Emerson VSM, VSR, VSS User Manual

Download

VSS/VSR/VSM single screw compressor

Operation and service manual

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: _________________

Table of Contents

Important Message ..............................................................................................................3

Standard VILTER Warranty Statement ..................................................................................6

Standard VILTER 5/15 Warranty Statement ..........................................................................7

Long Term Storage Requirements .........................................................................................8

Description .........................................................................................................................10

Foundation .........................................................................................................................12

Rigging and Lifting .............................................................................................................19

Installation .........................................................................................................................23

Slide Valve Actuator Installation & Calibration ...............................................................35

Slide Valve Operation ....................................................................................................38

Slide Valve Actuator Trouble Shooting Guide .................................................................39

Operation Section ..............................................................................................................43

Notice on using Non-Vilter Oils ......................................................................................43

Operation .....................................................................................................................44

Pre Start-Up Checklists ..................................................................................................52

Field Piping and Mechanical Requirements ....................................................................53

Field Wiring Requirements ............................................................................................54

Stop Check Valve Operation ..........................................................................................55

Service ..........................................................................................................................56

Maintenance .................................................................................................................87

VSS Parts Section ................................................................................................................88

Gate Rotor .....................................................................................................................89

Shaft Seal ......................................................................................................................93

Main Rotor ....................................................................................................................94

Slide Valve Cross Shafts and End Plate ............................................................................96

Slide Valve Carriage Assembly .......................................................................................98

Actuator & Command Shaft .........................................................................................102

Miscellaneous Frame Components ..............................................................................104

Replacement Tools ......................................................................................................108

VSM 301-701 Replacement Parts Section ..........................................................................111

Gaterotor Assembly ....................................................................................................112

Shaft Seal ....................................................................................................................115

Main Rotor, Slide Valve Cross Shafts & End Plate ..........................................................116

Slide Valve Carriage Assembly .....................................................................................120

Actuator & Command Shaft .........................................................................................122

Miscellaneous Frame Components ..............................................................................124

Replacement Tools ......................................................................................................128

Danfoss Liquid Injection Valve Setup .................................................................................129

Appendix A: Pre Start Up for Remote Oil Coolers ...............................................................143

Standard VILTER Warranty Statement

Seller warrants the products it manufactures to be free from defects in material and workmanship for a period of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the following extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and reciprocating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Seller of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim. Products supplied by Seller, which are manufactured by others, are not warranted by Seller, but rather Seller merely passes through the manufacturer’s warranty to Buyer.

SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Unless otherwise agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REMEDIES ARE EXCLUSIVE AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED. Products or parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory. Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved by Seller, or any alteration or repair by others which, in Seller’s judgement, adversely affects the Product, shall void all warranties and warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be in default of its payment obligations to Seller under this Agreement or any credit agreement.

Standard VILTER 5/15 Warranty Statement

The seller extends warranty, from date of shipment, to a period of fifteen (15) years on all compressor bearings, five (5) years on all internal compressor parts and two (2) years on the remainder of the parts on single screw compressor units. 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 Seller’s receiving written notice of any alleged defect within ten (10) days after its discovery and, at Seller’s option, return of such parts to Seller, F.O.B., freight prepaid to Seller’s factory. Expenses incurred by Buyer in repairing or replacing any defective product or any lost refrigerant will not be allowed except by written permission of Seller. This warranty is only applicable to products properly maintained and used according to Seller’s instructions, the use of genuine Vilter replacement parts and recommended oil in all repairs and replacements has demonstrated adherence to a scheduled maintenance program as detailed in the Single Screw Compressor operating manual. This warranty does not apply to normal wear and tear, or damage caused by corrosion, misuse, overloading, neglect, improper operation, accident or alteration, as determined by Seller. 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 the Seller may have from the original manufacturer. Labor and expenses for repair are not covered by warranty.

THE WARRANTY CONTAINED IN THIS SECTION IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND WARRANTIES (EXCEPT OF TITLE), EXPRESS OR IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Any description of the product, 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. The 5/15 Extended Warranty shall be applicable only if the specific maintenance guidelines as outlined in the technical manual are followed. This includes the compressor inspections, completing periodic oil analysis and the change out of the oil and oil filters, and related components as required with only genuine Vilter parts. The customer is required to keep a maintenance log and receipts demonstrating the use of Genuine Vilter parts for validation of a warranty claim, if requested.

Note: The 5/15 warranty applies to NEW compressors only, and does NOT include used or remanufactured compressors.

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 ﬁ 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 veriﬁ cation 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, ﬂ 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 speciﬁ c 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.

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 ﬂ 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.

Description

COMPRESSOR

The Vilter Single Screw Compressor is a positive displacement, capacity and volume controlled, oil ﬂ ooded, rotary compressor which uses a single main screw intermeshed by two opposing gate rotors. Gas compression occurs when the individual ﬁ ngers of each gate rotor sweep through the grooves, or ﬂ utes, of the main screw as the screw rotates. Compression occurs from the time the screw ﬂ ute is ﬁ rst closed off by the gate rotor ﬁ nger, until the time when the screw ﬂ 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 rotor assemblies. Each of these rotating assemblies use a common bearing conﬁ guration 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 ﬁ 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 ﬁ 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 ﬂ ange, at the driven end of the unit. The driven end of the compressor housing is ﬂ ooded with gas at suction pressure. The gas enters the open end of the main screw ﬂ utes at the driven end, and becomes trapped in the screw ﬂ ute as the screw rotates and the gate rotor tooth enters the end of the ﬂ ute. At this point, the compression process begins. Directly after the screw ﬂ 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 bearings. The mechanical shaft seal housing also contains oiling ports to lubricate, cool and provide a sealing ﬁ lm of oil for the mechanical shafts seal. Excess oil ﬂ ows through the check valves on the sealing bafﬂ e 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 ﬂ ute of the main screw.

Once the gas is swept from the main screw ﬂ 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

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 ﬂ ute and closes off the end of the groove. In this situation, the maximum volume of gas is trapped in the screw ﬂ 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 ﬂ 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 ﬂ 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 speciﬁ c process set points. By continuously adjusting the ﬂ 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 efﬁ ciency of the compressor by matching the gas pressure within the screw ﬂ 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 ﬂ ute continues until the screw rotates far enough for the ﬂ ute to pass the end of the volume ratio slide. At this point, the screw ﬂ ute lines up with the discharge port and the compressed gas is expelled from the screw ﬂ 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 ﬂ 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 efﬁ ciency is maximized. Proper positioning of the volume ratio slide prevents either over compressing or under compressing of the gas within the screw ﬂ ute. This allows the single screw compressor to efﬁ ciently handle a range of volume ratios from as low as 1.2 up to 7.0.

Foundation

Introduction

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. Included are speciﬁ cations for concrete, rebar, aggregate, anchors and grout.

Considerations Prior to Starting

Consult professionals, such as building inspectors, structural engineers, geotechnical engineers and/or construction contractors prior to starting. Below are a few points to consider:

Site Characteristics:

• Soil information

• Site drainage

• Wind data

• Seismic zone

• Ingress and egress

• Power and power lines

Site Layout:

• Plant elevations, grading, drainage and erosion

• Accessibility to compressors for service

• Location of surrounding buildings

• Property lines and roadways

• Power

• Fire safety

Safety:

NOTE

Always check with a safety engineer before proceeding.

• Arranging equipment with adequate access space for safe operation and maintenance

• Wherever possible, arrange equipment to be served by crane. If not feasible, consider other handling methods

• Make all valves and devices safely accessible

• Use special bright primary color schemes to differentiate service lines

• Lightening protection for outdoor installations

• Relief valve venting

Foundation Materials

Materials needed to build the foundation are forms, concrete, sand, rebar, wire, grout, anchor bolts, expansion board and shims. A set of concrete forms will need to be acquired; generally, these can be rented or constructed from dimensional lumber. There should be enough 4,000 psi concrete with one inch aggregate to build the foundation. Also, there should be enough sand to provide a base of compacted sand four inches thick for the foundation to rest on, see Figure 1 - Concrete Pad with Compressor Unit Dimensions - Side View. The rebar required is ASTM 615, grade 60, sizes #4 and #6. Wires will also be needed to tie the rebar together. The recommended grout is Masterﬂ ow 648CP high performance non-shirk grout to provide at least a 1” thick pad under each foot. The recommended anchors are 5/8” Diameter HILTI HAS SS threaded rod for outdoor installations or HAS-E rods for indoor installations. Anchor bolts shall have a ﬁ ve inch projection and 12-3/8” embedment. The required adhesive is HIT-ICE/HIT/HY 150 anchoring system. There should be enough one inch expansion boards to go around the perimeter of the foundation. Finally there should be enough shim stock and extra anchor bolt nuts to level the compressor unit.

Foundation

Building the Foundation

Use the Vilter General Arrangement (GA) and foundation drawings to help secure a building permit and foundation construction. The Vilter GA drawing will have the necessary dimensions required to determine the overall foundation size and where to locate the compressor unit on the foundation. It will also show the dimensions required to form up the housekeeping piers that the compressor unit rests on. The Vilter foundation drawing lists the necessary information to construct a suitable foundation. It includes the rebar requirements and locations. It also shows anchor bolt locations, grouting and the concrete speciﬁ cations. Using the Vilter GA drawing, Vilter foundation drawing and the information from site characteristics, site layout and safety studies will provide enough data to allow building the foundation to proceed.

The foundation is to be cast and permanently exposed against the earth. Therefore, if constructing on an existing ﬂ oor, typically indoors, the ﬂ oor will need to be broken up to get to the earth. If starting from undisturbed soil, it must be also be prepared accordingly. In either case, these are some check points to consider:

• Check the depth of your frost line to ensure the foundation extends below it

• Ensure the foundation rests entirely on natural rock or entirely on solid earth, but never on a combination of both

• Check the ability of the soil to carry the load

• Check wet season and dry season soil characteristics for static loading limits and elasticity

• Check local codes for Seismic Design requirements

For examples of foundation diagrams, refer to Figure 1 - Concrete Pad with Compressor Unit Dimensions - Side View and Figure 2 - Concrete Pad with Compressor Unit Dimensions - Front View

1'-0"

EL. TOP OF GRADE

3" CLR. 2" CLR.

G.A.

# 6 @ 12" EACH WAY TOP & BOTTOM

G.A.

CENTER LINE OF GAS COMPRESSION SYSTEM

2" (TYP.)

EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL WITH CLSM OR NON-FROST SUSCEPTIBLE FILL

COMPRESSOR UNIT

Figure 1. Concrete Pad with Compressor Unit Dimensions - Side View

4" COMPACTED SAND

Foundation

G.A.

COMPRESSOR UNIT

CENTER LINE OF GAS COMPRESSION SYSTEM

EL. TOP OF GRADE

# 6 @ 12" EACH WAY TOP & BOTTOM

EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL WITH CLSM OR NON-FROST SUSCEPTIBLE FILL

Figure 2. Concrete Pad with Compressor Unit Dimensions - Front View

Once the site has been excavated and prepared, place four inches of sand down on the bed where the foundation will rest. The sand must be compacted before placing the forms and rebar. After the sand is compacted, use the Vilter GA drawing to construct the forms for the foundation. With forms in place, install expansion boards on the inside of the forms, for example, see Figure 3 - Interior Foundation Isolation. Next, place your rebar in the forms as per the Vilter foundation drawing. When all rebars are in place the concrete can be poured. The concrete must then be trolled level and a surface texture etched in place. Leave the concrete to cure for at least 28 days.

ISOLATION JOINT, 1" MINIMUM

COMPRESSOR UNIT

CHAMFER EDGE

THICKNESS

FOUNDATION

CONCRETE SLAB IN

6”

BUILDING

Figure 3. Interior Foundation Isolation

Foundation

Compressor Unit Installation

Once the foundation has cured, the compressor unit can be placed on the foundation, see Figure 4. Foundation with Housekeeping Pads Dimensions - Top View and Figure 5. Housekeeping Pad Dimension Detail - Top View. With the appropriate material handling equipment, lift the compressor unit by locations shown on the Vilter GA drawing and slowly place it on the foundation housekeeping piers. As per the Vilter GA drawing, ensure the compressor unit is correctly placed on the foundation. Once placed, use the spherical washers directly under the compressor as the surface to level the compressor unit, see Figure 6 - Compressor with Spherical Washers. Place shims under the feet of the compressor unit, as needed, until it is leveled, see Figure 7 - Concrete Pad Housekeeping Detail. Select the correct drill bit and drill thru the anchor bolt hole in the mounting feet of the compressor unit to the depth called for on the Vilter foundation drawing. Finally using the HILTI instructions, put your anchor bolts in place and wait for them to cure. Then place the nuts on the anchor bolts to ﬁ nger tight and prepare to grout.

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

10'-0"

5'-0"

CENTER LINE GAS COMPRESSION SYSTEM

Figure 4. Foundation with Housekeeping Pads Dimensions - Top View

G.A.

1" (TYP.)

G.A.

Foundation

G.A.G.A.

(2) - # 4 CLOSED TIES

CENTER LINE

G.A. + 2"

G.A.

(5) - # 6 VERT. WITH STD. 90° HOOK

AT BOTTOM EACH

FAC E

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.

Figure 5. Housekeeping Pad Dimension Detail - Top View

(TYP.)

SPHERICAL

WASHER

SPHERICAL WASHER

Figure 6. Compressor with Spherical Washers

Foundation

70+6.')

