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Emerson VSG, VSSG manual Maintenance/Service, Lock Washer

Models: VSG

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Lock Washer

Section 5 • Maintenance/Service

personnel, remove compressor from frame.

17.Remove shims and spherical washers from com- pressor mounting locations.

18.Inspect shims and spherical washers for damage, replace as required.

INSTALLATION

19.Install shims and spherical washers on compressor mounting locations, see Figure 5-10.

20.Install appropriate lifting eyes on top of compressor.

21.Using appropriate lifting device, position compres- sor on compressor mounting locations on frame.

22.Loosely install studs, lock washers, ﬂat washers and nuts to secure compressor to frame until alignment is correct.

23.Check compressor for soft foot. Add or remove shims as required until measurements are within +/- 0.002”.

24.Tighten nuts to secure compressor to frame, refer to Appendix A.

25.If equipped with C-ﬂange, install bolts to se- cure C-ﬂange to compressor. Tighten bolts, see Appendix A.

26.If equipped with C-ﬂange, install C-ﬂange coupling, refer to C-ﬂange Coupling Replacement procedure.

27.Install coupling, see Drive Coupling Installation and Alignment procedure .

28.Install coupling guard.

29.Install nuts and bolts to secure discharge pipe to oil separator and compressor.

30.Tighten nuts on ‘discharge pipe-to-compressor ﬂange’ ﬁrst, then tighten nuts on ‘discharge pipe- to-oil separator ﬂange’, see Appendix A.

31.Install nuts to secure suction strainer/check valve assembly to compressor and suction stop valve.

32.Tighten nuts on ‘suction strainer/check valve as- sembly-to-compressor’ ﬁrst, then tighten nuts on ‘suction strainer/check valve assembly-to-suction stop valve’, refer to Appendix A.

33.Install all lines to compressor.

34.Install all cables to sensors on compressor and actuator.

35.Perform leak check, see Compressor Unit Leak Check procedure.

Compressor

Nut

Lock Washer

Flat Washer

Spherical

FrameShim Washer

Assembly

Stud

Flat Washer

Lock Washer

Nut

Figure 5-10. Compressor Replacement and Hardware Assembly (Models 2401-3001 Shown)

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

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Image 73

Emerson VSG, VSSG manual Maintenance/Service, Lock Washer

Contents

VSG/VSSG compressor unit Installation, operation & maintenance manualPage VSG/VSSG Standard Vilter Warranty Statement READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR Important MessageVilter Manufacturing LLC Section 3 Installation Table of ContentsSection Title Section 1 General InformationSection 6 Troubleshooting Section 5 Maintenance/ServiceSection Number Section 4 OperationList of Tables and Figures Section 7 Warranty and PartsAppendices Table/FigureList of Tables and Figures Figure 3-12. Installation of Coolers - Next to BuildlingTable/Figure Section NumberSection 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 Compressor Unit Component Identiﬁcation Section 1 General InformationFigure 1-2. Gas Compressor Unit Components 1 of 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 Section 1 General Information Symbols and IdentiﬁcationsPosition Transmitter 3-Way Thermostatic ValveHigh Side Float Valve Steady-Mount Bulb & Capillary Section 1 General Information1 - 10 / Blank Gas Flow Section 2 Theory of OperationOil Life and Oil Flow Figure 2-1. Gas Compressor Unit P&IDControl System RTDs and Pressure TransducersSection 2 Theory of Operation This is a continuous cycleDelivery Inspection Section 3 InstallationRigging and Lifting of Compressor Unit Figure 3-1. Rigging and Lifting PointsSection 3 Installation Long Term Storage RecommendationsThe following are recommendations regarding long term storage Recommended Onsite Tools Compressor Unit Inspections Prior to Storage or InstallationSection 3 Installation AIR COOLED OIL COOLERSLONG TERM STORAGE LOG Section 3 InstallationCompressor has been placed in operation as of Foundation Materials FoundationConsiderations Prior to Starting Building the FoundationSection 3 Installation Compressor Unit Installationof both Check the ability of the soil to carry the load Section 3 Installation Leveling and Groutingrecommendations for setting, precautions, mixing, and Additional Information Codes and Standards Section 3 InstallationFigure 3-6. Housekeeping Pad Dimension Detail - Top View Section 3 Installation2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT LEVELSection 3 Installation Piping010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5 Section 3 Installation Table 3-2. Maximum Allowable Flange LoadsNozzle Dia. in Fz lbfONE FAN DIAMETER Section 3 InstallationNOT PREFERRED Section 3 InstallationHOT AIR RECIRCULATION Section 3 InstallationFigure 3-14. Cooler Placement and Spacing Section 3 InstallationFigure 3-13. Discharge Elevation of Coolers PREFERREDInitial Oil Charging Using Non -Vilter Oils Pressure TestingUnit Oil Charging and Priming Section 3 InstallationNormal Operating Level Maximum NON-Operating Level Section 3 InstallationMinimum Operating Level Bypass ValveCLOSE Section 3 InstallationOIL MIXING CLOSECLOSE Section 3 InstallationOPEN OIL MIXINGInitial Oil Charging Section 3 InstallationPriming Remote Oil Cooler and Piping REMOTESUCTION INLET Section 3 InstallationREMOTE OIL SEPARATORPre 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 Operation Section 4 OperationOil Inspection Dual Oil FiltersStopping/Restarting Control System CalibrationStarting, Stopping and Restarting the Compressor Starting Calibrate Slide Valve ActuatorsSection 4 Operation Figure 4-2. Actuator AssemblySection 4 Operation Figure 4-5. Photo-chopper Figure 4-4. Slide Valve Calibration Screen Compact Logix PLCSection 4 Operation Section 4 Operation Table 4-1. Command Shaft Rotation SpeciﬁcationsAngle/Slide Travel CapacitySection 4 Operation Oil Temperature Control Valve Oil Mixing Valve Operation18. Press the “Set Max” button Fail Position Section 4 OperationSection 4 Operation Purging with Dry Nitrogen10. Close discharge bleed valve while still purging Section 4 OperationPressure Indicator Purging with Dry GasSection 4 Operation OIL SEPARATORSection 4 Operation Equalizing Solenoid for Suction Bypass Suction Bypass Valve Manual Section 4 OperationFigure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil Charging ValveSection 4 Operation Coalescing Oil Return Line SetupOil Circuit Table 5-1. Maintenance/Service ScheduleUnit ControlMaintenance/Service Section 5 Maintenance/ServiceMaintaining Proper Operation Compressor Unit Isolation forSection 5 Maintenance/Service Compressor Unit Leak CheckSection 5 Maintenance/Service Oil System Components Oil SamplingUse Vilter Oil Analysis Kit VPN 3097A to collect an oil sample for analysis. For an example, see Figure 5-2. FillSection 5 Maintenance/Service Oil ChargingSingle Oil Filter Assembly Oil Filter ReplacementDual Oil Filter Assembly Oil DrainingVent Valve Drain Valve Inlet Shut-Off Valves Section 5 Maintenance/ServiceSection 5 Maintenance/Service Coalescing Filter ReplacementCoalescing Filter Centering StrapSection 5 Maintenance/Service Oil Pump StrainerView From Back of Oil Pump Strainer Table 5-3. Shaft and Hub Distances Drive Coupling Form-Flex BPU Hub InstallationSection 5 Maintenance/Service SizeSection 5 Maintenance/Service Drive Center Member Installation and Alignment17. 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 SpeciﬁcationsSection 5 Maintenance/Service Angular AlignmentDrive Coupling Form-Flex BPU Center Member and Hub Removal Drive Coupling Type C Sure-Flex ReplacementSection 5 Maintenance/Service Table 5-6. Clamping Bolts and Set Screw Torque Speciﬁcations Compressor ReplacementSection 5 Maintenance/Service Lock Washer Section 5 Maintenance/ServiceFigure 5-11. Bearing Axial Float Inspection Compressor Shaft Bearing Float InspectionsSection 5 Maintenance/Service Table 5-7. Maximum Bearing Float Gate Rotor Float and Gate Rotor Bearing Float InspectionFigure 5-12. Bearing Radial Float Inspection Figure 5-13. Gate Rotor FloatFigure 5-14. Gate Rotor Bearing Float Table 5-8. Gate Rotor FloatSection 5 Maintenance/Service Applied Force Rigidly attach dial indicator Use bolt for fulcurmFigure 5-15. Gate Rotor and Support Clearance - Minimum Clearances Section 5 Maintenance/Service Gate Rotor and Support ClearanceSection 5 Maintenance/Service Figure 5-16. Gate Rotor and Support Clearance - MeasuringGate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor Gate Rotor Support Gate RotorVSG 301-701 Compressors Gate Rotor Assembly Replacement All VSG & VSSG Compressors ExceptTable 5-9. Gate Rotor Tool Sets Section 5 Maintenance/ServiceFigure 5-18. Gate Rotor Assembly Removal Figure 5-17. Gate Rotor Assembly Removal and ToolsSection 5 Maintenance/Service Figure 5-20. Gate Rotor and Shelf Clearance Figure 5-19. Gate Rotor Assembly and ToolsSection 5 Maintenance/Service Figure 5-21. Gate Rotor Assembly Breakdown Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLYSection 5 Maintenance/Service Figure 5-22. Gate Rotor Thrust Bearing Figure 5-23. Gate Rotor and Shelf ClearanceSection 5 Maintenance/Service Figure 5-25. Gate Rotor Blade Installation Gate Rotor DisassemblyFigure 5-24. Gate Rotor Blade Assembly Section 5 Maintenance/ServiceFigure 5-26. Gate Rotor Thrust Bearing Figure 5-27. Thrust Bearing InstallationSection 5 Maintenance/Service Figure 5-28. Roller Bearing Assembly Slide Valve Actuator Assembly ReplacementSection 5 Maintenance/Service Command Shaft Seal Replacement Command Shaft Assembly ReplacementFigure 5-29. Command Shaft Seal Section 5 Maintenance/ServiceSection 5 Maintenance/Service Figure 5-30. Command Shaft Seal InstallationProblem Section 6 TroubleshootingSolution Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 ofSection 6 Troubleshooting Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 ofProblem SolutionMeaning Flash PatternTable 6-2. Slide Valve Actuator LED Blink Codes* 1 of Section 6 Troubleshootingwill not move while this error code is displayed. To clear the error er before the calibration procedure was completed. The actuatorcalibrate the actuator. If this error has occurred and the cause was not the loss of 24V power during calibration, possible causes areSection 6 Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions 1 ofProblem SolutionSection 6 Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions 2 ofProblem SolutionSection 6 Troubleshooting Table 6-3. Troubleshooting Guide - General Problems & Solutions 3 ofProblem Solution6 - 8 / Blank Warranty Claim Processing Section 7 Warranty and PartsOn Site Service Support Warranty does not cover labor and extraneous expensesSection 7 Warranty and Parts Remanufactured Gas Bare Shaft Compressor ProcessRequest 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 Evaluation Appendix C Oil Analysis ReportPRODUCT ANALYSIS REPORT No Action RequiredAppendix D Recommended Header Piping OUTLET ON TOP Appendix E Recommended Remote Air Cooled Oil Cooler PipingINLET ON BOTTOM Blank