Emerson Vilter VSG128 Installation, Operation And Service Manual Download

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Section 5 • Maintenance/Service

HPLD Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391HP

Oil Sampling

WARNING

When working with LFG, NG or other dangerous

or ﬂ ammable gases, ensure there are adequate
ventilation and vapor detectors. Refer to national ﬁ re

and building codes. Failure to comply may result in

serious injury or death.

WARNING

Improper selection or application of ﬂ uid diagnostic

products can cause serious injury or damage. The

user is solely responsible for making the ﬁ nal

selection of products to ensure that the overall system
performance and safety requirements are met. These

include reviewing ﬂ uid compatibility with materials

and seals.

WARNING

Avoid skin contact with any condensate or oil. Wear
rubber gloves and a face shield when working with
condensate or oil. Failure to comply may result in

serious injury or death.

Recommendations

1. Make sure you´re aware of the risks associated with

the fluid being sampled or worked with. Check with

the manufacturer.

2. If you have not been trained to sample, service, re-

pair, or troubleshoot a pressurized fluid system,

especially a hydraulic system, you are at risk of suf-
fering an accident. Seek the proper training before
proceeding.

Installation of The Oil Sampler Valve

Lubricate the threads (1/4”-18 NPT) with Teflon

tape.

2. Tighten to the max. torque 25 ft-lbs (34 N-m). Use

11/16” open wrench. Avoid over tightening.

Pre-Sampling

Use the Vilter Oil Analysis Kit (VPN 3097A) to collect an
oil sample for analysis, see Figure 5-1.
Once the sample has been taken, the label must be

filled out and pasted on the bottle, and both must be

placed inside the mailing tube and sealed with the pre-
addressed mailing label.

Figure 5-1. Oil Analysis Kit (VPN 3097A)

DANGER

Sampling often releases hot ﬂ uid under high

velocity/pressure.

Hot ﬂ uid can cause severe burn injuries.

Skin penetration from high-pressure ﬂ uid

can occur, causing severe injury, gangrene
and/or death. If this happens, immediate-
ly contact an experienced medical practi-
tioner.

Hot ﬂ uid escaping to the atmosphere can

ignite if it comes into contact with an igni-
tion source. This can lead to severe property
damage.

Below are a few points to remember when taking a
sample:
• Sample running compressor units, not cold units.

Sample after minimum 30 minutes of compressor
operating time.

•

Sample after the oil filter.

• Sample according to the sampling procedure below.
• Ensure sampling valves and devices are thoroughly

flushed prior to taking a sample.

• Ensure samples are taken as scheduled in the

Maintenance and Service Schedule.

• Send samples to the oil analysis lab immediately af-

ter sampling, do not wait 24 hours.

Summary of Contents for Vilter VSG128

Page 1: ...HPLD Single Screw Bare Shaft Compressor Installation Operation and Service Manual ...

Page 2: ......

Page 3: ...sults to Vilter To the extent the Buyer has supplied specifications information representation of operating conditions or other data to Seller in the selection or design of the Products and the preparation of Seller s quotation and in the event that actual operating conditions or other conditions differ from those represented by Buyer any warranties or other provisions contained herein which are a...

Page 4: ...roducts found by Seller to be defective Failure by Buyer to give such written notice within the applicable time period will be deemed an absolute and unconditional waiver of Buyer s claim for such defects Buyer assumes all other responsibility for any loss damage or injury to persons or property arising out of connected with or resulting from the use of the Products either alone or in combination ...

Page 5: ...ompressor must not be subjected to liquid carry over Care must be exercised in properly designing and maintaining the system to prevent conditions that could lead to liquid carry over VilterTM Manufacturing is not responsible for the system or the controls needed to prevent liquid carry over and as such VilterTM Manufacturing cannot warrant equip ment damaged by improperly protected or operating s...

Page 6: ...ds have been used EN ISO 12100 1 2010 Safety of Machinery General principles for design Risk assessment and risk reduction EN ISO 13857 2008 Safety of Machinery Safety distances to prevent danger zones being reached by the upper and lower limbs EN349 1993 A1 2008 Safety of Machinery Minimum gaps to avoid crushing hazards EN ISO 13850 2015 Safety of Machinery Emergency stop equipment Principles for...

