Installation, Initial Oil Charging, Remote, Close | Emerson VSSG

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Emerson VSSG Installation, Initial Oil Charging, Priming Remote Oil Cooler and Piping, Oil Separator, Close, Oil Mixing

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 Table of Contents Section 3 InstallationSection Title Section 1 General Information Section 5 Maintenance/Service Section 6 TroubleshootingSection Number Section 4 Operation Section 7 Warranty and Parts List of Tables and FiguresAppendices 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 Section 2 Theory of Operation Gas FlowOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&ID Control System RTDs and Pressure TransducersThis is a continuous cycle Section 3 Installation Delivery InspectionRigging and Lifting of Compressor Unit 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 Foundation Foundation MaterialsConsiderations Prior to Starting 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 Figure 3-6. Housekeeping Pad Dimension Detail - Top View 2 - # CLOSED TIES CENTER LINE 5 - # 6 VERTLEVEL COMPRESSOR UNIT HOUSEKEEPING PADS Piping 010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Table 3-2. Maximum Allowable Flange Loads Nozzle Dia. inFz lbf Fy lbf ONE FAN DIAMETER NOT PREFERRED HOT AIR RECIRCULATION Figure 3-13. Discharge Elevation of Coolers Figure 3-14. Cooler Placement and SpacingPREFERRED Pressure Testing Initial Oil Charging Using Non -Vilter OilsUnit Oil Charging and Priming 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 Section 3 Installation Initial Oil ChargingPriming Remote Oil Cooler and Piping 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 Section 4 Operation OperationOil Inspection Dual Oil Filters Control System Calibration Stopping/RestartingStarting, Stopping and Restarting the Compressor Starting 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 Table 5-1. Maintenance/Service Schedule Oil CircuitUnit Control Section 5 Maintenance/Service Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation for Compressor Unit Leak Check Oil System Components Oil Sampling Use Vilter Oil Analysis Kit VPN 3097A to collect an oilsample for analysis. For an example, see Figure 5-2. Fill Send samples immediately to the oil analysis lab after Oil Charging Oil Filter Replacement Single Oil Filter AssemblyDual 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 Gate Rotor Float and Gate Rotor Bearing Float Inspection Table 5-7. Maximum Bearing FloatFigure 5-12. Bearing Radial Float Inspection Figure 5-13. Gate Rotor Float Table 5-8. Gate Rotor Float Figure 5-14. Gate Rotor Bearing FloatApplied Force Rigidly attach dial indicator Use bolt for fulcurm 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 Figure 5-16. Gate Rotor and Support Clearance - Measuring Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorGate 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 Section 6 Troubleshooting ProblemSolution 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 er before the calibration procedure was completed. The actuator will not move while this error code is displayed. To clear the errorcalibrate the actuator. If this error has occurred and the cause was 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 Section 7 Warranty and Parts Warranty Claim ProcessingOn Site Service Support 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 Appendix C Oil Analysis Report EvaluationPRODUCT ANALYSIS REPORT No Action Required Appendix D Recommended Header Piping OUTLET ON TOP Appendix E Recommended Remote Air Cooled Oil Cooler PipingINLET ON BOTTOM Blank