VSG/VSSG compressor unit Installation, operation & maintenance manual
VSG/VSSG Standard Vilter Warranty Statement Seller warrants all new single screw gas compression units and bareshaft single screw compressors manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of installation at the end user’s location, whichever occurs first.
Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR. The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw Compressors. Following these instructions will result in a long life of the compressor with satisfactory operation. The entire manual should be reviewed before attempting to install, operate, service or repair the compressor. A compressor is a positive displacement machine. It is designed to compress gas.
Table of Contents Section Title Section Number VSG/VSSG Standard Vilter Warranty Statement ..................................................................................... i Important Message................................................................................................................................ ii Section 1 • General Information How To Use This Manual.........................................................................................................................
Table of Contents Section Title Section Number Section 4 • Operation Oil Inspection ........................................................................................................................................ 4-1 Dual Oil Filters........................................................................................................................................ 4-1 Control System Calibration .....................................................................................................
List of Tables and Figures Section Title Section Number Section 7 • Warranty and Parts Warranty Claim Processing .................................................................................................................... 7-1 On Site Service Support ......................................................................................................................... 7-1 Remanufactured Bare Shaft Compressors Process ................................................................................
List of Tables and Figures Table/Figure Section Number Figure 3-12. Installation of Coolers - Next to Buildling ............................................................................ 3-13 Figure 3-13. Discharge Elevation of Coolers............................................................................................ 3-15 Figure 3-14. Cooler Placement and Spacing............................................................................................ 3-15 Figure 3-15. Oil Operating Levels ..
Section 1 • General Information How To Use This Manual This manual contains instructions for gas compressor units. It has been divided into eight sections: Section 1: General Information Section 2: Theory of Operation Section 3: Installation Section 4: Operation Section 5: Maintenance & Service Section 6: Troubleshooting Section 7: Warranty and Parts Appendices It is highly recommended that the manual be reviewed prior to servicing system parts. Figures and tables are included to illustrate key concepts.
Section 1 • General Information Gas Compressor Unit Model Designations The compressor unit model designation can be found on the nameplate. For nameplate location, see Component Identification on section page 1-4. VSG-601-VVR-L-HP-VFD-36H-NEC-ST-WTR 1 2 3 4 5 6 7 8 9 10 Figure 1-1. Gas Compressor Unit Model Designation 1. Compressor Model 7.
Section 1 • General Information System Unit Identification To keep definitions of units simple and consistent, Vilter 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.
Section 1 • General Information Compressor Unit Component Identification Each gas compressor unit may differ, but below are typical components that can be found on each unit.
Section 1 • General Information 4 3 20 18 19 17 22 21 14 20 23 Figure 1-2.
Section 1 • General Information Component Identification (Continued) 24 - RTD (Oil Filter Outlet) 28 - RTD (Suction) 31 - Block & Bleed Assembly 25 - Pressure Transducer (Oil Injection Temperature) 29 - Capacity Slide Valve Actuator 32 - Remote Oil Cooler (Finned Fan Heat Exchanger) 26 - Volume Slide Valve Actuator 27 - RTD (Discharge) 30 - Pressure Transducers (Discharge, Oil Filter Inlet and Outlet) 25 26 33 - RTD (Oil Separator) 27 28 24 29 30 31 33 32 OUTLET INLET Figure 1-2.
Section 1 • General Information Piping & Identification Component Tags Use this list to identify components shown in the Piping & Identification Diagram.