Page 7: ...mpressor Set 2 3 Critical Application Guidelines 2 4 Procedure For System Pressurization 2 5 Alarm and Shutdown Readings 2 6 HPLD Package Requirements 2 7 Section 3 Installation Delivery Inspection 3 1 Rigging and Lifting of the Compressor 3 1 Compressor Inspections Prior to Installation 3 2 Long Term Storage Recommendations 3 2 Long Term Storage Log 3 3 Notice on Using Non Vilter Oils 3 4 Instrum...

Page 8: ...tor Float Measurement 5 11 C Gaterotor Backlash Inspection 5 12 Important notes 5 14 Additional Inspections 5 14 Post Inspection 5 14 Gaterotor Removal and Installation 5 15 Removal 5 15 Installation 5 19 Gaterotor Blade Removal 5 21 Gaterotor Blade Installation 5 21 Gaterotor Ball Bearing Removal 5 22 Gaterotor Ball Bearing Installation 5 22 Gaterotor Roller Bearing Removal 5 22 Gaterotor Roller ...

Page 9: ... Single Screw Compressor 7 3 Explanation of Rebuild Levels 7 3 Section 8 Spare Parts List HPLD Recommended Spare Parts List 8 1 HPLD Compressor Kits 8 2 Gaterotor Kits 8 2 Shaft Seal Kit 8 2 Compressor Gasket and O Ring Kit 8 2 Tool Kit 8 2 Suction Covers 8 3 Discharge Manifold 8 4 Housing 8 5 Appendices Appendix A Torque Specifications A 1 Appendix B Vilter Oil B 1 ...

Page 10: ...mpler Valve VPN 3708A For Gas Compression Applications 5 4 Figure 5 3 Oil Sampling Valve VPN 3709A For Ammonia and Refrigerant Compressors 5 4 Figure 5 4 Operating the Oil Sampling Valve 5 5 Figure 5 5 Stages of the Oil Sample Taking Process 5 5 Figure 5 6 Bearing Radial Clearance Inspection 5 7 Figure 5 7 Bearing Axial Clearance Inspection 5 8 Figure 5 8 Gaterotor Bearing Clearance 5 9 Figure 5 9...

Page 11: ...f 5 20 Figure 5 27 Gaterotor and Support Assembly 5 21 Figure 5 28 Gaterotor Top Face Identification 5 21 Figure 5 29 Gaterotor Ball Bearing 5 22 Figure 5 30 Gaterotor Roller Bearing Assembly 5 23 Figure 5 31 Shaft Seal Assembly 5 24 Figure 5 32 Handling Seal Face with Care 5 24 Figure 5 33 Shaft Seal Breakdown 5 25 5 27 Figure 5 34 Shaft with Pin 5 26 Figure 5 35 Shaft Seal Housing 5 26 Figure 5 ...

Page 12: ...TOC 6 Blank HPLD Single Screw Compressor Installation Operation and Service Manual Emerson 35391HP ...

Page 13: ...s the following NOTICE Notice statements are shown when there are important information that shall be followed Not fol lowing such notices may result in void of warranty seri ous fines serious injury and or death WARNING Warning statements are shown when there are hazardous situations if not avoided will result in se rious injury and or death CAUTION Caution statements are shown when there are pot...

Page 14: ... Unit Bare Shaft Compressor A bare shaft compressor is just the compressor with no coupling and motor nor foundation Compressor Unit A compressor unit consists of the bare shaft compressor with the coupling motor oil separator frame micro control ler system and oil system A compressor unit typically a single screw compressor unit is not mounted on a structural steel base Package Unit A package uni...

Page 15: ...00 Flange Drive Shaft Type STD Standard Straight Drive Shaft Slide Design Type FV Fixed Volume Size CFM Nominal CFM displacement of the compressor at 3600 rpm 128 145 160 180 204 222 243 Seal Type AF Aflas O rings HV High Pressure Design w Viton O rings AHF Ammonia Service High Pressure Aflas O ring Compressor Model VSG Vilter Single Screw Compressor Gas Compression VSH Vilter Single Screw Heat Pu...

