Emerson VSSG manual

VSG/VS SG c ompre ssor unit Installa tion, oper ation & m aint en anc e manu al[...]

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i VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Selle r warrants all new single screw ga s compression units and baresh af t single screw compres sor s manufactured by it and supplied to Buy er to be free from def ec ts in mat erials and workm anship for a period of (a) e ighteen (18) months from th[...]

ii VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG READ C AREFULL Y BEFORE INST ALLING AND ST ARTING Y OUR COMPRESSOR. The follo wing instruc tions have bee n prepared to a ssist in inst allation, ope ration and remov al of Vilter Single Screw Compressors. Follo wing these instruc tions will result in[...]

T OC - 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG VSG/VSSG S t andard Vilte r Warran t y Stateme nt ................................................................................... .. i Impor tant Message........................................................................................[...]

T OC - 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Section 4 • O peration Oil Inspection ........................................................................................................................................ 4-1 Dual Oil Filte r s..............................................[...]

T OC - 3 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG T ables T able 3-1. Long T erm Storage C ompressor Hardware ............................................................................. 3 -2 T able 3-2. Maximum Allowable Flange Loads ...........................................................[...]

T OC - 4 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Figure 3-12. Installation of Coole rs - Nex t to Buildling ...................................................................... ...... 3-13 Figure 3-13. Dischar ge Elevation of Coole r s ........................................................[...]

1 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG How T o Use This Manual This manu al con t ains instruc tions for g as compres sor units. It ha s been divided into e ight sec tions: Section 1: General Inf ormation Section 2: Theor y of Ope ration Section 3: Inst allation Section 4: Operation S[...]

1 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 1. Compressor Model VSG = Vilter Single Screw C ompressor VSSG = Vilte r Single Screw Compressor (Compres sor models 291, 341, 451 & 601 - these are 240mm diame ter rot or s with coun ter clock wise rotation) VRSG = Vilter T win Screw 2. Size[...]

1 – 3 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Syste m Unit Identi fi cation T o kee p de fi nitions of units simple and consiste nt, Vilter h as de fi ned the following three : • Bare Sha f t Compressor • Compres sor Unit • Package Unit Bare Shaft Compressor A bare shaft compress or[...]

1 – 4 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 1 - Moto r 2 - Coupling 3 - Suction Strainer 4 - Suction Check Valv e 5a - Suction Stop V alve 5b - Suction Stop Butte r fl y Valv e (T ypically Shipped Loose) 6 - Compressor 7 - Dischar ge Pipe 8 - PL C Panel 9 - Block & Bleed Assembly 10 -[...]

1 – 5 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 19 20 21 20 22 18 23 Figure 1-2. Gas Compressor Unit Compone nts (2 of 3) Sec tion 1 • Gene ral Information 3 4 14 17[...]

1 – 6 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 24 - RTD (Oil Filte r Outlet) 25 - Pressure T ransducer (Oil In jec tion T empe rature) 26 - V olume Slide V alve Actuat or 27 - RTD (Disch arge) 28 - RTD (Suction) 29 - Capacity Slide V alve Actuator 30 - Pressure T ransducers (Dischar ge, Oil F[...]

1 – 7 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Piping & Identi fi cation Componen t T ags Use this list t o identif y compone nts shown in the Piping & Identi fi cation Diagram. A Atmos phere AN Anode - Sacri fi cial A V Angle V alve BFV Butter fl y V alve BDV A utomatic Blowdown [...]

1 – 8 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG TI T emperature Indica tor or Thermome ter TIT T empe rature Indicator T ransmitter TRV T ransfe r Valv e - 3-way or 6-way V alve TS Hea t Exchange r T ube Side TSH T empe rature Switch High TSHH T emperature Switc h Shutdown High High T TSL T em[...]

1 – 9 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG High Side Float V alve Stea dy - M ou nt Bulb & Capillar y Thermo s tatic Expansion Va l ve G Pilot Light (Color Inside) MW Man-W ay Co ver BY VIL TER BY OTHERS Scope o f Supply SV E1 Ec onomizer R egulator Compressor Mot or Hea t Exch anger [...]

