Emerson VSG Manual de usuario

VSG & VSSG

Single Screw Bare Shaft Compressor

The World’s Best Compressors

For Gas Compression

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

The following instructions have been prepared to assist in installation, operation and removal of Vilter Single

Screw Compressors. Following these instructions will result in a long life of the compressor with satisfactory

operation.

The entire manual should be reviewed before attempting to install, operate, service or repair the compressor.

A compressor is a positive displacement machine. It is designed to compress gas. The compressor 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. Vilter Manufacturing is not responsible

for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing can-

not warrant equipment damaged by improperly protected or operating systems.

Vilterscrewcompressorcomponentsarethoroughlyinspectedatthefactory. However,damagecanoccur

in shipment. For this reason, the equipment should be thoroughly inspected upon arrival. Any damage

noted should be reported immediately to the Transportation Company. This way, an authorized agent

can examine the unit, determine the extent of damage and take necessary steps to rectify the claim with

no serious or costly delays. At the same time, the local Vilter representative or the home office should

be notified of any claim made.

All inquires should include the Vilter sales order number, compressor serial and model number. These can be

found on the compressor name plate on the compressor.

All requests for information, services or parts should be directed to:

Vilter Manufacturing LLC

Customer Service Department

P.O. Box 8904

5555 South Packard Ave

Cudahy, WI 53110-8904 USA

Telephone: 1-414-744-0111

Fax:1-414-744-3483

e-mail: info.vilter@emerson.com

Equipment Identification Numbers:

Vilter Order Number: _______________________Compressor Serial Number: _________________

Important Message

Table of Contents

Important Message ............................................................................................ 3

VSG STANDARD VILTER WARRANTY STATEMENT ................................................ 6

Long Term Storage Requirements....................................................................... 7

Critical Applications Guidelines........................................................................... 8

Instrumentation Requirements ...................................................................... 9

Alarm and Shutdown Readings..................................................................... 11

VSG Package Requirements .............................................................................. 12

Description .................................................................................................. 13

installation................................................................................................... 16

Installation & Calibration of Slide Valve Actuators ............................................. 18

Slide Valve Operation................................................................................... 21

Slide Valve Actuator Trouble Shooting Guide................................................ 22

Operation Section ............................................................................................ 26

Notice on using Non -Vilter Oils.................................................................... 26

Maintenance................................................................................................ 29

Service ............................................................................................................. 30

Parts Section .................................................................................................... 57

Gate Rotor ................................................................................................... 58

Shaft Seal..................................................................................................... 62

Tandem Shaft Seal........................................................................................ 63

Main Rotor................................................................................................... 64

Slide Valve Cross Shafts and End Plate .......................................................... 66

Slide Valve Carriage Assembly...................................................................... 68

Actuator & Command Shaft ......................................................................... 72

Miscellaneous Frame Components ............................................................... 74

Replacement Tools....................................................................................... 78

VSG 301-701 Replacement Parts Section .......................................................... 81

Gaterotor Assembly ..................................................................................... 82

Shaft Seal..................................................................................................... 85

Main Rotor, Slide Valve Cross Shafts & End Plate ........................................... 86

Slide Valve Carriage Assembly...................................................................... 90

Actuator & Command Shaft ......................................................................... 92

Miscellaneous Frame Components ............................................................... 94

Replacement Tools....................................................................................... 98

VSG STANDARD VILTER WARRANTY STATEMENT

Seller warrants all new single screw gas compression units and bareshaft single screw compressors

manufactured by it and supplied to Buyer to be free from defects in materials and workmanship for a period

of (a) eighteen (18) months from the date of shipment or (b) twelve (12) months from the date of

installation at the end user’s location, whichever occurs first.

If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product

shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation

and Buyer’s exclusive remedy hereunder and shall be conditioned upon (a) Seller’s receiving written notice

of any alleged defect within ten (10) days after its discovery, (b) payment in full of all amounts owed by

Buyer to Seller and (c) at Seller’s option, Buyer shall have delivered such products to Seller, all expenses

prepaid to its factory. Expenses incurred by Buyer in repairing or replacing any defective product

(including, without limitation, labor, lost refrigerant or gas and freight costs) will not be allowed except by

written permission of Seller. Further, Seller shall not be liable for any other direct, indirect, consequential,

incidental, or special damages arising out of a breach of warranty.

This warranty is only applicable to products properly maintained and used according to Seller’s

instructions. This warranty does not apply (i) to ordinary wear and tear, damage caused by corrosion,

misuse, overloading, neglect, improper use or operation (including, without limitation, operation beyond

rated capacity), substitution of parts not approved by Seller, accident or alteration, as determined by Seller

or (ii) if the product is operated on a gas with an H2S level above 100 PPM. In addition, Seller does not

warrant that any equipment and features meet the requirements of any local, state or federal laws or

regulations. Products supplied by Seller hereunder which are manufactured by someone else are not

warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products

that Seller may have from the original manufacturer. Labor and expenses for repair are not covered by

warranty.

THE WARRANTY CONTAINED HEREIN IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND

WARRANTIES, EXPRESS OR IMPLIED, AND SELLER EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED

WARRANTY OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Any description of the products, whether in writing or made orally by Seller or Seller’s agents,

specifications, samples, models, bulletins, drawings, diagrams, engineering sheets or similar materials used

in connection with Buyer’s order are for the sole purpose of identifying the products and shall not be

construed as an express warranty. Any suggestions by Seller or Seller’s agents regarding use, application or

suitability of the products shall not be construed as an express warranty unless confirmed to be such in

writing by Seller.

Long Term Storage Requirements

Note: At the time of purchase Vilter Manufacturing must be notified.

1. The compressor(s) must be stored in a heated building, preferably air conditioned to control

moisture, to prevent corrosion of the main rotor shaft and for the compressor. The slide valve

(volume ratio& capacity) motors and gears.

2. The main rotor shaft must be coated with light grease to prevent rusting.

3. (For Screw Compressors) The volume and capacity slide valve motor enclosures should have

corrosion inhibitors installed in them and the enclosures should be sealed. On a six month basis

(depending on relative humidity), check and replace inhibitors as necessary, and check for

signs of corrosion.

4. Before leaving Vilter Manufacturing the compressor is evacuated and pressurized, with dry

nitrogen, to 5 psig. Pressure must be monitored with the gauge (provided by Vilter) and checked

on a regular basis (at least monthly).

5. The rotor shaft must be rotated every 3 months to prevent flat spots from developing on the

bearing surfaces and to keep the shaft seal lubricated.

6. A log should be maintained indicating that the above procedures have been completed.

When the compressor is installed.

A. Look into the suction and discharge connections and inspect for any signs of corrosion on parts.

B. Prelube the compressor with the main oil pump and rotate by hand several revolutions prior to

start.

C. Notify the Vilter Warranty Department when the compressor is started.

Critical Applications Guidelines

To ensure the successful operation of the VSG compressor, the guidelines described below

should be followed.

1. Proper lubrication is critical to the operation of the VSG compressor. The compressor relies on

the injected oil to absorb and remove the heat of compression, to seal the compression chambers

formed in the flutes of the screw, and to lubricate all moving parts. For this reason, it is impera-

tive that the oil chosen be of correct viscosity, and that sufficient oil flow be provided at all times,

using an auxiliary oil pump when necessary. The oil chosen must be compatible with the process

gas as well, to prevent absorption of the gas into the oil, which would dilute the oil and reduce the

viscosity. Also, oil filtration to 25 micron 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 application

and in sizing an auxiliary oil pump, consult a Vilter 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 dewpoint at anytime to prevent

condensation or liquid knockout from occurring within the compressor.

Gas composition plays a role in the performance of the VSG compressor as well. While the VSG is

capable of handling a wide variety of gases, it is required that the concentration of H2S in the pro-

cess gas not exceed 100 PPM. If H2S is present in the process gas in any concentration, special oil

additives are required to protect the compressor from corrosion.

Notice on using Non -Vilter Oils

Oil and its additives are crucial in refrigeration system performance. Vilter Manufacturing will NOT

APPROVE non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available

it is not possible for us to test all oils offered in the market place, and their effects on our equipment,

as we can with our own lubricants.

We realize that customers may choose compressor lubricants other than Vilter branded oil. This is

certainly within the customers’ right as owners of the equipment. When this choice is made, however,

Vilter is unable to accept responsibility for any detrimental affects those lubricants may have on the

equipment or system performance and durability.

Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny war-

ranty upon evaluation of the issue. This includes any parts’ failure caused by inadequate lubrication.

Certainly, there are many good refrigeration lubricants in the market place. The choice of a lubricant

for a particular application involves consideration of many aspects of the lubricant and how it and its

additive package, will react in the various parts of the entire refrigeration system. It is a complex choice

that depends on a combination of field experience, lab and field-testing, and knowledge of lubricant

chosen. Vilter will not accept those risks other than for our own compressor lubricants.

Instrumentation Requirements

Temperature

There are four temperature readings required for

processor control, as listed below.

5. Suction temperature RTD measures the tem-

perature of the incoming suction gas, and is

used to provide annunciation for low suction

temperature when the unit is running.

6. Discharge temperature RTD measures the

temperature of the gas/oil mixture as it is dis-

chargedfromthecompressorhousing,andpro-

vides annunciation for high running discharge

temperature.

7. Oil Separator temperature RTD measures the

temperature of the oil in the separator sump,

and gives the oil temperature start permissive

and low running separator temperature an-

nunciation.

8. Oil Injection temperature RTD measures the

temperature of the oil as it is injected into the

compressor, which provides annunciation for

either high or low running oil injection tem-

perature.

* Additional RTD’s may be required and installed

by the customer for temperature readings at

customer specified points such as discharge gas

temperature from the package boundary, cooling

water temperature to and/or from the oil cooler,

gas aftercooler temperature, etc.

Pressure

There are four pressure transducers required to read

system pressures as listed below.

1. Suction pressure transducer (-15.0 - 300 PSIG)

measures the gas suction pressure into the com-

pressor housing, which provides the permissive

to start for minimum suction pressure, and is

used for annunciation of low suction pressure

while running and in the capacity control logic.

2. Discharge pressure transducer (-15.0 - 300 PSIG)

measures the discharge pressure of the process

gas in the separator, which provides annuncia-

tion for high discharge pressure, and may also

be used for capacity control logic.

3. Oil Filter Inlet pressure transducer (-15.0 - 300

PSIG) measures the oil pressure as it enters the

oil filter canisters and is used to calculate oil filter

differential pressure to provide annunciation of

high filter differential pressure

4. Oil Manifold pressure transducer (-15.0 - 300

PSIG) measures the oil pressure downstream of

the oil filter as the oil is injected into the com-

pressor, and provides annunciation protection

for 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

pressure from the package boundary, cooling water

pressure to and/or from the oil cooler, etc.

Instrumentation Requirements

Miscellaneous: Additional instrumentation devices required are a current transformer mounted around one

phase of the drive motor leads to measure main motor amperage, and two rotary potentiometers to read the

position of the slides. The amperage signal provides annunciation for high motor amperage, and is used in the

capacity control logic. The rotary potentiometers indicate the position of the slides, which is used as a start-

ing permissive and in the capacity control logic. Also, additional input points may be required for customer

connection of remote signals such as Start and Stop commands, and capacity setpoint control.

MOTOR

OPTIONAL REMOTE AIR COOLED OIL COOLER

STANDARD WATER COOLED OIL COOLER

OIL SEPARATOR

OPTIONAL DUAL OIL FILTERS

STANDARD SINGLE

OIL FILTER

COMPRESSOR

OIL COOLER

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