Page 3 - rmed to be such in; VSG/VSSG Standard Vilter Warranty Statement
i VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Seller warrants all new single screw gas compression units and bareshaft single screw compressorsmanufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a periodof (a) eig...
Page 4 - ii; READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.; Customer Service Department; Important Message
ii VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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 in...
Page 5 - Motor; Table of Contents; Section Title
TOC - 1 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG VSG/VSSG Standard Vilter Warranty Statement ..................................................................................... iImportant Message..............................................................
Page 6 - Section 4 • Operation; Override; Section 5 • Maintenance/Service
TOC - 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 4 • Operation Oil Inspection ........................................................................................................................................ 4-1Dual Oil Filters.................
Page 7 - List of Tables and Figures; Appendix A
TOC - 3 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Tables Table 3-1. Long Term Storage Compressor Hardware ............................................................................. 3-2Table 3-2. Maximum Allowable Flange Loads ...............................
Page 8 - Table/Figure Section
TOC - 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Figure 3-12. Installation of Coolers - Next to Buildling ............................................................................ 3-13Figure 3-13. Discharge Elevation of Coolers ............................
Page 9 - How To Use This Manual; Figures and tables are included to illustrate key concepts.; Section 1 • General Information
1 – 1 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG How To Use This Manual This manual contains instructions for gas compressor units. It has been divided into eight sections: Section 1: General InformationSection 2: Theory of OperationSection 3: InstallationSe...
Page 10 - Gas Compressor Unit Model Designations; Figure 1-1. Gas Compressor Unit Model Designation
1 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 1. Compressor Model VSG = Vilter Single Screw CompressorVSSG = Vilter Single Screw Compressor (Compressor models 291, 341, 451 & 601 - these are 240mm diameter rotors with counter clockwise rotation) VRSG ...
Page 11 - To keep de
1 – 3 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG System Unit Identi fi cation To keep de fi nitions of units simple and consistent, Vilter has de fi ned the following three: • Bare Shaft Compressor• Compressor Unit• Package Unit Bare Shaft CompressorA bare s...
Page 12 - Compressor Unit Component Identi
1 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 1 - Motor2 - Coupling3 - Suction Strainer4 - Suction Check Valve5a - Suction Stop Valve5b - Suction Stop Butter fl y Valve (Typically Shipped Loose) 6 - Compressor7 - Discharge Pipe8 - PLC Panel 9 - Block &...
Page 14 - OUTLET
1 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 24 - RTD (Oil Filter Outlet) 25 - Pressure Transducer (Oil Injection Temperature) 26 - Volume Slide Valve Actuator27 - RTD (Discharge) 28 - RTD (Suction)29 - Capacity Slide Valve Actuator30 - Pressure Transduc...
Page 15 - cation Component Tags; fl
1 – 7 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Piping & Identi fi cation Component Tags Use this list to identify components shown in the Piping & Identi fi cation Diagram. A AtmosphereAN Anode - Sacri fi cial AV Angle Valve BFV Butter fl y Valve B...
Page 19 - Section 2 • Theory of Operation; Gas Flow; Oil Life and Oil Flow
2 – 1 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 2 • Theory of Operation The gas and oil systems work in unison, but each one will be explained separately. Reference Figure 3 - Gas Compressor Unit P&ID for gas and oil fl ow descriptions. Gas Flow...
Page 20 - Control System; c locations on the gas compressor
2 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG suction. The discharge temperature of the compressor must be kept a minimum of 30°F (or 17°C) above the dis-charge gas dew point to prevent the condensing of liq-uids in the oil separator. The oil separator sh...
Page 21 - Delivery Inspection; WARNING; ed personnel and additional personnel and; Section 3 • Installation
3 – 1 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Only quali fi ed personnel shall operate rigging and lift- ing equipment. Ensure that the lifting device is capable of lifting the weight of the compressor unit, refer to the supplied Vilter General Assembly (...
Page 22 - Long Term Storage Recommendations
3 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG COMPRESSOR MOTOR The following are general recommendations. Refer to speci fi c motor manufacturer instructions for storage recommendations.• Remove the condensation drain plugs from those units equipped with ...
Page 23 - Recommended Onsite Tools; AIR COOLED OIL COOLERS
3 – 3 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Compressor Unit Inspections Prior to Storage or Installation The compressor unit must be inspected prior to instal-lation since components could have come loose and/or damaged during shipment or moving.• Check...
Page 24 - LONG TERM STORAGE LOG; Vilter Order No; Compressor has been placed in operation as of:
3 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 3 • Installation LONG TERM STORAGE LOG Date: _______________________________ Name: _______________________________ Intial:_______________ Company: Vilter Order No . ____________________________________...
Page 25 - NOTE; Foundation Materials; Building the Foundation
3 – 5 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 3 • Installation Foundation Vilter Single Screw compressor units are low vibra-tion machines. Under most conditions, no elaborate foundation is necessary. However a sound foundation maintains motor ali...
Page 26 - Compressor Unit Installation
3 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG of both • Check the ability of the soil to carry the load• Check wet season and dry season soil characteristics for static loading limits and elasticity • Check local codes for Seismic Design requirements For ...
Page 27 - BUILDING; Leveling and Grouting; cient amount of grout. The grout
3 – 7 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG CENTER LINE OF GAS COMPRESSION SYSTEM 6" # 6 @ 12" EACH WAY TOP & BOTTOM COMPRESSOR UNIT G.A. G.A. EL. TOP OF GRADE EXCAVATE TO FROST DEPTH AS REQ'D AND BACKFILL WITH CLSM OR NON-FROST SUSCEPTIBLE ...
Page 28 - Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View
3 – 8 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Additional Information Codes and StandardsVilter followed the following codes and standards when designing your foundation: • ACI • ASTM• ASCE 7• IBC 2006 Operation and PerformanceThe foundation was designed f...
Page 29 - LEVEL; COMPRESSOR UNIT
3 – 9 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers Section 3 • Installation SPHERICAL WASHERS LEVEL Figure 3-6. Housekeeping Pad Dimension Detail - Top View 5/8" DIA. HILTI HAS SS THR...
Page 30 - Figure 3-8. Concrete Pad Housekeeping Detail; The ideal load applied to; CAUTION; Remote Air Cooled Oil Cooler Piping
3 – 10 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 010Ä5*4+0- '21:;)4176 4'%1//'0&'& (14 *175'-''2+0) %10%4'6' $#5' 70+6.') *1.&&190076 9#5*'4 .'8'.+0)076 #0%*14$1.6 /+0 Figure 3-8. Concrete Pad Housekeeping Detail Section 3 • Installation Pip...
Page 31 - Figure 3-9. Maximum Allowable Flange Loads; Table 3-2. Maximum Allowable Flange Loads
3 – 11 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Figure 3-9. Maximum Allowable Flange Loads DISCHARGE LINE 5 PIPE DIAMETERS CUSTOMER SUPPORT 3-4 PIPE DIAMETERS SUCTION LINE X Z Z Y X Y CUSTOMER SUPPORT HANGER CHECK VALVE CUSTOMER SUPPORTS WHEN CHECK VALVE I...
Page 33 - NOT PREFERRED
3 – 13 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 3 • Installation The equation used to calculate the leg height in Figure 3-11 is as follows: Leg Height = (Total Air fl ow/Intake velocity)/Intake Perimeter Leg Height = (247,000CFM/500FPM)/82ft Leg H...
Page 35 - Figure 3-13. Discharge Elevation of Coolers
3 – 15 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Figure 3-13. Discharge Elevation of Coolers Section 3 • Installation NOT PREFERRED PREFERRED Figure 3-14. Cooler Placement and Spacing PREFERRED NOT PREFERRED
Page 37 - Normal Operating Level
3 – 17 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 3 • Installation Figure 3-15. Oil Operating Levels Normal Operating Level Maximum NON-Operating Level Minimum Operating Level Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Fi...
Page 40 - may result in serious injury or death.; NOTICE; any and all warranties that may apply.
