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1. an an E LLL ei 82 Gate Rotor MODEL NUMBER DESCRIPTION VSS 451 VSS 601 TY GATE ROTOR BLADE AND BEARING REPLACEMENT KIT 111 118 120A 1208 121 122 123 124 125 126 130 131 141 142 amp 143 KT712A GATE ROTOR BLADE REPLACE KIT 111 118 120A 120B 121 122 123 124 130 141 142 amp 143 KT713A GATE ROTOR SUPPORT ASSEMBLY 100 111 120B 119 amp 130 A25161BB GATE ROTOR GASKET SET 118 141 142 amp 143 A25164B SHIM PACK SET 2 121 2 122 1 123 1 124 A25165B SUPPORT 25606A GATE ROTOR 25557A 25518A 25517A 25008A 25009A 25258A 25519A 25259A 25007A 25006A 25760A 25010AA 25010AB 25010AC 25010AD 2864B 2865B 2866A 2867A 2868B 25910A 2176M 2176R 2176N 2796AJ 2796B 2796CJ 2796E 2795E 25518A 25517A 25008A 25009A 25258A 25519A 25259A 25
2. awnjoA 91 92 Slide Valve Carriage Assembly DESCRIPTION CARRIAGE ASSEMBLY CAPACITY PISTON 340 341 350 amp 355 VOLUME PISTON 340 342 350 amp 355 GASKET SET 345B RACK RACK COVER SEPARATE VOL amp CAP COVER ONE PIECE CAST GASKET SEPARATE VOL amp n a CAP COVERS GASKET ONE PIECE CAST COVER PISTON RING SET EXPANSION PIN PIPE PLUG LOCK WASHER PAIR WASHER NUT HEX HEAD CAP SCREW SEPARATE VOL amp CAP COVERS HEX HEAD CAP SCREW ONE PIECE CAST COVER MODEL NUMBER VSS 291 Thru VSS 601 N N N N N N N 4 2 4 4 6 4 4 8 A25183B A25184B A25200B 25024A 25023A 25022A 25399A 25021A 25900A 2953AA 1193PP 2606D 3004C 13265B 2797A 2796N 2796B Slide Valve Carriage Assembly MODEL NUMBER DESCRIPTION CARRIAGE ASSEMBLY A25179C A25179C A25179D A25179D CAPACITY PISTON 340 341 350 amp m A25183C A25183C A25183D A25183D VOLUME PISTON 340 342 350 amp 355 A25184C A25184C A25184D A25184D GASKET SET 3458 amp 378 A25200C A25200C A25200D A25200D RACK 25080A 25080A 25080C 25080C RACK 25080B 25080B 25080D 25080D PISTON 25076A 25076A 25138A 25138A CAPACITY PISTON SHAFT 25078A 25078A 25078E 25078E VOLUME PISTON SHAFT 25078B 25078B 25078F 25078F C
3. mu 5 KK mm I ES Filter Element ELEMENT OUTLET INLET L CENTERING PIECE FIGURE 1 1833C FILTER ELEMENT TANKS 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 outlet connection Put the centering piece on the outer element and slide into tank making sure the center piece fits into the inner element Put spring plate on outer element and bolt the cover assembly in place 37 38 Operation 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 _ LOCKING TANK N RING N UU 2222 OUTLET 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 ordinances regarding the disposal of used refrigeration oil Loosen and
4. 77 Service 6 04 KT 773A amp BFILTER ELEMENTS Vilter Part KT 773A KT 773B Number TankO Ring 2176BY 2176BZ Usage 3109A 3111A Duplex Simplex Housing Housing Usage 1 VSM all models 4 1 00 to present 2 VSS 451 to 1201 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 Oneendofthe elementis solid while the other has a pilot hole with a 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 Usedin simplex and duplex applications 2 The O rings for the simplex and duplex housings are not interchangeable 6 05 KT 774 FILTER ELEMENTS Vilter Part Number Tank O Ring Usage Length KT 774 2176BY 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 39 C Characteristics 1 Pleated type element with a screen covering the surface of the element 2 Oneendofthe element is solid while the other has a pilot hole with a captive o ring 3 Only end cap 15 from the filter bowl D Usage 1 Usedin simplex and duplex applica tions Service Simplex filter housing 79 Maintenance Re
5. n G amp TE ae U laj ch CD S 7 J 2 4 L gt di Miscellaneous Frame Components po MODEL NUMBER ITEM DESCRIPTION ALL VSM 301 401 ALL VSM 501 701 VPN MANIFOLD GASKET 25737A 26037A ECON O MIZER GASKET 11323GG 11323D COUPLING LOCK PLATE 25004D LOCK WASHER 3004H ECON O MIZER PLUG 25419A 25397K O RING 2176BF DOWEL PIN 2868B 2868B PIPE PLUG 2606C 2606B HEX HEAD CAP SCREW 2796C BEARING OIL PLUG 25978A PLUG 25979A SPRING 3148A A AN Notes Not Pictured 118 Miscellaneous Frame Components 3Hl NI 38V S38U8331N0U3 9NIN U Okt 9110 922 buisnoH 119 120 Miscellaneous Frame Components Housing Accessories DESCRIPTION GATE ROTOR COVER COVER GASKET GASKET INLET SCREEN PISTON COVER DESCRIPTION MODEL NUMBER VSM 301 701 25416 25259B 11323T 25920A 25724B MODEL Se vn 301 401 RELENE 701 4 2176BX 2176CA 2 217686 217686 Replacement Tools ITEM 902 IS USED TU SET THE STAINLESS STEEL SEAL CUP INTO THE SEAL HOUSING WITHOUT TOUCHING THE CARBON SEAL NOSE N IT 1 2 ONRING 1 3 SCALE MODEL NUMBER DESCRIPTION ALL VSM 301 401 ALL VSM 501 701 GATEROTOR STABILIZER
6. 101 VSM 301 701 Replacement Parts Section 104 Gateroror Assembly 105 Shaft Sean usu 108 Main Rotor Slide Valve Cross Shafts amp End Plate 109 Slide Valve Carriage Assembly 113 Actuator amp Command ShalT 115 Actuator amp Command ShalT 116 Miscellaneous Frame Components 117 Replacement kwit dos ot a anna 121 Appendix A Pre Start Up for Remote Oil Coolers Standard Warranty Statement Seller warrants all new single screw gas compression units and bareshaft single screw compressors manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period of a eighteen 18 months from the date of shipment or b twelve 12 months from the date of installation at the end user s location whichever occurs first If within such period any such product shall be proved to Seller s satisfaction to be defective such product shall be repaired or replaced at Seller s option Such repair or replacement shall be Seller s sole obligation and
7. 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 fer to Service Section E 14 Yearly Items 1 thru 13 and above plus 14 thru 28 Check entire system thoroughly for leaks Installation 15 Remove all rust from equipment clean and paint 16 Flush out sediment etc from water circuits 17 Clean alloil 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 Checkoil pump for wear 26 Checkthecalibration ofthe microprocessor pressure transducers and RTD s for accu racy 27 Check mounting bolts for compressor and motor F System Leaks There are any number of reasons why leaks develop in a refr
8. 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 unitis designed for indoor duty it must be stored in a heated building If the unit is designed for outdoor duty and is to be stored outdoors a canvas tarp is recommended for protection until installation is imminent Adequate drainage should be provided by placing wood blocks under the base skid so that water does not collect inside the base perimeter or low spots in the tarp All compressor stop valves 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 metal 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 f
9. 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 hasreachedthe stop Doing so may 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 0V 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 no tension on the motor shaft Quickly press and release the blue button on the actuator one more time The red LED will stop flashing Theactuatoris nowcalibrated and knows the minimum and maximum positions ofthe slide valve it controls Now the capacity or volume channel of the control panel can be calibrated Use the Dec button to move the
10. ECON O MIZER PLUG O RING O RING PIPE PLUG MPT PIPE PLUG DOWEL PIN HEX HEAD CAP SCREW FOR OIL SUPPLY FLANGE HEX HEAD CAP SCREW FOR ECON O MIZER FLANGE HEX HEAD CAP SCREW HEX HEAD CAP SCREW HEX HEAD CAP SCREW HEX HEAD CAP SCREW O RING O RING Miscellaneous Frame Components MODEL NUMBER VSS 291 thru SS 601 KT710A1 A25190A A25190B 25503A 25058A 25058A 11323D 11323D 25199C 25199B n a n a n a n a 2176AB n a n a n an an a 2868B n a 2796C n a 2796C 2796C n a n a n a n a n a Miscellaneous Frame Components MODEL NUMBER DESCRIPTION VSS 1051 VSS 1201 VPN KT710B 1 KT710B 1 KT710C KT710C A25190A A25190A 1 A25190B A25190B 25541A 25541A 1 25324A 25324A 25058A 25058A 1 25058B 25058B 11323D 11323D 1 11323E 11323E 1 25199D 25199D 1 25199C 25199C 1 25223DB 25223DB 2912E 1 2912E 2912E 2176J 2 2176J 2176J 6 2 2 1 GASKET AND O RING KIT FLANGE SET 513 514 4 547 MANIFOLD GASKET FLANGE OIL FLANGE GASKET OIL SUCTION FLANGE GASKET DISCHARGE FLANGE GASKET ORIFICE PLATE WAVE SPRING O RING PIPE PLUG 3 4 DOWEL PIN HEX HEAD CAP SCREW HEX HEAD CAP SCREW 25199B 25223CB 2912E 2176J 25199B 25223CA 1 1 1 1 25199C 1 25199C 1 1 1 2 2606A 2606A 2868B 2868B 2796GP 2796GP 2796U 2796U 2868B 2 2868B 2796GP 2 2796GP 27960 1 27960 NNON sch sch gt N N 99 Miscellaneous
11. 2 Pp Fat ao pan ao Dry 4 AN lt 89 Slide Valve Cross Shafts and End Plate MODEL NUMBER VSS 291 601 DESCRIPTION SHAFT 25843A GEAR 4 25027A RACK CLAMP 25913A RACK CLAMP 25913B SPACER 25847A EXPANSION PIN 1193D EXPANSION PIN 2981AA SOCKET HEAD CAP SCREW 2795F SET SCREW 2060J SET SCREW 2060H N N N O N N N pe MODEL NUMBER ITE DESCRIPTION VSS 751 amp VSS 901 VSS 1051 amp VSS 1201 QTY VPN END PLATE 25543A 1 25593A SHAFT 25844A 25845A GEAR 25027A 25027A RACK CLAMP 25913C 25913C SPACER 25033C 25033C 2868B 2868B 1193D 1193D 2981AA 2981AA 2606E 2606E 2795F 2795F 2060J 2060J 2060H 2060H DOWEL PIN EXPANSION PIN EXPANSION PIN PIPE PLUG SOCKET HEAD CAP SCREW SET SCREW SET SCREW NN ON TL PS HAND N N ON N N MODEL NUMBER DESCRIPTION VSS 1551Thru VSS 2101 a UN END PLATE 25661A SHAFT 25793A GEAR 25027A RACK CLAMP 25913C SPACER 25033C DOWEL PIN 2868B EXPANSION PIN 1193D EXPANSION PIN 2981AA PIPE PLUG 2606A SOCKET HEAD CAP SCREW 2795F SET SCREW 2060J SET SCREW 2060H NN ON 45 45 HAND Slide Valve Carriage Assembly apis Apedej
12. 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 Control power of 115 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 a 10 amp fuse via the terminal marked L1 on the appropriate connector The neutral is brought in and connected to any of the N terminals located on left connectors Two separate line power feeds for the oil heaters are brought to two additional 10 amp fuses via the terminals marked L2 and L3 on the same connector just below the L1 terminal The neutrals for these circuits L2A and L3A are also connected to any of the N terminals For units with V PLUS oil cooling L1 must also be brought to the fuse in the V PLUS panel and 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 ofthe L terminals on the strip of connectors and returned to the terminal marked Motor Starter Aux Safety at the very top connector Adry contact from control relay K 22 must be wired to the compressor motor starter coil This dry contact is wired to terminals marked Compres
13. screw clockwise The thrust bearings and housing assembly will be pulled off the shaft and out ofthe 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 tilEthe 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 repeatthe procedure forthe remaining gate rotor support assembly Use flats provided on gaterotor support to prevent rotation when removing bearing retainer Service REMOVAL ALL VSM 301 701 MODELS The removal ofthe 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 i GE A Prepare the compressor for servicing B Removethe 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 71 C The side cover that contains the suction strainer should have the suction line properly supported 8 before the bolts securing the
14. 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 isa 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 5 limits before the compressor unit can be restarted 2 Slide Valve Control Actuators Capacity and volume ratio control of the screw compressor is achieved by movement of the respective slide valves actuated by electric motors Note Optical Actuators CAN NOT Capacity be manually rotated i The VSM 501 701 models will have motor locations opposite of figure 6 View Volume Ratio FIGURE 4 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 1026 and reverses to increase the capacity to 100 The lower motor is for volume ratio control T
15. 25614A 25587A GATE ROTOR 25608A 25554A 25610A 25588A GATE ROTOR COVER GASKET 25088A 25088A 25132A 25132A WASHER 25086A 25086A 25086A 25086A BUSHING SMALL DOWEL PIN 25087A 25087A 25104A 25104A BUSHING LARGE DOWEL PIN 25760B 25760B 25760B 25760B SHIM 0 002 25089AA 25089AA 25089AA 25089AA SHIM 0 003 25089AB 25089AB 25089AB 25089AB SHIM 0 005 25089AC 25089AC 25089AC 25089AC SHIM 0 010 25089AD 25089AD 25089AD 25089AD ROLLER BEARING 2864C 2864C 2864G 2864G BALL BEARING 2865A 2865A 2865A 2865A RETAINING RING 2866B 2866B 2866B 2866B RETAINING RING 2867E 2867E 2867L 2867L DOWEL PIN SMALL 0 3125 O D 2868F 2868F 2868H 2868H DOWEL PIN LARGE 0 4375 O D 25910B 25910B 25910B 25910B O RING ROLLER BRG HSG 2176N 2176N 2176AJ 2176AJ O RING BALL HSG 2176V 2176V 2176AM 2176AM O RING BRG HSG COVER 21760 21760 21760 21760 BO PO PO o NN o NNNNNNNAE NM NNNNNNNAEA NbD ar As Required 84 Gate Rotor ITEM DESCRIPTION VSS 1551 VSS1851 vss 2101 QTY VPN GATE ROTOR BLADE AND BEARING REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 125 126 130 131 141 142 amp 143 KT712M KT712L KT712K GATE ROTOR BLADE REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 130 141 142 amp 143 KT713N KT713M KT713L 101 GATE ROTOR ASSEMBLY 111 amp 120 A25160EB A25160EA A25160EA 102 105 GATE ROTOR SUPPORT ASSEMBLY 100 111 120B 119 amp 130 A25161EB A25161
16. 25742A 1 SEAL INSTALLATION TOOL 25455A 1 25742B 25455B 121 122 Suction Strainer Stop Check Valve Valve Note Bottom Site Glass Should Be Full x RA A Remote Coolers Only WARNING Failure to Follow These Steps Will Result in Bearing Damage and Compressor Seizing and Will Void Any and All Warranties That May Apply Discharge Single Screw Compressor Shipped Loosc Gas amp Oil Separator K CN Drain nl Straincr Oil Heater Stop Ce 2 Metering Valve Valve E Dec 59 Ball Valve e Oil Control 2 Valve Pump N gt x KJ uc na gt Remote _ IB e Air Cooled See Section On Set Points In Vission Vantage Manual Oil Cooler Wery Important Piping of the oil must enter the bottom connection of the oil cooler and leave the top connection 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 See Section On Start Up Check List In Manual FOR REMOTE OIL COOLERS ONLY READ BEFORE PROCEEDING 123 EmersonClimate com Vilter Manufacturing LLC P O Box 8904 Cudahy WI 53110 8904 414744 0111 414 744 1769 www vilter com VILTER Since 1867 Vilter Manufacturing LLC are trademarks of Emerson Electric Co or one of its affi liated companies 2010 Emerson Climate Technol
17. Buyer s exclusive remedy hereunder and shall be conditioned upon a Seller s receiving written notice of any alleged defect within ten 10 days after its discovery b payment in full of all amounts owed by Buyer to Seller and c at Seller s option Buyer shall have delivered such products to Seller all expenses prepaid to its factory Expenses incurred by Buyer in repairing or replacing any defective product including without limitation labor lost refrigerant or gas and freight costs will not be allowed except by written permission of Seller Further Seller shall not be liable for any other direct indirect consequential incidental or special damages arising out of a breach of warranty This warranty is only applicable to products properly maintained and used according to Seller s instructions This warranty does not apply i to ordinary wear and tear damage caused by corrosion misuse overloading neglect improper use or operation including without limitation operation beyond rated capacity substitution of parts not approved by Seller accident or alteration as determined by Seller or ii if the product is operated on a gas with an H2S level above 100 PPM In addition Seller does not warrant that any equipment and features meet the requirements of any local state or federal laws or regulations Products supplied by Seller hereunder which are manufactured by someone else are not warranted by Seller in any way but Seller agrees to
18. DAMPER ASSEMBLY 111 120 A26002BB 1 26002 1 A26002BC GATE ROTOR SUPPORT ASSEMBLY 100 101 119 amp 130 A26003BB 1 A26003BA 1 A26003BC SHIM PACK SET 2 121 2 122 1 123 1 124 A26035B A26035B A26035B SUPPORT 26030BB 26030BA 26030BA GATE ROTOR 26032A 26031A 26033A SNAP RING 2867U 2867U 2867U RETAINER BALL BEARING 25935B 25935B 25935B GATE ROTOR COVER GASKET 25259C 25259C 25259C WASHER 25007A 25007A 25007A DAMPER 25760A 25760A 25760A SHIM 0 002 26027AA 26027AA 26027AA SHIM 0 003 26027AB 26027AB 26027AB SHIM 0 005 26027AC 26027AC 26027AC SHIM 0 010 26027AD 26027AD 26027AD ROLLER BEARING 2864B 2864B 2864B BALL BEARING 2865B 2865B 2865B RETAINING RING 2866A 2866A 2866A RETAINING RING 2867A 2867A 2867A RETAINING RING 2866K 2866K 2866K DOWEL PIN 25910A 25910A 25910A O RING ROLLER BRG HSG 2176M 2176M 2176M O RING BALL BRG SUPPORT 2176R 2176R 2176R SHIM 25977G 25977G 25977G SHIM 25977H 25977H 25977H I lI lI D I lI D lI lI D w w NOTE Not pictured ar As Required 107 Shaft Seal QTY VPN MODEL NUMBER ITEM DESCRIPTION ALL VSM 301 401 ALL VSM 501 701 SHAFT SEAL KIT Viton Kit 219 230 amp 260 KT709DG KT709AG SHAFT SEAL A A OIL SEAL 2930C 25040A TEFLON SEAL 25939A 25939A RETAINER RING 2928M 2928M O RING 2176U 2176F O RING 205 Only 2176AE n a NOTE Not pictured A Sold on
19. Make sure the bearing is fully seated inthe 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 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 quide 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 VSG 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 discharge manifold D Remove one bolt each side of the discharge manifold and install 2 quide rods approximately 6 long to support the manifold Remove the remaining bolts note length and location of bolts and take off the discharge manifold Service DISCHARGE MANIFOLD INSTALLATION A Install 2 guide rods to position the discharge manifold Install a new manifold gasket and the discharge manifold Install the dowel p
20. The actuator motor will not run until it cools Once the motor cools the actuator will resume normal operation Motor overheating is sometimes a problem in hot and humid environments when process conditions demand that the slide valve reposition often Solutions are available consult your Vilter authorized distributor for details Another possible cause for this error is a stuck motor thermal switch The 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 The 24V supply is voltage is low This will occur momentarily when the actuator is powered up and on power down If the problem persists measure the voltage using a digital multi meter between terminals 3 and 4 of the small terminal block If the voltage is gt 24V replace the actuator The EEPROM data is bad This is usually caused by loss of 24V power before the calibration procedure was completed The actuator will not move while this error code is displayed To clearthe 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 The EEPROM memory in the micro controller is bad 2 Thelarge blue capacitor is bad or has a cracked lead Micro controller program failure Replace the actuator Note 1 TP1 and TP2 are plated thru holes located clos
21. VOLUME RATIO RACK 25023C 25023A VOLUME RATIO RACK SHAFT 25772D 25772B PISTON RING SET 2953AE 2953AA 3004C 3004C 13265B 13265B 2797A 2797A 2795M LOCK WASHER PAIR WASHER NUT SOCKET HEAD CAP SCREW N A N N N sch sch sa a E N N sch sch a sch sch 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 114 Actuator 8 Shaft No TITOLI e e S e e A A GE DEET Eeer e GE to 115 116 Actuator 8 Command Shaft MODEL NUMBER VSM 291 thru VSM 601 VSS 751 thru DESCRIPTION VSS 901 QTY VPN VPN COMMAND SHAFT ASSEMBLY SLIDEVALVE ACUATOR A25994B 25972D 2176X A25994C 25972D 2176X VSS 1051 thru VSS 1201 VPN A25994D 25972D 2176X VSS 1551 thru VSS 2101 VPN A25994E 25972D 2176X Miscellaneous Frame Components 117 528 D L PS o EN B H 7 D L up d E dacc4 mE E
22. a year may prevent extensive shutdowns later with subsequent product loss and expensive repairs 23 24 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 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 Coupling Installation ER 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 Ifassembled the locknuts are not torqued 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 is tapered check for good contact pa
23. actuator is powered 120V or 24V all the time 2 4 The position target signal from the com pressor controller is 4 20mA analog value 2 5 There is no feedback position from the ac tuator 3 Initial Position 3 1 With the electrical power to the valve de energized the valve is set to its initial position by ensuring that the ballis in the closed position and that the actuator indicator displays CLOSED 3 2 When the electrical power to the valve is energized the valve should rotate to fully OPEN 4 Operation 4 1 When initially installed the ball must be in the closed position 4 2 Whenelectrically energized if the compres soris not running the compressor controller will turn the valve fully open 100 4 3 When the compressor starts the valve remains fully open 100 until the oil injection temperature rises above the control setpoint 4 4 When the oil injection temperature rises above the control setpoint the oil temperature control valve will begin to close 4 5 The hot oil from the oil separator begins to divert to the oil cooler mixing the hot and cooled oil flow streams together downstream of the oil temperature control valve The valve can fully close 0 diverting the entire oil flow stream to the oil cooler 4 6 As the oil injection temperature drops be low the setpoint the oil temperature control valve begins to open so that the oil injection temperature does not become too cold 4 7 When
24. 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 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 29 30 21 22 23 24 25 26 27 28 29 Slide Valve Actuator Installation 8 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 Pulsethe INC button to carefully move the slide valve until the millivolt readout saturates or stops increasing This is around 9500 millivolts 8400 millivoltsfor2783 qualifiedanalog 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 t
25. 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 oilis recommended On size 226 and 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 Ifcoupling 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 4 Torque the long bolt locknuts at this time Installation NOTE With the couplingin good alignment the bolts will fit through the holes in the flanges and the disc pack more easily It is recommended that all locknuts beretightened after several hours of initial operation 5 For further help with the installation or align ment consult Rexnord F Disc Pack Replacement Ifitbecomes necessary to replace the disc pac
26. gas compression units the suction line should be supported to prevent it from sagging Replace oil drain in compressor housing and dis charge manifold after oil has stopped draining Remove all electrical connections to the com pressor May cause an electrical shock On compressors 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 On compressors with the motor C flange compressor assembly must be supported with a chain fall orotherlifting device before the bolts holding the compressor to the Cflange adapter can be removed 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 Lift compressor from the base verify the amount of room needed for clearance and weight of the bare compressor when the compressor is removed from the unit 49 50 Service INSTALLATION OF THE COMPRESSOR A After the work has been completed reinstall the compressor on the base or Cflange adapter dependent upon compressor model B On the units replace the shims under the com pressor feet Check for a soft foot This is ac complished by tighte
27. line to the cover can be removed Afterthe line isremoved the e cover can be removed per paragraph B D Turn the main rotor so the driving edge of the 08 AN SEZA z groove is between the top of the shelf or slightly x du LYE gt below the back of the gate rotor support At Gol TO S8 Z this point install the gate rotor stabilizing tool 22 Z Es N 143 A E ra DO NOT APPLY LOCKTITE TORQUE SCREWS TO TO THREADS TO 18 FT LBS O Service E Remove plug on the thrust bearing housing Loosen the socket head cap screw that is located underneath the plug This secures the inner races ofthe thrust bearings to the spindle N F Remove bolts that hold the thrust bearing hous ingtothe compressor Inserttwo of the bolts into the threaded jacking holes to assist in removing the bearing housing from the compressor When the housing is removed there will be shims 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 G Removethebolts from the roller bearing housing After the bolts have been removed the housing can be removed from the compressor H Toremove the ga
28. manual for further information E 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 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 afterthe king orliquid line valve Purge the air from the charging line 2 Invert the refrigerant drum if the drum is not equipped with Liquid and Vapor valves and place in such a position so the liquid refrigerant only can enter the 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 Itisimportantthat 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 desirabl
29. position Use the indicator as a guide 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 hold 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 25 26 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 notto be used for axial adjustments See documentation that came with the coupling for complete specifications 3 AngularAlignment 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 fl