Page 16: ...1 4 Blank HPLD Single Screw Compressor Installation Operation and Service Manual Emerson 35391HP ...

Page 17: ... a positive displacement capacity and volume controlled oil flood ed rotary compressor which uses a single main screw intermeshed by two opposing gaterotors Gas compres sion occurs when the individual teeth of each gaterotor sweep through the grooves or flutes of the main screw as the screw rotates Compression occurs from the time the screw flute is first closed off by the gaterotor finger until t...

Page 18: ...es the end of the groove thegrooverotatestoapositionthatlinesupwith thedischargeportinthecompressorhousingandthegas oilmixtureisdischargedfromthescrewathighpressure This completes the compression cycle for a single flute of the main screw Once the gas is swept from the main screw flute through the discharge port it passes into the discharge manifold ofthecompressor Fromthedischargemanifold thegas ...

Page 19: ... passes into the oil separator through a pipe elbow The separator vessel serves to separate the oil from the gas as the gas stream moves from one end of the separator to the other The majority oftheoilisseparatedfromthegasintheprimarychamber of the vessel due to changes in direction and velocity reduction Any remaining oil mist is separated from the gas stream as the stream passes through the coal...

Page 20: ...icron nominal particle size is required to ensure that only clean oil is injected into the compressor For assistance in choosing the correct oil for the applicationandinsizinganauxiliaryoilpump consult a VilterTM representative 2 Injection oil temperature must be closely controlled for optimum performance Oil temperature must be maintained a minimum of 15 20 F above the gas mixture dew point at an...

Page 21: ...crew compressor units must be brought up to pressure via the oil separator discharge side of the unit A tubing line connected before the suction shutoff valve and the top of the separator is provided with the units to pressurize the unit bypassing the compressor see Figure 2 2 If a pressurizing line is not present on the unit a tubing line 3 8 to 1 2 can be added before the suction shut off valve ...

Page 22: ... 6 High Oil Injection Temperature This point protects the compressor from running with hot oil being injected intothescrewhousing andisactivatedbyadirectreading from the RTD located at the oil injection line 7 Low Suction Pressure This point protects the compressor from drawing low suction pressure and is activated by a direct reading from the suction pressure transducer which reads the pressure f...

Page 23: ...isrequired Vilter sownavailablehorizontalorverticalseparatorisan ASME coded vessel which uses five stages of separation to achieve an oil loss of as little as 3 to 4 PPM 4 DischargeGasReliefValve Toprotectthecompressor package from damage due to over pressurization a relief valve must be installed inside of any discharge line hand block valves The relief valve must be set to open at a pressure low...

Page 24: ...2 8 Blank HPLD Single Screw Compressor Installation Operation and Service Manual Emerson 35391HP ...

Page 25: ...onnel and lifting equipment i e spreader bar as required Failure to comply may result in death serious injury and or damage to equipment Only qualified personnel shall operate rigging and lifting equipment Ensure that the lifting device is capable of lifting the weight of the compressor refer to the sup plied Vilter General Assembly GA drawing and to Table 3 1 for weights of bare shaft compressors...

Page 26: ...o help lubricate the surfaces of the shaft seal For cool compression there is no pre lube pump so the driveshaft must be turned by hand Maintenance log to be kept with documenting dates to show all the procedures have been completed see next page Compressor Inspections Prior to Installation The compressor must be inspected prior to installation since components could have come loose and or dam age...

Page 27: ...ning to atmo sphere are to be open Space Heater Panel Components Ensure space heater is energized and panel components are rust free Name Please Print Initial Date M D Y PSI Nitrogen Pressure Current PSI Nitrogen Pressure Recharged If pressure is low identify and fix leak prior to recharging see Compressor Unit Leak Check procedure in Section 5 Nitrogen Leak Location Briefly explain nature of leak...

Page 28: ...ure transducer 15 1000 psig measures the oil pressure downstream of the oil filter as the oil is injected into the compressor and provides de tection and protection against low prelube oil pressure and low running oil injection pressure Additional pressure transducers may be required and installed by the customer for pressure readings at cus tomer specified points such as process gas discharge pre...

Page 29: ...ent transformer is not needed Figure 3 2 Additional Instruments Temperature There are four pressure temperature readings required for processor control as listed below 5 Suction temperature RTD measures the temperature of the incoming suction gas and is used to provide de tection of low suction temperature when the unit is run ning 6 Discharge temperature RTD measures the tempera ture of the gas o...

Page 30: ... no foreign materials are left in the pipes and remove all burrs formed when cutting pipe For halocarbon piping only wrought copper fittings shouldbeused Castfittingsasusedforwaterservice are porous and will allow the refrigerant to escape Note this exception In larger pipe sizes wrought fittings are not available However specially tested cast fittings are available and these may be used with comp...

Page 31: ...oldered or welded joints while the system is under pressure Soldered joints should be opened and re soldered Do not simply add more solder to the leaking joint After all the joints have been repaired and the system is con sidered tight Remove the drum and bring the pressure to the recom mended test level with oil pumped dry nitrogen or CO2 Then check the entire system again for leaks using a halid...

Page 32: ...3 8 Blank HPLD Compressor Unit Installation Operation and Maintenance Manual Emerson 35391HPU ...

Page 33: ...setpoint 5 Oil Temperature The oil temperature cutout stops the compressor unit when the oil temperature is too high or too low 6 Discharge Temperature The high discharge temperature cutout stops the compressor unit when the discharge temperature exceeds the setpoint Notice on Using Non Vilter Oils CAUTION Do not mix oils Failure to comply may result in damage to equipment NOTICE Vilter does not a...

Page 34: ...ther VSG VSH or VSS from the Compressor combo box in page 2 of the Configuration Menu and then the Model from the next box see Figure 4 1 ThechoiceofanHPLDcompressorwillcausetherefriger ant combo box to be grayed out Once the compressor has been selected the Vis sion20 20 panel touchscreen will show an indicator of VFD speed percentage and buttons to increase and decrease it For more information o...

Page 35: ...e discharge temperature of the compressor must be kept a minimum of 30 F above the discharge gas dew point to prevent the condensing of liquids in the oil separator The oil separator shell and legs must be insulated when the gas stream has a high probability of having condensables Oil Filters Prepare to replace when the pressure drop reaches the given limits Oil Strainer I I I I I I I I I I I I I ...

Page 36: ... curve and as sections containing CO2 warm up pressures can rise dramatically well beyond system design WARNING When working with LFG NG or other dangerous or ﬂammable gases ensure there are adequate ventilation and vapor detectors Refer to national ﬁre and building codes Failure to comply may result in serious injury or death WARNING Avoid skin contact with any condensate or oil Wear rubber glove...

Page 37: ...nstallation of The Oil Sampler Valve 1 Lubricate the threads 1 4 18 NPT with Teflon tape 2 Tighten to the max torque 25 ft lbs 34 N m Use 11 16 open wrench Avoid over tightening Pre Sampling Use the Vilter Oil Analysis Kit VPN 3097A to collect an oil sample for analysis see Figure 5 1 Once the sample has been taken the label must be filled out and pasted on the bottle and both must be placed insid...

Page 38: ... 17 MPa THE OIL SAMPLING MUST BE DONE WHEN THE COMPRESSOR IS NOT RUNNING AND ENSURE THE SYSTEM PRESSURE IS WITHIN THE 5 TO 750 PSI 0 03 5 17 MPa SAMPLING RANGE A 1 4 NPT oil sampling valve is provided either in the oil filter canister cover or in the piping after the filter See Figure 5 2 or 5 3 a according to application 1 Unthread the oil sampling valve cap For valve 3709A you also need to turn ...

Page 39: ...Button released valve closed 3 In most cases there will be foam in the oil so you must fill the bottle up to the top and then wait for thefoamtodissipate Repeatthisstepasmanytimes as necessary around 4 to 6 times until the clear oil level reaches full see sequence in Figure 5 5 4 After all the foam dissipates tighten the sample bottle cap 5 Tighten the oil sampling valve cap 6 For valve 3709A only...

