Home

35391S - Rev 08b - Booklet.indb

1. Optional position feedback Only possible with EKC 347 WEE L Optional UPS battery back up e CUSTOMER SUPPLIED 6 DKRCI EI HTO A1 22 520H 1639 Danfoss USCO MKS 11 2006 ICM ICAD Motorized Valve Installation Programming and Troubleshooting Terminal box is customer supplied Wiring diagram showing ICAD wired with a digital input for ON OFF solenoid valve operation Note The ICAD motor can be programmed to open or close when the relay is closed See parameter j09 in programming section Optional UPS battery back up al E I n SUPPLIED Wiring diagram showing ICAD digital Terminal box is customer supplied outputs wired with customer supplied auxiliary relays E Note The same 24 Vd c power supply that powers the ICAD can be used with the ICAD digital outputs to power auxiliary relays or other small load devices but please note that the system will no longer be galvanically isolated K1 Common Alarm Optional UPS K2 ICM fully open battery back up K3 ICM fully closed 24V d c Power Supply an SUPPLIED Danfoss USCO MKS 11 2006 DKRCI EI HTO A1 22 520H1639 7 ICM ICAD Motorized Valve ICAD Overview Operating the ICAD Menu Darf Installation Programming and Troubleshooting Before programming it is important to understand the functionality ofthe ICAD actuator 1 The ICAD is a digital stepper mot
2. 25588A 25132A 25086A 25104A 25760 25089 25089AB 25089AC 25089AD 2864G 2865A 2866B 2867L 2868H 25910B 2176AJ 2176AM 2176U KT712Y KT713Y A25161DH A25164D 25587A 25588F 25132A 25086A 25104A 25760B 25089AA 25089AB 25089AC 25089AD 2864G 2865A 2866B 2867L 2868H 25910B 2176AJ 2176AM 2176U 91 Gate Rotor MODEL NUMBER VSS 1551 VSS 1851 VSS 2101 QTY VPN QTY VPN QTY VPN ITEM DESCRIPTION 92 GATE ROTOR BLADE AND BEARING REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 125 126 130 131 141 142 amp 143 GATE ROTOR BLADE REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 130 141 142 amp 143 GATE ROTOR ASSEMBLY 111 120 GATE ROTOR SUPPORT ASSEMBLY 100 111 120B 119 130 GATE ROTOR GASKET SET 118 141 142 amp 143 SHIM PACK SET 2 424 2 122 1 123 1 194 SUPPORT GATE ROTOR SMALL BEARING HOUSING LARGE BEARING HOUSING RETAINER RETAINER BALL BEARING COVER GATE ROTOR COVER GATE ROTOR COVER GASKET WASHER BUSHING SMALL DOWEL PIN BUSHING LARGE DOWEL PIN SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 ROLLER BEARING BALL BEARING RETAINING RING RETAINING RING DOWEL PIN SM 0 250 O D DOWEL PIN LARGE 0 500 O D O RING ROLLER BEARING HOUSING O RING BALL BEARING HOUSING O RING BEARING HOUSING COVER HEX HEAD CAP SCREW HEX HEAD CAP SCREW HEX HEAD CAP
3. If coupling is assembled remove the bolts that at tach the hubs to the disc packs Remove both hubs Leave the disc packs attached to the center member A Hub Mounting 1 Clean hub bores and shafts Remove any nicks or burrs If bore istapered check for good contact pattern If the bore is straight measure the bore and shaft diameters to assure proper fit The key s should have a snug side to side fit 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 1 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 fit 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 indica torto 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 de sired axial position Use the indicator as a quide only A pre set axial stop device can be helpful Check the final 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 ho
4. Vilter single screw compressor units are basi cally vibration free machines therefore no elaborate foundations are necessary The floor or foundation upon which the unit will be placed should be designed to support the entire op erating weight of the unit See Table 1 for unit weights See Foundation page 12 for additional foundation instructions II LOCATING UNIT DRIVE COUPLING The single screw compressor units are shipped with all major components mounted on struc tural steel Place the entire unit on the floor 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 con crete 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 compres sor 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 align ment 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 SYSTEM PIPING
5. een eier 12 ana HNO 19 gt gt gt _ ____________________ 23 Slide Valve Actuator Installation amp Calibration 35 Slide Valve Operation 38 Slide Valve Actuator Trouble Shooting Guide 39 S 43 Notice on using Non Vilter Oils 43 uu uuu Ad Pre StartUp Checklists nenne eins 52 Field Piping and Mechanical Requirements 53 Field Wiring Requirements 54 Stop Check Valve Operation 55 slc 56 Musicae 87 IIS S 6 Mizar eagle 98 24 0 10 RA 89 93 u u 94 Slide Valve Cross Shafts an
6. 2 889 0 74 266 2 889 0 74 266 2 889 0 74 266 2 889 0 74 266 2 889 0 82 295 3 200 162 1 767 162 1 767 162 1 767 162 1 767 162 1 767 162 1 767 162 1 767 162 1 767 162 1 767 Operation 3 Suction Pressure Low suction pressure cutout stops the compres sor unit when the suction pressure drops below the setpoint 4 Oil Filter Differential High oil filter differential cutout stops the com pressor unit when the difference between the outlet and inlet of the filter exceeds the setpoint 5 Oil Temperature The oil temperature cutout stops the compres sor 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 tem perature exceeds the setpoint INITIAL START UP A Setting of Controls Refer to the appropriate microprocessor manual for a list of initial settings B Valve Settings 1 The suction line uses separate stop and check valves Ensure the suction stop valve is open prior to starting 2 suction equalization valve should be closed during operation The valve enables the unit to slowly equalize to low side pressure dur ing off periods This valve must be adjusted to minimize oil loss when compressor stops 3 Thedischarge line uses separate stop and check valves Ensure the discharge valve is o
7. 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 filter and other piping becomes charged with the normal amount of oil that will be in circulation This drop in oil level should bring the level in the oil receiver separator into the normal operating range Do not mix oils A Oil For Single Screw Compressors Due to the need for adequate lubrication Vilter recommends only the use of Vilter lubricants designed specifically for Vilter compressors With the extensive research that has been per formed we are able to offer refrigerant specific lubricating oils Use of oil not specified or sup plied by Vilter will void the compressor warranty Please contact your local Vilter representative or the Home Office for further information VII SYSTEM REFRIGERANT CHARGING CAUTION When charging the system make sure the compressor unit is pressurized from the dis charge 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 27 28 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 refrigerat
8. 93 Main Rotor 94 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 25226 1 A25226CB A25226CA 207 SHIM PACK 1 25177 1 25177 1 25177 25177 MODEL NUMBER VSS 1051 VSS 1201 VSS 1301 VSS 1551 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN 201 ROTOR ASSEMBLY A25226DB A25226DA 25752 A25226EC 207 SHIM PACK A25177D A25177D 251770 25177 MODEL NUMBER VSS 1851 VSS 2101 ITEM DESCRIPTION QTY VPN QTY VPN 201 ROTOR ASSEMBLY A25226ED A25226EE 207 SHIM PACK A25177E A25177E 95 Slide Valve Cross Shafts and End Plate ra IPL ZZ A 7222 ZZ 22 N VSS 291 THRU VSS 601 ONLY SPACER THIS SIDE OF SG SHAFT ASSEMBLY 4 VSS 291 THRU VSS 601 ONLY NOTE BOTH ACTUATOR SHAFT ASSEMBLIES ARE IDENTICAL ON VSS COMPRESSORS 96 Slide Valve Cross Shafts and End Plate MODEL NUMBER VSS 1551 thru VSS 2101 VSS 291 thru VSS 601 VSS 751 VSS 901 VSS 1051 VSS 1201 VSS 1301 ITEM DESCRIPTION SHAFT GEAR RACK CLAMP RACK CLAMP SPACER DOWEL PIN EXPANSION PIN EXPANSION PIN PIPE PLUG SOCKET HEAD CAP SCREW SET SCREW SET SCREW QTY VPN QTY VPN QTY VPN QTY VPN NO 25843A 25027A 25913A 25913B 25847A N A 1193D 2981AA N A 2795 20604 2060 Oo Nj P N RAD n5 25844A 25027A 25913C N A 2
9. 2 4 20 Define condition at power cut when fail safe is installed 1 Close valve Fail safe i 2 Open valve 3 Maintain valve position 4 Go to OD given by 112 Define function when DI is ON short circuited DI terminals when j02 2 Digital Input function 1 2 1 Open ICM valve DI OFF gt Close ICM valve 2 Close ICM valve DI OFF gt Open ICM valve 199 Enter number to access password protected parameters 126 Password 11 old i AI A99 Old alarms will be listed with the latest shown first Alarm list can be reset by means of activating down arrow and up arrow at the same time for 2 seconds Only active 107 4 Jovatpowert m If fail safe supply is connected and powercut occurs ICM will go to entered OD NB Password protected Password 11 At first start up A1 will flash in display Enter valve type 0 No valve selected Alarm A1 will become active 1 ICM20 with ICAD 600 ICM configuration 2 ICM25 with ICAD 600 3 1CM32 with ICAD 600 4 ICM40 with ICAD 900 5 ICM50 with ICAD 900 6 ICM65 with ICAD 900 Danfoss USCO MKS 11 2006 DKRCI EI HTO A1 22 520H1639 9 Analog Output signal ICM ICAD Motorized Valve Troubleshooting The Manual Tool Service Parameters 10 Installation Programming and Troubleshooting The manual tool should always be ordered with any ICM ICAD assembly This tool gives the user the ability to remove the ICAD act
10. Attach the vacuum gauge to the system in accordance with the manufacturer s instructions A single evacuation of the system does not satis factorily remove all of the non condensable air and water vapor To do a complete job a triple evacuation is recommended When the pump is first 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 pres sure 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 syst
11. DESCRIPTION VSM 301 701 GATE ROTOR COVER 25416B COVER GASKET 25259B GASKET 11323 INLET SCREEN 25920A PISTON COVER 25724B MODEL NUMBER ITEM DESCRIPTION VSM 301 401 VSM 501 701 4 2176BX 2176CA 2 2176BG 2176BG 127 Replacement Tools ITEM 902 IS USED TO SET THE STAINLESS STEEL SEAL CUP INTO THE SEAL HOUSING WITHOUT TOUCHING THE CARBON SEAL NOSE SEAL NOSE CUP 172 SCALE O RING 173 SCALE ITEM DESCRIPTION 901 GATEROTOR STABILIZER 25742A 902 SEAL INSTALLATION TOOL 25455A 128 Danfoss Liquid Injection Valve Setup ICM ICAD Motorized Valve Setup Instructions The following items need to be setup in order for the valve to operate properly 1 2 9 Press the Circle button on the valve A value of 01 should be shown on the screen Press the Circle button There should be a value of 1 shown If not use the up down arrows to change it to the correct value Press the Circle button when done Press the Up arrow button A value of 02 should be shown on the screen Press the Circle button There should be a value of 1 shown If not use the up down arrow buttons to change it to the correct value Press the Circle button when done Press the Up arrow button A value of 03 should be shown on the screen Press the Circle button There should be a value of 2 shown If not use
12. Position the slide valves to the center of the car riage Placethe 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 75 76 Service COMMAND SHAFT ASSEMBLY REMOVAL The following steps can be used to remove or install either the capacity or volume command shaft as semblies 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 gt 4 amp V COMMAND SHAFT ASSEMBLY INSTALLATION A Install the command shaft assem
13. RTD s COMPRESSOR Inspect Compressor Bearings Key Inspect R Replace S Sample Notes 1 Theoilshould be changed at these intervals unless oil analysis results exceed the allowable limits The frequency of changes will depend on the system cleanliness 2 Oilanalysis should be done at these intervals as a minimum the frequency of analysis will depend on system cleanliness 3 The oil filter s 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 87 VSS Parts Section Recommended Spare Parts List Refer to the Custom Manual Spare Parts Section for Specific Applications Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate 88 Gate Rotor N N 99 Gate Rotor MODEL NUMBER VSS 451 VSS 601 VSS 751 QTY VPN QTY VPN QTY VPN ITEM DESCRIPTION GATE ROTOR BLADE AND BEARING REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 125 126 130 131 141 142 143 GATE ROTOR BLADE REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 KT712A KT712B KT712C 90 130 141 142 143 GATE ROTOR SUPPORT ASSEMBLY 100 111 120B 119 130 GATE ROTOR GASKET SE
14. dimensionally as blades installed originally at fac tory 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 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 Check for 0 003 to 0 004 Clearance Between Gaterotor Blade and Partition O RE 65 66 Check for 0 003 to 0 004 Clearance Service INSTALLATION All VSM 301 701 Models A Between Gaterotor Blade and Partition Gaterotor for C flange Models Install the gate rotor support Carefully tilt the roller bearing end of the gate rotor support to wards 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 the roller bearing housing with a new O ring Tighten the bolts to the recommended torque value Install the spindle with shims and o ring tighten the bolts to the recommended torque value measure the clearance between the shelf and blade Check the clearance between the entire gate rotor blade and the shelf rotate the gate rotor to find the tightest spot It should be between 0 003 0 004 Make adjustments if necessary
15. the actuator and drive it back to its mini mum position below 5 for pre start up Note Now the Current Cap or the Current Vol value will be displayed in the window onthe Main screen andthe Slide Calibration screen 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 Enable the Slide Non Movement Alarm by go ing to the Setup menu and choosing Alarm Enable for the Slide Non Movement Option This completes the calibration for this chan nel either capacity or volume Repeat the Same procedure to the other channel 3l 38 Slide Valve Operation Slide Valve Actuator Operation The slide valve actuator is a gear motor with a posi tion 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 mo tor turns On the shaft of the motor is a small alumi num photochopper It has a 180 degree fence that passes through the slots of two slotted optocouplers The optocouplers have an infrared
16. 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 mo tors 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 direc tion 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 49 Operation The Motor Amps Load Limit protects the com B Safety Setpoints pressor 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 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 pres sure between the oil manifold and suction 3 Oil Separator Heater The oil separator heater keeps the oil in the
17. 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 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 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 Compressor Serial Stop Check Valve Operation AUTO In the A
18. 2864C 2865A 2866B 2867E 2868F 25910B 2176N 2176V 21760 Gate Rotor MODEL NUMBER VSS 901 5510 1051 1201 VSS 1301 QTY VPN QTY VPN QTY VPN QTY VPN ITEM DESCRIPTION GATE 120A 120B 135A 135B GATE ROTOR BLADE AND BEARING REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 125 126 130 131 141 142 143 OTOR BLADE REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 130 141 142 143 GATE ROTOR SUPPORT ASSEMBLY 100 111 120B 119 130 GATE ROTOR GASKET SET 118 141 142 143 SUPPORT GATE ROTOR GATE ROTOR COVER GASKET WASHER BUSHING SMALL DOWEL PIN BUSHING LARGE DOWEL PIN SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 ROLLER BEARING BALL BEARING RETAINING RING RETAINING RING DOWEL PIN SMALL 0 3125 O D DOWEL PIN LARGE 0 4375 O D O RING ROLLER BEARING HOUSING O RING BALL BEARING HOUSING O RING BEARING HOUSING COVER KT712D KT713D A25161CA A25164C 25553A 25554A 25088A 25086A 25087A 25760B 25089AA 25089AB 25089AC 25089AD 2864C 2865A 2866B 2867E 2868F 25910B 2176N 2176V 2176U 712 71 2516108 A25164D 25614A 25610A 25132A 25086A 25104A 25760 2508 9 25089AB 25089AC 25089AD 2864G 2865A 2866B 28671 2868 25910 2176AJ 2176AM 2176U KT712F 71 A25161DA A25164D 25587
19. 28671 28671 RETAINER BALL BEARING 25935A 25935A 25935A GATE ROTOR COVER GASKET 25259B 25259B 25259B WASHER WAVE SPRING 3203A 3203A 3203A DAMPER 25760A 25760A 25760A SHIM 0 002 25921AA 25921AA 25921AA SHIM 0 003 25921AB 25921AB 25921AB SHIM 0 005 25921AC 25921AC 25921AC SHIM 0 010 25921AD 25921AD 25921AD ROLLER BEARING 2864F 2864F 2864F BALL BEARING 2865L 2865L 2865L RETAINING RING 2866H 2866H 2866H RETAINING RING 2867S 2867S 2867S RETAINING RING 2866 2866 2866 DOWEL PIN 25910A 25910A 25910A O RING ROLLER BRG HSG 21761 21761 21761 O RING BALL BRG SUPPORT 2176F 2176F 2176F SHIM 25977D 25977D 25977D SHIM 25977C 25977C 25977C Pree gt gt JJ JJ gt gt DO JJ JJ JJ 2 AR As Required 113 Gaterotor Assembly Part totals indicated are for one gate rotor assembly dual gate machines will require double the components MODEL NUMBER VSM 501 VSM 601 VSM 701 VPN VPN QTY VPN A26011BA 1 DESCRIPTION SUPPORT ASSEMBLY 110 amp 135B GATE ROTOR amp DAMPER ASSEMBLY 111 120 GATE ROTOR SUPPORT ASSEMBLY 100 101 119 amp 130 SHIM PACK SET 2 121 2 122 1 123 1 124 SUPPORT GATE ROTOR SNAP RING RETAINER BALL BEARING GATE ROTOR COVER GASKET WASHER DAMPER SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 ROLLER BEARING BALL BEARING RETAINING RING RE
20. 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 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 vent line must be returned to a suction trap Refer to the V PLUS manual for additional information _ 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 o
21. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf 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 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 119 CE C Checkdamperpin and bushing for excessive wear Replace if necessary a TOP of assembly Relief area faces TOP of assembly 67 68 Service Lip on gaterotor blade is positioned up and away from the support of Blade with Relief Back of Blade snap ring bevel must be positioned away from the blade on gaterotor 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 blad
22. ONLY ONE WAY 108 Replacement Tools 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 GATE ROTOR TOOLS A25205B A25205C A25205C A25205E 901A GATE ROTOR STABILIZER SET 901A 901B 901C A25698A A25698A A25698A N A 901B GATE ROTOR STABILIZER SET 901A 901B 901C 901D A25699A 109 110 VSM 301 701 Replacement Parts Section Recommended Spare Parts List Refer to the Custom Manual Spare Parts Section for Specific Applications Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate 111 Gaterotor Assembly LL LLLA VA uL de 8 SS Lr s NIA S lt OCE s H VILLA UL LU 112 Gaterotor Assembly Part totals indicated are for one gate rotor assembly machines with two gate rotors will require double the components listed below ITEM DESCRIPTION 100 SUPPORT ASSEMBLY 110 amp 135B A25222ABI 1 A25222AA 1 A25222AC 101 GATE ROTOR amp DAMPER ASSEMBLY 111 120 A25160AB 1 A25160AA A25160AC 102 GATE SUPPORT ASSEMBLY 100 101 119 amp 130 A25161AB A25161AA A25161AC SHIM PACK SET 2 121 2 122 1 123 1 124 A25165A A25165A A25165A SUPPORT 257230 25723C 25723B GATE ROTOR 25718B 25718C 25718D SNAP RING 28671
23. Refer to the ANSI ASME B31 5 Code for Refrig eration Piping All compressor oil supply and 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 connec tions are always necessary 23 24 Installation Care must be taken to avoid trapping the lines ex cept for specific 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 fittings Common pipe fittings 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 fitting should be carefully cleaned to remove all traces of grease or oil Threads should then be wiped dry with a lintless cloth Only thread fill ing compounds suitable for refrigeration service should be used for making steel pipe joints These compounds should be used sparingly and onthe pipe only Do not put any on the first 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 on
24. SCREW HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW 2 2 2 2 2 2 2 2 2 2 2 2 AR AR AR AR 2 NN KT712L KT713G A25160EB A25161EB A25164E A25165E 25687A 25647A 26507A 26506A 25141A 25789A 25351 26508 26509 25788 25760 25791 25791 25791 25791AD 2864K 2865K 2866G 2867R N A 25910C 2176U 2176BD 2176P 27960 2796 27960 27968 27956 KT712M KT713H A25160EA A25161EA A25164E A25165E 25665A 25645A 26507A 26506A 25141A 25789A 25351 A 26508A 26509A 25788 25760 25791 25791 25791 25791AD 2864K 2865K 2866G 2867R N A 25910C 21760 2176BD 2176P 27960 2796N 27960 27968 27956 KT712K KT713L A25160EA A25161EL A25164E A25165E 25495D 25744D 26507A 26506A 25141A 25789A 25351A 26508A 26509A 25788A N A 25760C 29791 25791 25791 25 91AD 2864K 2865K 2866G 2867R N A 25910C 2176U 217680 2176P 27960 2796N 27960 27968 27956 Shaft Seal Shaft Seal With Stationary Carbon Face Ks D e 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 KT709A KT709B KT709MB KT709C SHAFT SEAL R22 KIT 219 230 260 1 KT781A 1 KT781B KT709MA KT781C OIL SEAL 1 25040A 1 25064A 2930F 2930B O RING 1 2176 1 2176 2176 2176BH
25. above Free the command shaft Replace the actuator This could be caused by a mal functioning control panel Con sult the factory Slide Valve Actuator Trouble Shooting Guide Problem Reason Solution The motor runs sporadically Bad thermal switch Replace the actuator See above Any of the reasons listed in The motor will not move in either direc tion The motor runs but output Stripped gears inside the gear mo Replace the actuator shaft will not turn tor or the armature has come un pressed from the armature shaft 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 _ OFF m mop mo WCalibration step 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 Manually rotate the motor shaft until the aluminum photochopper fence is not blocking either of the optocoupl
26. approximately 500 millivolts 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 24 22 23 24 23 26 27 28 29 Slide Valve Actuator Installation amp Calibration Use the INC button to rotate the actuator to wards 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 mil livolts for the 2783 qualified analog boards You are nearing the mechanical stop position 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 qualified analog boards Pulse the DEC button until the millivolts just start to decrease This is the point where the channel drops out of saturation Ad just millivolt value to 300 millivolts below recorded maximum millivolts in step 22 Press the Set Max button Press the Main button to complete calibra tion and exit the Slide Calibration screen The controller will automatically energize
27. are used to axially fix 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 fixing 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 flange at the driven end of the unit The driven end of the compressor housing is flooded with gas at suction pressure The gas enters the open end of the main screw flutes at the driven end and becomes trapped in the screw flute as the screw rotates and the gate rotor tooth enters the end of the flute At this point the compression process begins Directly after the screw flute 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 is to absorb the heat of compression to seal the gate rotor tooth in the groove and to lubricate the moving parts Additional internal oiling ports are provided at the main and gate rotor bearings to cool and lubricate the bear ings The mechanical shaft seal housing also contains oiling ports to lubricate cool and provide a sealing fil
28. 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 e Secure and restrict access to the lift area consider vacating all non essential personnel from the area Provide qualified 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 e Ensure there are open channels for communications during the pre lift lift and post lift phases radio commu nications should be used if a direct line of sight is not possible Test and Balance the Compressor before the Lift e Slowly raise the crane to take slack out of the rigging without actually lifting the load Allow the rigging gear to settle into place e Check for twists and binds e 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 Ifthe Compressor is not balanced lower and adjust as necessary 21 Rigging and Lifting CONTACT VILTER While Vilter will not offer any specific feedback on the Plan or provide a specific Plan for rigging and lifting the Compressor Vilter may be able to answer questions about the Compressor that are important in developing you
29. 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 501 manually open the SOI solenoid valve below the compressor Drain the oil into appropriate con tainers 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 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 compressor housing and dis charge manifold after oil has stopped draining D Remove all electrical connections to the com pressor May cause an electrical shock E Oncompressors with mounting feet loosen and remove bolts holding the compressor to the base Possible hazard caused by unexpected rotation of coupling Keep compressor alignment shims together and mark the locations with a permanent marker F On compressors
30. 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 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 pres sure regulator in the oil supply line from the sepa rator controls upstream pressure to the compres sor 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 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 connec tion should be mad
31. larger a link must be put on bolt first 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 first Now install the rest of the long bolts in the same manner gt 34 Installation 4 Torque the long bolt locknuts at this time NOTE With the coupling in good alignment the bolts will fit through the holes in the flanges 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 align ment consult Rexnord 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
32. rotor 2 Usealeverarm 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 Damper Pin Dial Indicator D Measure the gate rotor to blade float Some movement between blade and support is neces saryto prevent damage to the compressor blade however at no time should the blade uncoverthe support 1 Positionthe blade with the gate rotor damper pin and 90 to the main rotor 2 Position a dial indicator at the tip of the sup port Thetotal movement of the damper pin in the bushing is the gate rotor float Refer to table 0 2 to find the maximum blade to sup port float on new compressor parts only 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 amp VSS 901 VSS 1051 THRU VSS 1301 VSS 1551 amp VSS 2101 NOTE Readings could be higher than 0 020 If readings are greater than 0 030 over table tolerance contact Vilter s home office Inspect the main and gate rotors for signs of ab normal wear due to dirt or other contaminants After the inspection is complete the covers coupling center member and guard can be rein stalled and the unit can then be evacuated and leak checked before starting 59 Service GATE ROTOR ASSEMBLY CAUTION Follow lockout procedure before servicing this unit Gate rotor re
33. separator from becoming too viscous and helps keep gas from condensing in the receiver section of the separator 2 Discharge Pressure High discharge pressure cutout stops the compres sor unit when the discharge pressure in the oil The heater is turned on only when the compres sor is off The separator heater is supplied with an integral temperature control TABLE 1 separator exceeds the setpoint VSS VSR VSM COMMAND SHAFT ROTATION AND TRAVEL 5 NO OF TURNS ROTATION ANGLE SLIDE TRAVEL COMP MODEL INC DEC INC DEC VSM 701 50 CW CCW CW CW CCW CW A CCW ay CCW CCW CCW CCW CCW CW n CW CCW ay CCW CW CCW CCW CW CAPACITY TURNS ANGLE TRAVEL 0 91 328 3 568 0 91 328 3 568 0 91 328 3 568 1 09 392 4 283 1 09 392 4 283 1 22 439 4 777 1 22 439 4 777 22 439 4 777 2 439 4 777 2 439 4 777 36 490 5 325 6 1 2 1 2 1 2 1 3 1 3 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 80 288 3 141 0 91 328 3 568 0 91 328 3 568 0 91 328 3 568 VOLUME TURNS ANGLE TRAVEL 0 52 187 2 045 0 52 187 2 045 0 52 187 2 045 0 63 227 2 473 0 63 227 2 473 0 74 266
34. the capacity slide and the vol ume 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 flute and closes off the end of the groove In this situation the maximum volume of gas is trapped in the screw flute 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 flute 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 flute 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 specific process set points By continuously adjusting the flow 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 r
35. the inner race to the part numbers outer race Press the bearing race numbers visible onto the gate rotor sup port 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 For installation of the bearing housing refer to section INSTALLATION All VSS 8 VSM Models Service COMPRESSOR SHAFT SEAL REPLACEMENT Follow lockout procedure before servicing this unit COMPRESSOR SHAFT SEAL REMOVAL A B Prepare the compressor for servicing as outlined in section REMOVAL 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 Remove the rotating portion of the shaft seal 2190 Remove oil seal 230 from cover 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 2190 Current Shaft Seal and for all Replacements Roll Pin 265 only used on VSS 751 and larger models 71 72 Service Seal Assembly w Stationary Mirror Face Align slot in seal dowel pin or key in sha Make that seal is bo
36. the up down arrow buttons to change it to the correct value Press the Circle button when done Press the Up arrow button until a value of 04 is shown on the screen Press the Circle button There should be a value of 50 shown If not use the up down arrow buttons to change it to the correct value Press the Circle button when done Press the Up arrow button until a value of 07 is shown on the screen 10 Press the Circle button There should be a value of 1 shown If not use the up down arrow buttons to change it to the correct value Press the Circle button when done 11 Press the Up arrow button until a value of 10 is shown on the screen 12 Press the Circle button Press the up down arrow button to change the value to 11 Press the Circle button 129 13 Press the Up arrow button until a value of 26 is shown on the screen 14 Press the Circle button Press the up down arrow buttons to change the value to the correct valve that is on the unit The value number is listed on the valve The values and valves are as follows 0 No valve selected Alarm A1 will become active 1 ICM20 with ICAD 600 2 ICM25 with ICAD 600 3 ICM32 with ICAD 600 A ICMAO with 900 5 ICM50 with 900 6 ICM65 with 900 15 Press the Circle button The valve is now ready to be used Note Refer to the
