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Emerson VILTER VSR manual available for free PDF download: Installation, Operation And Service Manual
Emerson VILTER VSR Installation, Operation And Service Manual (206 pages)
Single Screw Bare Shaft Compressor
Brand:
Emerson
| Category:
Air Compressor
| Size: 49.27 MB
Table of Contents
Table of Contents
7
Important Message
3
Standard Vilter™ Warranty Statement
4
Standard Vilter™ 5/15 Warranty Statement
5
EC Declaration of Incorporation
6
Table of Contents
7
Table / Figure
12
Table of Contents
12
Additional Important Notes
13
How to Use this Manual
13
Section 1 • General Information
13
System Unit Identification
14
Bare Shaft Refrigeration and Heat Pump Compressor Model Designations
15
Capacity and Volume Control
17
Compressor
17
Section 2 • Theory of Operation
17
Refrigerant and Oil System
18
Refrigerant Flow
18
Oil Life and Oil Flow
18
Figure 2-1. Refrigeration Compressor Unit P&ID (Thermosyphon Oil Cooling with Single Oil Filter Shown)
19
Control System
20
Temperature Elements, Pressure Transmitters and Indicators
20
Critical Application Guidelines
20
Alarm and Shutdown Readings
21
Figure 2-2. Basic Single Screw Compressor System
22
Single Screw Package Requirements
22
Bareshaft Compressor Lifting Points and Weights
23
Delivery Inspection
23
Rigging and Lifting of the Compressor
23
Section 3 • Installation
23
Table 3-1. Bareshaft Compressor Component Weights
23
Table 3-2. Bareshaft Compressor Component Lifting Hole Sizes
23
Figure 3-1. Bareshaft Compressor Lifting Points and Component Weights
24
Figure 3-2. Bareshaft Compressor Assembly Center of Gravity (Models 97-127)
24
Bareshaft Compressor Center of Gravity (Models 291-2101)
25
Figure 3-3. Bareshaft Compressor Assembly Center of Gravity (Models 291-2101)
25
Figure 3-4. Bareshaft Compressor Center of Gravity - Discharge Manifold and Main Compressor Assembly
25
Bareshaft Compressor Center of Gravity (Models 2401-3001)
26
Figure 3-5. Bareshaft Compressor Assembly Center of Gravity (Models 2401-3001)
26
Figure 3-6. Bareshaft Compressor Center of Gravity - Discharge Manifold and Main Compressor Assembly
26
Compressor Inspections Prior to Installation
27
Compressor Mounting
27
Notice on Using Non-Vilter Oils
27
Recommended On-Site Tools
27
Long Term Storage Recommendations
28
Long Term Storage Log
29
Figure 3-7. Stop/Check Valve Orientation
30
Stop/Check Valve Installation
30
Piping
31
Figure 3-8. Maximum Allowable Flange Loads
32
Flange Loads
32
Table 3-3. Maximum Allowable Flange Loads
32
Slide Valve Actuator Installations Instructions
33
Installation
33
Overview
33
Actuator Motor Control Module Calibration Procedure
33
Instrumentation Requirements
34
Pressure
34
Temperature
34
Figure 3-9. Additional Instruments
34
Miscellaneous
35
Testing Refrigeration System for Leaks
35
Ammonia Systems
35
Halocarbon Refrigerant Systems
35
Control System
37
Starting, Stopping and Restarting the Compressor
37
Emergency Shutdown
38
Capacity and Volume Ration Control through Slide Valve Actuators
38
Figure 4-1. Slide Valve Motor Location
38
Notice on Using Non-Vilter Oils
37
Operation
37
Section 4 • Operation
37
Slide Valve Actuator Operation
39
Calibrate Slide Valve Actuators (for Units Using Vission20/20™)
40
Figure 4-2. Actuator Assembly
40
Figure 4-3. Slide Valve Calibration Screen (Vission 20/20)
41
Figure 4-4. Menu Screen and Slide Calibration Button (Vission 20/20)
42
Figure 4-5. Wire Connections for Capacity and Volume Actuators
43
Table 4-1. Command Shaft Rotation Specifications
44
Figure 4-6. Photo-Chopper
45
Calibrate Slide Valve Actuators (for Units Using Compact Logix PLC)
46
Figure 4-7. Actuator Assembly
46
Figure 4-8. Overview, Main Menu and Instrument Calibration Screens (Compact Logix PLC)
48
Figure 4-10. Photo-Chopper
49
Figure 4-9. Slide Calibration Screen (Compact Logix PLC)
49
Compressor Control with Vission20/20™ Micro-Controller (no Slide Operation)
51
Suction Equalizing Line Setup - for VSS/VSM Compressors
52
Stop/Check Valve Operation
53
Table 4-2. Stop/Check Valve Open Positions
53
Maintenance and Service Schedule - for VSS/VSM Unit Only
55
Section 5 • Maintenance/Service
55
Maintenance and Service Schedule - for VSH/VSSH Unit Only
56
Preventive Maintenance, Checks and Services
58
Daily
58
Weekly
58
Monthly
58
Trimonthly
58
Annually
58
Compressor Unit Isolation for Maintenance/Service (Compressors with Slide Valves)
59
Preparation of Unit for Servicing
60
Recommendations When Servicing (Compressors Without Slide Valves)
60
Compressor Unit Leak Check after Servicing
61
Oil Sampling
61
Recommendations
61
Installation of the Oil Sampler Valve
62
Pre-Sampling
62
Sampling Procedure
62
Oil Sample Analysis Report
64
Compressor Replacement
65
Removal
65
Installation
66
Compressor Inspection
67
Compressor Shaft Bearing Clearance Inspections
67
Determine Maximum Applied Force
67
Main Rotor Bearing Axial Clearance Inspection
67
Main Rotor Bearing Radial Clearance Inspection
68
Table 5-3. Maximum Main Rotor Bearing Clearance
68
Gaterotor Bearing Inspection
69
Table 5-4. Maximum Gaterotor Bearing Clearance
69
Gaterotor Inspection
70
A) Gaterotor - Main Housing Shelf Clearance
70
B) Gaterotor Float Measurement
71
Table 5-5. Gaterotor Float
71
C) Gaterotor Backlash Inspection
72
Table 5-6. Backlash Range
73
Important Notes
74
Additional Inspections
74
Post Inspection
74
Gaterotor Assembly Replacement (All Compressors Except VSM 301-701 and VSM 97-127 Compressors)
74
Removal
74
Table 5-7. Gaterotor Tool Kits
74
Installation
75
Gaterotor Assembly Replacement (VSM 301-701 Compressors Only)
78
Removal
78
Installation
78
Gaterotor Assembly Replacement (VSM 97-127 Compressors Only)
80
Removal
80
Installation
80
Gaterotor Disassembly (All Compressors Except VSM 97-127 Compressors)
82
Gaterotor Blade Removal
82
Gaterotor Blade Installation
83
Gaterotor Thrust Bearing Removal
83
Gaterotor Thrust Bearing Installation
83
Gaterotor Roller Bearing Removal
84
Gaterotor Roller Bearing Installation
84
Gaterotor Disassembly (VSM 97-127 Compressors Only)
85
Gaterotor Blade Removal
85
Gaterotor Blade Installation
85
Gaterotor Thrust Bearing Removal
86
Gaterotor Thrust Bearing Installation
86
Gaterotor Roller Bearing Removal
86
Gaterotor Roller Bearing Installation
86
Compressor Shaft Seal Replacement
87
Shaft Seal Assembly
87
Handling Seal Face with Care
87
Compressor Shaft Seal Replacement - for VSS/VSM Units
88
Tools
88
Removal
88
Installation
88
Table 5-8. Shaft Seal Tool Kits
88
Compressor Shaft Seal Replacement - for VSH/VSSH Units
90
Table 5-9. VSH/VSSH Shaft Seals
90
Prior to Shaft Seal Installation
92
Shaft Seal Installation - for Part# 25985Y and 25985Y
93
Shaft Seal Installation - for Part# 28985W and 28985WA
94
Slide Valve Actuator Assembly Replacement
95
Removal
95
Installation
95
Actuator Installation Using Anti-Rotation Bolts
96
Slide Valve Command Shaft Assembly Replacement
97
Removal
97
Installation
97
Liquid Injection Control Valve Station (Danfoss ICF 20-40 Valve Station)
98
Table 5-10. Coils for Solenoid Valves (ICFE)
99
Table 5-11. Parts for Motorized Valve Station (ICF)
99
Main Rotor Assembly
100
Table 5-12. Torque Specifications (Ft-Lbs)
100
Torque Specifications
100
Nord-Lock ® Washers
101
Section 6 • Troubleshooting
103
Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 3)
103
Table 6-2. Slide Valve Actuator LED Blink Codes (1 of 2)
106
Using a Torque Wrench Correctly
101
Troubleshooting Guide - General Problems & Solutions
108
Section 7 • Warranty and Parts
111
Warranty Claim Processing
111
On-Site Service Support
113
Remanufactured Bare Shaft Single Screw Compressor Process
113
Explanation of Rebuild Levels
113
Bare Shaft Compressor Description
113
Section 8 • Spare Parts List
115
Gaterotor
118
Shaft Seal
125
Main Rotor
126
Slide Valve Cross Shafts and End Plate
128
End Plate (VSS 2401 - VSS 3001 Only)
130
Slide Valve Carriage Assembly
132
Miscellaneous Frame Components
136
Miscellaneous Frame Components Tubing and Fittings
139
Replacement Tools
142
Replacement Parts
143
Gaterotor Assembly
146
Shaft Seal
148
Main Rotor
149
Slide Valve Cross Shafts and End Plate
150
Slide Valve Carriage Assembly
152
Miscellaneous Frame Components
155
Housing Accessories
157
Replacement Tools
158
Kits
161
Appendix A Torque Specifications
163
Appendix B Vilter Oil
165
Appendix C Vibration Measurements - Single Screw Compressor
169
Appendix D Liquid Injection Valve Setup Instructions and ICM/ICAD Motorized Valve Quick Start Guide
175
Table of Contents
178
Installation
180
Wiring the ICAD
181
ICAD Overview
184
ICAD Programming
185
Troubleshooting
186
The Manual Tool
186
Service Parameters
186
Alarms
187
Tips
187
Common Questions
188
Appendix E Liquid Injection Valve Station ICF 20-40 Installation Guide
189
Appendix F Hand-Held Slide Valve Calibration Tool
201
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