30. remove the locking ring on filter tank by turning in a counter clockwise direction Re move 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 refrigera tion 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 3 Filter Removal VSS and VSM Units after 5 1 00 when using Vilter Part Numbers 3111A 16 Simplex or 3112A 39 Simplex oil filter housings Release the pressure in the oil filter housing by opening the bleed valves at the stop valve in the block and bleed assembly or at the bleed valve for the oil filter housing Be sure to follow all Local State and Federal ordinances regard ing the recovery of refrigerants Drain the filter bowl or housing in to an ap propriate container and dispose of the oil 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 the filter tank by turning it in a counter clock wise direction
31. 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 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 inthe 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 Depressthe button quickly and then let go Each 34 second the button is held down counts as another press Tape the end of white wire in 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 motor brake to where it operates freely and recalibrate Replace the actuator Slide Valve Actuator Trouble Sho
32. 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 proper level for the test The gas may be put into the system through the charging valve or any other suitable opening Adjust the pressure regulator on the bottle to prevent over pressurization Do not exceed the pressure rating on the vessel with the lowest pressure rating Carbon Dioxide should NOT be used as a 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 valves on the lowest part
33. 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 closing the discharge Stop valve Allow the unit to equalize to suction pressure before closing the Suction Bypass After the unit has equalized to suction pressure and suction valve closed use an acceptable means to depressurize the unit that complies with all Local State and Federal Ordinances C Remove drain plugs from the bottom of com pressor housing and the discharge manifold On units equipped with Suction Oil Injection SOI manually open the SOI solenoid valve below the compressor Drain the oil into appropriate con tainers REMOVAL OF COMPRESSOR FROM THE UNIT After preparing the unitfor service the following steps should be followed when removing the compressor from the unit Disconnect the motor drive coupling from the compressor input shaft Disconnect all gas and oil piping which is at tached to the compressor When removing the suction strainer on
34. 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 optocoupler 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 34 Slide Valve Actuator Trouble Shooting Guide ko b sk sk sk a b ok sk ok e e e xn ak ak ak ak s S GR b ck ok b ok ok e ok ok xn 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 The actuator is being operated where strong infrared light can falsely trigger the slotted optocouplers such as direct sunlight Shade the actuator when the cover is off for service and calibration Do not operate the actuator with the cover off The motor has overheated
35. 00 Service OIL FILTER ELEMENTS The following is a description of the oil filter elements supplied on standard VSS VSR and VSM single screw compressor units 6 001 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 2 The outside of the filter element is covered with a perforated metal surface At each end of the filter there is a large thick elastomeric seal The housing is a fabricated steel housing with bolted end cover The housing can contain one or two elements 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 Service 6 02 KT 721 FILTER ELEMENTS Vilter Part Number 721 Tank O Ring 2176BU Usage VSR Compressors Dates 1992 to 8 1 96 Length 8 A Characteristics 1 Pleatedtype 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 6 03 KT 722 FILTER ELEMENTS Vilter Part Number KT 722 Tank O Ring 2176A Usage VSR Compressors Dates 1996 to 2002 Length 16 8 A Characteristics 1 Pleatedtype 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
36. 007A 25006A 25760A 25010AA 25010AB 25010AC 25010AD 2864B 2865B 2866A 2867A 2868B 25910A 2176M 2176R 2176N 2796AJ 2796B 2796CJ 2796E 2795E 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 BRG HSG O RING BALL BRG HSG 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 DVHSIHZNNNNNNNAN EQ O 22ZLZNpNNNNNNNNN DFRSIDNNNNNNNAN2ZYZ2Z2Z2NNNNNNNNNI NOTE ar As Required Gate Rotor ITEM DESCRIPTION VSS 751 vss 901 VSS 1051 VSS 1201 GATE ROTOR BLADE AND BEARING REPLACEMENT KIT 111 118 120A 120B 121 122 123 124 125 126 130 131 141 142 amp 143 KT712C KT712D KT712E KT712F GATE ROTOR BLADE REPLACE KIT 111 118 120A 120B 121 122 123 124 130 141 142 amp 143 KT713C KT713D KT713E KT713F GATE ROTOR SUPPORT ASSEMBLY 100 111 120B 119 amp 130 A25161CB A25161CA A25161DB A25161DA GATE ROTOR GASKET SET 118 141 142 amp 143 A25164C A25164C A25164D A25164D SHIM PACK SET 2 121 2 122 1 123 1 124 A25165C A25165C A25165C A25165C SUPPORT 25612A 25553A
37. 141 0 45 162 1 767 VSM 91 CCW 0 80 288 3 141 0 45 162 1 767 VSM 101 CCW 0 80 288 3 141 0 45 162 1 767 VSM 151 CCW CCW 0 80 288 3 141 0 45 162 1 767 VSM 181 CCW CCW 0 80 288 3 141 0 45 162 1 767 VSM 201 CCW CW CCW CW 0 80 288 3 141 0 45 162 1 767 VSM 301 CCW CW CCW CW 0 80 288 3 141 0 45 162 1 767 VSM 361 CCW CCW 0 80 288 3 141 0 45 162 1 767 VSM 401 CCW CW CCW CW 0 80 288 3 141 0 45 162 1 767 VSM 501 CW CCW CW CCW 0 91 328 3 568 0 52 187 2 045 VSM601 CW CCW CW CCW 0 91 328 3 568 0 52 187 2 045 VSM701 CW CCW CW CCW 0 91 328 3 568 0 52 187 2 045 Operation 3 Suction Pressure Low suction pressure cutout stops the compres sorunitwhen 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
38. 81 2 750 2 750 VSM 201 2 750 2 750 VSM 301 2 850 2 850 VSM 361 2 850 2 850 VSM 401 2 850 2 850 VSM 501 4 000 4 000 VSM 601 4 500 4 500 VSM 701 5 000 5 000 VSS 451 4 000 4 000 VSS 601 4 500 4 500 VSS 751 5 300 5 300 VSS 901 5 300 5 300 VSS 1051 6 600 6 600 VSS 1201 6 700 6 700 VSS 1501 10 010 10 010 VSS 1801 10 010 10 010 VSS 1551 11 000 11 000 VSS 1851 11 000 11 000 VSS 2101 11 000 11 000 Does not include motor ll FOUNDATIONS 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 operating weight of the unit See Table 1 for unit weights Il LOCATING UNIT DRIVE COUPLING ALIGNMENT 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 Boltholes are located in the unit s mounting feet When locating the unit provide adequate space for service work Whenthe compressorunit is in place onthe 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 coup
39. 91CL 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 2 Discharge Pressure High discharge pressure cutout stops the compres sor unit when the discharge pressure in the oil separator exceeds the setpoint TABLE 1 VSS VSR VSM COMMAND SHAFT ROTATION AND TRAVEL COMMAND SHAFT ROTATION NO OF TURNS ROTATION ANGLE SLIDE TRAVEL COMP CAPACITY VOLUME CAPACITY VOLUME MODEL INC DEC INC DEC TURNS ANGLE TRAVEL TURNS ANGLE TRAVEL VSR 111 CCW 0 91 328 3 568 0 52 187 2 045 VSR 151 CCW CCW 0 91 328 3 568 0 52 187 2 045 VSR 221 CCW CW CCW CW 0 91 328 3 568 0 52 187 2 045 VSR 301 CCW CCW CW 0 91 328 3 568 0 52 187 2 045 55 451 CCW CCW 0 91 328 3 568 0 52 187 2 045 VSS 601 CCW CCW 0 91 328 3 568 0 52 187 2 045 VSS 751 CW CCW CW CCW 1 09 392 4 283 0 63 227 2 473 VSS 901 CW CCW CW CCW 1 09 392 4 283 0 63 227 2 473 VSS 1051 CW CCW CW CCW 1 22 439 4 777 0 74 266 2 889 VSS 1201 CW CCW CW CCW 1 22 439 4 777 0 74 266 2 889 VSS 1501 CW CCW CC CCW 1 36 490 5 325 0 82 295 3 200 VSS 1801 CW CCW CW CCW 1 36 490 5 325 0 82 295 3 200 VSM 71 CCW CCW 0 80 288 3
40. 9M 1193D 2981AA 25422A 2796N 2795 2060 2060 25177 25938 257190 25941 25027 25913A 25847A 25409AA 25409AB 25409AC 25409AD 25939A 3120A 3120B 2829M 1193D 2981AA 25422A 2796N 2795F 2060J 2060H 25177 25938 257190 25941 25027 25913A 25847A 25409AA 25409AB 25409AC 25409AD 25939A 3120A 3120B 2829M 1193D 2981AA 25422A 2796N 2795F 2060J 2060H NNOO P NNOO NNOO P gt gt gt gt Not pictured Required at top locate single gaterotor only A Asrequired Main Rotor Slide Valve Cross Shafts 8 Plate Models VSM 501 701 Clockwise ONLY INSTALL PIN WITH TOOL F5085AT 03 250 264 17 2 258 246 201 211 200 111 Main Rotor Slide Valve Cross Shafts 8 Plate Models VSM 501 701 Clockwise ONLY MODEL NUMBER DESCRIPTION VSM 501 VSM 601 VSM 701 QTY VPN MAIN ROTOR ASSEMBLY A26010B8 1 A26010BA A26010BC 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 CHECK VALVE CHECK VALVE RETAINING RING WASHER WASHER EXPANSION PIN EXPANSION PIN HEX HEAD CAP SC
41. AL REPLACEMENT Follow lockout procedure before servicing this unit 64 COMPRESSOR SHAFT SEAL REMOVAL A Prepare the compressor for servicing as outlined in section REMOVAL B Remove bolts 281 holding the shaft seal cover 218 Insert two of the bolts into the threaded jacking holes to assist in removing the cover There will be a small amount of oil drainage as the cover is removed C Remove the rotating portion of the shaft seal 219C D Remove oil seal 230 from cover E Remove the stationary portion of the shaft seal 219B from the seal cover using a brass drift and hammer to tap it out from the back side of the seal cover Seal with stationary mirror face 219B and rotating carbon face 219C Seal with stationary carbon face 219B and rotating mirror face 219C Current Shaft Seal and for all Replace ment 230 2 8 268 2198 Roll Din 265 only used on VSG and larger Service COMPRESSOR SEAL INSTALLATION Stationary seal 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 15 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 m
42. BILIZER SET 901A 901B amp 901C A25698A A25698A A25698A 1 A25698A 102 Replacement Tools DESCRIPTION GATEROTOR TOOLS 901 910 912 913 914 915 916 amp 917 GATEROTOR STABILIZER SET 901A 901B 901C amp 901D MODEL NUMBER VSS 1551 thru VSS 2101 QTY VPN 911 1 A25205E 1 A25699A 103 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 104 Gaterotor Assembly 5 8 4 ZAN LEZ V Mi D 08 02 Ks lt SE EI DO APPLY LOCKTITE TO SCREW THREADS d 105 Gaterotor Assembly Part totals indicated are for one gate rotor assembly machines with two gate rotors will require double the components listed below TEM DESCRIPTION MODEL NUMBER SUPPORTASSEMBLY 110 4 1358 GATE ROTOR 4 DAMPER AS
43. 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 The 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 open prior to starting 44 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 SIGHT HAND EXPANSION GLASS VALVE FIGURE 5 OIL SEPARATOR BLEED LINE NOTE The purpose of the 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 The hand expansion valve should be adjusted to prevent an oil level from forming in the sight glass when the compressor is at 100 capacity Generally 1 2 to 1 turn open is satisfactory 7 Open 1 4 high pressure gas line valve piped to oil injection line just enough to quiet compressor at 100 capacity E C
44. EA A25161EL GATE ROTOR GASKET SET 118 141 142 amp 143 A25164E A25164E A25164E SHIM PACK SET 2 121 2 122 25165 25165 25165 25687A 25665A 25495D 25647A 25645A 25744D 25667A 25667A 25667A 25669A 25669A 25669A 25141A 25141A 25141A 25789A 25789A 25789A 25351A 25351A 25351A 25354A 25354A 25354A 26590A 26590A 26590A 25788A 25788A 25788A 25104A 25104A 25104A 25760C 25760C 25760C 25791AA 25791AA 25791AA 25791AB 25791AB 25791AB 25791AC 25791AC 25791AC 25791AD 25791AD 25791AD 2864K 2864K 2864K 2865K 2865K 2865K 2866G 2866G 2866G 2867R 2867R 2867R 2868H 2868H 2868H 25910C 25910C 25910C 2176U 2176U 2176U 2176BD 2176BD 2176BD 2176P 2176P 2176P HEX HEAD CAP SCREW 2796CJ 2796CJ 2796CJ HEX HEAD CAP SCREW 2796N 2796N 2796N HEX HEAD CAP SCREW 2796CJ 2796CJ 2796CJ HEX HEAD CAP SCREW 2796R 2796R 2796R SOCKET HEAD CAP SCREW 2795G 2795G 2795G 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 SMALL 0 375 O D DOWEL PIN LARGE 0 500 O D O RING ROLLER BRG HSG O RING BALL BRG HSG O RING BRG HSG COVER NNNNNNNNNNNN D D AANNNNNNNEAND D ar As required 85 86 Sh
45. Frame Components MODEL NUMBER DESCRIPTION VSS 1551 THRU VSS 2101 GASKET AND O RING KIT KT710D FLANGE SET 513 514 8 547 A25190C FLANGE SET 513A 514A amp 547 ECON O MIZER PORT A25190D MANIFOLD GASKET 25676A FLANGE OIL 12477C FLANGE ECON O MIZER FLANGE GASKET OIL 11323F FLANGE GASKET ECON O MIZER SUCTION FLANGE GASKET 25199D DISCHARGE FLANGE GASKET 25199C O RING 2176J PIPE PLUG 3 4 MPT 2606A DOWEL PIN 2868K PIPE PLUG 3 4 MPT 13163F HEX HEAD CAP SCREW FOR OIL SUPPLY FLANGE 11397E NOTE Not pictured For VSS 1801 Serial Numbers 819 820 8 821 only 100 Replacement Tools L AINO 318 3SSV 3015 1081 LSSLTISA YON 3015 ISN ION 00 SMOSSFYANOD 109 160 955 404 WEEN Sv 406 318W3SSV LOZI G01 9SA 9 106 1SZ 9SA ONINV38 TIVISNI amp 9SH 988 TIVE INIAVJF Ol OSH 948 TIVE 1804805 90104319 101 Replacement Tools MODEL NUMBER DESCRIPTION VSS 291 thru VSS 601 GATEROTOR TOOLS 901 910 911 912 913 914 915 916 amp 917 A25205B GATEROTOR STABILIZER SET 901A 9018 4 901C A25698A MODEL NUMBER ITEM DESCRIPTION 55751 Ee 901 VSS 1051 55 1201 SC VPN 5 900 GATEROTOR TOOLS 901 910 911 912 913 914 915 916 amp 917 A25205C A25205C A25205C 1 A25205C GATEROTOR STA
46. KET 25384A PISTON SLEEVE 25786A PISTON RING SET 2953AD EXPANSION PIN 1193PP PIPE PLUG 2606E LOCK WASHER PAIR 3004C WASHER 13265B NUT 2797A HEX HEAD CAP SCREW 2796BL SOCKET HEAD CAP SCREW 2795AG LOCK WASHER PAIR 3004D O RING 2176AG RETAINER RING 2755AG 2 2 2 2 2 2 4 2 2 2 2 4 4 4 6 4 4 8 2 6 6 4 4 Actuator 8 Command Shaft 95 96 DESCRIPTION COMMAND SHAFT ASSEMBLY SLIDEVALVE ACUATOR O RING Actuator 8 Command Shaft MODEL NUMBER VSS 291 thru VSS 601 VSS 751 thru VSS 901 QTY VPN VPN A25994B 25972D 2176X A25994C 25972D 2176X VSS 1051 thru VSS 1201 VPN A25994D 25972D 2176X VSS 1551 thru VSS 2101 VPN A25994E 25972D 2176X Miscellaneous Frame Components VSS Screw Compressor 36 0 m B 5 97 98 DESCRIPTION GASKET AND O RING FLANGE SET 513 514 8 547A ECON O MIZER PORT MANIFOLD GASKET FLANGE OIL AFLANGE ECON O MIZER FLANGE GASKET OIL FLANGE GASKET ECON O MIZER SUCTION FLANGE GASKET DISCHARGE FLANGE GASKET COVER GASKET INLET SCREEN
47. OVER SEPARATE VOL amp CAP 25123B 25123B 25123C 25123C COVER ONE PIECE CAST 25279A 25279A 25401A 25401A COVER SEPARATE VOL 8 CAP 25123A 25123A n a n a GASKET SEPARATE VOL 4 CAP COVERS GASKET ONE PIECE CAST COVER GASKET SEPARATE VOL 8 CAP COVERS PISTON SLEEVE PISTON RING SET EXPANSION PIN PIPE PLUG LOCK WASHER PAIR WASHER NUT HEX HEAD CAP SCREW HEX HEAD CAP SCREW HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW LOCK WASHER PAIR O RING RETAINER RING NNNNNANNNNN ND NNNNNANNNNNE N ANN ANNNNNN N ANN ANNNNNN 25124B 25902A 25124B 4 25124C 4 25124C 25902A 25901A 25901A 2 2 N 25124A 25079A 2953AB 1193PP 2606D 3004C 25124A n a n a 25079A n a n a 2953AB 2953AC 2953AC 1193PP 1193PP 1193PP 2606D 2606E 2606E 3004C 3004C 3004C 13265B 13265B 13265B 13265B 2797A 2797A 2797A 2797A 2796B 2796B 2796B 2796B 2796P 2796P 2796P 2796P 2796BN 2796BN n a n a 2795N 2795N 2795P 2795P 3004C 3004C 3004D 3004D 2176Y 2176Y n a n a 2866C 2866C n a n a O N N O N N Fx 2X x N N N N N O 93 Slide Valve Carriage Assembly MODEL NUMBER ITEM DESCRIPTION VSS 1551 to 2101 2 CARRIAGE ASSEMBLY A25179E CAPACITY PISTON 340 341 350 amp 355 A25183E VOLUME PISTON 340 342 350 amp 355 A25184E GASKET SET 345 amp 378 A25200E RACK 25779A RACK 25780A SHAFT 25778A PISTON 25782A CAPACITY PISTON SHAFT 25784A VOLUME PISTON SHAFT 25783A COVER 25690A GAS
48. REW SOCKET HEAD CAP SCREW SET SCREW SET SCREW A26034B A26034B A26034B A25177B 26025B 25843A 25027A 25847A 25255AA 25255AB 25255AC 25255AD 25929B 3120A 3120B 2928N 25977E 25977F 1193D 2981AA 2796B 2795D 2060J 2060H A25177B 26025B 25843A 25027A 25847A 25255AA 25255AB 25255AC 25255AD 25929B 3120A 3120B 2928N 25977E 25977F 1193D 2981AA 2796B 2795D 2060J 2060H A25177B 26025B 25843A 25027A 25847A 25255AA 25255AB 25255AC 25255AD 25929B 3120A 3120B 2928N 25977E 25977F 1193D 2981AA 2796B 2795D 2060J 2060H gt p N O NOTE Not pictured A Asrequired 112 Slide Valve Carriage Assembly Ajquiassy sepi s pue abelue gt sapnpuj Ajquassy apis Apedej JBB 113 Slide Valve Carriage Assembly MODEL NUMBER DESCRIPTION CARRIAGE ASSEMBLY A25179A A26012B CAPACITY PISTON 340 341 350 amp 355 1 A25183A A25183B VOLUME PISTON 340 342 350 8 355 A25184A A25184B CAPACITY RACK 25023D 25024A CAPACITY RACK SHAFT 25772C 25772A
49. Remove the used element Wet the O ring in the new element with clean refrigeration oil Insert the new element into the filter tank with the closed end visible and attach the cover to the bowl HAND TIGHTEN the cover The filter housing can be evacuated and then slowly pressurized to check for leaks before returning to service Operation 4 Filter Removal VSS and VSM Units after 5 1 00 when using Vilter Part Numbers 3109A 16 Duplex or 3110A 39 Du plex oil filter housings Isolate the bowl to be worked on by turning handle The handle will cover the drain valve of active element Close commuter valve in center of handle Release the pressure in the isolated bowl by bleeding through the stop valve on the oil filter cover for Duplex Vilter Part 3109A 31104 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 into the filter tank with the close end visible and attach the coverto the bow
50. S Careful checking of a refrigeration system for leaks and proper operation of all components upon installation will start the system on its way to a long life of satisfactory service To ensure the desired trouble free operation however a systematic maintenance program is a prereq uisite The following 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 10 11 12 13 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
51. SEMBLY 111 120 GATE ROTOR SUPPORT ASSEMBLY 100 101 119 8 130 SHIM PACK SET 2 121 2 122 1 123 1 124 SUPPORT GATE ROTOR SNAP RING RETAINER BALL BEARING GATE ROTOR COVER GASKET WASHER WAVE SPRING DAMPER SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 A25222AB 1 A25160AB 1 A25161AB 1 A25165A 25723D 25718B 2867L 25935A 25259B 3203A 25760A 25921AA 25921AB 25921AC 25921AD A25222AA 1 A25160AA A25161AA A25165A 25723C 25718C 2867L 25935A 25259B 3203A 25760A 25921AA 25921AB 25921AC 25921AD A25222AC A25160AC A25161AC A25165A 25723B 25718D 2867L 25935A 25259B 3203A 25760A 25921AA 25921AB 25921AC 25921AD ROLLER BEARING BALL BEARING RETAINING RING RETAINING RING RETAINING RING DOWEL PIN O RING ROLLER BRG HSG O RING BALL BRG SUPPORT SHIM SHIM 2864F 2865L 2866H 28675 2866 25910A 2176L 2176F 25977D 25977C 2864F 2865L 2866H 28675 2866 25910A 2176L 2176F 25977D 25977C 2864F 2865L 2866H 28678 2866J 25910A 2176L 2176F 25977D 25977C a 1 2 1 1 1 1 1 1 w w w ar As required 106 Gaterotor Assembly Part totals indicated are for one gate rotor assembly dual gate machines will require double the components MODEL NUMBER DESCRIPTION VSM 701 VPN SUPPORT ASSEMBLY 110 amp 1358 A26011BB A26011BA 1 A26011BA GATE ROTOR 8
52. VSM units 1 Remove bolts 150 from the clamping ring 114 2 Remove thrust bearing clamping ring 3 Removethrust bearings 126 from housing 113 C Forremoval of thrust bearings on VSS units 1 Removeretaining ring from gate rotor sup port 2 Remove bearings from support 3 Remove bearing retainer from inner race 61 62 ROTOR THRUST BEARING INSTALLA TION Forinstallation ofthrust bearings on VSG and VSSG units 1 Install bearings 126 in the housing so the bearings are face to face The larger sides of the inner races are placed together A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the housing Center the bearing retainer ring on hous ing use Loctite 242 thread locker and evenly tighten the bolts to the recom mended torque value For installation of the bearing housing and the setting of the gate rotor blade clear ance refer to section INSTALLATION All VSG Models For installation of thrust bearings on VSM 301 701 units 1 Install retainer in the back of the inner race of one of the thrust bearings The back of the inner race is the narrower of the two sides 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 t
53. VSS VSR VSM Single Screw Compressor Operation and Service Manual SN VILTER qme Since 1867 z Climate Technologies Important Message Read and understand operator s manuals befare 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 Theentire manual should be reviewed before attempting to install operate service or repair the compressor A compressoris 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 Vilterscrew compressor components are thoroughly inspected at the factory However damage can occur in shipment Forthis reason the equipment should be thoroughly inspected upon arrival Any damage noted should be reported immediately to the Transport
54. ace and that all slings are protected from sharp edges Begin to raise the load to verify balance and check the braking system and If the Compressor is not balanced lower and adjust as necessary Rigging and Lifting CONTACT VILTER While Vilter will not offer any 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 your Plan Please contact Vilter at P O Box 8904 5555 S Packard Ave Cudahy WI 53110 8904 Telephone 1 414 744 0111 Fax 1 414 744 3483 email info vilter amp emerson com www vilter com 15 16 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 2 750 2 750 VSM 151 2 750 2 750 VSM 1
55. acking 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 57 Service Check for 0 003 to 0 004 Clearance D Setthe clearance between the gate rotor blade Between Gaterotor Blade and Partition and the shelf o e XCHA 1 Place a piece of 0 003 0 004 shim stock between the gate rotor blade and the shelf 2 Measure the depth from the top of the com pressor case to the top of the thrust bearing housing This determines the amount of shims needed for the correct clearance 3 Use factory installed shim pack 106 and bearing housing cover 116 without the 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 Itis preferable to shim the gate rotor blade looser rather than tighter against the shelf Note Replacement blades are precisely the same dimensionally as blades installed originally at 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 F Install side
56. 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 ofthe slide valve travel PLEASE NOTE Because there is an optical sensor on this motor do not attempt calibration 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 powerto the control panel completely 3 If not already done mount the slide valve actuator per Vilter Actuator set up for Capacity and Volume Slide Motors Next wire the actuator per the attached wiring diagrams using the already installed electri cal conduitto run the cables The old wiring can be used to pull the new cables through the conduitto 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 preventel
57. actuator mounting plate with the four socket head cap screws and Nord Lock washers securing it with proper torque C Theunit 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 69 70 C 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 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 C 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 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 Insertthe command shaft into the housing applying pressure on outer race of bearing
58. ad eyes Review and inspect all hoisting lifting and rigging equipment Select shackle size and prepare sketches or drawings for rigging Use proper conservative rigging techniques including spreader beams needed to lift the Compressor Pad sharp corners check the orientation of chocker hitches and the orientation of hooks Prevent the binding of hoist rings and Verify pad eye information TEST AND BALANCE THE COMPRESSOR It is essential to test and balance the compressor before executing the actual lift in order to identify potential causes of injury to Participants and the Compressor Secure Rigging and the Lift Site Reiterate that no one should walk under the raised load Secure and restrict access to the lift area consider vacating all non essential personnel from the area Provide 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 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 14 Slowly raise the crane to take slack out of the rigging without actually lifting the load Allow the rigging gear to settle into place Check for twists and binds Verify that all padding has remained in pl
59. aft Seal Shaft Seal With Stationary Carbon DESCRIPTION vss VSS 291 601 601 eme 751 1201 VSS 1551 thru 2101 1551 thru 2101 VPN QIY VPN _____ A SEAL VITON KIT 219 260 230 KT709AG KT7098G KT709CG Mie s ss OIL SEAL 25040A 25064A 1 29308 260 O RING 2176F 2176AC 1 2176BH Rotor DEG ees sbuly Q e3oN 87 FALZLISZV HASccScv LYVd ALO LOLZ SSA FLLISZV 58919 LYVd ALO 1581 SSA 922 607 94 196 L 942187 OLZISGY OZZISGVY azzisev L 922 83 L WIHS 202 102 WIHS JFJANTONI LON S300 gasgatezy L aaeerszv i wogaiszy 989192 vasgatszy 88891 027 L ASSY YOLOU L vd ALO L lVd ALO LYVd ALO LYVd ALO L Vd ALO LYVd ALO LYVd ALO 1991 SSA LOZI SSA LS0L SSA 106 SSA LSZ SSA 109 SSA L t SSA NOILdlHOS3G 88 Slide Valve Cross Shafts and End Plate 269 228 Ze 268 SPACER THIS SIDE F 240 VSS SHAFI ASSEMBLY 27 ts gt Et 6 effi EN lt n x mm C rl Gi Eu eL CR E EL
60. alibration 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 transmitter cable to the actuator Press INCand DECto movetheslidevalve and check forthe correct rotation See Table 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 itoutputs OV when the actuatoris running and 5V when itis still Thus as stated earlier the actuator voltage will fluctuate during calibra tion After the actuator has been calibrated 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 meaninglessuntil calibration has been completed 15 16 17
61. ange 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 within 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 movementin the equipment The coupling is capable of approximately four time the above shaft alignment tolerances However close alignment at installation will provide longer service with smoother operation E Final assembly With the coupling in good alignment the bolts will 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 m Parrallel 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
62. as 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 ofthe 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 67 68 Service D Locate andremove 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 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 wash
63. assign to Buyer any warranty rights in such products that Seller may have from the original manufacturer Labor and expenses for repair are not covered by warranty THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND WARRANTIES EXPRESS OR IMPLIED AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED WARRANTY OF OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Any description of the products whether in writing or made orally by Seller or Seller s agents specifications samples models bulletins drawings diagrams engineering sheets or similar materials used in connection with Buyer s order are for the sole purpose of identifying the products and shall not be construed as an express warranty Any suggestions by Seller or Seller s agents regarding use application or suitability of the products shall not be construed as an express warranty unless confirmed to be such in writing by Seller Long Term Storage Requirements The procedure described is a general recommendation for long term storage over one month of no operation of Vilter Manufacturing packages and compressors While this procedure is intended to cover most of the commonly encountered situations it is the responsibility of the installation 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
64. ation Company This way an authorized agent can examine the unit determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays At the same time the local Vilter representative or the home office should be notified of any claim made All inquires should include the Vilter sales order number compressor serial and model number These can be found on the compressor name plate on the compressor All requests for information services or parts should be directed to Vilter Manufacturing LLC Customer Service Department P O Box 8904 5555 South Packard Ave Cudahy WI 53110 8904 USA Telephone 1 414 744 0111 Fax 1 414 744 3483 e mail info vilter 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 3 Standard VILTER Warranty Statement 6 Long Term Storage Requirements 7 Descriptio 9 ke tl ty l kak nenne 11 Rigging and Lifting E 12 Installation ik s aa ka ala 16 Slide Valve Actuator Ins
65. bolting is tight ened incrementally in a diametrically staggered pattern Some maintenance manuals specify atightening 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 In some cases threads are required to be lubricated prior to tightening the bolt nut Whether a lubricant is used or not has considerable impact on the amount of torque required to achieve the proper preload in the bolt stud Use a lubricant if required or not if so specified Unlike a ratchet wrench a torque wrench is a calibrated instrument that requires care Recali bration is required periodically to maintain accuracy If you need to remove a bolt nut do not use the torque wrench The clockwise counterclockwise switch is for tightening right hand or left hand threads not for loosening a fastener Store the torque wrench in a location where it will not be bumped around Coarse serrations mate together Fine serrations face 0 Service 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 B The lock washer set is assembled so the course serrations that resemble ramps are mated together C Once the lock washer set is tightened down it takes more force to loosen the bolt that it did to tighten it This is caused by the washers riding up the opposing ramps 75 76 6
66. checked as outlined in section 0 03 59 Service GATE ROTOR BLADE REMOVAL A Remove the gate rotor assembly B Removethe snap ring and washer from the gate rotor assembly Lift gate rotor blade assembly off the gate rotor support C Checkdamperpin and bushing for excessive wear Replace if necessary 60 TOP of assembly Relief area faces TOP of assembly 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 Placethe blade assembly on the gate rotor sup port Locating Damper over pin C Install washer 119 and snap ring 130 on gate rotorassembly The bevel onthe snap ring must face away from the gate rotor blade After the gate rotor blade and support are assembled there should be a small amount of rotational movement between the gate rotor and support D For installation of the gate rotor assembly and setting of gate rotor clearance refer to section INSTALLATION All VSG 301 701 Models GATE ROTOR THRUST BEARING REMOVAL A Refertosection INSTALLATION All VSS Models for removal of the gate rotor bearing housings and gate rotor supports B Forremoval of thrust bearings on
67. 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 Gaterotor for C flange Models Service INSTALLATION All VSM 301 701 Models A Install the gate rotor support Carefully tilt the roller bearing end of the gate rotor support 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 ifnecessary 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
68. d 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 VSG 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 oilin a appropriate manner following all Local State and Federal ordinances regarding the disposal of used oil Unscrew the bolts holding the cover flange to the tank Remove the cover flange and spring plate Pull out the filter element s Before reassembling thoroughly clean the tank and spring plate to lengthen the life span of the filter element s lt SINGLE ELEMENT OIL FILTER TANK KE SPRING OIL FILTER PLATE ELEMENT TO INLET DUAL ELEMENT OIL FILTER TANK SPRING OIL FILTER Gig ELEMENTS Es C 1833C r
69. e 1 below for Unit Weights In high pressure screw compressor applications package vibration and noise levels may be higher than those found in standard refrigeration applications In these cases adequate foundation and proper installation are vital to ensure trouble free operation Additional sound attenuation measures may also be needed 11 Rigging and Lifting Thank you for purchasing a gas compressor the Compressor from Vilter Manufacturing LLC Vilter Rigging and Lifting a large piece of equipment like the Compressor is extremely dangerous DISCLAIMER Notice This rigging and lifting manual this Manual is provided to you as a courtesy by Vilter and is not intended to be a comprehensive guide to rigging and lifting the Compressor Vilter shall not be liable for errors contained herein or for incidental or consequential damages including any injury to persons performing the rigging or lifting in 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
70. e to charge the initial amount of refrigerant without water in the shell and tube equipment to eliminate the possibility of freeze up 3 After some refrigerant has entered the system the compressor unit starting pro cedure may befollowed See Start Up and Operation Section of this manual 4 Continue 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 21 Installation should show no bubbles and there will be a liquid seal in the receiver 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 IX MAINTENANCE SUGGESTION
71. e to the slotted optocouplers on the board They are clearly marked on the board silkscreen legend Note 2 The TS1 wire pads are where the motor thermal switch leads solder into the circuit board They are clearly marked on the board silkscreen legend and are oriented at a 45 degree angle 35 36 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 c
72. ead ing fromthe gauge s indicates when the system has reached the low absolute pressure required for complete system evacuation Connect the high vacuum pump into the re frigeration system by using the manufacturer s instructions Connect the pump both to the high side and low side of the system to insure system evacuation Attach the vacuum gauge to the system in accordance with the manufacturer s instructions Asingle 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 19 20 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 thisvacuum 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 Runthe pump an additional 6 hours and hold the sys
73. ectrical damage to the new actuator motor 4 When completing the calibration of the new actuators the motors are signaled to move to below 5 This may not completely occur when exiting the calibration screen due to a program timer HOWEVER when the compressor actually starts the motors will travel below 53 and function correctly The user may see that the actua tors are not below 5 after calibration and try to find the reason If the calibration screen is re entered right away and then exited the timer will allow the actuator to go below the 5 on the screen This may be perceived as a problem in reality it is not 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 Slide Valve Actuator Installation 8 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 C
74. eeping 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 Asthe 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 10 Description The Vilter compressors feature the exclusive Parallex Slide System which consists of a pair of slides for each gate rotor assembly These two independently operated slides are referred to as the capacity slide and the 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 1002 position the compression process begins immediately after the gate rotor tooth enters the screw f
75. erating practices Areview of who each person is and their specific role in the lift e Atutorial 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 Atutorial 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 Engineer 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 l
76. ers beneath the heads but do not tighten them C Work a piece of 0 005 shim stock between the slide valves and the main rotor to help position the carriage D Tighten to the correct torque the hold down bolts to secure the carriage in the frame The edges of the slide valves themselves should be at or slightly below the main rotor bore E Re Install the capacity and volume slide valve cross shafts slide valve racks and discharge manifold F Re install the gate rotor assemblies Service COMMAND SHAFT ASSEMBLY REMOVAL The following steps can be used to remove orinstall 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 COMMAND SHAFT ASSEMBLY INSTALLATION A Installthe command shaft assembly with a new o ring 446 onthe manifold Make sure that the command shaft tongue is engaged in the cross shaft slot Rotate the bearing housing so the vent holes point down this will prevent water and dust from entering the vents Rotate bearing housing so vent hole points down Align the ton ay the command sha with the groove in the cross shaft Command shaft assembly B Install the
77. essure 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 repaired and rechecked before the system can be considered tight again remembering that no repair should be made to welded or soldered joins while the system is under pressure C Evacuating The System A refrigeration system operates best when only refrigerant is present Steps must be taken to remove all air water vapor and all other 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 r
78. frigeration Maintenance and Inspection Schedule The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrig eration oil VSS VSM and VSR Single Screw Compressor units Inspection SERVICE INTERVAL HOURS Or Group Maintenance Item 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 CALIBRATION Transducers RTD s COMPRESSOR Inspect Compressor Bearings Inspect Replace Sample Notes 1 Theoil should be changed at these intervals unless oil analysis results exceed the allowable limits The frequency of changes will depend on the system cleanliness 2 Oilanalysis should be done atthese intervals as a minimum the frequency of analysis will depend on system cleanliness 3 The oil filter s on a minimum must be changed at these intervals or annually if not run continuously However the oil filter s must be changed if the oil filter differential exceeds 12 psi or oil analysis requires it NOTE See Motor Manual for proper lubrication procedures and service intervals 80 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 81 Gate Rotor
79. h 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 Oil Separator Size Approximate Oil Charge Gallons VSR 16 20 to 27 VSR 20 22 to 31 VSM 20 20 to 25 VSM 30 30 to 35 20 30 to 40 24 40 to 50 30 60 to 75 36 95 to 105 42 145 0 165 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 voidthe compressor warranty Please contact your local Vilter representative or the Home Office for further information VIII SYSTEM REFRIGERANT CHARGING CAUTION When charging the system make sure the compressor unit is pressurized from the dis charge side ofthe compressor Pre
80. he command shaft turns to reducethe 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 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 thesystemis allowed to stabilize before another change in slide valve position Operation The Motor Amps Load Limit protects the com 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 3 Oil Separator Heater The oil separator heater keeps the oil in the separator from becoming too viscous and helps keep gas from condensing in the receiver section of the separator The heater is turned on only when the compres sor is off The separator heater is supplied with anintegral temperature control B Safety Setpoints A detailed explanation of all safety setpoints can be found in the Compact Logix PLC manual p n 353
81. he compressor until they stop Install washers and jam nuts on the slide valve shafts Repeat the procedure for the remaining set of slide valve racks en installing the slide valve racks both racks must engage the axle shaft gears atthe same 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 Service TORQUE SPECIFICATIONS ALL UNITS IN FT LBS HEAD OUTSIDE DIAMETER OF BOLT SHANK TYPE BOLT MARKINGS 2 LA Ic pA e a i SOCKET HEAD 16 33 54 84 125 180 250 400 CAP SCREW TORQUE SPECIFICATION FOR 17 4 STAINLESS STEEL FASTENERS FT LBS HEX amp SOCKET HEAD CAP SCREW NOTE CONTINUE USE OF RED LOCTITE ON CURRENTLY APPLIED LOCATIONS USE BLUE LOCTITE ON ALL REMAINING LOCATIONS 13 74 Service USING A TORQUE WRENCH CORRECTLY e A qe guo TORQUE WRENCHES USING ATORQUE WRENCH CORRECTLY INVOLVES FOUR PRIMARY CONCERNS A A smooth even pull to the break point is required Jerking the wrench can cause the pivot point to break early leaving the bolt at a torque value lower then required Not stopping when the break point is reached results in an over torque condition 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
82. ift 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 The rigging plan and sketches of rigging to be attached to the Compressor Theroles and responsibilities of all Participants An emergency plan and contact information of the Plan preparer It is important to confirm that each Participant understands both the broader Plan and their specific 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 The lift capacity of the crane must exceed the Compressor s weight Confirm that the crane operator is qualified to work on the site 13 Rigging and Lifting Get third party confirmation that the crane owner and the crane operator are in compliance with applicable laws regulations and i
83. igeration 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 Forthese reasons the need for periodic leak testing cannot be over emphasized Similarly when any service opera tions are performed on the system care 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 G 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 Inthis way a small amount of time spent check ing machine conditions once
84. igies Inc All rights reserved Printed in the USA 35391S 06 EMERSON Climate Technologies
85. indrical 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 ofthe injected oil isto 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 film 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 sw
86. ins and bolts tighten manifold bolts to the recom mended torque value B On VSS 451 3001 compressors install the dis charge spool or elbow between the discharge manifold and oil separator with new gaskets When installing the discharge elbow tighten the bolts to the correct torque on the manifold flange first before tightening the separator flange bolts Install the drain plug in the bottom of the discharge manifold C 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 Checkrackto 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 0 003 to 0 005 Rack to clamp Rack to clamp spacer C Checktorque of socket heat cap screws D Check for excessive movement between the slide valve rack shafts and the rack The jam nuts on the end ofthe slide valve rack shaft should be tight E Checkforloose or broken roll pins in gears 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
87. irror 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 ortouch the carbon face Lubricate the sealing O ring with clean compressor lubricating oil If applicable align the hole on the back of the carbon cartridge with the dowel pin in the seal cover Install cartridge using seal installation tool or similar see tool lists C Wipe clean the compressor input shaft and the shaft seal cavity in the compressor housing Ap ply clean compressor oil to the shaft seal seating i Make sure that seal is area on input shaft bottomed against shoulder shaft E ane D Lubricate the inside area ofthe rotating seal with key in shaft clean compressor lubricating oil do not wipe or touch the face of the rotating portion of the seal Align the slot in the rotating seal with the drive pin on the compressor input shaft Care fully push the seal on holding onto the outside area of the seal until the seal seats against the 65 66 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 w
88. ith clean compressor oil may be used to lubricate the faces of the seals without touching the seal E Install a new O ring on the seal cover making sure the O ring is placed in the O ring groove and not the oil gallery groove Lubricate both seal faces with clean compressor lubricating oil F Carefully install the seal cover on the compressor shaft evenly tightening the bolts to the recom mended torque values G Install the coupling and coupling guard The unit can then be evacuated and leak checked MAIN ROTOR ASSEMBLY Due to the procedures and tools involved in the disassembly and reassembly the main rotor assembly must be performed by qualified individuals Please consult the factory if maintenance is required Service INSPECTION OF SLIDE VALVE ASSEMBLIES IN THE COMPRESSOR A Measure here D Follow lockout procedure before servicing this unit Prepare the compressor for servicing Remove the gate rotor access covers Usinga mirror and flashlight visually inspect the slide valve carriage through the gas bypass opening Look for any significant signs of wear on the slide valve carriage To check the clearance ofthe 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 g
89. k 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 Putthe nut on This will keep the discs together and maintains the discorientation for later reinstallation Remove the rest ofthe 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 27 Slide Valve Actuator Installation 8 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 Aftertheactuator motor control module has been calibrated for 0 5Volts the controlling channel corresponding to the
90. l 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 Acompressor 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 re turning to service C 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 D Oil Cooling Various types of oil coolers can be used to main tain the oil injection temperature usually either a water cooled shell amp tube heat exchanger mounted locally or a remotely located air cooled fan coil unit In either case the oil temperature control valve operates the same See Appendix A Pre Start Up for Remote Oil Coolers A two way ball valve is located in the main oil line between the oil separato
91. l guide studs in the holes Remove the remaining bolts and side cover There will be o some oil drainage when the cover is removed C Turnthe main rotor so a driving edge of any one of the main rotor grooves is even with the back ofthe gate rotor support Position leading edge of main rotor groove flush with or slightly below back of ga D Insert the gate rotor stabilizer The side rails are not required on VSS 451 thru 601 For the VSS 751 thru 901 and VSS 1051 thru 1201 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 to the gate rotor blade as the thrust bearings and housing is being removed Blades on gaterotor are sharp 59 54 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 Holdthe gate rotor support with a suitable wrench on the flats provided nearthe 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
92. 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 wa damge to gate rotor blade Direction ofrotor movement Axial force at gate rotor to be 200 to 300 D Force to be determined Rigidly attach by length of level arm dial indicator Use bolt for fulcrum Small wooden block or fulcrum COMPRESSOR INSPECTION The Vilter Single Screw Compressor is designed for long periods of trouble free operation withamini mum of maintenance However a yearly inspection is recommended so any irregular wear is noted and rectified At this time the bearing float is measured for the main rotor and gate rotors The following 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 Shut down and de pres
93. ling 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 IV SYSTEM PIPING Refer to the ANSI ASME B31 5 Code for Refrig eration Piping All compressor oil supply and oil return piping has been completed at the factory The necessary connections to be made to the screw compressor unit will vary depending on the type of oil cooling method purchased Main line refrigerant suction and discharge connec tions are always necessary Care must be taken to avoid trapping the lines except for specific purposes When traps are Installation used the horizontal dimensions should be as short as possible to avoid excessive oil trapping Lines for ammonia systems must be of steel pipe with specially designed ammonia service 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 Forthreaded 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 th
94. lt the factory See above Any of the reasons listed in The motor operates in one direction only The command shaft is janmed Free the command shaft Broken gears in the gearmotor Replace the actuator Motor is overheating and the thermal switch is tripping This could be caused by a mal functioning control panel Con sult the factory 33 Slide Valve Actuator Trouble Shooting Guide Problem Reason Solution The motor runs sporadically Bad thermal switch Replace the actuator Any of the reasons listed in The See above 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 el ctoec FlashPatten el ctoec FlashPatten Meaning ON 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 this is the case the slide valve actuator
95. lute 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 Asthe 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 103 of the full rated capacity The capacity slide provides the means for controlling specific process set points By continuously adjusting the flow of gasthrough the compressor either suction or discharge pressure in a particular process can be controlled When coupled with a microprocessor controller the adjustable capacity slide allows for precise and continuous automatic control of any parameter in the process to a chosen set point The second slide for each gate rotor is the volume ratio slide The purpose of the volume ratio slide isto 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 andactsto vary the position of the discharge port When the slide is e
96. ly as kit See recommended spare parts lists for complete assembly 230 108 Main Rotor Slide Valve Cross Shafts 8 Plate Models VSM 301 401 Counter Clockwise ONLY NOLVLOY FSIMADOTI AYIINNOIJ JOSSdHdNOD ISA ATBW3SSY JIJAVE XId9 6S ONIMVYC JIS a ao WW S 122498 S 195806 3 TOOL TIVLISN 109 10 Main Rotor Slide Valve Cross Shafts 8 Plate Models VSM 301 401 Counter Clockwise ONLY MODEL NUMBER DESCRIPTION MAIN ROTOR ASSEMBLY A25226AB 1 A25226AA 1 A25226AC OIL BAFFLE ASSEMBLY 1 217 1 244 1 248 1 249 1 252 SHIM ASSORTMENT 2 240 2 241 1 242 1 243 OIL BAFFLE PLATE END PLATE SHAFT GEAR CLAMP SPACER SHIM 0 002 SHIM 0 003 SHIM 0 005 SHIM 0 010 TEFLON RING CHECK VALVE CHECK VALVE RETAINING RING EXPANSION PIN EXPANSION PIN PLUG SOLID HEX HEAD CAP SCREW SOCKET HEAD CAP SCREW SET SCREW SET SCREW A25942AA A25942AA 1 A25942AA 25177 25938 257190 25941 25027 25913A 25847A 25409AA 25409AB 25409AC 25409AD 25939A 3120A 3120B 282
97. 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 of the compressor coupling is shipped loose to help facilitate final field alignment and allow for motor rotation check The motor alignment should be within 0 004 total indicator read ing in all directions a Both the compressor and motor hubs should be checked for concentricity and perpendicularity L 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 atthe time of start up Order Compressor Serial 46 O U 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
98. mounting pad or floor LI The suction and Discharge line must be piped and properly supported independent ofthe unit LI 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 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 C 4 A Dual Safety Relief Valve is shipped loose for field installation A connection is provided on the oil sepa rator for the relief valve Refer to ASHRAE ANSI Standard 15 Safety Code for Refrigeration for proper sizing and installation of Relief Valves and Vent Lines 5 Piping For Oil Cooling a Liquid Injection An adequate or dedicated liquid line is required for the Liquid Injection System A high pressure liquid source must be piped to the stop valve at the inlet ofthe Thermostatic Expansion Valve On booster units an additional line must be piped to the regulator from high stage discharge gas flow orthe Thermostatic Expansion Valve b V PLUS high pressure liquid source must be run to the V PLUS inlet Some subcooling is desirable high pressure float must be installed at the inlet of the pump and a vent line must be returned to asuction trap Refer to the V PLUS
99. mper pin inthe bushing is the gate rotor float Referto 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 amp VSS 1201 VSS 1551 amp VSS 2101 Readings could be higher than 0 020 If readings is greaterthan 0 030 overtable tolerance contact Vilter s home office Inspectthe 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 Service GATE ROTOR ASSEMBLY CAUTION Follow lockout procedure before servicing this unit Gate rotor removal and assembly is divided into dis tinct instructions instructions for all VSG and VSSG 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 ERI D A Prepare the compressor for servicing NOTE All parts must be kept with their appro For VSS 751 901 amp VSS 1051 1201 priate side and not mixed when the compres compressors use side rails and sor is reassembled assemble to gaterotor stabilizer as stamped me B Remove two upper bolts from the side cover TP and instal
100. nical 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 to withstand the operat ing pressures Inselecting 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 uni
101. ning down three of the hold down bolts and checking the clearance under 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 servicing the compressor LEAK CHECKING UNIT Note Unit can be leak checked before evacuation CAUTION Slowly pressurize the unit from the discharge side of the compressor Pressurizing the compressor from the 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 B Breakthe vacuum on the unit using dry nitrogen and checkfor leaks Concentrate on areas where work was done C If noleaks are found the unit can be returned to service Direction of rotor movement Axia to be 250 300lbs Service Rotor Being Pushed By Use Of Lever force at coupling Rigidly attach d Position it on th compressor Force to be determined ial indicator e axis of the TO by length of
102. nternal 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 Understand and interpret the load 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 Ensure that adequate space is provided to safely assemble erect and operate the crane and materials such as timber mats cribbing and blocks Identify and communicate to all Participants the access points lift radius swing radius clearances and ob structions Eliminate hazards and obstructions that may interfere with moving the Compressor and Inform all Participants of water lines sewer lines power lines and other obstructions ES 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 p
103. o 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 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 and the 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 Enablethe 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 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 t
104. of the system so the gas will float away from the compressor Installation This prevents any dirt or foreign particles from entering the compressor and contaminating the working parts The oil should then be charged into the compressor Charge asmallamount ofammonia into the sys tem and pressurize the system to its respective design 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 B 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 pr
105. ogether A light application of clean com pressor lubricating oil should be used to ease the installation of the bearings into the gate rotor support Install the bearing retaining snap ring For installation of the bearing housing and the setting of the gate rotor blade clear ance refer to section INSTALLATION All VSG Models Service The thrust bearings must be assembled face to face Inner Retainer W Ball Bearings Retaining Ring Service GATE ROTOR ROLLER BEARING REMOVAL A D Refer to section REMOVAL All VSG for removal ofthe gate rotor bearing housings and gate rotor supports Remove the snap ring 131 which retains the roller bearing in the bearing housing Removethe 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 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 VSG Models 63 Service COMPRESSOR SHAFT SE
106. omplex choice that depends on a combination of field experience lab and field testing and knowledge of lubricant chosen Vilter will not accept those risks other than for our own lubricants Operation OIL SYSTEM A Oil Charge Charge the oil separator with the proper quantity of lubricating oil see Table 2 in the Installation Section CAUTION It is imperative you charge the oil into the receiver separator prior to energizing the control panel to prevent burning out the immersion heater in the separator receiver During operation maintain the separator oil level in the normal operating range between the two bullseye sight glasses If the oil level is visible only in the lowest sight glass add oil to the operating compressor through the connection located at the compressor suction inlet Pump oil into the 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 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 rea
107. ompressor 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 Pre Start Up Checklists The following checklists are to help prepare the equipment before the Vilter Technician arrives at the jobsite Vilter recommends that a Trained Technician go through the following tasks The operating Manuals provided by Vilter can be referenced for any type of questions or special instructions Every Refrigeration unit includes a Vilter Start Up 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 45 Field Piping and Mechanical Requirements NOTE Ifstart up service has been purchased the following items should be completed before the start up technician arrives This will help save time and money The unit should be leveled and secured to the
108. ompressor package including vessels oil coolers controllers and all ancillary equipment See documentation for weight and dimension specifications A detailed general arrangement drawing is provided with all packages This drawing details foundation type mounting foot locations grouting and anchoring methods for the specific package Vilter Mfg recommends consulting a licensed architect to design a suitable foundation for the application Foundations must be built of industrial grade materials and conform to the appropriate building codes Mount the unit in a location which allows adequate clearance around the unit for maintenance The unit may be top heavy so caution should be taken when lifting and moving the unit See the Rigging and Lifting documentation provided with the unit Theunit must be securely bolted to the foundation and shims should be used to level the unit for proper opera tion Grouting must be used The compressor should be firmly mounted to the package isolation dampers should not be used between the compressor and the package frame Pipes and conduits are strictly step areas and could be damaged if used as foot or handholds Adequately support pipes conduits etc to prevent both transmission of vibration and failure due to stress at the flanges Suction and discharge lines must be supported with appropriate pipe hangers to prevent their movement if they are disconnected from the compressor package See Tabl
109. or 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 mustremain visible and tagged so they will be noticed and removed when the unit is prepared for service Long Storage Requirements 2 Coverthe unit completely to exclude dirt dust moisture and other foreign materials 3 Ifthe motor can be moved itis 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 bag
110. or 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 light emitting di ode LED on one side of the slot and a phototransistor on the other The phototransistor behaves as a light controlled switch When the photochopper fence is blocking the slot light from the LED is prevented from reaching the phototransistor and the switch is open When photochopper fence is not blocking the slot the switch is closed 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 motorturns 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 capacitor stores enough energ
111. oting Guide Problem The actuator does not trans mit the correct position after a power loss There is a rapid clicking noise 5 when the motor is operat ing The motor operates in one direction only The motor will not move in either direction The motor runs intermittently several minutes on several minutes off Reason Solution The motor was manually moved Recalibrate while the position sensor was not powered Get the motor brake to where it operates freely and then recali brate The motor brake is not working properly The position sensor s EEPROM memory has failed Replace the actuator The photochopper is misaligned with the slotted optocouplers Try to realign or replace the ac tuator The photochopper is positioned too low on the motor shaft Adjustthe photochopper so that the fence extends further into the optocoupler slots A motor bearing has failed Replace the actuator There is aloose connection in the Tighten screw terminal blocks There is a loose or dirty connec Clean and tighten tion in the yellow Turck cable The position sensor has failed Replace the actuator There is a broken motor lead or winding Replace the actuator The thermal switch has tripped because the motor is overheated The motor will resume opera tion when it cools This could be caused by a malfunctioning con trol panel Consu
112. r and the compressor The oil cooler is piped in parallel to the oil tem perature control valve which acts as a by pass valve Figure 3 OIL FILTER OIL SEPARATOR TO COMPRESSOR COMBINATION STOP ALYE PRIMER PUMP amp STRAINER ii T H DIL COCLER WATEROR REFRIGERANT FIGURE 3 TYPICAL WATER COOLED OIL COOLER DIAGRAM 1 Temperature Control Valve Installation amp Position Indication 1 1 The ball valve is installed with the ball closed 39 40 Operation 1 2 Theactuator mounts on the ball valve stem Flats onthe ball valve stem indicate the position of the ball OPEN stem flats are with the flow CLOSED stem flats are across the flow 1 3 On smaller valves the ball valve stem flats are nearly hidden between the stem extension and the stem lock nut The locking tabs on the stem lock nut are across the flow 1 4 The actuator position indicator stem flats are oriented in the same direction as the ball valve stem flats 1 5 There is a mechanical position indicator on the top of the actuator cover NOTE The oil temperature control valve comes from the vendor already assembled with the ball closed and the actuator in the CLOSED position 2 Control Action 2 1 The ball valve can rotate through a full 360 arc 2 2 The actuator restricts the ball to 90 arc of travel 2 3 The
113. read fill ing compounds suitable for refrigeration service should be used for making steel pipe joints These compounds should be used sparingly and on the pipe only Do not put any on the 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 only a skilled welder should attempt this kind of work Take care to see 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 mecha
114. rmer 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 currenttransformer 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 47 48 Stop Check Valve Operation AUTO In the Auto 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 Uer TELE Number of Turns Open 2 75 325 45 from closed position Service GENERAL COMMENTS When working on the compressor care must be taken to ensure that contaminants i e water from melting ice dirt and dust do not enter the compressor while it is being serviced It is essential that all dust oil or ice that has accumulated on the outside of
115. rnal pressure source with an accurate gauge may be attached at the bleed valve The discharge pressure transducer cannot be iso latedfromits pressure source so itis 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 41 42 Operation 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 mustbe in a normal condition and the suction pressure must be above the low suction pressure setpoint to assure that a load is present When the On Off switch or Manual Auto button is pressed the oil pump will start When sufficient oil pressure is built up and the compressor capacity control and volume ratio slide valves are at or below 10 the compressor unit will start If the compressor is in the automatic mode it will now load and unload and vary the volume ratio in response to the system demands Stopping the compressor unit can be accom plished a number of ways Any of the safety setpoints will stop the compressor unit if an abnormal 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
116. rtothe actuator NOTE The ball valve and the actuator must al ways be assembled in the CLOSED position See Section 3 Calibration above CAUTION move the ball stem during this operation Turning the ball valve 90 in either direction will reverse the control action ofthe valve and the compressor will experience high oil temperature within minutes Turning the ball valve 180 has no detrimental effect 9 Manual Override The actuator has a handwheel that can be en gaged to override the electrically determined position of the ball valve Push and rotate to engage Push a second time to de clutch 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 Touse the block and bleed valves to recalibrate the pressure transducers the block valve is shut offat the unit and the pressure is allowed to bleed off by opening the bleed valve near the pressure transducer enclosure The transducer can then be calibrated at atmospheric pressure 0 psig or an exte
117. s of silica gel desiccant put inside the bag around the motor When the moisture indicator shows that the desiccant has lost its effectiveness as by a change in color the bag should be opened and fresh replacement desiccants installed Whenever the motor cannot be sealed space heaters must be installed to keep the motor at least 10 F above the ambient temperature NOTE There is a potential for damage by small rodents and other animals that will inhabit motors in search of warm surroundings or food Due to this a possibility of motor winding destruction exists Sealing motor openings should restrict access to the motor 4 Rotate motor and compressor shafts several revolutions approximately 6 per month to eliminate flat spots onthe bearing surfaces If the compressor unitis installed wired and charged with oil open all oil line valves and run the oil pump for 10 seconds prior to rotating the compressor shaft Continue running the oil pump while the compressor shaft is being turned to help lubricate the surfaces of the shaft seal Description COMPRESSOR The Vilter Single Screw Compressor is a positive displacement capacity and volume controlled oil 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 fl
118. sor Start 441A and Compressor Start 18 Control powerfor 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 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 2 input relay A dry contact must be supplied and wired to one of the L terminals on any of 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 transfo
119. ssurizing the compressor from the suction side may cause rotation of the compressor without oil supply which could lead to internal damage Installation After the system is leak free and evacuation has been completed it is ready for charging Before actual charging however the entire operation of the refrigeration system should be inspected as outlined below A Low Side Equipment 1 Fans on air handling equipment running 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 Beltdrives correctly aligned and tensioned 8 Proper voltage to motors B 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 GY wurde pu PX C Condensers 1 Water available at water cooled condensers and supply line valve open 2 Water in receiver of evaporative condenser and makeup water available 3 Correct rotation of pump and fan motors 4 Belt drives aligned and tensioned correctly 5 Pump fans and motors lubricated D Controls Controls should be at the initial set points See microprocessor
120. surize the unit B Main rotor bearing float 1 Remove the coupling guard then remove the center member from the coupling 2 Attach a dial indicator to the compressor frame as shown and zero indicator Place a lever arm and fulcrum behind the compres sor coupling half and push the coupling towards the motor note measurement TABLE 1 MAXIMUM BEARING FLOAT MAN GATE Bearing Float 0 003 Maximum Force 250 to 300 50 to 100 Lbs Lbs 3 Re Zero indicator now position the fulcrum on the motor and use the lever arm to push the input shaft towards the compressor note measurement 51 Service 4 Add both readings the total indicator move ment is the bearing float and this should not exceed 0 003 C Gate rotor bearing float 52 1 Remove the side covers and position a dial indicator on the gate rotor 2 Usea lever arm pivoting on a bolt with a small block of wood against the gate rotor blade to protect the blade 3 The maximum amount of bearing float should not exceed 0 002 Damper Pin Dial Indicator and Bushing D Measure the gate rotor to blade float Some movement between blade and support is neces sary to prevent damage to the compressor blade however at no time should the blade uncover the support 1 Position the blade with the gate rotor damper pin and 90 to the main rotor 2 Position a dial indicator at the tip of the sup port The total movement of the da
121. t 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 Water 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 These precautions will avoid costly damage to the equipment due to freezing 17 18 Installation This information is taken from ASHRAE 15 89 and ANSI B31 5 The installing contractor should be thoroughly familiar with these codes as well as any local codes V ELECTRICAL CONNECTIONS The single screw compressor units are shipped with all package mounted controls wired The standard control power is 115 volts 60 Hertz single phase Ifa 115 volt supplyis notavailable 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 con
122. tacts 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 this wiring can be found on the wiring diagram supplied with this unit Additional aspects of the electrical operation of the single screw units are covered in the start up and operation section of this manual VI TESTING REFRIGERATION SYSTEM FOR LEAKS Vilter equipment is tested for leaks at the fac tory One the most important steps in putting a refrigeration system into operation is field test ing forleaks This must be done to assure a tight system that will operate without any appreciable loss of refrigerant To test for leaks the system pressure must be built up Test pressures for various refrigerants are listed in ANSI B9 1 1971 code brochure entitle Safety Code for Mechani cal Refrigeration These pressures will usually suffice 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 exceptthose leading to
123. tallation amp Calibration 28 Slide Valve Operation 31 Slide Valve Actuator Trouble Shooting Guide 32 Operation cc S 36 Notice on using Non Vilter Oils 36 37 Pre Start Up Checklists 45 Field Piping and Mechanical Requirements 46 Field Wiring Requirements 47 Stop Check Valve Operation 48 E 49 Maintenance eur 80 Parts SER E 81 Gate ROTOT una 82 Shaft S AM E 86 Mairi RO e 87 Slide Valve Cross Shafts and End Plate 89 Slide Valve Carriage Assembly 91 Actuator amp Command ShalT 95 Miscellaneous Frame Components 97 Replacement Tools
124. te 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 56 Service INSTALLATION All VSS Models A Install the gate rotor support by carefully tilting the roller bearing end of the gate rotor support towardsthe suction endofthe compressor The compressor input shaft may have to be rotated to facilitate the installation ofthe 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 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 Lubricatethe 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 andinstallation tool with the pusher shoe must be used Turnthe j
125. tem for approximately 12 hours at low pres sure Afterthis again breakthe vacuum with dry nitrogen and allow the pressure in the system to rise slightly above zero pounds psig Install new drier cartridges and moisture indicators Charge the system once more below the 1000 micron level and use the refrigerant designed for the system When properly evacuating the system as outlined above the system is dry oxygen free and free of non condensables The piping should not be 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 VII 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 throug
126. the compressor stops the valve re turns to fully open 100 5 Fail Position The actuator remains in its last position when power is removed 6 Screen Display The oil temperature control valve identified as OIL MIX on the main HMI display screen shows a numerical value with as units This is to be understood as OPEN It is a direct indication of the position of the ball valve 6 1 100 OPEN oil flow stream is entirely bypassing the oil cooler Operation 6 2 9975 to 1 OPEN oil flow stream is partially by passing the oil cooler and partially diverted to the oil cooler 6 3 0 OPEN oil flow stream is entirely diverted to the oil cooler G Control Settings The oil temperature control setpoints are en tered on the compressor controller screen Oil Mixing Valve PID Oil Return from Cooler 8 0 Rotating the Actuator for Convenience of Installation The actuator can be rotated to any one of four positions 8 1 Remove both 120V and 24V power from the actuator 8 2 Disconnect electrical leads at actuator 8 3 Remove four cap screws that fasten the actuator to the valve mounting bracket 8 4 Lift the actuator off the valve stem 8 5 Rotate the actuator to the desired position 8 6 Slide actuator down on the valve stem 8 7 Secure the actuator to the valve mounting bracket with four cap screws 8 8 electrical leads at the actua tor 8 9 Restore 120V and 24V powe
127. ttern 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 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 itup the shaft to the desired axial position A pre set axial stop device can be helpful C Taper Bore 1 Putthe hub on the shaft without key s in place Lightly tap hub up the shaft with a soft hammer This will assure metal to metal fit between shaft and hub This is the starting point for the axial draw Recordthis position between shaft and hub face with a depth micrometer Mount a dial indica torto read axial hub movement Setthe indicator to 0 Remove hub and install key s Remount hub drawing it up the shaft to the O set point Continue to advance hub up the taper to the de sired axial
128. 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 71 Service C Toremove the cross shafts remove socket head bolts clamp and spacers from both sides VSS 751 2101 compressors cross shafts Gay VSM 301 701 amp VSS 2601 3001 compressors cross shafts Volume control cross shaft e 2D ec 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 procedure for the 72 remaining cross shaft INSTALLATION OF CAPACITY OR VOLUME A C CROSS SHAFTS 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 The slide valve sets must be synchronized on VSS 451 3001 and dual gate VSM 301 701 units Both slide valve racks for either the volume ratio or capacity slide valves must engage the cross shaft gears at the same time Push the racks the way towards the suction end of t
129. ute 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 Fach 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 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 cyl
130. 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 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 liftEngineer Rigging Specialist Riggers and Safety Signaler 12 Rigging and Lifting Training curriculum for Participants at a minimum should include Areview of safe op
131. xtended fully to the discharge end of the screw the 1003 position the compression process within the screw flute continues until the screw rotates far enough forthe flute to pass the end ofthe 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 compressor 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 Foundation The foundation must adequately support the weight of the c
132. y to keep the position sensor circuitry alive long enough for the motor to come to a complete stop and then save the motor position to non volatile EEPROM memory When power is restored the saved motor position is read from EEPROM memory and the actuators resumes normal function 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 31 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 32 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 itto malfunction The calibrate button is stuck down The position sensor has failed Push button is being held down for more that 34

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