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manual VSG/VSSG compressor unit, Installation, operation & maintenance manual
Models:
VSG
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106 pages
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Troubleshooting
Specs
Install
Error messages
14. Cooler Placement and Spacing
Warranty
Dimension
Maintenance
Problem
Coalescing Oil Return Line Setup
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VSG/VSSG compressor unit
Installation, operation & maintenance manual
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Contents
VSG/VSSG compressor unit
Installation, operation & maintenance manual
Page
VSG/VSSG Standard Vilter Warranty Statement
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR
Important Message
Vilter Manufacturing LLC
Section 3 Installation
Table of Contents
Section Title
Section 1 General Information
Section 6 Troubleshooting
Section 5 Maintenance/Service
Section Number
Section 4 Operation
List of Tables and Figures
Section 7 Warranty and Parts
Appendices
Table/Figure
List of Tables and Figures
Figure 3-12. Installation of Coolers - Next to Buildling
Table/Figure
Section Number
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 Designations
Section 1 General Information System Unit Identification
Compressor Unit Component Identification
Section 1 General Information
Figure 1-2. Gas Compressor Unit Components 1 of
Section 1 General Information
Figure 1-2. Gas Compressor Unit Components 2 of
Figure 1-2. Gas Compressor Unit Components 3 of
Section 1 General Information Component Identification Continued
Section 1 General Information Piping & Identification Component Tags
Section 1 General Information
Symbols and Identifications
Position Transmitter
3-Way Thermostatic Valve
High Side Float Valve Steady-Mount Bulb & Capillary
Section 1 General Information
1 - 10 / Blank
Gas Flow
Section 2 Theory of Operation
Oil Life and Oil Flow
Figure 2-1. Gas Compressor Unit P&ID
Control System
RTDs and Pressure Transducers
Section 2 Theory of Operation
This is a continuous cycle
Delivery Inspection
Section 3 Installation
Rigging and Lifting of Compressor Unit
Figure 3-1. Rigging and Lifting Points
Section 3 Installation
Long Term Storage Recommendations
The following are recommendations regarding long term storage
Recommended Onsite Tools
Compressor Unit Inspections Prior to Storage or Installation
Section 3 Installation
AIR COOLED OIL COOLERS
LONG TERM STORAGE LOG
Section 3 Installation
Compressor has been placed in operation as of
Foundation Materials
Foundation
Considerations Prior to Starting
Building the Foundation
Section 3 Installation
Compressor Unit Installation
of both Check the ability of the soil to carry the load
Section 3 Installation
Leveling and Grouting
recommendations for setting, precautions, mixing, and
Additional Information Codes and Standards
Section 3 Installation
Figure 3-6. Housekeeping Pad Dimension Detail - Top View
Section 3 Installation
2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT
LEVEL
Section 3 Installation
Piping
010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5
Section 3 Installation
Table 3-2. Maximum Allowable Flange Loads
Nozzle Dia. in
Fz lbf
ONE FAN DIAMETER
Section 3 Installation
NOT PREFERRED
Section 3 Installation
HOT AIR RECIRCULATION
Section 3 Installation
Figure 3-14. Cooler Placement and Spacing
Section 3 Installation
Figure 3-13. Discharge Elevation of Coolers
PREFERRED
Initial Oil Charging Using Non -Vilter Oils
Pressure Testing
Unit Oil Charging and Priming
Section 3 Installation
Normal Operating Level Maximum NON-Operating Level
Section 3 Installation
Minimum Operating Level
Bypass Valve
CLOSE
Section 3 Installation
OIL MIXING
CLOSE
CLOSE
Section 3 Installation
OPEN
OIL MIXING
Initial Oil Charging
Section 3 Installation
Priming Remote Oil Cooler and Piping
REMOTE
SUCTION INLET
Section 3 Installation
REMOTE
OIL SEPARATOR
Pre Start-Up Checklist
Section 3 Installation Pre Start-Up
15. Verify that all valves are in the open position
Section 3 Installation
Section 3 Installation Start-Up
Operation
Section 4 Operation
Oil Inspection
Dual Oil Filters
Stopping/Restarting
Control System Calibration
Starting, Stopping and Restarting the Compressor Starting
Calibrate Slide Valve Actuators
Section 4 Operation
Figure 4-2. Actuator Assembly
Section 4 Operation
Figure 4-5. Photo-chopper
Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC
Section 4 Operation
Section 4 Operation
Table 4-1. Command Shaft Rotation Specifications
Angle/Slide Travel
Capacity
Section 4 Operation
Oil Temperature Control Valve Oil Mixing Valve Operation
18. Press the “Set Max” button
Fail Position
Section 4 Operation
Section 4 Operation
Purging with Dry Nitrogen
10. Close discharge bleed valve while still purging
Section 4 Operation
Pressure Indicator
Purging with Dry Gas
Section 4 Operation
OIL SEPARATOR
Section 4 Operation
Equalizing Solenoid for Suction Bypass Suction Bypass Valve Manual
Section 4 Operation
Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil
Charging Valve
Section 4 Operation
Coalescing Oil Return Line Setup
Oil Circuit
Table 5-1. Maintenance/Service Schedule
Unit
Control
Maintenance/Service
Section 5 Maintenance/Service
Maintaining Proper Operation
Compressor Unit Isolation for
Section 5 Maintenance/Service
Compressor Unit Leak Check
Section 5 Maintenance/Service
Oil System Components Oil Sampling
Use Vilter Oil Analysis Kit VPN 3097A to collect an oil
sample for analysis. For an example, see Figure 5-2. Fill
Section 5 Maintenance/Service
Oil Charging
Single Oil Filter Assembly
Oil Filter Replacement
Dual Oil Filter Assembly
Oil Draining
Vent Valve Drain Valve Inlet Shut-Off Valves
Section 5 Maintenance/Service
Section 5 Maintenance/Service
Coalescing Filter Replacement
Coalescing Filter
Centering Strap
Section 5 Maintenance/Service
Oil Pump Strainer
View From Back of Oil Pump Strainer
Table 5-3. Shaft and Hub Distances
Drive Coupling Form-Flex BPU Hub Installation
Section 5 Maintenance/Service
Size
Section 5 Maintenance/Service
Drive Center Member Installation and Alignment
17. Install set screw in hub cap to secure key in keyway of shaft
Table 5-4. Hub Clamp Bolt and Set Screw Torque Specifications
Table 5-5. Disc Pack Installation Torque Specifications
Section 5 Maintenance/Service
Angular Alignment
Drive Coupling Form-Flex BPU Center Member and Hub Removal
Drive Coupling Type C Sure-Flex Replacement
Section 5 Maintenance/Service
Table 5-6. Clamping Bolts and Set Screw Torque Specifications
Compressor Replacement
Section 5 Maintenance/Service
Lock Washer
Section 5 Maintenance/Service
Figure 5-11. Bearing Axial Float Inspection
Compressor Shaft Bearing Float Inspections
Section 5 Maintenance/Service
Table 5-7. Maximum Bearing Float
Gate Rotor Float and Gate Rotor Bearing Float Inspection
Figure 5-12. Bearing Radial Float Inspection
Figure 5-13. Gate Rotor Float
Figure 5-14. Gate Rotor Bearing Float
Table 5-8. Gate Rotor Float
Section 5 Maintenance/Service
Applied Force Rigidly attach dial indicator Use bolt for fulcurm
Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances
Section 5 Maintenance/Service Gate Rotor and Support Clearance
Section 5 Maintenance/Service
Figure 5-16. Gate Rotor and Support Clearance - Measuring
Gate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor
Gate Rotor Support Gate Rotor
VSG 301-701 Compressors
Gate Rotor Assembly Replacement All VSG & VSSG Compressors Except
Table 5-9. Gate Rotor Tool Sets
Section 5 Maintenance/Service
Figure 5-18. Gate Rotor Assembly Removal
Figure 5-17. Gate Rotor Assembly Removal and Tools
Section 5 Maintenance/Service
Figure 5-20. Gate Rotor and Shelf Clearance
Figure 5-19. Gate Rotor Assembly and Tools
Section 5 Maintenance/Service
Figure 5-21. Gate Rotor Assembly Breakdown
Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLY
Section 5 Maintenance/Service
Figure 5-22. Gate Rotor Thrust Bearing
Figure 5-23. Gate Rotor and Shelf Clearance
Section 5 Maintenance/Service
Figure 5-25. Gate Rotor Blade Installation
Gate Rotor Disassembly
Figure 5-24. Gate Rotor Blade Assembly
Section 5 Maintenance/Service
Figure 5-26. Gate Rotor Thrust Bearing
Figure 5-27. Thrust Bearing Installation
Section 5 Maintenance/Service
Figure 5-28. Roller Bearing Assembly
Slide Valve Actuator Assembly Replacement
Section 5 Maintenance/Service
Command Shaft Seal Replacement
Command Shaft Assembly Replacement
Figure 5-29. Command Shaft Seal
Section 5 Maintenance/Service
Section 5 Maintenance/Service
Figure 5-30. Command Shaft Seal Installation
Problem
Section 6 Troubleshooting
Solution
Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of
Section 6 Troubleshooting
Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 of
Problem
Solution
Meaning
Flash Pattern
Table 6-2. Slide Valve Actuator LED Blink Codes* 1 of
Section 6 Troubleshooting
will not move while this error code is displayed. To clear the error
er before the calibration procedure was completed. The actuator
calibrate the actuator. If this error has occurred and the cause was
not the loss of 24V power during calibration, possible causes are
Section 6 Troubleshooting
Table 6-3. Troubleshooting Guide - General Problems & Solutions 1 of
Problem
Solution
Section 6 Troubleshooting
Table 6-3. Troubleshooting Guide - General Problems & Solutions 2 of
Problem
Solution
Section 6 Troubleshooting
Table 6-3. Troubleshooting Guide - General Problems & Solutions 3 of
Problem
Solution
6 - 8 / Blank
Warranty Claim Processing
Section 7 Warranty and Parts
On Site Service Support
Warranty does not cover labor and extraneous expenses
Section 7 Warranty and Parts
Remanufactured Gas Bare Shaft Compressor Process
Request a “VSG Single Screw Compressor Rebuild Form”
Torque Specifications ft-lbs
Appendix A Torque Specifications
Torque Specifications for 17-4 Stainless Steel Fasteners ft-lbs
Appendix B Motor Compressor - General Storage Instructions
Evaluation
Appendix C Oil Analysis Report
PRODUCT ANALYSIS REPORT
No Action Required
Appendix D Recommended Header Piping
OUTLET ON TOP
Appendix E Recommended Remote Air Cooled Oil Cooler Piping
INLET ON BOTTOM
Blank
