Emerson VSG Oil Temperature Control Valve Oil Mixing Valve Operation, Press the “Set Max” button

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18.Press the “Set Max” button.

Section 4 • Operation

11.Use the INC button on the Control panel to drive the slide to its maximum “mechanical stop” posi- tion. Do not continue to run the actuator in this di- rection after the slide valve has reached the stop. Doing so may cause damage to the actuator or the slide valve. Press down on the photo-chopper shaft to disengage the brake, releasing tension from the motor mount. Use the DEC button to pulse the ac- tuator to where the slide is just off of its mechanical stop and there is no tension on the motor shaft.

12.Quickly press and release the blue button on the actuator one more time. The red LED will stop flashing. The actuator is now calibrated and knows the minimum and maximum positions of the slide valve it controls. Now the capacity or volume chan- nel of the PLC can be calibrated.

13.Use the DEC button to move the actuator towards its minimum position while watching the mV readout on the Control Panel screen. Discontinue pressing the DEC button when the mV reading the “Current” window above the “Set Min” button is approximately 500 mV.

14.Now use the DEC and INC buttons to position the slide valve until a value close to 300 mV is on the screen. Then, press the “Set Min” button in the ca- pacity or volume slide valve window to tell the con- troller that this is the minimum mV position. Note: The value in the “Current Cap” or “Current Vol” win- dow has no meaning right now.

15.Use the INC button to rotate the actuator towards its maximum position while watching the mV read- out on the controller screen. Discontinue press- ing the INC button when the mV reading in the “Current” window is approximately 4800 mV. You are nearing the mechanical stop position.

16.Pulse the INC button to carefully move the slide valve until the mV readout “saturates”, or stops in- creasing. This is around 4800 mV Record mV maxi- mum reading.

17.Pulse the DEC button until the mV just start to de- crease. (This is the point where the channel drops out of saturation). Adjust mV value to 300 mV be- low recorded maximum mV.

18.Press the “Set Max” button.

19.Press the “Main” button to complete calibration and exit the “Slide Calibration” screen. The con- troller will automatically energize the actuator and drive it back to its minimum position (below 5%) for pre-start-up.

NOTE

Now the “Current Cap” or the “Current Vol” value will be displayed in the window on the “Main” screen and

the “Slide Calibration” screen.

20.Gently lower the plastic cover over the top of the actuator to where it contacts the base and O-ring seal. After making sure the cover is seated prop- erly, gently tighten the four #10 screws. Caution: The plastic cover will crack if the screws are over tightened.

21.Enable the “Slide Non-Movement Alarm” by going to the “Setup” menu and choosing “Alarm Enable” for the “Slide Non-Movement Option”.

22.Repeat procedure to calibrate other slide valve actuator.

Oil Temperature Control Valve (Oil Mixing Valve) Operation

Initial Position

The temperature control valve is in the closed position when initially installed.

With the temperature control valve de-energized, the valve is set to its initial position. The temperature con- trol valve will be in the closed position with the actuator indicator displaying CLOSED.

When the temperature control valve is energized, the valve will rotate to fully OPEN.

Operation

With the compressor not running, when electrically en- ergized, the PLC will turn the temperature control valve to fully open (100%).

When the compressor starts, the valve remains fully open (100%) until the oil injection temperature rises above the control setpoint. When the oil injection tem- perature rises above the control setpoint, the oil temper- ature control valve will begin to close. The hot oil from the oil separator begins to divert to the oil cooler, mix- ing the hot and cooled oil flow streams together down- stream of the oil temperature control valve. The valve can fully close (0%) diverting the entire oil flow stream to the oil cooler.

As the oil injection temperature drops below the set- point, the oil temperature control valve begins to open so that the oil injection temperature does not become too cold.

When the compressor stops, the valve returns to fully open (100%).

VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG

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Contents VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSORVilter Manufacturing LLC Section 1 General Information Table of ContentsSection 3 Installation Section TitleSection 4 Operation Section 5 Maintenance/ServiceSection 6 Troubleshooting Section NumberTable/Figure Section 7 Warranty and PartsList of Tables and Figures AppendicesFigure 3-12. Installation of Coolers - Next to Buildling Section 1 General Information How To Use This Manual Figure 1-1. Gas Compressor Unit Model Designation Section 1 General Information Gas Compressor Unit Model DesignationsSection 1 General Information System Unit Identification Section 1 General Information Compressor Unit Component IdentificationFigure 1-2. Gas Compressor Unit Components 1 of Figure 1-2. Gas Compressor Unit Components 2 of Figure 1-2. Gas Compressor Unit Components 3 of Section 1 General Information Component Identification ContinuedSection 1 General Information Piping & Identification Component Tags Symbols and Identifications Position Transmitter3-Way Thermostatic Valve High Side Float Valve Steady-Mount Bulb & Capillary 1 - 10 / Blank Figure 2-1. Gas Compressor Unit P&ID Section 2 Theory of OperationGas Flow Oil Life and Oil FlowRTDs and Pressure Transducers Control SystemThis is a continuous cycle Figure 3-1. Rigging and Lifting Points Section 3 InstallationDelivery Inspection Rigging and Lifting of Compressor UnitThe following are recommendations regarding long term storage Long Term Storage RecommendationsCompressor Unit Inspections Prior to Storage or Installation Recommended Onsite ToolsAIR COOLED OIL COOLERS Compressor has been placed in operation as of LONG TERM STORAGE LOGBuilding the Foundation FoundationFoundation Materials Considerations Prior to Startingof both Check the ability of the soil to carry the load Compressor Unit Installationrecommendations for setting, precautions, mixing, and Leveling and GroutingAdditional Information Codes and Standards COMPRESSOR UNIT HOUSEKEEPING PADS Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT LEVEL010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 PipingFy lbf Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fz lbfONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersPREFERRED Do not hydro test compressur unit. Failure to comply Pressure TestingInitial Oil Charging Using Non -Vilter Oils Unit Oil Charging and PrimingNormal Operating Level Maximum NON-Operating Level Minimum Operating LevelBypass Valve CLOSE OIL MIXINGSUCTION INLET VALVE OPENREMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and PipingSUCTION INLET OIL FILTER OPENMOTOR Pre Start-Up Checklist Section 3 Installation Pre Start-Up15. Verify that all valves are in the open position Section 3 Installation Start-Up Dual Oil Filters Section 4 OperationOperation Oil InspectionCalibrate Slide Valve Actuators Control System CalibrationStopping/Restarting Starting, Stopping and Restarting the Compressor StartingFigure 4-2. Actuator Assembly Section 4 Operation Figure 4-5. Photo-chopper Figure 4-4. Slide Valve Calibration Screen Compact Logix PLCTable 4-1. Command Shaft Rotation Specifications Angle/Slide TravelCapacity 18. Press the “Set Max” button Oil Temperature Control Valve Oil Mixing Valve OperationFail Position Purging with Dry Nitrogen 10. Close discharge bleed valve while still purging Purging with Dry Gas Pressure IndicatorOIL SEPARATOR Section 4 Operation Figure 4-13. Suction Oil Charging Valve Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction OilCoalescing Oil Return Line Setup Control Table 5-1. Maintenance/Service ScheduleOil Circuit UnitCompressor Unit Isolation for Section 5 Maintenance/ServiceMaintenance/Service Maintaining Proper OperationCompressor Unit Leak Check Send samples immediately to the oil analysis lab after Oil System Components Oil SamplingUse Vilter Oil Analysis Kit VPN 3097A to collect an oil sample for analysis. For an example, see Figure 5-2. FillOil Charging Oil Draining Oil Filter ReplacementSingle Oil Filter Assembly Dual Oil Filter AssemblyVent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Replacement Coalescing FilterCentering Strap View From Back of Oil Pump Strainer Oil Pump StrainerDrive Coupling Form-Flex BPU Hub Installation Table 5-3. Shaft and Hub DistancesSize 17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and AlignmentTable 5-5. Disc Pack Installation Torque Specifications Table 5-4. Hub Clamp Bolt and Set Screw Torque SpecificationsAngular Alignment Drive Coupling Form-Flex BPU Center Member and Hub Removal Drive Coupling Type C Sure-Flex ReplacementTable 5-6. Clamping Bolts and Set Screw Torque Specifications Compressor ReplacementLock Washer Figure 5-11. Bearing Axial Float Inspection Compressor Shaft Bearing Float InspectionsFigure 5-13. Gate Rotor Float Gate Rotor Float and Gate Rotor Bearing Float InspectionTable 5-7. Maximum Bearing Float Figure 5-12. Bearing Radial Float InspectionGate rotor bearing float being measured Table 5-8. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Applied Force Rigidly attach dial indicator Use bolt for fulcurmFigure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support ClearanceStraight Edge Straight Edge Straight Edge Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorGate Rotor Assembly Replacement All VSG & VSSG Compressors Except VSG 301-701 CompressorsTable 5-9. Gate Rotor Tool Sets Figure 5-18. Gate Rotor Assembly Removal Figure 5-17. Gate Rotor Assembly Removal and ToolsFigure 5-20. Gate Rotor and Shelf Clearance Figure 5-19. Gate Rotor Assembly and ToolsFigure 5-21. Gate Rotor Assembly Breakdown Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLYFigure 5-22. Gate Rotor Thrust Bearing Figure 5-23. Gate Rotor and Shelf ClearanceGate Rotor Disassembly Figure 5-25. Gate Rotor Blade InstallationFigure 5-24. Gate Rotor Blade Assembly Figure 5-26. Gate Rotor Thrust Bearing Figure 5-27. Thrust Bearing InstallationFigure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly ReplacementCommand Shaft Assembly Replacement Command Shaft Seal ReplacementFigure 5-29. Command Shaft Seal Figure 5-30. Command Shaft Seal Installation Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Section 6 TroubleshootingProblem SolutionTable 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Flash Pattern MeaningTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of not the loss of 24V power during calibration, possible causes are er before the calibration procedure was completed. The actuatorwill not move while this error code is displayed. To clear the error calibrate the actuator. If this error has occurred and the cause wasTable 6-3. Troubleshooting Guide - General Problems & Solutions 1 of Table 6-3. Troubleshooting Guide - General Problems & Solutions 2 of Table 6-3. Troubleshooting Guide - General Problems & Solutions 3 of 6 - 8 / Blank Warranty does not cover labor and extraneous expenses Section 7 Warranty and PartsWarranty Claim Processing On Site Service SupportRequest a “VSG Single Screw Compressor Rebuild Form” Remanufactured Gas Bare Shaft Compressor ProcessAppendix A Torque Specifications Torque Specifications ft-lbsTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix B Motor Compressor - General Storage Instructions No Action Required Appendix C Oil Analysis ReportEvaluation PRODUCT ANALYSIS REPORTAppendix D Recommended Header Piping Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank