Emerson VSM manual

VS S/VSR/VS M single screw c ompre ssor Ope ration and se r vic e manu al[...]

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3 READ C AREFULL Y BEFORE INST ALLING AND ST ARTING YOUR C OMPRESSOR. The follo wing instruc tions hav e been prepared t o assist in installation, opera tion and removal o f V ilte r ™ Single Screw Compressors. F ollowing these instructions will result in a long life of the compre ssor with satisfac tory operation. The entire m anual should be re[...]

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5 T able o f Conten ts Impor tant Message ............................................................................................................. .3 Standard VIL TER W arrant y State ment ..................................................................................6 Standard VIL TER 5/15 W arrant y State ment ............................[...]

6 Standard VIL TER W arrant y S tatemen t Selle r warrants the products it manufac tures to be free from de fec ts in ma terial and w orkmanship for a period o f eightee n (18) months from the date o f shipment from Se ller’s manufacturing plant or t we lve (12) months from date o f installation at the initial e nd users location, whichev er occu[...]

7 The selle r ex tends w arrant y , from date o f shipment, to a pe riod of fif teen (15) y ears on all compressor be arings, five (5) y ears on all intern al compressor parts and t wo (2) ye ar s on the rem ainder of the parts on single screw compressor units. If within suc h period any such product shall be pro ved to Selle r’s satisfac tion to[...]

8 The procedure described is a ge neral recomme ndation f or long term storage (o ver one month o f no operation) of Vilte r Manufacturing packages and compress or s. While this procedure is in tended to c over mo st of the commonly e ncounte red situations, it is the res ponsibilit y of the installation fi rm and end u ser to addres s any unusu a[...]

9 Long T erm St orage Requireme nts 2) Cove r the unit complete ly to exclude dirt, dust, moisture, and o ther fore ign mate rials. 3) If the motor can be mo ved, it is suggested th at the entire mo tor be encased in a strong, trans parent pla stic bag. Bef ore sealing this bag, a moisture indicator should be a tt ached t o the side of the motor an[...]

10 COMPRESSOR The Vilter Single Screw C ompressor is a positiv e displace ment, capacity and volume con trolled, oil fl ooded, rotar y compre ssor which uses a single m ain screw inte rmeshed by t wo opposing g ate rotors. Ga s compression occurs when the individual fi ngers of e ach gat e rotor swee p through the grooves, or fl utes, of the m a[...]

11 The Vilter c ompressors fe ature the exclu sive Parallex™ Slide Syste m, which consists o f a pair of slides f or each gat e rotor asse mbly . These t wo inde pendently ope rated slides are re ferred to a s the capacit y slide and the vol- ume ratio slide . On the suc tion end o f the screw, the capac it y slide moves t o var y the timing of t[...]

12 F oundation Introduction Vilter Single Screw c ompressor units are low vibra tion machines. Unde r most conditions, no e laborate found ation is neces sar y . Howeve r a sound founda tion maintains mot or alignme nt and proper e levation, and is there fore required. Provided are rec ommendations f or the founda tion and ancho ring of the compres[...]

13 Building the Found ation Use the Vilte r General Arrange ment (GA) and f oundation drawing s to help secure a building pe rmit and founda tion construction. The Vilter GA drawing will h ave the nece ssar y dimensions required to de termine the ov erall found a - tion siz e and where to locate the c ompressor unit on the f o undation. It will als[...]

14 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 FILL Figure 2. Concret e Pad with Compressor Unit Dime nsions - Fron t View Once the site h as been [...]

15 Compressor Unit Installation Once the f oundation ha s cured, the compres sor unit can be placed on the f oundation, see Figure 4. Found ation with House kee ping Pads Dimensions - T op View and Figure 5. House keeping P ad Dimension Detail - T op View . With the appropriat e mate rial handling equipmen t, lif t the comp res sor unit by location[...]

16 5/8" DIA. HIL TI HAS SS THREADED ROD (HAS-E RODS ARE AC CEPT ABLE FOR INTERIOR INST ALLA TIONS) INST ALLED USING HIT -ICE/HIT -HY 150 ADHESIVE ANCHORING SYSTEM. (5" PROJEC TION, 12 3/8" EMBEDMENT .) HOLES TO BE INST ALLED WITH HAMMER DRILL. DO NOT DIAMOND CORE. (TY P . ) CENTER LINE G.A. G.A. G.A. G.A. G.A. + 2" G.A. G.A. 1&q[...]

17 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 /+0 Figure 7. Concret e Pad Housek eeping De t ail Leve ling and Grouting The unit should b[...]

18 Opera tion and Per f ormance The found ation was designed f or : • Outside en vironment sev ere exposure • Ambien t tempera ture -10 degrees F to 105 degrees F • Unit weight 20,000 lb s • RPM 3600 • Soil bearing capa cit y 1,500 lbs/sq.f t. • Wind speed 120 MPH • Exposure factor D • Wind impor tance factor 1.15 • Concret e pour[...]

19 Rigging and Lif ting Thank y ou for purcha sing a gas c ompressor (the “C ompressor”) from Vilter Manuf ac turing LL C (“ Vilter”). Rigging and Lif ting a lar ge piece of equipmen t like the Compre ssor is ex treme ly dangerou s. **DISCLAIMER** Notic e This rigging and lif ting manu al (this “Manual ”) is pro vided to you as a c our [...]

20 Rigging and Lif ting T raining curriculum for P ar ticipants, at a minimum, should inc lude: • A review of sa fe operating practices ; • A review o f who each person is and the ir speci fi c role in the lif t; • A tutorial on ho w to read lift char ts ; • A demonstra tion on how to use and inspect rigging hardware ; • A review of the [...]

