VSG/VSSG compressor unit Installation, operation & maintenance manual FOR UNITS BUILT AFTER JULY 1, 2013
VSG/VSSG Standard Vilter Warranty Statement Seller warrants all new single screw gas compression units and bare shaft 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.
Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR. The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw Compressors. Following these instructions will result in a long life of the compressor with satisfactory operation. The entire manual should be reviewed before attempting to install, operate, service or repair the compressor. A compressor is a positive displacement machine. It is designed to compress gas.
Table of Contents Section Title Section Number VSG/VSSG Standard Vilter Warranty Statement ..................................................................................... i Important Message................................................................................................................................ ii Section 1 • General Information How To Use This Manual.........................................................................................................................
Table of Contents Section Title Section Number Section 3 • Installation (Continued) Priming Remote Oil Cooler and Piping (Initial Oil Charging)........................................................ 3-20 Priming Compressor and Oil Filters ............................................................................................ 3-21 Pre Start-Up ........................................................................................................................................... 3-22 Start-Up .....
Table of Contents Section Title Section Number Section 6 • Troubleshooting Table 6-1. Slide Valve Actuator Troubleshooting Guide ........................................................................... 6-1 Table 6-2. Slide Valve Actuator LED Blink Codes ...................................................................................... 6-3 Table 6-3. Troubleshooting Guide - General Problems & Solutions ..........................................................
List of Tables and Figures Table/Figure Section Number Tables Table 3-1. Long Term Storage Compressor Hardware ............................................................................. 3-2 Table 3-2. Maximum Allowable Flange Loads ......................................................................................... 3-11 Table 4-1. Command Shaft Rotation Specifications ................................................................................ 4-6 Table 5-1. Maintenance/Service Schedule ......
List of Tables and Figures Table/Figure Section Number Figure 4-4. Slide Calibration Screen (Compact Logix PLC) ....................................................................... 4-5 Figure 4-5. Photo-chopper ..................................................................................................................... 4-5 Figure 4-6. Oil Temperature Control Valve (Oil Mixing Valve) ..................................................................4-8 Figure 4-7. PLC Main Screen ...............
Blank / TOC VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391STG
Section 1 • General Information How To Use This Manual This manual contains instructions for gas compressor units. It has been divided into eight sections: Section 1: General Information Section 2: Theory of Operation Section 3: Installation Section 4: Operation ADDITIONAL IMPORTANT NOTES • Installation, operation and maintenance instructions can be found in the associated software manual and bare shaft compressor manual. • Due to continuing changes and unit updates, always refer to the Vilter.
Section 1 • General Information Gas Compressor Unit Model Designations The compressor unit model designation can be found on the nameplate. For nameplate location, see Component Identification on section page 1-4. VSG-601-VVR-L-HP-VFD-36H-NEC-ST-WTR 1 2 3 4 5 6 7 8 9 10 Figure 1-1. Gas Compressor Unit Model Designation 1. Compressor Model 7.
Section 1 • General Information System Unit Identification To keep definitions of units simple and consistent, Vilter has defined the following three: • Bare Shaft Compressor • Compressor Unit • Package Unit Bare Shaft Compressor A bare shaft compressor is just the compressor with no coupling and motor nor foundation. Compressor Unit A compressor unit consists of the bare shaft compressor with the coupling, motor, oil separator, frame, micro-controller system and oil system.
Section 1 • General Information Compressor Unit Component Identification Each gas compressor unit may differ, but below are typical components that can be found on each unit.
Section 1 • General Information 4 3 20 18 19 17 22 21 14 20 23 Figure 1-2.
Section 1 • General Information Component Identification (Continued) 24 - RTD (Oil Filter Outlet) 29 - RTD (Discharge) 32 - Block & Bleed Assembly 25 - Suction Oil Charging Valve 30 - Capacity Slide Valve Actuator 26 - Pressure Transducer (Oil Injection Temperature) 31 - Pressure Transducers (Filter Inlet, Oil Pressure, Discharge 1 and 2) 33 - Remote Oil Cooler (Finned Fan Heat Exchanger) 27 - RTD (Suction) 34 - Oil Separator Drain 35 - RTD (Oil Separator) 28 - Volume Slide Valve Actuator 26 27 2
Section 1 • General Information Instrument Identification Letters Use this list to identify components shown in the Piping & Identification Diagram.
Section 1 • General Information SIC Speed Indicating Controller VU Vibration Monitoring System PDSH Pressure Differential Switch High T Temperature W Weight TC Temperature Controller XA PDSHH Pressure Differential Switch High High (Shutdown) TAH Temperature High TAHH Temperature High High (Shutdown) Status (Stopping/Not Running) Alarm/Common Alarm XC State Controller TAL Temperature Low XI Running Indication TALL Temperature Low Low (Shutdown) XV Solenoid Valve XY State Relay/Con
Section 1 • General Information Symbol Identification Use this list to identify symbols shown in the Piping & Identification Diagram.
