Vilter VSG VSSG Compressor Unit Manual Units Built Before July 1 2013 en Us 1574674
Vilter VSG VSSG Compressor Unit Manual Units Built Before July 1 2013 en Us 1574674
Vilter VSG VSSG Compressor Unit Manual Units Built Before July 1 2013 en Us 1574674
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.
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 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 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 MERCHANTABILITY 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.
The following instructions have been prepared to assist in installation, operation and removal of Vilter Single Screw
Compressors. Following these instructions will result in a long life of the compressor with satisfactory operation.
The entire manual should be reviewed before attempting to install, operate, service or repair the compressor.
A compressor is a positive displacement machine. It is designed to compress gas. The compressor must
not be subjected to liquid carry over. Care must be exercised in properly designing and maintaining the
system to prevent conditions that could lead to liquid carry over. Vilter Manufacturing is not responsible
for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot
warrant equipment damaged by improperly protected or operating systems.
Vilter screw compressor components are thoroughly inspected at the factory. However, damage can occur
in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage
noted should be reported immediately to the Transportation Company. This way, an 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.
Section 3 • Installation
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 ................................................................................................................................................. 3-24
Section 4 • Operation
Section 5 • Maintenance/Service
Appendices
Figures
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
9. Oil Cooler
4. Gas Compressed
PLT = Plate
L = Landfill Gas
ST = Shell and Tube
D = Digester Service Site Application
REM = Remote
N = Natural Gas (Primarily Methane)
G = Other Gas Type 10. Oil Cooling Medium
REF = Refrigerant
5. Application WTR = Water
HP = High Stage with Oil Pump GL = Glycol
HN = High Stage no Oil Pump
AIR = Air
6. Driver
VFD = Variable Frequency Drive
EMD = Electric Motor Drive
ENG = Engine Drive
To keep definitions of units simple and consistent, Vilter has defined the following three:
• Bare Shaft Compressor
• Compressor Unit
• Package Unit
Compressor Unit
A compressor unit consists of the bare shaft compressor with the coupling, motor, oil separator, frame, micro-control-
ler system and oil system. A compressor unit typically a single screw compressor unit, is not mounted on a structural
steel base.
Package Unit
A package unit is a complete system mounted on a structural steel base with interconnecting piping.
Each gas compressor unit may differ, but below are typical components that can be found on each unit.
5a - Suction Stop Valve 13 - Oil Temperature Control Valve (Optional Per Application)
8 - PLC Panel (Optional Dual Oil Filters Shown) 23 - Oil Cooler (Shell and Tube Heat
Exchanger)
5b
1 2 3 4 5a
6 7
17
8
16
9
11 15 14 13 12 11 10
4 3
20
18 19
17
22
21 14 20
23
25 26 27 28
24 29
30
31
33 32
OUTLET
INLET
Symbol Identification
Use this list to identify symbols shown in the Piping & Identification Diagram.
Use this list to identify major components shown in the Piping & Identification Diagram.
A Air Drive
Filter
Shell and Tube
Heat Exchanger
Fan
Compressor Finned Tube
Heat Exchanger
Motor
Engine Drive
Positive Displacement
Pump
Centrifugal Pump
Plate & Frame Heat Turbine
Exchanger
Rotary Pump
Programmable Logic Control, DCS or Remote Control Panel, Normally Accessible to Operator
SD
Safety Instrumented System Main Control Panel or DCS
Programmable Logic Control, Auxiliary (Local) Control Panel, Normally Accessible to Operator
SD
Safety Instrumented System Auxiliary (Local) Control Panel
Computer Function, Field Mounted
Computer Function, DCS or Remote Control Panel, Normally Accessible to Operator
Computer Function, Local Operator Panel, Normally Accessible to Operator
I Interlock
P Permissive
SAMPLE TAG
105-LSH-300-A
Process Cell/Compression
Stage Number Series Number
101-V-300
Equipment Type
EQUIPMENT TYPE
A - Agitator, Mechanical Mixers, Aerators F - Fans
B - Blowers P - Pumps
C - Compressors R - Reactors
D - Drivers U - Filters, Strainers
E - Heat Exchangers V - Vessels, Tanks, Separators, Scrubbers
E - Size
#” - Nominal Pipe Size (Inches)
F - Standard/Other Standard
STD -Vilter
0 - Other Standard (Not Vilter)
1 2 3 4 5
SUCTION GAS 6
TE CHECK DISCHARGE
VALVE STOP VALVE
1/4” OIL CHARGING
TE
COMPRESSOR
BLEED
1/4”
MOTOR
14 13 12
BLEED
15 OIL SEPARATOR
16
TE
11
FILTER
10 TE
BLEED
STANDARD SINGLE
DRAIN 100#
DRAIN OIL FILTER MOTOR
BLEED
M FG
1
PUMP
FILTER
DRAIN
FILTER
7
DRAIN
OPTIONAL DUAL OIL FILTERS
9
VENT
OIL COOLER
OIL
DRAIN
DRAIN
The gas and oil systems work in unison, but each one will the aftercooler and scrubber for cooling while the oil is
be explained separately. Reference Figure 2-1 for gas and pumped or syphoned back to the compressor.
oil flow descriptions. Check valves (3) and (6) are provided to stop the back
flow of gas in the system when the compressor is shut
Gas Flow down.
An equalizing line is also installed between the high
pressure side (oil separator) and low pressure side (suc-
The gas compression process begins as processed gas
tion) to allow separator pressure to equalize to suction
enters the suction inlet (1). The processed gas flows
pressure at shutdown. This is controlled by the equaliz-
through a stop valve (2), check valve (3) then through
a suction line strainer (4) to the compressor (13). The ing solenoid (5).
processed gas is then pressurized through the compres-
sor and discharged as high pressure gas vapor into the
oil separator (12). In the oil separator, the oil is then Oil Life and Oil Flow
separated from the discharged gas vapor by impinge-
ment separation. The high pressure gas flows out to The life of the oil is directly affected by the quality of the
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 2 – 1
Section 2 • Theory of Operation
Delivery Inspection Only qualified personnel shall operate rigging and lift-
ing equipment. Ensure that the lifting device is capable
All equipment supplied by Vilter are thoroughly inspect- of lifting the weight of the compressor unit, refer to the
ed at the factory. However, damage can occur in ship- supplied Vilter General Assembly (GA) drawing.
ment. For this reason, the units should be thoroughly To lift the compressor unit, use lifting points on com-
inspected upon arrival, prior to off-loading. Any dam- pressor unit frame to attach the lifting device, see Figure
age noted should be photographed and reported im- 3-1. There are a few points to consider prior to moving
mediately to the transportation company. This way, an the unit:
authorized agent can examine the unit, determine the
• Ensure that the weight is evenly distributed amongst
extent of damage and take necessary steps to rectify the
the lifting device (i.e. lifting chains and spreader bar)
claim with no serious or costly delays. At the same time,
prior to lifting.
the local Vilter representative or the home office should
be notified of any claims made within ten (10) days after • Ensure that the lifting device is not obstructed by any
its discovery. Refer to long term storage for additional parts of the compressor unit to prevent damage to
recommendations. components.
• Use additional personnel as needed to spot and aid in
maneuvering the compressor unit.
Rigging and Lifting of Compressor • Ensure there is plenty of space to maneuver the com-
Unit pressor unit and a clear path to its location.
WARNING
When rigging and lifting a compressor unit, use proper
lifting device capable of lifting and maneuvering the
weight and size of the compressor unit. Use only
qualified personnel and additional personnel and
lifting equipment (i.e. spreader bar) as required.
Failure to comply may result in death, serious injury
and/or damage to equipment. Lifting Point
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
The procedure described is a general recommendation turned to help lubricate the surfaces of the shaft seal.
for long term storage (over one month of no operation) For cool compression, there is no pre-lube pump, so
of Vilter compressor units. It is the responsibility of the the driveshaft must be turned by hand.
installation firm and end user to address any unusual
conditions. Use the supplied long term storage log sheet • Maintenance log to be kept with documenting dates
to help with record keeping, see section page 3-4. to show all the procedures have been completed.