21 • Get third-part y con fi rmation th at the crane owner and the crane ope rator are in compli ance with applicable laws, regul ations and inte rnal safe t y standards; • Consult with the crane owne r to dete rmine if any site prep aration is required for outriggers—imprope r use of outriggers is a signi fi cant cause o f crane failure; ?[...]

22 Rigging and Lif ting C O NT ACT VIL TER While Vilter will no t offe r any speci fi c feedback on the Pl an or provide a speci fi c Plan f or rigging and lif ting the Compress or , Vilter ma y be able to answer questions about the C ompressor that are important in deve loping your Plan. Plea se contact V ilte r at: P .O. Box 8904 5555 S Packard[...]

23 Installation I. DELIVER Y INS PECTION Vilter screw c ompressor compone nts are thor - oughly inspected at the factor y , as suring the shipmen t of a mechanically pe r fect piece of equip- men t. Damage can occur in shipme nt, howev er . For this re ason, the units should be thoroughly inspected upon arrival. Any d amage noted should be reported[...]

24 Installation Care must be take n to avoid trapping the line s e x - ce pt for s peci fi c purposes. Whe n traps are used, the horiz ontal dimensions should be as short as possible to a void exce ssive oil trapping. Lines f or ammonia systems mu st be of steel pipe with speci ally designed ammonia service fi ttings. Common pipe fi ttings must [...]

25 These precautions will av oid costly dam age to the equipmen t due to freezing. This inf ormation is take n from A SHRAE 15-89 and ANS I B31.5. The inst alling c ontrac tor should be thoroughly familiar with the se codes, as w ell as any local c odes. IV . ELECTRIC AL C O NNE C TIONS The single screw compre ssor units are shipped with all packag[...]

26 valves on the lo west par t of the syst em so the ga s will fl o at away from the c ompressor . This pre- ve nts any dir t or f oreign par ticles from e ntering the compres sor and contamina ting the working par ts. The oil should the n be charged int o the compres sor . Charge a sm all amount of ammonia in to the sys- tem and pre ssurize the s[...]

27 T o begin the second evacu ation, allow the pump to oper ate and reduce the pressure ag ain to within 50 to 1000 microns. After this reading is reac hed, allow the pump to operat e 2 or 3 hour s. St op the pump and let the system stand with this vacuum. Ag ain using dr y nitrogen, raise the system pre ssure to ze ro. For the thir d evacuation, f[...]

28 Af te r the system is leak -free and evacuation h as been c ompleted, it is ready f or charging. Be fore actual charging, ho wever , the entire ope ration of the refrige ration syste m should be inspec ted as outlined be low: A. Low Side E quipment 1. F ans on air handling equipme nt running. 2. Pumps on wate r cooling equipmen t r un- ning. 3. [...]

29 should show no bubbles, and there will be a liquid seal in the rec eive r . If these t wo c ondi - tions are not satis fi ed, additional re frigerant must be added. 5 . Whe n sufficient re frigerant ha s been char ged into the syste m, close the ch arging and drum valves. The n remov e the dr um from the system. 6. During the char ging period, [...]

30 15. Re move all ru st from equipment, cle an and paint. 16. Flush out sedime nt, et c. from water c ircuits. 17. Cle an all oil strainers. 18. Cle an suc tion straine r – compressors. 19. Check motors and fans f or shaft wear and end pl ay . 20. Check ope ration and gene ral condition of microproces sor and other e lec trical con- trols. 21. C[...]

31 St op Check V alve Installa tion Installation: The new design will apply only to the 2” thru 4” st op valves. R etro fi tting a fi eld install ation will require repl acing the bonnet asse mbly . The bonnet mu st be inst alled with the spring t owards the bottom (see illu strations abov e). The drill fi x ture is designed so th at the hol[...]

32 C OUPLING INFORMA TION COUPLING S INST ALLA TION AND ALIGNMENT These instructions are intended t o help you to install and align the coupling. C overed he re will be general inf ormation, hub mounting, alignme nt, asse mbly , locknut torquing, discp ack replace ment, and part numbers. The coupling a s receiv ed, may or m ay not be asse mbled. *I[...]

33 will result in a fl exing ele ment tha t is cen tered and parallel t o its mating fl ange fac es. Move the c on - nected equipment to acc omplish the above . NO TE: The disc pack is designed to an op timal thick - ness and is no t to be used f or axial adjustme nts. See documen tation that came with the c oupling for comple te speci fi cation[...]

34 4. T orque the long bolt locknuts at this time . NO TE: With the coupling in good alignmen t, the bolts will fi t through the holes in the fl anges and the disc pack more e asily . It is recomme nded that all locknuts be retighte ned af te r several hours of initi al operation. 5. For further help with the installa tion or align - men t, consu[...]

35 Slide V alve Actuator Installa tions Instruc tions Caution WHEN INST ALLING THE OPTIC AL SLIDE MO TOR, LOO SEN LOCKING C OLLAR BEFORE SLIDING THE COLLAR DO WN ON THE SHAF T . DO NOT U SE A SCREWDRIVER TO PR Y LOCKING C OLLAR INTO POS ITION. O VERVIEW Calibration of an op tical slide valve actuator is a two step proc ess tha t must be done for e [...]

36 Caution: there are wires attac hed to the con- nector on the plastic co ver . Handling the co ver too aggressive ly could break the wires. 7. Gently lif t the c over and tilt it t oward the T urck connectors. Raise the co ver e nough to be able to press the blue calibra te button and be able to see the red LED on the top o f assembly . 8. Press [...]

37 21. Use the INC button to ro tate the actuator to- wards its maximum po sition while watching the millivolt re adout on the controlle r screen. Discon tinue pressing the INC button when the millivolt re ading in the “Curren t” window is approxim ately 9200 milliv olts (7900 mil - livolts f or the 2783J quali fi ed analog bo ards). Y ou are [...]

38 Slide V alve Actuator Opera tion The slide valve actuat or is a gear -motor with a posi- tion sensor . The motor is powe red in the for ward and reve r se directions from the main comput er in the con trol panel. The position se nsor tells the main compute r the position of the slide valv e. The main comput er uses the po sition and process inf [...]

39 The actuator canno t be cali - brated The actuator goes in to cali- bration mode spon tane- ously The actuator goes in to cali- bration mode ev er y time powe r is restored after a powe r loss Dir t or debris is blocking one or both op tocoupler slo ts The photoc hopper fe nce extends less th an about half way into the optoc oupler slots The whi[...]

40 The motor wa s manually mov ed while the position sensor wa s not powe red. The motor brak e is not working properly The position se nsor’s EEPROM memory has failed The photoc hopper is misaligned with the slotted op tocouple r s The photoc hopper is positioned too low on the mo tor shaft. A motor be aring has f ailed There is a loo se connect[...]

41 Bad therm al switch Any o f the reasons listed in “The motor will no t move in e ither direc - tion” Stripped ge ars inside the gear mo - tor or the arma ture has c ome un - pressed from the arm ature shaft Re place the actuat or . See abov e. Re place the actuat or . The mot or r uns sporadically The mot or r uns but output sha f t will not[...]

42 Note 1: TP1 and TP2 are pl ated-thru holes located clo se to the slotted op tocouplers on the boar d. They are clearly mark ed on the board silkscreen lege nd. Note 2: The TS1 wire p ads are where the motor the rmal switch le ads solder int o the circuit board. They are c learly mark ed on the board silkscreen lege nd and are orient ed at a 45 d[...]

43 Operation Section Oil and its additives are cruc ial in system pe r formanc e. Vilte r Manufac turing will NO T APPRO VE non-Vilter oils for u se with Vilter compressors. Due to the innume rable choices a vailable it is not possible f or us to test all oils offe red in the marke t place , and their effects on our equipmen t. W e realize th at cu[...]

44 OIL SYSTEM A. Oil Charge Charge the oil se parator with the proper qu antit y of lubricating oil (see T able 2 in the Installation Section). CAUTION It is imperativ e you charge the oil into the rec eive r/ separat or prior to energi zing the control panel to preve nt burning out the immersion heater in the separat or/receiv er . During operatio[...]

45 T o replac e the filter ele ment(s), on single ele- ment tanks, inse r t the eleme nt and mak e sure it fits onto the outlet c onnec tion. Install spring plate , and bolt the co ver as sembly in place . On units equipped with dual ele ment tanks, insert inner e lement and m ake sure it fits onto the out - let connection. Put the ce ntering piec [...]

46 W et the O -ring in the new ele ment with cle an refriger ation oil. Inser t the new e lement in to the filter tank with the clo sed end visible and attach the co ver to the bowl. HAND TIGHTEN the c ove r . The filter hou sing can be evacuat ed and then slowly pressuri zed to check f or leaks bef ore re - turning to service. 4. Filter Remov al, [...]

47 FIGURE 3. T YPICAL WA TER C OOLED OIL COOLER DIAGRAM The solenoid valv e provides positiv e water shut - off when the c ompressor is not in opera tion. A tempe rature of 150°F is c onsidered high in most circumstance s and the compressor is protected by a safe t y control to prev ent ope ration of the com- pressor abo ve this tempe rature. Unle[...]

48 As the oil and desupserhe ating load varies, the tempe rature controlle r adjusts the speed of the pump/motor c ombination to main t ain a constan t oil temperature. NO TE: See separa te V-PLU S® instruc tion manu al for de- tailed star t -up and operation. 4. Thermo s yphon Oil Cooling Using a braz ed plate or an one pass she ll and tube t ype[...]

49 “Manual-Auto ” button is pressed, the oil pump will star t. When sufficie nt oil pressure is built up and the compressor cap acit y control and volume ratio slide v alves are at or belo w 10%, the compressor unit will start. If the compressor is in the aut omatic mode, it will now load and unload and vary the volume ratio in response t o the[...]

50 The Motor Amps Load Limit pro tec ts the c om - pressor from ov erloading by decre asing the compressor cap acit y if the motor amperage is at the Maximum Amps se tpoint, or preve nting an increa se in capacit y if the motor ampe rage is abov e the Full Load Amps setpoin t. ( See manual for the appropri ate microprocessor .) 3. Oil Separat or He[...]

51 Oper ation 4. Manually open the oil isola ting valve at the oil separat or outlet connection. 5. Open the isola ting valve(s) bef ore and af ter the oil filter hou sings. 6. Manually ope n the stop valve on the oil bleed return line from the ele ment section and open the expansion valv e 1/2 of a turn. FIGURE 6. OIL SEP ARA TOR BLEED LINE NOTE: [...]

52 Pre Star t -Up Checklists The follo wing checklists are to help pre pare the equipmen t before the Vilte r T echnician arriv es at the jobsite . Vilter rec ommends tha t a T rained T echnic ian go through the follo wing t a sks. The operating Manuals pro vided by Vilter , can be ref erenc ed for an y t ype of questions or speci al instr uctions.[...]

53 Field Piping and Mec hanical Require ments NOTE: If start-up service has been purchased, the follo wing items should be completed before the start- up technici an arrives. This will help sav e time and money . 1. The unit should be leve led and secured to the mounting pad or floor . 2. The suction and Discharge line must be piped and prope rly s[...]

54 Field Wiring R equireme nts VRS SCREW COMPRESSOR, VSS/VSM SINGLE SCREW COMPRES SOR UNITS PREST ART -UP CHECKLIST FIELD WIRING RE QU IREMENTS FOR UNITS WITH F ACT ORY WIRED VISSION ® MICR OPROCESSORS NO TE: If st ar tup se r vice has bee n purchased, t o save time and money , the following ite ms should be completed before the star tup technici [...]

55 St op Check V alve Ope ration AU T O In the “ Auto Po sition”, the stop valv e is opera ting as a check valve , allowing fl ow in the directions of the arrows. T o set the valve t o the automatic po si - tion, fully clos e the valve, and turn the ste m out as indicated b y the char t belo w. CL OSED In the manu ally “Closed Po stion”, t[...]

56 A) Disconnect the motor driv e coupling from the compres sor input shaft. B) Disconnect all ga s and oil piping which is at - tached to the c ompressor . Whe n removing the suction strainer on gas c ompression units, the suction line should be suppor ted to preve nt it from sagging. C) Re place oil drain in compre ssor housing and dis- char ge m[...]

57 INST ALLA TION OF THE COMPRESSOR A) Af ter the work h as been c ompleted, reinstall the compres sor on the base or C - fl ange ad apter (depe ndent upon c ompressor model). B) On the units, replac e the shims under the com- pressor f eet. Check for a soft foot. This is ac - complished b y tightening down three o f the hold down bolts and checki[...]

58 To p V i e w Direction of roto r moveme nt. Axial forc e at coupling to be 250-300l bs. Rigidly attach dial indicator . Position it on the axis of the compre ssor . Small woode n block or fulcrum. Force to be deter mine d by length of level arm. Ro tor Being Pushed By Use O f Lever Direc tion of rotor movement. Axial force at gate rotor to be 25[...]

59 T ABLE 2. GA TE RO T OR FLO A T E) NOTE: R eadings could be higher than 0.020. If readings are greater than 0.030 o ver table tolerance c ontac t Vilter’s home office . F) Inspec t the main and g ate rotors for signs o f ab - normal we ar due to dir t or othe r contaminan ts. G) Af te r the inspec tion is comple te, the c overs, coupling c ent[...]

60 For VS S 751/901 & VSS 1051 THRU 1301 compressors, use side rails and a ssemble to gaterotor st abilizer as stamped. Drive End GA TE RO TOR ASSEMBL Y C AUTION Gat e rotor remo val and assembly is divided int o distinct instr uctions, instruc tions for all VS S models and diffe rent instructions for all VSM mode ls. Please follo w the appropr[...]

61 E) Remo ve the hex head and sock et he ad bolts from the thrust be aring cove r . Insert t wo of the bolts into the thre aded jacking holes to a ssist in remo v- ing the co ver . Retain the shim pack and k eep it with the bearing hou sing cov er . F) Hold the gate ro tor suppor t with a suitable wrench on the fl a ts provided near the rolle r b[...]

62 REMO V AL (ALL VSM 301-701 MODELS) The remo val of the gate ro tor asse mbly for the VSM 301-701 compre ssors is similar for the VSS 901- 3001 compres sor s. The inne r races are secured to the stationary bearing spindle . A) Prepare the c ompressor for se r vicing. B) R emov e the upper bolt from the side co ver and install a guide stud in the [...]

63 E) Re move plug on the thrust be aring housing. Loose n the socke t head cap screw that is loca ted underne ath the plug. This secures the inner rac es of the thrust be arings to the s pindle. F) Remo ve bolts that hold the thru st bearing hous- ing to the c ompressor . Insert t wo of the bolts in to the threaded j acking holes to as sist in rem[...]

64 INST ALLA TION (All VSS Models) A) Install the gate ro tor suppor t by carefully tilting the roller be aring end of the g ate rotor support towar ds the suc tion end of the c ompressor . The compres sor input shaft may ha ve to be rotated to faci lit at e the inst alla tion of the gate ro tor sup - por t. Install gate ro tor stabilize r . The ga[...]

65 D) Se t the clearance be t ween the g ate rotor bl ade and the shelf . 1. Place a piece o f 0.003”-0.004” shim stock between the gat e rotor blade and the she lf. 2. Me asure the dep th from the top of the c om - pressor ca se to the top of the thru st bearing housing. This de termines the amount o f shims needed for the c orrec t cle arance[...]

66 Gaterotor for C - fl ange Models INST ALLA TION (All VSM 301-701 Models) A) Inst all the ga te rotor support. Carefully tilt the roller be aring end of the g ate rotor support to - wards the suction end of the c ompressor . The compres sor input shaft may ha ve to be rotated to fac ilit at e the installation of the ga te rotor suppor t. B) Inst[...]

67 GA TE RO TOR BLADE REMO V AL A) Re move the g ate rotor a ssembly . B) R emov e the snap ring and washe r from the gate rotor a ssembly . Lif t gate ro tor blade asse mbly off the gat e rotor suppor t. C) Check d amper pin and bushing f or exce ssive wear . Re place if nec essar y . Ser vice Re lief area faces T OP of asse mbly. T OP of assembly[...]

68 GA TE RO T OR BLADE INST ALLA TION A) Install dampe r pin bushing (120) in gat e rotor blade (111) from the back side of the bl ade. Be sure the bushing is fully se ated. B) Plac e the blade asse mbly on the gate ro tor sup - por t. Locating D amper ov er pin. C) Install washer (119) and sn ap ring (130) on gate rotor a ssembly . The bevel on th[...]

69 GA TE RO T OR THRUST BEARING INST ALLA- TION A) For install ation of thrust be arings on VSS units : 1) Inst all be arings (126) in the housing so the bearing s are face to fac e. The large r sides of the inne r races are plac ed together . A light application of clean c ompressor lubricating oil should be used t o ease the installa tion of the [...]

70 GA TE RO T OR ROLLER BEARING REMOV AL A) Re fer to section REMO V AL ( All VSS & VSM) for remo val of the gate ro tor bearing hou sings and gat e rotor suppor ts. B) Remo ve the snap ring (131), which re t ains the roller be aring in the bearing housing. C) R emov e the roller bearing (125) from the be aring housing (112). D) Use a be aring [...]

71 COMPRESSOR S HAF T SE AL REPLA CEMENT COMPRESS OR SHAF T SE AL REMO V AL A) Prepare the c ompressor for se r vicing as outlined in section REMOV AL. B) Remo ve bolts (281) holding the shaft seal c over (218). Insert t wo of the bolts int o the threaded jacking holes t o assist in remo ving the cov er . There will be a sm all amount of oil draina[...]

72 COMPRES SOR SE AL INST ALLA TION NO TE: When re placing the stationary members of the seal on the VSS 451 thru VSS 601 the roll pin in the c over is us ed only with the seal ass embly having a station- ar y mirror fac e. If a seal a ssembly with a st ationar y carbon fa ce is installed, the roll pin mu st be removed . A) Install new oil seal in [...]

73 shoulder on the input sh af t. Mak e sure the seal is sea ted against the shoulder . If the seal is not fully sea ted against the shoulder , the shaft seal carbon will be dam aged when the seal c ove r is ins talled. Mainte nance Suggestion: A spray bo ttle fi lled with clean c ompressor oil may be u sed to lubricate the f aces of the se als wi[...]

74 INSP ECTION OF SLIDE V AL VE ASSEMBLIES IN THE COMPRESS OR Prepare the c ompressor for se r vicing. A) Re move the ga te rotor acc ess cov ers. Using a mirror and fl ashlight, visu ally inspec t the slide valve carri age through the gas bypa ss opening. Look f or any signi fi cant signs o f wear on the slide valve carri age. B) T o check the c[...]

75 D) Locate and re move the sock et head plug s above the slide valve carri age attachment bolts. R e- mov e the bolts located under the plug s. E) The slide valve carriage ma y now be remov ed. On newe r carriages there is a thre aded hole in the back of the slide valve carri age to aid in its remo val. Use a threaded tip slide h ammer to aid in [...]

76 COMMAND S HAF T A SSEMBL Y REMOV AL The follo wing steps can be u sed to remov e or install eithe r the capacit y or volume c ommand sha f t as- semblies. A) Prepare the c ompressor for se r vicing. B) Follow the appropri ate instruc tions to re move con trol ac tuat or . C) R emov e four socke t head cap screws (457) and Nord-Lock washe r s (47[...]

77 C) The command sh af t bearing (435) is a pre ss fi t on the comm and shaft (413). Remo ve the comm and shaft bearing with a suitable press. D) Re move the O-ring seal (445) from the com- mand sh af t housing. The c ommand shaft bush- ing (433 and 436) might hav e to be remo ved to gain acc ess to o -rings. R epl ace bushing if the bore is deep[...]

78 DISCHAR GE MANIFOLD INST ALLA TION A) Install (2) guide rods to position the dischar ge manif old. Install a new manifold g aske t and the dischar ge manifold. Install the dowe l pins and bolts, tighten m anifold bolts to the rec om - mended t orque value. B) On VSS 451-3001 c ompressors install the dis- char ge spool or elbow be t ween the disc[...]

79 C) T o remo ve the cross sha f ts, remov e socket he ad bolts, clamp and s pacers from both sides. VSS 751-2101 compressors cross shafts. VSM 301-701 & VSS 2601-3001 c ompressor s cross shafts V olume con trol cross shaft. Capacity control cros s shaft. D) Drive the roll pins from pinion gear from one side. R emo ve pinion gear . Slide the c[...]

80 T orque Specifications (ft -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 Grade 5 Coarse (UNC) -- 1 8 ------- SAE Grade 8 Coarse (UNF) - 11 22 39 63 96 138 191 338 546 Sock[...]

81 Ser vice USING A T ORQUE WRENCH C ORRECTL Y T ORQUE WRENCHES USING A T ORQUE WRENCH CORRE CTL Y INVOL VES FOUR PRIMARY C ONCERNS: A. A smooth ev en pull to the break point is required. Je rking the wrench can cause the piv ot point to break e arly leaving the bolt at a tor que value lower then required. No t stopping when the break point is re a[...]

82 A. The Nord -Lock ® lock washer sets are u sed in many area s in both the VSG & VSSG screw c ompressors that require a vibration proof lock wa sher . B. The lock washe r set is asse mbled so the course serrations th at resemble ramps are m ated togethe r . C. Once the lock wa sher set is tighte ned down, it takes more f orce to loo sen the [...]

83 Ser vice 6.00 OIL FIL TER ELEMENTS The follo wing is a description of the oil filte r eleme nts supplied on standard VSS, VSR and VS M single screw compressor units 6.01 1833C FIL TER ELEMENTS Vilter P ar t Number 1833C Usage VSS 451 to VS S 1801 Dates All units prior to 3-1-00 Length 18” Diamet er 6-1/8” A) Characteristics ; 1) The outside [...]

84 6.02 K T 721 FIL TER ELEMENTS Vilter Part Number K T 721 T ank O -Ring 2176BU Usage VSR Compressors Dates 1992 to 8-1-96 Length 8” A) Characteristics ; 1) Pleated type eleme nt with a screen co vering the sur face o f the eleme nt. 2) One end of the ele ment is solid while the othe r has a pilot hole with a captiv e “o ”-ring. 6.03 K T 722[...]

85 Simplex filter hou sing. Duplex filter hou sing. 6.04 KT 773A & B FIL TER ELEMENTS Vilter P ar t K T 773A K T 773B Number T ank O -Ring 2176BY 2176BZ Usage 3109A 3111A Duplex Simplex Housing Housing Usage 1. VS M all models 4/1/00 to presen t. 2. VS S 451 to 1301 models with 30” and smalle r oil separators 3/1/00 to present. Length 16” A[...]

86 6.05 K T 774 FIL TER ELEMENTS Vilter Part K T 774 Number T ank O -Ring 2176BY Usage 3112A 3110A Simplex Duplex Housings Housing s 1. VSS 1501 & 1801 3-1-00 to presen t. 2. All othe r VSS models with 30” and large r oil separators 3/1/00 to prese nt. Length 39” C) Characteristics ; 1) Pleated type eleme nt with a screen co vering the surf[...]

87 Mainte nance NO TE: See Motor Manu al for proper lubrication proc edures and ser vic e intervals. Re frigeration Mainte nance and Inspection Schedule The follo wing ser vice int er vals are based on the u sage of Vilter Manufacturing Corporation Premium Grade re frig - era tion oil in VSS, VSM and VSR Single Screw Compressor units. SERVICE INTER[...]

88 R ecomme nded Spare Par ts List R efer t o the Custom Manual Spare Par ts Section for Speci fi c Applications Plea se have y our Model # and Sales Orde r # available whe n ordering. These are found on the c ompressor’s Name Plate . VSS P ar ts Sec tion[...]

89 Gate Rotor 111 120 135 11 9 130 141 131 125 11 0 126 142 143 11 8 121 122 123 124[...]

90 Gate Rotor MODEL NUMBER VSS 451 VSS 601 VSS 751 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN GA TE ROTOR BLADE AND BEARING REPLACEMENT KIT (1 1 1, 1 18, 120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 141, 142, 143) 2 KT712A 2 KT712B 2 KT712C GA TE ROTOR BLADE REPLACEMENT KIT (1 1 1, 1 18, 120A, 120B, 121, 122, 123, 124, 130, 141, 142, 143) 2 KT[...]

91 Gate Rotor MODEL NUMBER VSS 901 VSS 1051 VSS 1201 VSS 1301 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN GA TE ROTOR BLADE AND BEARING REPLACEMENT KIT (1 1 1, 1 18, 120A, 120B, 121, 122, 123, 124, 125, 126, 130,131, 141, 142, 143) 2 KT712D 2 KT712E 2 KT712F 2 KT712Y GA TE ROTOR BLADE REPLACEMENT KIT (1 1 1, 1 18, 120A, 120B, 121, 122, 123, 12[...]

92 Gate Rotor MODEL NUMBER VSS 1551 VSS 1851 VSS 2101 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN GA TE ROTOR BLADE AND BEARING REPLACEMENT KIT (1 1 1, 1 18, 120A, 120B, 121, 122, 123, 124, 125, 126, 130, 131, 141, 142 & 143) 2 KT712L 2 KT712M 2 KT712K GA TE ROTOR BLADE REPLACEMENT KIT (1 1 1, 1 18, 120A, 120B, 121, 122, 123, 124, 130, 141, 142 &a[...]

93 Shaf t Seal 230 260 219 Shaf t Se al With Stationar y Carbon F ace 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[...]

94 Main R otor 207 201[...]

95 MODEL NUMBER VSS 451 VSS 601 VSS 751 VSS 901 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN 201 ROTOR ASSEMBL Y 1 A25226BB 1 A25226BA 1 A25226CB 1 A25226CA 207 SHIM P ACK 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 ASSEMBL Y 1 A25226DB 1 A25[...]

96 Slide V alv e Cross Shaf ts and End Plate 297 286 226 298 222 268 269 297 228 226 227 VSS 291 THRU VSS 601 ONL Y 286 221 268 222 298 269 228 VSS 291 THRU VSS 601 ONL Y NO SP ACER THIS SIDE OF SHAFT ASSEMBL Y NOTE: BOTH ACTUA TOR SHAFT ASSEMBLIES ARE IDENTICAL ON VSS COMPRESSORS.[...]

97 Slide V alv e Cross Shaf ts 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[...]

98 305 300 345 316 347 378 380 350 360 361 363 323 304 343 Capac it y Slid e V olume Slide Carriage Assembly Slide V alv e C arriage Assembly[...]

99 Slide V alv e C arriage 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 ASSEMBL Y 2 A25179B 2 A25179C 2 A25179D 2 A25179DSR 304 CAP ACITY PISTON (340, 341, 350, 355) 2 A25183B 2 A25183C 2 A25183D 2 A25183DN 305 VOLUME PISTON (340, 342, 350, 355) 2[...]

100 Slide V alv e C arriage Assembly MODEL NUMBER VSS 1551 thru VSS 2101 ITEM DESCRIPTION QTY VPN 300 CARRIAGE ASSEMBL Y 2 A25179E 304 CAP ACITY 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 2[...]

101[...]

102 Actuator & Command Shaft 401 400 446[...]

103 Actuator & Command Shaft 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 400 COMMAND SHAFT ASSEMBL Y 2 A25994B 2 A25994C 2 A25994D 2 A25994E 401 SLIDE V AL VE ACTUA TOR 2 25972D 2 25972D 2 25972D 2 25972D 446 O-RING SEAL 2 2176X 2 2176X 2 21[...]

104 VSS Screw Compressor 512 530 530 536 536 540 513 545 518 506 504 514 513 514 506 554 545 519 528 536 536 536 536 547 504 528 545 514 513 545 514 504 514 545 Misce llaneous F rame Componen ts * *[...]

105 Misce llaneous F rame Componen ts 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 - GASKET & O-RING KIT 1 KT710A 1 KT710B 1 KT710C 1 KT710J 504A FLANGE SET (513A, 514A, 545A) 1 A25190A 1 A25190A 1 A25190B 1 A25190A 504B* FLANGE SET (513B, 514B, 545B) 2 A25190B - N[...]

106 Misce llaneous F rame Componen ts MODEL NUMBER VSS 1551 thru VSS 2101 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN - GASKET & O-RING KIT 1 KT710D 504A FLANGE SET (513A, 514A, 545A) 1 A25190C 504B* FLANGE SET (513B, 514B, 545B) 2 A25190D 504C* FLANGE SET (513B, 514C, 545C) - N/A 506A PLUG SET , ECONOMIZER (514C, 528, 545B) - N/A 506B PLU[...]

107[...]

108 R eplac ement T ools T O REMOVE BEARING T O INST ALL BEARING 901 FOR VSS 451, VSS 601, DO NOT USE SIDE RAILS. FOR VSS 751, VSS 901, VSS 1051 AND VSS 1201, ASSEMBLE SIDE RAILS AS ST AMPED. FOR VSS 1551 AND 1801, SIDE RAILS ASSEMBLE ONL Y ONE W A Y . GA TE ROTOR SUPPORT 901 900 BALL BEARING HOUSING 901 900[...]

109 R eplac ement T ools 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 900 GA TE ROTOR T OOLS 1 A25205B 1 A25205C 1 A25205C 1 A25205E 901A GA TE ROTOR ST ABILIZER SET (901A, 901B, 901C) 1 A25698A 1 A25698A 1 A25698A - N/A 901B GA TE ROTOR ST ABILI[...]

11 0[...]

111 VSM 301-701 R eplac ement P ar ts Sec tion R ecomme nded Spare Par ts List R efer t o the Custom Manual Spare Par ts Section for Speci fi c Applications Plea se have y our Model # and Sales Orde r # available whe n ordering. These are found on the c ompressor’s Name Plate .[...]

11 2 Gate rotor Assembly[...]

11 3 Gate rotor Assembly Part totals indicated are for one gate rotor assembly , machines with two gate rotors will require double the components listed below . MODEL NUMBER ITEM DESCRIPTION VSM 301 VSM 361 VSM 401 QTY VPN QTY VPN QTY VPN 100 SUPPORT ASSEMBL Y 1 10 & 135B. 1 A25222AB 1 A25222AA 1 A25222AC 101 GA TE ROTOR & DAMPER ASSEMBL Y [...]

11 4 Part totals indicated are for one gate rotor assembly , dual gate machines will require double the components. MODEL NUMBER ITEM DESCRIPTION VSM 501 VSM 601 VSM 701 QTY VPN QTY VPN QTY VPN 100 SUPPORT ASSEMBL Y 1 10 & 135B. 1 A2601 1BB 1 A2601 1BA 1 A2601 1BA 101 GA TE ROTOR & DAMPER ASSEMBL Y 1 1 1,120. 1 A26002BB 1 A26002BA 1 A26002B[...]

11 5 MODEL NUMBER ITEM DESCRIPTION ALL VSM 301-401 ALL VSM 501-701 QTY VPN QTY VPN * SHAFT SEAL KIT (AMM) 219, 230, & 260. 1 KT709D 1 KT709A * SHAFT SEAL KIT (HALO) 219, 230, & 260 1 KT781D 1 KT781A 219 SHAFT SEAL. 1 A 1 A 230 OIL SEAL. 1 2930C 1 25040A 244- TEFLON SEAL 1 25939A 1 25939A 252- RET AINER RING 1 2928M 1 2928M 260 O-RING 1 2176[...]

11 6 Main R otor , Slide V alve Cro ss Shaf ts & End Plate Models VSM 301-401 Coun ter Clockwise ONL Y[...]

11 7 MODEL NUMBER ITEM DESCRIPTION VSM 301 VSM 361 VSM 401 QTY VPN QTY VPN QTY VPN 201 MAIN ROT OR ASSEMBL Y . 1 A25226AB 1 A25226AA 1 A25226AC 203 OIL BAFFLE ASSEMBL Y (1) 217, (1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA SHIM ASSORTMENT (2) 240, (2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A 220 END PLA TE. 1 2571[...]

11 8 Main R otor , Slide V alve Cro ss Shaf ts & End Plate Models VSM 501-701 C lock wise ONL Y[...]

11 9 MODEL NUMBER ITEM DESCRIPTION VSM 501 VSM 601 VSM 701 QTY VPN QTY VPN QTY VPN 201 MAIN ROTOR ASSEMBL Y . 1 A26010BB 1 A26010BA 1 A26010BC 203 OIL BAFFLE ASSEMBL Y (1) 217, (1) 244, (1) 248, (1) 249, (1) 252. 1 A26034B 1 A26034B 1 A26034B SHIM ASSORTMENT (2) 240, (2) 241, (1) 242, (1) 243 1 A25177B 1 A25177B 1 A25177B 220 END PLA TE. 1 26025B 1[...]

120 V olume Ratio Capac it y Slide Carriage Assembly Slide V alv e C arriage Assembly Assembly Includes Carriage and Slides.[...]

121 Slide V alv e C arriage Assembly MODEL NUMBER ITEM DESCRIPTION ALL VSM 301-401 ALL VSM 501-701 QTY VPN QTY VPN 300 CARRIAGE ASSEMBL Y . 1 A25179A 1 A26012B 304 CAP ACITY PISTON 340, 341, 350 & 355. 1 A25183A 1 A25183B 305 VOLUME PISTON 340, 342, 350 & 355 . 1 A25184A 1 A25184B 316 CAP ACITY RACK. 1 25023D 1 25024A 318 CAP ACITY RACK SHA[...]

122 Actuator & Command Shaft[...]

123 MODEL NUMBER VSM 291 thru VSS 751 thru VSS 1051 thru VSS 1551 thru ITEM DESCRIPTION VSM 601 VSS 901 VSS 1201 VSS 2101 QTY VPN VPN VPN VPN 400 COMMAND SHAFT ASSEMBL Y 2 A25994B A25994C A25994D A25994E 401 SLIDEV AL VE ACUA TOR 2 25972D 25972D 25972D 25972D 446 O-RING SEAL 2 2176X 2176X 2176X 2176X Actuator & Command Shaft[...]

124 Model VSM 501-701 Misce llaneous F rame Componen ts Model VSM 301-401[...]

125 MODEL NUMBER ITEM DESCRIPTION ALL VSM 301-401 ALL VSM 501 - 701 QTY VPN QTY VPN 512 MANIFOLD GASKET . 1 25737A 1 26037A 514 ECON-O-MIZER GASKET . 2 1 1323GG 2 1 1323D 522 COUPLING LOCK PLA TE N/A 1 25004D 523 LOCK W ASHER N/A 1 3004H 528 ECON-O-MIZER PLUG. 2 25419A 2 25397K 530 O-RING N/A 2 2176BF 540 DOWEL PIN 2 2868B 2 2868B 542 PIPE PLUG 3 2[...]

126 Housing Acc essories Misce llaneous F rame Componen ts[...]

127 MODEL NUMBER ITEM DESCRIPTION VSM 301 - 701 QTY VPN 1 17 GA TE ROTOR COVER. 1 25416B 1 18 COVER GASKET . 2 25259B 129 GASKET . 1 1 1323T 180 INLET SCREEN. 1 25920A 343 PISTON COVER. * 1 25724B Housing Acc essories Misce llaneous F rame Componen ts MODEL NUMBER ITEM DESCRIPTION VSM 301 - 401 VSM 501 - 701 QTY VPN QTY VPN 345 O-RING. 4 2176BX 4 2[...]

128 MODEL NUMBER ITEM DESCRIPTION ALL VSM 301-401 ALL VSM 501-701 QTY VPN QTY VPN 901 GA TEROTOR ST ABILIZER. 1 25742A 1 25742B 902 SEAL INST ALLA TION TOOL 1 25455A 1 25455B R eplac ement T ools[...]

129 ICM/IC AD Mot orized V alve Setup Instructions The f ollowing items need t o be setup in order f or the valv e to operat e properly . 1. Press the “ Circle” button on the valv e. A v alue of “01” should be shown on the screen. 2. Press the “ Circle” button. The re should be a value of “1” shown. If no t use the up/down arrows to[...]

130 13. Press the “Up” arro w button until a value of “26” is sho wn on the screen. 14. Press the “ Circle” button. Pre ss the up/down arrow buttons to c hange the value to the correct valve th at is on the unit. The value number is list ed on the valve . The values and valve s are as follo ws: 0: No valve se lec ted. Al arm A1 will bec[...]

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ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting 2 DKRCI.EI.HT0.A1.22 / 520H1639  ¢ Danfoss (USCO / MKS), 11- 2006 Cont ents Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting 4 DKRCI.EI.HT0.A1.22 / 520H1639  ¢ Danfoss (USCO / MKS), 11- 2006 Care should be tak en to protect the ICM func tion module while it is remov ed from the valve body . 3. W eld the valve body in line making sure the arrow on the valve body is pointing in the direction of [...]

ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting ¢ Danfoss (USCO / MKS), 11 - 2006 DKRCI.EI.HT0.A1.22 / 520H1639 5 Wiring the ICAD Note: The ICAD is powered by a 24 V olt DC power source . There are tw o cables pre -mounted and connected to the ICAD motor actuator . Never try to open the ICAD motor because the special moi[...]

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ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting ¢ Danfoss (USCO / MKS), 11 - 2006 DKRCI.EI.HT0.A1.22 / 520H1639 9 ICAD Parameters Description Display name Min. M ax. F actor y setting Unit Comments ICM OD (Opening Degree) - 0 100 - % ICM valve Opening Degree is display ed during nor mal operation. Running display value ([...]

ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting 10 DKRCI.EI.HT0.A1.22 / 520H1639  ¢ Danfoss (USCO / MKS), 11- 2006 T roubleshooting The Manual T ool The manual tool should alway s be ordered with any ICM/ICAD assembly . This tool gives the user the ability to remove the ICAD actuator and manually rota te the valve in [...]

ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting ¢ Danfoss (USCO / MKS), 11 - 2006 DKRCI.EI.HT0.A1.22 / 520H1639 11 Alarms There ar e a number of alarms which are excellent indicators of impr oper installation or set-up: Description ICM alarm text Comments No valve type selected A1 At start-up A1 and CA will be displayed [...]

ICM/ICAD Motorized Valv e Installation, Programming , and T roubleshooting 12 DKRCI.EI.HT0.A1.22 / 520H1639  ¢ Danfoss (USCO / MKS), 11- 2006 Danfoss · Refrigeration & Air-Conditioning Division · 7941 Corporate Drive · Baltimore, MD 21236 Ph 410-931-8250 · Fax 410-931-8256 · E-mail: baltimore@danfoss.com · I nternet: ww w .danfoss.com[...]

143 Appendix A: Pre S tar t Up for R emote Oil Coole r s[...]

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35391S Rev . 8b (10/12) Emerson and Vilter are trade marks of Emerson Electric Co. or one of its affi liated c ompanies. © 2012 Emerson Climate T echnologies, Inc. All rights reserved. Printed in the USA.[...]