Section 1 • General Information Major Component Identification (Continued) Centrifugal Pump Plate & Frame Heat Exchanger Rotary Pump Turbine Control and Instrument Identification Discrete Instrument, Field Mounted Discrete Instrument, Remote, Mount, Normally Accessible to Operator Discrete Instrument, Local Rack Mounted, Normally Accessible to Operator Shared Display/Control, Field Mounted Shared Display/Control, DCS or Remote Control Panel Normally Accessible to Operator Shared Display/Control, Local Co
Section 1 • General Information Valve and Instrument Tagging a-bc-yz = ABC-DEFGH-IJKL a = ABC, b = DE, c = FGH, y = IJK, z = L A - Process cell or stage of compressor D - Measured variable B - Unit number in process cell or stage of compression E - Variable Modifiers C - Service in process cell or stage of compression F - Readout or passive function 1 - Gas lines G - Output or active function 2 - Coolant lines H - Function modifier 3 - Oil lube lines I - Loop number or sequential number 4 - Refr
Section 1 • General Information Pipe Line Data Identification AB - C - D - E - F 20-LFG-001-10-STD X-Y-Z PS-1-ET A - Process cell or stage of compression X - Insulation 1 - Process cell first stage of compression AC -Acoustic Control 2 - Process cell first stage of compression CC - Cold Service 3 - Process cell first stage of compression CP - Condensation Control 4 - Process cell first stage of compression N - Not Required 5 - Process cell low pressure refrigeration (booster) PP - Personnel P
Section 2 • Theory of Operation 1 2 3 4 5 6 SUCTION GAS CHECK DISCHARGE VALVE STOP VALVE TE 1/4” OIL CHARGING TE COMPRESSOR BLEED 1/4” MOTOR 13 14 12 BLEED BLEED 15 16 OIL SEPARATOR 11 TE FILTER DRAIN STANDARD SINGLE OIL FILTER BLEED BLEED 10 TE DRAIN 100# MOTOR M FG 1 PUMP FILTER DRAIN FILTER OPTIONAL DUAL OIL FILTERS 7 DRAIN 9 OIL COOLER VENT 8 OIL DRAIN DRAIN STANDARD WATER COOLED OIL COOLER OPTIONAL REMOTE AIR COOLED OIL COOLER Figure 2-1.
Section 2 • Theory of Operation gas. Proper separation of any liquids must be accomplished before any liquids can get to the compressor suction. The discharge temperature of the compressor must be kept a minimum of 30°F (or 17°C) above the discharge gas dew point to prevent the condensing of liquids in the oil separator. The oil separator shell and legs must be insulated when the gas stream has a high probability of having condensables. Oil in the gas compressor unit serves three primary purposes.
Section 3 • Installation Delivery Inspection All equipment supplied by Vilter are thoroughly inspected at the factory. However, damage can occur in shipment. For this reason, the units should be thoroughly inspected upon arrival, prior to off-loading. Any damage noted should be photographed and reported immediately to the transportation company. This way, an authorized agent can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays.
Section 3 • Installation Long Term Storage Recommendations 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. For cool compression, there is no pre-lube pump, so the driveshaft must be turned by hand. The procedure described is a general recommendation for long term storage (over one month of no operation) of Vilter compressor units.
Section 3 • Installation AIR COOLED OIL COOLERS The following are general recommendations. Refer to specific air cooled oil cooler manufacturer instructions for storage recommendations. • If the coolers are to be stored or not operated for an extended period of time, the fan motors may ingress moisture if they are not protected or operated regularly.
Long Term Storage Log Company: Sales Order Number: Serial Number: Name (Please Print): Initial: Date (M/D/Y): PSI Nitrogen Pressure - Current PSI Nitrogen Pressure - Recharged (If pressure is low, identify and fix leak prior to recharging, see Compressor Unit Leak Check procedure in Section 5) Nitrogen Leak Location (Briefly explain nature of leak): Compressor Shaft (Rotate shafts at least 6 revolutions) Motor Shaft (Rotate shafts at least 6 revolutions) Motor Bearings Greased Air Cooled Oil Cooler Rot
Section 3 • Installation Foundation Vilter Single Screw compressor units are low vibration machines. Under most conditions, no elaborate foundation is necessary. However a sound foundation maintains motor alignment and proper elevation, and is therefore required. Provided are recommendations for the foundation and anchoring of the compressor unit. The Vilter foundation supports the entire operating weight of the unit and is suitable for years of continuous duty.
Section 3 • Installation of both • Check the ability of the soil to carry the load trolled level and a surface texture etched in place. Leave the concrete to cure for at least 28 days. • Check wet season and dry season soil characteristics for static loading limits and elasticity Compressor Unit Installation • Check local codes for Seismic Design requirements For examples of foundation diagrams, see to Figure 3-2 and Figure 3-3.
Section 3 • Installation Leveling and Grouting The unit should be level in all directions. Wet the concrete pad according to the grout manufacturer’s directions. Mix a sufficient amount of grout. The grout must be an expanding grout rather than shrinking to provide a tighter bond. Follow the manufacturer’s recommendations for setting, precautions, mixing, and grout placement, finishing and curing. The grout must be worked under all areas of the feet with no bubbles or voids.