37. 00 1 2A ICAD 900 2 0A Anolog input Current or Voltage Current 0 4 20 mA Load 2000 Voltage 0 2 10V d c Load 10 Analog output 0 4 20 mA Load lt 250 Q Digital input Digital ON OFF input by means of voltfree contact Signal Telecom relays with gold plated contacts recommended Voltage input used ON contact impedance lt 50 OFF contact impedance gt 100 Digital output 3 pcs NPN transistor output External supply 5 24 V d c same supply as for ICAD can be used but please note that the galvanically isolated system will then be spoiled Outputload 500 Load Max 50 MA Danfoss USCO MKS 11 2006 DKRCI EI HTO A1 22 520H1639 5 ICM ICAD Motorized Valve Installation Programming and Troubleshooting Terminal box is customer supplied Wiring diagram showing ICAD wired with a PLC or other type of third party electronics Note The ICAD supplies the power for the 4 20 mA feedback signal for valve position feedback for valve position feedback White Optional UPS battery back up Brown Green 24Vdc Power Supply CUSTOMER SUPPLIED Passive 4 20 mA PLC input Wiring diagram with Danfoss Terminal box is customer supplied controllers Note For instructions on completely wiring an EKC controller please see the relevant EKC controller manual EKC 347 EKC 315A EKC 361
38. 199 25395 2176 2868 25324 25058 25058 11323E 11323E 11323E 25199D 25199C 25391D 2176 2606A 2868B N A N A 25324A 25058ASW 25058B 11323D 11323E 11323E 25199D 25199C 25391 A 2176AB 2606A 2868B N A 4 4 2 1 2 2 1 1 2 2 2 NN 105 Miscellaneous Frame Components MODEL NUMBER VSS 1551 thru VSS 2101 ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN GASKET amp O RING KIT KT710D FLANGE SET 513A 514A 545A A25190C FLANGE SET 513B 514B 545B A25190D FLANGE SET 513B 514C 545C N A PLUG SET ECONOMIZER 514C 528 545B N A PLUG SET ECONOMIZER 514A 514C 528 545C A25243ED MANIFOLD GASKET 25676A FLANGE 12477C FLANGE 25058ASW GASKET 11323F GASKET 11323S GASKET 11323G GASKET SUCTION 25199D GASKET DISCHARGE 25199C ECON O MIZER PLUG 25393A O RING 2176J PIPE PLUG 3 4 MPT 2606A DOWEL PIN 2868K PIPE PLUG 3 4 MPT 13163F HEX HEAD CAP SCREW 11397E HEX HEAD CAP SCREW 2796GP HEX HEAD CAP SCREW 11397E HEX HEAD CAP SCREW N A HEX HEAD CAP SCREW N A N NO PNP ND AH Optional 106 107 Replacement Tools FOR VSS 451 VSS 601 DO NOT USE SIDE RAILS FOR VSS 751 VSS 901 VSS 1051 AND VSS 1201 ASSEMBLE SIDE RAILS AS STAMPED FOR VSS 1551 AND 1801 SIDE RAILS ASSEMBLE
39. 22 520 1639 11 ICM ICAD Motorized Valve Common Questions Installation Programming Troubleshooting What happens in the event of a power failure The ICAD will remain in the position it is in when power is lost There are two ways to address this condition Adda UPS Uninterruptible Power Supply to the power wiring This is easily accomplished with the green and white wires in the power cable A UPS is available from Danfoss The UPS can provide service for up to 9 ICAD 6005 or up to 6 ICAD 9005 Note The UPS is not a continuous power supply It is used to change the valve position usually to close the valve in the event of a power failure Therefore the system is not to be run in the UPS mode Adda solenoid valve in front of the ICM This is a very simple solution provided that there is no issue associated with the additional pressure drop through the solenoid valve How much power do need to supply to the ICAD total power required depends on both the ICAD size and the number of ICAD s powered by the DC power supply The power for each ICAD is For the ICAD 600 used on ICM 20 25 and 32 the power requirement is approximately 30 W For the ICAD 900 used on ICM 40 50 and 65 the power requirement is approximately 50 W How can monitor the valve position remotely The control wiring provides for a 4 to 20 mA or 0 to 20 mA signal output blue and yellow wires This signal can be
40. 27A 25847A 25255AA 25255AB 25255AC 25255AD 25929B 3120A 3120B 2928N 25977E 25977F 1193D 2981AA 2796B 2795D 2060J 2060H DDDORRNDD DDDDRr ANH A26010BC A26034B A25177B 26025B 25843A 25027A 25847A 25255AA 25255AB 25255AC 25255AD 25929B 3120A 3120B 2928N ZSITLE 25977F 1193D 2981AA 27968 27950 2060 2060H 119 Slide Valve Carriage Assembly Ajquiassy TI 120 Slide Valve Carriage Assembly MODEL NUMBER ALL VSM 301 401 ALL VSM 501 701 VPN VPN B A25179A A26012B A25183A A25183B A25184A A25184B DESCRIPTION CARRIAGE ASSEMBLY CAPACITY PISTON 340 341 350 amp 355 VOLUME PISTON 340 342 350 amp 355 CAPACITY RACK CAPACITY RACK SHAFT VOLUME RATIO RACK VOLUME RATIO RACK SHAFT PISTON RING SET LOCK WASHER PAIR WASHER NUT SOCKET HEAD CAP SCREW 25023D 25772C 25023C 257720 2953AE 3004C 13265B 2797A N A 25024A 25772A 25023A 25772B 2953AA 3004C 13265B 2797A 2795 D NNN SH Notes There are two slide valve carriages per compressor Each one each has its own Volume Ratio and Capacity slide valves The above totals are per side of the compressor double the quantities if both slide valve carriages are being worked on Not Pictured 121 Actuator amp Command Shaft 555 222 NN lt lt S
41. 5 lb ft DKRCI EI HTO A1 22 520H1639 O Danfoss USCO MKS 11 2006 ICM ICAD Motorized Valve Installation Programming and Troubleshooting Wiring the ICAD Note The ICAD is powered by a 24 Volt DC power source There are two cables pre mounted and connected to the ICAD motor actuator Never try to open the ICAD motor because the special moisture seal will be damaged The power cable consists of 3 wires Green common ground Brown positive from 24VDC power source White positive from UPS battery backup optional The control cable consists of 7 wires Yellow common ground Gray positive 4 20mA or 0 20mA input to control motor Blue positive 4 20mA or 0 20mA output from ICAD for valve position feedback e Pink positive 2 10V or 0 10V input to control ICAD motor Also used as a digital input with the yellow wire for on off solenoid valve operation e White common alarm digital NPN transistor output when combined with yellow wire Brown indicates ICM is fully open digital NPN transistor output when combined with yellow wire Green indicates ICM is fully closed digital NPN transistor output when combined with yellow wire Electrical Data Supply voltage is galvanically isolated from input and output wires Supply voltage 24 V d c 10 15 Load ICAD 600 1 2 ICAD 900 2 0 A Fail safe supply Min 19 V d c Load ICAD 6
42. 5033C 2868B 1193D 2981AA 2606E 2 95F 2060J 2060H Oo N P N RAD NO 25845A 25027A 25913C N A 25033C 2868B 1193D 2981AA 2606E 2795F 2060 2060H Oo N P N RAD N 25793A 25027A 25913C N A 25033C 2868B 1193D 2981AA 2606A 2 95F 2060J 2060H 977 98 Volume Slide Slide Valve Carriage Assembly Capacity Slide Carriage Assembly Slide Valve Carriage Assembly MODEL NUMBER VSS 291 thru VSS 751 VSS 1051 VSS 1301 VSS 601 VSS 901 VSS 1201 CARRIAGE ASSEMBLY A25179B A25179C A25179D 2 A25179DSR CAPACITY PISTON 340 341 350 355 2 A25183B 2 A25183C A25183D 2 A25183DN VOLUME PISTON 340 342 350 355 2 A25184B 2 A25184C A25184D 2 A25184DN GASKET SET 345 2 A25200B N A A25200D 2 A25200D GASKET SET 345 378 N A 2 A25200C N A RACK 2 25024A 2 25080A 25080C 2 25779B RACK 2 25023A 2 25080B 25080D 2 25080DH SHAFT N A N A N A PISTON N A 4 25076A 25138A A 25138A CAPACITY PISTON SHAFT N A 2 25078A 25078E 2 25078G VOLUME PISTON SHAFT N A 2 25078B 25078F 2 25078H COVER ONE PIECE CAST 2 25399A 2 25279A 25401A 2 25401A GASKET ONE PIECE CAST COVER 2 25900A 2 25902A 25901A 2 25901A GASKET ONE PIECE CAST COVER 2 25124 PISTON SLEEVE 2 25079 PISTON RING SET 4 2953AA 4 2953AB 2953AC 4 2953AC EXPANSION PIN 4 1193PP 4 1193PP 1193PP 4 1193PP PIPE PLUG 6 2606D 6 2606D 2606E 6 2606E LOCK WASHER
43. A 25913D 25847A 25409AA 25409AB 25409AC 25409AD 25939A 3120A 3120B 2829M 1193D 2981AA 25422A 2796N 2795 2060 2060H 117 118 N NN INSTALL PIN 222 Wa IN 2 I S SS boon 5 028 WITH TOOL JF5085AT EN Main Rotor Slide Valve Cross Shafts amp End Plate Models VSM 501 701 Clockwise ONLY e X lt gt N DSS Main Rotor Slide Valve Cross Shafts amp Plate Models VSM 501 701 Clockwise ONLY MODEL NUMBER VSM 501 VSM 601 VSM 701 QTY VPN QTY VPN DESCRIPTION MAIN ROTOR ASSEMBLY OIL BAFFLE ASSEMBLY 1 217 1 244 1 248 1 249 1 252 SHIM ASSORTMENT 2 240 2 241 1 242 1 243 END PLATE SHAFT GEAR SPACER SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 TEFLON RING BAFFLE CHECK VALVE BAFFLE CHECK VALVE BAFFLE RETAINING RING BAFFLE WASHER WASHER EXPANSION PIN EXPANSION PIN HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW SET SCREW SET SCREW Not pictured As required NNN gt gt gt gt A 2601088 1 A26034B A25177B 26025B 25843A 25027A 25847A 25255AA 25255AB 25255AC 25255AD 25929B 3120A 3120B 2928N 25977E 25977F 1193D 2981 AA 27968 27990 2060 2060H WN MOA AWS cx cx c ys qe qe qe de BR EA 26010 1 A26034B A25177B 26025B 25843A 250
44. NUMBER VSS 291 thru VSS 751 VSS 1051 VSS 1551 thru VSS 601 VSS 901 VSS 1201 VSS 2101 VSS 1301 QTY VPN QTY VPN QTY VPN QTY VPN 2 A25994B 2 A25994C 2 A25994D 2 A25994E 2 25972D 2 25972D 2 259720 2 259720 2 2176 2 2176 2 2176 2 2176 103 Miscellaneous Frame Components VSS Screw Compressor ar e une A 104 Miscellaneous Frame Components 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 amp O RING KIT KT710A KT710B KT710C KT710J FLANGE SET 513A 514A 545A A25190A A25190A A25190B A25190A FLANGE SET 513B 514B 545B A25190B N A A25190B A25190B FLANGE SET 513B 514C 545C N A A25190D N A N A PLUG SET ECONOMIZER 514C 528 545B A25243BE A25243CC A25243DC A25243DD PLUG SET ECONOMIZER 514A 514C 528 545C MANIFOLD GASKET FLANGE FLANGE GASKET GASKET GASKET GASKET SUCTION GASKET DISCHARGE ECONOMIZER PLUG O RING PIPE PLUG 3 4 MPT DOWEL PIN PIPE PLUG 3 4 MPT HEX HEAD CAP SCREW 2796GP 2796GP 2796C 2796GP HEX HEAD CAP SCREW 2796C 2796C 2796C 2796C HEX HEAD CAP SCREW N A 2796GP N A N A HEX HEAD CAP SCREW 2796C 2796GP 2796GP 2796F HEX HEAD CAP SCREW 2796U 2796U 2796U 2796U N A 25503A 25058ASW 250588 11323D 11323E 11323D 25199C 25199B 25397G 2176AB N A 2868B N A N A 25541A 25058ASW 25058ASW 11323D N A 113235 25199 25
45. 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 war ranty 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 Manufact
46. PAIR 4 3004C 4 3004C 3004C 4 3004C WASHER 4 13265B 4 13265B 13265B 4 13265B NUT 8 2797 8 2797 2797 8 2797 SCREW 24 27968 12 2796P 2796P 24 2796 SCREW 12 2796BN N A N A SOCKET HEAD CAP SCREW 6 2795N 2795P 6 2795P LOCK WASHER PAIR N A 6 3004C 3004D 6 3004C O RING N A 2 2176Y N A N A RETAINER RING N A 2 2866C N A N A 99 ITEM 100 DESCRIPTION CARRIAGE ASSEMBLY CAPACITY PISTON 340 341 350 355 VOLUME PISTON 340 342 350 355 GASKET SET 345 GASKET SET 345 378 RACK RACK SHAFT PISTON CAPACITY PISTON SHAFT VOLUME PISTON SHAFT COVER ONE PIECE CAST GASKET ONE PIECE CAST COVER GASKET ONE PIECE CAST COVER PISTON SLEEVE PISTON RING SET EXPANSION PIN PIPE PLUG LOCK WASHER PAIR WASHER NUT HEX HEAD CAP SCREW HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW LOCK WASHER PAIR O RING RETAINER RING VSS 1551 thru VSS 2101 nl __ A25179E A25183E A25184E A25200E A25200E 25779A 25780A 25778A 25782A 25784A 25783A 25690A 25384A N A 25786 2953AD 1193PP 2606E 3004C 13265B 2797A 2796BL N A 2795AG 3004D 2176AG 2755AG Slide Valve Carriage Assembly MODEL NUMBER 101 102 Actuator amp Command Shaft ITEM 400 401 446 DESCRIPTION COMMAND SHAFT ASSEMBLY SLIDE VALVE ACTUATOR O RING SEAL Actuator amp Command Shaft MODEL
47. S 122 DESCRIPTION COMMAND SHAFT ASSEMBLY SLIDEVALVE ACUATOR O RING SEAL Actuator amp Command Shaft MODEL NUMBER VSM 291 thru VSS 751 thru VSM 601 VSS 901 QTY VPN VPN A25994B A25994C 25972D 25972D 2176X 2176X VSS 1051 thru VSS 1201 VPN A25994D 25972D 2176X VSS 1551 thru VSS 2101 VPN A25994E 25972D 2176X 123 Miscellaneous Frame Components Model VSM 301 401 Model VSM 501 701 124 Miscellaneous Frame Components ITEM DESCRIPTION ALL VSM 301 401 ALL VSM 501 701 QTY VPN QTY VPN MANIFOLD GASKET 25737A 1 ECON O MIZER GASKET 11323GG COUPLING LOCK PLATE LOCK WASHER ECON O MIZER PLUG 25419A O RING DOWEL PIN 2868B PIPE PLUG 2606C HEX HEAD CAP SCREW BEARING OIL PLUG 25978A PLUG 25979A SPRING 3148A GASKET O RING SET KT1075A KT1075B Notes Not Pictured 125 Miscellaneous Frame Components DNISNOH NI JAV SINALYALNNDI SNIS D 055 22 buisnoH 126 Miscellaneous Frame Components Housing Accessories MODEL NUMBER
48. T 118 141 142 143 SHIM PACK SET 2 121 2 122 1 123 1 124 SUPPORT GATE ROTOR SMALL BEARING HOUSING LARGE BEARING HOUSING RETAINER RETAINER BALL BEARING COVER GATE ROTOR COVER GATE ROTOR COVER GASKET WASHER BUSHING SMALL DOWEL PIN BUSHING LARGE DOWEL PIN SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 ROLLER BEARING BALL BEARING RETAINING RING RETAINING RING DOWEL PIN SM 0 250 O D DOWEL PIN LG 0 4375 O D O RING ROLLER BEARING HOUSING O RING BALL BEARING HOUSING O RING BRG HSG COVER HEX HEAD CAP SCREW HEX HEAD CAP SCREW HEX HEAD CAP SCREW HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW KT713A A25161BB A25164B A25165B 25606A 25557 25518 25517 25008 25009 25258 25519 25259 25007 25006 25760 25010 25010 25010 25010AD 2864B 2865B 2866A 2867A 2868B 25910A 2176M 2176R 2176N 2 96AJ 2 96B 27960 2796E 2795 KT713B A25161BA A25164B A25165B 25520A 25534 25518 25517 25008A 25009A 25258A 25519A 25259A 25007 25006A 25760 25010 25010 25010 25010AD 2864B 2865B 2866A 2867A 2868B 25910A 2176M 2176R 2176N 2 96AJ 2 96B 27960 2 96E 2795 2 2 2 2 2 2 2 2 4 2 2 2 2 2 2 2 KT713C A25161CB A25164C A25165C 25612A 25608A N A N A N A N A N A N A 25088A 25086A 25087A 25760 25089AA 25089AB 25089AC 25089AD
49. TAINING RING RETAINING RING DOWEL PIN O RING ROLLER BRG HSG O RING BALL BRG SUPPORT SHIM SHIM NOTE 7 Not pictured AR As Required 114 1 1 gt JJ gt JJ gt gt A26011BB 1 A26002BB 1 A26003BB 1 A26035B 1 26030BB 1 26032A 1 28670 1 25935 1 252590 1 25007 1 25760 1 26027 26027 26027 AR 26027AD 28648 28658 2866A 2867A 2866K 25910A 2176M 2176R 25977G 25977H gt gt A26002BA 1 A26003BA 1 260358 26030BA 26031A 2867U 25935B 25259C 25007A 25760 26027 26027 26027 26027AD 2864B 2865B 2866A 2867A 2866K 25910A 2176M 2176R 25977G 25977H gt gt A26011BA A26002BC A26003BC A26035B 26030BA 26033A 28670 25935 25259 25007 25760 26027 26027 26027 26027AD 2864B 2865B 2866A 2867A 2866K 25910A 2176M 2176R 25977G 25977 Shaft Seal MODEL NUMBER DESCRIPTION ALL VSM 301 401 ALL VSM 501 701 VPN SHAFT SEAL KIT AMM 219 230 amp 260 KT709D 1 KT709A SHAFT SEAL KIT HALO 219 230 amp 260 KT781D KT781A SHAFT SEAL A A OIL SEAL 2930C 25040A TEFLON SEAL 25939A 25939A RETAINER RING 2928M 2928M O RING 2176U 2176 O RING 205 Only 2176AE N A NOTE Not pictured A Sold only as kit See recommended spare parts lists for complete assembly 115 Main Rotor Slide Valve Cr
50. VSS VSR VSM single screw compressor Operation and service manual gt VILTER EMERSON Since 1867 Important Message Read and understand operator s manuals before using this machine Failure to follow operating instructions could result in serious injury 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 can not 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 authori
51. a positive displacement capacity and volume controlled oil flooded rotary compressor which uses a single main screw intermeshed by two opposing gate rotors Gas compression occurs when the individual fingers of each gate rotor sweep through the grooves or flutes of the main screw as the screw rotates Compression occurs from the time the screw flute is first closed off by the gate rotor finger until the time when the screw flute 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 can celled out also Main shaft bearings have no net forces except the weight of the screw and the shaft assembly The compressors are comprised of three rotating assemblies the main screw assembly and the two gate ro tor assemblies Each of these rotating assemblies use a common bearing configuration 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
52. ance refer to section INSTALLATION All VSS Models B Forinstallation 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 posi tioned face to face This means that the larger sides of the inner races are placed together Alight application of clean com pressor lubricating oil should be used to ease the installation of the bearings into the gate rotor support NSS FILI T oo 4 h Ball Bearings Retaining Ring 3 Install the bearing retaining snap ring 4 Forinstallation of the bearing housing and the setting of the gate rotor blade clear VSM Model ance refer to section INSTALLATION All VSM Models 69 70 Service GATE ROTOR ROLLER BEARING REMOVAL A D Refer to section REMOVAL All VSS amp VSM for removal of the gate rotor bearing housings and gate rotor supports Remove the snap ring 131 which retains the roller bearing in the bearing housing Remove the roller bearing 125 from the bearing housing 112 Use a bearing puller to remove the roller bearing race 125 from the gate rotor support 110 GATE ROTOR ROLLER BEARING INSTALLATION A Match up the part numbers on
53. and will then be ready for control a 4 20mA signal For most applications this is the only programming that will need to be done if the ICAD is going to be controlled by a 4 20mA input ICAD Parameters name setting ICM OD Opening ICM valve Opening Degree is displayed during normal operation Degree Running display value see 101 105 Internal main switch Main Switch 1 Normal operation 2 Manual operation Valve Opening Degree will be flashing With the down arrow and the up arrow push buttons the OD can be entered manually Operation mode Mode 1 Modulating ICM positioning according to Analog Input see 103 2 ON OFF operating the ICM valve like an ON OFF solenoid valve controlled via Digital Input See also 109 Type of Analog Input signal from external controller 1 0 20mA 2 4 20mA 3 0 10V 4 2 10V Analog Input signal Speed can be decreased Max speed is 100 96 Not active when 101 2 If 02 2 the display will indicate speed in display Low Med and High also means ON OFF operation If j04 lt 33 Low is displayed 33 lt 11104 lt 66 Med is displayed If j04 gt 67 High is displayed Not active before j26 has been operated Always auto reset to 0 CA will flash in the display during calibration if Enter push button has been activated for two seconds Speed at ON OFF and Modulating Mode Automatic calibration Type of AO signal for ICM valve position 0 No signal 1 0 20mA
54. appropriate controller manual for control setup 130 ICM ICAD Motorized Valve Installation Programming and Trouble shooting REFRIGERATION amp AIR CONDITIONING Quick Start Guide ICM ICAD Motorized Valve Contents Installation Programming and Troubleshooting Page Oi ___ __ ____ _ 6_ __6_ _6__ __ 6_6 _ _ _ _ _6 6_ vas 3 ae engeren 5 OVGIVIEW 8 9 Troubleshooting THE Namal OO 10 10 CR T TT RR TT 11 lop 11 COMMON QUESTIONS E 12 DKRCI EI HTO A1 22 520H1639 Danfoss USCO MKS 11 2006 ICM ICAD Motorized Valve Installation Danfoss USCO MKS 11 2006 Installation Programming and Troubleshooting 1 The ICM valve and ICAD motor actuator must be installed in horizontal pipelines with the motor actuator pointing upwards 2 To prevent damage to O rings and the valve seat remove the one piece ICM bonnet and function module from the valve body prior to welding the valve body in the line For ICM 20 3 4 size the valve seat is not integrated with the valve bonnet and must be separately removed from the valve body with a 12 mm hex key prior to welding se
55. ate variable speed controller and solid state temperature controller This meth od 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 47 48 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 de tailed 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 re frigerant 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 foul ing problems associated with open circuit water cooling Since the oil cooling load is rejecte
56. atio slide The purpose of the volume ratio slide is to maximize the efficiency of the compressor by matching the gas pressure within the screw flute 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 flute continues until the screw rotates far enough for the flute to pass the end of the volume ratio slide At this point the screw flute lines up with the discharge port and the compressed gas is expelled from the screw flute 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 flute 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 capac ity 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 comp
57. ation with Housekeeping Pads Dimensions Top View 15 Foundation 1 TYP 2 4 CLOSED TIES CENTER LINE G A 2 5 6 VERT WITH STD 90 HOOK AT BOTTOM EACH FACE 5 8 DIA HILTI HAS SS THREADED ROD 5 RODS ARE ACCEPTABLE FOR INTERIOR INSTALLATIONS INSTALLED USING HIT ICE HIT HY 150 ADHESIVE ANCHORING SYSTEM 5 PROJECTION 12 3 8 EMBEDMENT HOLES TO BE INSTALLED WITH HAMMER DRILL DO NOT DIAMOND CORE TYP Figure 5 Housekeeping Pad Dimension Detail Top View SPHERICAL WASHER uw 1 2220 SPHERICAL WASHER ID Figure 6 Compressor with Spherical Washers 16 Foundation UNIT LEG NON SHRINK HOLD DOWN NUT EPOXY GROUT WASHER ra 77 C J I LEVELING NUT 6 RECOMMENDED FOR HOUSEKEEPING q ANCHOR BOLT CONCRETE BASE q Figure 7 Concrete Pad Housekeeping Detail Leveling and Grouting The unit should be level in all directions Wet concrete pad according to the grout manufacturer s directions Mix a sufficient amount of grout The grout must be an expanding grout rather than shrinking to provide a tighter bond Follow the manufacturer s recommendations for setting precautions mixing and grout placement finishing and curing The grout must be worked under all areas of the feet with no bubbles or voids If the grout is settled with a slight outside slope oil and water can run off of the base Once the
58. 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 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 Install command shaft assembly 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 Guide rods 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 flange from the d
59. bly with a new o ring 446 on the manifold Make sure that the command shaft tonque 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 Rotate bearing housing so vent hole points down Align the tan I command shaft with The groove in the cross shaft Command shaft assembly 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 as sembly out of the housing 433 Vent hole Service The command shaft bearing 435 is a press fit on the command shaft 413 Remove the command shaft bearing with a suitable press COO LS Reference Parts Section for current Housing D Remove the O ring seal 445 from the com mand shaft housing The command shaft bush ing 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 A SEAL REASSEMBLY 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
60. cause dam age to the actuator or the slide valve When the slide has reached the mechanical stop posi tion 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 Quickly press and release the blue button on the actuator again The red LED will now flash at a slower rate indication that the minimum slide valve position OV position has been set Use the INC button on the control panel to drive the slide to its maximum mechanical stop posi tion 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 actua tor 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 tension on the motor shaft Quickly press and release the blue button on the actuator one more time The red LED will stop flashing The actuatoris nowcalibrated 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 Use the Dec button to move the actuator towards its minimum position while watching the milli volt readout on the control panel screen Discon tinue pressing the DEC button when the millivolt reading in the Current window above the Set Min button is
61. ch 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 12 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 founda tion 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 specifications 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 Foundation The foundation is to be cast and permanently exposed against the earth Therefore if constructing on an existing floor typically indoors the floor 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
62. cific responsibilities during the lift Participants should be encouraged to contact the Plan preparer at any time if they have questions In addition the Plan preparer should be on site during the lift to ensure that the lift is being executed in accor dance with the Plan Finally well in advance of the lift date it should be confirmed 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 e The lift capacity of the crane must exceed the Compressor s weight Confirm that the crane operator is qualified to work on the site 20 Rigging and Lifting Get third party confirmation 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 significant cause of crane failure Determine the level of supervision to be supplied by the crane owner and Review all crane maintenance and inspection records including without limitation the crane log book main tenance records inspection reports and the physical condition of the crane Take all Appropriate Measurements e Understand and interpret the l
63. creen legend and are oriented at a 45 degree angle 42 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 ap plication 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 43 44 Operation OIL SYSTEM A Oil Charge Cha
64. d Plate 96 Slide Valve Carriage Assembly 98 Actuator amp Command Shaft cccerrrerereereeeeeezicie serie eos enie 102 Miscellaneous Frame Components 104 16 25 erii 108 VSM 301 701 Replacement Parts Section 111 Gaterotor 112 ____ _______ 115 Main Rotor Slide Valve Cross Shafts amp Plate 116 Slide Valve Carriage Assembly 120 Actuator amp Command 122 Miscellaneous Frame Components 124 Replacement Tools nun E i i i a E kirE ians 128 Danfoss Liquid Injection Valve Setup 129 Appendix A Pre Start Up for Remote Oil Coolers 143 Standard Warranty Statement Seller warrants the products it manufactu
65. d housing is being removed Blades on gaterotor are sharp 60 Service 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 remov ing the cover Retain the shim pack and keep it with the bearing housing cover Hold the gate rotor support with suitable wrench on the flats 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 Remove the bolts on the roller bearing housing Thread two bolts into the jack screw holes pro vided in the housing to assist in removing it 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 Use flats provided on gaterotor support to prevent rotation when removing bearing retainer 2 2 2 r gt A 61 Service REMOVAL ALL VSM 301 701 MODELS The remo
66. d distributor for details Another possible cause for this error is a stuck motor thermal switch The ther mal 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 opera tion you will measure 0 Volts K kK OK OK k k KK ck OK The 24V supply is voltage 15 low This willoccur 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 gt 24V replace the actuator EE 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 oc curred and the cause was not the loss of 24V power during calibration possible Causes are 1 EEPROM memory in the micro controller is bad 2 Thelarge blue capacitor is bad or has a cracked lead uu MEN _ _ Micro controller program failure Replace the actuator Note 1 TP1 and TP2 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 silks
67. d in the condenser this type of cooling is practical The temperature limits here are the same as those regarding the water cooled oil coolers 5 Oil Pump This system is designed to provide adequate com pressor 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 amp 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 pres sure ratio is 3 0 1 CONTROL SYSTEM Equipped for automatic operation the screw com pressor unit has safety controls to protect it from irregular operating conditions an automatic start ing and stopping sequence capacity and volume ratio control systems Check all pressure controls with a remote pres sure 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 transduc ers 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 atmospher
68. d 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 83 94 Service 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 39 other has a pilot hole with a captive o ring 6 03 KT 722 FILTER ELEMENTS Vilter Part Number KT 722 Tank O Ring 2176 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 99 other has a pilot hole with a captive o ring Service 6 04 773A 8 FILTER ELEMENTS Vilter Part KT 773A KT 7738 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 cover ing the surface of the element 2 Oneend ofthe element is solid while the other has a pi
69. e 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 con nection 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 docu ments 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
70. e 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 Referto section INSTALLATION All VSS Models for removal of the gate rotor bearing housings and gate rotor supports B Forremoval 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 Forremoval of thrust bearings on VSS units 1 Remove retaining ring from gate rotor sup port 2 Remove bearings from support 3 Remove bearing retainer from inner race Service GATE ROTOR THRUST BEARING INSTALLA TION The thrust bearings must be assembled face to face A Forinstallation of thrust bearings on VSS units 1 Install bearings 126 inthe 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 hous ing use Loctite 242 thread locker and evenly tighten the bolts to the recom mended torque value 3 Forinstallation of the bearing housing and the setting of the gate rotor blade clear
71. e diagrams below Removing ICM 25 to 65 bonnets 1 Remove the 4 bolts 2 Rotate the bonnet as shown 3 Pry the bonnet out of the valve body by using screw drivers between the bonnet and valve body as shown Part descripion _ EN ICM body housing ICM bonnet function module O ring for bonnet function 2a module O ring for bonnet function 2b module O ring for sealing ICAD motor 2c with ICM valve ICM adapter valve stem 4 ICM bonnet gasket Bolts for ICM Cw CAD motor scio _ O ring for ICM 20 seat orifice ICM 20 valve seat orifice DKRCI EI HTO A 1 22 520H1639 3 ICM ICAD Motorized Valve Installation Programming and Troubleshooting Care should be taken to protect the ICM function module while it is removed from the valve body 3 Weld the valve body in line making sure the arrow on the valve body is pointing in the direction of flow 4 Remove all debris from the valve body before re installing the bonnet 5 Install the bonnet function module into the valve body a For ICM 20 make sure that the removable orifice seat is installed in the valve body with the small O ring between the orifice seat and body Make sure the bonnet gasket is installed and in good condition b For ICM 25 through ICM 65 check that the two O rings on the bonnet and gasket located between the bonnet and valve body are installed and in good condition A light coating of r
72. e 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 COMBINATION STOP VALVE amp STRAINER Operation OIL FILTER OIL SEPARATOR N n OIL COOLER WATER OR REFRIGERANT FIGURE 3 TYPICAL WATER COOLED OIL COOLER DIAGRAM The solenoid valve provides positive water shut off 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 com pressor 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 injec tion 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 injec tion port in response to the discharge tempera ture 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 regula tor can be used to adjust superheat Normally this regulator should be adjusted to maintain 70 psig pressure at the external equalizing port of the ex pans
73. e should be exercised to insure all opened flanges are tightened all plugs that were removed are re placed with a suitable thread filling 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 Year Round Operation On a continual basis 1 Guard against liquid slugging of compres sor 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 recommend ed 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 check ing machine conditions once a year may prevent extensive shutdowns later with subsequent product loss and expensive repairs Stop Check Valve Installation Correct Correct 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 Retrofitting a
74. ed 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 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 non condensables 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 con junction with the high vacuum pump The read ing from the gauge s indicates when the system has reached the low absolute pressure required for complete system evacuation Connect the high vacuum pump into the re frigeration system by using the manufacturer s instructions Connect the pump both to the high side and low side of the system to insure system evacuation
75. efrigerant oil on the bonnet O rings will facilitate installation of the bonnet 6 Install the four bolts and torque to the following specifications ws 7 Install the ICAD motor actuator on the ICM valve The valve must not be in its fully opened position while the ICAD motor is calibrated with the valve at a later step Therefore if the opening degree of the ICM valve was changed from the factory setting it should be set to an opening degree between 096 and 7596 using the manual magnet tool To easily ensure correct positioning turn the manual tool counter clockwise until it is clear that it cannot be turned further b Make sure that the ICM adapter valve stem and inner ICAD motor magnets are completely dry and free from any debris C Forapplications below freezing the ICM adapter O ring position 2c in the diagram on page 3 must be removed and Molycote G 4500 grease supplied with ICAD motor needs to be applied in the O ring groove on the adapter and on the O ring before it is re installed on the ICM adapter The Molycote grease ensures a good seal between the ICAD motor and the ICM adapter to prevent moisture from entering the ICAD magnets d Place the ICAD motor on the valve stem e Push the ICAD motor completely down to the identification ring on the valve stem and use a 2 5 mm hex key to tighten the set screws evenly so the ICAD motor is centered on the ICM adapter torque 3 Nm 2
76. em When properly evacuating the system as outlined above the system is dry oxygen free and free of non condensables The piping should not be in sulated before the evacuation process is started If moisture is in the system before evacuating it condenses in low places and freezes If this hap pens 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 va por 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 UNIT OIL CHARGING 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 separa tor 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 TABLE 2 OIL CHARGE Approximate Oil Charge Gallons Oil Separator Size VSR 16 20 to 27 VSR 20 22 to 31 VSM 20 20 to 25 VSM 30
77. 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 3 CLR EL TOP OF Fig Z N BR ene ang ya TRO EDI ERE ER RERO eee ee SIDS RAR TT m INTE ZII A k COMPRESSOR UNIT I I CENTER LINE OF GAS COMPRESSION SYSTEM NE OR EES E gi SE y es AN n NS TA I CLR a OA MP ve n A sgt ee BEL LTE ga a T n AST ri RIETI a m 2 TOP amp BOTTOM mip n eme E E EET TTE ETE gt AR s AR y 4 COMPACTED SAND 277 2 PY UNI SIA SIONS gt N EXCAVATE TO FROST DEPTH AS REQ D AND BACKFILL WITH CLSM OR NON FROST SUSCEPTIBLE FILL ure 1 Concrete Pad with Compressor Unit Dimensions Side V
78. enu screen appears 1 Down arrow push button 2 Enter 3 Up arrow push button 4 Display 2 Once you are in the menu use the up 3 and down 1 arrow keys to move through the list of parameters 3 To display the current setting of a parameter press the middle button a To change the value of a parameter setting use the up or down arrow to establish the new setting while in that particular parameter s display mode b Once the new setting for a parameter has been selected push the center button to save the charge and retum to the menu 4 Repeat this procedure for all parameters 5 Exit from the parameter list by pressing and holding the middle button for 2 seconds The ICAD will automatically exit if no buttons are pushed for 20 seconds DKRCI EI HTO A1 22 520H 1639 Danfoss USCO MKS 1 1 2006 Motorized Valve Installation Programming and Troubleshooting Programming the ICAD When the ICAD motor is first powered the ICAD display will flash an alarm This means that the ICM valve size that is being used with the ICAD motor needs to be selected in parameter 26 Parameter 26 is password protected and will not appear in the parameter list until the user enters the password in parameter 10 The password 15 11 and will allow the user to access parameter 26 where the appropriate valve size is selected When the ICM valve size is selected the ICAD will calibrate itself to the ICM valve
79. er cable to the actuator Press INCand DECto move the slide valve and check forthe correct rotation See Table 10n page 48 for Actuator command shaft rotation specifications 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 Quickly press and release the blue push but ton on the actuator one time This plac es the actuator in calibration mode The red LED will begin flashing rapidly Note When the actuator is in calibration mode it outputs OV when the actuator is running and 5V when it is still Thus as stated earlier the actuator voltage will fluctuate during calibra tion After the actuator has been calibrated OV output will correspond to the minimum position and 5V to the maximum position Note The Slide calibration screen on the con trol 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 15 16 17 18 19 20 Use the DEC button on the control panel to drive the slide valve to its minimum mechani cal stop position Do not continue to run the actuator in this direction after the slide valve has reached the stop Doing so may
80. er slots 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 Next measure the DC voltage between terminal 3 and TP2 on the circuit board You should measure between 0 1 and 0 2 Volts 41 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 transmit ting 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 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 authorize
81. er to Service Section E Yearly Items 1 thru 13 and D above plus 14 thru 28 14 Check entire system thoroughly for leaks 29 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 con trols 21 Clean all water strainers 22 Check drains to make sure water will flow away from equipment 23 Drainand clean entire oil system at receiver drain Recharge with new clean moisture free oil For proper procedure for changing micronic oil filter 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 accu racy 27 Check mounting bolts for compressor and motor System Leaks There are any number of reasons why leaks develop in a refrigeration system i e such as drying out of valve packing yielding of gaskets improper replacement of valve caps and loosen ing of joints due to vibration For these reasons the need for periodic leak testing cannot be over emphasized Similarly when any service opera tions are performed on the system car
82. erm Storage Requirements 2 Cover the unit completely to exclude dirt dust moisture and other foreign materials 3 Ifthe motor 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 destruc tion exists Sealing motor openings should restrict access to the motor 4 Rotate motor and compressor shafts several revolutions approximately 6 per month to eliminate flat 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 10 Description COMPRESSOR The Vilter Single Screw Compressor is
83. etal surfaces coupling flange 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 specific recommendations 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 T
84. f 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 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 53 O Li L NOTE 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 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 Order 54 Control power of 115 VAC 50 60 HZ must be wired to the left side terminals of the digital board inside the ViSSion cabinet Line power L1 is brought in to 10 amp fuse via the terminal marked 11 on the appropriate connector The neutral is brought in and connected
85. field installation will require replacing the bonnet assembly The bonnet must be installed with the spring towards the bottom see illustrations above The drill fixture 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 31 Coupling Installation B Straight Bore 1 Install key s in the shaft If the hub is an interfer ence fit heat the hub in an oil bath or oven until bore is sufficiently larger than the shaft 350 F is usually sufficient An open flame is not recom mended However if flame heating is necessary use a very large rose bud tip to give even heat distribution A thermal heat stick will help deter mine 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 il C Taper Bore 32 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
86. for sizes 7 8 and above and therefore the torque values are less than smaller sizes of the same grade Torque Specifications for 17 4 Stainless Steel Fasteners ft lbs Type Head Nominal Size Numbers or Inches Bolt Nut Markings Hex amp Socket IT NOTE Continue use of red loctite 271 VPN 2205E on currently applied locations Use blue loctite 243 VPN 2205F or 2205G on all remaining uer Service USING A TORQUE WRENCH CORRECTLY TORQUE WRENCHES USING A TORQUE WRENCH CORRECTLY INVOLVES FOUR PRIMARY CONCERNS A Asmooth 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 tight ened 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 Insome 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 lubr
87. ft gears atthe same time Push the racks all the way towards the suction end of the compressor until VSM 301 701 amp VSS 2601 3001 compressors they stop Install washers and jam nuts on the cross shafts slide valve shafts Repeat the procedure for the remaining set of slide valve racks Volume control cross shaft en installing the slide valve racks both racks i must engage the axle shaft gears atthe same Ime 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 recom mended torque value 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 29 80 Torque Specifications ft lbs Head Nominal Size Numbers or Inches Markings va spe ans 12 Jone si 3 2 18 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 specific torque specifications when supplied 2 When using loctite torque values in this table are only accurate if bolts are tightened immediately after loctite is applied proof strength of Grade 2 bolts is less
88. gineer please see the section immediately below entitled Create and Communicate the Plan Individuals participating in the lift should fully understand the scientific 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 fitness 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 finalized and distributed for review and com ment The Plan should clearly define requirements expectations and specifications for lifting the Compressor At a mini mum the Plan should include e Standard lifting and rigging procedures in place at the lift site including proper classification of the lift as a critical lift a serious lift or a standard lift Drawings of the Compressor Adescription of the lifting task Anevaluation of the hazards e The rigging plan and sketches of rigging to be attached to the Compressor The roles and responsibilities of all Participants Anemergency plan and e The contact information of the Plan preparer It is important to confirm that each Participant understands both the broader Plan and their spe
89. greed 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 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
90. grout has cured torque the anchor bolts as per HILTI instructions 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 e ASTM e ASCE 7 IBC 2006 17 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 Ibs RPM 3600 Soil bearing capacity 1 500 Ibs 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 sufficient depth to dampen vibrations 18 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 th
91. hin 002 inch per inch of the axial length between flex elements See drawing below Note If the driver or driven equipment alignment specification is tighter than these recommendations the specification should be used Also be sure to compensate for thermal movement inthe 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 fit through the holes in the flanges and the disc packs more easily 1 Ifthe 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 Offset ing the discs packs off first 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
92. his 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 TESTING REFRIGERATION SYSTEM FOR LEAKS Vilter equipment is tested for leaks at the factory One the most important steps in putting a refrig eration system into operation is field 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 pres sure 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 suf fice 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 regula tors 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 pro
93. ic 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 iso lated 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 Recheck the transducers periodically for any drift of calibration A Screw Compressor Control And Operation 1 Starting Stopping and Restarting the Com pressor 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 Operation Manual Auto button is pressed the oil pump Note will start When sufficient oil pressure is built Optical Actuators CAN NOT Capacity up and the compressor capacity control and be manually rotated f volume ratio slide valves are at or below 10 the compressor unit will start N ER The VSM 501 701 models will have motor locations opposite of figure 6 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 accom plished a number of ways Any of the safety setpoints will stop the compressor unit if an abnor
94. icant if required or not if so specified D Unlike 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 81 Service Fine serrations face A The Nord Lock lock washer sets are used in many areas in both the VSG amp VSSG screw compressors that require a vibration proof lock washer 4 The lock washer set is assembled so the course I serrations that resemble ramps 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 82 Service 6 00 OILFILTER 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 Ateachend ofthe filter there is a large thick elastomeric seal 3 The housing is a fabricate
95. iew 13 Foundation COMPRESSOR UNIT CENTER LINE OF GAS COMPRESSION SYSTEM EL TOP OF GRADE 1 oa Rx WA 25 X A 77 S 2 NOT ET D A AS Tan can a Dp YS KE Sa er a RR 2 Q a Nr i k Tea et 555 nn A IT TN 12 ae 22 HU TE EACHWAY I amp BOTTOM Zo TTE nn nn EXCAVATE TO FROST DEPTH AS REQ D AND BACKFIL 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 Thesand must be compacted before placing the forms and rebar Afterthe 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 ofthe 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 c
96. ion system should be inspected as outlined below A Low Side Equipment 1 Fans on air handling equipment running Pumps on water cooling equipment run ning 3 Proper location and attachment of thermo static 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 Compressors Proper oil level Voltage agrees with motor characteristics Properly sized motor fuses and heaters Direct drivers aligned and couplings tight All suction and discharge valves open All transducers and RTD s calibrated and reading correctly ea 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 Initial Charging High Side Charging There are two methods of charging refriger ant into the system through the high side or through the low side High side charging is usually used for initial charging as filling of the system is much faster Low side charging
97. ion valve Raising the pressure beyond 70 psig tends to raise the discharge temperature while lowering the pressure lowers the discharge tem perature Secondly the standard superheat adjust ing screw on the thermostatic expansion valve can be used to adjust the discharge temperature SIGHT GLASS EXPANSION VALVE STRAINER HIGH GAUGE PRESSURE REGULATOR 1 4 Fine Adjustment Valve OIL SEPARATOR 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 horse power penalty 3 V PLUS Oil Cooling System This system consists of a liquid pump shut off valves motor solid st
98. 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 gener ally located in the liquid line immediately after the king or liquid line valve Purge the air from the charging line 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 sys tem Close the liquid line or king valve if itis 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 After some refrigerant has entered the system the compressor unit starting pro cedure may be followed See Start Up and Operation Section of this manual Con
99. ischarge 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 dI Service DISCHARGE MANIFOLD INSTALLATION 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 recom mended torque value 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 flange bolts Install the drain plug in the bottom of the discharge manifold On VSM 301 701 compressors install the bolts in the discharge flange Install the drain plug in the bottom of the discharge manifold D Install both command shaft assemblies and control actuators 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 0 005 to 0 010 Rack to clamp 78 0 003 to 0 005 Rack to clamp spacer C Check torque of socket heat cap screws D Check for excessive
100. ld hub in place D Shaft Alignment Move equipment into place 1 Soft Foot The equipment must sit flat 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 flex 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 flexing element that is centered and parallel to its mating flange faces Move the con nected equipment to accomplish the above NOTE The disc pack is designed to an optimal thick ness and is not to be used for axial adjustments See documentation that came with the coupling for complete specifications 3 Angular Alignment Rigidly mount a dial indicator on one hub or shaft reading the face of the other hub flange as shown on next page Rotate both shafts together making sure the shaft axial spacing remains constant Adjust the equipment by shim ming and or moving so that the indicator reading is within 002 inch per inch of coupling flange 4 Parallel Offset Rigidly mount a dial indicator on one hub or shaft reading the other hub flange 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 wit
101. 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 par ticular 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 e Riggers and Safety Signaler 19 Rigging and Lifting Training curriculum for Participants at a minimum should include Areview of safe operating practices Areview of who each person is and their specific role in the lift e A tutorial on how to read lift charts Ademonstration on how to use and inspect rigging hardware Areview 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 Areview of the Compressor s specific rig and lift plan the Plan developed by the Lift Coordinator and Lift En
102. light emitting di ode LED on 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 As the motor turns the photochopper fence al ternately blocks and opens the optocoupler slots generating a sequence that the position sensor mi crocontroller can use to determine motor position by counting Because the motoris 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 posi tion 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 sa
103. lot hole with captive o ring 3 Onduplex models only the end cap is removed from the filter bowl Simplex filter housing Duplex filter housing B Usage 1 Used in simplex and duplex applications 2 The O rings for the simplex and duplex housings are not interchangeable 85 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 amp 1801 3 1 00 to present 2 All other VSS models with 30 and larger oil separators 3 1 00 to present Length 39 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 Onlyend cap is removed from the filter bowl D Usage 1 Used in simplex and duplex applica tions 86 Service Simplex filter housing Maintenance Refrigeration Maintenance and Inspection Schedule The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrig eration oil in VSS VSM and VSR Single Screw Compressor units Inspection SERVICE INTERVAL HOURS Or Group Maintenance ltem OIL CIRCUIT Oil Change 1 Oil Analysis 2 Oil Filters 3 Oil Strainer PACKAGE Coalescing Elements Suction Screen Liquid Line Strainers Coupling Alignment and Integrity CONTROL CALIBRATION Transducers
104. lt so Oil Control Valve lt Remote Air Cooled Cooler IN Shows the Flow for Priming the Oil Cooler Steps 1 5 Shows the Flow for Priming the Compressor Prior to Start Up Steps 6 11 Discharge Gas Shipped Loose Y Oil Heater E Ball Valve See Section On Set Points In Compact Logix Manual See Section On Start Up Check List In Manual IMPORTANT FOR REMOTE OIL COOLERS ONLY READ BEFORE PROCEEDING 143 353915 Rev 8b 10 12 Emerson are trademarks of Emerson Electric Co or one of its affiliated companies 2012 Emerson Climate Technologies Inc All rights reserved Printed in the USA EMERSON CONSIDER IT SOLVED
105. lt for fulcrum 58 Small wooden block or fulcrum COMPRESSOR INSPECTION The Vilter Single Screw Compressor is designed for long periods of trouble free operation with a mini mum of maintenance However a yearly inspection is recommended so any irregular wear is noted and rectified Atthis time the bearing float is measured for the main rotor and gate rotors Thefollowing are the procedures used in measuring the main rotor and gate rotor bearing float 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 Shutdown and de pressurize the unit B Main rotor bearing float 1 Remove the coupling quard 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 compres sor coupling half and push the coupling towards the motor note measurement TABLE 1 MAXIMUM BEARING FLOAT MAIN GATE Bearing Float 0 003 300 50 to 100 3 Re Zero indicator now position the fulcrum onthe motor and use the lever arm to push the input shaft towards the compressor note measurement Service 4 Addboth readings the total indicator move mentis the bearing float and this should not exceed 0 003 Gate rotor bearing float 1 Remove the side covers and position a dial indicator on the gate
106. ly 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 Itis important to avoid short rigid pipe lines that do not allow any degree of flexibility This must be done to prevent vibration being transmitted through the pipe lines to the buildings One method of providing the needed flexibility 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 fittings where possible The use of screw type fittings 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 Halocar bon lines type K or L conforming to ASTM B88 should be used Soft annealed copper tub ing conforming to ASTM B280 can also be used for tube sizes not larger than 1 3 8 in outside diameter These requirements are in accordance 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 require ments Never use type M as it does not have adequate wall thickness
107. ly starts the motors will travel below 5 and function correctly The user may see that the actua tors 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 belowthe 5 on the screen This may be perceived as a problem in reality it is not 5 Note The 0 to 5V position transmitter output of the actuator will fluctuate wildly during the calibration process To prevent damage to the actuators do not connect the yellow power cable orthe gray position transmitter cable until instructed to do so later on 6 Openthe plastic cover of the capacity motor by removing the four 10 screws 35 36 Slide Valve Actuator Installation amp Calibration Caution there are wires attached to the con 10 11 12 13 14 nector on the plastic cover Handling the cover too aggressively could break the wires 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 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 Now connect the yellow power cable and the gray position transmitt
108. m of oil for the mechanical shafts seal Excess oil flows through the check valves on the sealing baffle 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 flute of the main screw Once the gas is swept from the main screw flute 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
109. mal operating condition exists The com pressor 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 ap propriate 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 fail ure option is selected see appropriate Micro processor Instruction Manual the compressor unit will start up after a waiting period With both options the compressor slide valves must return below their respective 525 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 View Volume Ratio FIGURE 5 SLIDE VALVE MOTOR LOCATION When viewing the compressor from the dis charge end opposite the drive end the upper motor is for capacity control The command shaft turns see Table 1 to decrease the ity to 10 and reverses to increase the capacity to
110. moval 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 REMOVAL use side rails A Prepare the compressor for servicing NOTE All parts must be kept with their appro For VSS 751 901 amp VSS 1051 THRU 1301 priate side and not mixed when the compres compressors use side rails and assemble sor is reassembled to gaterotor stabilizer as stamped me B Remove two upper bolts from the side cover and install quide studs the holes Remove the remaining bolts and side cover There will be some oil drainage when the cover is removed Turn the main rotor so a driving edge of any one ofthe main rotor grooves is even with the back of the gate rotor support e Position leading edge of main rotor groove flush with or slightly below back of gater rotor support Insertthe 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 compres sors 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 Drive End The gate rotor stabilizer is designed to hold the gate rotor support in place and prevent damage tothe gate rotor blade asthe thrust bearings an
111. 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 CN Check Rack to torque clamp on cap SPESSI Screws Rack to Rall pins clamp 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 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 Toremovethe cross shafts remove socket head INSTALLATION OF CAPACITY OR VOLUME bolts clamp and spacers from both sides CROSS SHAFTS VSS 751 2101 compressors 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 recom mended torque values B Theslide 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 sha
112. nances regarding the disposal of used refrigeration oil Loosen and remove the locking ring on filter tank by turning in a counter clockwise direc tion Remove filter tank with the used element Remove the filter element from the tank Be fore 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 re frigeration 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 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 regard ing the recovery of refrigerants Drain the filter bowl or housing in to an ap propriate container and dispose of the oil in a appropriate manner following all Local State and Federal ordinances regarding the disposal of used refrigeration oil Loosen and remove the cover on the bowl of
113. 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 align ment per Section D Reassemble per Section E Slide Valve Actuator Installation amp 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 Briefly 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 ro tational 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 Afterthe 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 amp rotational 100 position of the slide valve travel PLEASE NOTE Because there is an optical sensor on this motor do not attempt calibrati
114. oad charts Review all Compressor drawings for unit size weight center of gravity and other specifications Communicate incident response procedures in writing prior to the lift and verbally immediately before the lift Determine the initial position final position orientation and elevation of the Compressor e Ensure that adequate space is provided to safely assemble erect and operate the crane and materials such as timber mats cribbing and blocks e Identify and communicate to all Participants the access points lift radius swing radius clearances and ob structions e Eliminate hazards and obstructions that may interfere with moving the Compressor and e Inform all Participants of water lines sewer lines power lines and other obstructions De Proper Rigging Methods Determine diameter length and quantity of necessary rigging hardware design and detail the rigging hard ware to suit lifting the Compressor at the supplied pad eyes Review and inspect all hoisting lifting and rigging equipment e Select shackle size and prepare sketches or drawings for rigging e Use proper conservative rigging techniques including spreader beams needed to lift the Compressor e 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
115. of the filter element s SINGLE ELEMENT OIL FILTER TANK SPRING OIL FILTER PLATE ELEMENT a OUTLET INLET E DUAL ELEMENT OIL FILTER TANK SPRING OIL FILTER 2 1833 Filter Element ELEMENT OUTLET INLET CENTERING PIECE FIGURE 1 1833C FILTER ELEMENT TANKS Operation To replace the filter element s on single ele ment 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 out let 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 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 Lo cal State and Federal ordinances regarding the recovery of refrigerants FILTER OUTLET TANK FILTER ELEMENT INLET FIGURE 2 TYPICAL CANISTER TYPE FILTER CROSS SEC TION Drain the filter bowl or housing in to an appro priate container and dispose of the oil in a ap propriate manner following all Local State and Federal ordi
116. ollowing maintenance schedule is suggested A Daily 1 Check oil levels 2 Check all pressure and temperature read ings 3 Check micronic oil filter inlet and outlet pres sures for excessive pressure drop Change filter when pressure drop exceeds 45 psi or every six months whichever occurs first For proper procedure for changing micronic oil filter and for charging oil into the system see Operation Section Clean strainers each time filter cartridge if replaced Check compressor sound for abnormal noises Check shaft seals for excessive oil leakage A small amount of oil leakage approxi mately 10 drops min is normal This allows lubrication of the seal faces Weekly Items 1 thru 6 above plus 7 thru 9 Check the refrigeration system for leaks with a suitable leak detector Check oil pressures and review micropro cessor log and log sheets Check refrigerant levels in vessels Monthly Items 1 thru 8 above plus 9 thru 13 Oil all motors and bearings Follow manu facturer s instructions on lubrication Check calibration and operation of all controls particularly safety controls Check oil cooler for any evidence of cor rosion scaling or other fouling Operate compressor capacity and volume ratio controls through their range both automatically and manually Trimonthly About 2000 operating hours Check movement of compressor rotor at drive coupling end to determine bearing float Re f
117. on in direct sunlight 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 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 electri cal conduitto runthe 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 Runthe yellow AC power cable s and the gray DC position transmitter cable s in different conduit This prevents the DC position transmitter cable from pick ing 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 gear motors on early units you must remove the capaci tors and associated wiring from inside the control panel Thisis necessaryto 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 actual
118. oncrete to cure for at least 28 days ISOLATION JOINT 1 MINIMUM COMPRESSOR UNIT THICKNESS FOUNDATION CHAMFER EDGE CONCRETE SLAB IN BUILDING 14 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 finger tight and prepare to grout OVER ALL G A LENGTH 4 0 10 0 5 0 CENTER LINE GAS COMPRESSION SYSTEM Figure 4 Found
119. or As such it will count steps up and down from the position it believes it is in Every time the ICAD is powered on it will drive itself to the closed position in order to re establish its base point of reference It willthen move back to the position corresponding to the signal it is receiving from the control wiring 2 The ICAD can be put into manual mode to move it using the up and arrows to a location different from the location that the signal is telling it to be in see parameter 01 p 6 When in the manual mode the display screen will be flashing and will continue to flash flashing the opening of the valve until the ICAD is taken out of the manual mode 3 The ICAD can be operated in analog mode for modulating operation or in digital mode for solenoid operation The ICAD can receive a variety of control signals see parameter j03 p 6 and can send a valve position output signal to modulate another ICAD or to a PC or PLC for monitoring see parameter j06 p 6 4 Because the ICAD is employs a digital stepper motor its speed can be adjusted to any percentage of full speed through the parameter menu see parameter j04 p 6 5 The ICAD can be connected to a 24 VDC UPS Uninterruptible Power Supply and can be programmed for actions when the normal power has been cut and the ICAD is operating off of the UPS power see parameter 07 and j12 p 6 1 In order to access the menu PRESS and HOLD the middle button 2 until the m
120. or special instructions Every Refrigeration unit includes a Vilter Start Up Confirm 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 pur chase 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 amp Void future Warranty considerations 32 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 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
121. or will not move in either direction The motor runs intermittently several minutes on several minutes off 40 Reason 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 aloose connection in the screw terminal blocks There is a loose or dirty connec tion in the yellow Turck cable 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 Solution Recalibrate Get the motor brake to where it operates freely and then recali brate Replace the actuator Try to realign or replace the ac tuator Adjust the photochopper so that the fence extends further into the optocoupler slots Replace the actuator Tighten Clean and tighten Replace the actuator Replace the actuator The motor will resume opera tion when it cools This could be caused by a malfunctioning con trol panel Consult the factory See
122. oss Shafts amp Plate Models VSM 301 401 Counter Clockwise ONLY COUNTER CLOCKWISE ROTATION CU L C2 v2 gt SEE DRAWING 25976PIX FOR BAFFLE ASSEMBLY F SO085AT INSTALL PIN WITH TOOL 116 Main Rotor Slide Valve Cross Shafts amp End Plate Models VSM 301 401 Counter Clockwise ONLY MODEL NUMBER VSM 301 VPN DESCRIPTION MAIN ROTOR ASSEMBLY OIL BAFFLE ASSEMBLY 1 217 1 244 1 248 1 249 1 252 SHIM ASSORTMENT 2 240 2 241 1 242 1 243 END PLATE SHAFT GEAR CLAMP SPACER SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 TEFLON RING BAFFLE CHECK VALVE BAFFLE CHECK VALVE BAFFLE RETAINING RING BAFFLE EXPANSION PIN EXPANSION PIN PLUG SOLID HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW SET SCREW SET SCREW Not pictured A As required NN OO P pp p gt gt gt A25226AB A25942AA A25177A 25719D 25941A 25027A 25913D 25847A 25409AA 25409AB 25409AC 25409AD 25939A 3120A 3120B 2829M 1193D 2981AA 25422A 2796N 2795F 2060 2060H Required at top locate single gaterotor only A25226AA 1 A25942AA 1 A25177A 25719D 25941A 25027A 25913D 25847A 25409 25409 25409 25409AD 25939 3120 3120 2829 11930 2981AA 25422A 2796N 2795 2060 2060 25226 25942 25177 257190 25941A 25027
123. pen prior to starting 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 TO COMPRESSOR N HAND EXPANSION GLASS VALVE FIGURE 6 OIL SEPARATOR BLEED LINE NOTE The purpose ofthe oil bleed return assembly is to collect any oil that passes through the oil separat ing element and returns that oil to the compres sor Thehand 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 7 Open 1 4 high pressure gas line valve piped to oil injection line just enough to quiet compres sor at 10076 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 ar rives See next page 51 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
124. per 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 test ing gas in a system where ammonia is already dissolved in any moisture remaining This will Cause ammonium carbonate to precipitate when the CO 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 flanges threaded joints and welds Repair all visible leaks If possible leave the pressure on over night A small pres sure drop of 5 Ibs 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 25 26 Installation valves on the lowest part of the system so the gas will float 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 sys tem and pressurize the system to its respective design
125. pressor input shaft Care fully 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 filled with clean compressor oil may be used to lubricate the faces of the seals without touching the seal 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 Carefully install the seal cover on the compressor shaft evenly tightening the bolts to the recom mended torque values 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 73 74 Measure here Service A D INSPECTION OF SLIDE VALVE ASSEMBLIES IN THE COMPRESSOR Follow lockout procedure before servicing this unit Prepare the compressor for servicing Remove the gate rotor access covers Using a mirror and flashlight visually inspect the slide valve carriage th
126. pressor via an additional injection orifice C Oil Filter Change the oil filter after the first 200 hours of opera tion 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 oc curs first The pressure drop across the filter is read on the microprocessor panel Check the pressure drop and record it daily To prepare for the removal of the filter shut down the compressor Isolate the filter housing appropri ately 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 filter 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
127. pressure Pass a lit sulfur stick around all joints and connections Any leaks will be indi cated 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 consid ered tight and ready for evacuation Halocarbon Refrigerant Systems Oil pumped dry nitrogen or anhydrous CO in this order of preference may be used to raise the pressure to the proper level for testing When the proper pressure is attained test for leaks with the soap mixture previously described After all leaks are found and marked relieve the system pressure and repair the leaks Never at tempt to repair soldered or welded joints while the system is under pressure Soldered joints should be opened and re soldered Do not simply add more solder to the leaking joint After all the joints have been repaired and the system is considered tight the system may be tested with refrigerant Attach a drum of the refrigerant to be used in the system and allow the gas to enter until a pressure of 5 psig is reached Remove the refrigerant drum and bring the pressure to the recommended test level with oil pumped dry nitrogen or CO Then check the entire system again for leaks using a halide torch or electronic leak detector Be sure to check all flanged welded screwed and soldered joints all gasketed joints and all parting lines on castings If any leaks are found they must be repair
128. quipment 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 e 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 Masterflow 648CP high performance non shirk grout to provide at least a 1 thick pad under each foot The recommended anchors are 5 8 Diameter HILT HAS SS threaded rod for outdoor installations or HAS E rods for indoor installations Anchor bolts Shall have a five inch projection and 12 3 8 embedment The required adhesive is HIT ICE HIT HY 150 anchoring system There should be enough one in
129. r 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 22 Installation DELIVERY INSPECTION Vilter screw compressor components are thor oughly inspected at the factory assuring the shipment of a mechanically perfect piece of equip ment 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 ex amine 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 TABLE 1 UNIT WEIGHTS LBS MODEL STANDARD ECON O MIZER VSM 71 2 750 2 750 VSM 91 2 750 2 750 VSM 101 2 790 2 750 VSM 151 2 750 2 750 VSM 181 2 50 2 50 VSM 201 2 50 2 50 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 FOUNDATIONS
130. res 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 reciprocat ing compressor parts and 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 a
131. ressor efficiency is maximized Proper positioning of the volume ratio slide prevents either over compressing or under compressing of the gas within the screw flute This allows the single screw compressor to efficiently handle a range of volume ratios from as low as 1 2 up to 7 0 11 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 sup ports the entire operating weight of the unit and is suitable for years of continuous duty Included are specifications 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 e 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 NOTE Always check with a safety engineer before proceeding e Arranging e
132. rge 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 compres sor 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 combi nation vessel B Oil Separator The refrigerant oil mixture is led into the first part of oil separator There the first step of oil separa tion is performed by a combined agglomerator demister At the same time these part of the oil separator serves as oil collector In the second part of the oil separator the fine separation of the aerosol oil portion from the re frigerant 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 com
133. ring 141 Tighten the bolts 152 to the recommended torque value When installing the thrust bearing housing 113 a new O ring 142 must be used when the housingis installed Lubricate the outside of the housing and bearings with clean compressor oil to aid in the installation Due to the fit of the bearings on the gate rotor shaft the thrust bear ing removal and installation tool with the pusher shoe must be used Turnthe jacking screw clock wise 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 Place a piece of 0 003 0 004 shim stock between the gate rotor blade and the shelf Measure the depth from the top of the com pressor case to the top of the thrust bearing housing This determines the amount of shims needed for the correct clearance Use factory installed shim pack 106 and bearing housing cover 116 without the O ring 143 Check the clearance between the entire gate rotor blade and the shelf rotate the gate rotor to find the tightest spot It should be between 0 003 0 004 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
134. rough the gas bypass opening Look for any significant signs of wear on the slide valve carriage To check the clearance of the slide valve clamps the gate rotor support must be removed Refer to removal of the gate rotor support 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 If the slide valves are worn in excess of the toler ances the factory should be contacted REMOVAL SLIDE VALVE CARRIAGE ASSEM BLIES Prepare the compressor for servicing 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 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 Re move 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
135. rvicing the compressor LEAK CHECKING UNIT Note Unit can be leak checked before evacuation CAUTION Slowly pressurize the unit from the discharge side ofthe compressor Pressurizing the compressor from the suc tion 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 Break the vacuum on the unit using dry nitrogen and check for leaks Concentrate on areas where work was done C Ifno leaks are found the unit can be returned to Service 27 Service Top View Rotor Being Pushed By Use Of Lever 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 determined by length of level arm Side View Showing gate rotor bearing float being measured Wooden block to prevent damge to gate rotor blade Direction of rotor movement Axial force at gate rotor to be 250 to 300 Ibs Force to be determined Rigidly attach by length of level arm dial indicator Use bolt for fulcrum Blades on gaterotor are sharp Side View Showing gate rotor bearing float being measured Wooden block to prevent NT damge to gate rotor blade Direction of rotor movement Axial force at gate rotor to be 250 to 300 Ibs Force to be determined by length of level arm Rigidly attach dial indicator Use bo
136. 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 defec tive 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
137. safe supply 18V d c Check Supply to ICAD 45 If supply voltage lt 18 V d c Tips Problem Possible cause and solution The valve 15 not working and 1 15 The ICM valve size was not selected in flashing in the display parameter 26 See the programming section on page 9 The valve does not appear to be opening ICAD was not mounted properly or closing properly on the valve stem Solution Check to make sure that the ICAD was mounted evenly on the ICM valve The ICAD is not receiving a proper input signal Solution Use the service parameters j51 for a mA input or j52 for a voltage input to check the input signal that the ICAD is receiving The valve position feedback signal is not A power supply was installed in the working when using customer supplied 4 20mA 0 20mA feedback loop controller PLC The ICAD motor actuator supplies the power for the 4 20mA 0 20mA feedback loop Solution Remove any power source that may be supplied to the feedback loop Wiring problem Solution Check the service parameter 53 to see what the ICAD is outputting If this does not reveal anything check the current output yellow and blue wires in ICAD control cable with an ammeter The feedback output signal was turned off in parameter 06 Solution Check to make sure the setting in parameter 06 IS correct For all other problems contact Danfoss Danfoss USCO MKS 11 2006 DKRCI EI HTO A1
138. sent to Aremote display APLCor PC Another ICAD motor to give the same opening position Danfoss Refrigeration amp Air Conditioning Division 7941 Corporate Drive Baltimore MD 21236 Ph 410 931 8250 Fax 410 931 8256 E mail baltimore danfoss com Internet www danfoss com North_America Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved 12 DKRCI EI HTO A1 22 520H1639 Danfoss USCO MKS 11 2006 Appendix A Pre Start Up for Remote Oil Coolers A Remote Coolers Only Suction Strainer 6 2 0 Single Screw Stop Valve Check Compressor t u Valve Verify Oil is in Separator Note Bottom Site Glass Should Be Full Very Important Piping of the oil must enter the bottom connection of the oil cooler and leave the top connection Failure to Follow These Steps Will Result in Bearing Damage and Com pressor Seizing and Will Void Any and All Warranties That May Apply Metering Valve
139. sor When the housing is removed there will be shims be tween 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 Remove the bolts from the roller bearing housing After the bolts have been removed the housing can be removed from the compressor To remove the gate rotor support carefully move the support opposite the direction of rotation and tilt the roller bearing end towards the suc tion 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 63 gt es k 64 a HE Service INSTALLATION All VSS Models A Install the gate rotor support by carefully tilting 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 sup port Install gate rotor stabilizer The gate rotor sta bilizer 901 will hold the gate rotor support in place as the thrust bearing housing is being installed If the gate rotor support is not re stricted from moving the gate rotor blade may be damaged Install the roller bearing housing 112 with a new O
140. 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 work ing properly see theory section above Solution Clean the optocoupler slots with a Q Tip and rubbing alco hol Adjust the photochopper so that the fence extends further into the optocoupler slots Make sure the motor brake operates freely and the pho tochopper 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 elec tronics cleaner or compressed air Try to free the stuck button Replace the actuator Depress the button quickly and then let go Each second the button is held down counts as another press 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 actua tor Install additional metal shield ing 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 39 Slide Valve Actuator Trouble Shooting Guide Problem The actuator does not trans mit the correct position after a power loss There is a rapid clicking noise when the motor is operat ING The motor operates in one direction only The mot
141. tatus ON whenOD gt 97 1 Digital Output alarm status ON when an alarm is detected 0 0 8 Software version for MASTER Microprocessor 100 100 Software version for SLAVE Microprocessor It is also possible to restore the original factory settings to the ICAD by the following procedure o podee 786 0_ 79 MAS mP SW we se fo SLA mP SW ver To restore factory settings Remove the power supply Activate down arrow and up arrow push buttons at the same time While holding the up and down arrow reconnect the power supply Release down arrow and up arrow push buttons When the display on ICAD is alternating between showing CA and A1 the factory resetting is complete pos DKRCI EI HTO A1 22 520H1639 Danfoss USCO MKS 11 2006 ICM ICAD Motorized Valve Installation Programming and Troubleshooting Alarms There are a number of alarms which are excellent indicators of improper installation or set up ICM Description Comments alarm text No valve type selected At start up A1 and will be displayed Controller fault 2 Internal fault inside electronics Input error Not applicable 101 2 or j02 2 When 103 1 and AI gt 22 mA When 103 2 and Al gt 22 mA or Al lt 2 mA When 103 3 and Al gt 12V When 103 4 and Al gt 12VorAl lt 1V Low voltage of fail safe supply If 5 V d c lt Fail
142. ter supply and drain connections and equip ment 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 Ifa 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 field mounted starters and package mounted motors Additional control wiring in the field 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 compres sor motor starter A normally open auxiliary contact from the compressor motor starter is also required Terminal locations for t
143. the filter tank by turning it in a counter clock wise direction Remove the used element 45 46 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 re turning to service Filter Removal VSS and VSM Units after 5 1 00 when using Vilter Part Numbers 3109A 16 Duplex 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 hous ing Be sure to follow all Local State and Federal ordinances regarding the recovery of refrigerants Drain the filter bowl or housing in to an appro priate container and dispose of the oil in a ap propriate manner following all Local State and Federal ordinances regarding the disposal of used refrigeration oil 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
144. tinue charging refrigerant into the system until the proper operating require ments are satisfied Then close the liquid charging connection and open the liquid line valve allowing the system to operate normally To check that enough refriger ant has been added the liquid sight glass Installation should show no bubbles and there will bea liquid seal in the receiver If these two condi tions are not satisfied 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 dif ficulties 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 SUGGESTIONS Careful checking of a refrigeration system for leaks and proper operation of all components uponinstallation 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 prereq uisite The f
145. to any ofthe 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 12 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 must also be brought to the terminal 28 in the V PLUS panel 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 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 and Compressor Start N O 18 Control power for this coil should come from a source which will be de energized with the compressor disconnect 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 An auxiliary safety cutout is available to shut down the compressor package using the K
146. to withstand the operat ing pressures In selecting fittings for Halocarbon piping only wrought copper fittings should be used Cast fittings 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 fittings are available and these may be used with complete safety In larger pipe sizes wrought fittings are not avail able However specially tested cast fittings 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 A second method would be to install flexible pipe couplings as close to the compressor unit as possible with connections run in two different directions 90 apart These flexible 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 pro longed 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 Wa
147. ttomed against shoulder on shaft COMPRESSOR SEAL INSTALLATION Follow lockout procedure before servicing this unit 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 station ary 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 Wipe clean the compressor input shaft and the shaft seal cavity inthe compressor housing Ap ply 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 com
148. uator and manually rotate the valve in the open or close direction depending on need and application When using the manual tool a clock wise rotation will open the valve and a counter clockwise rotation will close the valve NOTE It is very important to remember that when rotating the valve manually you are changing the position from that in the actuator s memory If power is removed from the actuator prior to using the manual tool no problem will occur because once the ICAD is powered up again it will automatically recalibrate to the fully closed position before returning to the position in memory to which the control signal last set the valve This recalibration will not occur if power is not removed from the ICAD prior to using the manual tool and erroneous operation will likely occur Always remove power before using the manual tool and restore power afterward to ensure recalibration and trouble free operation The user will be able to troubleshoot and determine many of the conditions and set points within the ICAD by accessing the Service Menu A list of those service parameters follows below Service Menu Displ name 60 100 ewvaweOpenmgDegee i ms s o 20 ma Analoginputsignal o 10 v Analoginputsignal gt 1 Digital nputsignal 1 Digita Output closed satus ON whenOD lt 3 Digita Output Open s
149. uring packages and compressors While this procedure is intended to cover most of the commonly encountered situations it is the responsibility of the installation firm 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 verification 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 pre lube 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 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 to be closed to isolate the compressor from the remainder of the system 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 m
150. uto Position the stop valve is operating as a check valve allowing flow in the directions of the arrows To set the valve to the automatic posi tion 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 flow in either direction OPEN In the manually Open Position with the valve stem fully back seated the valve disc is lifted slightly allowing flow in either direction Number of Turns Open from closed position 55 56 Service GENERAL COMMENTS When working onthe 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 com pressor 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 Follow lockout procedure before servicing this unit 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 Puta lock on the disconnect switch and tag the switch to indicate that maintenance is being performed B Isolate the unit by manually
151. val of the gate rotor assembly for the VSM 301 701 compressors is similar for the VSS 901 3001 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 VLA 99 ui i C Theside coverthat contains the suction strainer O should have the suction line properlysupported 1 before the bolts securing the line to the cover can be removed After the line is removed the x 3 cover can be removed per paragraph B 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 I mi k SS OOOO We v E LL n nz DO NOT APPLY LOCKTITE TO SCREW THREADS e Lu Cx gt gt LU gt gt Qe I TO THREADS 62 Service 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 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 compres
152. ved motor position is read from EEPROM memory and the actuators resumes normal function 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 ac tuator will become lost A brake failure can sometimes be detected by the position sensor Ifthe 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 Slide Valve Actuator Trouble Shooting Guide Problem The actuator cannot be cali brated The actuator goes into cali bration mode spontane ously The actuator goes into cali bration mode every time power is restored after a power loss Reason Dirt or debris is blocking one or both optocoupler slots 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 second when going through the calibration procedure The white calibrate wire in the grey Turck cable is grounding intermit tently Avery strong source of electromag netic interference EMI
153. with Cflange the motor C flange compressor assembly must be supported with a chain fall or other lifting device before the bolts holding the compressor to the C flange 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 Liftcompressorfromthe base verifythe 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 adapter dependent upon compressor model B Onthe units replace the shims under the com pressor feet Check for a soft foot This is ac complished 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 ac cordingly Align the compressor and motor On compressors the discharge elbow should be tightened on the separator first before the compressor manifold flange is tightened This should be done to prevent compressor to motor misalignment Replace all electrical gas and oil connections removed when se
154. zed 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 amp 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 TEE EM 3 Standard VILTER Warranty Statement 6 Standard VILTER 5 15 Warranty Statement 7 Long Term Storage Requirements 8 BIT a e C S 10 I Gill

35391S - Rev 08b - Booklet.indb

Contents

Download Pdf Manuals

Related Search

Related Contents