010Ä5*4+0-

'21:;)4176

/+0

4'%1//'0&'&

(14

*175'-''2+0)

%10%4'6'

$#5'

Figure 7. Concrete Pad Housekeeping Detail

Leveling and Grouting

The unit should be level in all directions. Wet the concrete pad according to the grout manufacturer’s directions. Mix a sufﬁ cient amount of grout. The grout must be an expanding grout rather than shrinking to provide a tighter bond. Follow the manufacturer’s recommendations for setting, precautions, mixing, and grout placement, ﬁ nishing and curing. The grout must be worked under all areas of the feet with no bubbles or voids. If the grout is settled with a slight outside slope, oil and water can run off of the base. Once the grout has cured, torque the anchor bolts as per HILTI instructions.

*1.&&190076

9#5*'4

.'8'.+0)076

#0%*14$1.6

Piping Connections Piping Stress

Once the screw compressor package has been installed, properly grouted and anchored, it is imperative that the piping bolted to the screw compressor not impose excessive forces on the compressor. Suction and discharge lines should be supported so the lines will not move if disconnected from the compressor.

Additional Information

Codes and Standards Vilter followed the following codes and standards when designing your foundation:

• ACI

• ASTM

• ASCE 7

• IBC 2006

Foundation

Operation and Performance The foundation was designed for:

• Outside environment severe exposure

• Ambient temperature -10 degrees F to 105 degrees F

• Unit weight 20,000 lbs

• RPM 3600

• Soil bearing capacity 1,500 lbs/sq.ft.

• Wind speed 120 MPH

• Exposure factor D

• Wind importance factor 1.15

• Concrete poured on and permanently cast against the earth

General Design Requirements The compressor foundation is designed to:

• Maintain the compressor in alignment and at proper elevation.

• Minimize vibration and prevents its transmission to other structures

• Provide a permanently rigid support

• Provide sufﬁ cient depth to dampen vibrations.

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.

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 speciﬁ c 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 speciﬁ c 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 scientiﬁ c 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 ﬁ 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 ﬁ nalized and distributed for review and com- ment.

The Plan should clearly deﬁ ne requirements, expectations and speciﬁ cations for lifting the Compressor. At a mini- mum, the Plan should include:

• Standard lifting and rigging procedures in place at the lift site (including proper classiﬁ cation 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 conﬁ rm that each Participant understands both the broader Plan and their speciﬁ c 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 accordance with the Plan. Finally, well in advance of the lift date, it should be conﬁ rmed 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;

• Conﬁ rm that the crane operator is qualiﬁ ed to work on the site;

Rigging and Lifting

• Get third-party conﬁ rmation 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 signiﬁ cant 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, maintenance 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 speciﬁ cations;

• Communicate incident response procedures in writing prior to the lift and verbally immediately before the lift;

• Determine the initial position, ﬁ 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 qualiﬁ ed 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 communications 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.

Rigging and Lifting

CONTACT VILTER

While Vilter will not offer any speciﬁ c feedback on the Plan or provide a speciﬁ c 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

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 ofﬁ ce should be notiﬁ ed 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 1301 6,750 6,750 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 necessary. The ﬂ 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. See Foundation, page 12, for additional foundation instructions.

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 ﬂ 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.

III. 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.

Installation

Care must be taken to avoid trapping the lines except for speciﬁ c purposes. When traps are used, the horizontal dimensions should be as short as possible to avoid excessive oil trapping.

Lines for ammonia systems must be of steel pipe with specially designed ammonia service ﬁ ttings. Common pipe ﬁ 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 ﬁ 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 ﬁ ll- ing 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 ﬁ 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.

for tube sizes not larger than 1-3/8” in outside diameter. These requirements are in accordance with the mechanical code for refrigeration ANSI B9.1-1971. The type of copper tubing to be used for a given pressure is dependent on the strength of the copper at the design temperature. Some local codes forbid the use of Type “L”. Therefore, before installation, be sure to check local requirements. Never use type “M” as it does not have adequate wall thickness to withstand the operating pressures. In selecting ﬁ ttings for Halocarbon piping, only wrought copper ﬁ ttings should be used. Cast ﬁ 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 ﬁ ttings are available and these may be used with complete safety.

In larger pipe sizes, wrought ﬁ ttings are not avail- able. However, specially tested cast ﬁ 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 ﬂ exibility. This must be done to prevent vibration being transmitted through the pipe lines to the buildings. One method of providing the needed ﬂ 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

ﬁ ttings where possible. The use of screw type ﬁ 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

A second method would be to install ﬂ exible pipe couplings as close to the compressor unit as possible with connections run in two different directions, 90° apart. These ﬂ 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.

Installation

These precautions will avoid costly damage to the equipment due to freezing.

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.

IV. 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 ﬁ eld mounted starters and package mounted motors.

Additional control wiring in the ﬁ eld is also re- quired. 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.

V. 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 ﬁ 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 Mechanical Refrigeration”. These pressures will usually sufﬁ ce, 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 ﬂ 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

Installation

valves on the lowest part of the system so the gas will ﬂ oat away from the compressor. This pre- vents 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 attempt to repair soldered or welded joints while the system is under pressure. Soldered joints should be opened and re soldered.

Do not simply add more solder to the leaking joint. After all the joints have been repaired and the system is considered “tight” the system may be tested with refrigerant.

Attach a drum of the refrigerant to be used in the system and allow the gas to enter until a pressure of 5 psig is reached.

Remove the refrigerant drum and bring the pressure to the recommended test level with oil pumped dry nitrogen or CO2. Then check the entire system again for leaks, using a halide torch or electronic leak detector. Be sure to check all ﬂ 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.

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 refrigeration system by using the manufacturer’s instructions. Connect the pump both to the high side and low side of the system, to insure system evacuation. Attach the vacuum gauge to the system in accordance with the manufacturer’s instructions.

A single evacuation of the system does not satisfactorily remove all of the non-condensable, air and water vapor. To do a complete job, a triple evacuation is recommended.

When the pump is ﬁ 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.

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.

VI. 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 ﬁ 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 performed, we are able to offer refrigerant speciﬁ c lubricating oils. Use of oil not speciﬁ ed or sup- plied by Vilter will void the compressor warranty.

Please contact your local Vilter representative or the Home Ofﬁ ce for further information.

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.

VII. 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 ﬁ 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 requirements are satisﬁ ed. 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

Installation

should show no bubbles, and there will be a liquid seal in the receiver. If these two conditions are not satisﬁ ed, additional refrigerant must be added.

5. When sufficient refrigerant 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 difﬁ 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”.

VIII. 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 ﬁ lter inlet and outlet pres- sures for excessive pressure drop. Change ﬁ lter when pressure drop exceeds 45 psi or every six months, whichever occurs ﬁ rst. For proper procedure for changing micronic oil ﬁ lter and for charging oil into the system, see Operation Section.

4. Clean strainers each time ﬁ 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 manufacturer’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 ﬂ oat. (Re- fer to Service Section.)

E. Yearly

(Items 1 thru 13 and “D” above plus 14 thru 28)

14. Check entire system thoroughly for leaks.

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 ﬂ 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 ﬁ 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 replaced with a suitable thread ﬁ 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 loosening 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

Stop Check Valve Installation

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. Retroﬁ tting a ﬁ eld installation will require replacing the bonnet assembly.

The bonnet must be installed with the spring towards the bottom (see illustrations above). The drill ﬁ xture is designed so that the hole for the spring will always be drilled on the oppo- site 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.

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 interference ﬁ t, heat the hub in an oil bath or oven until bore is sufﬁ ciently larger than the shaft. 350º F. is usually sufﬁ cient. An open ﬂ ame is not recom- mended. However, if ﬂ 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 ﬁ 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 ﬁ 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 ﬁ t. The key(s) should have a snug side-to-side ﬁ 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 ﬂ 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 (ﬂ ex- ing 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

Installation

will result in a ﬂ exing element that is centered and parallel to its mating ﬂ ange faces. Move the con- nected equipment to accomplish the above.

NOTE: The disc pack is designed to an optimal thickness and is not to be used for axial adjustments.

See documentation that came with the coupling for complete speciﬁ cations.

3. Angular Alignment. Rigidly mount a dial indicator on one hub or shaft, reading the face of the other hub ﬂ 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 ﬂ ange.

4. Parallel Offset. Rigidly mount a dial indicator on one hub or shaft, reading the other hub ﬂ ange out- side 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 ﬂ ex

elements. See drawing below.

Note: If the driver or driven equipment alignment speciﬁ cation is tighter than these recommendations, the speciﬁ cation should be used. Also, be sure to compensate for thermal movement in the equipment. The coupling is capable of approximately four time the above shaft alignment tolerances. However, close alignment at installation will provide longer service with smoother operation.

E. Final assembly

With the coupling in good alignment the bolts will ﬁ t through the holes in the ﬂ 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, ﬁ 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 ﬁ 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 ﬁ rst. Now install the rest of the long bolts in the same manner.

Installation

4. Torque the long bolt locknuts at this time.

NOTE: With the coupling in good alignment, the bolts will ﬁ t through the holes in the ﬂ 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.

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. Brieﬂ y, 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.

5. Note: The 0 to 5V-position transmitter output of

the actuator will ﬂ 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 ﬂ 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 speciﬁ cations.

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 red LED will begin flashing rapidly.

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 ﬂ uctuate during calibra- tion. 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 ﬂ ashing. The actuator is now calibrated and knows the minimum and maximum positions of the slide valve it controls. Now the capacity or volume 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.

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 qualiﬁ ed 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 qualiﬁ ed 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).Adjust 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 procedure to the other channel.

Slide Valve Operation

Slide Valve Actuator Operation

The slide valve actuator is a gear-motor with a position sensor. The motor is powered in the forward and reverse directions from the main computer in the control panel. The position sensor tells the main computer the position of the slide valve. The main computer uses the position and process information to decide where to move the slide valve next.

The position sensors works by optically counting motor turns. On the shaft of the motor is a small aluminum “photochopper”. It has a 180 degree fence that passes through the slots of two slotted optocouplers. The optocouplers have an infrared light emitting diode (LED) on one side of the slot and a phototransistor on the other. The phototransistor behaves as a light controlled switch. When the photochopper fence is blocking the slot, light from the LED is prevented from reaching the phototransistor and the switch is open. When photochopper fence is not blocking the slot, the switch is closed.

This scheme is not foolproof. If the motor is moved manually while the power is off or the motor brake has failed, allowing the motor to free wheel for too long after the position sensor looses power, the actuator will become lost.

A brake failure can sometimes be detected by the position sensor. If the motor never stops turning after a power loss, the position sensor detects this, knows it will be lost, and goes immediately into calibrate mode when power is restored.

As the motor turns, the photochopper fence alternately blocks and opens the optocoupler slots, generating a sequence that the position sensor microcontroller can use to determine motor position by counting. Because the motor is connected to the slide valve by gears, knowing the motor position means knowing the slide valve position.

During calibration, the position sensor records the high and low count of motor turns. The operator tells the position sensor when the actuator is at the high or low position with the push button. Refer to the calibration instructions for the detailed calibration procedure.

The position sensor can get “lost” if the motor is moved while the position sensor is not powered. To prevent this, the motor can only be moved electrically while the position sensor is powered. When the position sensor loses power, power is cut to the motor. A capacitor stores enough energy to keep the position sensor circuitry alive long enough for the motor to come to a complete stop and then save the motor position to non-volatile EEPROM memory. When power is restored, the saved motor position is read from EEPROM memory and the actuators resumes normal function

Slide Valve Actuator Trouble Shooting Guide

Problem Reason Solution

The actuator cannot be calibrated

Dirt or debris is blocking one or both optocoupler slots

Clean the optocoupler slots with a Q-Tip and rubbing alcohol.

The photochopper fence extends less than about half way into the optocoupler slots

The white calibrate wire in the grey Turck cable is grounded

Dirt and/or condensation on the position sensor boards are causing it to malfunction

The calibrate button is stuck down

The position sensor has failed

Push button is being held down for more that ¾ second when going through the calibration procedure

Adjust the photochopper so that the fence extends further into the optocoupler slots. Make sure the motor brake operates freely and the photochopper will not contact the optocouplers when the shaft is pressed down.

Tape the end of the white wire in the panel and make sure that it cannot touch metal

Clean the boards with an electronics cleaner or compressed air.

Try to free the stuck button.

Replace the actuator.

Depress the button quickly and then let go. Each ¾ second the button is held down counts as another press.

The actuator goes into calibration mode spontaneously

The actuator goes into calibration mode every time power is restored after a power loss

The white calibrate wire in the grey Turck cable is grounding intermittently

A very strong source of electromagnetic interference (EMI), such as a contactor, is in the vicinity of the actuator or grey cable

There is an intermittent failure of the position sensor

The motor brake is not working properly (see theory section above.)

Tape the end of the white wire in the panel and make sure that it cannot touch metal.

Increase the distance between the EMI source and the actuator.

Install additional metal shielding material between the EMI source and the actuator or cable.

Replace the actuator.

Get the motor brake to where it operates freely and recalibrate.

Replace the actuator.

Slide Valve Actuator Trouble Shooting Guide

Problem Reason Solution

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.

The motor brake is not working properly

The position sensor’s EEPROM memory has failed

The photochopper is misaligned with the slotted optocouplers

The photochopper is positioned too low on the motor shaft.

A motor bearing has failed

There is a loose connection in the screw terminal blocks

There is a loose or dirty connection in the yellow Turck cable

Recalibrate.

Get the motor brake to where it operates freely and then recalibrate.

Replace the actuator.

Try to realign or replace the actuator.

Adjust the photochopper so that the fence extends further into the optocoupler slots.

Replace the actuator.

Tighten.

Clean and tighten.

The motor will not move in either direction

The motor runs intermittently, several minutes on, several minutes off

The position sensor has failed

There is a broken motor lead or winding

The thermal switch has tripped because the motor is overheated

Any of the reasons listed in “The motor operates in one direction only”

The command shaft is jammed

Broken gears in the gearmotor

Motor is overheating and the thermal switch is tripping

Replace the actuator.