Section 1 • General Information TI Temperature Indicator or Thermometer TW Thermowell V Vent TIT Temperature Indicator Transmitter VG Gauge Valve Transfer Valve - 3-way or 6-way Valve VTRI Venturi VLV Stop Valve Solenoid Valve TRV YZT Axial proximitor Transmitter - Axial Displacement YZU Axial Proximitor Monitoring System ZE Position Element - Positioner TS Heat Exchanger Tube Side XV TSH Temperature Switch High YE Vibration Probe ZI Position Indicator YSH Vibration Switch Hi
Section 1 • General Information High Side Float Valve Control Panel, Normally Accessible to Operator Horizontal Tank/Drum Vessel Programmable Logic Control, Local Control Panel, Normally Accessible to Operator Positive Displacement Pump Pneumatic Signal Steady-Mount Bulb & Capillary Thermostatic Expansion Valve X X X X X Centrifugal Pump Electrical Signal Pilot Light (Color Inside) G Capillary Tube Rotary Pump MW Man-Way Cover Filter BY VILTER BY OTHERS Internal System Link (Software or Da
1 – 10 / Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 2 • Theory of Operation 1 2 3 4 5 6 SUCTION GAS CHECK DISCHARGE VALVE STOP VALVE TE 1/4” OIL CHARGING TE COMPRESSOR BLEED 1/4” MOTOR 14 13 BLEED OIL SEPARATOR 15 12 TE FILTER DRAIN STANDARD SINGLE OIL FILTER BLEED BLEED 11 TE DRAIN 100# MOTOR M 7 FG 1 PUMP FILTER DRAIN FILTER OPTIONAL DUAL OIL FILTERS 8 DRAIN 10 OIL COOLER VENT 9 OIL DRAIN DRAIN STANDARD WATER COOLED OIL COOLER OPTIONAL REMOTE AIR COOLED OIL COOLER Figure 2-1.
Section 2 • Theory of Operation suction. The discharge temperature of the compressor must be kept a minimum of 30°F (or 17°C) above the discharge gas dew point to prevent the condensing of liquids in the oil separator. The oil separator shell and legs must be insulated when the gas stream has a high probability of having condensables. Oil in the gas compressor unit serves three primary purposes.
Section 3 • Installation 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.
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 section page 3-3. Warranty of the system remains in effect as described at the beginning of this manual, section page i.
Section 3 • Installation AIR COOLED OIL COOLERS The following are general recommendations. Refer to specific air cooled oil cooler manufacturer instructions for storage recommendations. • If the coolers are to be stored or not operated for an extended period of time, the fan motors may ingress moisture if they are not protected or operated regularly.
Section 3 • Installation LONG TERM STORAGE LOG Date: _______________________________ Name: _______________________________ Intial:_______________ Company: Vilter Order No.
Section 3 • Installation Foundation Vilter 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 Vilter foundation supports the entire operating weight of the unit and is suitable for years of continuous duty.
Section 3 • Installation of both • Check the ability of the soil to carry the load trolled level and a surface texture etched in place. Leave the concrete to cure for at least 28 days. • Check wet season and dry season soil characteristics for static loading limits and elasticity Compressor Unit Installation • Check local codes for Seismic Design requirements For examples of foundation diagrams, see to Figure 3-2 and Figure 3-3.
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 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.
Section 3 • Installation Additional Information Codes and Standards Vilter followed the following codes and standards when designing your foundation: • ACI • ASTM • ASCE 7 • IBC 2006 Operation and Performance The foundation was designed for: • Outside environment severe exposure General Design Requirements The compressor foundation is designed to: • Maintain the compressor in alignment and at proper elevation.
Section 3 • Installation 1" (TYP.) G.A. G.A. CENTER LINE G.A. G.A. G.A. + 2" G.A. G.A. (2) - # 4 CLOSED TIES (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.
Section 3 • Installation 70+6 .') *1.& &190 076 010Ä5*4+0- '21:; )4176 9#5*'4 .'8'.+0) 076 /+0 4'%1//'0&'& (14 *175'-''2+0) #0%*14 $1.6 %10%4'6' $#5' Figure 3-8. Concrete Pad Housekeeping Detail Piping Header Piping and Drains 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.
Section 3 • Installation Table 3-2. Maximum Allowable Flange Loads Nozzle Dia. (in.
Section 3 • Installation General Installation Guideline for calculations for each guideline. Let’s assume the following coolers are being installed in a common area: Multiple Air Coolers Installed in a • Cooler 1 - 7’ wide x 10’ long with a 6’ fan moving 55,000CFM of air. Face velocity is 785FPM. Common Area • Cooler 2- 8’ wide x 12’ long with a 7’ fan moving 72,000CFM of air. Face velocity is 750FPM.
Section 3 • Installation Intake Velocity More Less Figure 3-11.
Section 3 • Installation HOT AIR RECIRCULATION There are two situations where hot recirculation could occur. • Intake velocity of the cooler is higher than the discharge velocity • Environmental issues such as strong cross winds which is installation specific We addressed how to minimize the opportunity for hot air recirculation involving the operation of the air coolers under the guidelines for the Free Flow section above.
Section 3 • Installation NOT PREFERRED PREFERRED Figure 3-13. Discharge Elevation of Coolers NOT PREFERRED PREFERRED Figure 3-14.
Section 3 • Installation NOTICE Pressure Testing CAUTION Do not hydro test compressur unit. Failure to comply may result in damage to equipment. CAUTION The compressor unit along with other system units contain many components with various pressure ratings. Pressure relief protection provided considers the design pressure of a system components. Before replacing a pressure relief valve with a relief valve having a higher presure setting, all system components must be evaluated for acceptability.
Section 3 • Installation Normal Operating Level Maximum NON-Operating Level Minimum Operating Level Figure 3-15. Oil Operating Levels Suction Oil Charging Valve Oil Drain Valve (Oil Separator) Bypass Valve (Oil Cooler) View Rotate 180° Oil Filter Shut-Off Valves View From Back - View Rotate 180° Figure 3-16.
Section 3 • Installation NOTE PRIMING COMPRESSOR AND OIL FILTERS Oil mixing valve can remain in Manual Mode since the setpoint will change the mode to Auto when reached. For further details, see PLC Compact Logix manual. NOTE Running the compressor oil pump at this point will help lubricate the compressor bearings and shaft seal surfaces. 16. Refer to Pre Start-Up Checklist and ensure all items are ready prior to starting the compressor. 17.
Section 3 • Installation NOTE Oil separator does not need to be filled again until oil level reaches Minimum Operating Level. Every size of compressor will hold different amounts of oil, so amount of oil draining back into oil separator will vary. 21. More accurate fill levels can be accomplished by marking the level on the oil separator (2) after correct levels have been achieved during the unit operation and when the compressor unit has been down for 1 hour.
Section 3 • Installation (Reference Figure 3-19) 1. Verify oil level (8) is at Maximum Non-Operating Oil Level in separator (3). If oil level is not at Maximum Non-Operating Oil Level, add oil, see Initial Oil Charging - Unit Oil Charging procedure. 2. Close shut-off valve(s) (7) at oil filter inlet(s). 3. Open oil bypass shut-off valve (4). 4. Energize compressor unit. 5. Close oil mixing valve (oil temp. control valve) (6) via control panel. In Manual Mode, change “Manually Open (%)” value to “0”.
Section 3 • Installation 14. When ready, run compressor unit and allow it to reach normal operating temperature. 15. Using a properly selected oil pump, connect oil pump to suction oil charging valve (1). For suction oil charging valve location, see Figure 3-16. 16. Open suction oil charging valve (1) and fill oil separator (3) to Normal Operating Level. 17. Once the Normal Operating level has been reached, shut off the oil pump and close the suction oil charging valve (1). Disconnect and remove oil pump.
Section 3 • Installation Pre Start-Up The following check list is to help prepare the equipment before the Vilter technician arrives at the jobsite. Vilter recommends that a trained technician go through the following tasks. The operating manuals provided by Vilter can be referenced for any type of questions or special instructions. Every gas compressor unit includes a Vilter start-up (confirm on P.O.). The following tasks are not included in the Vilter start-up provided in your equipment purchase.
Section 3 • Installation 8. On air cooled oil coolers, the oil lines from the compressor must be connected to the air cooled oil cooler. Oil cooler fans will need to be wired and checked for proper rotation. Refer to supplied GA drawing for connection points and piping sizes. 9. The oil separator should be charged with oil to the Maximum NON-Operating Level. 10. The center member of the compressor is shipped loose to help facilitate final field alignment and allow for motor rotation check. 11.
Section 3 • Installation Start-Up The following check list is to help verify and check equipment prior to start-up. This is the responsibility of the Vilter Technician. 1. Review pre start-up checklist. 2. Check oil pump rotation. This can be done by using the “Diagnostic Force Outputs” from Main Menu. Refer to Compact Logix PLC Software Manual. 3. Check compressor motor rotation (CCW or CW rotation facing compressor shaft). This can be done by using the “Diagnostic Force Outputs” from Main Menu.
Section 4 • Operation Operation All operation (setpoint adjustments, calibrations, monitoring) of the compressor unit is done through the Compact Logix PLC. For additional procedural information, refer to Compact Logix PLC Software Manual (35391CL). 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.
Section 4 • Operation 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.
Section 4 • Operation View Rotate 180° Actuator Assembly Actuator Plastic Cover Red LED Blue Calibrate Button Figure 4-2. Actuator Assembly • 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. 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.
Section 4 • Operation Figure 4-3.
Section 4 • Operation Figure 4-4. Slide Valve Calibration Screen (Compact Logix PLC) 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. Press down on Photo-chopper 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.
Section 4 • Operation Table 4-1. Command Shaft Rotation Specifications* Command Shaft Rotation Capacity Compressor Model No. of Turns/Rotation Angle/Slide Travel Capacity Volume Volume INC DEC INC DEC Turns Degrees Travel Turns Degrees Travel CW CCW CW CCW 0.91 328 3.568” 0.52 187 2.045” CW CCW CW CCW 0.80 288 3.141” 0.45 162 1.767” CCW CW CCW CW 0.91 328 3.568” 0.52 187 2.045” CCW CW CCW CW 1.09 392 4.283” 0.63 227 2.473” CCW CW CCW CW 1.
Section 4 • Operation 11. Use the INC button on the Control panel to drive the slide to its maximum “mechanical stop” position. Do not continue to run the actuator in this direction after the slide valve has reached the stop. Doing so may cause damage to the actuator or the slide valve. Press down on the photo-chopper shaft to disengage the brake, releasing tension from the motor mount.
Section 4 • Operation Fail Position MANUAL OVERRIDE The temperature control valve remains in the last position when power is removed. The actuator of the oil temperature control valve has a handwheel that can be engaged to override the electrically determined position of the ball valve. Screen Display 1. The oil temperature control valve, identified as “OIL MIX” on the main PLC display screen, shows a numerical value with “%” as units. This is to be understood as “% OPEN.
Section 4 • Operation Purging with Dry Nitrogen Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3. 4. Close suction and discharge shut-off valves to isolate the compressor unit from house system. Lockout/tagout valves. 5. Slowly open suction oil charging valve to depressurize compressor unit to atmosphere, see Figure 4-8. Keep valve in open position.
Section 4 • Operation NOTE Purging is performed through the suction oil charging valve so that trapped gas can be pushed out of the compressor. This will help minimize metal surface oxidation of the compressor (due to the gas) while not in service. 9. Purge compressor unit for 5 minutes. Check discharge pressure on PLC main screen to make sure pressure is increasing. 12. Once pressure is reached, stop purging and close suction oil charging valve.
Section 4 • Operation NOTICE Purging with Dry Gas Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3. To purge the compressor unit using a dry gas (i.e. methane), a purge line must be installed. If there is not enough purge pressure, connect purge line to a lower pressure line or to atmosphere.
Section 4 • Operation 9. NOTE Plugs are installed on bleed valves. Remove and install plugs prior to and after bleeding. Ensure to keep valves closed when removing and installing plugs. 6. Slowly open suction oil charging valve and bleed remaining pressure in compressor unit to atmosphere, see Figure 4-13. Leave suction oil charging valve in open position. 7. If equipped with pressure indicator on purge line, open shut-off valve to pressure indicator. 8.
Section 4 • Operation View Rotate 180° Equalizing Solenoid for Suction Bypass Suction Bypass Valve (Manual) Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil Charging Valve View Rotate 180° Figure 4-13.
Section 4 • Operation Coalescing Oil Return Line Setup 3. 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: Slowly open needle valve more until a small amount of oil is seen in the sight-glass.
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 45,000 40,000 30,000 25,000 20,000 10,000 5,000 2,500 200 I - I - I - I - I - I - I I I - I - I - I R I R I I I - I - I - I - I - I I I R I 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 R I R I I I I I - I - I I I - I - I - - Bearings - I - - - I - - - I - - - I - - - I - - -
Section 5 • Maintenance/Service Maintaining Proper Operation To ensure proper operation, the following items should be checked: • Calibrate all transducer and RTDs. • Check capacity and volume actuator calibration. • Check fuses in the PLC panel. • Check for loose wiring connections in the PLC panel. • Check relay and contact operation for relays in the PLC panel. • Verify the operation of the suction and discharge check valves.
Section 5 • Maintenance/Service 2. If equipped with equalizing solenoid to control suction by-pass, allow solenoid to remain open until pressures equalize, see Figure 5-1 (2 of 2). 3. Turn motor and oil pump starter disconnect switches into the OFF position. Lockout/tagout disconnect switches. 4. If equipped with manual suction by-pass valve and it is not open, open suction by-pass valve to allow oil separator pressure to vent to low-side system pressure, see Figure 5-1 (1 of 2).
Section 5 • Maintenance/Service Oil System Components NOTE A copy of the oil analysis report is also sent to Vilter. See Appendices for a sample of the oil analysis report. Oil Sampling An oil analysis report will show the physical properties of the oil, such as: 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.
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.
Section 5 • Maintenance/Service Oil Draining NOTE Ensure to check the oil pressure drop and record it daily. 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. If the compressor unit is equipped with only a single oil filter, the compressor unit must be shut down prior to servicing, see Stopping/Restarting procedure in Section 4.
Section 5 • Maintenance/Service Outlet Shut-Off Valves Vent Valve Drain Valve Vent Valve Drain Valve Inlet Shut-Off Valves Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves 1. If equipped with dual oil filters, open inlet shut-off valve for non-operating oil filter to put it into operation, see Figure 5-5. 2. To isolate oil filter for servicing, close inlet and outlet shut-off valves for the oil filter. centering piece, if damaged, replace as required.
Section 5 • Maintenance/Service Oil Separator Vessel Oil Separator Manhole Cover Pipe Stub Coalescing Filter Hold-Down Rod Centering Strap Flat Washer 3/4 in. O.D. Tubing, 6 ft. long Flat Washer Nuts Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly Coalescing Filter Replacement 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.
Section 5 • Maintenance/Service WARNING 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. Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in serious injury or death. 1.
Section 5 • Maintenance/Service Drive Coupling (Form-Flex BPU) Hub Installation 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. 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.
Section 5 • Maintenance/Service 16. If locking tab is being used, bend locking tabs in gap towards shaft and around bolt. 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.
Section 5 • Maintenance/Service Angular Alignment Parallel Offset Figure 5-9. Angular Alignment and Parallel Offset the disc pack. distance accordingly until disc pack is straight. 24. Install bolts and locking nuts to secure both disc packs to center member. 30. Install bolts and locking nuts to secure disc pack to motor hub. 25. Tighten locking nuts. 31. Tighten locking nuts, see Table 5-4. 26. If room is required to install center member, adjust hub position accordingly.
Section 5 • Maintenance/Service 32. Perform hot alignment. Run compressor unit and allow to warm up completely. 33. Power down compressor unit and re-check alignments. Loosen motor mounting nuts to add shims or to adjust alignments as required. 34. Install coupling guard. Drive Coupling (Form-Flex BPU) Center Member and Hub Removal 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.
Section 5 • Maintenance/Service Compressor Replacement compressor shaft. 12. Remove hub and key from compressor shaft. INSTALLATION Notify Vilter prior to performing a compressor replacement. See Warranty instructions in Section 7. 13. Install key and hub on compressor shaft as noted during removal. REMOVAL 14. Install set screw in compressor hub to secure key in keyway, see Table 5-6, To replace a compressor on a unit, proceed with the following steps: NOTICE 15.
Section 5 • Maintenance/Service personnel, remove compressor from frame. 17. Remove shims and spherical washers from compressor mounting locations. 18. Inspect shims and spherical washers for damage, replace as required. INSTALLATION 19. Install shims and spherical washers on compressor mounting locations, see Figure 5-10. 20. Install appropriate lifting eyes on top of compressor. 21. Using appropriate lifting device, position compressor on compressor mounting locations on frame. 22.
Section 5 • Maintenance/Service Compressor Shaft Bearing Float Inspections motor and use the lever arm to push the input shaft towards the compressor. Record measurement 5. If float measurements are out of tolerance, contact Vilter Customer Service for further assistance. BEARING AXIAL FLOAT INSPECTION Add both measurements. If measurement is out of allowable tolerance shown in Table 5-7, the bearing may need to be replaced. Contact Vilter Customer Service. BEARING RADIAL FLOAT INSPECTION CAUTION 6.
Section 5 • Maintenance/Service Table 5-7. Maximum Bearing Float Compressor Model Max. Axial Float Max. Radial Float Max. Force at Hub/ Shaft Max. Applied Force (36” Lever, 6” Pivot) in. (mm) in. (mm) 0.002 (0.051) - 300 (1335) 60 (267) 151, 181, 201, 152, 182, 202, 301, 361, 401 0.006 (0.152) 100 (444) 20 (89) 501, 601, 701 0.007 (0.178) 150 (667) 30 (133) 291, 341, 451, 601 0.007 (0.178) 150 (667) 30 (133) 751, 901 0.006 (0.152) 200 (890) 40 (178) 791, 891, 1051, 1201, 1301 0.
Section 5 • Maintenance/Service GATE ROTOR BEARING FLOAT INSPECTION NOTE Measurements can be an additional 0.020” higher than float dimensions on Table 5-8. If measurement is an additional 0.030” greater than float dimensions, contact Vilter for further assistance. 6. Side View Total movement of damper pin in bushing is the gate rotor float. 4. Using dial indicator, position a dial indicator on the gate rotor, see Figure 5-14. Gate rotor bearing float being measured.
Section 5 • Maintenance/Service Gate Rotor and Support Clearance When measuring, push the gate rotor against the pin to remove float. 1. Place a straight edge along the side of the gate rotor, see Figure 5-16. 2. Measure the gap from the straight edge to the peak of the gate rotor support. For minimum distance, see Figure 5-15. 3. Repeat steps 1 to 2 to check gap along entire gate rotor edge on both sides. Figure 5-15.
Section 5 • Maintenance/Service Gate Rotor Support Straight Edge Gate Rotor Gate Rotor Support Straight Edge Gate Rotor Gate Rotor Support Straight Edge Gate Rotor Figure 5-16.
Section 5 • Maintenance/Service Gate Rotor Assembly Replacement (All VSG & VSSG Compressors Except VSG 301-701 Compressors) The following table lists the gate rotor tool sets needed to remove and install gate rotor assemblies. Table 5-9. Gate Rotor Tool Sets Model Tool Set VPN VSSG 291-601 A25205B VSG 301-401 N/A VSG 501-701 A25205B VSG 751-1301 A2520 5C VSG 1551-2101 A25205E VSG 2401-3001 A25205F REMOVAL 1. Remove center member, see appropriate Drive Coupling Replacement procedure.
Section 5 • Maintenance/Service NOTE This measurement determines the amount of shims needed for the correct clearance. 21. Measure depth from top of compressor case to top of thrust bearing housing. 22. Use factory installed shim pack (106) and bearing housing cover (116) without the O-ring (143). NOTE Replacement blades are precisely the same dimensionally as blades installed originally at factory: Therefore, the same amount of shims will be required for replacement blades.
Section 5 • Maintenance/Service 23. Check the clearance between the entire gate rotor blade and the shelf, rotate the gate rotor to find the tightest spot. It should be between 0.003-0.004“ (0.076-0.102 mm). Make adjustments, if necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf, see Figure 5-20. 24. After clearance has been set install a new O-ring (143) on bearing housing cover, install cover and tighten the bolts to the recommended torque value. 25.
Section 5 • Maintenance/Service Gate Rotor Assembly Replacement (VSG 301-701 Compressors ONLY) REMOVAL The removal of the gate rotor assembly for the VSG 301701 compressors is similar for the VSG 901- 2101 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.
Section 5 • Maintenance/Service necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf. 14. Once the clearance is set remove the spindle. Install new O-ring, apply Loctite 242 thread locker to the socket head cap screw clamping the thrust 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.
Section 5 • Maintenance/Service Gate Rotor Disassembly 1. GATE ROTOR BLADE REMOVAL To perform gate rotor disassembly, remove gate rotor from compressor, see Gate Rotor Assembly Replacement procedure (All VSG-VSSG Compressors Except VSG 301-701 Compressors) or Gate Rotor Assembly procedure (VSG 301-701 Compressors ONLY). 2. Remove the snap ring and washer from the gate rotor assembly. Lift gate rotor blade assembly off the gate rotor support, see Figure 5-24. 3.
Section 5 • Maintenance/Service GATE ROTOR THRUST BEARING REMOVAL For removal of thrust bearings on VSG units: 7. Remove bolts (150) from the clamping ring (114), see Figure 5-26. 8. Remove thrust bearing clamping ring. 9. Remove thrust bearings (126) from housing (113). 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 gate rotor support. 17. Install the bearing retaining snap ring.
Section 5 • Maintenance/Service The bevel on the snap ring must face away from the roller bearing. 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.
Section 5 • Maintenance/Service Command Shaft Assembly Replacement cover. 5. Seal with stationary carbon face (219B) and rotating mirror face (219C). 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 Replacement procedure. 3.
Section 5 • Maintenance/Service shaft seal cavity in the compressor housing. Apply clean compressor oil to the shaft seal seating area on input shaft. 8. Lubricate the inside area of the rotating seal with clean compressor lubricating oil, do not wipe or touch the face of the rotating portion of the seal. Align the slot in the rotating seal with the drive pin on the compressor input shaft, see Figure 5-30.
Section 6 • Troubleshooting Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2) Problem Reason Solution Dirt or debris is blocking one or both Clean the optocoupler slots with a optocoupler slots Q-Tip and rubbing alcohol.
Section 6 • Troubleshooting Table 6-1. Slide Valve Actuator Troubleshooting Guide (2 of 2) Problem Reason The actuator does not transmit the correct position after a power loss There is a rapid clicking noise when the motor is operating The motor operates in one direction only The motor was manually moved while the position sensor was not powered. Recalibrate. The motor brake is not working properly Get the motor brake to where it operates freely and then recalibrate.
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 Meaning *=ON _=OFF *_*_*_*_*_*_*_*_*_*_*_ *___*___*___*___*___ Calibration step 1 Calibration step 2 This indicates a zero span. This error can only occur during calibration.
Section 6 • Troubleshooting Table 6-2. Slide Valve Actuator LED Blink Codes (2 of 2) Flash Pattern Meaning The motor has overheated. The actuator motor will not run until it cools. Once the motor cools, the actuator will resume normal operation. *__*__*____________ Motor overheating is sometimes a problem in hot and humid environments when process conditions demand that the slide valve reposition often. Solutions are available; consult your Vilter authorized distributor for details.
Section 6 • Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3) Problem Solution • 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.
Section 6 • Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions (2 of 3) Problem Solution • Oil return line from coalescing side of oil separator to suction is closed, not open enough (.
Section 6 • Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions (3 of 3) Problem High Amp Draw Solution • Check Main Motor Amps scaling and PLC. • Check that unit is leveled and secured to mounting pad or floor. Vibration • 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.
6 – 8 / Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 7 • Warranty and Parts Warranty Claim Processing This section explains how the warranty claim is processed and to help clear any questions that may arise prior to contacting customer service. For additional warranty information, refer to the VSG/VSSG Standard Vilter Warranty Statement on page i. Vilter contact information can be found on page ii. 1. The warranty process starts with contacting a Vilter Service and Warranty (S&W) department representative.
Section 7 • Warranty and Parts Remanufactured Gas Bare Shaft Compressor Process These instructions are an overview of how the process works when a bare shaft compressor is in need of being remanufactured. This is to help clear any questions that may arise prior to contacting customer service. The process begins by contacting Vilter’s Customer Service Department. Vilter contact information can be found on page ii. • Request a “VSG Single Screw Compressor Rebuild Form”.
Appendix A • Torque Specifications Torque Specifications (ft-lbs) Type Bolt Head Markings SAE Grade 2 Coarse (UNC) SAE Grade 5 Coarse (UNC) SAE Grade 5 Coarse (UNC) SAE Grade 8 Coarse (UNF) Nominal Size Numbers or Inches #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 - 5 10 18 29 44 63 87 155 150* - 8 16 28 44 68 98 135 240 387 - - 18 - - - - - - - - 11 22 39 63 96 138 191 338 546 5 13 26 46 73 112 115 215 380 614 Socket Head Cap Screw (ASTM A574) C
Appendix B • Motor (Compressor) - General Storage Instructions Short Term Storage Lubrication If the equipment is not put into immediate use it should be stored in a clean, dry location. For all Weather Protected Type II (WPII) motors, motor heaters should be activated upon arriving at the jobsite to prevent condensation. This is required for warranty considerations. Refer to manufacturer’s lubrication instructions.
Appendix C • Oil Analysis Report PRODUCT ANALYSIS REPORT No Action Required Customer Name Customer Address Report Date: 3/4/2013 Report Number: ********* Customer Customer Comp. Mfr. Vilter Oil Type VILTER-717 Serial Number ****-*** Model Number VSM-601 Hrs. on Fluid 6049 Hrs. on Machine 11239 Sample Date Feb 21, 2013 Receive Date Mar 01, 2013 I.D. # ********* Evaluation: The fluid is in good condition. Sample again in 6 months.
Appendix D • Recommended Header Piping D VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
OUTLET ON TOP VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG • 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.
Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
35391SSG Rev. 10 (3/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.