Section 3 • Installation Additional Information Codes and Standards Vilter followed the following codes and standards when designing your foundation: • ACI • ASTM • ASCE 7 • IBC 2006 Operation and Performance The foundation was designed for: • Outside environment severe exposure General Design Requirements The compressor foundation is designed to: • Maintain the compressor in alignment and at proper elevation.
Section 3 • Installation 1" (TYP.) G.A. G.A. CENTER LINE G.A. G.A. G.A. + 2" G.A. G.A. (2) - # 4 CLOSED TIES (5) - # 6 VERT. WITH STD. 90° HOOK AT BOTTOM EACH FACE 5/8" DIA. HILTI HAS SS THREADED ROD (HAS-E RODS ARE ACCEPTABLE FOR INTERIOR INSTALLATIONS) INSTALLED USING HIT-ICE/HIT-HY 150 ADHESIVE ANCHORING SYSTEM. (5" PROJECTION, 12 3/8" EMBEDMENT.) HOLES TO BE INSTALLED WITH HAMMER DRILL. DO NOT DIAMOND CORE. (TYP.) Figure 3-6.
Section 3 • Installation 70+6 .') *1.& &190 076 010Ä5*4+0- '21:; )4176 9#5*'4 .'8'.+0) 076 /+0 4'%1//'0&'& (14 *175'-''2+0) #0%*14 $1.6 %10%4'6' $#5' Figure 3-8. Concrete Pad Housekeeping Detail Piping Header Piping and Drains The ideal load applied to flanges of the compressor unit is zero. However, it’s not practical to expect that no loads will be applied to unit connections. Thermal, dead, live, wind & seismic loads must be considered and even tolerated.
Section 3 • Installation Table 3-2. Maximum Allowable Flange Loads Nozzle Dia. (in.
Section 3 • Installation General Installation Guideline for calculations for each guideline. Let’s assume the following coolers are being installed in a common area: Multiple Air Coolers Installed in a • Cooler 1 - 7’ wide x 10’ long with a 6’ fan moving 55,000CFM of air. Face velocity is 785FPM. Common Area • Cooler 2- 8’ wide x 12’ long with a 7’ fan moving 72,000CFM of air. Face velocity is 750FPM.
Section 3 • Installation Intake Velocity More Less Figure 3-11.
Section 3 • Installation HOT AIR RECIRCULATION There are two situations where hot recirculation could occur. • Intake velocity of the cooler is higher than the discharge velocity • Environmental issues such as strong cross winds which is installation specific We addressed how to minimize the opportunity for hot air recirculation involving the operation of the air coolers under the guidelines for the Free Flow section above.
Section 3 • Installation NOT PREFERRED PREFERRED Figure 3-13. Discharge Elevation of Coolers NOT PREFERRED PREFERRED Figure 3-14.
Section 3 • Installation NOTICE Pressure Testing CAUTION Do not hydro test compressur unit. Failure to comply may result in damage to equipment. CAUTION The compressor unit along with other system units contain many components with various pressure ratings. Pressure relief protection provided considers the design pressure of a system components. Before replacing a pressure relief valve with a relief valve having a higher presure setting, all system components must be evaluated for acceptability.
Section 3 • Installation Normal Operating Level Maximum NON-Operating Level Minimum Operating Level Figure 3-15. Oil Operating Levels Suction Oil Charging Valve Oil Drain Valve (Oil Separator) Bypass Valve (Oil Cooler) View Rotate 180° Oil Filter Shut-Off Valves View From Back - View Rotate 180° Figure 3-16.
Section 3 • Installation NOTE PRIMING COMPRESSOR AND OIL FILTERS Oil mixing valve can remain in Manual Mode since the setpoint will change the mode to Auto when reached. For further details, see PLC Compact Logix manual. NOTE Running the compressor oil pump at this point will help lubricate the compressor bearings and shaft seal surfaces. 16. Refer to Pre Start-Up Checklist and ensure all items are ready prior to starting the compressor. 17.
Section 3 • Installation NOTE Oil separator does not need to be filled again until oil level reaches Minimum Operating Level. Every size of compressor will hold different amounts of oil, so amount of oil draining back into oil separator will vary. 21. More accurate fill levels can be accomplished by marking the level on the oil separator (3) after correct levels have been achieved during the unit operation and when the compressor unit has been down for 1 hour.
Section 3 • Installation (Reference Figure 3-19) 1. Verify oil level (8) is at Maximum Non-Operating Oil Level in separator (3). If oil level is not at Maximum Non-Operating Oil Level, add oil, see Initial Oil Charging - Unit Oil Charging procedure. 2. Close shut-off valve(s) (7) at oil filter inlet(s). 3. Open oil bypass shut-off valve (4). 4. Energize compressor unit. 5. Close oil mixing valve (oil temp. control valve) (6) via control panel. In Manual Mode, change “Manually Open (%)” value to “0”.
Section 3 • Installation 14. When ready, run compressor unit and allow it to reach normal operating temperature. 15. Using a properly selected oil pump, connect oil pump to suction oil charging valve (1). For suction oil charging valve location, see Figure 3-16. 16. Open suction oil charging valve (1) and fill oil separator (3) to Normal Operating Level. 17. Once the Normal Operating level has been reached, shut off the oil pump and close the suction oil charging valve (1). Disconnect and remove oil pump.
Section 3 • Installation Pre Start-Up The following check list is 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. NOTICE Each item below must be checked-off, signed and returned to Vilter Service Department. Failure to do so will “Null & Void” future warranty considerations.
Section 3 • Installation 9. The oil separator should be charged with oil to the Maximum NON-Operating Level. 10. The center member of the compressor is shipped loose to help facilitate final field alignment and allow for motor rotation check. 11. Both the compressor and motor hubs should be checked for concentricity and perpendicularity. 12. The motor should be checked and shimmed for a soft foot prior to attempting final alignment. 13.
Section 3 • Installation Start-Up The following check list is to help verify and check equipment prior to start-up. This is the responsibility of the Vilter Technician. 1. Review pre start-up checklist. 2. Check oil pump rotation. This can be done by using the “Diagnostic Force Outputs” from Main Menu. Refer to Compact Logix PLC Software Manual. 3. Check compressor motor rotation (CCW or CW rotation facing compressor shaft). This can be done by using the “Diagnostic Force Outputs” from Main Menu.
Section 4 • Operation Operation All operation (setpoint adjustments, calibrations, monitoring) of the compressor unit is done through the Compact Logix PLC. For additional procedural information, refer to Compact Logix PLC Software Manual (35391CL). separator, see Figure 4-1. Oil Operating Levels. Drain or fill oil as required. For oil draining and filling procedures, refer to Section 5. Dual Oil Filters On compressor units equipped with dual oil filters, only one filter should be in operation at a time.
Section 4 • Operation Control System Calibration Equipped for automatic operation, the screw compressor unit has safety controls to protect it from irregular operating conditions, an automatic starting and stopping sequence, capacity and volume ratio control systems. Check all pressure controls with a remote pressure source, to assure that all safety and operating control limits operate at the point indicated on the microprocessor.
Section 4 • Operation View Rotate 180° Actuator Assembly Actuator Plastic Cover Red LED Blue Calibrate Button Figure 4-2. Actuator Assembly • There is an error code flashing on the actuator’s circuit board - an attempt to recalibrate should be made. • The range of travel is not correct and the command shaft travel is physically correct. • The compressor is pulling high amperage, the calibration of the volume slide should be checked.
Section 4 • Operation Figure 4-3.
Section 4 • Operation Figure 4-4. Slide Calibration Screen (Compact Logix PLC) Screen colors inverted for ease of reading. NOTE If the UP (increase) and DOWN (decrease) buttons do not correspond to increase (INC) or decrease (DEC) shaft rotation, swap the blue and brown wires of the “power cable” in the control panel. This will reverse the rotation of the actuator/command shaft. 8. Press UP or DOWN to move the slide valve and check for the correct rotation, see Table 4-1.
Section 4 • Operation Table 4-1. Command Shaft Rotation Specifications* Command Shaft Rotation Capacity Compressor Model No. of Turns/Rotation Angle/Slide Travel Capacity Volume Volume INC DEC INC DEC Turns Degrees Travel Turns Degrees Travel CW CCW CW CCW 0.91 328 3.568” 0.52 187 2.045” CW CCW CW CCW 0.80 288 3.141” 0.45 162 1.767” CCW CW CCW CW 0.91 328 3.568” 0.52 187 2.045” CCW CW CCW CW 1.09 392 4.283” 0.63 227 2.473” CCW CW CCW CW 1.
Section 4 • Operation CAUTION DO NOT CONTINUE TO ENERGIZE THE ACTUATOR MOTOR AFTER THE SLIDE HAS REACHED THE MECHANICAL STOP. Doing so may cause mechanical damage to the motor or shear the motor shaft key. When the slide has reached the mechanical stop position, press the button in the center of the photochopper to release the brake, and thereby release the tension on the actuator motor.
Section 4 • Operation Oil Temperature Control Valve (Oil Mixing Valve) Operation FAIL POSITION INITIAL POSITION SCREEN DISPLAY The temperature control valve is in the closed position when initially installed. • The oil temperature control valve, identified as “OIL MIX” on the main PLC 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.
Section 4 • Operation Purging with Dry Nitrogen the compressor and oil separator. 5. Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3. PREPARATION WARNING When working with LFG, NG or other dangerous or flammable gases, ensure there are adequate ventilation and vapor detectors. Refer to national fire and building codes.
Section 4 • Operation NOTE Purging is performed through the suction oil charging valve so that trapped gas can be pushed out of the compressor. This will help minimize metal surface oxidation of the compressor (due to the gas) while not in service. 9. Purge compressor unit for 10 minutes. Check discharge pressure on PLC main screen to make sure pressure is increasing. 10. Close discharge bleed valve while still purging. 11. Observe discharge pressure through the PLC main screen.