3 – 20 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG OIL PT 004 FG 001 TE 001 PT 001 BLEED BLEED DRAIN PT 002 BLEED TE 004 QE 101 QE 102 QE 103 TE 005 1000W 1000W 1000W LG 001 LG 002 OIL CHARGE TE 002 DRAIN VENT TE 003 QE 007 TE 007 COMPRESSOR MOTOR REMOTE OIL ...
Page 42 - so will “Null & Void” future warranty considerations.; Pre Start-Up Checklist
3 – 22 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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 ...
Page 45 - Dual Oil Filters
4 – 1 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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 Comp...
Page 46 - Calibrate Slide Valve Actuators; Do not calibrate in direct sunlight. Failure to comply
4 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 4 • Operation Control System Calibration Equipped for automatic operation, the screw compres-sor unit has safety controls to protect it from irregular operating conditions, an automatic starting and st...
Page 49 - release the tension on the actuator motor.
4 – 5 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 8. Quickly press and release the blue push button on the actuator one time. This places the actuator in calibration mode. The red LED will begin fl ashing rapidly. CAUTION DO NOT CONTINUE TO ENERGIZE THE ACTUA...
Page 53 - Purging with Dry Nitrogen
4 – 9 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Purging with Dry Nitrogen 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. ...
Page 55 - associated valves and gauges are not provided from the
4 – 11 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG NOTICE To purge the compressor unit using a dry gas (i.e.methane), a purge line must be installed. If there isnot enough purge pressure, connect purge line to alower pressure line or to atmosphere. The purge ...
Page 56 - Do not purge compressor unit with oxygen. Failure to; comply may result in damage to equipment.
4 – 12 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Figure 4-11. PLC Main Screen Section 4 • Operation Stop Button DischargeStatus 9. Connect purging hose from gas cylinder to suction oil charging valve. NOTE Purging is performed through the suction oil chargi...
Page 57 - Equalizing Solenoid
4 – 13 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Suction Oil Charging Valve View Rotate 180° Figure 4-13. Suction Oil Charging Valve Section 4 • Operation Equalizing Solenoid for Suction Bypass Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Sucti...
Page 60 - Maintaining Proper Operation; • Verify the operation of the suction and discharge; Restarting procedure in Section 4.
5 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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 pan...
Page 61 - Do not hydro test compressur unit. Failure to comply
5 – 3 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 2. If equipped with equalizing solenoid to control suc- tion 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 switch- es i...
Page 64 - Failure to comply may result in serious injury.; Oil Filter Replacement
5 – 6 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 5 • Maintenance/Service Figure 5-4. Oil Filter Assemblies (Single and Dual) Cover Flange Spring Plate Element Canister Spring Plate Elements Single Oil Filter Assembly Dual Oil Filter Assembly Outlet I...
Page 66 - serious injury or death.
5 – 8 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 5 • Maintenance/Service Coalescing Filter Replacement WARNING Use appropriate lifting devices and additionalpersonnel when lifting heavy components. Ensurelifting devices are capable of lifting the wei...
Page 70 - Table 5-5. Disc Pack Installation Torque; Angular Alignment
5 – 12 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 5 • Maintenance/Service the disc pack. 24. Install bolts and locking nuts to secure both disc packs to center member. 25. Tighten locking nuts.26. If room is required to install center member, adjust ...
Page 74 - Figure 5-11. Bearing Axial Float Inspection; Applied Force
5 – 16 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG motor and use the lever arm to push the input shaft towards the compressor. Record measurement 5. Add both measurements. If measurement is out of allowable tolerance shown in Table 5-7, the bearing may need t...
Page 75 - Compressor; Figure 5-12. Bearing Radial Float Inspection
5 – 17 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Gate Rotor Float and Gate Rotor Bearing Float Inspection GATE ROTOR FLOAT INSPECTION To inspect gate rotor fl oat and bearing fl oat, proceed with the following steps:1. Remove center member, see appropriate ...
Page 77 - Gate Rotor and Support Clearance; Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances
5 – 19 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Gate Rotor and Support Clearance When measuring, push the gate rotor against the pin to remove fl oat. 1. Place a straight edge along the side of the gate ro- tor, see Figure 5-16. 2. Measure the gap from the...
Page 80 - Figure 5-17. Gate Rotor Assembly Removal
5 – 22 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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)...
Page 81 - Figure 5-19. Gate Rotor Assembly and Tools; Check the clearance between the entire gate rotor
5 – 23 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 5 • Maintenance/Service Figure 5-19. Gate Rotor Assembly and Tools Figure 5-20. Gate Rotor and Shelf Clearance Check for 0.003-0.004” (0.076- 0.102 mm) clearance between gate rotor blade and partition...
Page 82 - Figure 5-21. Gate Rotor Assembly Breakdown; REMOVAL
5 – 24 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG bearing end of the gate rotor support towards the suction end of the compressor. The compressor input shaft may have to be rotated to facilitate the installation of the gate rotor support. 11. Install the rol...
Page 83 - Once the clearance is set remove the spindle. Install; Figure 5-23. Gate Rotor and Shelf Clearance
5 – 25 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 5 • Maintenance/Service Figure 5-22. Gate Rotor Thrust Bearing necessary. It is preferable to shim the gate rotor blade looser rather than tighter against the shelf. 14. Once the clearance is set remo...
Page 84 - Figure 5-25. Gate Rotor Blade Installation; Gate Rotor Disassembly; To perform gate rotor disassembly, remove
5 – 26 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG GATE ROTOR BLADE REMOVAL 2. Remove the snap ring and washer from the gate ro- tor assembly. Lift gate rotor blade assembly off the gate rotor support, see Figure 5-24. 3. Check damper pin and bushing for exce...
Page 87 - Command Shaft Seal Replacement
5 – 29 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Command Shaft Assembly Replacement 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 Compr...
Page 88 - Lubricate the inside area of the rotating seal with; Figure 5-30. Command Shaft Seal Installation
5 – 30 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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, ...
Page 91 - Calibration step 1; Section 6 • Troubleshooting
6 – 3 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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. Fla...
Page 92 - The EEPROM memory in the micro-controller is bad.
6 – 4 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG *There are two versions of slide valve actuators, version A and B. Only version B is able to display LED blink codes. Slide valve actuator version B can be distinguished by only having a single circuit board a...
Page 97 - Ensure to have the original Vilter sales order; On Site Service Support; Warranty does not cover labor and extraneous expenses.
7 – 1 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Section 7 • Warranty and Parts Warranty Claim Processing This section explains how the warranty claim is pro-cessed and to help clear any questions that may arise prior to contacting customer service. For addi...
Page 98 - Section 7 • Warranty and Parts
7 – 2 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 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...
Page 99 - Appendix A • Torque Specifications
A VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Torque Specifications (ft-lbs) Type Bolt Head Markings Nominal Size Numbers or Inches #10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 SAE Grade 2 Coarse (UNC) - 5 10 18 29 44 63 87 155 150* SAE Grade 5 Coarse (UNC) - 8...
Page 100 - Appendix B • Motor (Compressor) - General Storage Instructions
B VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Short Term Storage If the equipment is not put into immediate use it should be stored in a clean, dry location. For all Weather Protected Type II (WPII) motors, motor heaters should be activated upon arriving at t...
Page 101 - Appendix C • Oil Analysis Report; PRODUCT ANALYSIS REPORT; No Action Required
C VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Appendix C • Oil Analysis Report I.D. # ********* Customer Name Comp. Mfr. Vilter Serial Number ****-*** Model Number VSM-601 Hrs. on Fluid 6049 Hrs. on Machine 11239 Sample Date Feb 21, 2013 Water by Karl Fischer...
Page 102 - Appendix D • Recommended Header Piping
D VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Appendix D • Recommended Header Piping
Page 103 - Appendix E • Recommended Remote Air Cooled Oil Cooler Piping
E VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG Appendix E • Recommended Remote Air Cooled Oil Cooler Piping OUTLE T ON T O P INLE T ON BO TT OM • Ve rtical drop s should be no highe r th an 8 t o 10 f ee t. • If the re is no c hoic e and the v er tical drop s ...
Page 104 - Blank
Blank VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG