
1 A25156B
6
STUD .375-16 X 4.9
2 25908A
7
STUD .250-20 X 4.4
2 25908B
8
STUD .312-18 X 7.5
2 25908C
- SCREW 1/4-20 NC X 1-3/4 CAP SOCK 2 2795W
9
PLAIN NUT 5/16-18NC-2B HEX
2
1726B
* Assembly A25205B contains all parts listed. Parts are shown independently for illustration purposes only.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 45
Section 8 · Spare Parts List
VSM 97-127 Recommended Spare Parts List
Refer to the Custom Manual Spare Parts Section for Specific Applications
Please have your Model # and Sales Order # available when ordering. These are found on the compressor's Name Plate.
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
8 - 46
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Section 8 · Spare Parts List Kits
Gaterotor Kits For VSM127*
ITEM
VPN
QUANTITY
-
KT759J
1
-
KT1098G
1
*Contact Vilter for Other Sizes
DESCRIPTION Blade & Bearing
Blade
Shaft Seal Kit
ITEM -
VPN KT709P
QUANTITY 1
DESCRIPTION Shaft Seal Kit (143mm Compressor)
Vilter parts get renewed from time to time, so be sure to ask if the part listed in your manual is still the best for your compressor. Parts that appear on diagrams might be shown separately for reference, but are sold as an assembly or kit only.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
8 - 47
8 - 48 / Blank
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix A · Torque Specifications
Torque Specifications
Refer to the following tables for torque specifications.
Table A-1. 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 FINE (UNF)
16
SAE GRADE 8 COARSE (UNC)
11 22 39 63 96 138 191 338 546
SOCKET HEAD CAP SCREW (ASTM A574)
COARSE (UNC)
5 13 26 46 73 112 155 215 380 614
1) Torque values on this sheet are not to override those given on the individual drawings.
NOTES:
2) When using loctite, the torque value on this sheet 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.
Table A-2. Torque Specifications for 17-4 Stainless Steel Fasteners (ft-lbs)
Type Bolt/Nut
Head Markings #10
Nominal Size Numbers or Inches ¼" 5/16" 3/8" 7/16" ½" 9/16" 5/8" ¾"
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.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
A - 1
A - 2 / Blank
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix B · Vilter Oil
Oil Analysis Report
Customer Name Customer Address
Evaluation:
The fluid is in good condition. Sample again in 6 months.
PRODUCT ANALYSIS REPORT No Action Required
Report Date:
Report Number:
Customer Comp. Mfr. Oil Type Serial Number Model Number Hrs. on Fluid Hrs. on Machine Sample Date Receive Date I.D. #
3/4/2013
*********
Customer Vilter VILTER-717 ****-*** VSM-601 6049 11239 Feb 21, 2013 Mar 01, 2013 *********
Physical Properties Results *
Sample Date (Lube Hours) Water by Karl Fischer (ppm) Viscosity 40 C (cSt) TAN Total Acid # ISO Code
Feb 21, 2013 (6049) 19.5
64.23 0.077 21/20/16
Oct 19, 2012 (4809) 147.7 64.47 0.106
21/19/16
Jul 26, 2010 (5190) 41.4
66.00 0.080 21/19/14
Spectrochemical Analysis
Wear Metals (ppm) Silver (Ag) Aluminum (Al) Chromium (Cr) Copper (Cu) Iron (Fe) Nickel (Ni) Lead (Pb) Tin (Sn) Titanium (Ti) Vanadium (V) Contaminant/Additive Metals (ppm) Barium (Ba) Calcium (Ca) Magnesium (Mg) Molybdenum (Mo) Sodium (Na) Phosphorus (P) Silicon (Si) Zinc (Zn)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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
Accuracy of recommendations is dependent on representative oil samples and complete correct data on both unit and oil
* Property values should not be construed as specifications
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
B - 1
Appendix B · Vilter Oil
Storage Guidelines For Vilter B and Fl Type Lubricants
Vilter Type B and FL lubricants are ester-based fluids and are hygroscopic by nature. This means that they absorb water moisture from the surrounding environment. Compared to mineral based lubricants which are typically saturated with water at less than 100 PPM, ester based lubricants become saturated with water at approximately 2,500 PPM.
High water moisture levels cannot be tolerated in the refrigeration systems where ester based lubricants are utilized and require specific handling and storage guidelines, in addition to the normal precautions for system dehydration prior to system start-up. All Vilter lubricants are manufactured to meet strict requirements to ensure minimal water moisture content as shipped. The following guidelines are provided for the end-user of the equipment as a means to minimize the water content of lubricants in storage.
Guidelines
· Use a suitable dehydration process for the complete refrigeration system to ensure that the system as a whole is completely dry and water free. This can be accomplished by the use of vacuum pumps and checked by a vacuum gauge to ensure that a suitable micron value has been reached, and maintained.
· Store all lubricant containers in a dry environment. Do not expose the lubricant to the atmosphere by opening the container until the compressor sump or separator is ready to be charged.
· Keep the lubricant in its original container. Some plastic containers allow water moisture to pass through the container itself.
· If possible, use container sizes appropriate to the compressor charge to avoid leaving partially filled containers open for long period of times. Vilter B Type lubricant is available in 5 and 55 gallon containers.
· Refrigeration systems using ester based lubricants will require suitable high capacity moisture filter/ driers to maintain low total moisture content in the refrigerant and lubricant.
Compatibility & Misc.
· Vilter Type B lubricant has been extensively tested with many of the components in a refrigeration system. Elastomers, driers, etc. for use with HFCs have demonstrated no adverse effects when tested for hardness, swelling and brittleness.
· Vilter Type B lubricant cannot be used in conjunction with a mineral based oils are not miscible with HFCs. The performance of a refrigeration system is optimized when the lubricant is allowed to be miscible with the refrigerant to aid in the oil return to the compressor. If the oil used in an HFC refrigeration system does not provide oil return capability, the oil will tend to accumulate in the evaporator reducing the overall system capacity.
· CFC and HCFC refrigerants should not be used with Vilter Type B lubricant since these types of refrigerants greatly reduce the viscosity of ester based lubricants, resulting in inadequate compressor lubrication.
