Emerson VSSG, VSG instruction

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35391SSG Rev. 10 (3/13) Emerson and Vilter are trademarks of Emerson Electric Co. or one of its afﬁliated companies. © 2012 Emerson Climate Technologies, Inc. All rights reserved. Printed in the USA.

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Emerson VSSG, VSG manual

Contents

Installation, operation & maintenance manual VSG/VSSG compressor unitPage VSG/VSSG Standard Vilter Warranty Statement READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR Important MessageVilter Manufacturing LLC Section Title Table of ContentsSection 3 Installation Section 1 General Information Section Number Section 5 Maintenance/ServiceSection 6 Troubleshooting Section 4 Operation Appendices Section 7 Warranty and PartsList of Tables and Figures Table/Figure Figure 3-12. Installation of Coolers - Next to Buildling Section 1 General Information How To Use This Manual Section 1 General Information Gas Compressor Unit Model Designations Figure 1-1. Gas Compressor Unit Model Designation Section 1 General Information System Unit Identiﬁcation Compressor Unit Component Identiﬁcation Section 1 General InformationFigure 1-2. Gas Compressor Unit Components 1 of Figure 1-2. Gas Compressor Unit Components 2 of Section 1 General Information Component Identiﬁcation Continued Figure 1-2. Gas Compressor Unit Components 3 of Section 1 General Information Piping & Identiﬁcation Component Tags Position Transmitter Symbols and Identiﬁcations3-Way Thermostatic Valve High Side Float Valve Steady-Mount Bulb & Capillary 1 - 10 / Blank Oil Life and Oil Flow Section 2 Theory of OperationGas Flow Figure 2-1. Gas Compressor Unit P&ID Control System RTDs and Pressure TransducersThis is a continuous cycle Rigging and Lifting of Compressor Unit Section 3 InstallationDelivery Inspection Figure 3-1. Rigging and Lifting Points Long Term Storage Recommendations The following are recommendations regarding long term storage Recommended Onsite Tools Compressor Unit Inspections Prior to Storage or InstallationAIR COOLED OIL COOLERS LONG TERM STORAGE LOG Compressor has been placed in operation as of Considerations Prior to Starting FoundationFoundation Materials Building the Foundation Compressor Unit Installation of both Check the ability of the soil to carry the load Leveling and Grouting recommendations for setting, precautions, mixing, and Additional Information Codes and Standards LEVEL Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT COMPRESSOR UNIT HOUSEKEEPING PADS Piping 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Fz lbf Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fy lbf ONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-13. Discharge Elevation of Coolers Figure 3-14. Cooler Placement and SpacingPREFERRED Unit Oil Charging and Priming Pressure TestingInitial Oil Charging Using Non -Vilter Oils Do not hydro test compressur unit. Failure to comply Minimum Operating Level Normal Operating Level Maximum NON-Operating LevelBypass Valve OIL MIXING CLOSESUCTION INLET OPEN VALVE Priming Remote Oil Cooler and Piping Section 3 InstallationInitial Oil Charging REMOTE OIL FILTER OPEN SUCTION INLETMOTOR Section 3 Installation Pre Start-Up Pre Start-Up Checklist 15. Verify that all valves are in the open position Section 3 Installation Start-Up Oil Inspection Section 4 OperationOperation Dual Oil Filters Starting, Stopping and Restarting the Compressor Starting Control System CalibrationStopping/Restarting Calibrate Slide Valve Actuators Figure 4-2. Actuator Assembly Section 4 Operation Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC Figure 4-5. Photo-chopper Angle/Slide Travel Table 4-1. Command Shaft Rotation SpeciﬁcationsCapacity Oil Temperature Control Valve Oil Mixing Valve Operation 18. Press the “Set Max” button Fail Position Purging with Dry Nitrogen 10. Close discharge bleed valve while still purging Pressure Indicator Purging with Dry GasOIL SEPARATOR Section 4 Operation Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil Figure 4-13. Suction Oil Charging Valve Coalescing Oil Return Line Setup Unit Table 5-1. Maintenance/Service ScheduleOil Circuit Control Maintaining Proper Operation Section 5 Maintenance/ServiceMaintenance/Service Compressor Unit Isolation for Compressor Unit Leak Check sample for analysis. For an example, see Figure 5-2. Fill Oil System Components Oil SamplingUse Vilter Oil Analysis Kit VPN 3097A to collect an oil Send samples immediately to the oil analysis lab after Oil Charging Dual Oil Filter Assembly Oil Filter ReplacementSingle Oil Filter Assembly Oil Draining Vent Valve Drain Valve Inlet Shut-Off Valves Coalescing Filter Coalescing Filter ReplacementCentering Strap Oil Pump Strainer View From Back of Oil Pump Strainer Table 5-3. Shaft and Hub Distances Drive Coupling Form-Flex BPU Hub InstallationSize 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 SpeciﬁcationsAngular Alignment Drive Coupling Type C Sure-Flex Replacement Drive Coupling Form-Flex BPU Center Member and Hub Removal Compressor Replacement Table 5-6. Clamping Bolts and Set Screw Torque Speciﬁcations Lock Washer Compressor Shaft Bearing Float Inspections Figure 5-11. Bearing Axial Float Inspection Figure 5-12. Bearing Radial Float Inspection Gate Rotor Float and Gate Rotor Bearing Float InspectionTable 5-7. Maximum Bearing Float Figure 5-13. Gate Rotor Float Applied Force Rigidly attach dial indicator Use bolt for fulcurm Table 5-8. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Gate rotor bearing float being measured Section 5 Maintenance/Service Gate Rotor and Support Clearance Figure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Gate Rotor Support Gate Rotor Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Straight Edge Straight Edge Straight Edge VSG 301-701 Compressors Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptTable 5-9. Gate Rotor Tool Sets Figure 5-17. Gate Rotor Assembly Removal and Tools Figure 5-18. Gate Rotor Assembly Removal Figure 5-19. Gate Rotor Assembly and Tools Figure 5-20. Gate Rotor and Shelf Clearance Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLY Figure 5-21. Gate Rotor Assembly Breakdown Figure 5-23. Gate Rotor and Shelf Clearance Figure 5-22. Gate Rotor Thrust Bearing Figure 5-25. Gate Rotor Blade Installation Gate Rotor DisassemblyFigure 5-24. Gate Rotor Blade Assembly Figure 5-27. Thrust Bearing Installation Figure 5-26. Gate Rotor Thrust Bearing Slide Valve Actuator Assembly Replacement Figure 5-28. Roller Bearing Assembly Command Shaft Seal Replacement Command Shaft Assembly ReplacementFigure 5-29. Command Shaft Seal Figure 5-30. Command Shaft Seal Installation Solution Section 6 TroubleshootingProblem Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Meaning Flash PatternTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of calibrate the actuator. If this error has occurred and the cause was er before the calibration procedure was completed. The actuatorwill not move while this error code is displayed. To clear the error not the loss of 24V power during calibration, possible causes are Table 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 On Site Service Support Section 7 Warranty and PartsWarranty Claim Processing Warranty does not cover labor and extraneous expenses Remanufactured Gas Bare Shaft Compressor Process Request a “VSG Single Screw Compressor Rebuild Form” Torque Specifications ft-lbs Appendix A Torque SpecificationsTorque Specifications for 17-4 Stainless Steel Fasteners ft-lbs Appendix B Motor Compressor - General Storage Instructions PRODUCT ANALYSIS REPORT Appendix C Oil Analysis ReportEvaluation No Action Required Appendix D Recommended Header Piping OUTLET ON TOP Appendix E Recommended Remote Air Cooled Oil Cooler PipingINLET ON BOTTOM Blank