Page 40: ...Sample Analysis Report NOTE A copy of the oil analysis report is also sent to Vilter See Appendices for a sample of the oil analysis report An oil analysis report will show the physical properties of the oil such as Water content Viscosity Acid number Particle count Antioxidant level Wear metals Contaminating additive metals ...

Page 41: ...ion NOTICE If clearance measurements are out of tolerance contact Vilter Service Department for further assistance CAUTION When taking the measurements do not exceed 100 lbs of force at point of contact or damage may result to the bearings Determining Maximum Applied Force For Main Rotor Bearings And Gaterotor Bearings To determine maximum applied force take the maxi mum applied force at hub shaft...

Page 42: ... and use the lever arm to push the compressor shaft to wards the compressor record measurement 5 Add both readings the total indicator movement is the bearing axial clearance and this should not exceed 0 002 see Table 5 2 for maximum bearing clearance values Top View Small wooden block or fulcrum Direction of shaft movement Shaft being pushed by use of lever Applied Force Rigidly attach dial indic...

Page 43: ...or axial bearing clearance position a dial indicator on the gaterotor as shown in Figure 5 8 b 3 To check axial bearing clearance use a lever arm piv oting on a bolt with a small block of wood against the gaterotor to protect it as shown in Figure 5 8 b Record the measurement See table 5 3 for the maximum axial clearance value Models VSG VSH VSS Max Axial Clearance in mm Max Radial Clearance in mm...

Page 44: ...Without moving the feeler gauge slowly rotate the gaterotor so that the feeler gauge tip stays between the gaterotor and the shelf See Figure 5 10 c CAUTION Do not over rotate If the rotor catches the feeler gauge apiececanbreakandfallintotherotorgroove 3 Gently pull the feeler gauge out in the direction shown in Figure 5 10 d Figure 5 9 Gaterotor and Shelf Clearance Check for 0 003 0 004 0 076 0 ...

Page 45: ...olerance contact Vilter Service Department for further assistance Clearance and Shims Under 0 003 0 003 0 004 Over 0 004 Remove shims 103 in Figure 5 21 to achieve 0 003 0 004 Perfect Add shims 103 in Figure 5 21 to achieve 0 003 0 004 B Gaterotor Float Measurement 1 Before doing any measurements first conduct a vi sual check to see if there is any noticeable clearance between the gaterotor and it...

Page 46: ...so that a tooth in the rotor is perpendicular to the Main Axis as shown in Figure 5 14 The tooth should be in the center axis of the housing 2 A dial indicator with magnetic base can be used Vilter part numbers 9994ARE or 9994ARJ for the dial indicator and 9994ARD for the magnetic base See Figure 5 15 for location Figure 5 13 Gaterotor Float Figure 5 14 Alignment of Gaterotor Inside Tooth is Perpe...

Page 47: ...5 17 move the gaterotor with two fingers back and forth rapidly several times while reading the dial indicator to see what the displacement range is This displacement range will be the total backlash Contact Vilter Service Department if the measurement is above the ranges shown on Table 5 5 Models VSG VSH VSS Backlash in mm 128 145 160 180 204 222 243 Up to 0 012 Up to 0 305 mm Table 5 5 Backlash ...

Page 48: ... gaterotor bushing and the damper pins Additional Inspections In addition visually inspect the main rotor and gatero tors for signs of abnormal wear due to dirt or other contaminants If some chipping is present on the edges of the gatero tor this will not influence the compressor performance If chipping is more than what s shown on Figure 5 18 take pictures and contact Vilter Service Department Po...

Page 49: ... Figure 5 20 Gaterotor Support Assembly Removal Position of rotor before removing the gaterotor support assembly Discharge end Removal 1 Prepare the compressor for servicing please see Preparation of Unit for Servicing on page 5 2 for procedure details Use Tool Kit A24061A to re move suction tee See Figure 5 22 for details NOTE Each gaterotor assembly must be reassembled on the same side that it i...

Page 50: ...Gaterotor Assembly 4 Using Figure 5 21 as a guide remove the screws 110 and the washers 115 5 Remove ball bearing housing cover screws 112 113 washers 116 and cover 106 6 Remove ball bearing retainer screws 111 washer 114 and retainer 109 7 Remove shim pack 103 and O ring 104 2 8 Remove roller bearing housing 105 9 Remove O ring 104 3 ...

Page 51: ...05 104 107 106 101 102 2X TORQUE 87 FT LBS 103 See Note 2 4X TORQUE 96 IN LBS 8 FT LBS 105 110 111 ALL DIMENSIONS ARE FOR REFERENCE ONLY SHAFT 32 2 23 2 11 1 18 7 16 2 14 9 TORQUE AS PER TORQUE VALUE STAMPED ON THE HOIST RING WARNING Do not use this tooling to lift objects weighing more than 140 LBS Figure 5 22 Tool A24061A To Handle Suction Tee Assembly NOTES 1 Tooling assembly approx Weight 37 l...

Page 52: ...gure 5 24 by hand tightening the bolt 109 this will hold the gaterotor support in place Turn the jacking screw 105 in Figure 5 23 clockwise The ball bearing housing assembly will be pulled off the gaterotor support Remove entire tool set 11 Remove O ring 104 1 in Figure 5 21 12 Make sure the rotor is in position as shown in Figure 5 19 Remove support assembly 101 in Figure 5 21 as shown in Figure ...

Page 53: ...port the gaterotor tool set A25205G must be used Assemble the tool set according to Figure 5 25 and 5 19 by hand tighten ing the bolt 109 this will hold the gaterotor sup port in place Evenly turn the jacking studs 102 clockwise This will push the ball bearing housing onto the gaterotor support Remove entire tool set 15 Install the inner retainer 109 washers 114 and bolts 111 using Loctite 242 thr...

Page 54: ... against the shelf see Figure 5 26 23 After clearance has been set install a new O ring 104 2 on ball bearing housing cover install cover 106 and tighten the bolts 112 and 113 to the recommended torque values 24 Install side cover with a new gasket Tighten the bolts to the recommended torque value The unit can then be evacuated and leak checked Torque values for screws 110 20 ft lbs 112 35 ft lbs ...

Page 55: ...ls Figure 5 27 Gaterotor and Support Assembly Gaterotor Blade Installation 1 Install bushings 101 12b in gaterotor blade 101 12a from the back side of the blade Be sure bush ing is fully seated and torqued to 5 ft lbs using red Loctite 271 see Figure 5 28 2 Place blade assembly 101 12 on gaterotor sup port 101 11 Locate bushing over pin see Figure 5 27 3 After the gaterotor and support are assem b...

Page 56: ...earings 102 2 in the housing 102 1 so the first two bearings are back to back and the second and third bearings are face to face the larger sides of the inner races are placed to gether as shown in Figure 5 29 A light applica tion of clean compressor lubricating oil should be used to ease the installation of the bearings into the housing 2 Center the bearing outer retainer 102 3 on hous ing 102 1 ...

Page 57: ...aring inner race 101 3a from the gaterotor support 101 1 Figure 5 30 Gaterotor Roller Bearing Assembly Gaterotor Roller Bearing Installation 1 Match up the part numbers on the inner race and outer race of the bearing 101 3a 101 3b 2 Install the outer race 101 3b into the bearing housing 105 Install baffle washer 108 with in ner bevel facing the bearing rollers 101 3b Install the snap ring retainer...

Page 58: ...ed in the shaft Carbon or SC component is the stationary part of the seal and is installed into the shaft seal housing using an O ring The shaft seal housing with the stationary part is assem bled in the compressor main housing using an O ring see Figure 5 31 The shaft seal needs to be carefully handled and installed to function properly Please see Figure 5 32 for details Figure 5 31 Shaft Seal As...

Page 59: ...1 into threaded jacking holes to assist in removing shaft seal housing 218 3 Remove silicon carbide rotating face 219 6 O ring 219 7 from shaft 4 Remove spring holder 219 8 from shaft 5 Removeoilseal 230 fromshaftsealhousing 218 6 Remove retaining ring 219 5 from seal housing 7 Flip the seal housing over and carefully tap the stationary silicon carbide piece 219 3 retainer 219 4 and O ring 219 2 o...

Page 60: ...ay potentially damage the O ring on the inner diameter of the shaft seal see Figure 5 34 Figure 5 35 Shaft Seal Housing Figure 5 34 Shaft with Pin Drive Pin on Shaft Lead Chamfer on Outer Diameter of Shaft Shoulder to Which Seal Will Bottom on Figure 5 36 The Alignment of Compressor Shaft and Mating Ring Shoulder on Compressor Shaft Align slot in mating ring 219C with Drive pin on compressor shaft...

Page 61: ...fullyseatedagainst the shoulder of the compressor shaft If the spring holder 219 8 is not fully seated against the shoulder the carbon component of the stationary assembly 219B will be damaged when the shaft seal housing 218 is installed 3 Place O ring 219 7 inside rotating silicon carbide piece 219 6 and carefully assemble onto shaft You should feel some resistance in sliding this onto the shaft ...

Page 62: ...13 26 46 73 112 155 215 380 614 NOTES 1 Torque values on this sheet are not to override those given on the individual drawings 2 When using loctite the torque value on this sheet are only accurate if bolts are tightened immediately after loctite is applied The proof strength of Grade 2 bolts is less for sizes 7 8 and above and therefore the torque values are less than smaller sizes of the same gra...

Page 63: ...eads are required to be lubricated prior to tightening the bolt nut Whether a lubricant is used or not has considerable impact on the amount of torque required to achieve the proper preload in the bolt stud Use a lubricant if required or not if so specified D Unlike a ratchet wrench a torque wrench is a calibrated instrument that requires care Recalibration is required periodically to maintain acc...

Page 64: ...5 30 Blank HPLD Compressor Unit Installation Operation and Maintenance Manual Emerson 35391HPU ...

Page 65: ... is proper discharge pressure ratio to create differential pres sure otherwise oil pressure can t be maintained Oil pressure is manifold oil pressure minus the suction pressure It is a net pressure If the oil pump is selected to be a part time oil pump in the Setup menu then ensure that it only shuts off at an appropriate pressure ration that takes into account pressure drops through the oil coole...

Page 66: ...stops Viscosity of oil incorrect send sample for testing There is an oil leak somewhere in the system High oil temperature liquid injection Check for correct setting of all manual values Check for correct operation of 2 way automatic oil mixing valve In the Vilter Only menu ensure that you select Yes this unit has the oil mixing valve to enable it If your are controlling a step type oil cooler or ...

Page 67: ...veled and secured to mounting pad or floor Check supported pipes i e suction and discharge pipe and make sure they are adequately supported Check for loose bolts and nuts Check condition of compressor and motor i e alignments Excessive Motor Backspin If there is more than normal motor backspin at shutdown check suction check valve for proper operation Table 6 1 Troubleshooting Guide General Proble...

Page 68: ...6 4 Blank HPLD Compressor Unit Installation Operation and Maintenance Manual Emerson 35391HPU ...

Page 69: ...ideration STEP 2 Return the parts freight prepaid to VILTER MANUFACTURING CORPORATION 5555 South Packard Avenue Cudahy WI 53110 8904 STEP 3 Upon receipt of the returned part s Vilter will complete a timely evaluation of the part s STEP 4 You will be contacted with Vilter s decision once the final report is completed STEP 5 If approved the approved warranty will be credited excluding freight to you...

Page 70: ...ith locating motor shops that are manufacturer approved in your area The shop will diagnose the root cause submit a report to the OEM and the motor OEM will make the determination of warranty coverage If warranty is approved the OEM will either have the motor repaired by the motor shop or send a new replacement motor to the site Note Motor warranty is a pass thru warranty as stated in Vilter Manuf...

Page 71: ...ubmit the Rebuild Form and a Purchase Order PO for the inspection A fee is required for the ini tial inspection and tear down report contact Vilter Customer Service representative for the latest fee A Return Material Authorization RMA number will be provided Send the compressor to Vilter in the condition as stated on the Rebuild Form i e no oil in the compres sor Charges may apply if conditions ar...

Page 72: ...7 4 Blank HPLD Compressor Unit Installation Operation and Maintenance Manual Emerson 35391HPU ...

Page 73: ...lation Operation and Service Manual Emerson 35391HP HPLD Recommended Spare Parts List Refer to the Custom Manual Spare Parts Section for Specific Applications Please have your Model and Sales Order available when ordering These are found on the compressor s Name Plate ...

Page 74: ...aterotor Kits Compressor Model With Bearings Without Bearings 128 KT712ABAAF KT712ABAV KT713ABAAF KT713ABAV 145 KT712ABBAF KT712ABBV KT713ABBAF KT713ABBV 160 KT712ABCAF KT712ABCV KT713ABCAF KT713ABCV 180 KT712ABDAF KT712ABDV KT713ABDAF KT713ABDV 204 KT712ABEAF KT712ABEV KT713ABEAF KT713ABEV 222 KT712ABFAF KT712ABFV KT713ABFAF KT713ABFV 243 KT712ABGAF KT712ABGV KT713ABGAF KT713ABGV All HPLD Models ...

Page 75: ...NG WITH BEVEL SIDE FACING COMPRESSOR HOUSING 109 102 107 110 111 16X TORQUE 87 FT LBS 8X TORQUE 30 FT LBS 112 Suction Covers Suction Covers Components MODELS VSG VSH VSS128 to VSG VSH VSS243 ITEM DESCRIPTION VPN QUANTITY 103 SCREEN 205MM SUCTION 25920A 1 104 RING 4 500X0 109 RETAINING INT BEVELED 2867AS 1 105 O RING 8 484 X 8 762 AFLAS VP101 3547AD 2 106 SPRING SSB0433 WAVE SMALLEY 2912G 1 ...

Page 76: ... A574 2795AL 24 104 WASHER 1 2 HIGH STRENGTH PLAIN 2826E 24 105 PLUG 7 16 HEX SAE FOR J1926 PORT AFLAS 3647E 1 106 1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8 9 9 1 1 A B C D E F 104 105 101 103 102 103 0 INITIAL RELEASE ECO S 005797 PVP ANP JLP 3 11 2016 REVISION HISTORY REV DESCRIPTION DWN BY CHK BY APPR BY DATE 24X TORQUE 87 FT LBS 106 TORQUE 84 IN LBS 7 FT LBS Discharge Manifold Components MODELS VSG VSH ...

Page 77: ... Emerson 35391HP Housing Housing Components MODELS VSG VSH VSS128 to VSG VSH VSS243 ITEM DESCRIPTION VPN QUANTITY 103 O RING 796X1 074 AFLAS VP101 3547M 3 104 PLUG 1 4 18NPTF FLUSH SEAL SOC HD 2606C 1 105 PLUG 5 16 HEX SAE FOR J1926 PORT AFLAS 3647A 1 106 PLUG 9 16 HEX SAE FOR J1926 PORT AFLAS 3647D 5 ...

Page 78: ...8 6 Blank HPLD Compressor Unit Installation Operation and Maintenance Manual Emerson 35391HPU ...

Page 79: ...6 28 44 68 98 135 240 387 SAE GRADE 5 FINE UNF 16 SAE GRADE 8 COARSE UNC 11 22 39 63 96 138 191 338 546 SOCKET HEAD CAP SCREW ASTM A574 COARSE UNC 5 13 26 46 73 112 155 215 380 614 NOTES 1 Torque values on this sheet are not to override those given on the individual drawings 2 When using loctite the torque value on this sheet are only accurate if bolts are tightened immediately after loctite is ap...

Page 80: ...A 2 Blank HPLD Single Screw Compressor Installation Operation and Service Manual Emerson 35391HP ...

Page 81: ...B 1 HPLD Single Screw Compressor Installation Operation and Service Manual Emerson 35391HP Appendix B Vilter Oil Oil Analysis Report ...

Page 82: ...B 2 Blank HPLD Single Screw Compressor Installation Operation and Service Manual Emerson 35391HP ...

Page 83: ......

Page 84: ...ty in cooling recovery and compression It combines best in class technology with proven engineering and design to create quality products and latest solutions for customers worldwide About Emerson Vilter Manufacturing LLC is a business segment of Emerson a global leader in bringing technology and engineering together to provide innovative solutions for customers in industrial commercial and consum...

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