Table B-1 Oil Recommendations for Standard Warranty Coverage Single Screw Compressors Only
Vilter Oil Type ISO Grade
@ 100°F (cSt) Viscosity Index Spec. Gravity Density lbm/gal, 60°F Flash Point - °F Fire Point - °F Pour Point - °F Floc Point - °F Refrigerant Type
717 68 77 100 0.867 7.4 440 475 -38.2 -25 R-717
HCL-68 68 75.7 132
0.835 6.95 525 570 -67 NA R-717 R-22 R-1270
F-68 68 65.67 79 0.876 7.3 295 315 -31 -75 R-22
FL-100 100 76.4 115 0.96 8.26 558 633 Pending NA R-22
B-68 68 71 108 0.957 7.96 505 560 -45 NA R-134a R-507 R-404A R-407C R-410A
HC-68 68 67.2 168
0.989 8.25 425 465 -55 NA R-290
B - 2
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix B · Vilter Oil
Table B-2 Cross Reference Index
Vilter Part No. Oil Type Vilter Lube Type Container Size
Applications
2939A
HMO
R717
5 gallon pail R-717 (Ammonia)
2939AFG
HMO
717FG
55 gallon drum R-717 (Ammonia)
2939B
HMO
R717
5 gallon pail R-717 (Ammonia)
2939BFG
HMO
717FG
55 gallon drum R-717 (Ammonia)
3098A
PAG
HC-68
5 gallon pail R-290
3098B
PAG
HC-68
55 gallon drum R-290
3099A
PAG
HC-100
5 gallon pail Hydrocarbon
3100A
Naphthenic
VILTER D
5 gallon pail R-22, R-123 & R-414A
3100B
Naphthenic
VILTER D
55 gallon drum R-22, R-123 & R-414A
3101A
POE
FL-100
5 gallon pail R-22
3101B
POE
FL-100
55 gallon drum R-22
3103A
PAO
HCL-68
5 gallon pail Ammonia
3103B
PAO
HCL-68
55 gallon drum Ammonia
3103C
PAO
HCL-15
5 gallon pail R-717
3105A
BLEND
F-68
5 gallon pail R-22, R-123 & R-502
3105B
BLEND
F-68
55 gallon drum R-22, R-123 & R-502
3106A
POE
B-68
5 gallon pail All HFC applications (including R-134a, R-404A, R-407C, R-410A, R-507)
3106B
POE
B-68
55 gallon drum All HFC applications (including R-134a, R-404A, R-407C, R-410A, R-507)
3107A
POE
B-120
5 gallon pail R-134A, R-404A, R-407C, R-410A
3107B 3143A
POE PAO-100
B-120 METHANE
55 gallon drum R-134A, R-404A, R-407C, R-410A 5 gallon pail Hydrocarbon/natural gas, Landfill gas, Turbine feed gas
3143B
PAO-100
METHANE 55 gallon drum Hydrocarbon/natural gas, Landfill gas, Turbine feed gas
3143C
PAO-68
METHANE
5 gallon pail Hydrocarbon/natural gas, Landfill gas, Turbine feed gas
3143D 3143G 3143H 3143J
PAO-68 PAO-150 PAO-150 PAO-100
METHANE METHANE METHANE DIGESTER
55 gallon drum 5 gallon pail
55 gallon drum 5 gallon pail
Hydrocarbon/natural gas, Landfill gas, Turbine feed gas Hydrocarbon/natural gas, Landfill gas, Turbine feed gas Hydrocarbon/natural gas, Landfill gas, Turbine feed gas Hydrocarbon/natural gas, Landfill gas, Turbine feed gas
3143K
PAO-100
DIGESTER 55 gallon drum Hydrocarbon/natural gas, Landfill gas, Turbine feed gas
3339A
PAO
CO2 GAS
5 gallon pail CO2, CO
3339B
PAO
CO2 GAS
55 gallon drum CO2, CO
3456A
POE
B-32
5 gallon pail All HFC applications (including R-134a, R-404A, R-407C, R-410A)
3456B
POE
B-32
55 gallon drum All HFC applications (including R-134a, R-404A, R-407C, R-410A)
3595A
HMO
NH3-100-CI
5 gallon pail Ammonia
3595B
HMO
NH3-100-CI 55 gallon drum Ammonia
3603B
POE
B-68AWAF 55 gallon drum All HFC applications (including R-134a, R-404A, R-407C, R-410A, R-507)
3603C
POE
B-68AWAF
5 gallon pail All HFC applications (including R-134a, R-404A, R-407C, R-410A, R-507)
3603D
POE
B-100AWAF 55 gallon drum All HFC applications (including R-134a, R-404A, R-407C, R-410A, R-507)
3603E
POE
B-100AWAF
5 gallon pail All HFC applications (including R-134a, R-404A, R-407C, R-410A, R-507)
3636A 3636B 3643A
PAO
CO2
5 gallon pail Gas streams containing moisture, CO2, CO and/or H2S
PAO
CO2
55 gallon drum Gas streams containing moisture, CO2, CO and/or H2S
PAO
XG 105-100
5 gallon pail Hydrocarbon/natural gas
3643B
PAO
XG 105-100 55 gallon drum Hydrocarbon/natural gas
3653A
POE
POE-100
5 gallon pail Air Compressor Lubricant
3653B
POE
POE-100
55 gallon drum Air Compressor Lubricant
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix C · Vibration Measurements - Single Screw Compressor
Vibration Measurements - Single Screw Compressor
Scope
The vibration criteria provided applies to broad-band vibration measurements taken on the bearings and housing of the Single Screw compressors under steadystate operating conditions within the nominal operating speed range in addition to the piping and tubing on the compressor unit. They relate to both acceptance testing and operational monitoring. The evaluation criteria is intended to apply to both continuous and non-continuous monitoring situations. The scope does not address the diagnostic evaluation of the condition of the roller element bearings. The criteria are applicable only for the vibration produced by the machine itself and not for vibration which is transmitted to the machine set from external sources. Information used in this chapter was taken from ISO Standard 10816-3, Mechanical Vibration Evaluation of Machine Vibration by Measurements on Non-Rotating Parts Part 3, First Edition, 1998.
Measurement Procedures and Operational Conditions
Measurement Equipment
The measurement equipment shall be capable of measuring broad-band rms vibration with flat response over a frequency range of at least 10 Hz to 1000 Hz. Depending on the vibration criteria, this may require measurements
of displacement or velocity or combinations thereof.
Care should be taken to ensure that the measuring system is not influenced by environmental factors such as:
· temperature variations; · magnetic fields; · sound fields;
· power source variations;
· transducer cable length;
· transducer orientation.
Particular attention should be given to ensure that the vibration transducers are correctly mounted and that such mountings do not degrade the accuracy of the measurements.
Compressor Measurement locations
Measurements taken on the compressor will usually be taken on exposed parts that are normally accessible. Care shall be taken to ensure that measurements reasonably represent the vibration of the bearing housing and do not include any local resonances or amplification. The locations and directions of vibration measurements shall be such that they provide adequate sensitivity to the machine dynamic forces. Typically, this will require two radial measurement locations on each bearing cover on the gate rotor housing support and back plate (near the compressor shaft). Vertical and horizontal directions are preferred for Single Screw compressors. The specific locations and directions shall be recorded with the measurement.
Figure C-1. Compressor Bearing Vibration Measurement Location
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
C - 1
Appendix C · Vibration Measurements - Single Screw Compressor
Figure C-2. Main Rotor Cross-Section VSS/VSMC Compressors
Continuous and Non-continuous Monitoring
While it is common practice on large or critical machinery to have installed instrumentation for continuous online monitoring of vibration values at key measurement points, this is not necessarily carried out in industrial applications.
Changes in unbalance, bearing performance, alignment, etc. can be detected with sufficient reliability from periodic measurements with permanently installed or handheld instruments. The use of computers for trend analysis and warning against malfunctions is also becoming more common.
Operational Conditions
Measurements shall be carried out when the compressor has reached normal steady-state operating temperatures and with the machine running under specified conditions. If the measured vibration is greater than the acceptance criteria allowed and an excessive background vibration is suspected, measurements should be made with the machine shut down to determine the degree of external influence. If the vibration with the machine stationary exceeds 25% of the value measured when the machine is running, corrective action may be necessary to reduce the effect of the background vibration.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix C · Vibration Measurements - Single Screw Compressor
Evaluation
There are two evaluation criteria used to assess vibration severity on various classes of machines. One criteria considers the magnitude of observed broad-band vibration; the second considers changes in magnitude, irrespective of whether they are increases or decreases.