The motor will resume operation when it cools. This could be caused by a malfunctioning control panel. Consult the factory.

See above.

Free the command shaft.

Replace the actuator.

This could be caused by a malfunctioning control panel. Consult the factory.

Slide Valve Actuator Trouble Shooting Guide

Problem Reason Solution

The motor runs sporadically

Bad thermal switch

Any of the reasons listed in “The motor will not move in either direction”

The motor runs but output shaft will not turn

Slide Valve Actuators communicate problems discovered by internal diagnostics via LED blink codes. Only one blink code is displayed, even though it is possible that more than one problem has been detected.

Flash Pattern Meaning

*=ON

_=OFF

*_*_*_*_*_*_*_*_*_*_*_ Calibration step 1

Stripped gears inside the gear motor or the armature has come unpressed from the armature shaft

Replace the actuator.

See above.

Replace the actuator.

*___*___*___*___*___ Calibration step 2

*__*________________ This indicates a zero span. This error can only occur during calibration. The typical

cause is forgetting to move the actuator when setting the upper limit of the span. If this is the case, press the blue button to restart the calibration procedure. This error can also occur if either or both of the slotted optocouplers are not working. If this is the case, the slide valve actuator will have to be replaced.

The operation of the slotted optocouplers is tested as follows:

1. Manually rotate the motor shaft until the aluminum photochopper fence is not blocking either of the optocoupler slots.

2. Using a digital multi-meter, measure the DC voltage between terminal 3 of the small terminal block and TP1 on the circuit board (see Note 1). You should measure between 0.1 and 0.2 Volts.

3. Next, measure the DC voltage between terminal 3 and TP2 on the circuit board. You should measure between 0.1 and 0.2 Volts.

Slide Valve Actuator Trouble Shooting Guide

*__________________ This indicates a skipped state in the patterns generated by the optocouplers as the

motor moves. This error means that the slide valve actuator is no longer transmitting accurate position information. The actuator should be recalibrated as soon as possible. This code will not clear until the actuator is recalibrated.

This code can be caused by:

1. The motor speed exceeding the position sensors ability to measure it at some time during operation. A non-functioning motor brake is usually to blame.

2. The actuator is being operated where strong infrared light can falsely trigger the slotted optocouplers, such as direct sunlight. Shade the actuator when the cover is off for service and calibration. Do not operate the actuator with the cover off.

*__*__*____________ The motor has overheated. The actuator motor will not run until it cools. Once the

motor cools, the actuator will resume normal operation.

Motor overheating is sometimes a problem in hot and humid environments when process conditions demand that the slide valve reposition often. Solutions are available; consult your Vilter authorized distributor for details.

Another possible cause for this error is a stuck motor thermal switch. The thermal switch can be tested by measuring the DC voltage with a digital multi-meter between the two TS1 wire pads (see Note 2). If the switch is closed (normal operation) you will measure 0 Volts.

******************** The 24V supply is voltage is low. This will occur momentarily when the actuator is

powered up and on power down.

If the problem persists, measure the voltage using a digital multi-meter between terminals 3 and 4 of the small terminal block. If the voltage is >= 24V, replace the actuator.

_******************* The EEPROM data is bad. This is usually caused by loss of 24V power before the

calibration procedure was completed. The actuator will not move while this error code is displayed. To clear the error, calibrate the actuator. If this error has occurred and the cause was not the loss of 24V power during calibration, possible causes are:

1. The EEPROM memory in the micro-controller is bad.

2. The large blue capacitor is bad or has a cracked lead.

*****____*__________ Micro-controller program failure. Replace the actuator.

Note 1: TP1 and TP2 are plated-thru holes located close to the slotted optocouplers on the board. They are clearly marked on the board silkscreen legend.

Note 2: The TS1 wire pads are where the motor thermal switch leads solder into the circuit board. They are clearly marked on the board silkscreen legend and are oriented at a 45 degree angle.

Operation Section

Notice on using Non -Vilter Oils

Oil and its additives are crucial in system performance. Vilter Manufacturing will NOT APPROVE non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available it is not possible for us to test all oils offered in the market place, and their effects on our equipment.

We realize that customers may choose lubricants other than Vilter branded oil. This is certainly within the customers’ right as owners of the equipment. When this choice is made, however, Vilter is unable to accept responsibility for any detrimental affects those lubricants may have on the equipment or system performance and durability.

Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warranty upon evaluation of the issue. This includes any parts’ failure caused by inadequate lubrication.

Certainly, there are many good lubricants in the market place. The choice of a lubricant for a particular application involves consideration of many aspects of the lubricant and how it and its additive package will react in the various parts of the entire system. It is a complex choice that depends on a combination of field experience, lab and field-testing, and knowledge of lubricant chosen. Vilter will not accept those risks other than for our own lubricants.

Operation

OIL SYSTEM

A. Oil Charge

Charge the oil separator with the proper quantity of lubricating oil (see Table 2 in the Installation Section).

CAUTION It is imperative you charge the oil into the receiver/ separator prior to energizing the control panel to prevent burning out the immersion heater in the separator/receiver.

During operation, maintain the separator oil level in the normal operating range between the two bullseye sight glasses. If the oil level is visible only in the lowest sight glass, add oil to the operating compressor through the connection located at the compressor suction inlet. Pump oil into the compressor until the oil level in the separator is between the two bullseye sight glasses. Watch this level carefully to maintain proper operation. Never allow the oil to reach a level higher than indicated on the highest sight glass, since this may impair the operation and efficiency of the oil separator portion of this combination vessel.

B. Oil Separator

The refrigerant-oil mixture is led into the first part of oil separator. There, the first step of oil separation is performed by a combined agglomerator/ demister. At the same time, these part of the oil separator serves as oil collector.

To prepare for the removal of the filter, shut down the compressor. Isolate the filter housing appropriately. If unit is equipped with duplex filter housings the unit does not have to be shut down, however the filter to be serviced must be isolated before the tank can be opened.

1. Filter Removal, VSS Units using Vilter Part Number 1833C oil ﬁ lter elements.

Release the pressure in the oil filter housing by opening the bleed valves at the stop valve in the block and bleed assembly, or at the bleed valve for the oil filter housing. Be sure to follow all Local, State, and Federal ordinances regarding the recovery of refrigerants.

Drain the filter housing in to an appropriate container and dispose of the oil in a appropriate manner following all Local, State and Federal ordinances regarding the disposal of used oil.

Unscrew the bolts holding the cover flange to the tank. Remove the cover flange and spring plate. Pull out the filter element(s). Before reassembling, thoroughly clean the tank and spring plate to lengthen the life span of the filter element(s).

In the second part of the oil separator, the fine separation of the aerosol oil portion from the refrigerant is performed by means of replaceable fine oil separation cartridges. The oil separated in the fine section of the oil separator is returned to the compressor via an additional injection orifice.

C. Oil Filter

Change the oil filter after the first 200 hours of operation, as noted on the hour meter. Thereafter, replace the filter every six months, or when the oil pressure drop through the filter reaches 45 psi, whichever occurs first. The pressure drop across the filter is read on the microprocessor panel. Check the pressure drop and record it daily.

1833C

Filter

Element

FIGURE 1.

1833C FILTER ELEMENT TANKS

LOCKING

RING

FILTER

ELEMENT

FILTER

TANK

INLET

OUTLET

Operation

To replace the filter element(s), on single element tanks, insert the element and make sure it fits onto the outlet connection. Install spring plate, and bolt the cover assembly in place. On units equipped with dual element tanks, insert inner element and make sure it fits onto the outlet connection. Put the centering piece on the outer element and slide into tank making sure the center piece fits into the inner element. Put spring plate on outer element and bolt the cover assembly in place.

2. Filter Removal and installation, all VSR Units.

Release the pressure in the oil filter housing by opening the bleed valves at the stop valve in the block and bleed assembly, or at the bleed valve for the oil filter housing. Be sure to follow all Local, State and Federal ordinances regarding the recovery of refrigerants.

Loosen and remove the locking ring on filter tank by turning in a counter clockwise direction. Remove filter tank with the used element.

Remove the filter element from the tank. Before reassembling, thoroughly clean the tank to lengthen the life span of the filter element.

Wet the threads and O-ring on the head and the O-ring in the new element with clean refrigeration oil.

CAUTION

Do not use a pipe wrench, hammer or any other tool to tighten the locking ring.

nsert new element into the filter tank with the open end visible. Attach tank to head and HAND TIGHTEN the locking ring.

The filter housing can be evacuated and then slowly pressurized to check for leaks before returning to service.

FIGURE 2.

TYPICAL CANISTER TYPE FILTER CROSS SEC-

TION

Drain the filter bowl or housing in to an appropriate container and dispose of the oil in a appropriate manner following all Local, State and Federal ordinances regarding the disposal of used refrigeration oil.

3. Filter Removal, VSS and VSM Units (after 5/1/00) when using Vilter Part Numbers 3111A (16” Simplex), or 3112A (39” Simplex) oil filter housings.

Release the pressure in the oil filter housing by opening the bleed valves at the stop valve in the block and bleed assembly, or at the bleed valve for the oil filter housing. Be sure to follow all Local, State and Federal ordinances regarding the recovery of refrigerants.

Loosen and remove the cover on the bowl of the filter tank by turning it in a counter clockwise direction. Remove the used element.

Operation

Wet the O-ring in the new element with clean refrigeration oil. Insert the new element into the filter tank with the closed end visible and attach the cover to the bowl. HAND TIGHTEN the cover.

The filter housing can be evacuated and then slowly pressurized to check for leaks before returning to service.

4. Filter Removal, VSS and VSM Units (after 5/1/00) when using Vilter Part Numbers 3109A (16” Duplex), or 3110A (39” Du plex) oil filter housings.

Isolate the bowl to be worked on by turning handle. The handle will cover the drain valve of active element. Close commuter valve in center of handle. Release the pressure in the isolated bowl by bleeding through the stop valve on the oil filter cover for Duplex (Vilter Part #3109A or 3110A), or through the stop valve for the oil filter housing. Be sure to follow all Local, State and Federal ordinances regarding the recovery of refrigerants.

CAUTION When changing filter, discard clogged filter only. Save and reuse spring plate and centering piece. This filter MUST be installed with the spring plate. A compressor that is allowed to operate without the spring plate is running with unfiltered oil.

The filter housing can be evacuated and then slowly pressurized to check for leaks before returning to service.

D. Oil Pressure Regulating

On units with a full time oil pump, the back pressure regulator, in the oil supply line from the separator, controls upstream pressure to the compressor bearings and should be adjusted to hold the oil pressure at 50 psig above suction pressure. Excess oil not required for bearing lubrication is passed through the regulator and flows into the separator.

E. Oil Cooling

1. Water Cooled Oil Cooler

Loosen and remove the cover on the bowl of the filter tank by turning it in a counter clockwise direction. Remove the used element.

Wet the O-ring in the new element with clean refrigeration oil. Insert the new element into the filter tank with the close end visible and attach the cover to the bowl. HAND TIGHTEN the cover.

The filter housing can be evacuated and then slowly pressurized by opening the commuter valve on handle. This will pressurize the housing. Check for leaks. The filter can now be returned to service. Repeat for other filter bowl if needed.

In lieu of the three way oil temperature valve to control the temperature of the oil used for lubrication and cooling of the compressor, it is required to install a water regulating valve and solenoid valve combination to control the water supply to the oil cooler. The water inlet connection should be made on the bottom and the outlet connection on the top. The water supply is controlled by the water regulating valve to maintain the oil temperature at approximately 120°F.

Operation

FIGURE 3.

TYPICAL WATER COOLED OIL COOLER

DIAGRAM

The solenoid valve provides positive water shutoff when the compressor is not in operation. A temperature of 150°F is considered high in most circumstances and the compressor is protected by a safety control to prevent operation of the compressor above this temperature. Unless otherwise specified, the oil cooler is sized for an 85°F water inlet temperature and 10°F temperature rise.

2. Liquid Injection Oil Cooling.

The components are furnished with liquid injection for a typical system. The liquid solenoid valve opens whenever the compressor is in operation. The thermostatic expansion valve controls the flow of liquid refrigerant to the compressor injection port in response to the discharge temperature. The discharge temperature is maintained at a minimum of 120°F with a maximum of 140°F. The discharge temperature can be adjusted either of two ways. First, the small outlet pressure regulator can be used to adjust superheat. Normally, this regulator should be adjusted to maintain 70 psig pressure at the external equalizing port of the expansion valve. Raising the pressure beyond 70 psig tends to raise the discharge temperature, while lowering the pressure lowers the discharge temperature. Secondly, the standard superheat adjusting screw on the thermostatic expansion valve can be used to adjust the discharge temperature.

FIGURE 4.

TYPICAL LIQUID INJECTION OIL COOLING

SCHEMATIC DIAGRAM

Liquid injection cooling on booster compressors is handled in the following manner. Using high pressure liquid, the point of injection can be the discharge line and no horsepower penalty is paid by injecting liquid into the compressor discharge line. The high pressure gas source normally used for the pressure regulator would be compressor discharge pressure. Since, on a booster unit, this intermediate pressure is very rarely as high as the nominal setting of 70 psig, high stage discharge gas is used. On high stage compressors, the liquid is injected directly into the compressor. However, there is a horsepower penalty when the liquid is injected into the compressor. This will vary with refrigerant and operating condition. The liquid is injected into the compressor at a point in the compressor cycle that minimizes the brake horsepower penalty.

3. V-PLUS Oil Cooling System

This system consists of a liquid pump, shut-off valves, motor, solid state variable speed controller and solid state temperature controller. This method of oil cooling is not available on the VSM or VSR compressor units. The pump and solenoid valve cycle on and off in parallel with the compressor drive motor. The temperature controller receives a temperature signal from the sensor located in the discharge and oil lines and in turn, sends a signal to the motor speed controller.

