Emerson VSR, VSM, VSS User Manual
VSS / VSR / VSM
Single Screw Compressor
Operation and Service Manual
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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. The compressor must
not be subjected to liquid carry over. Care must be exercised in properly designing and maintaining the
system to prevent conditions that could lead to liquid carry over. Vilter Manufacturing is not responsible
for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot warrant equipment damaged by improperly protected or operating systems.
Vilter screw compressor components are thoroughly inspected at the factory. However, damage can occur
in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage
noted should be reported immediately to the Transportation Company. This way, an authorized agent
can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with
no serious or costly delays. At the same time, the local Vilter representative or the home office should
be notified of any claim made.
All inquires should include the Vilter sales order number, compressor serial and model number. These can be
found on the compressor name plate on the compressor.
All requests for information, services or parts should be directed to:
Vilter Manufacturing LLC
Customer Service Department
P.O. Box 8904
5555 South Packard Ave
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax:1-414-744-3483
e-mail: info.vilter@emerson.com
Equipment Identification Numbers:
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
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Table of Contents
Important Message .......................................................................................... 3
Standard VILTER Warranty Statement .............................................................. 6
Long Term Storage Requirements .....................................................................7
Description .......................................................................................................9
Foundation ..................................................................................................... 11
Rigging and Lifting ......................................................................................... 12
Installation ..................................................................................................... 16
Slide Valve Actuator Installation & Calibration ............................................28
Slide Valve Operation ................................................................................. 31
Slide Valve Actuator Trouble Shooting Guide ..............................................32
Operation Section .......................................................................................... 36
Notice on using Non -Vilter Oils .................................................................. 36
Operation ..................................................................................................37
Pre Start-Up Checklists ............................................................................... 45
Field Piping and Mechanical Requirements .................................................46
Field Wiring Requirements .........................................................................47
Stop Check Valve Operation ....................................................................... 48
Service .......................................................................................................49
Maintenance .............................................................................................. 80
Parts Section .................................................................................................. 81
Gate Rotor ................................................................................................. 82
Shaft Seal ...................................................................................................86
Main Rotor ................................................................................................. 87
Slide Valve Cross Shafts and End Plate ........................................................ 89
Slide Valve Carriage Assembly .................................................................... 91
Actuator & Command Shaft ....................................................................... 95
Miscellaneous Frame Components ............................................................. 97
Replacement Tools ................................................................................... 101
VSM 301-701 Replacement Parts Section ...................................................... 104
Gaterotor Assembly ................................................................................. 105
Shaft Seal ................................................................................................. 108
Main Rotor, Slide Valve Cross Shafts & End Plate .......................................109
Slide Valve Carriage Assembly .................................................................. 113
Actuator & Command Shaft ..................................................................... 115
Actuator & Command Shaft ..................................................................... 116
Miscellaneous Frame Components ........................................................... 117
Replacement Tools ................................................................................... 121
Appendix A: Pre Start Up for Remote Oil Coolers
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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.
If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product
shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation
and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice
of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by
Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses
prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product
(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by
written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,
incidental, or special damages arising out of a breach of warranty.
This warranty is only applicable to products properly maintained and used according to Seller’s
instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,
misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond
rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller
or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not
warrant that any equipment and features meet the requirements of any local, state or federal laws or
regulations. Products supplied by Seller hereunder which are manufactured by someone else are not
warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products
that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by
warranty.
THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND
WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED
WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Any description of the products, whether in writing or made orally by Seller or Seller’s agents,
specifications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used
in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be
construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or
suitability of the products shall not be construed as an express warranty unless confirmed to be such in
writing by Seller.
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Long Term Storage Requirements
The procedure described is a general recommendation for long term storage (over one month of no operation)
of Vilter Manufacturing packages and compressors. While this procedure is intended to cover most of the
commonly encountered situations, it is the responsibility of the installation rm and end user to address any
unusual conditions. We suggest using the accompanying Long Term Storage Log sheet for recording purposes
to validate the appropriate procedures.
Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verication
of the system integrity, a comprehensive evacuation procedure should be completed to ensure a dry system
before gas is introduced. The oil circuit of any compressor is to be primed at initial start-up through the prelube oil pump on screw compressors.
Warranty of the system remains in effect as described in Section 5, Product Warranty and Procedures.
* 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 is imminent. Adequate drainage should be provided, by placing 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. It is essential that the nitrogen holding
charge integrity be maintained.
* Cover all bare metal surfaces (coupling, ange faces, etc.) with rust inhibitor.
* Desiccant is to be installed in the control panel. If the panel is equipped with a space heater, it is to be
energized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light bulb.
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.
* System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5 psi
above atmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be necessary to
add a gauge to monitor the system 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.
* Motors – (NOTE: The following are general recommendations. Consult the manufacturer of your motor
for specic recommendations.)
1) Remove the condensation drain plugs from those units equipped with them and insert silica-gel into the
openings. Insert one-half pound bags of silica-gel (or other desiccant material) into the air inlets and outlets
of drip-proof type motors.
NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when
the unit is prepared for service.
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Long Term Storage Requirements
2) Cover the unit completely to exclude dirt, dust, moisture, and other foreign materials.
3) 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 put inside the bag, around the motor. When the moisture indicator shows
that the desiccant has lost its effectiveness, as by a change in color, the bag should be opened and fresh
replacement desiccants installed.
Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F
above the ambient temperature.
NOTE: There is a potential for damage by small rodents and other animals that will inhabit
motors in search of warm surroundings or food. Due to this, a possibility of motor
winding destruction exists. Sealing motor openings should restrict access to the
motor.
4) Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate at 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.