Criterion 1: Vibration Magnitude
This criterion is concerned with defining limits for vibration magnitude consistent with acceptable dynamic loads on the bearings and acceptable vibration transmission into the environment through the support structure and foundation. The maximum vibration magnitude observed at each bearing or pedestal is assessed against the evaluation zones for the support class. The evaluation zones have been established from international experience.
The following evaluation zones are defined to permit a qualitative assessment of the vibration of a given machine and provide guidelines on possible actions.
· Zone A: The vibration of newly commissioned machines would normally fall within this zone.
· Zone B: Machines with vibration within this zone are normally considered acceptable for unrestricted long-term operation.
· Zone C: machines with vibration within this zone are normally considered unsatisfactory for long term continuous operation. Generally, the machine may be operated for a limited period in this condition until a suitable opportunity arises for remedial action.
· Zone D: Vibration values within this zone are normally considered to be of sufficient severity to cause damage to the machine.
Numerical values assigned to the zone boundaries are not intended to serve as acceptance specifications, which shall be subject to agreement between VilterTM manufacturing and the customer. However, these values provide guidelines for ensuring that gross deficiencies or unrealistic requirements are avoided. In certain cases, there may be specific features associated with a particular machine which would require different zone boundary values (higher or lower) to be used
Figure C-3. Gaterotor Cross-Section VSS/VSR/VSMC Compressors
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
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Appendix C · Vibration Measurements - Single Screw Compressor
Evaluation Zone limits
The values for the zone boundaries given below are based on the maximum broad-band values of velocity and displacement when measurements are taken from two orthogonally oriented radial transducers. Therefore when using these tables, the higher of each of the values measured from the two transducers in each measurement plane should be used. When the maximum measured values of velocity and displacement are compared to the corresponding values in the table, the severity zone which is most restrictive shall apply.
Operational limits
For long-term operation, it is common practice to establish operational vibration limits. These limits take the form of ALARM and TRIP set points.
ALARM: To provide a warning that a defined value of vibration has been reached or a significant change has occurred, at which remedial action may be necessary. In general, if an ALARM situation occurs, operation can continue for a period while investigations are carried out to identify the reason for the change in vibration and define any remedial action.
TRIP: To specify the magnitude of vibration beyond which further operation of the machine may cause damage. If the TRIP value is exceeded, immediate action should be taken to reduce the vibration or the machine should be shut down.
Different operational limits, reflecting differences in dynamic loading and support stiffness, may be specified for different measurement positions and directions.
VIBRATION MEASUREMENTS SINGLE SCREW COMPRESSOR*
RMS Displacement ZONE
RMS Velocity
Support
A
Class
B
mm 0-30 30-57
mils 0-1.15 1.15-2.25
mm/s 0-2.3 2.3-4.5
In/sec 0-.09 .09-.18
C
57-90 2.25-3.55 4.5-7.1 .18-.28
D Above 90 Above 3.55 Above 7.1 Above .28
*RMS= 0.707 X peak (sine wave only)
Table C-1. Vibration Zone Values
Setting of ALARMS
The ALARM values may vary considerably, up or down, for different machines. The values chosen will normally be set relative to a baseline value determined from experience for the measurement position or direction for that particular machine.
It is recommended that the ALARM value should be set higher than the baseline by an amount equal to 25% of the upper limit for zone B. If the baseline is low, the ALARM may be below zone C.
Where there is no established baseline (for example with a new machine) the initial ALARM setting should be based either on experience with other similar machines or relative to agreed acceptance values. After a period of time, the steady-state baseline value will be established and the ALARM setting should be adjusted accordingly.
It is recommended that the ALARM value should not
normally exceed 1.25 times the upper limit of zone B.
If the steady-state baseline changes (for example after a machine overhaul), the ALARM setting should be revised accordingly.
Setting of TRIPS
The TRIP values will generally relate to the mechanical integrity of the machine and be dependent on any specific design features which have been introduced to enable the machine to withstand abnormal dynamic forces. The values used will, therefore, generally be the same for all machines of similar design and would not normally be related to the steady-state baseline value used for setting ALARMS.
There may, however, be differences for machines of different designs and it is not possible to have clear guidelines for absolute TRIP values. In general, the TRIP value will be within zone C or D, but it is recommended that
C - 4
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Appendix C · Vibration Measurements - Single Screw Compressor
the TRIP value should not exceed 1.25 times the upper limit of zone C.
Vibration limits For piping and Tubing
The piping and tubing on the compressor units must be supported with the appropriate brackets and supports to minimize the vibration levels. These brackets and supports should also be strategically placed to prevent the natural frequency from matching the normal operating speed. The typical goal is to have the natural frequency of an assembly to be at least 10% above or below the operating speed. In the case when a compressor is operated by a VFD (Variable Frequency Drive), there is a high probability that there will be an opportunity to match either the natural frequency of the assembly or it's 2nd or 3rd order since the compressor's speed will vary within a large range of RPM's.
The compressor unit should first be operated at either the normal operating speed or if it utilizes a VFD, through the operating range of speed. Visual observations of the vibration levels of all the piping and tubing should first be observed. After this initial survey, the vibration measurement equipment should be individually mounted or attached to each specific piece of piping or tubing as required in the location of what is perceived as the maximum amplitude or worse vibration.
While there are references which specifically allow higher levels of vibration for piping, the goals for the vibration levels of the piping and tubing on the compressor unit should still utilize the same criteria outlined in this standard. If possible, the vibration levels should be within the zone boundaries of Zone B or better. These values will ensure that the stress levels in the piping and tubing are acceptable for continuous operation. These values provide guidelines for ensuring that gross deficiencies or unrealistic requirements are avoided. In certain cases, there may be specific features associated with a particular compressor unit which would require different zone boundary values.
For compressors that are operated at a fixed speed, brackets and supports may be added or moved to reduce the vibration levels of the specific component. If the compressor is operated utilizing a VFD, a skip frequency should be inputted into the controls to ensure the compressor passes through the harmonic and that it operates either below or above the operating speed that matches the natural frequency of the specific component. It is not unusual to have three or four skip frequencies within the normal operating ranges of a compressor utilizing a VFD.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix D · Liquid Injection Valve Setup Instructions and Quick Start Guide
Appendix D Liquid Injection Valve Setup Instructions and ICM/ICAD Motorized Valve Quick Start Guide
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
D - 1
Appendix D · Liquid Injection Valve Setup Instructions and Quick Start Guide
Danfoss ICM/ICAD Valve Setup Instructions
The following items need to be setup in order for the valve to operate properly.
