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Emerson VSSG, VSG manual Operation

Models: VSG

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Section 4 • Operation

Figure 4-3. Menu Screen and Slide Calibration Button (Compact Logix PLC)

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

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Emerson VSSG, VSG manual Operation

Contents

Installation, operation & maintenance manual VSG/VSSG compressor unitPage VSG/VSSG Standard Vilter Warranty Statement Important Message READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSORVilter Manufacturing LLC Table of Contents Section 3 InstallationSection Title Section 1 General InformationSection 5 Maintenance/Service Section 6 TroubleshootingSection Number Section 4 OperationSection 7 Warranty and Parts List of Tables and FiguresAppendices Table/FigureFigure 3-12. Installation of Coolers - Next to Buildling List of Tables and FiguresTable/Figure Section NumberSection 1 General Information How To Use This Manual Section 1 General Information Gas Compressor Unit Model Designations Figure 1-1. Gas Compressor Unit Model DesignationSection 1 General Information System Unit Identiﬁcation Section 1 General Information Compressor Unit Component IdentiﬁcationFigure 1-2. Gas Compressor Unit Components 1 of Figure 1-2. Gas Compressor Unit Components 2 of Section 1 General InformationSection 1 General Information Component Identiﬁcation Continued Figure 1-2. Gas Compressor Unit Components 3 ofSection 1 General Information Piping & Identiﬁcation Component Tags Symbols and Identiﬁcations Section 1 General InformationPosition Transmitter 3-Way Thermostatic ValveSection 1 General Information High Side Float Valve Steady-Mount Bulb & Capillary1 - 10 / Blank Section 2 Theory of Operation Gas FlowOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&IDRTDs and Pressure Transducers Control SystemSection 2 Theory of Operation This is a continuous cycleSection 3 Installation Delivery InspectionRigging and Lifting of Compressor Unit Figure 3-1. Rigging and Lifting PointsLong Term Storage Recommendations Section 3 InstallationThe following are recommendations regarding long term storage Compressor Unit Inspections Prior to Storage or Installation Recommended Onsite ToolsSection 3 Installation AIR COOLED OIL COOLERSSection 3 Installation LONG TERM STORAGE LOGCompressor has been placed in operation as of Foundation Foundation MaterialsConsiderations Prior to Starting Building the FoundationCompressor Unit Installation Section 3 Installationof both Check the ability of the soil to carry the load Leveling and Grouting Section 3 Installationrecommendations for setting, precautions, mixing, and Section 3 Installation Additional Information Codes and StandardsSection 3 Installation Figure 3-6. Housekeeping Pad Dimension Detail - Top View2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT LEVELPiping Section 3 Installation010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Table 3-2. Maximum Allowable Flange Loads Section 3 InstallationNozzle Dia. in Fz lbfSection 3 Installation ONE FAN DIAMETERSection 3 Installation NOT PREFERREDSection 3 Installation HOT AIR RECIRCULATIONSection 3 Installation Figure 3-14. Cooler Placement and SpacingFigure 3-13. Discharge Elevation of Coolers PREFERREDPressure Testing Initial Oil Charging Using Non -Vilter OilsUnit Oil Charging and Priming Section 3 InstallationSection 3 Installation Normal Operating Level Maximum NON-Operating LevelMinimum Operating Level Bypass ValveSection 3 Installation CLOSEOIL MIXING CLOSESection 3 Installation CLOSEOPEN OIL MIXINGSection 3 Installation Initial Oil ChargingPriming Remote Oil Cooler and Piping REMOTESection 3 Installation SUCTION INLETREMOTE OIL SEPARATORSection 3 Installation Pre Start-Up Pre Start-Up ChecklistSection 3 Installation 15. Verify that all valves are in the open positionSection 3 Installation Start-Up Section 4 Operation OperationOil Inspection Dual Oil FiltersControl System Calibration Stopping/RestartingStarting, Stopping and Restarting the Compressor Starting Calibrate Slide Valve ActuatorsFigure 4-2. Actuator Assembly Section 4 OperationSection 4 Operation Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC Figure 4-5. Photo-chopperSection 4 Operation Table 4-1. Command Shaft Rotation Speciﬁcations Section 4 OperationAngle/Slide Travel CapacityOil Temperature Control Valve Oil Mixing Valve Operation Section 4 Operation18. Press the “Set Max” button Section 4 Operation Fail PositionPurging with Dry Nitrogen Section 4 OperationSection 4 Operation 10. Close discharge bleed valve while still purgingPurging with Dry Gas Pressure IndicatorSection 4 Operation OIL SEPARATORSection 4 Operation Section 4 Operation Equalizing Solenoid for Suction Bypass Suction Bypass Valve ManualFigure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil Charging ValveCoalescing Oil Return Line Setup Section 4 OperationTable 5-1. Maintenance/Service Schedule Oil CircuitUnit ControlSection 5 Maintenance/Service Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation forCompressor Unit Leak Check Section 5 Maintenance/ServiceOil System Components Oil Sampling Section 5 Maintenance/ServiceUse Vilter Oil Analysis Kit VPN 3097A to collect an oil sample for analysis. For an example, see Figure 5-2. FillOil Charging Section 5 Maintenance/ServiceOil Filter Replacement Single Oil Filter AssemblyDual Oil Filter Assembly Oil DrainingSection 5 Maintenance/Service Vent Valve Drain Valve Inlet Shut-Off ValvesCoalescing Filter Replacement Section 5 Maintenance/ServiceCoalescing Filter Centering StrapOil Pump Strainer Section 5 Maintenance/ServiceView From Back of Oil Pump Strainer Drive Coupling Form-Flex BPU Hub Installation Table 5-3. Shaft and Hub DistancesSection 5 Maintenance/Service SizeDrive Center Member Installation and Alignment Section 5 Maintenance/Service17. Install set screw in hub cap to secure key in keyway of shaft Table 5-5. Disc Pack Installation Torque Speciﬁcations Table 5-4. Hub Clamp Bolt and Set Screw Torque SpeciﬁcationsSection 5 Maintenance/Service Angular AlignmentDrive Coupling Type C Sure-Flex Replacement Drive Coupling Form-Flex BPU Center Member and Hub RemovalSection 5 Maintenance/Service Compressor Replacement Table 5-6. Clamping Bolts and Set Screw Torque SpeciﬁcationsSection 5 Maintenance/Service Section 5 Maintenance/Service Lock WasherCompressor Shaft Bearing Float Inspections Figure 5-11. Bearing Axial Float InspectionSection 5 Maintenance/Service 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 FloatTable 5-8. Gate Rotor Float Figure 5-14. Gate Rotor Bearing FloatSection 5 Maintenance/Service Applied Force Rigidly attach dial indicator Use bolt for fulcurmSection 5 Maintenance/Service Gate Rotor and Support Clearance Figure 5-15. Gate Rotor and Support Clearance - Minimum ClearancesFigure 5-16. Gate Rotor and Support Clearance - Measuring Section 5 Maintenance/ServiceGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorGate Rotor Assembly Replacement All VSG & VSSG Compressors Except VSG 301-701 CompressorsTable 5-9. Gate Rotor Tool Sets Section 5 Maintenance/ServiceFigure 5-17. Gate Rotor Assembly Removal and Tools Figure 5-18. Gate Rotor Assembly RemovalSection 5 Maintenance/Service Figure 5-19. Gate Rotor Assembly and Tools Figure 5-20. Gate Rotor and Shelf ClearanceSection 5 Maintenance/Service Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLY Figure 5-21. Gate Rotor Assembly BreakdownSection 5 Maintenance/Service Figure 5-23. Gate Rotor and Shelf Clearance Figure 5-22. Gate Rotor Thrust BearingSection 5 Maintenance/Service Gate Rotor Disassembly Figure 5-25. Gate Rotor Blade InstallationFigure 5-24. Gate Rotor Blade Assembly Section 5 Maintenance/ServiceFigure 5-27. Thrust Bearing Installation Figure 5-26. Gate Rotor Thrust BearingSection 5 Maintenance/Service Slide Valve Actuator Assembly Replacement Figure 5-28. Roller Bearing AssemblySection 5 Maintenance/Service Command Shaft Assembly Replacement Command Shaft Seal ReplacementFigure 5-29. Command Shaft Seal Section 5 Maintenance/ServiceFigure 5-30. Command Shaft Seal Installation Section 5 Maintenance/ServiceSection 6 Troubleshooting ProblemSolution Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 ofTable 6-1. Slide Valve Actuator Troubleshooting Guide 2 of Section 6 TroubleshootingProblem SolutionFlash Pattern MeaningTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of Section 6 Troubleshootinger 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 areTable 6-3. Troubleshooting Guide - General Problems & Solutions 1 of Section 6 TroubleshootingProblem SolutionTable 6-3. Troubleshooting Guide - General Problems & Solutions 2 of Section 6 TroubleshootingProblem SolutionTable 6-3. Troubleshooting Guide - General Problems & Solutions 3 of Section 6 TroubleshootingProblem Solution6 - 8 / Blank Section 7 Warranty and Parts Warranty Claim ProcessingOn Site Service Support Warranty does not cover labor and extraneous expensesRemanufactured Gas Bare Shaft Compressor Process Section 7 Warranty and PartsRequest a “VSG Single Screw Compressor Rebuild Form” Appendix A Torque Specifications Torque Specifications ft-lbsTorque 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 RequiredAppendix D Recommended Header Piping Appendix E Recommended Remote Air Cooled Oil Cooler Piping OUTLET ON TOPINLET ON BOTTOM Blank