1 – 10 / Blank VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG[...]

2 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 2 • Theor y of Operation The ga s and oil systems work in unison, but e ach one will be explained se parately . Re fere nce Figure 3 - Gas Compres sor Unit P&ID for ga s and oil fl ow descriptions. Gas Flow The ga s compression pr[...]

2 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG suction. The discharge te mperature of the c ompressor must be k ept a minimum o f 30°F (or 17°C) above the dis- char ge gas dew poin t to preven t the condensing o f liq - uids in the oil separa tor . The oil separat or shell and legs must be [...]

3 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Only quali fi ed personnel shall ope rate rigging and lift- ing equipmen t. Ensure that the lif ting device is cap able of lifting the weight of the c ompressor unit, ref er to the supplied Vilter Ge neral Assembly (GA) drawing. T o lif t the co[...]

3 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG COMPRESS OR MO TOR The follo wing are general recomme ndations. R efe r to speci fi c motor manufacturer instructions for storage recomme ndations. • Re move the conde nsation drain plugs from those units equipped with them and inse r t silica[...]

3 – 3 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Compressor Unit Inspec tions Prior to St orage or Inst allation The compre ssor unit mu st be inspec ted prior to instal- lation sinc e componen ts could hav e come loose and/or dam aged during shipment or moving. • Check f or loose bolts, par [...]

3 – 4 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation LONG TERM STORAGE LOG Date: ________________ _______________ Name: _________________ ______________ Intial:_______________ Company: Vilter Order No . _______________ ______________________________ Compressor Serial Num[...]

3 – 5 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation F oundation Vilter Single Scre w compres sor units are low vibra - tion machine s. Under most conditions, no e laborate found ation is necessary . Howeve r a sound foundation maintains mo tor alignment and prope r elev[...]

3 – 6 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG of both • Check the abilit y of the soil to carr y the load • Check wet sea son and dr y sea son soil characteristics for static lo ading limits and elasticity • Check local codes f or Seismic Design require ments For examples o f foundatio[...]

3 – 7 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG CENTER LINE OF GAS COMPRESSION SYSTEM 6" # 6 @ 12" EACH W A Y TOP & BO T TOM COMPRESSOR UNIT G.A. G.A. EL. TOP OF GRADE E X C AVAT E T O F R O S T D E P T H A S R E Q ' D A N D B A C K F I L L WITH CLSM OR NON-FROST SUSCEPTIBLE[...]

3 – 8 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Additional Inf ormation Codes and S tandards Vilter f ollowed the follo wing codes and standards whe n designing your f oundation : • ACI • ASTM • ASCE 7 • IBC 2006 Opera tion and Per form ance The found ation was designed f or : • Outs[...]

3 – 9 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Figure 3-7. Lev el Compressor Unit U sing T op Sur face of Sphe rical Wa shers Sec tion 3 • Installation SPHERICAL W ASHERS LEVEL Figure 3-6. House keeping P ad Dimension Detail - T op V iew 5/8" DIA. HIL TI HAS SS THREADED ROD (HAS-E RODS[...]

3 – 10 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 010Ä5*4+0- '21:;)4176 4'%1//'0&'& (14 *175'-''2+0) %10%4'6' $#5' 70+6.') *1.&&190076 9#5*'4 .'8'.+0)076 #0%*14$1.6 ?[...]

3 – 11 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Figure 3-9. Maximum Allowable Flange L oads DISCHARGE LINE 5 PIPE DIAMETERS CUSTOMER SUPPORT 3-4 PIPE DIAMETERS SUCTION LINE X Z Z Y X Y CUSTOMER SUPPORT HANGER CHECK VA LV E CUSTOMER SUPPORTS WHEN CHECK VAL VE IS MOUNTED HERE 5 PIPE DIAMETERS 5[...]

3 – 12 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation Gene ral Inst allation Guide line for Multiple Air Coolers Installed in a Common Area NO TE This gene ral inst allation guide line applies to all air coole r s on site , whether if they are supplied b y or not supplie[...]

