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Emerson VSG, VSSG manual General Information System Unit Identiﬁcation

Models: VSG

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Section 1 • General Information

System Unit Identiﬁcation

To keep deﬁnitions of units simple and consistent, Vilter has deﬁned the following three:

•Bare Shaft Compressor

•Compressor Unit

•Package Unit

Bare Shaft Compressor

A bare shaft compressor is just the compressor with no coupling and motor nor foundation.

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.

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

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Page 11

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Emerson VSG, VSSG manual General Information System Unit Identiﬁcation

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 AppendicesSection Number Figure 3-12. Installation of Coolers - Next to BuildlingList of Tables and Figures Table/FigureSection 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 Section 1 General Information Figure 1-2. Gas Compressor Unit Components 2 ofFigure 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 IdentiﬁcationsSection 1 General Information Position TransmitterHigh Side Float Valve Steady-Mount Bulb & Capillary Section 1 General Information1 - 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 Section 2 Theory of OperationFigure 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 RecommendationsSection 3 Installation AIR COOLED OIL COOLERS Compressor Unit Inspections Prior to Storage or InstallationRecommended Onsite Tools Section 3 InstallationCompressor has been placed in operation as of Section 3 InstallationLONG TERM STORAGE LOG Building the Foundation FoundationFoundation Materials Considerations Prior to Startingof both Check the ability of the soil to carry the load Compressor Unit InstallationSection 3 Installation recommendations for setting, precautions, mixing, and Leveling and GroutingSection 3 Installation Additional Information Codes and Standards Section 3 InstallationLEVEL Section 3 InstallationFigure 3-6. Housekeeping Pad Dimension Detail - Top View 2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 PipingSection 3 Installation Fz lbf Table 3-2. Maximum Allowable Flange LoadsSection 3 Installation Nozzle Dia. inONE FAN DIAMETER Section 3 InstallationNOT PREFERRED Section 3 InstallationHOT AIR RECIRCULATION Section 3 InstallationPREFERRED Section 3 InstallationFigure 3-14. Cooler Placement and Spacing Figure 3-13. Discharge Elevation of CoolersSection 3 Installation Pressure TestingInitial Oil Charging Using Non -Vilter Oils Unit Oil Charging and PrimingBypass Valve Section 3 InstallationNormal Operating Level Maximum NON-Operating Level Minimum Operating LevelCLOSE Section 3 InstallationCLOSE OIL MIXINGOIL MIXING Section 3 InstallationCLOSE OPENREMOTE Section 3 InstallationInitial Oil Charging Priming Remote Oil Cooler and PipingOIL SEPARATOR Section 3 InstallationSUCTION INLET REMOTEPre Start-Up Checklist Section 3 Installation Pre Start-Up15. Verify that all valves are in the open position Section 3 InstallationSection 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 StartingSection 4 Operation Figure 4-2. Actuator AssemblySection 4 Operation Section 4 Operation Figure 4-4. Slide Valve Calibration Screen Compact Logix PLCFigure 4-5. Photo-chopper Capacity Table 4-1. Command Shaft Rotation SpeciﬁcationsSection 4 Operation Angle/Slide Travel18. Press the “Set Max” button Oil Temperature Control Valve Oil Mixing Valve OperationSection 4 Operation Fail Position Section 4 OperationSection 4 Operation Purging with Dry Nitrogen10. Close discharge bleed valve while still purging Section 4 OperationOIL SEPARATOR Purging with Dry GasPressure Indicator Section 4 OperationSection 4 Operation Charging Valve Section 4 OperationEqualizing Solenoid for Suction Bypass Suction Bypass Valve Manual Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction OilSection 4 Operation Coalescing Oil Return Line SetupControl Table 5-1. Maintenance/Service ScheduleOil Circuit UnitCompressor Unit Isolation for Section 5 Maintenance/ServiceMaintenance/Service Maintaining Proper OperationSection 5 Maintenance/Service Compressor Unit Leak Checksample for analysis. For an example, see Figure 5-2. Fill Oil System Components Oil SamplingSection 5 Maintenance/Service Use Vilter Oil Analysis Kit VPN 3097A to collect an oilSection 5 Maintenance/Service Oil ChargingOil Draining Oil Filter ReplacementSingle Oil Filter Assembly Dual Oil Filter AssemblyVent Valve Drain Valve Inlet Shut-Off Valves Section 5 Maintenance/ServiceCentering Strap Coalescing Filter ReplacementSection 5 Maintenance/Service Coalescing FilterView From Back of Oil Pump Strainer Oil Pump StrainerSection 5 Maintenance/Service Size Drive Coupling Form-Flex BPU Hub InstallationTable 5-3. Shaft and Hub Distances Section 5 Maintenance/Service17. Install set screw in hub cap to secure key in keyway of shaft Drive Center Member Installation and AlignmentSection 5 Maintenance/Service Angular Alignment Table 5-5. Disc Pack Installation Torque SpeciﬁcationsTable 5-4. Hub Clamp Bolt and Set Screw Torque Speciﬁcations Section 5 Maintenance/ServiceSection 5 Maintenance/Service Drive Coupling Type C Sure-Flex ReplacementDrive Coupling Form-Flex BPU Center Member and Hub Removal Section 5 Maintenance/Service Compressor ReplacementTable 5-6. Clamping Bolts and Set Screw Torque Speciﬁcations Lock Washer Section 5 Maintenance/ServiceSection 5 Maintenance/Service Compressor Shaft Bearing Float InspectionsFigure 5-11. Bearing Axial Float Inspection Figure 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 InspectionApplied Force Rigidly attach dial indicator Use bolt for fulcurm Table 5-8. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Section 5 Maintenance/ServiceFigure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support ClearanceGate Rotor Support Gate Rotor Figure 5-16. Gate Rotor and Support Clearance - MeasuringSection 5 Maintenance/Service Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorSection 5 Maintenance/Service Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptVSG 301-701 Compressors Table 5-9. Gate Rotor Tool SetsSection 5 Maintenance/Service Figure 5-17. Gate Rotor Assembly Removal and ToolsFigure 5-18. Gate Rotor Assembly Removal Section 5 Maintenance/Service Figure 5-19. Gate Rotor Assembly and ToolsFigure 5-20. Gate Rotor and Shelf Clearance Section 5 Maintenance/Service Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLYFigure 5-21. Gate Rotor Assembly Breakdown Section 5 Maintenance/Service Figure 5-23. Gate Rotor and Shelf ClearanceFigure 5-22. Gate Rotor Thrust Bearing Section 5 Maintenance/Service Gate Rotor DisassemblyFigure 5-25. Gate Rotor Blade Installation Figure 5-24. Gate Rotor Blade AssemblySection 5 Maintenance/Service Figure 5-27. Thrust Bearing InstallationFigure 5-26. Gate Rotor Thrust Bearing Section 5 Maintenance/Service Slide Valve Actuator Assembly ReplacementFigure 5-28. Roller Bearing Assembly Section 5 Maintenance/Service Command Shaft Assembly ReplacementCommand Shaft Seal Replacement Figure 5-29. Command Shaft SealSection 5 Maintenance/Service Figure 5-30. Command Shaft Seal InstallationTable 6-1. Slide Valve Actuator Troubleshooting Guide 1 of Section 6 TroubleshootingProblem SolutionSolution Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 ofSection 6 Troubleshooting ProblemSection 6 Troubleshooting Flash PatternMeaning Table 6-2. Slide Valve Actuator LED Blink Codes* 1 ofnot 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 wasSolution Table 6-3. Troubleshooting Guide - General Problems & Solutions 1 ofSection 6 Troubleshooting ProblemSolution Table 6-3. Troubleshooting Guide - General Problems & Solutions 2 ofSection 6 Troubleshooting ProblemSolution Table 6-3. Troubleshooting Guide - General Problems & Solutions 3 ofSection 6 Troubleshooting Problem6 - 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 ProcessSection 7 Warranty and Parts Torque 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