1. Press the "Circle" button on the valve. A value of "01" should be shown on the screen. 2. Press the "Circle" button. There should be a value of "1" shown. If not use the up/down arrows to change it to
the correct value. Press the "Circle" button when done. 3. Press the "Up" arrow button. A value of"02" should be shown on the screen. 4. Press the "Circle" button. There should be a value of "1" shown. If not use the up/down arrow buttons to change
it to the correct value. Press the "Circle" button when done. 5. Press the "Up" arrow button. A value of "03" should be shown on the screen. 6. Press the "Circle" button. There should be a value of "2" shown. If not, use the up/down arrow buttons to change
it to the correct value. Press the "Circle" button when done. 7. Press the "Up" arrow button until a value of "04" is shown on the screen. 8. Press the "Circle" button. There should be a value of "50" shown. If not, use the up/down arrow buttons to
change it to the correct value. Press the "Circle" button when done. 9. Press the "Up" arrow button until a value of "07" is shown on the screen. 10. Press the "Circle" button. There should be a value of "1" shown. If not, use the up/down arrow buttons to change
it to the correct value. Press the "Circle" button when done. 11. Press the "Up" arrow button until a value of "10" is shown on the screen. 12. Press the "Circle" button. Press the up/down arrow button to change the value to "11". Press the "Circle" button. 13. Press the "Up" arrow button until a value of "26" is shown on the screen. 14. Press the "Circle" button. Press the up/down arrow buttons to change the value to the correct valve that is on the
unit. The value number is listed on the valve. The values and valves are as follows: 0: No valve selected. Alarm A1 will become active. 1: ICM20 with ICAD 600 2: ICM25 with ICAD 600 3: ICM32 with ICAD 600 4: ICM40 with ICAD 900 5: ICM50 with ICAD 900 6: ICM65 with ICAD 900
15. Press the "Circle" button.
The valve is now ready to be used.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
ICM/ICAD Motorized Valve
Installation, Programming, and Troubleshooting
Contents
Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Wiring the ICAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 ICAD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 ICAD Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Troubleshooting
The Manual Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Service parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Common questions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DKRCI.EI.HT0.A1. / 50H1639
Danfoss (USCO / MKS), 11- 006
ICM/ICAD Motorized Valve
Installation, Programming, and Troubleshooting
Care should be taken to protect the ICM function module while it is removed from the valve body.
3. Weld the valve body in line making sure the arrow on the valve body is pointing in the direction of flow.
4. Remove all debris from the valve body before re-installing the bonnet. 5. Install the bonnet/function module into the valve body.
a. For ICM 0, make sure that the removable orifice seat is installed in the valve body with the small O-ring between the orifice seat and body. Make sure the bonnet gasket is installed and in good condition.
b. For ICM 5 through ICM 65, check that the two O-rings on the bonnet and gasket located between the bonnet and valve body are installed and in good condition. A light coating of refrigerant oil on the bonnet O-rings will facilitate installation of the bonnet.
6. Install the four bolts and torque to the following specifications:
Valve body Nm ft lbs
ICM 0
50 37
ICM 5
80 59
ICM 3
80 59
ICM 40
90 66
ICM 50
100 74
ICM 65 110 81
7. Install the ICAD motor actuator on the ICM valve: a. The ICM valve must not be in its fully opened position while the ICAD motor is calibrated with the valve at a later step. Therefore, if the opening degree of the ICM valve was changed from the factory setting, it should be set to an opening degree between 0% and 75% using the manual magnet tool. To easily ensure correct positioning, turn the manual tool counter-clockwise until it is clear that it cannot be turned further. b. Make sure that the ICM adapter/valve stem and inner ICAD motor magnets are completely dry and free from any debris. c. For applications below freezing, the ICM adapter O-ring (position c in the diagram on page 3) must be removed, and Molycote G 4500 grease (supplied with ICAD motor) needs to be applied in the O-ring groove on the adapter and on the O-ring before it is re-installed on the ICM adapter. The Molycote grease ensures a good seal between the ICAD motor and the ICM adapter to prevent moisture from entering the ICAD magnets. d. Place the ICAD motor on the valve stem. e. Push the ICAD motor completely down to the identification ring on the valve stem and use a .5 mm hex key to tighten the set screws evenly so the ICAD motor is centered on the ICM adapter (torque: 3 Nm/ .5 lb-ft).
4
DKRCI.EI.HT0.A1. / 50H1639
Danfoss (USCO / MKS), 11- 006
ICM/ICAD Motorized Valve
Installation, Programming, and Troubleshooting
Wiring the ICAD Electrical Data
Danfoss (USCO / MKS), 11 - 006
Note: The ICAD is powered by a 24 Volt DC power source.
There are two cables pre-mounted and connected to the ICAD motor actuator. Never try to open the ICAD motor because the special moisture seal will be damaged.
The power cable consists of 3 wires: · Green: () common (ground) · Brown: (+) positive from 4VDC power source · White: (+) positive from UPS/battery backup (optional)
The control cable consists of 7 wires: · Yellow: () common (ground) · Gray: (+) positive 4-0mA or 0-0mA input to control ICAD motor · Blue: (+) positive 4-0mA or 0-0mA output from ICAD for valve position feedback · Pink: (+) positive -10V or 0-10V input to control ICAD motor. Also used as a digital input with the yellow wire for on/off solenoid valve operation. · White: common alarm (digital NPN transistor output when combined with yellow wire) · Brown: indicates ICM is fully open (digital NPN transistor output when combined with yellow wire) · Green: indicates ICM is fully closed (digital NPN transistor output when combined with yellow wire)
Supply voltage is galvanically isolated from input and output wires.
Supply voltage 4 V d.c., +10% / -15% Load ICAD 600: 1. A
ICAD 900: .0 A
Fail safe supply Min. 19 V d.c. Load ICAD 600: 1. A
ICAD 900: .0 A
Anolog input - Current or Voltage Current
0/4 - 0 mA Load: 00 W Voltage 0/ - 10 V d.c. Load: 10 kW
Analog output 0/4 - 0 mA Load: 50 W
Digital input - Digital ON/OFF input by means of voltfree contact (Signal/Telecom relays with
gold-plated contacts recommended) Voltage input used ON: contact impedance < 50 W) OFF: contact impedance > 100 kW
Digital output - 3 pcs. NPN transistor output
External supply: 5 - 4 V d.c. (same supply as for ICAD can be used, but please note that the
galvanically isolated system will then be spoiled).
Output load: 50 W
Load:
Max. 50 mA
DKRCI.EI.HT0.A1. / 50H1639
5
ICM/ICAD Motorized Valve
Installation, Programming, and Troubleshooting
Programming the ICAD
ICAD Parameters
Description ICM OD (Opening Degree)
Main Switch
Display name
Min.
-
0
¡01
1
Mode
¡02
1
Analog Input signal
¡03
1
Speed at ON/OFF and Modulating Mode
¡04
1
Automatic calibration
¡05
0
Analog Output signal
¡06
0
Fail safe
¡07
1
Digital Input function
¡09
1
Password Old Alarms OD at powercut
¡10
0
¡11
A1
¡12
0
ICM configuration
¡26
0
When the ICAD motor is first powered, the ICAD display will flash an A1 alarm. This means that the ICM valve size that is being used with the ICAD motor needs to be selected in parameter ¡26. Parameter ¡26 is password protected and will not appear in the parameter list until the user enters the password in parameter ¡10. The password is "11," and will allow the user to access parameter ¡26 where the appropriate valve size is selected. When the ICM valve size is selected, the ICAD will calibrate itself to the ICM valve and will then be ready for control by a 4-0mA signal. For most applications, this is the only programming that will need to be done if the ICAD is going to be controlled by a 4-0mA input.
Max.
Factory setting
Unit Comments
100
-
%
ICM valve Opening Degree is displayed during normal operation. Running display value (see ¡01, ¡05).
Internal main switch
1
-
1: Normal operation : Manual operation. Valve Opening Degree will be flashing. With the down arrow
and the up arrow push buttons the OD can be entered manually.
Operation mode
1
-
1: Modulating ICM positioning according to Analog Input (see ¡03) : ON/OFF - operating the ICM valve like an ON/OFF solenoid valve controlled via
Digital Input. See also ¡09.
Type of Analog Input signal from external controller
1: 0 - 0 mA
4
-
: 4 - 0 mA
3: 0 - 10 V
4: - 10 V
100
100
Speed can be decreased. Max. speed is 100 % Not active when ¡01 = If ¡02 = the display will indicate speed in display. Low, Med and High also % means ON/OFF operation. If ¡04 < = 33, Low is displayed 33 < If ¡04 < = 66, Med is displayed If ¡04 > = 67 High is displayed
Not active before ¡26 has been operated.
1
0
-
Always auto reset to 0. CA" will flash in the display during calibration, if Enter push button has been
activated for two seconds.
Type of A0 signal for ICM valve position
-
0: No signal 1: 0 - 0 mA
: 4 - 0 mA
Define condition at power cut when fail safe is installed.
1: Close valve
4
1
-
: Open valve
3: Maintain valve position
4: Go to OD given by ¡12
1
Define function when DI is ON (short circuited DI terminals) when ¡02 = 1: Open ICM valve (DI = OFF = > Close ICM valve) : Close ICM valve (DI = OFF = > Open ICM valve)
199
0
-
Enter number to access password protected parameters: ¡26 Password = 11
A99
-
-
Old alarms will be listed with the latest shown first. Alarm list can be reset by means of activating down arrow and up arrow at the same time for seconds.
100
50
-
Only active if ¡07 = 4 If fail safe supply is connected and powercut occurs ICM will go to entered OD.
6
0
NB: Password protected. Password = 11 At first start up A1 will flash in display. Enter valve type 0: No valve selected. Alarm A1 will become active. 1: ICM0 with ICAD 600 : ICM5 with ICAD 600 3: ICM3 with ICAD 600 4: ICM40 with ICAD 900 5: ICM50 with ICAD 900 6: ICM65 with ICAD 900
Danfoss (USCO / MKS), 11 - 006
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9
ICM/ICAD Motorized Valve Troubleshooting The Manual Tool
Service Parameters
Installation, Programming, and Troubleshooting
The manual tool should always be ordered with any ICM/ICAD assembly. This tool gives the user the ability to remove the ICAD actuator and manually rotate the valve in the open or close direction depending on need and application. When using the manual tool, a clockwise rotation will open the valve and a counter-clockwise rotation will close the valve.
NOTE: It is very important to remember that when rotating the valve manually you are changing the position from that in the actuator's memory. If power is removed from the actuator prior to using the manual tool, no problem will occur because, once the ICAD is powered up again, it will automatically recalibrate to the fully closed position before returning to the position in memory to which the control signal last set the valve. This recalibration will not occur if power is not removed from the ICAD prior to using the manual tool, and erroneous operation will likely occur. Always remove power before using the manual tool, and restore power afterward to ensure recalibration and trouble-free operation.
The user will be able to troubleshoot and determine many of the conditions and set points within the ICAD by accessing the Service Menu. A list of those service parameters follows below:
Service Menu
Description
Display name
Min.
Max.
Unit
Comments
OD %
¡50 0 100 % ICM valve Opening Degree
AI [mA]
¡51 0 0 mA Analog Input signal
AI [V]
¡52 0 10 V Analog Input signal
AO [mA]
¡53 0 0 mA Analog Output signal
DI
¡54 0 1 - Digital Input signal
DO Close
¡55 0 1 - Digital Output Closed status. ON when OD < 3 %
DO Open
¡56 0 1 - Digital Output Open status. ON when OD > 97 %
DO Alarm
¡57 0 1 - Digital Output alarm status. ON when an alarm is detected
MAS mP SW ver.
¡58 0 100 - Software version for MASTER Microprocessor
SLA mP SW ver. ¡59 0 100 - Software version for SLAVE Microprocessor
It is also possible to restore the original factory settings to the ICAD by the following procedure:
To restore factory settings: 1. Remove the power supply. . Activate down arrow and up arrow push buttons at the same time. 3. While holding the up and down arrow reconnect the power supply. 4. Release down arrow and up arrow push buttons. 5. When the display on ICAD is alternating between showing: CA and A1 the factory
resetting is complete.
10
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ICM/ICAD Motorized Valve Alarms
Troubleshooting Tips
Installation, Programming, and Troubleshooting
There are a number of alarms which are excellent indicators of improper installation or set-up:
Description
ICM alarm text
Comments
No valve type selected
A1 At start-up A1 and CA will be displayed
Controller fault
A2 Internal fault inside electronics
Input error
A3 Not applicable if ¡01 = or ¡02 = When ¡03 = 1 and AI > mA When ¡03 = and AI > mA or AI < mA When ¡03 = 3 and AI >1 V When ¡03 = 4 and AI >1 V or AI < 1 V
Low voltage of fail safe supply
A4 If 5 V d.c. < Fail safe supply < 18 V d.c.
Check Supply to ICAD
A5 If supply voltage < 18 V d.c.
Problem
Possible cause and solution
The valve is not working and an A1 is flashing in the display.
The ICM valve size was not selected in parameter ¡26. See the programming section on page 9.
The valve does not appear to be opening or closing properly
1. The ICAD was not mounted properly on the valve stem. Solution: Check to make sure that the ICAD was mounted evenly on the ICM valve
. The ICAD is not receiving a proper input signal. Solution: Use the service parameters (¡51 for a mA input or ¡52 for a voltage input) to check the input signal that the ICAD is receiving.
The valve position feedback signal is not working when using customer supplied controller/PLC
1. A power supply was installed in the 4-0mA/0-0mA feedback loop. The ICAD motor actuator supplies the power for the 4-0mA/0-0mA feedback loop. Solution: Remove any power source that may be supplied to the feedback loop.
. Wiring problem. Solution: Check the service parameter ¡53 to see what the ICAD is outputting. If this does not reveal anything, check the current output (yellow and blue wires in ICAD control cable) with an ammeter.
3. The feedback output signal was turned off in parameter ¡06. Solution: Check to make sure the setting in parameter ¡06 is correct.
For all other problems, contact Danfoss.
Danfoss (USCO / MKS), 11 - 006
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11
ICM/ICAD Motorized Valve Common Questions
Installation, Programming, and Troubleshooting
What happens in the event of a power failure? The ICAD will remain in the position it is in when power is lost. There are two ways to address this condition:
· Add a UPS (Uninterruptible Power Supply) to the power wiring. This is easily accomplished with the green and white wires in the power cable. A UPS is available from Danfoss. The UPS can provide service for up to 9 ICAD 600's or up to 6 ICAD 900's.
Note: The UPS is not a continuous power supply. It is used to change the valve position (usually to close the valve) in the event of a power failure. Therefore, the system is not to be run in the UPS mode.
· Add a solenoid valve in front of the ICM. This is a very simple solution provided that there is no issue associated with the additional pressure drop through the solenoid valve.