Warranty of the system remains in effect as described at • Notify Vilter Service and Warranty Department when
the beginning of this manual, section page i. the compressor is started.
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):
Space Heater & Panel Components (Ensure space heater is energized and panel components are rust-free)
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):
G.A.
CENTER LINE OF
GAS COMPRESSION
SYSTEM
2" (TYP.)
2" (TYP.)
EL. TOP OF
2" CLR.
GRADE
4" COMPACTED
SAND
6"
1'-0"
# 6 @ 12"
3" CLR.
EACH WAY
TOP & BOTTOM
Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View
G.A.
G.A.
COMPRESSOR UNIT
CENTER LINE OF
GAS COMPRESSION
SYSTEM
EL. TOP OF
GRADE
6"
# 6 @ 12"
EACH WAY
TOP & BOTTOM
Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View
ISOLATION JOINT,
1" MINIMUM
COMPRESSOR UNIT CHAMFER EDGE THICKNESS
FOUNDATION
CONCRETE
SLAB IN
6” BUILDING
Additional Information
Codes and Standards General Design Requirements
Vilter followed the following codes and standards when The compressor foundation is designed to:
designing your foundation: • Maintain the compressor in alignment and at proper
• ACI elevation.
• ASTM • Minimize vibration and prevents its transmission to
• ASCE 7 other structures
• IBC 2006
• Provide a permanently rigid support
Operation and Performance • Provide sufficient depth to dampen vibrations.
The foundation was designed for:
• Outside environment severe exposure
• Ambient temperature -10 degrees F to 105 degrees F
• Unit weight 20,000 lbs
• RPM 3600
• Soil bearing capacity 1,500 lbs/sq.ft.
• Wind speed 120 MPH
• Exposure factor D
• Wind importance factor 1.15
• Concrete poured on and permanently cast against
the earth
1" (TYP.)
G.A. G.A.
(2) - # 4
CLOSED TIES
G.A.
G.A.
G.A. + 2"
G.A.
(5) - # 6 VERT.
WITH STD. 90° HOOK
AT BOTTOM EACH
FACE
COMPRESSOR UNIT
LEVEL
HOUSEKEEPING PADS
SPHERICAL
WASHERS
Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers
70+6.')
010Ä5*4+0- *1.&&190076
'21:;)4176
9#5*'4
.'8'.+0)076
/+0
4'%1//'0&'&
(14
*175'-''2+0)
#0%*14$1.6
%10%4'6'
$#5'
HANGER
CUSTOMER SUPPORTS 5 PIPE
WHEN CHECK VALVE DISCHARGE
DIAMETERS LINE
IS MOUNTED HERE
5 PIPE
DIAMETERS
3-4 PIPE
5 PIPE DIAMETERS
DIAMETERS
CHECK
VALVE
SUCTION
CUSTOMER LINE
SUPPORT
Y
Z X
X
Z
CUSTOMER
SUPPORT
PREFERRED
Intake Velocity
More
Less
The equation used to calculate the leg height in Figure • The total airflow of the installation is 247,000CFM
3-11 is as follows: • We have an intake perimeter of 3 sides 16ft, 16ft, and
Leg Height = (Total Airflow/Intake velocity)/Intake Perimeter 25ft which totals 57’
Leg Height = (247,000CFM/500FPM)/82ft • Our intake velocity guideline is 500FPM
Leg Height = 6ft
In this particular case the calculated minimum height is The equation used to calculate the leg height in Figure
6 feet to maintain an intake velocity of 500FPM or less 3-11 is as follows:
based on having the coolers place 1 fan diameter away Leg Height = (Total Airflow/Intake velocity)/Intake Perimeter
from the nearest obstruction. Let’s look at an instal-
lation where the coolers need to be placed next to the Leg Height = (247,000CFM/500FPM)/57ft
building as in Figure 3-12. Leg Height = 8.667ft
Based on the information above, we are going to solve We would round the leg height up to 9ft for this particu-
for the leg height that will provide an intake velocity of lar situation.
500FPM. We know the following:
NOT PREFERRED
HOT AIR RECIRCULATION This is especially critical if all of the air coolers are not
There are two situations where hot recirculation could place as close together as possible.
occur.
• Intake velocity of the cooler is higher than the dis- Cooler Placement and Spacing
charge velocity The concern about cooler placement as far as proximity
• Environmental issues such as strong cross winds from one another has to do with the potential for hot
which is installation specific air recirculation due to cross winds. Let’s look at only
having coolers 1 and 3 in the same area. The leg height
requirement of cooler 1 is 3.23ft so we would use a 4ft
We addressed how to minimize the opportunity for hot leg height. The leg height requirement for cooler 3 is
air recirculation involving the operation of the air cool- 4.61ft but we would put a 7 foot leg height on the cooler
ers under the guidelines for the Free Flow section above. due to size and for serviceability. Figure F. shows this
However, environmental hot air recirculation is some- installation.
thing that is outside of the control of the cooler manu-
facturer. If the site has the potential for strong cross In this case, if you get a strong cross wind from left to
winds or tunneling then you may want to consider the right there is the potential that the discharge coming
following items to minimize the potential of hot air recir- from the top of cooler 1 could easily be pushed into the
culation due to the environment. intake of cooler 3. Thus, in Figure 3-14, the not preferred
configuration is more susceptible to the potential of hot
• All air coolers should discharge at the same elevation. air recirculation due to the environment and is not rec-
• If feasible all of the air coolers in a common area ommended. The preferred configuration is the recom-
should be placed as close to the next cooler as mended installation of the coolers with a space between
possible. them.
Unfortunately this comes with a cost. By reducing the in- All of the information provided is a general guideline for
take perimeter available, the leg height increases, which installing multiple air coolers in a common area. If you
is a cost. In addition there is no guarantee that hot air minimally follow all of the Free Flow requirements and
recirculation can be eliminated due to environmental keep the air coolers discharging at the same elevation
issues. then you have a good basis for site layout.
Sometimes due to extenuating circumstances, the
above guidelines cannot be followed. Please contact en-
Discharge Elevation gineering to discuss remedies to accommodate different
In order to minimize the potential for hot air recircula- configurations.
tion, it is recommended to install the air coolers so that
they all discharge at the same elevation. This is impor-
tant because not all air coolers have the same plenum
heights. You can satisfy the leg height requirements by
the calculation above but not satisfy the requirements
for discharge elevation. Based on the size of the cool-
ers above, cooler 1 has a plenum height of 36”, cooler
2 has a plenum height of 42”, and cooler 3 has a plenum
height of 54”. Plenum heights are calculated from the
standard of a 45 degree dispersion angle in API 661. If
you would like more details on this calculation please
contact engineering.
As you can see in Figure 3-13 in the not preferred con-
figuration. the leg height requirement in the first cal-
culation is satisfied. However, the coolers are not at the
same discharge elevation. This could be an issue if there
is a cross wind from left to right. Cooler 3 could block the
discharge air flow from coolers 1 and 2 and recirculate it
back down to the intake of the coolers. The best way to
address this is to increase the leg heights on coolers 1
and 2 as shown in the preferred configuration.
NOT PREFERRED
PREFERRED
CAUTION two sight glasses on the oil separator, see Figure 3-15.
Refer to supplied GA drawing for unit specific oil charge
The compressor unit along with other system units requirement.
contain many components with various pressure
For regular oil charging and draining procedures, see
ratings. Pressure relief protection provided considers
Section 5.
the design pressure of a system components.
Before replacing a pressure relief valve with a relief
valve having a higher presure setting, all system Tool Required:
components must be evaluated for acceptability. • Oil Pump, Maximum 2-3 GPM with Motor approved
for Division 1 or Division 2 and with ability to over-
Pressure test in compliance with Chapter VI of the ASME come suction pressure.
B31.3 Process Piping Code.
(Reference Figure 3-17)
1. At initial start up, compressor unit must be off and
depressurized prior to initial oil charging.
Initial Oil Charging 2. Using a properly selected oil pump, connect oil
pump to oil separator drain valve (4). For oil separa-
tor drain valve location, see Figure 3-16.
Using Non -Vilter Oils 3. Open oil separator drain valve (4) and fill oil separa-
tor (3) to Maximum NON-Operating Level.
WARNING 10. Run the oil pump (6) twice for 1-2 minutes. Repeat
this step until the oil level (9) is constant.
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.
Figure 3-16. Suction Oil Charging Valve, Oil Cooler Drain Valve and Oil Filter Shut-Off Valves
DISCHARGE OUTLET
TE PT
002 004
BLEED
SUCTION INLET
OIL CHARGE
EQUALIZING LINE
PT
1
TE
TE RETURN COOLING
PRESSURE
001 001
004
BLEED WATER
SUPPLY
MOTOR VENT DRAIN
COMPRESSOR
2 OIL COOLER
COALESCING OIL RETURN LINE
PT
002
BLEED
DRAIN
OIL SEPARATOR 3
9
LG
001
LG
FG
OIL 002
001
1000W 1000W 1000W
TE QE QE QE
005 101 102 103 DRAIN 4
5 OPEN
8
BLEED
Figure 3-17. Priming Oil Cooler (Shell & Tube) and Piping
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 cor-
rect levels have been achieved during the unit oper-
ation and when the compressor unit has been down
for 1 hour.
DISCHARGE OUTLET
TE PT
002 004
BLEED
SUCTION INLET
OIL CHARGE
EQUALIZING LINE
PT
1
TE
TE RETURN COOLING
PRESSURE
001 001
004
BLEED WATER
SUPPLY
MOTOR VENT DRAIN
COMPRESSOR
2 OIL COOLER
COALESCING OIL RETURN LINE
PT
002
BLEED
DRAIN
OIL SEPARATOR 3
9
LG
001
LG
FG
OIL 002
001
1000W 1000W 1000W
TE QE QE QE
005 101 102 103 DRAIN 4
5 CLOSE
8
BLEED
Figure 3-18. Priming Compressor (with Shell & Tube Oil Cooler) and Piping
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 3 – 19
Section 3 • Installation
PT
1 TE
TE REMOTE
PRESSURE
001 001
004
2
COALESCING OIL RETURN LINE
PT
002
QE
007
BLEED
3 TE
8 OIL SEPARATOR DRAIN 003
LG
001
LG
FG
OIL 002
001
1000W 1000W 1000W
TE QE QE QE
005 101 102 103 DRAIN
4
OPEN
OIL FILTER 6
CLOSE PT
003
DRAIN
7
BLEED
PRIMING COMPRESSOR AND OIL FILTERS 14. When ready, run compressor unit and allow it to
NOTE reach normal operating temperature.
Running the compressor oil pump at this point will 15. Using a properly selected oil pump, connect oil
help lubricate the compressor bearings and shaft pump to suction oil charging valve (1). For suction
seal surfaces. oil charging valve location, see Figure 3-16.
16. Open suction oil charging valve (1) and fill oil separa-
(Reference Figure 3-20) tor (3) to Normal Operating Level.
8. Open shut-off valve(s) (7) at oil filter inlet(s). 17. Once the Normal Operating level has been reached,
9. Close oil bypass shut-off valve (4). shut off the oil pump and close the suction oil charg-
10. Open oil mixing valve (6) via control panel. In Manual ing valve (1). Disconnect and remove oil pump.
Mode, change “Manually Open (%)” value to “100”. NOTE
11. Run oil pump (5) for approximately 20 seconds only.
12. Stop oil pump and wait for a minimum of 30 min- Oil separator does not need to be filled again until oil
utes. This will allow oil in the compressor (2) to drain level reaches Minimum Operating Level.
and oil level (8) in separator (3) to settle. Every size of compressor will hold different amounts
NOTE of oil, so amount of oil draining back into oil
Oil mixing valve can remain in Manual Mode since separator will vary.
the setpoint will change it to Auto mode. For further 18. More accurate fill levels can be accomplished by
details, see PLC Compact Logix manual. marking the level on the oil separator (2) after cor-
13. Refer to Pre Start-Up Checklist and ensure all items rect levels have been achieved during the unit oper-
are ready prior to starting the compressor. ation and when the compressor unit has been down
for 1 hour.
DISCHARGE OUTLET
TE PT
002 004
BLEED
SUCTION INLET
OIL CHARGE
EQUALIZING LINE
PT 1 TE
TE REMOTE
PRESSURE
001 001
004
PT
002
QE
007
BLEED
3 TE
8 OIL SEPARATOR DRAIN 003
LG
001
LG
FG
OIL 002
001
1000W 1000W 1000W
TE QE QE QE
005 101 102 103 DRAIN
4
CLOSE
OIL FILTER 6
OPEN PT
003
DRAIN
7
BLEED
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.
1. The unit should be leveled and secured to the concrete pad foundation.
2. Proper electric supply and grounding need to be supplied to the unit. All power and control lines should be
wired to unit. Electric supply to be verified at each device requiring power.
3. Verify any type of level switches that are on a vessel before the compressor are hardwired and able to shut
off the compressor (should be wired to “Aux” on micro-controller and starter).
4. The suction and discharge line must be piped and properly supported independent of the unit.
5. The discharge stop and check valve is shipped loose and must be installed. During off periods, liquid can
condense in the line downstream of the discharge stop and check valve. It is recommended that the stop and
check valve be located horizontally to minimize the quantity of liquid that can accumulate downstream of the
check valve.
6. A dual safety relief valve is shipped loose for field installation. A connection is provided on the oil separator
for the relief valve. Refer to ASME Code for proper sizing of relief valves and vent lines.
7. On water cooled oil coolers, the water lines must be connected to the front head of the oil cooler. Water
regulating and solenoid valves are recommended.
8. On air cooled oil coolers, the oil lines from the compressor must be connected to the air cooled oil cooler. Oil
cooler fans will need to be wired and checked for proper rotation. Refer to supplied GA drawing for connection
points and piping sizes.
(Continued on next page)
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. The motor should be checked to make sure that it is lubricated properly. Proper re-lubrication amounts/
types are provided on the motor’s lubrication plate. These instructions should be closely followed to achieve
optimum bearing life and to avoid consequential damage to the bearings and motor.
14. The center section of the coupling should be left out to allow the start-up technician to verify the final
alignment and motor rotations.
16. Verify that the visual indicator on the Oil Temperature Control Valve (Oil Mixing Valve) position corresponds
with “% OPEN” on the control panel. CLOSE position is 0% OPEN, OPEN position is 100% OPEN.
18. The unit should be pressure tested and purged with a dry gas. Care should be taken to not pressurize exces-
sively from the suction end of the compressor, as this will drive the compressor in a forward motion without
lubrication and may cause damage.
20. Keep a hard copy of the final set points in case the micro-controller gets corrupted or if they are required by
Vilter technicians for troubleshooting.
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.
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. Refer to Compact Logix PLC Software Manual.
5. Verify capacity slide calibration and correct command shaft rotation, even though it is factory calibrated.
6. Verify volume slide calibration and correct command shaft rotation, even though it is factory calibrated.
10. Verify correct direction of flow for the oil line check valve.
11. Run oil pump to pre-lube the compressor (oil level in the oil separator should drop as lines are filled).
15. Record running data and final set points on data sheets.
WARNING NOTE
During operation, both oil filter outlet shut-off valves
When working with LFG, NG or other dangerous
should be open. This will help minimize the sudden loss
or flammable gases, ensure there are adequate
of oil pressure when switching between oil filters for
ventilation and vapor detectors. Refer to national fire
servicing.
and building codes. Failure to comply may result in
serious injury or death. For further details, refer to Oil Filter Replacement in
Section 5.
WARNING
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.
WARNING
be in a normal condition, and the suction pressure must
be above the low suction pressure setpoint to ensure a
load is present. When the “ON/OFF” switch or “Manual- After stopping the compressor, allow the compressor
Auto” button is pressed, the oil pump will start. When and surrounding components to cool down prior
sufficient oil pressure has built up and the compressor to servicing. Failure to comply may result in serious
capacity control and volume ratio slide valves are at or injury.
below 10%, the compressor unit will start.
NOTE CAUTION
The amount of oil pressure that needs to be achieved Do not calibrate in direct sunlight. Failure to comply
before compressor start is at least 6 psig above the may result in damage to equipment.
discharge pressure. For additional information on
Low Oil Pressure at Start, see Troubleshooting Guide -
General Problems and Solutions in Section 6. Both the capacity and volume slide actuators should be
calibrated when one or more of these have occurred:
If the compressor is in the automatic mode, it will now • Compressor unit starting up for the first time.
load and unload and vary the volume ratio in response
to the system demands. • A new actuator motor has been installed.
Actuator
Assembly
Actuator
Plastic Cover
Red LED
Blue
Calibrate
Button
Figure 4-3. Menu Screen and Slide Calibration Button (Compact Logix PLC)
NOTE
If the INC (increase) and DEC (decrease) buttons do
not correspond to increase or decrease 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 INC and DEC to move the slide valve and
check for the correct rotation, see Table 4-1.
NOTE
When the actuator is in calibration mode, it outputs
0V when the actuator is running and 5V when it is
still. Thus, as stated earlier, the actuator voltage will
fluctuate during calibration. After the actuator has been
calibrated, 0V output will correspond to the minimum
position and 5V to the maximum position.
9. Quickly press and release the blue push button on Figure 4-5. Photo-chopper
the actuator one time. This places the actuator in Press down on Photo-chopper to release tension from mo-
calibration mode. The red LED will begin flashing tor shaft.
rapidly.
VSSG 291
VSSG 341
CW CCW CW CCW 0.91 328 3.568” 0.52 187 2.045”
VSSG 451
VSSG 601
VSG 301
VSG361 CW CCW CW CCW 0.80 288 3.141” 0.45 162 1.767”
VSG 401
VSG 501
VSG 601 CCW CW CCW CW 0.91 328 3.568” 0.52 187 2.045”
VSG 701
VSG 751
CCW CW CCW CW 1.09 392 4.283” 0.63 227 2.473”
VSG 901
VSG 791
VSG 891
VSG 1051 CCW CW CCW CW 1.22 439 4.777” 0.74 266 2.889”
VSG 1201
VSG 1301
VSG 1551
VSG 1851 CCW CW CCW CW 1.48 533 5.823” 0.87 313 3.433”
VSG 2101
VSG 2401
VSG 2601
CCW CW CCW CW 1.80 648 7.072” 1.36 490 5.341”
VSG 2801
VSG 3001
*The large gear on the command shaft has 50 teeth. The teeth are counted when moving the command shaft from
the minimum stop position to the maximum stop position.
The manual operating shaft on the gear motor should be turned the opposite direction of the desired command shaft
rotation.
The capacity and volume control motors are equipped with a brake, if it is necessary to operate the control motors
manually, the brake must be disengaged. The brake can be disengaged by pushing on the motor shaft on the cone
end. The shaft should be centered in its travel. Do not use excessive force manually operating the motor or damage
may result.
Visual Indicator
Purging with Dry Nitrogen 4. Close suction and discharge shut-off valves to
isolate the compressor unit from house system.
Lockout/tagout valves.
Purging is recommended if the compressor will be
inactive for 12 hours or more. For additional long 5. Close any other valves that may feed gas or oil to
term storage information, refer to Long Term Storage the compressor and oil separator.
Recommendations in Section 3. 6. Slowly open suction oil charging valve to depres-
surize compressor unit to atmosphere, see Figure
4-9. Keep valve in open position.
PREPARATION
NOTE
WARNING Plugs are installed on bleed valves. Remove and install
When working with LFG, NG or other dangerous plugs prior to and after bleeding. Ensure to keep valves
or flammable gases, ensure there are adequate closed when removing and installing plugs.
ventilation and vapor detectors. Refer to national fire
7. Open discharge bleed valve to allow nitrogen to
and building codes. Failure to comply may result in
purge through compressor unit, see Figure 4-8.
serious injury or death.
8. Refer to PLC main screen for discharge pressure
WARNING when purging.
When working with pressurized system, always wear
safety glasses and/or face shield. Failure to comply
PURGE
may result in serious injury.
1. Press “Stop” button to stop compressor unit, see CAUTION
Figure 4-7. Do not purge compressor unit with oxygen. Failure to
comply may result in damage to equipment.
2. If equipped with equalizing solenoid, allow pres-
sure in compressor unit to equalize to suction pres-
sure, see Figure 4-8. CAUTION
Do not allow compressor to spin while purging.
3. If equipped with manual suction bypass valve and Regulate purging pressure as needed. Failure to
it is not open, open suction bypass valve. Allow comply may result in damage to equipment.
pressure in compressor unit to equalize to suction
pressure.
Discharge
Status
Stop Button
9. Connect purging hose from nitrogen cylinder to screen. Allow pressure to build to approximately 10
suction oil charging valve. psig.
NOTE 13. Once pressure is reached, stop purging and close
Purging is performed through the suction oil charging suction oil charging valve. If pressure is greater
valve so that trapped gas can be pushed out of the than 10 psig, crack open discharge bleed valve,
compressor. This will help minimize metal surface as needed, to slowly bleed the system to approxi-
oxidation of the compressor (due to the gas) while not mately 10 psig.
in service. 14. Wait 10 minutes to make sure there are no leaks
10. Purge compressor unit for 10 minutes. Check dis- and that the pressure is holding. If the unit does not
charge pressure on PLC main screen to make sure hold pressure, check all isolation valves for correct
pressure is increasing. operation; discharge, suction and oil return valves.
11. Close discharge bleed valve while still purging. 15. Remove purging hose from suction oil charging
valve.
12. Observe discharge pressure through the PLC main
CAUTION
With a purged system, when getting the compressor
unit ready for start-up, it is important to slowly open
View Rotate 180° the suction valve to prevent a sudden rush of gas
and oil. Failure to comply may result in damage to
equipment.
Equalizing Solenoid
for Suction Bypass
Suction Oil
Charging Valve
Discharge
Bleed Valve
View Rotate 180°
Figure 4-9. Suction Oil Charging Valve and Discharge Bleed Valve
Drain Valve
PI
002
PT TE
TE REMOTE
PRESSURE
001 001
004
PT
002
QE
007
BLEED
TE
003
OIL SEPARATOR DRAIN
LG
001
LG
FG 002
001
TE QE
1000W QE
1000W QE
1000W
005 101 102 103
DRAIN
6. Close any other valves that may feed gas or oil to NOTE
the compressor and oil separator. Purging is performed through the suction oil charging
NOTE valve so that trapped gas can be pushed out of the
Plugs are installed on bleed valves. Remove and install compressor. This will help minimize metal surface
plugs prior to and after bleeding. Ensure to keep valves oxidation of the compressor (due to the gas) while not
closed when removing and installing plugs. in service.
7. Slowly open suction oil charging valve and bleed 11. Purge compressor unit for 10 minutes. Check pres-
remaining pressure in compressor unit to atmo- sure indicator or discharge status on PLC main
sphere, see Figure 4-13. Leave suction oil charging screen to make sure pressure is increasing.
valve in open position. 12. Close shut-off valve on purge line while still purging.
8. If equipped with pressure indicator on purge line, 13. Observe discharge pressure of compressor unit
open shut-off valve to pressure indicator. through the PLC main screen.
9. If not equipped with pressure indicator, refer to PLC 14. Allow pressure to build to approximately 10 psig in
main screen for discharge pressure when purging. the compressor unit.
15. Once pressure is reached, stop purging and close
PURGE suction oil charging valve.
16. Wait 10 minutes to make sure there are no leaks
CAUTION and that the pressure is holding. If the unit does not
Do not purge compressor unit with oxygen. Failure to hold pressure, check all isolation valves for correct
comply may result in damage to equipment. operation; discharge, suction and oil return valves.
Discharge
Status
Stop Button
Equalizing Solenoid
for Suction Bypass
Suction Oil
Charging Valve
Coalescing Oil Return Line Setup 3. Slowly open needle valve more until a small amount
of oil is seen in the sight-glass.
Over time, oil will accumulate on the coalescing side
of the oil separator. As a result, an oil return line with a NOTE
shut-off valve, sight-glass, check valve and needle valve
The sight-glass should never be full with oil.
are installed between the coalescing side and compres-
sor to return this oil back to the compressor. 4. Periodically check oil in the sight-glass and ensure
that there is flow.
To adjust the return flow, proceed with the follow
procedure:
NOTE
Do not fully open the needle valve unless directed by
Vilter Customer Service. Leaving the needle valve fully
open will reduce efficiency of the compressor unit.
1. Open shut-off valve on coalescing side of oil separa-
tor, see Figure 4-14.
2. While the unit is in operation, crack open needle
valve and observe oil flow through sight-glass.
Needle
Valve
Check Valve
Sight-Glass
Shut-Off
Valve
Figure 4-14. Coalescing Oil Return Line
200
2,500
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000
55,000
60,000
Oil Change Replace oil based on oil analysis report or visual contamination.
Oil sampling is recommended every 2 to 3 months for the first year. Thereafter, as required, increase
sampling time period if contamination of oil is unlikely or decrease sampling time period if contami-
Oil Analysis
Oil Circuit nation of oil is evident. Take an oil sample any time during operation If there’s reason to believe that
the oil is contaminated. For additional information on oil, refer to Oil and Oil Flow operation.
Section 5 • Maintenance/Service
Oil Strainer I I I I I I I I I I I I I I
Coalescing Filter - - - - R - - R - - R - - R
Coalescing Drain Line I I I I I I I I I I I I I I
Compressor Suction Screen I - - I - I - I - I - I - I
Unit Coupling Alignment
I I I I I I I I I I I I I I
and Integrity
Motor (Compressor) See Motor Manual for proper lubrication procedures and service intervals.
Transducers I I I I I I I I I I I I I I
Control RTDs I I I I I I I I I I I I I I
Slide valve calibration should be inspected monthly. Inspections can be performed through the
Slide Valve Motors
control panel. If a Non-Movement Alarm appears, calibrate immediately.
Compressor (6) - I - I - I - I - I - I - I
Compressor (4) (5)
Bearings - - - - - - - - - - - - - I
I = Inspect S = Sampling R = Replace
(1) Vilter recommends that a Preventative Maintenance Program be developed by Vilter GC (Gas Compression) Service Center.
(2) Daily records should be kept on suction, discharge, oil pressures & temperatures, along with ensuring Temp Leaving Oil Separator is above Dew Point.
(3) Replace oil filters when pressure drop reaches 7 PSID (maximum allowable pressure drop is 15 PSID).
(4) The life of the compressor will be increased by purging the compressor unit with dry nitrogen or sweet, dry natural gas at shutdown.
(5) Header drains should periodically be drained for liquid build-up to prevent compressor damage, see Piping in Section 3.
(6) Inspections include: gate rotor inspection, backlash measurement, shelf clearance, end play measurement (main rotor & gate rotor), gate rotor float, slide valve inspection.
5 – 1
Section 5 • Maintenance/Service
2. If equipped with equalizing solenoid to control suc- Compressor Unit Leak Check
tion by-pass, allow solenoid to remain open until
pressures equalize, see Figure 5-1 (2 of 2).
The compressor unit must be checked for leaks after
3. Turn motor and oil pump starter disconnect switch- servicing to ensure a tight system. For additional leak
es into the OFF position. Lockout/tagout discon- testing information, refer to Chapter VI of ASME B31.3
nect switches. Process Piping Code.
4. If equipped with manual suction by-pass valve and
it is not open, open suction by-pass valve to allow CAUTION
oil separator pressure to vent to low-side system Do not hydro test compressur unit. Failure to comply
pressure, see Figure 5-1 (1 of 2). Close suction by- may result in damage to equipment.
pass valve when complete.
1. If servicing the compressor unit was completed,
5. Isolate the compressor unit by closing all valves to proceed to step 2. Otherwise, isolate the compres-
the house system. Lockout/tagout valves. sor unit from the house system, see Compressor
NOTE Unit Isolation procedure.
If drain valves are installed on suction and discharge 2. Open all shut-off valves, check valves, control valves
headers, open these valves too to remove build up and solenoid valves in the system to be tested.
of liquid during shut-down periods. 3. Slowly pressurize compressor unit through suction
6. Open any other valves that may trap liquid. Lockout/ oil charging port with dry nitrogen.
tagout valves. 4. Using appropriate soap solution, check for leaks on
7. Recover or transfer all gas vapors. joints and connections of the serviced component.
8. Open discharge pressure bleed valve at block and 5. If leaks are found, depressurize system and fix leaks.
bleed assembly and allow remaining pressure in oil Repeat steps 3 and 4 until all leaks are fixed.
separator to equalize to atmospheric pressure. 6. Typically, no evacuation is required for open loop
9. Servicing the compressor unit can proceed at this systems. If evacuation is required, evacuate from
point. After servicing, ensure to perform a leak suction oil charging port. Otherwise, bleed nitro-
check, see Compressor Unit Leak Check procedure. gen to atmosphere.
7. Close all valves previously opened in the sys-
tem. Open suction and discharge shut-off valves.
Remove tags as per local lockout/tagout procedure.
8. Turn motor and oil pump disconnect switches to
the ON position.
9. The compressor unit can now be started, refer to
Start-Up procedure in Section 4.
Line Line to
from Oil Solenoid Suction
Line from Oil Separator Separator
to Shut-off Valve Shut-off Needle
Line from Needle Valve Valve
Valve to Suction
WARNING 2. Open suction oil charging valve and fill oil separator
to Normal Operating Level.
Avoid skin contact with oil. Wear rubber gloves and a 3. Once the Normal Operating Level has been reached,
face shield when working with oil. Failure to comply shut off the oil pump and close the valve. Disconnect
may result in serious injury or death. and remove oil pump.
Figure 5-3. Suction Oil Charging Valve, Oil Separator Drain Valve and Oil Cooler Drain Valve
WARNING REMOVAL
Avoid skin contact with oil. Wear rubber gloves and a
face shield when working with oil. Failure to comply NOTE
may result in serious injury or death.
Both outlet shut-off valves should be open. If the
Change the oil filter as outlined in the Maintenance and outlet valve is closed for the oil filter that is not in
Service Interval, see Table 5-1. Maintenance & Service operation, slowly open the outlet shut-off valve until
Interval. fully open. This will help reduce a sudden pressure
drop when switching oil filters for servicing.
Outlet
Element Outlet
Inlet Inlet Centering
Piece
Figure 5-4. Oil Filter Assemblies (Single and Dual)
Drain Valve
Vent Valve
Drain Valve
1. If equipped with dual oil filters, open inlet shut-off centering piece, if damaged, replace as required.
valve for non-operating oil filter to put it into opera-
tion, see Figure 5-5.
INSTALLATION
2. To isolate oil filter for servicing, close inlet and out-
let shut-off valves for the oil filter. NOTE
NOTE Ensure oil filter element on the outlet side is fully
seated on the outlet pipe when installed.
To reduce unwanted oil splash from a vent or drain
valve, connect a hose to the valve port and direct 9. If equipped with single oil filter element, install oil
the gas and oil into a drain pan. filter element in canister in orientation noted dur-
ing removal.
3. Slowly release pressure in the oil filter canister by
opening the vent valve. Allow pressures to equalize 10. If equipped with dual oil filter elements, install two
to atmosphere. oil filter elements and centering piece in orientation
noted during removal.
11. Position spring plate in orientation noted during
NOTICE removal and install bolts and nuts to secure cover
flange to oil filter canister.
Dispose of the oil in a appropriate manner following
all Local, State and Federal ordinances regarding the 12. Tighten nuts, see Appendix A.
disposal of used oil.
13. Using dry nitrogen gas, pressurize oil filter canister
4. Using an drain pan, open drain valve and allow the through vent valve and check for leaks.
oil to completely drain from the oil filter canister. 14. Close the vent valve and drain valve.
NOTE 15. Open outlet shut-off valve for the oil filter that is not
Note orientation of components to aid in installation. in operation.
5. Remove bolts and nuts securing cover flange to the 16. Repeat for second oil filter, as required.
oil filter canister. Remove cover flange and spring
plate. Retain spring plate.
6. If equipped with a single oil filter element, remove
filter element from oil filter canister.
7. If equipped with dual oil filter elements, remove
two filter elements and filter element centering
piece from oil filter canister. Retain filter element
centering piece.
8. Thoroughly clean the oil filter canister, spring
plate and centering piece. Inspect spring plate and
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 5 – 7
Section 5 • Maintenance/Service
Oil Separator
Manhole Cover
Pipe Stub
Flat Washer
3/4 in. O.D.
Flat Washer Tubing, 6 ft. long
Nuts
Figure 5-6. Oil Separator Manhole Cover and Coalescing Filter Assembly
Coalescing Filter Replacement 2. If required, install lifting eyes on oil separator man-
hole cover, see Figure 5-6.
WARNING equipped.
16. Start compressor unit.
Follow local lockout/tagout procedure. Failure to
comply may result in serious injury, death and/or
damage to equipment.
Drive Coupling (Form-Flex BPU) Hub with a small clearance over the top.
Installation NOTE
If hub position on shaft does not allow enough room
On all single screw units, the coupling assembly is to install bolts, install bolts and disc pack before
shipped loose and will have to be installed and aligned mounting hub on shaft.
on site. This is to allow a check of proper electrical phas- Hubs come in two different types, straight bore and
ing and direction of motor rotation. The motor and tapered bore. Tapered bore hubs have additional
compressor have been aligned from the factory with the hardware. Typically, a compressor will have a
coupling hubs already installed. Using a dial indicator for tapered shaft and therefore use a tapered bore hub.
aligning is recommended.
NOTE
STRAIGHT BORE HUBS
Drive coupling type and size can be determined
5. For straight bore hubs, install key in keyway of shaft.
by the information on the compressor nameplate
when ordering; Order Number and Compressor 6. Install hub on shaft. If installing straight bore hubs
Model Number. on motor and compressor shafts, allow 1/16” gap
between the outer face of the hub to the outer face
To install the coupling, proceed with the following steps:
of the shaft for both hub installation. This will allow
some play when installing the spacer. If installing
16. If locking tab is being used, bend locking tabs in operating conditions. This means there is a mini-
gap towards shaft and around bolt. mal amount of waviness in the flex disc pack when
17. Install set screw in hub cap to secure key in keyway viewed from the side. This will result in a flex disc
of shaft. 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.
Drive Center Member Installation and 21. Angular Alignment. Rigidly mount a dial indicator on
one hub or shaft, reading the face of the other hub
Alignment flange. Rotate both shafts together, making sure
the shaft axial spacing remains constant. Adjust the
NOTE
motor by shimming and/or moving so that the indi-
Always adjust motor to the compressor. The cator reading is within 0.002” per inch of coupling
compressor is aligned to the frame. flange, see Figure 5-9.
22. Parallel Offset. Rigidly mount a dial indicator on one
18. Adjust motor position as needed to obtain a dis- hub or shaft, reading the other hub flange outside
tance of 5” between both hub faces. diameter. Indicator set-up sag must be compen-
19. Soft Foot. The motor must sit flat on its base (+/- sated for. Rotate both shafts together. Adjust the
0.002”). Any soft foot must be corrected prior to equipment by shimming and/or moving so that the
center member installation. indicator reading is within 0.002” per inch of the
axial length between flex disc packs, see Figure 5-9.
NOTE
If the driver or driven equipment alignment
specification is tighter than these recommendations, With the coupling in good alignment the bolts will fit
the specification should be used. Also, be sure through the holes in the flanges and the disc packs more
to compensate for thermal movement in the easily.
equipment. The coupling is capable of approximately NOTE
four time the above shaft alignment tolerances. All bolt threads should be lubricated. A clean motor
However, close alignment at installation will provide oil is recommended. On size 226 and larger, a link
longer service with smoother operation. must be put on bolt first. Remove the disc pack
The flex disc pack is designed to an optimal thickness alignment bolt. Proceed to mount the second disc
and is not to be used for axial adjustments. pack to the other hub in the same way.
20. Axial Spacing. The axial spacing of the shafts should Ensure that the beveled part of the washer is against
be positioned so that the flex disc packs are flat the disc pack.
when the equipment is running under normal
23. Install bolts and locking nuts to secure both disc
packs to center member.
Hub Distance
24. Tighten locking nuts. 30. Tighten locking nuts, see Table 5-4.
25. If room is required to install center member, adjust
hub position accordingly. If both the motor and Table 5-5. Disc Pack Installation Torque
compressor hubs are straight bores, adjust either
hubs. If one hub is tapered and the other a straight,
Specifications
adjust the straight bore hub. Tightening
Coupling Lock Nut
26. Using additional supports supporting center mem- Torque
Size Size
ber. Install bolts and locking nuts to secure center ft-lbs (Nm)
member to compressor hub. BP38U 5/16-24 22 (30)
27. Tighten locking nuts. BP41U 7/16-20 55 (75)
28. Position hubs, ensure distance between face of BP47U 9/16-18 120 (163)
both hubs is 5”. BP54U 9/16-18 120 (163)
NOTE BP56U 9/16-18 120 (163)
If there is waviness with the disc pack installed, adjust
distance accordingly until disc pack is straight.
31. Perform hot alignment. Run compressor unit and
29. Install bolts and locking nuts to secure disc pack to allow to warm up completely.
motor hub.
32. Power down compressor unit and re-check
Table 5-4. Hub Clamp Bolt and Set Screw Torque Specifications
Clamping Bolt Set Screw
Coupling
Series/Size Torque Torque
# Bolts Size-Pitch Size
ft-lbs (Nm) ft-lbs (Nm)
BH38U 4 1/4-28 12 (16) 3/8 10 (13)
BH41U 4 5/16-24 23 (31) 3/8 10 (13)
BH47U 4 3/8-24 49 (66) 1/2 20 (27)
BH54U 4 7/16-20 78 (106) 1/2 20 (27)
BH56U 4 1/2-20 120 (163) 5/8 40 (54)
DP42 4 1/2-20 120 (163) 1/2 20 (27)
alignments. Loosen motor mounting nuts to add Drive Coupling (Type C Sure-Flex)
shims or to adjust alignments as required.
Replacement
33. Install coupling guard.
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. Position hub on
motor shaft on coupling sleeve as noted during
removal.
18. Install set screw in compressor hub to secure key in
keyway. Tighten set screw, see Table 5-6,
19. Install clamping bolts to secure hub to motor shaft.
Tighten clamping bolts, see Table 5-6.
Compressor
Nut
Lock Washer
Flat Washer
Spherical
Frame Shim Washer
Assembly
Stud
Flat Washer
Lock Washer
Nut
Figure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown)
E D
Main Compressor
C Assembly
B E
Gate Rotor
Cover
A
Main Lift
Point
Lifting Eyes
Center of
Gravity
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.
Main Lift
Point
Lifting Eyes
Figure 5-13. Bare Shaft Compressor Center of Gravity - Discharge Manifold and Main
Compressor Assembly (Models 291-2101)
5 – 18 VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
Section 5 • Maintenance/Service
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
Figure 5-15. Bare Shaft Compressor Center of Gravity - Discharge Manifold and Main
Compressor Assembly (Models 2401-3001)
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 5 – 19
Section 5 • Maintenance/Service
Compressor Shaft Bearing Float motor and use the lever arm to push the input shaft
towards the compressor. Record measurement
Inspections
5. Add both measurements. If measurement is out of
allowable tolerance shown in Table 5-9, the bearing
If float measurements are out of tolerance, contact Vilter may need to be replaced. Contact Vilter Customer
Customer Service for further assistance. Service.
So, using a 36” (or 1 m) lever with pivot space of 6” (or Top View
15 cm) would make the maximum applied force to be 60 Shaft being pushed by use of lever.
lbf (or 235 N). Calculation is as follows:
(300 lbf x 6”)/30” = 60 lbf (Max. Applied Force) Direction of
shaft movement.
(1335 N x 15 cm)/85 cm = 235 N (Max. Applied Force)
Force at
Hub/Shaft
Applied
Force
A Rigidly attach dial indicator.
B Lever Position on axis of compressor.
Table 5-9. Maximum Bearing Float Gate Rotor Float and Gate Rotor
Max. Max.
Max. Max. Bearing Float Inspection
Force Applied
Compressor Axial Radial
at Hub/ Force
Model Float Float (36” Lever, 6” GATE ROTOR FLOAT INSPECTION
in. (mm) in. (mm) Shaft Pivot)
lbf (N) lbf (N) To inspect gate rotor float and bearing float, proceed
0.002 300 60
with the following steps:
All -
(0.051) (1335) (267) 1. Remove center member, see appropriate Drive
151, 181, 201, Coupling Replacement procedure.
0.006 100 20
152, 182, 202,
301, 361, 401 (0.152) (444) (89) 2. Remove the side covers from compressor.
0.007 150 30 3. Position gate rotor blade and damper pin at 90° to
501, 601, 701
(0.178) (667) (133) the main rotor, see Figure 5-18.
291, 341, 451, 0.007 150 30
601 (0.178) (667) (133)
Dial Indicator Gate Rotor Blade
0.006 200 40
751, 901 - (0.152) (890) (178)
791, 891,
0.006 300 60
1051, 1201,
1301 (0.152) (1335) (267)
1501, 1551,
0.007 400 80
1801, 1851,
2101 (0.178) (1780) (356)
Bushing
Some movement between blade and support is 10. Install center member, see Drive Coupling
necessary to prevent damage to the compressor Replacement procedure.
blade; however at no time should the blade uncover 11. Perform compressor unit leak check, see
the support. Compressor Unit Leak Check procedure.
5. Inspect main rotor and gate rotor for abnormal
wear due to dirt or other contaminants. If dam-
aged, replace gate rotor and/or main rotor.
Gate Rotor
Support
Straight Edge
Gate Rotor
Gate Rotor
Support
Straight Edge
Gate Rotor
Gate Rotor
Support
Straight Edge
Gate Rotor
5. Turn main rotor so a driving edge of any one of the 16. Install the roller bearing housing (112) with a new
main rotor grooves is even with the back of the gate O-ring (141).
rotor support. 17. Tighten bolts (152), see Appendix A.
NOTE 18. When installing the thrust bearing housing (113), a
The gate rotor stabilizer is designed to hold the gate new O-ring (142) must be used when the housing
rotor support in place and prevent damage to the is installed, see Figure 5-19. Lubricate the outside
gate rotor blade as the thrust bearings and housing of the housing and bearings with clean compres-
is being removed. sor oil to aid in the installation. Due to the fit of the
bearings on the gate rotor shaft, the thrust bearing
6. Insert gate rotor stabilizer. The side rails are not re- removal and installation tool with the pusher shoe
quired on VSSG 291 thru 601. For the VSG 751 thru must be used. Turn the jacking screw clockwise.
901 and VSG 1051 thru 1301 compressors, use the This will push the thrust bearings onto the shaft
side rails and assemble to the gate rotor stabilizer and push the housing assembly into the frame.
as stamped. For the VSG 1551 thru 3001, use the Install the inner retainer (115) and bolts (151) us-
side rails and assemble to the gate rotor stabilizer. ing Loctite® 242 thread locker. Tighten bolts, see
7. Remove hex head bolts and socket head bolts from Appendix A.
thrust bearing cover. 19. Set clearance between gate rotor blade and shelf.
8. Re-install two bolts into the threaded jacking holes 20. Place a piece of 0.003”-0.004” shim stock between
to assist in removing thrust bearing cover. Retain gate rotor blade and shelf.
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 5 – 25
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.
Figure 5-24. Gate Rotor Assembly and Tools Figure 5-25. Gate Rotor and Shelf Clearance
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG 5 – 27
Section 5 • Maintenance/Service
Gate Rotor Assembly Replacement bearing end of the gate rotor support towards the
suction end of the compressor. The compressor
(VSG 301-701 Compressors ONLY) input shaft may have to be rotated to facilitate the
installation of the gate rotor support.
REMOVAL 11. Install the roller bearing housing with a new O-ring.
The removal of the gate rotor assembly for the VSG 301- Tighten the bolts to the recommended torque
701 compressors is similar for the VSG 901- 2101 com- value.
pressors except that the inner races are secured to the 12. Install the spindle with shims and O-ring, tighten
stationary bearing spindle. bolts, see Appendix A. Measure the clearance be-
1. Remove center member, see appropriate Drive tween the shelf and blade.
Coupling Replacement procedure. 13. Check the clearance between the entire gate ro-
2. Remove the upper bolt from the side cover and in- tor blade and the shelf, rotate the gate rotor to
stall a guide stud in the hole. find the tightest spot. It should be between 0.003-
0.004“ (0.076-0.102 mm). Make adjustments, if
3. Remove remaining bolts and side cover. There will
be some oil drainage when the cover is removed.
4. The side cover that contains the suction strainer
should have the suction line properly supported
before the bolts securing the line to the cover can
be removed. After the line is removed, the cover
can be removed per paragraph B.
5. Turn the main rotor so the driving edge of the
groove is between the top of the shelf or slightly
below the back of the gate rotor support. At this
point install the gate rotor stabilizing tool.
6. Remove plug on the thrust bearing housing. Loosen
the socket head cap screw that is located under-
neath the plug. This secures the inner races of the
thrust bearings to the spindle.
7. Remove bolts that hold the thrust bearing housing
to the compressor. Insert two 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 between
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.
8. Remove the bolts from the roller bearing housing.
After the bolts have been removed, the housing
can be removed from the compressor.
9. To remove the gate rotor support, carefully move
the support opposite the direction of rotation and
tilt the roller bearing end towards the suction end
of the compressor. The compressor input shaft may
have to be turned to facilitate the removal of the
gate rotor support. On dual gate versions, repeat
the procedure for the remaining gate rotor support
assembly.
INSTALLATION
Figure 5-26. Gate Rotor Assembly Breakdown
10. Install the gate rotor support. Carefully tilt the roller
GATE ROTOR THRUST BEARING REMOVAL sides of the inner races are placed together. A light
For removal of thrust bearings on VSG units: application of clean compressor lubricating oil
should be used to ease the installation of the bear-
7. Remove bolts (150) from the clamping ring (114), ings into the gate rotor support.
see Figure 5-31.
17. Install the bearing retaining snap ring.
8. Remove thrust bearing clamping ring.
9. Remove thrust bearings (126) from housing (113).
The bevel on the snap ring must face away from the Restarting procedure in Section 4.
roller bearing. 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 compo-
nents to cool prior to servicing.
4. Disconnect connectors from actuator.
NOTE
Note orientation of components to aid in installation.
INSTALLATION
CAUTION
When installing the slide valve actuator assembly,
loosen locking collar down the shaft. Do not use a
screwdriver to pry locking collar into position.
Figure 5-33. Roller Bearing Assembly
NOTE
This procedure is applicable to both capacity and
volume slide valve actuator assemblies.
REMOVAL
NOTE
The following steps can be used to remove or install
either the capacity or volume command shaft
assemblies.
INSTALLATION
Figure 5-34. Command Shaft Seal
5. Install the command shaft assembly with a new
O-ring (446) on the manifold. Make sure that the
command shaft tongue is engaged in the cross INSTALLATION
CAUTION
shaft slot. Rotate the bearing housing so the vent
holes point down, this will prevent water and dust
from entering the vents. Care must be taken when handling the shaft seal and
6. Install the actuator mounting plate with the four mirror face so it is not damaged. Do not touch the
socket head cap screws and Nord-Lock washers se- carbon or mirror face as body oil and sweat will cause
curing it with proper torque.
the mirror face to corrode.
7. Perform leak check, see Compressor Unit Leak
Check procedure. NOTE
When replacing the stationary members of the seal
on the VSSG 291 thru VSSG 601 the roll pin in the
Command Shaft Seal Replacement cover is used only with the seal assembly having a
stationary mirror face. If a seal assembly with a
REMOVAL stationary carbon face is installed, the roll pin must
1. Remove bolts (281) holding the shaft seal cover be removed.
(218). Insert two of the bolts into the threaded
jacking holes to assist in removing the cover. There 6. To install the carbon cartridge part of the seal in the
will be a small amount of oil drainage as the cover seal cover; clean the seal cover, remove protective
is removed. plastic from the carbon cartridge, do not wipe or
2. Remove the rotating portion of the shaft seal touch the carbon face. Lubricate the sealing O-ring
(219C). with clean compressor lubricating oil. If applicable,
align the hole on the back of the carbon cartridge
3. Remove oil seal (230) from cover.
with the dowel pin in the seal cover. Install car-
4. Remove the stationary portion of the shaft seal tridge using seal installation tool or similar (see tool
(219B) from the seal cover using a brass drift and lists).
hammer to tap it out from the back side of the seal
The actuator cannot be calibrated or The white calibrate wire in the grey Tape the end of the white wire in the
exit calibration mode panel and make sure that it cannot
Turck cable is grounded
touch metal
Dirt and/or condensation on the
Clean the boards with an electronics
position sensor boards are causing it
cleaner or compressed air.
to malfunction
The calibrate button is stuck down Try to free the stuck button.
The position sensor has failed
Replace the actuator.
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.
Calibration step 1
*_*_*_*_*_*_*_*_*_*_*_
Calibration step 2
*___*___*___*___*___
This indicates a zero span. This error can only occur during calibration. The typi-
cal 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 proce-
dure. This error can also occur if either or both of the slotted optocouplers are
not working. If this is the case, the slide valve actuator will have to be replaced.
*__________________ 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.
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
operation) 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 be-
tween terminals 3 and 4 of the small terminal block. If the voltage is >= 24V,
replace the actuator.
The EEPROM data is bad. This is usually caused by loss of 24V pow-
er before the calibration procedure was completed. The actuator
will not move while this error code is displayed. To clear the error,
calibrate the actuator. If this error has occurred 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. The large blue capacitor is bad or has a cracked lead.
*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 as supposed to two circuit boards in version A.
Note 1: TP1 and TP2 are plated-thru holes located close to the slotted optocouplers on the board. They are clearly marked on the board silkscreen
legend.
Note 2: The TS1 wire pads are where the motor thermal switch leads solder into the circuit board. They are clearly marked on the board silkscreen
legend and are oriented at a 45 degree angle.
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, contin-
ue troubleshooting with items below.
• Reset Prelube Oil Pressure Setpoint in Alarms and Trip Setpoints screen to
lowest recommended setpoints.
• Check calibration of oil manifold transducer, discharge pressure transducer,
and suction transducer.
• Check for correct oil pump motor rotation and operation.
Low Oil Pressure at Start
• Ensure transducer isolation valves are open.
• Verify that the correct transducer ranges are selected.
• Check to see all oil line valves are open except the oil dump valve used to fill
the lines and oil cooler.
• Check oil strainer for dirt.
• Check oil filter pressure drop.
• Check “Prelube Oil Pump Time Limit” setpoint is sufficient in Compressor
Timer Setpoints screen.
• Prelube pressure is manifold pressure minus discharge pressure.
• Check solutions in “Low Oil Pressure at Start”.
• Check that there is proper discharge pressure ratio to create differential pres-
sure, otherwise oil pressure can’t be maintained. Oil pressure is manifold oil
pressure minus the suction pressure. It is a net pressure.
• If the oil pump is selected to be a part time oil pump in the “Setup” menu,
Low Run Oil Pressure then ensure that it only shuts off at an appropriate pressure ration that takes
into account pressure drops through the oil cooler. This is a set point in the
“Compressor Control Setpoints” menu called “Oil Pump Restart.” It is a pres-
sure ratio. (discharge pressure in psia/suction pressure in psia) Default ratio
is a pressure ratio of 3.00:1 that stops the pump and 2.80:1 that restarts the
pump. This ratio can be increased. Do not decrease without consulting Vilter.
• Clean oil strainer screen.
• Change oil filter, maybe plugged or collapsed.
Oil flow or oil pressure • Oil pump gears worn internally, excessive end-clearance.
problems • Oil priming valve used on air-cooled cooler units is open.
• Relief in-line check valve stuck open.
• Pressure ratio too low, oil pump should be on.
Problem Solution
• Oil return line from coalescing side of oil separator to suction is closed, not
open enough (.75 turns should be sufficient), or plugged with debris
• The check valve in the oil return line could be stuck closed or the flow is in the
wrong direction
• There may be water in the oil affecting the coalescing elements
• Coalescent elements in need of replacement due to age or damage (water
contamination)
Oil Loss Issues
• The operating conditions are not correct (too high of suction and/or too low
discharge pressure) This creates increased gas flow which could make the oil
separator too small
• The suction or discharge check valve is not working correctly causing oil to
escape when the unit stops
• Viscosity of oil incorrect; send sample for testing
• There is an oil leak somewhere in the system
• Check for correct setting of all manual values.
• Check for correct operation of 2-way automatic oil mixing valve.
• In the “Vilter Only” menu, ensure that you select “Yes this unit has the oil
mixing valve” to enable it.
• If your are controlling a step type oil cooler or a VFD oil cooler, verify the
correct one is selected in the “Vilter Only” menu and the amount of steps are
entered in the menu screen “Oil Cooler Step Control” menu.
High oil temperature (liquid • Check the oil cooler and associated piping to make sure it is full of oil before
injection) starting.
• Check the oil strainer for debris and clean if necessary.
• Verify that the volume slide actuator is functioning correctly and that the
correct compressor size (type) is selected in the “Vilter Only” menu.
• Check that all fans are working.
• Check for correct fan rotation on the oil cooler.
• Check that your operating conditions are within the “As Sold” design
conditions.
• Calibration method not correct
• Actuator or Gear motor not working, or off on overload
• Slide valve carriage assembly out of position, slides binding
Capacity/Volume Slide • Cross-shaft gears, broken pins
Actuator Alarms/Trips/
Symptoms: • Command shaft broken
• Slide valve rack or rack shaft damaged
• Check balance piston movement
• Reference Slide Valve Actuator Troubleshooting Guide
• Check I/O fusing
Problem Solution
High Amp Draw • Check Main Motor Amps scaling and PLC.
Remanufactured Gas Bare Shaft Level 3 - Current Reman Compressor requires complete
rebuilding and re-conditioning to “as-new” condition.
Compressor Process All the components listed in Level 2 are replaced plus all
hardware, slide assemblies, pistons, and a main rotor (if
These instructions are an overview of how the process damaged) and/or gate rotor supports.
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. NOTE
A Level 1 and Level 2 rebuild will include washing
the housing and repainting over the current paint.
The process begins by contacting Vilter’s Customer A Level 3 rebuild will include blasting all the current
Service Department. Vilter contact information can be paint off before repainting.
found on page ii.
Level 1
Compressor is in good condition. Replace bearings, gas-
kets, shaft seal and o-rings. All hardware is intended to
be re-used (when possible). Parts are organized in part
kit form.
Level 2
Compressor is in good condition, but requires new gate
rotor blades. Replace all items in Level 1 plus new gate
rotor blades and bushings.
SAE Grade 2
- 5 10 18 29 44 63 87 155 150*
Coarse (UNC)
SAE Grade 5
- 8 16 28 44 68 98 135 240 387
Coarse (UNC)
SAE Grade 5
- - 18 - - - - - - -
Coarse (UNC)
SAE Grade 8
- 11 22 39 63 96 138 191 338 546
Coarse (UNF)
Socket Head
Cap Screw
5 13 26 46 73 112 115 215 380 614
(ASTM A574)
Coarse (UNC)
1) Torque values in this table are not to override other specific torque specifications when supplied.
2) When using loctite, torque values in this table are only accurate if bolts are tightened immediately after
loctite is applied.
* The proof strength of Grade 2 bolts is less for sizes 7/8 and above and therefore the torque values are less
than smaller sizes of the same grade.
Nut - 8 - 25 - - - - -
NOTE: Continue use of red loctite #271 (VPN 2205E) on currently applied locations. Use blue loctite #243
(VPN 2205F or 2205G) on all remaining locations.
Customer Customer
Comp. Mfr. Vilter
Oil Type VILTER METHANE 100
Serial Number ****-***
Customer Name Model Number VSG-1801
Hrs. on Fluid 6049
Customer Address
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.
OUTLET ON TOP
INLET ON BOTTOM