Section 4 • Operation NOTICE Purging with Dry Gas Purging is recommended if the compressor will be inactive for 12 hours or more. For additional long term storage information, refer to Long Term Storage Recommendations in Section 3. To purge the compressor unit using a dry gas (i.e. methane), a purge line must be installed. If there is not enough purge pressure, connect purge line to a lower pressure line or to atmosphere.
Section 4 • Operation NOTE NOTE Plugs are installed on bleed valves. Remove and install plugs prior to and after bleeding. Ensure to keep valves closed when removing and installing plugs. Purging is performed through the suction oil charging valve so that trapped gas can be pushed out of the compressor. This will help minimize metal surface oxidation of the compressor (due to the gas) while not in service. 6. 7. 8.
Section 4 • Operation Equalizing Solenoid for Suction Bypass Figure 4-12. Equalizing Solenoid Suction Oil Charging Valve View Rotate 90° Figure 4-13.
Section 4 • Operation Coalescing Oil Return Line Setup 3. Over time, oil will accumulate on the coalescing side of the oil separator. As a result, an oil return line with a shut-off valve, sight-glass, check valve and needle valve are installed between the coalescing side and compressor to return this oil back to the compressor. To adjust the return flow, proceed with the follow procedure: Slowly open needle valve more until a small amount of oil is seen in the sight-glass.
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391STG 200 40,000 30,000 25,000 20,000 10,000 5,000 2,500 I - I - I - I I I - I - I - I R I R I I I - I - I - I - I - I I I R I R I - I - I - I I I - I - I I I I I I I I I I I I I I I I I I I I I - I R I R I I I I I - I - I I I - I - I - - Bearings - I - - - I - - - I - - - I - - - I - - - I - - Slide valve cali
Section 5 • Maintenance/Service Maintaining Proper Operation To ensure proper operation, the following items should be checked: • Calibrate all transducer and RTDs. • Check capacity and volume actuator calibration. • Check fuses in the PLC panel. • Check for loose wiring connections in the PLC panel. • Check relay and contact operation for relays in the PLC panel. • Verify the operation of the suction and discharge check valves.
Section 5 • Maintenance/Service Compressor Unit Leak Check 2. If equipped with equalizing solenoid to control suction by-pass, allow solenoid to remain open until pressures equalize, see Figure 5-1 (2 of 2). 3. Turn motor and oil pump starter disconnect switches into the OFF position. Lockout/tagout disconnect switches. The compressor unit must be checked for leaks after servicing to ensure a tight system. For additional leak testing information, refer to Chapter VI of ASME B31.3 Process Piping Code.
Section 5 • Maintenance/Service Oil System Components NOTE A copy of the oil analysis report is also sent to Vilter. See Appendices for a sample of the oil analysis report. Oil Sampling An oil analysis report will show the physical properties of the oil, such as: WARNING When working with LFG, NG or other dangerous or flammable gases, ensure there are adequate ventilation and vapor detectors. Refer to national fire and building codes. Failure to comply may result in serious injury or death.
Section 5 • Maintenance/Service Oil Charging WARNING Avoid skin contact with oil. Wear rubber gloves and a face shield when working with oil. Failure to comply may result in serious injury or death. CAUTION Do not add oil to the coalescent side of the oil separator. Failure to comply may result in damage to equipment. Normal oil level operating range must be maintained for optimum performance and to prevent damage to equipment. See Figure 4-1. for normal operating levels.
Section 5 • Maintenance/Service Oil Draining NOTE Ensure to check the oil pressure drop and record it daily. WARNING Do not drain oil from drain valve while the compressor unit is running. Shutdown the unit and allow pressures to equalize to suction pressure prior to draining. Failure to comply may result in serious injury. If the compressor unit is equipped with only a single oil filter, the compressor unit must be shut down prior to servicing, see Stopping/Restarting procedure in Section 4.
Section 5 • Maintenance/Service Vent Valve Outlet Shut-Off Valves Drain Valve Vent Valve Drain Valve Inlet Shut-Off Valves Figure 5-5. Oil Filter Drain, Vent and Shut-Off Valves 1. If equipped with dual oil filters, open inlet shut-off valve for non-operating oil filter to put it into operation, see Figure 5-5. 2. To isolate oil filter for servicing, close inlet and outlet shut-off valves for the oil filter. centering piece, if damaged, replace as required.
Section 5 • Maintenance/Service Oil Separator Vessel Oil Separator Manhole Cover Pipe Stub Coalescing Filter Hold-Down Rod Centering Strap Flat Washer 3/4 in. O.D. Tubing, 6 ft. long Flat Washer Nuts Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly Coalescing Filter Replacement WARNING Use appropriate lifting devices and additional personnel when lifting heavy components. Ensure lifting devices are capable of lifting the weight of the component. Use lifting points (i.e.
Section 5 • Maintenance/Service coalescing filter over tubing and through hole of centering strap. WARNING 13. Remove tubing. Avoid skin contact with any condensate or oil. Wear rubber gloves and a face shield when working with condensate or oil. Failure to comply may result in serious injury or death. 14. Position cover plate and flat washer on hold-down rod on end of the coalescing filter. 1. 15. Install nut to secure flat washer and cover plate to coalescing filter. Tighten nut to 25 ft-lbs.
Section 5 • Maintenance/Service Drive Coupling (Form-Flex BPU) Hub Installation with a small clearance over the top. NOTE If hub position on shaft does not allow enough room to install bolts, install bolts and disc pack before mounting hub on shaft. On all single screw units, the coupling assembly is shipped loose and will have to be installed and aligned on site. This is to allow a check of proper electrical phasing and direction of motor rotation.
Section 5 • Maintenance/Service 16. If locking tab is being used, bend locking tabs in gap towards shaft and around bolt. operating conditions. This means there is a minimal amount of waviness in the flex disc pack when viewed from the side. This will result in a flex disc pack that is centered and parallel to its mating flange faces. Move the motor to obtain the correct axial spacing, see Table 5-3 and Figure 5-8. 17. Install set screw in hub cap to secure key in keyway of shaft.
Section 5 • Maintenance/Service Angular Alignment Parallel Offset Figure 5-9. Angular Alignment and Parallel Offset 30. Tighten locking nuts, see Table 5-4. 24. Tighten locking nuts. 25. If room is required to install center member, adjust hub position accordingly. If both the motor and compressor hubs are straight bores, adjust either hubs. If one hub is tapered and the other a straight, adjust the straight bore hub. Table 5-5.
Section 5 • Maintenance/Service alignments. Loosen motor mounting nuts to add shims or to adjust alignments as required. 33. Install coupling guard. Drive Coupling (Form-Flex BPU) Center Member and Hub Removal Drive Coupling (Type C Sure-Flex) Replacement Drive couplings that are the Type C Sure-Flex type, are always installed with a C-flange between the compressor and motor. The coupling assembly alignments are built into the design and therefore, should not require alignment.
Section 5 • Maintenance/Service compressor shaft. 12. Remove hub and key from compressor shaft. INSTALLATION 13. Install key and hub on compressor shaft as noted during removal. 14. Install set screw in compressor hub to secure key in keyway, see Table 5-6, 15. Install clamping bolts to secure hub on compressor shaft. Tighten clamping bolts, see Table 5-6, 16. Install key and hub on motor shaft as noted during removal. Allow gap to install coupling sleeve. 17. Install coupling sleeve on hubs.
Section 5 • Maintenance/Service WARNING Compressor Replacement Notify Vilter prior to performing a compressor replacement. See Warranty instructions in Section 7. REMOVAL To replace a compressor on a unit, proceed with the following steps: NOTICE Dispose of the oil in a appropriate manner following all Local, State and Federal ordinances regarding the disposal of used oil. 1. Shut down and isolate the compressor unit, see Compressor Unit Isolation for Maintenance and Service procedure.
Section 5 • Maintenance/Service 31. Install nuts to secure suction strainer/check valve assembly to compressor and suction stop valve. 32. Tighten nuts on ‘suction strainer/check valve assembly-to-compressor’ first, then tighten nuts on ‘suction strainer/check valve assembly-to-suction stop valve’, refer to Appendix A. 33. Install all lines to compressor. 34. Install all cables to sensors on compressor and actuator. 35. Perform leak check, see Compressor Unit Leak Check procedure.
Section 5 • Maintenance/Service Bare Shaft Compressor Lifting Points and Weights Table 5-7.
Section 5 • Maintenance/Service Bare Shaft Compressor Center of Gravity (Models 291-2101) Main Lift Point Lifting Eyes Center of Gravity Center of Gravity Range Model 1551-2101 Shown Figure 5-12. Bare Shaft Compressor Assembly Center of Gravity (Models 291-2101) Center of gravity may differ slightly between models 291-2101. Adjust main lift point within the range to keep bare shaft compressor as leveled as possible when lifting.
Section 5 • Maintenance/Service Bare Shaft Compressor Center of Gravity (Models 2401-3001) Main Lift Point Lifting Eyes Center of Gravity Figure 5-14. Bare Shaft Compressor Assembly Center of Gravity (Models 2401-3001) Main Lift Point Lifting Eyes Center of Gravity Discharge Manifold Main Compressor Assembly Figure 5-15.
Section 5 • Maintenance/Service Compressor Shaft Bearing Float Inspections motor and use the lever arm to push the input shaft towards the compressor. Record measurement 5. If float measurements are out of tolerance, contact Vilter Customer Service for further assistance. BEARING AXIAL FLOAT INSPECTION Add both measurements. If measurement is out of allowable tolerance shown in Table 5-9, the bearing may need to be replaced. Contact Vilter Customer Service. BEARING RADIAL FLOAT INSPECTION CAUTION 6.
Section 5 • Maintenance/Service Table 5-9. Maximum Bearing Float Compressor Model Max. Axial Float Max. Radial Float Max. Force at Hub/ Shaft Max. Applied Force (36” Lever, 6” Pivot) in. (mm) in. (mm) 0.002 (0.051) - 300 (1335) 60 (267) 151, 181, 201, 152, 182, 202, 301, 361, 401 0.006 (0.152) 100 (444) 20 (89) 501, 601, 701 0.007 (0.178) 150 (667) 30 (133) 291, 341, 451, 601 0.007 (0.178) 150 (667) 30 (133) 751, 901 0.006 (0.152) 200 (890) 40 (178) 791, 891, 1051, 1201, 1301 0.
Section 5 • Maintenance/Service GATE ROTOR BEARING FLOAT INSPECTION NOTE Measurements can be an additional 0.020” higher than float dimensions on Table 5-10. If measurement is an additional 0.030” greater than float dimensions, contact Vilter for further assistance. 6. Side View Total movement of damper pin in bushing is the gate rotor float. 4. Using dial indicator, position a dial indicator on the gate rotor, see Figure 5-19. Gate rotor bearing float being measured.
Section 5 • Maintenance/Service Gate Rotor and Support Clearance When measuring, push the gate rotor against the pin to remove float. 1. Place a straight edge along the side of the gate rotor, see Figure 5-21. 2. Measure the gap from the straight edge to the peak of the gate rotor support. For minimum distance, see Figure 5-20. 3. Repeat steps 1 to 2 to check gap along entire gate rotor edge on both sides. Figure 5-20.
Section 5 • Maintenance/Service Gate Rotor Support Straight Edge Gate Rotor Gate Rotor Support Straight Edge Gate Rotor Gate Rotor Support Straight Edge Gate Rotor Figure 5-21.
Section 5 • Maintenance/Service Gate Rotor Assembly Replacement (All VSG & VSSG Compressors Except VSG 301-701 Compressors) The following table lists the gate rotor tool sets needed to remove and install gate rotor assemblies. Table 5-11. Gate Rotor Tool Sets Model Tool Set VPN VSSG 291-601 A25205B VSG 301-401 N/A VSG 501-701 A25205B VSG 751-1301 A2520 5C VSG 1551-2101 A25205E VSG 2401-3001 A25205F REMOVAL 1. Remove center member, see appropriate Drive Coupling Replacement procedure.
Section 5 • Maintenance/Service NOTE This measurement determines the amount of shims needed for the correct clearance. 21. Measure depth from top of compressor case to top of thrust bearing housing. 22. Use factory installed shim pack (106) and bearing housing cover (116) without the O-ring (143). NOTE Replacement blades are precisely the same dimensionally as blades installed originally at factory: Therefore, the same amount of shims will be required for replacement blades.
Section 5 • Maintenance/Service 23. 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“ (0.076-0.102 mm). Make adjustments, if necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf, see Figure 5-25. 24. 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. 25.
Section 5 • Maintenance/Service Gate Rotor Assembly Replacement (VSG 301-701 Compressors ONLY) REMOVAL The removal of the gate rotor assembly for the VSG 301701 compressors is similar for the VSG 901- 2101 compressors except that the inner races are secured to the stationary bearing spindle. 1. Remove center member, see appropriate Drive Coupling Replacement procedure. 2. Remove the upper bolt from the side cover and install a guide stud in the hole. 3. Remove remaining bolts and side cover.
Section 5 • Maintenance/Service necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf. 14. 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, see Appendix A. 15. Install side covers with new gaskets. Tighten bolts, see Appendix A. The unit can now be evacuated and leak checked. Check for 0.003-0.004” (0.076- 0.
Section 5 • Maintenance/Service Gate Rotor Disassembly 1. GATE ROTOR BLADE REMOVAL To perform gate rotor disassembly, remove gate rotor from compressor, see Gate Rotor Assembly Replacement procedure (All VSG-VSSG Compressors Except VSG 301-701 Compressors) or Gate Rotor Assembly procedure (VSG 301-701 Compressors ONLY). 2. Remove the snap ring and washer from the gate rotor assembly. Lift gate rotor blade assembly off the gate rotor support, see Figure 5-29. 3.
Section 5 • Maintenance/Service GATE ROTOR THRUST BEARING REMOVAL For removal of thrust bearings on VSG units: 7. Remove bolts (150) from the clamping ring (114), see Figure 5-31. 8. Remove thrust bearing clamping ring. 9. Remove thrust bearings (126) from housing (113). sides of the inner races are placed together. A light application of clean compressor lubricating oil should be used to ease the installation of the bearings into the gate rotor support. 17. Install the bearing retaining snap ring.
Section 5 • Maintenance/Service The bevel on the snap ring must face away from the roller bearing. Restarting procedure in Section 4. 2. Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped. 3. Allow compressor, motor and surrounding components to cool prior to servicing. 4. Disconnect connectors from actuator. NOTE Note orientation of components to aid in installation. 5.
Section 5 • Maintenance/Service Command Shaft Assembly Replacement cover. 5. Seal with stationary carbon face (219B) and rotating mirror face (219C). REMOVAL NOTE The following steps can be used to remove or install either the capacity or volume command shaft assemblies. 1. Shut down and isolate compressor unit, see Compressor Unit Shutdown and Isolation procedure. 2. Remove actuator, see Replacement procedure. 3.