How much power do I need to supply to the ICAD? The total power required depends on both the ICAD size and the number of ICAD's powered by the DC power supply. The power for each ICAD is:
· For the ICAD 600 (used on ICM 0, 5, and 3), the power requirement is approximately 30 W
· For the ICAD 900 (used on ICM 40, 50, and 65), the power requirement is approximately 50 W
How can I monitor the valve position remotely? The control wiring provides for a 4 to 0 mA or 0 to 0 mA signal output (blue and yellow wires). This signal can be sent to:
· A remote display · A PLC or PC · Another ICAD motor to give the same opening position
Danfoss · Refrigeration & Air-Conditioning Division · 7941 Corporate Drive · Baltimore, MD 136 Ph 410-931-850 · Fax 410-931-856 · E-mail: baltimore@danfoss.com · Internet: www.danfoss.com/North_America
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Appendix E · Liquid Injection Valve Station ICF 20-40 Installation Guide
Appendix E Liquid Injection Valve Station ICF 20-40
Installation Guide
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
E - 1
027R9782
ICM
027R9782
Installation Guide
Valve Station ICF 20-40
ICF xx-4
Direction and position ICF xx-6
ICF xx-4 / ICF xx-6 with ICM
ICM
ICM
Fig. 1a
Fig. 1b
Welding
TIG/MIG/SMAW welding
Inlet and outlet stop valves must be closed all the time before commissioning of the installation in ordre to prevent rust formations in the valve. The stop valves are closed when delivered from the factory. ICF must be cooled during the welding (e.g. by means of a wet cloth).
Fig. 1c
Other welding methods
Remove all parts before welding. When the valve is assembled make sure that some rust protective oil is supplied in the valve. Before commissioning inlet and outlet valves must be closed at all time.
ICM
Danfoss M27H0049_1
Fig. 2
Fig. 3
© Danfoss A/S (AC-MCI/MWA), 2012-12
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1
For both ICF 20 and ICF 25-40 with ICM and ICFE 25-40 Please Note: When used in CO2, the o-rings (see fig. 4) on the ICM and ICFE 25-40 modules can swell (grow). At service it is recommend that new o-rings are installed, before the ICM and ICFE 25-40 function modules are reinstalled in the ICV valve body.
Service and maintenance
2a
4
o-rings
2b
12
Fig. 4
Fig. 5 2
Tightening torques For the 4 bolts in all ICF modules
ICF 20:
ICF 25-40:
50 Nm (36 ft lbs) 80 Nm (58 ft lbs)
50 Nm (36 ft lbs) 50 Nm (36 ft lbs)
DKRCI.PI.FT0.C4.02 / 520H5450
© Danfoss A/S (AC-MCI/MWA), 2012-12
ICF 20
ICFS - stop valve module ICFR - manual regulating valve module
ICFN - stop/check valve module
ICFO - manual opening module
Before remounting the cap on the modules ICFS (stop valve module), ICFR (manual regulating valve module) or ICFN (stop/check valve module) please ensure that the gasket is present in the cap. Then tighten the cap with 16 Nm (12 ft lbs).
ICF 25 - 40
ICFS - stop valve module ICFR - manual regulating valve module
ICFN - stop/check valve module
ICFE - solenoid valve module
Packing gland If the packing gland is leaking, tighten it carefully with a wrench.
Do not apply too much force.
Danfoss recommends that you conduct a stepwise tightening of the packing gland. For each turn check for possible leaks.
Before remounting the cap on the modules ICFS (stop valve module), ICFR (manual regulating valve module) or ICFN (stop/check valve module) please ensure that the gasket is present in the cap. Then tighten the cap with 24 Nm (18 ft lbs).
© Danfoss A/S (AC-MCI/MWA), 2012-12
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3
Operating the manual opener on ICFE 25 solenoid module
To force open the solenoid by the manual stem turn it counter clockwise full way up. (Manual mode) To operate the solenoid in automatic mode, turn the manual stem clockwise until the locking ring stops. Do not force the spindle further. If the locking ring is damaged or removed the spindle will start to leak. The valve cannot be forced closed by the manual stem.
ICFE 25-40 solenoid valve module Locking ring
Turn spindle counter clockwise to open
Operating the manual opener on ICFE 20H solenoid valve module
Remove the cap on the side of the ICFE 20H At 9 o'clock position the manual opener is disabled (not active) To force the ICFE 20H solenoid to open use a 5 mm Allen key and turn it clockwise to 3 o'clock position.
Manual opener disabled
Position for forced open
4
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© Danfoss A/S (AC-MCI/MWA), 2012-12
ICF 20-4
Module location
In order to supply the ICF valve station best suited for liquid lines and hot gas lines certain function modules are dedicated to specific module ports.
0, 2 or 4 optional side ports (up to 6 on request)
Function
M1 M2 M3 M4
ICFS 20 - Stop valve module
ICFR 20A - Manual regulating valve module
ICFF 20 - Filter module
ICFE 20 - Solenoid valve module
ICFE 20H - Solenoid valve module
ICFA 10 - Electronic expansion valve module
ICFO 20 - Manual opening module
ICFC 20 - Check valve module
ICFN 20 - Stop/check valve module
ICM 20-A, B or C - Motor valve module
ICFB 20 - Blank top cover
location not possible
Fig. 6
ICF 20-6
In order to supply the ICF valve station best suited for liquid lines and hot gas lines certain function modules are dedicated to specific module ports.
Function
M1 M2 M3 M4 M5 M6
ICFS 20 - Stop valve module
ICFR 20A - Manual regulating valve module
ICFF 20 - Filter module
ICFE 20 - Solenoid valve module
ICFE 20H - Solenoid valve module
ICFA 10 - Electronic expansion valve module
ICFO 20 - Manual opening module
ICFC 20 - Check valve module
ICFN 20 - Stop/check valve module
ICM 20-A, B or C - Motor valve module
ICFB 20 - Blank top cover
location not possible
0, 4 or 6 optional side ports (up to 10 on request)
Fig. 7
© Danfoss A/S (AC-MCI/MWA), 2012-12
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5
Danfoss M27H0004_1
ICF 25-4 40-4
Module location
In order to supply the ICF valve station best suited for liquid lines and hot gas lines certain function modules are dedicated to specific module ports.
Function
M1 M2 M3 M4
ICFS 25-40 - Stop valve module
ICFR 25-40 A or B - Manual regulating valve module
ICFF 25-40 - Filter module
ICFE 25-40 - Solenoid valve module
ICFC 25-40 - Check valve module
ICFN 25-40 - Stop/check valve module
ICM 25-A or C - Motor valve module
ICFB 25-40 - Blank top cover
ICFW 25-40 - Welding module, 25DIN
location not possible
0, 2 or 4 optional side ports (up to 6 on request)
Fig. 8
ICF 25-6 40-6
In order to supply the ICF valve station best suited for liquid lines and hot gas lines certain function modules are dedicated to specific module ports.
Function
M1 M2 M3 M4 M5 M6
ICFS 25-40 - Stop valve module
ICFR 25-40 A or B - Manual regulating valve module
ICFF 25-40 - Filter module
ICFE 25-40 - Solenoid valve module
ICFC 25-40 - Check valve module
ICFN 25-40 - Stop/check valve module
ICM 25-A or C - Motor valve module
ICFB 25-40 - Blank top cover
ICFW 25-40 - Welding module, 25DIN
location not possible
0, 4 or 6 optional side ports (up to 10 on request)
Fig. 9 6
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ICFS 20 stop valve module
The function modules - ICF 20 ICFR 20 manual regulating valve module
ICFF 20 filter module
1. Spindle 2. Thread part 3. AL-gasket 4. Bonnet 5. Hex-head bolt 6. Flange 7. Gasket
1. Gasket 2. Bonnet 3. Hex-head bolt 4. Flange 5. Gasket 6. Filter element 7. Plug 8. Plug ¼" RG or 3/8" NPT
ICFE 20 solenoid valve module
1. Armature tube 2. Armature tube nut 3. Flange 4. Gasket 5. Hex-head bolt 6. Seat
ICFO 20 manual opening module
1. Seal cap 2. Gland nut 3. Seal cap gasket 4. Sealing ring 5. Rubber gasket 6. Spindle 7. Hex-head bolt 8. Flange
1. Spindle 2. Thread part 3. AL-gasket 4. Bonnet 5. Hex-head bolt 6. Flange 7. Gasket 8. Seat
ICFC 20 check valve module
1. Bonnet 2. Hex-head bolt 3. Flange 4. Gasket
ICFE 20H solenoid valve module 1. Piston
3. Piston ring 4. Bonnet cylindre 5. Manual opener 6. Armature tube 7. Armature tube nut 8. Gasket
ICM 20 A, 20 B or 20 C motor valve module
1. Adapter 2. Hex-head bolt 3. O-ring 4. Bonnet 5. Gasket 6. Seat
© Danfoss A/S (AC-MCI/MWA), 2012-12
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7
ICFN 20 stop/check valve module
The function modules - ICF 20
ICFB 20 blank top cover module
1. Hex-head bolt 2. Flange 3. Gasket
1. Spindle 2. Thread part 3. AL-gasket 4. Bonnet 5. Hex-head bolt 6. Flange 7. Gasket
ICFF 20E extended filter module
1. Dirt protection plug 2. Bonnet 3. Hex-head bolt M12x80 4. Flange 5. Gasket 6. Filter element 7. Plug 3/8" NPT 8. Filter adaptor
ICFS 25-40 stop valve module
ICFA 10 Electronic expansion valve
1. Armature tube 2. Armature tube nut 3. Hex-head bolt 4. Flange 5. Gasket 6. Adaptor
ICFR 25- 40 A or B manual regulating valve module
1. Spindle 2. Thread part 3. O-ring 4. Bonnet 5. Hex-head bolt 6. Flange 7. Gasket
1. Spindle 2. Thread part 3. O-ring 4. Bonnet 5. Hex-head bolt 6. Flange 7. Gasket
8
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ICFF 25-40 filter module
The function modules - ICF 25-40 ICFC 25-40 check valve module
1. Al gasket 2. Bonnet 3. Hex-head bolt 4. Flange 5. Gasket 6. Filter element 7. Plug ¼" RG or 3/8" NPT
1. Bonnet 2. Hex-head bolt 3. Flange 4. Gasket
ICFE 25-40 solenoid valve module
ICM 25 A or 20 B motor valve module
1
2
1. Armature tube
3
2. Armature tube nut
4
3. Bonnet
5
4. Gasket
6
5. Hex-head bolt
6. Seat
ICFN 25-40 stop/check valve module
1. Adapter 2. Hex-head bolt 3. O-ring 4. Bonnet 5. Gasket 6. Seat
ICFB 25-40 blank top cover module
1. Spindle 2. Thread part 3. O-ring 4. Bonnet 5. Hex-head bolt 6. Flange 7. Gasket
ICFF 25-40E extended filter module
1. Hex-head bolt 2. Flange 3. Gasket
ICFW 25-40 Welding module 25 DIN
1. Hex-head bolt 2. Flange 3. Gasket 4. Weld connection
1. Dirt protection plug 3/8" NPT
2. Bonnet 3. Hex-head bolt M12x140 4. Flange 5. Gasket 6. Filter element 7. Plug 3/8" NPT
© Danfoss A/S (AC-MCI/MWA), 2012-12
DKRCI.PI.FT0.C4.02 / 520H5450
9
ENGLISH
Installation
Refrigerants Applicable to HCFC, non flammable HFC, R717 (Ammonia) and R744 (CO2).
The use of ICF valve stations with flammable hydrocarbons is not recommended.
The ICF is only recommended for use in closed circuits. For further information please contact Danfoss.
Temperature range 60/+120°C (76/+248°F)
Pressure range The ICF is designed for a max. working pressure of 52 bar g (754 psi g).
Technical data The ICF can be used in suction, liquid, hotgas and liquid/vapor lines. The ICF are available with 4 or 6 function modules. The ICF regulates the flow of the medium by modulation or on/off function, depending on function modules installed on the ICF.
Regulating range Dependent on the chosen type and combination of modules installed in the valve.
Installation The ICF must be installed according to fig. 1. The ICF must be installed with the arrow in the direction of the flow).
The ICF will be delivered with all the function modules fully assembled. The modules can be taken off for service or inspection and may be rotated 4 x 90° in relation to the valve body upon installation.
The ICF may be fitted with a spindle for manual opening of the solenoid valve.
The ICF is designed to withstand a high internal pressure. However, the piping system should be designed to avoid liquid traps and reduce the risk of hydraulic pressure caused by thermal expansion.
It must be ensured that the ICF is protected from pressure transients like "liquid hammer" in the system.
The ICF valves are delivered with closed stop valves. During Gas welding the modules must be removed. Avoid welding debris and dirt in the valve body and the function module. The housing must be free from stresses (external loads) after installation. The ICF must not be mounted in systems where the outlet side of the ICF is open to atmosphere. The outlet side of the ICF must always be connected to the system or properly capped off, for example with a welded-on end plate.
Surface protection and identification The external surface is zinc-chromated to provide corrosion protection according to EN 12284:2003 8.13. The ZincChromatization does not cover the welding connections. After installation has been completed the external surface of the valve must be protected against corrosion with a suitable top coating. Protection of the ID label when painting the ICF is recommended.
Precise identification of the ICF is made via the ID label on each of the 4 or 6 function modules.
Maintenance
Service The ICF valve stations are easy to service. Do not open the ICF while the it is still under pressure.
Debris blocking the bolt hole will need cleaning. Upon opening and removal of the function modules: - Check that the O-rings on the function
module has not been damaged. A valve with a damaged o-ring might not modulate according to the specification.
For both ICF 20 and ICF 25 - 40 with ICM
Please Note: When used in CO2, the o-rings (see fig.4) on the ICM and ICFE 25-40 modules can swell (grow). At service it is recommend that new o-rings are installed, before the ICM function module is reinstalled in the ICF valve body.
- On ICM 20 motor valve modules check that the PEEK seat has not been damaged or scratched. If damaged or scratched; replace the PEEK seat.
Assembly Remove any dirt from the housing before the ICF is assembled. - Check that all channels in the ICF
are free of particles or similar debris. If possible, apply some refrigeration oil to ease the insertion of the modules and to protect the O-rings.
Tightening (fig. 5) Tighten the top cover with a torque wrench, to the values indicated in the table. Use only original Danfoss parts, including O-rings and gaskets for replacement.
Materials of new parts are certified for the relevant refrigerant.
In cases of doubt, please contact Danfoss.
Drawings are only for illustration, not for dimensioning or construction. Danfoss accepts no responsibility for errors and omissions.
Danfoss Industrial Refrigeration reserves the right to make changes to products and specifications without prior notice.
Welding The ICF valve station can be welded by using either TIG/MIG/SMAW welding (fig. 2) or gas welding (fig. 3).
Attention! It is not necessary to remove any of the modules before TIG/MIG/SMAW welding; however, it must be ensured that the valve is cooled during the welding ( e. g. by wet cloth) and that the ICF is protected against weld splatter. Inlet and outlet stop valves must be closed all the time before commissioning in order to protect ICF against rust formations.
- Check that the piston and cylinder is free of scratches and look for wear marks. If the wear is excessive the function module should be replaced to prevent false pilot signal around the piston ring.
- Check that the movement of the cylinder and valve seat is free and with low friction.
- If the teflon valve plate has been damaged, the function module must be replaced.
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VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix F · Hand-Held Slide Valve Calibration Tool
Appendix F Hand-Held Slide Valve Calibration Tool
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
F - 1
Appendix F · Hand-Held Slide Valve Calibration Tool
Hand-Held Slide Valve Calibration Tool By VilterTM
The Slide Valve Calibration Tool allows the operator to perform the calibration procedure of Vilter´s slide valve actuators (VPN 25972D) single-handedly, while standing at the actuator, without multiple trips to the panel screen, or the need of another person at the panel.
How It Works
The calibration tool replaces the power cable that feeds the actuator during normal operation, and provides 115 volts to the actuator motor using the CW and CCW push buttons. The regular control cable which provides 24 volts DC to the actuator must be connected at all times. The greatest advantage from this set up is that the operator can perform the whole calibration procedure in front of the compressor, and therefore can easily detect if the actuator is driving the slide valves up against the mechanical stop inside the compressor.
Calibration Procedure
1. Look for the motor control cable on the actuator (connector J2), and disconnect it. Connect the calibration tool´s turck connector to the actuator.
2. Remove the screws securing the actuator cover to the actuator assembly, and carefully lift the actuator cover and tilt it towards connectors. Raise the cover high enough to attain access to the blue calibration button and be able to see the red LED on the top of assembly.
3. Press "CW" or "CCW" on the calibration tool to move the slide valve and check for the correct rotation, see the Increase Direction for Single Screw Compressors Table on the next page to establish which one is the increase button and which one the decrease button for your compressor model.
Red LED
Blue Calibrate Button
For use in non-hazardous locations
Features
The calibration procedure may be performed directly at the actuator, so the operator can immediately detect when the actuators start to slow down and reach
the mechanical stop Using this tool bypasses the standard calibration procedure which requires several trips between the actuator and the control panel, or to have two opera-
tors available
Electrical Rating of 125V and 5A (not fuse protected)
Light and easy to move around the compressors room
Pendant switch for easy access and comfortable handling
4. Quickly press and release the blue push button on the actuator once. This places the actuator in calibration mode. The red LED will start flashing rapidly.
5. Use the decrease button on the calibration tool to drive the slide valve to its minimum "mechanical stop" position. Release the decrease button when the slowing of the motor rotation and a winding sound from the actuator motor is noted.
6. Press and hold down on the photo-chopper shaft to disengage the brake slowly, releasing tension from the motor mount. Use the increase 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.
F - 2
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix F · Hand-Held Slide Valve Calibration Tool
Slide Valve Increase Direction for Single Screw Compressors Table
Compressor Model Number
151 VSM / VSG 152 VSM / VSG 181 VSM / VSG 182 VSM / VSG 201 VSM / VSG 202 VSM / VSG 291 VSS / VSSH / VSSG 301 VSM / VSG 341 VSS / VSSH / VSSG 361 VSM / VSG 401 VSM / VSG 451 VSS / VSSH / VSSG 501 VSM / VSG 601 VSM / VSG 601 VSS / VSSH / VSSG 701 VSM / VSG 751 VSS / VSG 791 VSS/VSH/VSG 891 VSS/VSH/VSG 901 VSS / VSG 1051 VSS / VSH / VSG 1201 VSS / VSH / VSG 1301 VSS / VSH / VSG 1501 VSS / VSG 1551 VSS / VSG 1801 VSS / VSG 1851 VSS / VSG 2101 VSS / VSG 2401 VSS / VSG 2601 VSS / VSG 2801 VSS / VSG 3001 VSS / VSG
Capacity Slide Valve
CW CW CW CW CW CW CW CW CW CW CW CW CCW CCW CW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW
Volume Slide Valve
CW CW CW CW CW CW CW CW CW CW CW CW CCW CCW CW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW CCW
7. Quickly press and release the blue button on the actuator again. The red LED will now flash at a slower rate, indicating that the minimum slide valve position (zero position) has been set.
8. Use the increase button on the calibration tool to drive the slide to its maximum "mechanical stop" position. Release the increase button when the slowing of the motor rotation and a winding sound from the actuator motor is noted.
9. Press and hold down on the photo-chopper shaft to disengage the brake slowly, releasing tension from the motor mount. Use the decrease button to pulse the actuator to where the slide is just off of its mechanical stop and there is no tension on the motor shaft.
10. Quickly press and release the blue button on the actuator one more time. The red LED will stop flashing. The actuator is now calibrated and knows the minimum and maximum positions of the slide valve it controls.
11. Disconnect the calibration tool's turck from the actuator, and connect the motor control cable on the actuator (connector J2).
Order Vilter Slide Valve Calibration Tool Using VPN 75002
General Inquiries 5555 S. Packard Ave. Cudahy, WI 53110 United States Phone: 414-744-0111 Fax: 414-744-3483 Web: www.Vilter.com
Customer Service Phone: 1-800-862-2677 Service.Vilter@emerson.com
Parts Parts.Vilter@Emerson.com
For more product information and to order online visit: VPI.Emerson.com
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
F - 3
Appendix F · Hand-Held Slide Valve Calibration Tool
F - 4
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
Appendix G · Pre Start Up For Remote Oil Coolers
IMPORTANT! FOR REMOTE OIL COOLERS ONLY. READ BEFORE PROCEEDING.
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
G - 1
G - 2 / Blank
VSS/VSM/VSH/VSSH · Installation, Operation and Maintenance Manual · Emerson · 35391SD
About Vilter
Vilter is a technology leader in energy-efficient, environmentally conscious solutions in its industry. The 150-year history of the Vilter brand tells a rich story of perseverance and drive to cultivate continuous innovation within the industrial refrigeration and gas compression industries. Vilter offers unprecedented efficiency, productivity and reliability in cooling, recovery, and compression. It combines bestin-class technology with proven engineering and design to create quality products and latest solutions for customers worldwide.
About Emerson
Vilter Manufacturing LLC is a business segment of Emerson, a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial, commercial and consumer markets around the world. Our Emerson Automation Solutions business helps process, hybrid, and discrete manufacturers maximize production, protect personnel and the environment while optimizing their energy and operating costs. Our Emerson Commercial and Residential Solutions business helps ensure human comfort and health, protect food quality and safety, advance energy efficiency, and create sustainable infrastructure. For more information please visit Emerson.com
Emerson.com/Vilter
Vilter Manufacturing LLC reserves the right to make changes in design and specifications without notice. 35391SD Rev. 06A (05/21) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. ©2021 Emerson Climate Technologies, Inc. All rights reserved.