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Troubleshooting
Specification
Install
Error codes
14. Cooler Placement and Spacing
Warranty
Dimension
Maintenance
Problem
Coalescing Oil Return Line Setup
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6 – 8 / Blank
VSG/VSSG • Installation, Operation and Maintenance Manual •Vilter/Emerson • 35391SSG
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Contents
Installation, operation & maintenance manual
VSG/VSSG compressor unit
Page
VSG/VSSG Standard Vilter Warranty Statement
Important Message
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR
Vilter Manufacturing LLC
Table of Contents
Section 3 Installation
Section Title
Section 1 General Information
Section 5 Maintenance/Service
Section 6 Troubleshooting
Section Number
Section 4 Operation
Section 7 Warranty and Parts
List of Tables and Figures
Appendices
Table/Figure
Figure 3-12. Installation of Coolers - Next to Buildling
List of Tables and Figures
Table/Figure
Section Number
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
Section 1 General Information
Compressor Unit Component Identification
Figure 1-2. Gas Compressor Unit Components 1 of
Figure 1-2. Gas Compressor Unit Components 2 of
Section 1 General Information
Section 1 General Information Component Identification Continued
Figure 1-2. Gas Compressor Unit Components 3 of
Section 1 General Information Piping & Identification Component Tags
Symbols and Identifications
Section 1 General Information
Position Transmitter
3-Way Thermostatic Valve
Section 1 General Information
High Side Float Valve Steady-Mount Bulb & Capillary
1 - 10 / Blank
Section 2 Theory of Operation
Gas Flow
Oil Life and Oil Flow
Figure 2-1. Gas Compressor Unit P&ID
RTDs and Pressure Transducers
Control System
Section 2 Theory of Operation
This is a continuous cycle
Section 3 Installation
Delivery Inspection
Rigging and Lifting of Compressor Unit
Figure 3-1. Rigging and Lifting Points
Long Term Storage Recommendations
Section 3 Installation
The following are recommendations regarding long term storage
Compressor Unit Inspections Prior to Storage or Installation
Recommended Onsite Tools
Section 3 Installation
AIR COOLED OIL COOLERS
Section 3 Installation
LONG TERM STORAGE LOG
Compressor has been placed in operation as of
Foundation
Foundation Materials
Considerations Prior to Starting
Building the Foundation
Compressor Unit Installation
Section 3 Installation
of both Check the ability of the soil to carry the load
Leveling and Grouting
Section 3 Installation
recommendations for setting, precautions, mixing, and
Section 3 Installation
Additional Information Codes and Standards
Section 3 Installation
Figure 3-6. Housekeeping Pad Dimension Detail - Top View
2 - # CLOSED TIES CENTER LINE 5 - # 6 VERT
LEVEL
Piping
Section 3 Installation
010Ä5*4+0- 214176 4%1//0&& 14 175-2+0 10%46 $#5
Table 3-2. Maximum Allowable Flange Loads
Section 3 Installation
Nozzle Dia. in
Fz lbf
Section 3 Installation
ONE FAN DIAMETER
Section 3 Installation
NOT PREFERRED
Section 3 Installation
HOT AIR RECIRCULATION
Section 3 Installation
Figure 3-14. Cooler Placement and Spacing
Figure 3-13. Discharge Elevation of Coolers
PREFERRED
Pressure Testing
Initial Oil Charging Using Non -Vilter Oils
Unit Oil Charging and Priming
Section 3 Installation
Section 3 Installation
Normal Operating Level Maximum NON-Operating Level
Minimum Operating Level
Bypass Valve
Section 3 Installation
CLOSE
OIL MIXING
CLOSE
Section 3 Installation
CLOSE
OPEN
OIL MIXING
Section 3 Installation
Initial Oil Charging
Priming Remote Oil Cooler and Piping
REMOTE
Section 3 Installation
SUCTION INLET
REMOTE
OIL SEPARATOR
Section 3 Installation Pre Start-Up
Pre Start-Up Checklist
Section 3 Installation
15. Verify that all valves are in the open position
Section 3 Installation Start-Up
Section 4 Operation
Operation
Oil Inspection
Dual Oil Filters
Control System Calibration
Stopping/Restarting
Starting, Stopping and Restarting the Compressor Starting
Calibrate Slide Valve Actuators
Figure 4-2. Actuator Assembly
Section 4 Operation
Section 4 Operation
Figure 4-4. Slide Valve Calibration Screen Compact Logix PLC
Figure 4-5. Photo-chopper
Section 4 Operation
Table 4-1. Command Shaft Rotation Specifications
Section 4 Operation
Angle/Slide Travel
Capacity
Oil Temperature Control Valve Oil Mixing Valve Operation
Section 4 Operation
18. Press the “Set Max” button
Section 4 Operation
Fail Position
Purging with Dry Nitrogen
Section 4 Operation
Section 4 Operation
10. Close discharge bleed valve while still purging
Purging with Dry Gas
Pressure Indicator
Section 4 Operation
OIL SEPARATOR
Section 4 Operation
Section 4 Operation
Equalizing Solenoid for Suction Bypass Suction Bypass Valve Manual
Figure 4-12. Suction Bypass Valve and Equalizing Solenoid Suction Oil
Charging Valve
Coalescing Oil Return Line Setup
Section 4 Operation
Table 5-1. Maintenance/Service Schedule
Oil Circuit
Unit
Control
Section 5 Maintenance/Service
Maintenance/Service
Maintaining Proper Operation
Compressor Unit Isolation for
Compressor Unit Leak Check
Section 5 Maintenance/Service
Oil System Components Oil Sampling
Section 5 Maintenance/Service
Use Vilter Oil Analysis Kit VPN 3097A to collect an oil
sample for analysis. For an example, see Figure 5-2. Fill
Oil Charging
Section 5 Maintenance/Service
Oil Filter Replacement
Single Oil Filter Assembly
Dual Oil Filter Assembly
Oil Draining
Section 5 Maintenance/Service
Vent Valve Drain Valve Inlet Shut-Off Valves
Coalescing Filter Replacement
Section 5 Maintenance/Service
Coalescing Filter
Centering Strap
Oil Pump Strainer
Section 5 Maintenance/Service
View From Back of Oil Pump Strainer
Drive Coupling Form-Flex BPU Hub Installation
Table 5-3. Shaft and Hub Distances
Section 5 Maintenance/Service
Size
Drive Center Member Installation and Alignment
Section 5 Maintenance/Service
17. 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 Specifications
Section 5 Maintenance/Service
Angular Alignment
Drive Coupling Type C Sure-Flex Replacement
Drive Coupling Form-Flex BPU Center Member and Hub Removal
Section 5 Maintenance/Service
Compressor Replacement
Table 5-6. Clamping Bolts and Set Screw Torque Specifications
Section 5 Maintenance/Service
Section 5 Maintenance/Service
Lock Washer
Compressor Shaft Bearing Float Inspections
Figure 5-11. Bearing Axial Float Inspection
Section 5 Maintenance/Service
Gate Rotor Float and Gate Rotor Bearing Float Inspection
Table 5-7. Maximum Bearing Float
Figure 5-12. Bearing Radial Float Inspection
Figure 5-13. Gate Rotor Float
Table 5-8. Gate Rotor Float
Figure 5-14. Gate Rotor Bearing Float
Section 5 Maintenance/Service
Applied Force Rigidly attach dial indicator Use bolt for fulcurm
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
Section 5 Maintenance/Service
Gate Rotor Support Gate Rotor Gate Rotor Support Gate Rotor
Gate Rotor Support Gate Rotor
Gate Rotor Assembly Replacement All VSG & VSSG Compressors Except
VSG 301-701 Compressors
Table 5-9. Gate Rotor Tool Sets
Section 5 Maintenance/Service
Figure 5-17. Gate Rotor Assembly Removal and Tools
Figure 5-18. Gate Rotor Assembly Removal
Section 5 Maintenance/Service
Figure 5-19. Gate Rotor Assembly and Tools
Figure 5-20. Gate Rotor and Shelf Clearance
Section 5 Maintenance/Service
Gate Rotor Assembly Replacement VSG 301-701 Compressors ONLY
Figure 5-21. Gate Rotor Assembly Breakdown
Section 5 Maintenance/Service
Figure 5-23. Gate Rotor and Shelf Clearance
Figure 5-22. Gate Rotor Thrust Bearing
Section 5 Maintenance/Service
Gate Rotor Disassembly
Figure 5-25. Gate Rotor Blade Installation
Figure 5-24. Gate Rotor Blade Assembly
Section 5 Maintenance/Service
Figure 5-27. Thrust Bearing Installation
Figure 5-26. Gate Rotor Thrust Bearing
Section 5 Maintenance/Service
Slide Valve Actuator Assembly Replacement
Figure 5-28. Roller Bearing Assembly
Section 5 Maintenance/Service
Command Shaft Assembly Replacement
Command Shaft Seal Replacement
Figure 5-29. Command Shaft Seal
Section 5 Maintenance/Service
Figure 5-30. Command Shaft Seal Installation
Section 5 Maintenance/Service
Section 6 Troubleshooting
Problem
Solution
Table 6-1. Slide Valve Actuator Troubleshooting Guide 1 of
Table 6-1. Slide Valve Actuator Troubleshooting Guide 2 of
Section 6 Troubleshooting
Problem
Solution
Flash Pattern
Meaning
Table 6-2. Slide Valve Actuator LED Blink Codes* 1 of
Section 6 Troubleshooting
er before the calibration procedure was completed. The actuator
will not move while this error code is displayed. To clear the error
calibrate 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
Section 6 Troubleshooting
Problem
Solution
Table 6-3. Troubleshooting Guide - General Problems & Solutions 2 of
Section 6 Troubleshooting
Problem
Solution
Table 6-3. Troubleshooting Guide - General Problems & Solutions 3 of
Section 6 Troubleshooting
Problem
Solution
6 - 8 / Blank
Section 7 Warranty and Parts
Warranty Claim Processing
On Site Service Support
Warranty does not cover labor and extraneous expenses
Remanufactured Gas Bare Shaft Compressor Process
Section 7 Warranty and Parts
Request a “VSG Single Screw Compressor Rebuild Form”
Appendix A Torque Specifications
Torque Specifications ft-lbs
Torque Specifications for 17-4 Stainless Steel Fasteners ft-lbs
Appendix B Motor Compressor - General Storage Instructions
Appendix C Oil Analysis Report
Evaluation
PRODUCT ANALYSIS REPORT
No Action Required
Appendix D Recommended Header Piping
Appendix E Recommended Remote Air Cooled Oil Cooler Piping
OUTLET ON TOP
INLET ON BOTTOM
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