Section 5 • Maintenance/Service 7. Wipe clean, the compressor input shaft and the shaft seal cavity in the compressor housing. Apply clean compressor oil to the shaft seal seating area on input shaft. 8. Lubricate the inside area of the rotating seal with clean compressor lubricating oil, do not wipe or touch the face of the rotating portion of the seal. Align the slot in the rotating seal with the drive pin on the compressor input shaft, see Figure 5-35.
Section 6 • Troubleshooting Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 2) Problem Reason Solution Dirt or debris is blocking one or both Clean the optocoupler slots with a optocoupler slots Q-Tip and rubbing alcohol.
Section 6 • Troubleshooting Table 6-1. Slide Valve Actuator Troubleshooting Guide (2 of 2) Problem Reason The actuator does not transmit the correct position after a power loss There is a rapid clicking noise when the motor is operating The motor operates in one direction only The motor was manually moved while the position sensor was not powered. Recalibrate. The motor brake is not working properly Get the motor brake to where it operates freely and then recalibrate.
Section 6 • Troubleshooting 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. Table 6-2. Slide Valve Actuator LED Blink Codes* (1 of 2) Flash Pattern Meaning *=ON _=OFF *_*_*_*_*_*_*_*_*_*_*_ *___*___*___*___*___ Calibration step 1 Calibration step 2 This indicates a zero span. This error can only occur during calibration.
Section 6 • Troubleshooting Table 6-2. Slide Valve Actuator LED Blink Codes (2 of 2) Flash Pattern Meaning The motor has overheated. The actuator motor will not run until it cools. Once the motor cools, the actuator will resume normal operation. *__*__*____________ Motor overheating is sometimes a problem in hot and humid environments when process conditions demand that the slide valve reposition often. Solutions are available; consult your Vilter authorized distributor for details.
Section 6 • Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3) Problem Solution • After failing to start compressor with “Prelube Oil Pump Inhibit”, first allow Discharge pressure, Oil Filter In pressure and Out pressure to equalize. Then restart compressor. If compressor fails to start due to low oil pressure, continue troubleshooting with items below. • Reset Prelube Oil Pressure Setpoint in Alarms and Trip Setpoints screen to lowest recommended setpoints.
Section 6 • Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions (2 of 3) Problem Solution • Oil return line from coalescing side of oil separator to suction is closed, not open enough (.
Section 6 • Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions (3 of 3) Problem High Amp Draw Solution • Check Main Motor Amps scaling and PLC. • Check that unit is leveled and secured to mounting pad or floor. Vibration • Check supported pipes (i.e. suction and discharge pipe) and make sure they are adequately supported. • Check for loose bolts and nuts. • Check condition of compressor and motor (i.e.
6 – 8 / Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391STG
Section 7 • Warranty and Parts Warranty Claim Processing This section explains how the warranty claim is processed and to help clear any questions that may arise prior to contacting customer service. For additional warranty information, refer to the VSG/VSSG Standard Vilter Warranty Statement on page i. Vilter contact information can be found on page ii. 1. The warranty process starts with contacting a Vilter Service and Warranty (S&W) department representative.
Section 7 • Warranty and Parts Remanufactured Gas Bare Shaft Compressor Process These instructions are an overview of how the process works when a bare shaft compressor is in need of being remanufactured. This is to help clear any questions that may arise prior to contacting customer service. The process begins by contacting Vilter’s Customer Service Department. Vilter contact information can be found on page ii. • Request a “VSG Single Screw Compressor Rebuild Form”.
Appendix A • Torque Specifications Torque Specifications (ft-lbs) Type Bolt Head Markings SAE Grade 2 Coarse (UNC) SAE Grade 5 Coarse (UNC) SAE Grade 5 Coarse (UNC) SAE Grade 8 Coarse (UNF) Nominal Size Numbers or Inches #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 - 5 10 18 29 44 63 87 155 150* - 8 16 28 44 68 98 135 240 387 - - 18 - - - - - - - - 11 22 39 63 96 138 191 338 546 5 13 26 46 73 112 115 215 380 614 Socket Head Cap Screw (ASTM A574) C
Appendix B • Oil Analysis Report PRODUCT ANALYSIS REPORT No Action Required Customer Name Customer Address Report Date: 3/4/2013 Report Number: ********* Customer Customer Comp. Mfr. Vilter Oil Type VILTER METHANE 100 Serial Number ****-*** Model Number VSG-1801 Hrs. on Fluid 6049 Hrs. on Machine 11239 Sample Date Feb 21, 2013 Receive Date Mar 01, 2013 I.D. # ********* Evaluation: The fluid is in good condition. Sample again in 6 months.
Appendix C • Recommended Header Piping VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391STG C
D INLET ON BOTTOM Recommended location of drain connections as required. • Vertical drops should be no higher than 8 to 10 feet. • If there is no choice and the vertical drops need to be higher, then an electronic service valve needs to be installed in the return line at the compressor. Consult Factory. • If ambient temperatures get below 50° F, heat trace and insulation on oil lines and air cooler headers needs to be used.
35391STG Rev. 0 (8/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its affiliated companies. © 2013 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.