3 – 13 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation The equation u sed to calcula te the leg height in Figure 3-11 is as f ollows: Leg Height = (T otal Air fl ow/Intak e velocity)/Intake Pe rimeter Leg Height = (247,000CFM/500FPM)/82ft Leg Height = 6ft In this par tic[...]

3 – 14 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG HO T AIR RECIR CULA TION There are two situations whe re hot recircula tion could occur . • Intak e velocity of the coole r is higher than the dis- char ge velocity • Environme ntal issues such as strong cro ss winds which is installation s [...]

3 – 15 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Figure 3-13. Dischar ge Elevation of Coole r s Sec tion 3 • Installation NO T PREFERRED PREFERRED Figure 3-14. Cooler Pl aceme nt and Spacing PREFERRED NO T PREFERRED[...]

3 – 16 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation Initial Oil Ch arging Using Non - Vilter Oils C A UTION Do not mix oils. F ailure to comply may result in damage to equipme nt. NO TICE Vilter does not appro ve non-Vilter oils f or use with Vilter compressors. Use o [...]

3 – 17 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation Figure 3-15. Oil Operating Le vels Normal Ope rating Lev el Maximum NON-Operating Le vel Minimum Opera ting Level Figure 3-16. Suc tion Oil Charging V alve, Oil C ooler Drain V alve and Oil Filter Shut -Off Valv es Su[...]

3 – 18 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG OIL PT 004 FG 001 TE 001 PT 001 BLEED BLEED DRAIN PT 002 BLEED TE 004 QE 101 QE 102 QE 103 TE 005 1000W 1000W 1000W LG 001 LG 002 OIL CHARGE TE 002 COMPRESSOR MOTOR OIL COOLER MOTOR OIL PUMP OIL FIL TER OIL FIL TER COALESCING OIL RETURN LINE PRE[...]

3 – 19 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG OIL PT 004 FG 001 TE 001 PT 001 BLEED BLEED DRAIN PT 002 BLEED TE 004 QE 101 QE 102 QE 103 TE 005 1000W 1000W 1000W LG 001 LG 002 OIL CHARGE TE 002 COMPRESSOR MOTOR OIL COOLER MOTOR OIL PUMP OIL FIL TER OIL FIL TER COALESCING OIL RETURN LINE PRE[...]

3 – 20 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG OIL PT 004 FG 001 TE 001 PT 001 BLEED BLEED DRAIN PT 002 BLEED TE 004 QE 101 QE 102 QE 103 TE 005 1000W 1000W 1000W LG 001 LG 002 OIL CHARGE TE 002 DRAIN VENT TE 003 QE 007 TE 007 COMPRESSOR MOTOR REMOTE OIL COOLER MOTOR OIL PUMP OIL FIL TER OIL[...]

3 – 21 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation PRIMING COMPRES SOR AND OIL FIL TER S NO TE Running the c ompressor oil pump at this poin t will help lubrica te the compressor be arings and sha f t seal surfaces. (Ref erenc e Figure 3-20) 8. Open shut -off valve(s)[...]

3 – 22 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 3 • Installation Pre Start -Up The follo wing check list is to help prep are the equipment bef ore the V ilter t echnician arrive s at the jobsite . V ilter recomme nds that a trained technici an go through the following tasks. The op[...]

3 – 23 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 8. On air cooled oil c oolers, the oil lines from the compre ssor must be connected to the air c ooled oil cooler . Oil coole r fans will need to be wired and check ed for proper ro t ation. R efe r to supplied GA drawing for c onnec tion points[...]

3 – 24 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG St ar t-U p The follo wing check list is to help ve rif y and check equipment prior t o st ar t -up. This is the responsibility of the Vilter T echnici an. 1. Revie w pre st ar t -up checklist. 2. Check oil pump rotation. This can be done b y us[...]

4 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation Oper ation All opera t ion (setpoin t adjustments, calibra tions, monitoring) of the c ompressor unit is done through the Compact Logix PL C. For additional proc edural inf ormation, ref er to Compact Logix PL C Sof t war[...]

4 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation Control Syste m C alibration Equipped f or automatic oper ation, the screw compres- sor unit ha s safety controls to pro tec t it from irregular opera ting conditions, an automatic starting and stop - ping sequenc e, capa[...]

4 – 3 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation • The re is an error code fl ashing on the actuator’s circuit boar d - an attempt t o recalibrate should be made . • The range of tra vel is no t correc t and the comm and shaft trave l is physically correct. • T[...]

4 – 4 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation Figure 4-3. Menu Scree n and Slide C alibration Button (Compact Logix PLC)[...]

4 – 5 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 8. Quickly pres s and releas e the blue push button on the actuator one time . This places the actuat or in calibration mode . The red LED will begin fl ashing rapidly . C A UTION DO NO T CONTINUE T O ENERGIZE THE A C TUA T O R MO TOR AFTER THE [...]

4 – 6 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Compress or Model Command Sh af t Ro tation No. o f T urns/Ro tation Angle/Slide T rave l Capacity V olume Capacity V olume INC DE C INC DEC T urns Degrees T rave l T urns Degrees T ravel VSSG 291 VS SG 341 VSSG 451 VSSG 601 CW CCW CW CCW 0.91 32[...]

4 – 7 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation 11. Use the INC button on the C ontrol panel to driv e the slide to its maximum “ mechanical stop ” posi- tion. Do not c ontinue to run the ac tua tor in this di - rection af ter the slide valv e has reac hed the stop[...]

4 – 8 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation F ail Position The tempe rature con trol valve remains in the l ast posi- tion when pow er is remov ed. Screen Dis play The oil tempe rature con trol valve, ide nti fi ed as “OIL MIX” on the main PL C displa y screen[...]

4 – 9 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Purging with Dr y Nitrogen Purging is rec ommended if the compress or will be inactive for 12 hours or more . For additional long term st orage inform ation, refe r to Long T erm S torage Rec ommenda tions in Sec tion 3. PREP ARA TION W ARNING Wh[...]

4 – 10 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation NO TE Purging is pe r f ormed through the suc tion oil charging valve so th at trapped gas can be pu shed out of the compre ssor . This will help minimiz e metal sur face oxid ation of the compres sor (due to the gas) wh[...]

4 – 11 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG NO TICE T o purge the c ompressor unit using a dr y ga s (i.e. methane), a pur ge line must be installed. If there is not e nough purge pressure , connec t purge line to a lowe r pressure line or to atmos phere. The purge line , ass ociated valv[...]

4 – 12 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Figure 4-11. PLC M ain Screen Sec tion 4 • Operation St op Button Dischar ge St atus 9. Connect purging hose from ga s c ylinder to suction oil char ging valve. NO TE Purging is pe r f ormed through the suc tion oil charging valve so th at tra[...]

4 – 13 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Suction Oil Charging V alve View R otate 180° Figure 4-13. Suc tion Oil Charging V alve Sec tion 4 • Operation Equ alizing Solenoid for Suction Bypas s Figure 4-12. Suc tion Bypas s Valv e and Equalizing Sole noid Suction Bypass V alve (Manua[...]

4 – 14 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 4 • Operation Figure 4-14. Coalescing Oil R eturn Line Coalesc ing Oil Return Line Needle Va l ve Sight -Glass Shut -Off Va l ve Check V alve Coalescing Oil R eturn Line Setup Ove r time, oil will accumula te on the coalescing side of[...]

5 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Mainte nance and Se r vice Schedule Follo w this table for m aintaining and ser vicing the compres sor unit at hourly inte r vals. T able 5-1. Mainten ance/Ser vice Schedule Sec tion 5 • Mainte nance/Se r vice Group Inspection/ Mainte nance (2)[...]

5 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Maintaining Proper Opera tion T o ensure prope r operation, the follo wing items should be check ed: • Calibrate all transduc er and RTDs. • Check capacity and volume ac tuat or calibration. • Check fuses in the PL C panel. • Check for lo[...]

5 – 3 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG 2. If equipped with equalizing solenoid t o control suc - tion by-pa ss, allow solenoid to re main open until pressures equ alize , see Figure 5-1 (2 of 2). 3. T urn motor and oil pump star ter disc onnec t switch- es int o the OFF position. Lock[...]

5 – 4 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Oil Syste m Components Oil Sampling W ARNING When working with LF G, NG or other dangerous or fl ammable ga ses, ensure there are adequat e ven tilation and vapor detectors. Refe r to national fi re and building codes. F ailure to comply may re[...]

5 – 5 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice Oil Charging W ARNING Av oid skin contact with oil. Wear rubbe r gloves and a face shield whe n working with oil. F ailure to comply may result in se rious injur y or death. C A UTION Do not add oil to the c [...]

5 – 6 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice Figure 5-4. Oil Filter Assemblies (Single and Du al) Cov er Flange Spring Plate Eleme nt Caniste r Spr ing Plate Eleme nts Single Oil Filte r A ssembly Dual Oil Filte r A sse mbly Outlet Inlet Outlet Eleme nt[...]

5 – 7 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice 1. If equipped with dual oil fi lters, open inle t shut-o ff valve f or non -operating oil fi lter t o put it into opera- tion, see Figure 5-5. 2. T o isolate oil fi lte r for ser vicing, close inle t and [...]

5 – 8 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice Coalescing Filte r Re placeme nt W ARNING Use appropria te lif ting devices and additional personnel whe n lif ting heav y componen ts. Ensure lif ting device s are capable of lif ting the weight o f the comp[...]

5 – 9 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Figure 5-7. Oil Pump Strainer and Drain V alve Straine r Drain V alve Oil Pump Straine r Bolts Straine r Cove r Nuts W ARNING Av oid skin contact with any condensat e or oil. Wear rubber glo ves and a face shield whe n working with condensa te or[...]

5 – 10 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice with a small cle arance ov er the top . NO TE If hub position on sha f t does not allow enough room to install bolts, install bolts and disc pack bef ore mounting hub on sha f t. Hubs c ome in t wo diffe ren[...]

5 – 11 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice 16. If locking tab is be ing used, bend locking tabs in gap to wards shaft and around bolt. 17. Install set screw in hub cap to secure k ey in ke yway of sh af t. 18. T ighte n set screw , see T able 5-4. Dr[...]

5 – 12 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice the disc pack. 24. Install bolts and locking nuts to sec ure both disc packs to c ente r member . 25. T ighte n locking nuts. 26. If room is required to install ce nter me mber , adjust hub position acc ordi[...]

5 – 13 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice 32. Perform hot alignme nt. Run c ompressor unit and allow to warm up c ompletely . 33. Po wer do wn compressor unit and re-c heck align - men ts. Loosen mo tor mounting nuts to add shims or to adjust alignm[...]

5 – 14 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG compre ssor sha f t. 12. Remo ve hub and ke y from compressor sha f t. INST ALLA TION 13. Install key and hub on c ompressor shaft as not ed during remo val. 14. Inst all set screw in c ompressor hub to secure k ey in ke yway , see T able 5-6, 1[...]

5 – 15 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice 26. If equipped with C - fl ange, install C - fl ange coupling, ref er to C - fl ange Coupling Re place m en t procedure. 27. Install coupling, see Driv e Coupling Installation and Alignmen t procedure . [...]

5 – 16 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG motor and u se the leve r arm to push the input sha f t towar ds the compres sor . Rec ord measure ment 5. Add both me asuremen ts. If measure ment is out of allowable tole rance shown in T able 5-7, the bearing ma y need to be repl aced. Contac[...]

5 – 17 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Gat e Rot o r Float and Ga te Ro tor Bearing Floa t Inspec tion GA TE RO TOR FL OA T INSPE C TION T o inspect gate ro tor fl oat and bearing fl oat, proc eed with the follo wing steps : 1. Re move ce nter me mber , see appropriate Driv e Coupl[...]

5 – 18 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG NO TE Mea suremen ts can be an additional 0.020” higher than fl oat dimensions on T able 5-8. If mea surement is an additional 0.030” gre ater th an fl oat dimensions, con t act V ilte r for fur ther as sist ance . T otal mov ement o f dam[...]

5 – 19 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Gat e Rot or and Suppor t Cle arance When me asuring, push the g ate rotor ag ainst the pin to remo ve fl oat. 1. Place a straight edge along the side of the g ate ro - tor , see Figure 5-16. 2. Measure the g ap from the straight edge to the pe[...]

5 – 20 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice Figure 5-16. Gat e Ro tor and Suppor t Clearance - Me asuring Gat e Rot or Suppor t Gate Rotor Straight E dge Gat e Rot or Suppor t Gate Rotor Straight E dge Gat e Rot or Suppor t Gate Rotor Straight E dge[...]

5 – 21 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Gat e Rot or A ssembly R eplac ement (All VSG & VSSG Compressors Exc ept VSG 301-701 Compressors) The follo wing t able lists the gat e rotor tool se ts needed to remo ve and install gate ro tor asse mblies. T able 5-9. Gate R otor T ool Set[...]

5 – 22 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG NO TE This mea suremen t determines the amoun t of shims needed for the c orrec t clearanc e. 21. Measure de pth from top of c ompressor case t o top of thrust be aring housing. 22. Use factor y inst alled shim pack (106) and be aring housing c [...]

5 – 23 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice Figure 5-19. Gat e Ro tor A sse mbly and T ools Figure 5-20. Gat e Ro tor and She lf Clearance Check for 0.003-0.004” (0.076- 0.102 mm) cle arance between gat e rotor bl ade and par tition. 23. Check the c[...]

5 – 24 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG bearing e nd of the gat e rotor suppor t towards the suction end of the c ompressor . The compressor input shaft may h ave to be ro t ated to f acilitate the installation o f the gat e rotor suppor t. 11. Install the roller be aring housing with[...]

5 – 25 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 5 • Mainte nance/Se r vice Figure 5-22. Gat e Ro tor Thrust Bearing neces sar y . It is prefe rable to shim the gate ro tor blade loose r rather than tight er against the she lf . 14. Once the cle arance is set re move the spindle . I[...]

5 – 26 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG GA TE RO TOR BLADE REMO V AL 2. R emove the sn ap ring and washer from the g ate ro - tor as sembly . Lif t gate ro tor blade as sembly off the gat e rotor suppor t, see Figure 5-24. 3. Check dampe r pin and bushing for ex cessive w ear . Re pla[...]

5 – 27 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG GA TE RO TOR THR UST BE ARING REMO V AL For re moval of thrust be arings on VSG units: 7. R emove bolts (150) from the c lamping ring (114), see Figure 5-26. 8. Re move thrust be aring clamping ring. 9. Re move thrust be arings (126) from housin[...]

5 – 28 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG The beve l on the snap ring must fac e away from the roller be aring. Figure 5-28. R oller Bearing Asse mbly Sec tion 5 • Mainte nance/Se r vice Slide V alve Actuator Assembly R eplace ment T o replac e slide valve actuator a ssembly , proceed[...]

5 – 29 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Command Shaf t Assembly R eplace ment REMO V AL NO TE The follo wing steps can be us ed to remov e or inst all eithe r the capacit y or volume c ommand shaft asse mblies. 1. Shut down and isolat e compressor unit, see Compressor Unit Shut down a[...]

5 – 30 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG shaft seal cavity in the compressor hou sing. Apply clean c ompressor oil to the sh af t seal sea ting area on input shaft. 8. Lubricate the inside are a of the rotating se al with cle an compressor lubricating oil, do no t wipe or touch the fa [...]

6 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG T able 6-1. Slide V alve Actuator T roubleshooting Guide (1 of 2) Sec tion 6 • T roubleshooting Problem R eason Solution The actuator cannot be calibra ted or exit calibration mode Dir t or debris is blocking one or both optoc oupler slots Clea[...]