Operation

As the oil and desupserheating load varies, the temperature controller adjusts the speed of the pump/motor combination to maintain a constant oil temperature.

NOTE: See separate V-PLUS® instruction manual for detailed start-up and operation.

4. Thermosyphon Oil Cooling

Using a brazed plate or an one pass shell and tube type vessel, similar to the water cooled oil cooler, oil is circulated on the shell side and liquid refrigerant from the receiver is circulated through the tubes. Thermosyphon systems use a 3-way temperature sensing control valve to regulate oil at 120°F. Oil is bypassed around the thermosyphon oil cooler. When oil is higher than 120°F, the oil is passed through the thermosyphon oil cooler. A 1/4” tubing line w/valve adds high pressure gas to the oil to quiet the sound of injection. Open this valve in small amounts, until noise subsides. The closed type cooling circuit is free from the fouling problems associated with open circuit water cooling. Since the oil cooling load is rejected in the condenser, this type of cooling is practical. The temperature limits here are the same as those regarding the water cooled oil coolers.

CONTROL SYSTEM

Equipped for automatic operation, the screw compressor unit has safety controls to protect it from irregular operating conditions, an automatic starting and stopping sequence, capacity and volume ratio control systems.

Check all pressure controls with a remote pressure source, to assure that all safety and operating control limits operate at the point indicated on the microprocessor.

The unit is equipped with block and bleed valves that are used to recalibrate the pressure transducers. To use the block and bleed valves to recalibrate the pressure transducers, the block valve is shut off at the unit and the pressure is allowed to bleed off by opening the bleed valve near the pressure transducer enclosure. The transducer can then be calibrated at atmospheric pressure (0 psig), or an external pressure source with an accurate gauge may be attached at the bleed valve.

The discharge pressure transducer cannot be isolated from its pressure source, so it is equipped with only a valve to allow an accurate pressure gauge to be attached and the pressure transducer calibrated at unit pressure.

5. Oil Pump

This system is designed to provide adequate compressor lubrication when there is low differential oil pressure across the compressor suction and discharge for some high stage applications and booster applications as required.

On start-up, the control system will calculate the pressure differential between the compressor oil manifold & suction pressure. If this differential pressure ratio is less than 2.8:1, then the oil pump will turn on and will continue to run until the pressure ratio is 3.0:1.

Recheck the transducers periodically for any drift of calibration.

A. Screw Compressor Control And Operation

1. Starting, Stopping and Restarting the Compressor.

Before the screw compressor unit is started, certain conditions must be met. All of the safety setpoints must be in a normal condition, and the suction pressure must be above the low suction pressure setpoint to assure that a load is present. When the “On-Off” switch or

Operation

“Manual-Auto” button is pressed, the oil pump will start. When sufficient oil pressure is built up and the compressor capacity control and volume ratio slide valves are at or below 10%, the compressor unit will start.

If the compressor is in the automatic mode, it will now load and unload and vary the volume ratio in response to the system demands.

Stopping the compressor unit can be accomplished a number of ways. Any of the safety setpoints will stop the compressor unit if an abnormal operating condition exists. The compressor unit “On-Off” or stop button will turn the compressor unit off as will the low pressure setpoint. If any of these conditions turns the compressor unit off, the slide valve motors will immediately energize to drive the slide valves back to 5% limit. The control motors will be de-energized when the respective slide valve moves back below 5%. If there is a power failure, the compressor unit will stop. If the manual start on power failure option is selected (see appropriate Microprocessor Instruction Manual), restarting from this condition is accomplished by pushing the reset button to insure positive operator control. If the auto start on power failure option is selected (see appropriate Microprocessor Instruction Manual), the compressor unit will start up after a waiting period. With both options, the compressor slide valves must return below their respective 5% limits before the compressor unit can be restarted.

2. Slide Valve Control Actuators

Capacity and volume ratio control of the screw compressor is achieved by movement of the respective slide valves, actuated by electric motors.

Note: Optical Actuators CAN NOT be manually rotated.

(The VSM 501-701 models will have motor locations

opposite of ﬁ gure #6)

FIGURE 5.

SLIDE VALVE MOTOR LOCATION

When viewing the compressor from the discharge end (opposite the drive end), the upper motor is for capacity control. The command shaft turns (see Table 1) to decrease the capacity to 10% and reverses to increase the capacity to 100%. The lower motor is for volume ratio control. The command shaft turns to reduce the volume ratio to 2.0, and reverses to increase the volume ratio to 5.0.

Actuation of the electric motors can be done manually or automatically. To actuate the motors manually, place the desired mode selector in the manual position and push the manual Increase or Decrease buttons. In the automatic mode, the microprocessor determines the direction to actuate the electric motors. However, in the automatic mode, there is an “On” and “Off” time for the capacity control motor. The “On” time is the time in which the slide valve moves, and the “Off” time is the time in which the system is allowed to stabilize before another change in slide valve position.

Operation

The Motor Amps Load Limit protects the compressor from overloading by decreasing the compressor capacity if the motor amperage is at the Maximum Amps setpoint, or preventing an increase in capacity if the motor amperage is above the Full Load Amps setpoint. ( See manual for the appropriate microprocessor.)

3. Oil Separator Heater

The oil separator heater keeps the oil in the separator from becoming too viscous and helps keep gas from condensing in the receiver section of the separator.

The heater is turned on only when the compressor is off. The separator heater is supplied with an integral temperature control.

TABLE 1. VSS / VSR / VSM COMMAND SHAFT ROTATION AND TRAVEL

COMMAND SHAFT ROTATION NO. OF TURNS / ROTATION ANGLE / SLIDE TRAVEL COMP. CAPACITY VOLUME CAPACITY VOLUME MODEL INC DEC INC DEC TURNS/ANGLE/TRAVEL TURNS/ANGLE/TRAVEL VSS 291 CW CCW CW CCW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045” VSS 341 CW CCW CW CCW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045” VSS 451 CW CCW CW CCW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045” VSS 601 CW CCW CW CCW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045” VSS 751 CCW CW CCW CW 1.09 / 392 / 4.283” 0.63 / 227 / 2.473” VSS 901 CCW CW CCW CW 1.09 / 392 / 4.283” 0.63 / 227 / 2.473” VSS 791 CCW CW CCW CW 1.22 / 439 / 4.777” 0.74 / 266 / 2.889” VSS 891 CCW CW CCW CW 1.22 / 439 / 4.777” 0.74 / 266 / 2.889” VSS 1051 CCW CW CCW CW 1.22 / 439 / 4.777” 0.74 / 266 / 2.889” VSS 1201 CCW CW CCW CW 1.22 / 439 / 4.777” 0.74 / 266 / 2.889” VSS 1301 CCW CW CCW CW 1.22 / 439 / 4.777” 0.74 / 266 / 2.889” VSS 1501 CCW CW CCW CW 1.36 / 490 / 5.325” 0.82 / 295 / 3.200” VSS 1801 CCW CW CCW CW 1.36 / 490 / 5.325” 0.82 / 295 / 3.200” VSM 71 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 91 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 101 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 151 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 181 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 201 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 301 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 361 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 401 CW CCW CW CCW 0.80 / 288 / 3.141” 0.45 / 162 / 1.767” VSM 501 CCW CW CCW CW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045” VSM 601 CCW CW CCW CW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045” VSM 701 CCW CW CCW CW 0.91 / 328 / 3.568” 0.52 / 187 / 2.045”

NOTE: These refer to the old style gear motors and DO NOT apply to the new optical motors.Rotation for the optical motors is the OPPOSITE of what is shown in the chart.

B. Safety Setpoints

A detailed explanation of all safety setpoints can be found in the Compact Logix PLC manual, p/n 35391CL.

1. Oil Pressure

Low oil pressure differential stops the compressor unit when there is an insufficient difference in pressure between the oil manifold and suction.

2. Discharge Pressure

High discharge pressure cutout stops the compressor unit, when the discharge pressure in the oil separator exceeds the setpoint.

Operation

3. Suction Pressure

Low suction pressure cutout stops the compressor unit when the suction pressure drops below the setpoint.

4. Oil Filter Differential

High oil filter differential cutout stops the compressor unit when the difference between the outlet and inlet of the filter exceeds the setpoint.

5. Oil Temperature

The oil temperature cutout stops the compressor unit when the oil temperature is too high or too low.

6. Discharge Temperature

The high discharge temperature cutout stops the compressor unit when the discharge temperature exceeds the setpoint.

INITIAL START-UP

A. Setting of Controls

(Refer to the appropriate microprocessor manual for a list of initial settings.)

4. Manually open the oil isolating valve at the oil separator outlet connection.

5. Open the isolating valve(s) before and after the oil filter housings.

6. Manually open the stop valve on the oil bleed return line from the element section and open the expansion valve 1/2 of a turn.

STRAINER

SIGHT GLASS

CHECK VALVE

TO COMPRESSOR

HAND EXPANSION VALVE

FIGURE 6.

OIL SEPARATOR BLEED LINE

NOTE: The purpose of the oil bleed return assembly is to collect any oil that passes through the oil separating element and returns that oil to the compressor. The hand expansion valve should be adjusted to prevent an oil level from forming in the sight glass when the compressor is at 100% capacity. Generally 1/2 to 1 turn open is satisfactory.

B. Valve Settings

1. The suction line uses separate stop and check valves. Ensure the suction stop valve is open prior to starting.

2. The ¼” suction equalization valve should be closed during operation. The valve enables the unit to slowly equalize to low side pressure during off periods. This valve must be adjusted to minimize oil loss when compressor stops.

3. The discharge line uses separate stop and check valves. Ensure the discharge valve is open prior to starting.

7. Open 1/4” high pressure gas line valve piped to oil injection line just enough to quiet compressor at 100% capacity.

C. Compressor Pre Start-Up Check List

Before proceeding with actual starting of the compressor, the items listed on the “Pre Start-Up Check List” must be verified. Time and money will be saved before the Vilter start-up technician arrives. (See next page.)

Pre Start-Up Checklists

The following checklists are 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 Refrigeration unit includes a Vilter Start-Up (Conﬁ rm on PO). The following tasks are not included in the Vilter Start-up provided in your equipment purchase. Any tasks below that are done by the Vilter Technician will take away from the pre-determined time that was provided with the equipment purchase. Vilter suggests that the Vilter Technician’s time be used during the start-up of the System and not for the below System Preparation.

Note: Each item below MUST be “Checked-Off”, Signed and Returned to the Vilter Service Department. Failure to do so will “Null & Void” future Warranty considerations.

Field Piping and Mechanical Requirements

NOTE: If start-up service has been purchased, the following items should be completed before the start-

up technician arrives. This will help save time and money.

1. The unit should be leveled and secured to the mounting pad or floor.

2. The suction and Discharge line must be piped and properly supported, independent of the unit

3. The Discharge Stop/Check Valve is shipped loose and must be installed in a vertical up flow direction or in a horizontal line with the valve stem pointing upward at a 45° angle. During off periods, refrigerant can condense in the line downstream of the Discharge Stop/Check Valve. It is recommended the Stop/ Check Valve be located to minimize the quantity of liquid that can accumulate downstream of the valve.

4. A Dual Safety Relief Valve is shipped loose for field installation. A connection is provided on the oil sepa rator for the relief valve. Refer to ASHRAE/ANSI Standard 15 (Safety Code for Refrigeration) for proper sizing and installation of Relief Valves and Vent Lines.

5. Piping For Oil Cooling

a) Liquid Injection

An adequate, or dedicated, liquid line is required for the Liquid Injection System. A high pressure liquid source must be piped to the stop valve at the inlet of the Thermostatic Expansion Valve. On booster units, an additional 3/8” line must be piped to the regulator from high stage discharge gas flow or the Thermostatic Expansion Valve.

b) V-PLUS

A high pressure liquid source must be run to the V-PLUS® inlet. Some subcooling is desirable. A high pressure float must be installed at the inlet of the pump and a 3/8” vent line must be returned to a suction trap. Refer to the V-PLUS manual for additional information.

c) External Oil Cooler

On thermosyphon oil coolers, the refrigerant lines must be connected to the front head of the oil cooler. On water cooled oil coolers, the water lines must be connected to the front head of the oil cooler. Installation of water regulating and solenoid valves are recommended.

6. The oil separator should be provided with oil until the oil level is between the (2) sight glasses. An oil

charging connection is provided on the bottom of the oil separator.

7. The center member of the compressor coupling is shipped loose to help facilitate final field alignment and allow for motor rotation check. The motor alignment should be within 0.004” total indicator read ing in all directions.

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

b) The motor should be checked and shimmed for soft foot prior to attempting final alignment.

c) The center section of the coupling should be left out to allow the start-up technician to verify the

final alignment and motor rotations.

8. The unit should be pressure tested, evacuated and a system load should be available at the time of start-up.

Order #_______________________________Compressor Serial #________________________

Field Wiring Requirements

VRS SCREW COMPRESSOR, VSS/VSM SINGLE SCREW COMPRESSOR UNITS

PRESTART-UP CHECKLIST

FIELD WIRING REQUIREMENTS FOR UNITS WITH FACTORY WIRED VISSION® MICROPROCESSORS

NOTE: If startup service has been purchased, to save time and money, the following items should be completed

before the startup technician arrives.

The unit is pre-wired at the factory. The necessary field wiring connections are described below.

1. Control power of 115 VAC 50/60 HZ must be wired to the left side terminals of the digital I/O board inside the ViSSion® cabinet. Line power (L1) is brought in to a 10-amp fuse via the terminal marked “L1” on the appropriate connector. The neutral (L1A) is brought in and connected to any of the “N” terminals located on left connectors. Two separate line power feeds for the oil heaters are brought to two additional 10 amp fuses via the terminals marked “L2” and “L3” on the same connector just below the “L1” terminal. The neutrals for these circuits (L2A and L3A) are also connected to any of the “N” terminals. For units with V-PLUS® oil cooling, L1 must also be brought to the fuse in the V-PLUS® panel, and L1A must also be brought to the terminal #2B in the V-PLUS® panel.

2. An auxiliary contact from the compressor motor starter is required. This isolated contact is connected to the K-1 input relay using any of the “L” terminals on the strip of connectors, and returned to the terminal marked “Motor Starter Aux. Safety” at the very top connector.

3. A dry contact from control relay K-22 must be wired to the compressor motor starter coil. This dry contact is wired to terminals marked “Compressor Start – N.O. #1A” and “Compressor Start – N.O. #1B”. Control power for this coil should come from a source, which will be de-energized with the compressor disconnect.

4. A dry contact from control relay K-19 must be wired to the oil pump motor starter coil. This dry contact is wired to the two terminals marked “Oil Pump Starter”. Control power for this coil should come from a source, which will be de-energized with the compressor disconnect.

5. An auxiliary safety cutout is available to shut down the compressor package using the K-2 input relay. A dry contact must be supplied and wired to one of the “L” terminals on any of the connectors, and returned to the terminal marked “Auxiliary #1 Safety” at the top connector. The jumper to the “Auxiliary #1 Safety” terminal must be removed to use this cutout. The contact, if closed, will allow the compressor to run. If this contact opens at any time, the compressor will shut down.

6. Indication of the compressor alarm or shutdown status is also available via two control relays. Relay K-20 is provided for remote trip indication and relay K-21 is provided for remote alarm indication. Each relay has three terminals available: a common input, a normally open contact, and a normally closed contact. For both relays, the energized state represents a “trip” or “alarm” condition. Loss of voltage to the relay coil and the resultant return to normal state indicates “safe” condition.

7. The current transformer supplied in the compressor motor conduit box should be checked to insure that the motor leads of one leg are pulled through the transformer. Note that there is a dot on one side of the current transformer. This dot must face away from the motor. Typically, a wye delta started motor should have leads 1 and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as different motors and starting methods will require different leads to be used.

Order #_______________________________Compressor Serial #________________________

Stop Check Valve Operation

AUTO In the “Auto Position”, the stop valve is operating as a check valve, allowing ﬂ ow in the directions of the arrows.

To set the valve to the automatic position, fully close the valve, and turn the stem out as indicated by the chart below.

CLOSED

In the manually “Closed Postion”, the stop check is operating as a conventional stop valve, not allowing ﬂ ow in either direction.

OPEN

In the manually ” Open Position”, with the valve stem fully back seated, the valve disc is lifted slightly, allowing ﬂ ow in either direction.

Valve Size 1.5” 2” 2.5” 3” 4” 5” 6” 8”

Number of Turns Open 2 2.25 2.75 3.25 4.5 3.75 5.75 7.75 (from closed position)

Service

GENERAL COMMENTS

When working on the compressor, care must be taken to ensure that contaminants (i.e. water from melting ice, dirt and dust) do not enter the compressor while it is being serviced. It is essential that all dust, oil or ice that has accumulated on the outside of the compressor be removed before servicing the compressor.

When servicing the compressor, all gaskets, O-rings, roll pins and lock washers must be replaced when reassembling the compressor.

PREPARATION OF UNIT FOR SERVICING

A) Shut down the unit, open the electrical discon-

nect switch and pull the fuses for the compressor motor to prevent the unit from starting. Put a lock on the disconnect switch and tag the switch to indicate that maintenance is being performed.

A) Disconnect the motor drive coupling from the

compressor input shaft.

B) Disconnect all gas and oil piping which is at-

tached to the compressor. When removing the suction strainer on gas compression units, the suction line should be supported to prevent it from sagging.

C) Replace oil drain in compressor housing and dis-

charge manifold after oil has stopped draining.

D) Remove all electrical connections to the com-

pressor.

E) On compressors with mounting feet, loosen and

remove bolts holding the compressor to the base.

B) Isolate the unit by manually closing the discharge

Stop valve. Allow the unit to equalize to suction pressure before closing the Suction Bypass. After the unit has equalized to suction pressure and suction valve closed, use an acceptable means to depressurize the unit that complies with all Local, State and Federal Ordinances.

C) Remove drain plugs from the bottom of com-

pressor housing and the discharge manifold On units equipped with Suction Oil Injection (SOI) manually open the SOI solenoid valve below the compressor. Drain the oil into appropriate containers.

REMOVAL OF COMPRESSOR FROM THE UNIT

After preparing the unit for service, the following steps should be followed when removing the compressor from the unit:

Keep compressor alignment shims together and

mark the locations with a permanent marker.

F) On compressors with C-flange the motor/C-

ﬂ ange/compressor assembly must be supported with a chain fall or other lifting device before the bolts holding the compressor to the C-ﬂ ange adapter can be removed.

G) Install appropriate lifting eye into the threaded

hole on the top of the compressor.

Verify unit is properly secured to avoid compressor

from falling. Re-verify all piping and electrical are properly disconnected prior to lifting unit.

H) Lift compressor from the base, verify the amount

of room needed for clearance and weight of the bare compressor when the compressor is removed from the unit.

Service

INSTALLATION OF THE COMPRESSOR

A) After the work has been completed, reinstall

the compressor on the base or C-ﬂ ange adapter (dependent upon compressor model).

B) On the units, replace the shims under the com-

pressor feet. Check for a soft foot. This is accomplished by tightening down three of the hold down bolts and checking the clearance under the fourth compressor foot. If there is clearance, add the appropriate amount of shims. Tighten down the fourth bolt and loosen either adjacent bolt and check again for clearance, adding shims accordingly. Align the compressor and motor.

On compressors the discharge elbow should be tightened on the separator ﬁ rst, before the compressor manifold ﬂ ange is tightened. This should be done to prevent compressor to motor misalignment.

Replace all electrical, gas and oil connections removed when servicing the compressor.

LEAK CHECKING UNIT

Note: Unit can be leak checked before evacuation.

CAUTION

Slowly pressurize the unit 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.

A) Use a vacuum pump to evacuate the unit.

B) Break the vacuum on the unit using dry nitrogen

and check for leaks. Concentrate on areas where work was done.

C) If no leaks are found, the unit can be returned to

service.

Rotor Being Pushed By

Direction of rotor movement. Axial force at coupling to be 250-300lbs.

Rigidly attach dial indicator. Position it on the axis of the compressor.

Force to be determ ined by length of level arm.

Showing gate rotor bearing float

Direction of rotor movement. Axial force at gate rotor to be 250 to 300 lbs.

Top Vie w

Use Of Lever

Side View

being measured.

Service

Small wooden block or fulcrum.

Wooden block to prev ent damge to gate rotor blade.

COMPRESSOR INSPECTION

The Vilter Single Screw Compressor is designed for long periods of trouble free operation with a minimum of maintenance. However, a yearly inspection is recommended so any irregular wear is noted and rectiﬁ ed. At this time, the bearing ﬂ oat is measured for the main rotor and gate rotors.

The following are the procedures used in measuring the main rotor and gate rotor bearing ﬂ oat.

BEARING CHECK

CAUTION

When taking the measurements, do not exceed 250 to 300 Lbs. of force at point of contact or damage may result to the bearings

A) Shut down and de-pressurize the unit.

Rigidly attach dial indicator.

Direction of rotor movement. Axial force at gate rotor to be 250 to 300 lbs.

Rigidly attach dial indicator.

Use bolt for fulcrum.

Side View

Showing gate rotor bearing float

being measured.

Use bolt for fulcrum.

Force to be determined by length of level arm.

Wooden block to prev ent damge to gate rotor blade.

Force to be determined by length of level arm.

B) Main rotor bearing ﬂ oat.

1) Remove the coupling guard, then remove the center member from the coupling.

2) Attach a dial indicator to the compressor frame as shown and zero indicator. Place a lever arm and fulcrum behind the compressor coupling half and push the coupling towards the motor (note measurement).

TABLE.1 MAXIMUM BEARING FLOAT

MAIN GATE Bearing Float 0.003” 0.002” Maximum Force 250 to 300 50 to 100 Lbs. Lbs.

3) Re-Zero indicator, now position the fulcrum on the motor and use the lever arm to push the input shaft towards the compressor (note measurement).

Service

4) Add both readings, the total indicator movement is the bearing ﬂ oat and this should not exceed 0.003”.

C) Gate rotor bearing ﬂ oat.

1) Remove the side covers and position a dial indicator on the gate rotor.

2) Use a lever arm pivoting on a bolt with a small block of wood against the gate rotor blade to protect the blade.

3) The maximum amount of bearing float should not exceed 0.002”.

TABLE 2. GATE ROTOR FLOAT

MODEL FLOAT VSM 301 THRU 401 0.045” VSM 501 THRU 701 0.045” VSS 291 THRU VSS 601 0.045” VSS 751 & VSS 901 0.055” VSS 1051 THRU VSS 1301 0.060” VSS 1551 & VSS 2101 0.060”

E) NOTE: Readings could be higher than 0.020.

If readings are greater than 0.030 over table tolerance contact Vilter’s home office.

F) Inspect the main and gate rotors for signs of ab-

normal wear due to dirt or other contaminants.

G) After the inspection is complete, the covers,

coupling center member and guard can be reinstalled and the unit can then be evacuated and leak checked before starting.

D) Measure the gate rotor to blade float. Some

movement between blade and support is necessary to prevent damage to the compressor blade, however at no time should the blade uncover the support.

1) Position the blade with the gate rotor damper pin and 90º to the main rotor.

2) Position a dial indicator at the tip of the support. The total movement of the damper pin in the bushing is the gate rotor ﬂ oat. Refer to table 0.2 to ﬁ nd the maximum blade to sup- port ﬂ oat (on new compressor parts only).

Service

GATE ROTOR ASSEMBLY CAUTION

Gate rotor removal and assembly is divided into distinct instructions, instructions for all VSS models and different instructions for all VSM models. Please follow the appropriate set of instructions.

For VSM 451 thru 601 compressors, do not use side rails.

901A

For VSS 751/901 & VSS 1051 THRU 1301 compressors, use side rails and assemble to gaterotor stabilizer as stamped.

Drive End

901B

901D

901C

REMOVAL

A) Prepare the compressor for servicing.

NOTE: All parts must be kept with their appro-

priate side and not mixed when the compressor is reassembled.

B) Remove two upper bolts from the side cover,

and install guide studs in the holes. Remove the remaining bolts and side cover. There will be some oil drainage when the cover is removed.

C) Turn the main rotor so a driving edge of any one

of the main rotor grooves is even with the back of the gate rotor support.

D) Insert the gate rotor stabilizer. The side rails are

not required on VSS 451 thru 601. For the VSS 751 thru 901 and VSS 1051 thru 1301 compressors, use the side rails and assemble to the gate rotor stabilizer as stamped. For the VSS 1551 thru 3001, use the side rails and assemble to the gate rotor stabilizer.

The gate rotor stabilizer is designed to hold the gate rotor support in place and prevent damage to the gate rotor blade as the thrust bearings and housing is being removed.

Service

E) Remove the hex head and socket head bolts from

the thrust bearing cover. Insert two of the bolts into the threaded jacking holes to assist in removing the cover. Retain the shim pack and keep it with the bearing housing cover.

F) Hold the gate rotor support with a suitable wrench

on the ﬂ ats provided near the roller bearing hous- ing. Remove the inner retainer bolts and the retainer. To remove the thrust bearing housing, install the thrust bearing removal and installation tool with the smaller puller shoe. Turn the jacking screw clockwise. The thrust bearings and housing assembly will be pulled off the shaft and out of the frame.

G) Remove the bolts on the roller bearing housing.

Thread two bolts into the jack screw holes provided in the housing to assist in removing it.

H) To remove the gate rotor support, carefully move

the support opposite the direction of rotation and tilt the roller bearing end towards the suction end of the compressor. The compressor input shaft may have to be turned to facilitate the removal of the gate rotor support. On dual gate compressor units, repeat the procedure for the remaining gate rotor support assembly.

Service

REMOVAL (ALL VSM 301-701 MODELS)

The removal of the gate rotor assembly for the VSM 301-701 compressors is similar for the VSS 9013001 compressors. The inner races are secured to the stationary bearing spindle.

A) Prepare the compressor for servicing.

B) Remove the upper bolt from the side cover and

install a guide stud in the hole. Remove the remaining bolts and side cover. There will be some oil drainage when the cover is removed.

C) The side cover that contains the suction strainer

should have the suction line properly supported before the bolts securing the line to the cover can be removed. After the line is removed, the cover can be removed per paragraph B.

D) Turn the main rotor so the driving edge of the

groove is between the top of the shelf or slightly below the back of the gate rotor support. At this point install the gate rotor stabilizing tool.

Service

E) Remove plug on the thrust bearing housing.

Loosen the socket head cap screw that is located underneath the plug. This secures the inner races of the thrust bearings to the spindle.

F) Remove bolts that hold the thrust bearing hous-

ing to the compressor. Insert two of the bolts into the threaded jacking holes to assist in removing the bearing housing from the compressor. When the housing is removed, there will be shims between the spindle and thrust bearings. These control the clearance between the shelf and gate rotor blades. These must be kept with their respective parts for that side of the compressor.

G) Remove the bolts from the roller bearing housing.

After the bolts have been removed, the housing can be removed from the compressor.

H) To remove the gate rotor support, carefully move

the support opposite the direction of rotation and tilt the roller bearing end towards the suction end of the compressor. The compressor input shaft may have to be turned to facilitate the removal of the gate rotor support. On dual gate versions, repeat the procedure for the remaining gate rotor support assembly.

Service

INSTALLATION (All VSS Models)

A) Install the gate rotor support by carefully tilting

B) Install the roller bearing housing (112) with a

C) When installing the thrust bearing housing

the roller bearing end of the gate rotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gate rotor support.

Install gate rotor stabilizer. The gate rotor stabilizer (901) will hold the gate rotor support in place as the thrust bearing housing is being installed. If the gate rotor support is not restricted from moving, the gate rotor blade may be damaged.

new O-ring (141). Tighten the bolts (152) to the recommended torque value.

(113), a new O-ring (142) must be used when the housing is installed. Lubricate the outside of the housing and bearings with clean compressor oil to aid in the installation. Due to the ﬁ t of the bearings on the gate rotor shaft, the thrust bearing removal and installation tool with the pusher shoe must be used. Turn the jacking screw clockwise. This will push the thrust bearings onto the shaft and push the housing assembly into the frame. Install the inner retainer (115) and bolts (151) using Loctite® 242 thread locker. Tighten the bolts to the recommended torque value.

Service

D) Set the clearance between the gate rotor blade

and the shelf.

1. Place a piece of 0.003”-0.004” shim stock between the gate rotor blade and the shelf.

2. Measure the depth from the top of the compressor case to the top of the thrust bearing housing. This determines the amount of shims needed for the correct clearance.

3. Use factory installed shim pack (106) and bearing housing cover (116) without the Oring (143). Check the clearance between the entire gate rotor blade and the shelf, rotate the gate rotor to ﬁ nd the tightest spot. It should be between 0.003”-0.004”. Make adjustments, if necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf.

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.

E) 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.

F) Install side cover with a new gasket. Tighten the

bolts to the recommended torque value. The unit can then be evacuated and leak checked as outlined in section 0.03.

Gaterotor for C-ﬂ ange Models

Service

INSTALLATION (All VSM 301-701 Models)

A) Install the gate rotor support. Carefully tilt the

roller bearing end of the gate rotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gate rotor support.

B) Install the roller bearing housing with a new

O-ring. Tighten the bolts to the recommended torque value.

C) Install the spindle with shims and o -ring, tighten

the bolts to the recommended torque value, measure the clearance between the shelf and blade.

D) Check the clearance between the entire gate

rotor blade and the shelf, rotate the gate rotor to ﬁ nd the tightest spot. It should be between

0.003”-0.004”. Make adjustments, if necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf.

E) 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 to the recommended torque values.

F) Install side covers with new gaskets. Tighten

bolts to the recommended torque value. The unit can now be evacuated and leak checked as outlined in section 0.03.

Service

GATE ROTOR BLADE REMOVAL

A) Remove the gate rotor assembly.

B) Remove the snap ring and washer from the gate

rotor assembly. Lift gate rotor blade assembly off the gate rotor support.

C) Check damper pin and bushing for excessive wear.

Replace if necessary.

TOP of assembly

Relief area faces TOP of assembly.

(with Relief)

Service

GATE ROTOR BLADE INSTALLATION

A) Install damper pin bushing (120) in gate rotor

blade (111) from the back side of the blade. Be sure the bushing is fully seated.

B) Place the blade assembly on the gate rotor sup-

port. Locating Damper over pin.

C) Install washer (119) and snap ring (130) on gate

rotor assembly. The bevel on the snap ring must face away from the gate rotor blade. After the gate rotor blade and support are assembled, there should be a small amount of rotational movement between the gate rotor and support.

D) For installation of the gate rotor assembly and

setting of gate rotor clearance, refer to section INSTALLATION (All VSM 301-701 Models).

GATE ROTOR THRUST BEARING REMOVAL

A) Refer to section INSTALLATION (All VSS Models)

for removal of the gate rotor bearing housings and gate rotor supports.

B) For removal of thrust bearings on VSM units:

1) Remove bolts (150) from the clamping ring (114).

2) Remove thrust bearing clamping ring.

3) Remove thrust bearings (126) from housing (113).

C) For removal of thrust bearings on VSS units:

1) Remove retaining ring from gate rotor support.

2) Remove bearings from support.

3) Remove bearing retainer from inner race.

VSS Models

GATE ROTOR THRUST BEARING INSTALLA-

TION

A) For installation of thrust bearings on VSS units:

1) Install bearings (126) in the housing so the bearings are face to face.

The larger sides of the inner races are placed together. A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the housing.

2) Center the bearing retainer ring on housing, use Loctite® 242-thread locker and evenly tighten the bolts to the recommended torque value.

3) For installation of the bearing housing and the setting of the gate rotor blade clearance, refer to section INSTALLATION (All

VSS Models).

Service

B) For installation of thrust bearings on VSM 301-

701 units:

1) Install retainer in the back of the inner race of one of the thrust bearings. The back of the inner race is the narrower of the two sides.

2) The bearing with the retainer should be placed in the housing first, retainer towards the support. Install the second bearing. The bearings should be positioned face to face. This means that the larger sides of the inner races are placed together. A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the gate rotor support.

3) Install the bearing retaining snap ring.

4) For installation of the bearing housing and the setting of the gate rotor blade clearance, refer to section INSTALLATION (All

VSM Models).

Inner Retainer

Ball Bearings

Retaining Ring

VSM Models

Service

GATE ROTOR ROLLER BEARING REMOVAL

A) Refer to section REMOVAL ( All VSS & VSM) for

B) Remove the snap ring (131), which retains the

C) Remove the roller bearing (125) from the bearing

D) Use a bearing puller to remove the roller bearing

GATE ROTOR ROLLER BEARING INSTALLATION

A) Match up the part numbers on the inner race to

removal of the gate rotor bearing housings and gate rotor supports.

roller bearing in the bearing housing.

housing (112).

race (125) from the gate rotor support (110).

the part numbers outer race. Press the bearing race (numbers visible) onto the gate rotor support.

B) Install the outer bearing into the bearing housing

so the numbers match the numbers on the inner race. Install the snap ring retainer in the housing. The bevel on the snap ring must face away from the roller bearing.

C) For installation of the bearing housing, refer to

section INSTALLATION (All VSS & VSM Models).

Service

COMPRESSOR SHAFT SEAL REPLACEMENT

COMPRESSOR SHAFT SEAL REMOVAL

A) Prepare the compressor for servicing as outlined

in section REMOVAL.

B) Remove bolts (281) holding the shaft seal cover

(218). Insert two of the bolts into the threaded jacking holes to assist in removing the cover. There will be a small amount of oil drainage as the cover is removed.

C) Remove the rotating portion of the shaft seal

(219C).

D) Remove oil seal (230) from cover.

Current Shaft Seal and for all Replacements.

(Roll Pin #265 only used on VSS 751 and

larger models.)

E) Remove the stationary portion of the shaft seal

(219B) from the seal cover using a brass drift and hammer to tap it out from the back side of the seal cover.

Seal with stationary carbon face (219B) and rotating mirror face (219C).

Service

Seal Assembly w/ Stationary Mirror Face

COMPRESSOR SEAL INSTALLATION

NOTE: When replacing the stationary members of the seal on the VSS 451 thru VSS 601 the roll pin in the cover is used only with the seal assembly having a stationary mirror face. If a seal assembly with a stationary carbon face is installed, the roll pin must be removed.

A) Install new oil seal in cover.

CAUTION Care must be taken when handling the shaft seal and mirror face so it is not damaged. Do not touch the carbon or mirror face as body oil and sweat will cause the mirror face to corrode.

B) To install the carbon cartridge part of the seal

in the seal cover; clean the seal cover, remove protective plastic from the carbon cartridge, do not wipe or touch the carbon face. Lubricate the sealing O-ring with clean compressor lubricating oil. If applicable, align the hole on the back of the carbon cartridge with the dowel pin in the seal cover. Install cartridge using seal installation tool or similar (see tool lists).

C) Wipe clean, the compressor input shaft and the

shaft seal cavity in the compressor housing. Apply clean compressor oil to the shaft seal seating area on input shaft.

D) 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. Carefully push the seal on, holding onto the outside area of the seal until the seal seats against the

Service

shoulder on the input shaft. Make sure the seal is seated against the shoulder. If the seal is not fully seated against the shoulder, the shaft seal carbon will be damaged when the seal cover is installed.

Maintenance Suggestion:

A spray bottle ﬁ lled with clean compressor oil

may be used to lubricate the faces of the seals without touching the seal.

E) Install a new O-ring on the seal cover, making

sure the O-ring is placed in the O-ring groove and not the oil gallery groove. Lubricate both seal faces with clean compressor lubricating oil.

F) Carefully install the seal cover on the compressor

shaft, evenly tightening the bolts to the recommended torque values.

G) Install the coupling and coupling guard. The unit

can then be evacuated and leak checked.

MAIN ROTOR ASSEMBLY

Due to the procedures and tools involved in the disassembly and reassembly, the main rotor assembly must be performed by qualified individuals. Please consult the factory if maintenance is required.

Service

INSPECTION OF SLIDE VALVE ASSEMBLIES IN

THE COMPRESSOR

Prepare the compressor for servicing.

A) Remove the gate rotor access covers. Using a

mirror and ﬂ ashlight, visually inspect the slide valve carriage through the gas bypass opening. Look for any signiﬁ cant signs of wear on the slide valve carriage.

B) To check the clearance of the slide valve clamps,

the gate rotor support must be removed. Refer to removal of the gate rotor support.

C) Using a feeler gauge, inspect the clearance be-

tween capacity and volume slide valve clamps and slide valve carriage through the gas bypass opening. The clearance should be less than

0.002”.

D) If the slide valves are worn in excess of the toler-

ances, the factory should be contacted.

REMOVAL SLIDE VALVE CARRIAGE ASSEM-

BLIES

A) Prepare the compressor for servicing.

B) If only one of the slide valve carriages is removed

only the corresponding gate rotor support needs to be removed. If both carriages are removed both gate rotors must be removed. Remove the gate rotor assemblies.

C) Remove the capacity and volume actuators.

Remove the discharge manifold, capacity and volume cross shafts and the slide valve racks.

Service

D) Locate and remove the socket head plugs above

the slide valve carriage attachment bolts. Remove the bolts located under the plugs.

E) The slide valve carriage may now be removed.

On newer carriages there is a threaded hole in the back of the slide valve carriage to aid in its removal. Use a threaded tip slide hammer to aid in the removal of the carriage.

Note: Slide Valves may be re-positioned to aid in removal of assembly.

INSTALLATION OF SLIDE VALVE CARRIAGE AS-

SEMBLIES

A) Position the slide valves to the center of the car-

riage. Place the slide valve assembly in the bore of frame and use the slide hammer to slowly tap the carriage into position. Re-positioning slide valves once inside bore may aid installation. Adjust the carriage so that the 3-holes line up.

B) Install the 3 socket head cap screws with new

Nord-Lock washers beneath the heads, but do not tighten them.

C) Work a piece of 0.005”shim stock between the

slide valves and the main rotor to help position the carriage.

D) Tighten, to the correct torque the hold down

bolts to secure the carriage in the frame. The edges of the slide valves themselves should be at or slightly below the main rotor bore.

E) Re- Install the capacity and volume slide valve

cross shafts, slide valve racks and discharge manifold.

F) Re-install the gate rotor assemblies.

Service

COMMAND SHAFT ASSEMBLY REMOVAL

The following steps can be used to remove or install either the capacity or volume command shaft assemblies.

A) Prepare the compressor for servicing.

B) Follow the appropriate instructions to remove

control actuator.

C) Remove four socket head cap screws (457) and

Nord-Lock washers (477) securing mounting plate (415) to manifold.

D) The command shaft and mounting plate may

now be removed from the compressor.

477

457

415

COMMAND SHAFT ASSEMBLY INSTALLATION

A) Install the command shaft assembly with a new

o-ring (446) on the manifold. Make sure that the command shaft tongue is engaged in the cross shaft slot. Rotate the bearing housing so the vent holes point down, this will prevent water and dust from entering the vents.

B) Install the actuator mounting plate with the four

socket head cap screws and Nord-Lock washers securing it with proper torque.

C) The unit can now be leak checked.

COMMAND SHAFT BEARING AND O-RING SEAL

REPLACEMENT

A) Remove command shaft assembly.

B) Remove snap ring retainer (451) from command

shaft housing (412). Push the command shaft assembly out of the housing.

436

445

Vent hole.

Service

C) The command shaft bearing (435) is a press

ﬁ t on the command shaft (413). Remove the command shaft bearing with a suitable press.

Reference “Parts

Section” for current

Housing

D) Remove the O-ring seal (445) from the com-

mand shaft housing. The command shaft bushing (433 and 436) might have to be removed to gain access to o-rings. Replace bushing if the bore is deeply scored or excessively worn.

COMMAND SHAFT BEARING AND O-RING

SEAL REASSEMBLY

DISCHARGE MANIFOLD REMOVAL

A) Remove both control actuators and command

shaft assemblies.

B) On VSS 451-3001 compressors, remove the dis-

charge spool between the manifold and separator. Remove one bolt from each side of the discharge manifold and install (2) guide rods approximately 6” long, to support the manifold. Remove the remaining bolts (note length and location of bolts) and take off the discharge manifold.

Note: Mainfold has dowel pins to locate it on the

compressor housing. Therefore, remove manifold straight back approximately 1” as not to break dowel pins.

A) Install new O-ring seal in housing and lubricate

the O-ring with clean compressor oil. A vent hole is provided in the command shaft bearing housing to allow any refrigerant and oil that may leak past the O-ring seal to vent to atmosphere and not into the slide valve motor housing. Install snap ring retainer and washer on the command shaft.

B) Remove any burrs from the command shaft to

prevent damage to the O-ring when assembling. Press the command shaft bearing onto the command shaft. Insert the command shaft into the housing applying pressure on outer race of bearing. Make sure the bearing is fully seated in the command shaft housing. Install the snap ring retainer in the command shaft housing.

C) Install command shaft assembly.

NOTE:

When removing the discharge manifold on VSM 301-701 compressor the compressor must be properly supported to keep the compressor from moving when the manifold is removed.

C) On VSM 301-701 compressors unbolt the dis-

charge ﬂ ange from the discharge manifold.

D) Remove one bolt from each side of the discharge

manifold and install (2) guide rods approximately 6” long, to support the manifold. Remove the remaining bolts (note length and location of bolts) and take off the discharge manifold.

Service

DISCHARGE MANIFOLD INSTALLATION

A) Install (2) guide rods to position the discharge

manifold. Install a new manifold gasket and the discharge manifold. Install the dowel pins and bolts, tighten manifold bolts to the recommended torque value.

B) On VSS 451-3001 compressors install the dis-

charge spool or elbow between the discharge manifold and oil separator with new gaskets. When installing the discharge elbow tighten the bolts to the correct torque on the manifold flange first before tightening the separator ﬂ ange bolts. Install the drain plug in the bottom of the discharge manifold.

C) On VSM 301-701 compressors install the bolts

in the discharge ﬂ ange. Install the drain plug in the bottom of the discharge manifold.

D) Install both command shaft assemblies and

control actuators.

F) Look for any excessive wear on all moving parts

and replace the worn parts.

G) Reassemble the manifold and discharge elbow.

REMOVAL OF CAPACITY OR VOLUME CROSS

SHAFTS

SLIDE VALVE GEAR AND RACK INSPECTION

A) Remove the discharge manifold.

B) Check rack to rack clamp and rack clamp spacer

clearance on all four slide valves.

TABLE 4.1

RACK CLEARANCE VALUES

MEASUREMENT CLEARANCE Rack to clamp. 0.005 to 0.010” Rack to clamp spacer. 0.003 to 0.005”

C) Check torque of socket heat cap screws.

D) Check for excessive movement between the

slide valve rack shafts and the rack. The jam nuts on the end of the slide valve rack shaft should be tight.

E) Check for loose or broken roll pins in gears.

A) Remove the discharge manifold.

B) To remove the capacity or volume ratio slide

valve racks, remove the two jam nuts and lock washers (361) securing the rack (316) to the slide valve shafts. The racks can now be pulled off the slide valve shafts. Repeat the procedure for the remaining pair of slide valve racks.

Service

C) To remove the cross shafts, remove socket head

bolts, clamp and spacers from both sides.

VSS 751-2101 compressors cross shafts.

VSM 301-701 & VSS 2601-3001 compressors

cross shafts

Volume control cross shaft.

INSTALLATION OF CAPACITY OR VOLUME

CROSS SHAFTS

A) To reassemble either set of capacity or volume

ratio slide valve racks, install the cross shaft with the pinion gear onto the back plate, place the remaining pinion gear on the shaft and drive in the roll pins. Install clamps, spacers and bolts on both sides. Tighten the bolts to the recommended torque values.

B) The slide valve sets must be synchronized on VSS

451-3001 and dual gate VSM 301-701 units. Both slide valve racks for either the volume ratio or capacity slide valves must engage the cross shaft gears at the same time. Push the racks all the way towards the suction end of the compressor until they stop. Install washers and jam nuts on the slide valve shafts. Repeat the procedure for the remaining set of slide valve racks.

Capacity control cross shaft.

D) Drive the roll pins from pinion gear from one

side. Remove pinion gear. Slide the cross shaft with the remaining pinion gear or spacers out of the opposite side. Repeat the procedure for the remaining cross shaft.

C) Install (2) guide rods to position the discharge

manifold. Install a new manifold gasket and the discharge manifold. Install the dowel pins and bolts, tighten manifold bolts to the recommended torque value.

Torque Specifications (ft-lbs)

Type

Bolt

SAE Grade 2

Coarse (UNC)

SAE Grade 5

Coarse (UNC)

SAE Grade 5

Coarse (UNC)

SAE Grade 8

Coarse (UNF)

Socket Head

Cap Screw

(ASTM A574)

Coarse (UNC)

1) Torque values in this table are not to override other speciﬁ c torque speciﬁ cations when supplied.

2) When using loctite, torque values in this table are only accurate if bolts are tightened immediately after loctite is applied.

* The proof strength of Grade 2 bolts is less for sizes 7/8 and above and therefore the torque values are less than smaller sizes of the same grade.

Head

Markings

#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

Nominal Size Numbers or Inches

Torque Specifications for 17-4 Stainless Steel Fasteners (ft-lbs)

Type

Bolt/Nut

Hex & Socket

Head Cap Screws

Nut -8-25-----

NOTE: Continue use of red loctite #271 (VPN 2205E) on currently applied locations. Use blue loctite #243 (VPN 2205F or 2205G) on all remaining locations.

Head

Markings

#10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4

3 8 14 25 40 60 101 137 245

Nominal Size Numbers or Inches

Service

USING A TORQUE WRENCH CORRECTLY

TORQUE WRENCHES

USING A TORQUE WRENCH CORRECTLY INVOLVES FOUR PRIMARY CONCERNS:

A. A smooth even pull to the break point is required. Jerking the wrench can cause the pivot point

to break early leaving the bolt at a torque value lower then required. Not stopping when the break point is reached results in an over torque condition.

B. When more than one bolt holds two surfaces together there is normally a sequence that

should be used to bring the surfaces together in an even manner. Generally bolting is tightened incrementally in a diametrically staggered pattern. Some maintenance manuals specify a tightening scheme. If so, the manual scheme shall be followed. Just starting on one side and tightening in a circle can cause the part to warp, crack, or leak.

C. In some cases threads are required to be lubricated prior to tightening the bolt/nut. Whether

a lubricant is used or not has considerable impact on the amount of torque required to achieve the proper preload in the bolt/stud. Use a lubricant, if required, or not if so speciﬁ ed.

D. Unlike a ratchet wrench a torque wrench is a calibrated instrument that requires care. Recali-

bration is required periodically to maintain accuracy. If you need to remove a bolt/nut do not use the torque wrench. The clockwise/counterclockwise switch is for tightening right hand or left hand threads not for loosening a fastener. Store the torque wrench in a location where it will not be bumped around.

Service

A. The Nord-Lock® lock washer sets are used in many areas in both the VSG & VSSG screw compressors that require a vibration proof lock washer.

B. The lock washer set is assembled so the course serrations that resemble ramps are mated together.

C. Once the lock washer set is tightened down, it takes more force to loosen the bolt that it did to tighten it. This is caused by the washers riding up the opposing ramps.

Service

6.00 OIL FILTER ELEMENTS

The following is a description of the oil filter elements supplied on standard VSS, VSR and VSM single screw compressor units

6.01 1833C FILTER ELEMENTS

Vilter Part Number 1833C

Usage VSS 451 to VSS 1801 Dates All units prior to 3-1-00 Length 18” Diameter 6-1/8”

A) Characteristics;

1) The outside of the filter element is covered with a perforated metal surface.

2) At each end of the filter, there is a large thick elastomeric seal.

3) The housing is a fabricated steel housing with bolted end cover. The housing can contain one or two elements.

4) Simplex filter housing is standard with duplex filter housings with a bypass valve arrangement is optional, so that the filter can be changed while unit is in operation.

6.02 KT 721 FILTER ELEMENTS

Vilter Part Number KT 721

Tank O-Ring 2176BU Usage VSR Compressors Dates 1992 to 8-1-96 Length 8”

A) Characteristics;

1) Pleated type element with a screen covering the surface of the element.

2) One end of the element is solid while the other has a pilot hole with a captive “o”-ring.

Service

6.03 KT 722 FILTER ELEMENTS

Vilter Part Number KT 722

Tank O-Ring 2176AJ Usage VSR Compressors Dates 1996 to 2002 Length 16.8”

A) Characteristics;

1) Pleated type element with a screen covering the surface of the element.

2) One end of the element is solid while the other has a pilot hole with a captive “o”-ring.

Service

6.04 KT 773A & B FILTER ELEMENTS

Vilter Part KT 773A KT 773B Number

Tank O-Ring 2176BY 2176BZ

Usage 3109A 3111A Duplex Simplex Housing Housing Usage 1. VSM all models 4/1/00 to present.

2. VSS 451 to 1301 models with 30” and smaller oil separators 3/1/00 to present. Length 16”

A) Characteristics;

1) Pleated type element with a screen covering the surface of the element.

2) One end of the element is solid while the other has a pilot hole with a captive “o”ring.

3) On duplex models only the end cap is removed from the filter bowl

B) Usage;

1) Used in simplex and duplex applications.

2) The O-rings for the simplex and duplex housings are not interchangeable.

Simplex filter housing. Duplex filter housing.

6.05 KT 774 FILTER ELEMENTS

Vilter Part KT 774 Number Tank O-Ring 2176BY

Usage 3112A 3110A Simplex Duplex Housings Housings

1. VSS 1501 & 1801 3-1-00 to present.

2. All other VSS models with 30” and larger oil separators 3/1/00 to present. Length 39”

Service

Simplex filter housing.

C) Characteristics;

1) Pleated type element with a screen covering the surface of the element.

2) One end of the element is solid while the other has a pilot hole with a captive “o”-ring.

3) Only end cap is removed from the filter bowl.

D) Usage;

1) Used in simplex and duplex applications.

Maintenance

Refrigeration Maintenance and Inspection Schedule

The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrigeration oil in VSS, VSM and VSR Single Screw Compressor units.

Inspection

SERVICE INTERVAL (HOURS)

Or Group Maintenance Item

OIL CIRCUIT Oil Change (1) R R R R R R R Oil Analysis (2) S S S S S S S S S S S S S Oil Filters (3) R R R R R R R R R R R R R R Oil Strainer I I I I I I I I I I I I I I PACKAGE Coalescing Elements R R R R Suction Screen I I I I I I I I I I I I I I Liquid Line Strainers I I I I I I I I I I I I I I Coupling Alignment and Integrity I I I I I I I I I I I I I I CONTROL CALIBRATION Transducers I I I I I I I I I I I I I I RTD’s I I I I I I I I I I I I I I COMPRESSOR Inspect Compressor I I I I I I I Bearings I

200

5,000

10,000

20,000

30,000

40,000

50,000

60,000

70,000

80,000

90,000

100,000

110,000

120,000

Key I Inspect. R Replace. S Sample.

Notes: (1) The oil should be changed at these intervals, unless oil analysis results exceed the allowable limits. The frequency of changes will depend on the system cleanliness.

(2) Oil analysis should be done at these intervals as a minimum; the frequency of analysis will depend on system cleanliness.

(3) The oil filter(s) on a minimum must be changed at these intervals or annually if not run continuously. However, the oil filter(s) must be changed if the oil filter differential exceeds 12 psi or oil analysis requires it.

NOTE: See Motor Manual for proper lubrication procedures and service intervals.

VSS Parts Section

Recommended Spare Parts List

Refer to the Custom Manual

Spare Parts Section for Speciﬁ c Applications

Please have your Model # and Sales Order # available when ordering.

These are found on the compressor’s Name Plate.

125

131

141

130

Gate Rotor

119

111

120

135

110

126

118

142

143

121 122 123 124

Gate Rotor

MODEL NUMBER

VSS 451 VSS 601 VSS 751

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN

GATE ROTOR BLADE AND BEARING REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 141, 142, 143) 2 KT712A 2 KT712B 2 KT712C GATE ROTOR BLADE REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 130, 141, 142, 143) 2 KT713A 2 KT713B 2 KT713C 102 GATE ROTOR SUPPORT ASSEMBLY (100, 111, 120B, 119, 130) 2 A25161BB 2 A25161BA 2 A25161CB 105 GATE ROTOR GASKET SET (118, 141, 142, 143) 2 A25164B 2 A25164B 2 A25164C 106 SHIM PACK SET ((2) 121, (2) 122, (1) 123, (1) 124) 2 A25165B 2 A25165B 2 A25165C 110 SUPPORT 2 25606A 2 25520A 2 25612A 111 GATE ROTOR 2 25557A 2 25534A 2 25608A 112 SMALL BEARING HOUSING 113 LARGE BEARING HOUSING 114 RETAINER 115 RETAINER 116 BALL BEARING COVER 117 GATE ROTOR COVER 118 GATE ROTOR COVER GASKET 119 WASHER 120A BUSHING, SMALL DOWEL PIN 120B BUSHING, LARGE DOWEL PIN 121 SHIM 0.002” 122 SHIM 0.003” 123 SHIM 0.005” 124 SHIM 0.010” 125 ROLLER BEARING 126 BALL BEARING 130 RETAINING RING 131 RETAINING RING 135A DOWEL PIN, SM, 0.250” O.D. 135B DOWEL PIN, LG, 0.4375” O.D. 141 O-RING ROLLER BEARING HOUSING 142 O-RING BALL BEARING HOUSING 143 O-RING BRG HSG COVER 150 HEX HEAD CAP SCREW 151 HEX HEAD CAP SCREW 152 HEX HEAD CAP SCREW 153 HEX HEAD CAP SCREW 160 SOCKET HEAD CAP SCREW

2 25518A 2 25517A 2 25008A 2 25009A 2 25258A 2 25519A 2 25259A 2 25007A 2 25006A 2 25760A AR 25010AA AR 25010AB AR 25010AC AR 25010AD 2 2864B 4 2865B 2 2866A 2 2867A 2 2868B 2 25910A 2 2176M 2 2176R 2 2176N 12 2796AJ 6 2796B 40 2796CJ 32 2796E 12 2795E

- N/A

- N/A 2 25088A 2 25086A 2 25087A 2 25760B AR 25089AA AR 25089AB AR 25089AC AR 25089AD 2 2864C 4 2865A 2 2866B 2 2867E 2 2868F 2 25910B 2 2176N 2 2176V 2 2176U

- N/A

Gate Rotor

MODEL NUMBER

VSS 901 VSS 1051 VSS 1201 VSS 1301

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

GATE ROTOR BLADE AND BEARING REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 125, 126, 130,131, 141, 142,

143) 2 KT712D 2 KT712E 2 KT712F 2 KT712Y GATE ROTOR BLADE REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 130, 141, 142, 143) 2 KT713D 2 KT713E 2 KT713F 2 KT713Y 102 GATE ROTOR SUPPORT ASSEMBLY (100, 111, 120B, 119,

130) 2 A25161CA 2 A25161DB 2 A25161DA 2 A25161DH 105 GATE ROTOR GASKET SET (118, 141, 142, 143) 2 A25164C 2 A25164D 2 A25164D 2 A25164D 110 SUPPORT. 2 25553A 2 25614A 2 25587A 2 25587A 111 GATE ROTOR 2 25554A 2 25610A 2 25588A 2 25588F 118 GATE ROTOR COVER GASKET 2 25088A 2 25132A 2 25132A 2 25132A 119 WASHER 2 25086A 2 25086A 2 25086A 2 25086A 120A BUSHING, SMALL DOWEL PIN 2 25087A 2 25104A 2 25104A 2 25104A 120B BUSHING, LARGE DOWEL PIN 2 25760B 2 25760B 2 25760B 2 25760B 121 SHIM 0.002” AR 25089AA AR 25089AA AR 25089AA AR 25089AA 122 SHIM 0.003” AR 25089AB AR 25089AB AR 25089AB AR 25089AB 123 SHIM 0.005” AR 25089AC AR 25089AC AR 25089AC AR 25089AC 124 SHIM 0.010” AR 25089AD AR 25089AD AR 25089AD AR 25089AD 125 ROLLER BEARING 2 2864C 2 2864G 2 2864G 2 2864G 126 BALL BEARING 4 2865A 4 2865A 4 2865A 4 2865A 130 RETAINING RING 2 2866B 2 2866B 2 2866B 2 2866B 131 RETAINING RING 2 2867E 2 2867L 2 2867L 2 2867L 135A DOWEL PIN, SMALL, 0.3125” O.D. 2 2868F 2 2868H 2 2868H 2 2868H 135B DOWEL PIN, LARGE, 0.4375” O.D. 2 25910B 2 25910B 2 25910B 2 25910B 141 O-RING ROLLER BEARING HOUSING 2 2176N 2 2176AJ 2 2176AJ 2 2176AJ 142 O-RING BALL BEARING HOUSING 2 2176V 2 2176AM 2 2176AM 2 2176AM 143 O-RING BEARING HOUSING COVER 2 2176U 2 2176U 2 2176U 2 2176U

Gate Rotor

MODEL NUMBER

VSS 1551 VSS 1851 VSS 2101

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN

GATE ROTOR BLADE AND BEARING REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 141, 142 & 143) 2 KT712L 2 KT712M 2 KT712K GATE ROTOR BLADE REPLACEMENT KIT (111, 118, 120A, 120B, 121, 122, 123, 124, 130, 141, 142 & 143) 2 KT713G 2 KT713H 2 KT713L 101 GATE ROTOR ASSEMBLY (111, 120) 2 A25160EB 2 A25160EA 2 A25160EA 102 GATE ROTOR SUPPORT ASSEMBLY (100, 111, 120B, 119, 130) 2 A25161EB 2 A25161EA 2 A25161EL 105 GATE ROTOR GASKET SET (118, 141, 142 & 143) 2 A25164E 2 A25164E 2 A25164E SHIM PACK SET ((2) 121, (2) 122, (1) 123, (1) 124) 2 A25165E 2 A25165E 2 A25165E 110 SUPPORT 2 25687A 2 25665A 2 25495D 111 GATE ROTOR 2 25647A 2 25645A 2 25744D 112 SMALL BEARING HOUSING 2 26507A 2 26507A 2 26507A 113 LARGE BEARING HOUSING 2 26506A 2 26506A 2 26506A 114 RETAINER 2 25141A 2 25141A 2 25141A 115 RETAINER 2 25789A 2 25789A 2 25789A 116 BALL BEARING COVER 2 25351A 2 25351A 2 25351A 117 GATE ROTOR COVER 2 26508A 2 26508A 2 26508A 118 GATE ROTOR COVER GASKET 2 26509A 2 26509A 2 26509A 119 WASHER 2 25788A 2 25788A 2 25788A 120A BUSHING, SMALL DOWEL PIN - N/A - N/A - N/A 120B BUSHING, LARGE DOWEL PIN 2 25760C 2 25760C 2 25760C 121* SHIM 0.002” AR 25791AA AR 25791AA AR 25791AA 122* SHIM 0.003” AR 25791AB AR 25791AB AR 25791AB 123* SHIM 0.005” AR 25791AC AR 25791AC AR 25791AC 124* SHIM 0.010” AR 25791AD AR 25791AD AR 25791AD 125 ROLLER BEARING 2 2864K 2 2864K 2 2864K 126 BALL BEARING 4 2865K 4 2865K 4 2865K 130 RETAINING RING 2 2866G 2 2866G 2 2866G 131 RETAINING RING 2 2867R 2 2867R 2 2867R 135A DOWEL PIN, SM, 0.250” O.D. - N/A - N/A - N/A 135B DOWEL PIN, LARGE, 0.500” O.D. 2 25910C 2 25910C 2 25910C 141 O-RING ROLLER BEARING HOUSING 2 2176U 2 2176U 2 2176U 142 O-RING BALL BEARING HOUSING 2 2176BD 2 2176BD 2 2176BD 143 O-RING BEARING HOUSING COVER 2 2176P 2 2176P 2 2176P 150 HEX HEAD CAP SCREW 12 2796CJ 12 2796CJ 12 2796CJ 151 HEX HEAD CAP SCREW 8 2796N 8 2796N 8 2796N 152 HEX HEAD CAP SCREW 32 2796CJ 32 2796CJ 32 2796CJ 153 HEX HEAD CAP SCREW 44 2796R 44 2796R 44 2796R 160 SOCKET HEAD CAP SCREW 16 2795G 16 2795G 16 2795G

Shaft Seal

Shaft Seal With Stationary Carbon Face

230 260 219

MODEL NUMBER

VSS 291 thru VSS 751 thru VSS 1301 VSS 1551 thru VSS 601 VSS 1201 VSS 2101

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

SHAFT SEAL AMM KIT (219, 230, 260) 1 KT709A 1 KT709B 1 KT709MB 1 KT709C SHAFT SEAL R22 KIT (219, 230, 260) 1 KT781A 1 KT781B 1 KT709MA 1 KT781C 230 OIL SEAL 1 25040A 1 25064A 1 2930F 1 2930B 260 O-RING 1 2176F 1 2176AC 1 2176AC 1 2176BH

201

Main Rotor

207

MODEL NUMBER

VSS 451 VSS 601 VSS 751 VSS 901

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

201 ROTOR ASSEMBLY 1 A25226BB 1 A25226BA 1 A25226CB 1 A25226CA 207 SHIM PACK 1 A25177B 1 A25177B 1 A25177C 1 A25177C

MODEL NUMBER

VSS 1051 VSS 1201 VSS 1301 VSS 1551

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

201 ROTOR ASSEMBLY 1 A25226DB 1 A25226DA 1 A25752HA 1 A25226EC 207 SHIM PACK 1 A25177D 1 A25177D 1 A25177D 1 A25177E

MODEL NUMBER

VSS 1851 VSS 2101

ITEM DESCRIPTION QTY VPN QTY VPN

201 ROTOR ASSEMBLY 1 A25226ED 1 A25226EE 207 SHIM PACK 1 A25177E 1 A25177E

Slide Valve Cross Shafts and End Plate

297

286

222

268

298

226

226 227

VSS 291 THRU

VSS 601 ONLY

228

269

228

VSS 291 THRU VSS 601 ONLY NO SPACER THIS SIDE OF SHAFT ASSEMBLY

297

286

269

221

268

NOTE:

BOTH ACTUATOR SHAFT ASSEMBLIES ARE IDENTICAL ON VSS COMPRESSORS.

222

298

Slide Valve Cross Shafts and End Plate

MODEL NUMBER

VSS 291 thru VSS 751 VSS 1051 VSS 1551 thru VSS 601 VSS 901 VSS 1201 VSS 2101 VSS 1301

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

221 SHAFT 2 25843A 2 25844A 2 25845A 2 25793A 222 GEAR 4 25027A 4 25027A 4 25027A 4 25027A 226 RACK CLAMP 2 25913A 4 25913C 4 25913C 4 25913C 227 RACK CLAMP 2 25913B - N/A - N/A - N/A 228 SPACER 2 25847A 4 25033C 4 25033C 4 25033C 267 DOWEL PIN - N/A 2 2868B 2 2868B 2 2868B 268 EXPANSION PIN 4 1193D 4 1193D 4 1193D 4 1193D 269 EXPANSION PIN 4 2981AA 4 2981AA 4 2981AA 4 2981AA 270 PIPE PLUG - N/A 2 2606E 2 2606E 2 2606A 286 SOCKET HEAD 8 2795F 8 2795F 8 2795F 8 2795F CAP SCREW 297 SET SCREW 2 2060J 2 2060J 2 2060J 2 2060J 298 SET SCREW 2 2060H 2 2060H 2 2060H 2 2060H

305

Slide Valve Carriage Assembly

Capacity SlideVolume Slide Carriage Assembly

343

345

350

304

380

378

347

360

316

323

300

361

363

Slide Valve Carriage Assembly

MODEL NUMBER

VSS 291 thru VSS 751 VSS 1051 VSS 1301 VSS 601 VSS 901 VSS 1201

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

300 CARRIAGE ASSEMBLY 2 A25179B 2 A25179C 2 A25179D 2 A25179DSR 304 CAPACITY PISTON (340, 341, 350, 355) 2 A25183B 2 A25183C 2 A25183D 2 A25183DN 305 VOLUME PISTON (340, 342, 350, 355) 2 A25184B 2 A25184C 2 A25184D 2 A25184DN 307A GASKET SET (345) 2 A25200B - N/A 2 A25200D 2 A25200D 307B GASKET SET (345, 378) - N/A 2 A25200C - N/A - N/A 316 RACK 2 25024A 2 25080A 2 25080C 2 25779B 323 RACK 2 25023A 2 25080B 2 25080D 2 25080DH 325 SHAFT - N/A - N/A - N/A - N/A 340 PISTON - N/A 4 25076A 4 25138A 4 25138A 341 CAPACITY PISTON SHAFT - N/A 2 25078A 2 25078E 2 25078G 342 VOLUME PISTON SHAFT - N/A 2 25078B 2 25078F 2 25078H 343 COVER, ONE PIECE CAST 2 25399A 2 25279A 2 25401A 2 25401A 345 GASKET, ONE PIECE CAST COVER 2 25900A 2 25902A 2 25901A 2 25901A 346 GASKET, ONE PIECE CAST COVER - N/A 2 25124A - N/A - N/A 347 PISTON SLEEVE - N/A 2 25079A - N/A - N/A 350 PISTON RING SET 4 2953AA 4 2953AB 4 2953AC 4 2953AC 355 EXPANSION PIN 4 1193PP 4 1193PP 4 1193PP 4 1193PP 359 PIPE PLUG 6 2606D 6 2606D 6 2606E 6 2606E 360 LOCK WASHER (PAIR) 4 3004C 4 3004C 4 3004C 4 3004C 361 WASHER 4 13265B 4 13265B 4 13265B 4 13265B 363 NUT 8 2797A 8 2797A 8 2797A 8 2797A 366 HEX HEAD CAP SCREW 24 2796B 12 2796P 24 2796P 24 2796P 367 HEX HEAD CAP SCREW - N/A 12 2796BN - N/A - N/A 373 SOCKET HEAD CAP SCREW - N/A 6 2795N 6 2795P 6 2795P 374 LOCK WASHER (PAIR) - N/A 6 3004C 6 3004D 6 3004C 378 O-RING - N/A 2 2176Y - N/A - N/A 380 RETAINER RING - N/A 2 2866C - N/A - N/A

Slide Valve Carriage Assembly

MODEL NUMBER

VSS 1551 thru VSS 2101

ITEM DESCRIPTION QTY VPN

300 CARRIAGE ASSEMBLY 2 A25179E 304 CAPACITY PISTON (340, 341, 350, 355) 2 A25183E 305 VOLUME PISTON (340, 342, 350, 355) 2 A25184E 307A GASKET SET (345) 2 A25200E 307B GASKET SET (345, 378) 2 A25200E 316 RACK 2 25779A 323 RACK 2 25780A 325 SHAFT 2 25778A 340 PISTON 4 25782A 341 CAPACITY PISTON SHAFT 2 25784A 342 VOLUME PISTON SHAFT 2 25783A 343 COVER, ONE PIECE CAST 2 25690A 345 GASKET, ONE PIECE CAST COVER 2 25384A 346 GASKET, ONE PIECE CAST COVER - N/A 347 PISTON SLEEVE 4 25786A 350 PISTON RING SET 4 2953AD 355 EXPANSION PIN 4 1193PP 359 PIPE PLUG 6 2606E 360 LOCK WASHER (PAIR) 4 3004C 361 WASHER 4 13265B 363 NUT 8 2797A 366 HEX HEAD CAP SCREW 28 2796BL 367 HEX HEAD CAP SCREW - N/A 373 SOCKET HEAD CAP SCREW 6 2795AG 374 LOCK WASHER (PAIR) 6 3004D 378 O-RING 4 2176AG 380 RETAINER RING 4 2755AG

100

Emerson VSM, VSR, VSS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual