Emerson VSG, VSSG manual Drive Coupling Type C Sure-Flex Replacement, Maintenance/Service

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Drive Coupling (Type C Sure-Flex) Replacement

Section 5 • Maintenance/Service

32.Perform hot alignment. Run compressor unit and allow to warm up completely.

33.Power down compressor unit and re-check align- ments. Loosen motor mounting nuts to add shims or to adjust alignments as required.

34.Install coupling guard.

Drive Coupling (Type C Sure-Flex) Replacement

Drive couplings that are the Type C Sure-Flex type, are always installed with a C-flange between the compres- sor and motor. The coupling assembly alignments are built into the design and therefore, should not require

Drive Coupling (Form-Flex BPU) Center Member and Hub Removal

To remove coupling assembly, proceed with the follow- ing steps:

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to equipment.

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or damage to equipment.

NOTE

Drive coupling type and size can be determined by the information on the compressor nameplate when ordering; Order Number and Compressor Model Number.

1.Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

2.Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped.

3.Allow compressor, motor and surrounding compo- nents to cool prior to servicing.

4.Remove coupling guard.

5.Remove lock nuts and bolts securing disc pack to hub on compressor shaft.

6.If additional room is required to remove the center member, loosen clamping bolts on straight bore hub(s).

7.Move straight bore hub on shaft as required to al- low center member removal.

8.Remove lock nuts and bolts securing disc pack to hub on motor shaft. Remove center member.

9.For straight bore hubs, remove clamping bolts and hub from shaft.

10.For tapered bore hubs, remove bolt, lock washers, large washer and hub from shaft.

alignment.

NOTE

Drive coupling type and size can be determined by the information on the compressor nameplate when ordering; Order Number and Compressor Model Number.

REMOVAL

To remove Type C Sure-Flex coupling, proceed with the following steps:

WARNING

At shutdown, open any other valves that may trap liquids to prevent serious injury and/or damage to equipment.

WARNING

Follow local lockout/tagout procedure. Failure to comply may result in serious injury, death and/or damage to equipment.

1.Shut down the compressor unit, refer to Stopping/ Restarting procedure in Section 4.

2.Turn disconnect switches to the OFF position for the compressor unit and oil pump motor starter, if equipped.

3.Allow compressor, motor and surrounding compo- nents to cool prior to servicing.

4.Remove C-flange access cover.

NOTE

Mark locations of hubs prior to removal.

5.Loosen set screw in motor hub securing key in keyway.

6.Loosen clamping bolts securing hub to motor shaft.

7.Pry hub up motor shaft for space to remove cou- pling sleeve.

8.Remove coupling sleeve from hub.

9.Remove hub and key from motor shaft.

10.Loosen set screw in compressor hub securing key in keyway.

11.Loosen clamping bolts securing hub from

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

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Page 70 Page 72
Contents VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement Vilter Manufacturing LLC Important MessageREAD CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR 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 Figure 1-2. Gas Compressor Unit Components 1 of Section 1 General InformationCompressor Unit Component Identification 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 3-Way Thermostatic Valve Symbols and IdentificationsPosition Transmitter 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 FlowThis is a continuous cycle RTDs and Pressure TransducersControl System 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 RecommendationsAIR COOLED OIL COOLERS Compressor Unit Inspections Prior to Storage or InstallationRecommended Onsite Tools 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 PREFERRED Figure 3-14. Cooler Placement and SpacingFigure 3-13. Discharge Elevation of Coolers Do not hydro test compressur unit. Failure to comply Pressure TestingInitial Oil Charging Using Non -Vilter Oils Unit Oil Charging and PrimingBypass Valve Normal Operating Level Maximum NON-Operating LevelMinimum Operating Level SUCTION INLET CLOSEOIL MIXING VALVE OPENREMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and PipingMOTOR SUCTION INLETOIL FILTER OPEN 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 PLCCapacity Table 4-1. Command Shaft Rotation SpecificationsAngle/Slide Travel 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 OIL SEPARATOR Purging with Dry GasPressure Indicator 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 Centering Strap Coalescing Filter ReplacementCoalescing Filter View From Back of Oil Pump Strainer Oil Pump StrainerSize Drive Coupling Form-Flex BPU Hub InstallationTable 5-3. Shaft and Hub Distances 17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and AlignmentAngular Alignment Table 5-5. Disc Pack Installation Torque SpecificationsTable 5-4. Hub Clamp Bolt and Set Screw Torque Specifications 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 RotorTable 5-9. Gate Rotor Tool Sets Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptVSG 301-701 Compressors 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 ClearanceFigure 5-24. Gate Rotor Blade Assembly Gate Rotor DisassemblyFigure 5-25. Gate Rotor Blade Installation Figure 5-26. Gate Rotor Thrust Bearing Figure 5-27. Thrust Bearing InstallationFigure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly ReplacementFigure 5-29. Command Shaft Seal Command Shaft Assembly ReplacementCommand Shaft Seal Replacement 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 Table 6-2. Slide Valve Actuator LED Blink Codes* 1 of Flash PatternMeaning 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 ProcessTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix A Torque SpecificationsTorque Specifications ft-lbs Appendix B Motor Compressor - General Storage Instructions No Action Required Appendix C Oil Analysis ReportEvaluation PRODUCT ANALYSIS REPORTAppendix D Recommended Header Piping INLET ON BOTTOM Appendix E Recommended Remote Air Cooled Oil Cooler PipingOUTLET ON TOP Blank
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