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Description
COMPRESSOR
The Vilter Single Screw Compressor is a positive displacement, capacity and volume controlled, oil ooded,
rotary compressor which uses a single main screw intermeshed by two opposing gate rotors. Gas compression
occurs when the individual ngers of each gate rotor sweep through the grooves, or utes, of the main screw as
the screw rotates. Compression occurs from the time the screw ute is rst closed off by the gate rotor nger,
until the time when the screw ute has rotated to the point of lining up with the discharge port in the compres-
sor housing. A labyrinth type seal is used to prevent gas at discharge pressure from leaking past the end of the
screw. Any discharge gas leakage past the labyrinth seal is vented back to suction via four longitudinal holes
drilled through the body of the screw.
By venting the discharge end of the main screw back to suction, forces on each end of the screw are equal. This
results in zero net axial forces on the main bearings. With twin opposing gate rotors, all radial forces are cancelled out also. Main shaft bearings have no net forces except the weight of the screw and the shaft assembly.
The compressors are comprised of three rotating assemblies: the main screw assembly and the two gate ro-
tor assemblies. Each of these rotating assemblies use a common bearing conguration consisting of a single,
cylindrical rolling element bearing at one end, and a pair of angular contact ball bearings at the other end. The
pair of angular contact ball bearings are used to axially x one end of the rotating shafts, and to absorb the small
amount of thrust loads on the shafts. The inner races of the ball bearings are securely clamped to the rotating
shafts, while the outer races are securely held in the bearing housing, thus xing the axial position of the shaft
in relation to the bearing housings. The cylindrical roller bearings at the opposite end of the shafts allow for
axial growth of the shafts while supporting the radial loads from the shafts.
The suction gas enters the compressor housing through the top inlet ange, at the driven end of the unit. The
driven end of the compressor housing is ooded with gas at suction pressure. The gas enters the open end of
the main screw utes at the driven end, and becomes trapped in the screw ute as the screw rotates and the
gate rotor tooth enters the end of the ute. At this point, the compression process begins. Directly after the
screw ute is closed off by the gate rotor tooth, oil is injected into the groove.
The oil enters the compressor through a connection at the top of the compressor. The purpose of the injected oil
is to absorb the heat of compression, to seal the gate rotor tooth in the groove, and to lubricate the moving parts.
Additional internal oiling ports are provided at the main and gate rotor bearings to cool and lubricate the bear-
ings. The mechanical shaft seal housing also contains oiling ports to lubricate, cool and provide a sealing lm
of oil for the mechanical shafts seal. Excess oil ows through the check valves on the sealing bafe plate. This
oil is directed at the main rotor roller bearing, which cools and lubricates the front roller bearing.
As the main screw rotates, the gate rotor is also driven, causing the gate rotor tooth to sweep the groove in the
main screw. This sweeping action reduces the volume of the groove ahead of the gate rotor tooth and causes
the trapped gas and oil to be compressed in the reduced volume. As the main screw continues to rotate, the
gate rotor tooth continues to reduce the groove volume to a minimum, thus compressing the trapped gas to
a maximum pressure. A labyrinth seal arrangement prevents the compressed gas from leaking past the end of
the screw. As the gate rotor tooth reaches the end of the groove, the groove rotates to a position that lines up
with the discharge port in the compressor housing and the gas/oil mixture is discharged from the screw at high
pressure. This completes the compression cycle for a single ute of the main screw.
Once the gas is swept from the main screw ute through the discharge port, it passes into the discharge manifold
of the compressor. From the discharge manifold, the gas/oil exits the compressor housing
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Description
The Vilter compressors feature the exclusive Parallex™ Slide System, which consists of a pair of slides for each
gate rotor assembly. These two independently operated slides are referred to as the capacity slide and the volume ratio slide. On the suction end of the screw, the capacity slide moves to vary the timing of the beginning
of the compression process. With the slide moved all the way out to the suction end of the screw (the 100%
position), the compression process begins immediately after the gate rotor tooth enters the screw ute and
closes off the end of the groove. In this situation, the maximum volume of gas is trapped in the screw ute at
the start of the compression process. As the slide is pulled back away from the suction end of the screw, the
start of the compression process is delayed as some of the suction gas is allowed to spill back out of the screw
ute until the screw rotates far enough to pass the end of the capacity slide and begin compressing. This causes
a reduced volume of gas to be trapped in the screw ute when the compression process begins. In this way, the
capacity of the compressor is reduced from 100% down to as low as 10% of the full rated capacity.
The capacity slide provides the means for controlling specic process set points. By continuously adjusting the
ow of gas through the compressor, either suction or discharge pressure in a particular process can be controlled.
When coupled with a microprocessor controller, the adjustable capacity slide allows for precise and continuous
automatic control of any parameter in the process to a chosen set point.
The second slide for each gate rotor is the volume ratio slide. The purpose of the volume ratio slide is to maximize
the efciency of the compressor by matching the gas pressure within the screw ute at the point of discharge
to the downstream process requirements. The volume ratio slide operates at the discharge end of the screw,
and acts to vary the position of the discharge port. When the slide is extended fully to the discharge end of the
screw (the 100% position), the compression process within the screw ute continues until the screw rotates
far enough for the ute to pass the end of the volume ratio slide. At this point, the screw ute lines up with the
discharge port and the compressed gas is expelled from the screw ute. As the volume ratio slide is pulled back
away from the discharge end of the screw, the position of the discharge port is changed and the gas is allowed
to escape the screw ute earlier in the compression process, at a reduced pressure.
The overall volume ratio within the compressor is determined by the distance between the front of the capacity slide (the start of compression) and the back of the volume ratio slide (the completion of compression).
Therefore, the volume ratio slide must respond to changes in the downstream pressure measured in the oil
separator and position itself for the required compression ratio based on the position of the capacity slide. By
only compressing the gas within the screw as far as required to match the pressure in the downstream receiver,
the compressor efciency is maximized. Proper positioning of the volume ratio slide prevents either over
compressing or under compressing of the gas within the screw ute. This allows the single screw compressor
to efciently handle a range of volume ratios from as low as 1.2 up to 7.0.
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Foundation
• The foundation must adequately support the weight of the compressor package, including vessels, oil coolers,
controllers, and all ancillary equipment. (See documentation for weight and dimension specications
• A detailed general arrangement drawing is provided with all packages. This drawing details foundation type,
mounting foot locations, grouting, and anchoring methods for the specic package.
• Vilter Mfg. recommends consulting a licensed architect to design a suitable foundation for the application.
• Foundations must be built of industrial-grade materials and conform to the appropriate building codes.
• Mount the unit in a location which allows adequate clearance around the unit for maintenance.
• The unit may be top-heavy so caution should be taken when lifting and moving the unit; See the “Rigging and
Lifting” documentation provided with the unit.
• The unit must be securely bolted to the foundation and shims should be used to level the unit for proper operation. Grouting must be used.
• The compressor should be rmly mounted to the package; isolation dampers should not be used between the
compressor and the package frame.
• Pipes and conduits are strictly “no step” areas and could be damaged if used as foot or handholds.
• Adequately support pipes, conduits, etc. to prevent both transmission of vibration and failure due to stress at
the anges. Suction and discharge lines must be supported with appropriate pipe hangers to prevent their
movement if they are disconnected from the compressor package. (See Table 1 below for Unit Weights.)
• In high-pressure screw compressor applications, package vibration and noise levels may be higher than those
found in standard refrigeration applications. In these cases, adequate foundation and proper installation are
vital to ensure trouble-free operation. Additional sound attenuation measures may also be needed.
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Rigging and Lifting
Thank you for purchasing a gas compressor (the “Compressor”) from Vilter Manufacturing LLC (“Vilter”). Rigging
and Lifting a large piece of equipment like the Compressor is extremely dangerous.
**DISCLAIMER**
Notice
This rigging and lifting manual (this “Manual”) is provided to you as a courtesy by Vilter and is not intended to be a
comprehensive guide to rigging and lifting the Compressor. Vilter shall not be liable for errors contained herein or
for incidental or consequential damages (including any injury to persons performing the rigging or lifting) in connection with the furnishing, performance, or use of this Manual. This Manual is only a set of suggestions and you
may not rely solely on the information contained in this Manual to conduct the lift. In addition, information in this
Manual is subject to change without notice.
Limited Warranty
The information is this Manual does not constitute any warranty as to the Compressor. The warranty provision
contained in the terms and conditions pursuant to which the Compressor was sold serves as the sole and exclusive
warranty.
Safety
To correctly and safely operate the Compressor, you must consult all of the documentation that was provided to
you with the purchase of the Compressor (including all information sheets, warning notices and any other documents). This Manual is not intended to summarize or supplant any directions regarding how to safely operate or
move the Compressor.
BEFORE LIFTING AND RIGGING THE COMPRESSOR
In order to minimize the inherent risk involved in rigging and lifting a large piece of equipment, before attempting
to lift the Compressor, the actions of all parties involved in the lift must be carefully planned.
The following is provided merely to encourage purchasers to think about all of the steps necessary to rig and lift
the Compressor. Vilter can neither anticipate all of the dangers involved in a particular lift, nor evaluate the particular capabilities of each of person who will participate in the lift.
Educate and Select Lift Participants
To rig and lift the Compressor in a safe manner, you will need to select experienced, trained people (“Participants”)
to take on (and successfully perform) at a minimum the tasks associated with each of the following positions:
• Crane Operator;
• Crane Owner;
• Lift Coordinator;
• Lift Engineer;
• Rigging Specialist;
• Riggers; and
• Safety Signaler.
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Rigging and Lifting
Training curriculum for Participants, at a minimum, should include:
• A review of safe operating practices;
• A review of who each person is and their specic role in the lift;
• A tutorial on how to read lift charts;
• A demonstration on how to use and inspect rigging hardware;
• A review of the company’s general lift plans and procedures;
• A tutorial on hand signals normally used to communicate with crane operators (a copy of such hand signals
may be obtained from machine safety vendors); and
• A review of the Compressor’s specic rig and lift plan (the “Plan”) (developed by the Lift Coordinator and Lift
Engineer); please see the section immediately below entitled “Create and Communicate the Plan.”
Individuals participating in the lift should fully understand the scientic principles pursuant to which a successful
lift is dependent—for example, center of gravity, equilibrium, and mechanics of load stabilization, critical angle
considerations and force.
All Participants should undergo a tness-for-duty program, including drug testing and medical examinations.
Create and Communicate the Plan
Well in advance of the planned lift date, lift planning meetings and hazard assessment meetings should be held
with all Participants in attendance. In addition, the Plan should be nalized and distributed for review and comment.
The Plan should clearly dene requirements, expectations and specications for lifting the Compressor. At a minimum, the Plan should include:
• Standard lifting and rigging procedures in place at the lift site (including proper classication of the lift as a
“critical lift” a “serious lift” or a “standard lift”);
• Drawings of the Compressor;
• A description of the lifting task;
• An evaluation of the hazards;
• The rigging plan and sketches of rigging to be attached to the Compressor;
• The roles and responsibilities of all Participants;
• An emergency plan; and
• The contact information of the Plan preparer
It is important to conrm that each Participant understands both the broader Plan and their specic responsibilities
during the lift. Participants should be encouraged to contact the Plan preparer at any time if they have questions.
In addition, the Plan preparer should be on-site during the lift to ensure that the lift is being executed in accor-
dance with the Plan. Finally, well in advance of the lift date, it should be conrmed that all necessary permits have
been obtained.
Inspect and Use the Appropriate Lifting Equipment
Verify Crane Operator and Crane Owner Credentials
Prior to rigging and lifting the Compressor, certain precautions should be taken with regards to the crane, the
crane operator and the crane owner.
• The lift capacity of the crane must exceed the Compressor’s weight;
• Conrm that the crane operator is qualied to work on the site;
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Rigging and Lifting
• Get third-party conrmation that the crane owner and the crane operator are in compliance with applicable
laws, regulations and internal safety standards;
• Consult with the crane owner to determine if any site preparation is required for outriggers—improper use of
outriggers is a signicant cause of crane failure;
• Determine the level of supervision to be supplied by the crane owner; and
• Review all crane maintenance and inspection records, including without limitation, the crane log book, main-
tenance records, inspection reports and the physical condition of the crane.
Take all Appropriate Measurements
• Understand and interpret the load charts;
• Review all Compressor drawings for unit size, weight, center of gravity and other specications;
• Communicate incident response procedures in writing prior to the lift and verbally immediately before the lift;
• Determine the initial position, nal position, orientation and elevation of the Compressor;
• Ensure that adequate space is provided to safely assemble, erect, and operate the crane and materials (such as
timber mats, cribbing and blocks);
• Identify and communicate to all Participants the access points, lift radius, swing radius, clearances, and obstructions;
• Eliminate hazards and obstructions that may interfere with moving the Compressor; and
• Inform all Participants of water lines, sewer lines, power lines and other obstructions.
Use Proper Rigging Methods
• Determine diameter, length and quantity of necessary rigging hardware (design and detail the rigging hardware to suit lifting the Compressor at the supplied pad eyes);
• Review and inspect all hoisting, lifting and rigging equipment;
• Select shackle size and prepare sketches or drawings for rigging;
• Use proper, conservative rigging techniques—including spreader beams—needed to lift the Compressor;
• Pad sharp corners, check the orientation of chocker hitches and the orientation of hooks;
• Prevent the binding of hoist rings; and
• Verify pad eye information.
TEST AND BALANCE THE COMPRESSOR
It is essential to test and balance the compressor before executing the actual lift in order to identify potential
causes of injury to Participants and the Compressor.
Secure Rigging and the Lift Site
• Reiterate that no one should walk under the raised load;
• Secure and restrict access to the lift area (consider vacating all non-essential personnel from the area);
• Provide qualied supervision for the duration of the lift;
• If applicable, assess the weather conditions and decide if it is safe to proceed;
• Stop the lift when any potentially unsafe conditions are recognized; and
• Ensure there are open channels for communications during the pre-lift, lift and post-lift phases (radio commu-
nications should be used if a direct line of sight is not possible).
Test and Balance the Compressor before the Lift
• Slowly raise the crane to take slack out of the rigging without actually lifting the load;
• Allow the rigging gear to settle into place;
• Check for twists and binds;
• Verify that all padding has remained in place and that all slings are protected from sharp edges;
• Begin to raise the load to verify balance and check the braking system; and
• If the Compressor is not balanced, lower and adjust as necessary.
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Rigging and Lifting
CONTACT VILTER
While Vilter will not offer any specic feedback on the Plan or provide a specic Plan for rigging and lifting the
Compressor, Vilter may be able to answer questions about the Compressor that are important in developing your
Plan.
Please contact Vilter at:
P.O. Box 8904
5555 S Packard Ave
Cudahy, WI 53110-8904
Telephone: 1-414-744-0111
Fax: 1-414-744-3483
email: info.vilter@emerson.com
www.vilter.com
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Installation
I. DELIVERY INSPECTION
Vilter screw compressor components are thoroughly inspected at the factory, assuring the
shipment of a mechanically perfect piece of equipment. Damage can occur in shipment, however.
For this reason, the units 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 ofce
should be notied of any claim made.
TABLE 1. UNIT WEIGHTS (LBS)*
MODEL STANDARD ECON-O MIZER
VSM 71 2,750 2,750
VSM 91 2,750 2,750
VSM 101 2,750 2,750
VSM 151 2,750 2,750
VSM 181 2,750 2,750
VSM 201 2,750 2,750
VSM 301 2,850 2,850
VSM 361 2,850 2,850
VSM 401 2,850 2,850
VSM 501 4,000 4,000
VSM 601 4,500 4,500
VSM 701 5,000 5,000
VSS 451 4,000 4,000
VSS 601 4,500 4,500
VSS 751 5,300 5,300
VSS 901 5,300 5,300
VSS 1051 6,600 6,600
VSS 1201 6,700 6,700
VSS 1501 10,010 10,010
VSS 1801 10,010 10,010
VSS 1551 11,000 11,000
VSS 1851 11,000 11,000
VSS 2101 11,000 11,000
* Does not include motor.
II. FOUNDATIONS
Vilter single screw compressor units are basically vibration free machines, therefore, no
elaborate foundations are necessar y. The
oor or foundation upon which the unit will
be placed should be designed to support the
entire operating weight of the unit. See Table
1 for unit weights.
III. LOCATING UNIT - DRIVE
COUPLING ALIGNMENT
The single screw compressor units are shipped
with all major components mounted on structural steel. Place the entire unit on the oor
on a concrete pad and securely bolt in place.
Review local codes and ASHRAE Safety Code for
Mechanical Refrigeration. Bolt holes are located
in the unit’s mounting feet. When locating the
unit, provide adequate space for service work.
When the compressor unit is in place on the concrete pad, check both lengthwise and crosswise
to assure it is level. Use shims and wedges as
needed under the mounting feet to adjust the
level of the unit.
On single screw units, the motor and compressor have been roughly aligned at the factory.
The coupling center section was shipped loose
to allow a check of proper electrical phasing,
direction of rotation of the motor and final
coupling alignment. The dial indicator alignment method is recommended. Final alignment
should be within 0.004 inches total indicator
reading in all direction for the VSS models and
0.010 inches for the VSM models.
IV. SYSTEM 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.
16
Care must be taken to avoid trapping the lines
except for specic purposes. When traps are
Installation
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 ttings.
Common pipe ttings 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 tting should be carefully cleaned to remove
all traces of grease or oil. Threads should then be
wiped dry with a lintless cloth. Only thread lling compounds suitable for refrigeration 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 rst two threads
to prevent any of the 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.
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 operat-
ing pressures. In selecting ttings for Halocarbon
piping, only wrought copper ttings should be
used. Cast ttings 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 ttings are available and these may
be used with complete safety.
In larger pipe sizes, wrought ttings are not available. However, specially tested cast ttings 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.
It is important to avoid short, rigid pipe lines that
do not allow any degree of exibility. This must
be done to prevent vibration being transmitted
through the pipe lines to the buildings. One
method of providing the needed exibility to
absorb the vibration is to provide long lines that
are broken by 90° Ells in three directions.
Smaller Halocarbon and Hydroflourocarbon
installations use copper pipes with solder type
ttings where possible. The use of screw type
ttings 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
A second method would be to install exible
pipe couplings as close to the compressor unit
as possible with connections run in two different
directions, 90° apart. These exible 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.
Water supply and drain connections, and equipment using water, should be installed so all the
water 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.
17
Installation
This information is taken from ASHRAE 15-89 and
ANSI B31.5. The installing contractor should be
thoroughly familiar with these codes, as well as
any local codes.
V. ELECTRICAL CONNECTIONS
The 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 eld mounted starters and package mounted
motors.
Additional control wiring in the eld 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.
VI. TESTING REFRIGERATION
SYSTEM FOR LEAKS
Vilter equipment is tested for leaks at the factory. One the most important steps in putting a
refrigeration system into operation is eld 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 Mechani-
cal Refrigeration”. These pressures will usually
sufce, 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.
A. 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 moisture remaining. This will
cause ammonium carbonate to precipitate
when the CO2 is added. If heavy enough, this
precipitate may cause the machine to freeze
and clog the strainer.
A mixture of four parts water to one part liquid
soap, with a few drops of glycerin added, makes
a good solution. Apply this mixture with a one
inch round brush at all anges, 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 oat away from the compressor.
18
Installation
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.
B. Halocarbon Refrigerant Systems
“Oil pumped” dry nitrogen, or anhydrous CO2 in
this order of preference may be used to raise the
pressure to 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 at-
tempt 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.
C. 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 noncondensables 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 non-condensables, 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 60F 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 re-
frigeration 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.
Remove the refrigerant drum and bring the
pressure to the recommended test level with oil
pumped dry nitrogen or CO2. Then check the
entire system again for leaks, using a halide torch
or electronic leak detector. Be sure to check all
anged, welded, screwed and soldered 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.
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 rst 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.
19
Installation
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
non-condensables. 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.
VII. UNIT OIL CHARGING
TABLE 2. OIL CHARGE
Oil Separator Size Approximate Oil
Charge (Gallons)
VSR 16” 20 to 27
VSR 20” 22 to 31
VSM 20” 20 to 25
VSM 30” 30 to 35
20” 30 to 40
24” 40 to 50
30” 60 to 75
36” 95 to 105
42” 145 to 165
The oil level may be above the top sight glass
at this time. Later, when the unit is placed in
operation, there will be some drop in the oil level
as the various oil lines, oil lter and other piping
becomes charged with the normal amount of
oil that will be in circulation. This drop in oil
level should bring the level in the oil receiver/
separator into the normal operating range. Do
not mix oils.
A. Oil For Single Screw Compressors
Due to the need for adequate lubrication, Vilter
recommends only the use of Vilter lubricants,
designed specifically for Vilter compressors.
With the extensive research that has been per-
formed, we are able to offer refrigerant specic
lubricating oils. Use of oil not specied or sup-
plied by Vilter will void the compressor warranty.
Please contact your local Vilter representative or
the Home Ofce for further information.
The compressor unit is shipped from Vilter with
no oil charge. The initial oil charge can be made
through the drain valve at the oil receiver/separator. Vilter motor driven and manually operated
oil chargers are available for this purpose. Once
the unit has been started and is operating above
50% capacity, oil may have to be added to bring
the oil level to the normal operating point. With
the unit operating, oil should be added through
the charging connection at the suction strainer.
The normal operating level is between the (2)
sight glasses on the oil separator. See Table 2 for
approximate oil charge requirements.
20
VIII. SYSTEM REFRIGERANT CHARGING
CAUTION
When charging the system, make sure the
compressor unit is pressurized from the discharge side of the compressor. Pressurizing the
compressor from the suction side may cause
rotation of the compressor, without oil supply,
which could lead to internal damage.
Installation
After the system is leak-free and evacuation has
been completed, it is ready for charging. Before
actual charging, however, the entire operation
of the refrigeration system should be inspected
as outlined below:
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 expansion 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 RTD’s 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.
E. Initial Charging – High Side Charging
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 lling 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. Invert the refrigerant drum if the drum is
not equipped with “Liquid” and “Vapor”
valves, and place in such a position so the
liquid refrigerant only can enter the system. 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.
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. After some refrigerant has entered the
system, the compressor unit starting procedure may be followed. See Start-Up and
Operation Section of this manual.
4. Continue charging refrigerant into the
system until the proper operating require-
ments are satised. 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
21
Installation
should show no bubbles, and there will be a
liquid seal in the receiver. If these two condi-
tions are not satised, additional refrigerant
must be added.
5. Wh en suf ficient refr igerant has been
charged into the system, close the charging
and drum valves. Then remove the drum
from the system.
6. During the charging period, observe the
gauge carefully to insure no operating dif-
culties. Watch head pressures closely to
make sure the condensers are functioning
properly.
Since it is usually necessary to use several drums
when charging a system, follow the procedures
in paragraphs E1 and E2 of the above description
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”.
IX. MAINTENANCE SUGGESTIONS
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 maintenance schedule is
suggested.
A. Daily
1. Check oil levels.
2. Check all pressure and temperature readings.
3. Check micronic oil lter inlet and outlet pressures for excessive pressure drop. Change
lter when pressure drop exceeds 45 psi or
every six months, whichever occurs rst. For
proper procedure for changing micronic oil
lter and for charging oil into the system, see
Operation Section.
4. Clean strainers each time lter 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 10 drops/min) is normal. This
allows lubrication of the seal faces.
B. Weekly
(Items 1 thru 6 above plus 7 thru 9)
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.
C. Monthly
(Items 1 thru 8 above plus 9 thru 13)
10. Oil all motors and bearings. Follow manu-
facturer’s instructions on lubrication.
11. Check calibration and operation of all
controls, particularly safety controls.
12. Check oil cooler for any evidence of corrosion, scaling or other fouling.
13. Operate compressor capacity and volume
ratio controls through their range both
automatically and manually.
D. Trimonthly
(About 2000 operating hours)
Check movement of compressor rotor at drive
coupling end to determine bearing oat. (Refer to Service Section.)
E. Yearly
(Items 1 thru 13 and “D” above plus 14
thru 28)
14. Check entire system thoroughly for leaks.
22
Installation
15. Remove all rust from equipment, clean and
paint.
16. Flush out sediment, etc. from water circuits.
17. Clean all oil strainers.
18. Clean suction strainer – compressors.
19. Check motors and fans for shaft wear and
end play.
20. Check operation and general condition of
microprocessor and other electrical controls.
21. Clean all water strainers.
22. Check drains to make sure water will ow
away from equipment.
23. Drain and clean entire oil system at receiver
drain. Recharge with new clean moisture
free oil. For proper procedure for changing
micronic oil lter and charging oil into the
system, see Start-Up and Operation section.
24. Check compressor coupling. For integrity
and alignment.
25. Check oil pump for wear.
26. Check the calibration of the microprocessor
pressure transducers and RTD’s for accuracy.
tightened, all plugs that were removed are re-
placed with a suitable thread lling compound,
all packing glands on valve stems are tightened,
and all valve caps are replaced. When operation
is restored, all joints opened or any valves moved
during the servicing should be checked for leaks.
G. Year Round Operation
On a continual basis:
1. Guard against liquid slugging of compressor.
2. Maintain unit in clean condition and paint
as necessary.
3. Grease valve stems and threads for the
valve caps.
When refrigeration equipment is operated 24
hours a day year round, it is highly recommended that a yearly check of all internal parts be
made (see Service Section). While the highest
material standards are maintained throughout
all Vilter compressors, continuous operation
and any presence of dirt may prove injurious to
the machine. To forestall needless shutdowns
or prevent possible machine breakdowns, the
side covers should be removed yearly, and a
visual inspection be made of the internal parts.
In this way, a small amount of time spent checking machine conditions once a year may prevent
extensive shutdowns later with subsequent
product loss and expensive repairs.
27. Check mounting bolts for compressor and
motor.
F. System Leaks
There are any number of reasons why leaks
develop in a refrigeration system (i.e. such as
drying out of valve packing, yielding of gaskets,
improper replacement of valve caps and loosen-
ing of joints due to vibration). For these reasons,
the need for periodic leak testing cannot be overemphasized. Similarly, when any service operations are performed on the system, care should
be exercised to insure all opened flanges are
23
Stop Check Valve Installation
Correct
Correct
Wrong Wrong
Verify the location of the Spring and note the Vilter name.
Installation:
The new design will apply only to the 2” thru 4” stop valves. Retrotting a eld installation will
require replacing the bonnet assembly.
The bonnet must be installed with the spring towards the bottom (see illustrations above).
The drill xture 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.
See Operation Section on Stop Check Operation.
24
Coupling Installation
COUPLING INFORMATION
COUPLINGS INSTALLATION AND ALIGNMENT
These instructions are intended to help you to install
and align the coupling. Covered here will be general
information, hub mounting, alignment, assembly,
locknut torquing, discpack replacement, and part
numbers. The coupling as received, may or may not
be assembled.
*If assembled, the locknuts are not torqued.
*If coupling is assembled, remove the bolts that attach the hubs to the disc packs. Remove both hubs.
Leave the disc packs attached to the center member.
B. Straight Bore:
1. Install key(s) in the shaft. If the hub is an interfer-
ence t, heat the hub in an oil bath or oven until
bore is sufciently larger than the shaft. 350º F.
is usually sufcient. An open ame is not recommended. However, if ame heating is necessary,
use a very large rose bud tip to give even heat
distribution. A thermal heat stick will help determine hub temperature. DO NOT SPOT HEAT THE
HUB OR DISTORTION MAY OCCUR. With the hubs
expanded, slide it up the shaft to the desired axial
position. A pre-set axial stop device can be helpful.
C. Taper Bore:
1. Put the hub on the shaft without key(s) in place.
Lightly tap hub up the shaft with a soft hammer.
This will assure a metal-to-metal t between shaft
and hub. This is the starting point for the axial
draw. Record this position between shaft and hub
face with a depth micrometer. Mount a dial indicator to read axial hub movement. Set the indicator
to “0”. Remove hub and install key(s). Remount
hub, drawing it up the shaft to the “0” set point.
Continue to advance hub up the taper to the desired axial position. Use the indicator as a guide
only. A pre-set axial stop device can be helpful.
Check the nal results with a depth micrometer.
The hub may have to be heated in order to reach
the desired position on the shaft. DO NOT SPOT
HEAT THE HUB OR DISTORTION MAY OCCUR.
Install shaft locknut to hold hub in place.
A. Hub Mounting:
1. Clean hub bores and shafts. Remove any nicks
or burrs. If bore is tapered, check for good contact
pattern. If the bore is straight, measure the bore
and shaft diameters to assure proper t. The key(s)
should have a snug side-to-side t with a small
clearance over the top.
NOTE: If the hub position on the shaft does not allow
enough room to install the short bolts in the hub after
hub mounting, install the bolts and disc pack before
mounting hub on shaft.
D. Shaft Alignment.
Move equipment into place.
1. Soft Foot. The equipment must sit at on its
base (+/- 0.002 inches). Any soft foot must be
corrected now.
2. Axial Spacing. The axial spacing of the shafts
should be positioned so that the disc packs (exing elements) are flat when the equipment is
running under normal operating conditions. This
means there is a minimal amount of waviness in
the disc pack when viewed from the side. This
25
Installation
will result in a exing element that is centered and
parallel to its mating ange faces. Move the con-
nected equipment to accomplish the above.
NOTE: The disc pack is designed to an optimal thick-
ness and is not to be used for axial adjustments.
See documentation that came with the coupling for
complete specications.
3. Angular Alignment. Rigidly mount a dial indicator
on one hub or shaft, reading the face of the other
hub ange, as shown on next page. Rotate both
shafts together, making sure the shaft axial spacing
remains constant. Adjust the equipment by shimming and/or moving so that the indicator reading
is within .002 inch per inch of coupling ange.
4. Parallel Offset. Rigidly mount a dial indicator on
one hub or shaft, reading the other hub ange outside diameter, as shown in Figure 3. 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
.002 inch per inch of the axial length between ex
elements. See drawing below.
Note: If the driver or driven equipment alignment
specication is tighter than these recommendations,
the specication 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.
E. Final assembly
With the coupling in good alignment the bolts will t
through the holes in the anges and the disc packs
more easily.
1. If the coupling arrived assembled, the disc packs
are still attached to the center ring. Before tak-
Note: Alignment of C-Flange Units should be
checked when compressor or motor are replaced.
ing the discs packs off, rst install one hub bolt
through each disc pack and secure with lock out.
This will help when the pack is reinstalled late. If
the coupling was shipped disassembled, the bolt
through the pack is not required as the discs in the
pack are factory taped together.
2. Remove the long bolts. Mount the disc packs
on the hubs with one bolt through the disc pack
aligned with a clearance hole in the hub. Install
the short bolts through the hub, disc pack, bevel
washer or link, and secure with a lockout.
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 rst. Remove the disc pack
alignment bolt. Proceed to mount the second disc
pack to the other hub in the same way.
3. Position one set of short bolts in each hub on
top. Now slide the center ring down into place
straddling the short bolts with the center ring
bushings. If coupling is dynamically balanced, the
center ring match marks must lineup with both
hub match marks. When one bushing is in-line
with the hole in the disc pack, slide one long bolt
through washer or link, disc pack, center ring,
disc pack, washer or link, and then secure with a
locknut. On size 226 and larger a link must be put
on the bolt rst. Now install the rest of the long
bolts in the same manner.
26
4. Torque the long bolt locknuts at this time.
Installation
NOTE: With the coupling in good alignment, the bolts
will t through the holes in the anges and the disc
pack more easily. It is recommended that all locknuts
be retightened after several hours of initial operation.
5. For further help with the installation or alignment, consult Rexnord.
F. Disc Pack Replacement.
If it becomes necessary to replace the disc pack, it can
be done as follows:
1. Remove all the long bolts and lower the center
ring by sliding it our from between the two disc
packs.
2. Remove one short bolt from the disc pack/hub
connection and reinstall it through a hub clearance
hole and into the hole in the disc pack. Put the nut
on. This will keep the discs together and maintains
the disc orientation for later reinstallation. Remove
the rest of the short bolts and takeoff the disc pack.
Repeat for the second disc pack.
3. Replace the pack(s) if required. Recheck alignment per Section D. Reassemble per Section E.
27
Slide Valve Actuator Installation & Calibration
Slide Valve Actuator Installations Instructions
Caution
WHEN INSTALLING THE OPTICAL SLIDE MOTOR,
LOOSEN LOCKING COLLAR BEFORE SLIDING THE
COLLAR DOWN ON THE SHAFT. DO NOT USE A
SCREWDRIVER TO PRY LOCKING COLLAR INTO
POSITION.
OVERVIEW
Calibration of an optical slide valve actuator is a two
step process that must be done for each actuator
installed of the compressor. Briey, the steps are as
follows.
1) The actuator motor control module, located
inside the actuator housing, is calibrated so
that it knows the minimum and maximum rotational positions of the slide valve it controls.
The calibrated actuator will output 0 VDC at the
minimum position and 5 VDC at the maximum
position.
2) After the actuator motor control module has been
calibrated for 0-5Volts, the controlling channel
corresponding to the actuator motor (either the
capacity or volume) has to be calibrated. This
instructs the control panel to learn the rotational
0% position & rotational 100% position of the slide
valve travel.
PLEASE NOTE:
Because there is an optical sensor on this motor, do
not attempt calibration in direct sunlight.
3. If not already done, mount the slide valve
actuator per (“Vilter Actuator set up for
Capacity and Volume Slide Motors). Next,
wire the actuator per the attached wiring
diagrams, using the already installed electrical conduit to run the cables. The old wiring
can be used to pull the new cables through
the conduit to the control panel. The cables
may also be externally tie-wrapped to the
conduit. Run the yellow AC power cable(s)
and the gray DC position transmitter
cable(s) in different conduit. This prevents
the DC position transmitter cable from picking up electrical noise from the AC power
cable. Do not connect either of the cables
to the actuators yet.
In addition, if the actuators are replacing old gearmotors on early units, you must remove the capaci-
tors and associated wiring from inside the control
panel. This is necessary to prevent electrical damage
to the new actuator motor.
4. When completing the calibration of the
new actuators, the motors are signaled to
move to below 5%. This may not completely
occur when exiting the calibration screen
due to a “program timer”. HOWEVER,
when the compressor actually starts, the
motors will travel below 5% and function
correctly. The user may see that the actuators are not below 5% after calibration and
try to find the reason. If the calibration
screen is re-entered right away and then
exited, the timer will allow the actuator to
go below the 5% on the screen. This may be
perceived as a problem; in reality,it is not.
ACTUATOR MOTOR CONTROL
MODULE CALIBRATION PROCEDURE
1. Disable the Slide Non-Movement Alarm by
going to the “Setup” menu on the control
panel and choosing “Alarm Disable” for the
Slide Non-Movement Option. (If applicable).
2. Completely shut off the power to the control
panel completely.
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5. Note:
The 0 to 5V-position transmitter output of
the actuator will uctuate wildly during the
calibration process. To prevent damage to
the actuators, do not connect the yellow
power cable or the gray position transmitter
cable until instructed to do so later on.
6. Open the plastic cover of the capacity motor by
removing the four #10 screws.
Slide Valve Actuator Installation & Calibration
Caution: there are wires attached to the con-
nector on the plastic cover. Handling the
cover too aggressively could break the wires.
7. Gently lift the cover and tilt it toward the Turck
connectors. Raise the cover enough to be able
to press the blue calibrate button and be able
to see the red LED on the top of assembly.
8. Press “Menu” on the main screen and then press
the “Slide Calibration” button, to enter the slide
calibration screen. (Note: you must be in this slide
calibration screen before attaching the yellow
power cable or gray position transmitter cable.)
15. Use the DEC button on the control panel to
drive the slide valve to its minimum “mechanical stop” position. Do not continue to run the
actuator in this direction after the slide valve
has reached the stop. Doing so may cause damage to the actuator or the slide valve. When
the slide has reached the mechanical stop position, use the INC button to pulse the actuator
to where the slide is just off of the mechanical
stop and there is no tension on the motor shaft.
16. Quickly press and release the blue button on
the actuator again. The red LED will now ash
at a slower rate, indication that the minimum
slide valve position (0V position) has been set.
9. Now connect the yellow power cable and the
gray position transmitter cable to the actuator.
10. Press INC and DEC to move the slide valve and check
for the correct rotation. See Table 1on page 48 for
Actuator/command shaft rotation specications.
11. Note: If the increase and decrease buttons do
not correspond to increase or decrease shaft
rotation, swap the blue and brown wires of
the “yellow power cable”. This will reverse
the rotation of the actuator/command shaft.
12. Quickly press and release the blue push button on the actuator one time. This places the actuator in calibration mode. The
r e d L E D w i ll b e gi n f la sh in g r ap id ly .
13. 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 uctuate during calibration. After the actuator has been calibrated,
0V output will correspond to the minimum
position and 5V to the maximum position.
14. 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.
17. 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. When the slide valve has
reached the mechanical stop position, use the
DEC 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.
18. Quickly press and release the blue button on the
actuator one more time. The red LED will stop
ashing. 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 control panel can be calibrated.
19. Use the Dec button to move the actuator towards
its minimum position while watching the millivolt readout on the control panel screen. Discontinue pressing the DEC button when the millivolt
reading in the “Current” window above the “Set
Min” button is approximately 500 millivolts.
20. Now use the DEC and INC buttons to position the
slide valve until a value close to 300 millivolts is on
the screen. Then, press the “Set Min” button for
the capacity or volume slide valve window to tell
the controller that this is the minimum millivolt
position. Note: The value in the “Current Cap” or
“Current Vol” window has no meaning right now.
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Slide Valve Actuator Installation & Calibration
21. Use the INC button to rotate the actuator towards its maximum position while watching
the millivolt readout on the controller screen.
Discontinue pressing the INC button when
the millivolt reading in the “Current” window
is approximately 9200 millivolts (7900 millivolts for the 2783J qualied analog boards).
You are nearing the mechanical stop position.
22. Pulse the INC button to carefully move the slide
valve until the millivolt readout “saturates”, or
stops increasing. This is around 9500 millivolts
(8400 millivolts for 2783 qualied analog boards).
23. Pulse the DEC button until the millivolts just
start to decrease. (This is the point where
the channel drops out of saturation).Ad-
just millivolt value to 300 millivolts below
recorded maximum millivolts in step #22.
24. Press the “Set Max” button.
25. 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.
26. 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.
27. 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. Caution: The plastic cover
will crack if the screws are over tightened.
28. Enable the “Slide Non-Movement Alarm” by going to the “Setup” menu and choosing “Alarm
Enable” for the “Slide Non-Movement Option”.
29. This completes the calibration for this channel either capacity or volume. Repeat the
same p rocedure to t h e oth er channel.
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