6 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 6 • T roubleshooting Problem R eason Solution The actuator does no t transmit the correct position after a pow er loss The motor wa s manually mov ed while the position sensor wa s not powe red. Recalibra te. The motor brak e is not wo[...]

6 – 3 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Slide V alve Actuat or s communicat e problems discov ered by in ternal di agnostics via LED blink codes. Only one blink code is dis played, ev en though it is possible th at more than one problem h as been det ec ted. Flash P attern Meaning *=ON[...]

6 – 4 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG *There are two versions of slide valv e ac tuators, ve r sion A and B. Only version B is able to dis play LED blink codes. Slide val ve actuat or version B can be distinguished by only ha ving a single circuit board as suppos ed to t wo circuit b[...]

6 – 5 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Problem Solution Low Oil Pre ssure at Start • Af ter failing t o st ar t compres sor with “Prelube Oil Pump Inhibit”, fi rst allow Dischar ge pressure, Oil Filte r In pressur e and Out pressure t o equalize . Then restar t compres sor . If[...]

6 – 6 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 6 • T roubleshooting Problem Solution Oil Los s Issues • Oil return line from co alescing side of oil separa tor to suction is closed, not open e nough (.75 turns should be suf fi cient), or plugged with de bris • The check valve [...]

6 – 7 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Problem Solution High Amp Draw • Check Main Motor Amp s scaling and PLC. Vibra tion • Check that unit is lev eled and secured to moun ting pad or fl oor . • Check suppor ted pipes (i.e. suction and dischar ge pipe) and make sure the y are [...]

6 – 8 / Blank VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG[...]

7 – 1 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 7 • W arrant y and Par ts W arrant y Claim Processing This section explains how the warranty claim is pro - ces sed and to help cle ar any questions tha t may arise prior to con tac ting custome r ser vice. F or additional war - ranty [...]

7 – 2 VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Sec tion 7 • W arrant y and Par ts R emanufactured Gas Bare Shaft Compressor Process These instructions are an overview of how the proce ss works when a bare sh af t compres sor is in need of being rem anufac tured. This is to help c lear any q[...]

A VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG T orque Specifications (f t -lbs) T ype Bolt Head Markings Nominal Siz e Numbers or Inches #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 SAE Grade 2 Coarse (UNC) - 5 10 18 29 44 63 87 155 150* SAE Grade 5 Coarse (UNC) - 8 16 28 44 68 98 135 240 387 SAE Gr[...]

B VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Shor t T erm St orage If the equipmen t is not put into immedia te use it should be stored in a cle an, dr y location. For all W eathe r Protected T y pe II (WPII) mot or s, motor he aters should be activated upon arriving at the jobsit e to prev ent c[...]

C VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Appendix C • Oil An alysis R epor t I.D. # ********* Customer Name Comp. Mfr. Vilter Serial Num ber ****-*** Model Number VSM-601 Hrs. on Fluid 6049 Hrs. on Machine 11239 Sample Date Feb 21, 2013 W ater by Karl Fi scher (ppm ) Viscos ity 40 C (cSt ) [...]

D VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Appendix D • R ecomme nded Header Piping[...]

E VSG/VSSG • Installa tion, Operation and M aintenanc e Manual •Vilter/Eme r son • 35391SSG Appendix E • R ecommended R emo te Air Cooled Oil Cooler Piping OUTLET ON T OP INLET ON BOTT OM • V er tical drops should be no highe r than 8 to 10 fee t. • If the re is no choice and the ve r tical drops need t o be higher , then an electronic [...]

Blank VSG/VSSG • Install ation, Operation and Maint enance M anual •Vilter/Emerson • 35391SSG[...]

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35391SSG Re v. 10 (3/13) Emerson and Vilter are trade marks of Emerson Electric Co. or one of its af fi liated companies. © 2012 Emerson Clim ate T echnologies, Inc. All rights reserved. Printed in the USA.[...]