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Emerson Vilter VSS User Manual

Emerson Vilter VSS
250 pages
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VSS/VSM/VSH/VSSH Compressor Unit
Installation, Operation & Maintenance Manual
FOR UNITS BUILT AFTER JANUARY 1, 2015

Table of Contents

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Emerson Vilter VSS Specifications

General IconGeneral
BrandEmerson
ModelVilter VSS
CategoryAir Compressor
LanguageEnglish

Summary

VSS/VSM/VSH/VSSH Compressor Unit Manual

Installation, Operation & Maintenance Manual

Covers installation, operation, and maintenance procedures for the compressor unit.

Standard Vilter Warranty Statement

Important Message

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

Crucial instructions for safe and proper installation and operation of the compressor.

Section 3: Installation

Rigging and Lifting of Compressor Unit

Provides essential safety warnings and procedures for safely rigging and lifting the compressor unit.

Compressor Unit Inspections Prior To Installation

Checks to be performed on the compressor unit before installation to ensure proper condition.

Foundation

Recommendations and specifications for the foundation and anchoring of the compressor unit.

Compressor Unit Installation

Steps for placing and leveling the compressor unit on the foundation and installing anchor bolts.

Leveling and Grouting

Procedure for leveling the unit and applying grout, ensuring proper bond and torque.

Stop/Check Valve Installation

Provides instructions for installing the new design of 2” thru 4” stop valves, including bonnet orientation.

Piping

Guidelines for piping installation, including support, cleanliness, and flexibility to avoid vibration.

Electrical Connections

Information on connecting power sources and control wiring for the compressor unit.

Testing Refrigeration System For Leaks

Procedures for testing the refrigeration system for leaks using various refrigerants and methods.

Unit Initial Oil Charging

Steps for charging the compressor unit with oil, including oil separator levels and pump usage.

System Refrigerant Charging

Procedures and checks required before charging the refrigeration system with refrigerant.

Field Wiring Instructions

Step-by-step instructions for wiring the Vission 20/20 micro-controller and related components.

Evacuating The System

Detailed steps for evacuating the system to remove air, water, and non-condensables for proper refrigerant charging.

Unit Initial Oil Charging and Priming

Instructions for safely charging the compressor unit with oil and priming the system.

Section 4: Operation

Emergency Shutdown

Initiation procedures for emergency shutdown due to process variables or local push button activation.

Calibrate Slide Valve Actuators (For Units Using Vission20/20™)

Procedure for calibrating slide valve actuators using the Vission20/20 system, including safety precautions.

Calibrate Slide Valve Actuators (For Units Using Compact Logix PLC)

Procedure for calibrating slide valve actuators using a Compact Logix PLC, including safety precautions.

Control System

Details on the control system, including calibration of pressure transducers and safety controls.

Operation

Overview of unit operation, emphasizing microprocessor control for set-point adjustments and monitoring.

Starting, Stopping and Restarting The Compressor

Steps for starting, stopping, and restarting the compressor, including required conditions and safety measures.

Section 5: Maintenance/Service

Maintenance and Service Schedule - For VSS/VSM Unit Only

Provides a table of inspection and maintenance tasks for VSS/VSM units at various service intervals.

Maintenance and Service Schedule - For VSH/VSSH Unit Only

Provides a table of inspection and maintenance tasks for VSH/VSSH units at various service intervals.

Maintenance/Service Schedule (For VSH/VSSH Compressor Only)

Provides a table of inspection and maintenance tasks for VSH/VSSH compressors based on discharge and differential pressure.

Preventive Maintenance, Checks and Services

Details daily, weekly, monthly, trimonthly, and annually recommended maintenance tasks.

Compressor Unit Isolation For Maintenance/Service (Compressors with Slide Valves)

Procedures for safely isolating the compressor unit for maintenance, including lock-out/tag-out.

Compressor Unit Leak Check After Servicing

Procedure for checking the compressor unit for leaks after servicing to ensure system tightness.

Oil Draining

Procedure for draining oil from the compressor unit, including safety warnings and locations of drain valves.

Oil Charging

Instructions for charging oil into the compressor unit, both during operation and shutdown.

Filter Element Replacement (Single Oil Filter Assembly) and Oil Pump Strainer Servicing

Procedure for replacing single oil filter elements and servicing the oil pump strainer.

Filter Element Replacement (Duplex Oil Filter Assembly)

Procedure for replacing filter elements in a duplex oil filter assembly, including isolation and draining.

Filter Element Replacement (Dual Oil Filter Assembly)

Procedure for replacing filter elements in a dual oil filter assembly, noting differences from duplex filters.

Oil Separator Coalescing Filter Replacement

Procedure for replacing the coalescing filter in the oil separator, including removal and installation steps.

Oil Separator Heater Cartridge Replacement

Procedure for replacing the oil separator heater cartridge, covering removal and installation for different connector types.

Compressor Replacement

Instructions for notifying Vilter before compressor replacement and the removal process.

Installation

Steps for installing the gaterotor support, roller bearing housing, and thrust bearing housing.

Compressor Shaft Bearing Clearance Inspections

Instructions for inspecting compressor shaft bearing clearances, including determining maximum applied force.

Main Rotor Bearing Radial Clearance Inspection

Procedure for inspecting the radial clearance of the main rotor bearings using a dial indicator.

Gaterotor Bearing Inspection

Procedure for inspecting gaterotor radial and axial bearing clearances, including oil draining.

Gaterotor Inspection

Steps for checking the clearance between the gaterotor and the shelf using feeler gauges.

Gaterotor Backlash Inspection

Steps to perform gaterotor backlash inspection, measuring clearance between teeth and rotor groove.

Gaterotor Assembly Replacement (All Compressors Except VSM 301-701 and VSM 97-127 Compressors)

Procedure for replacing the gaterotor assembly for specific compressor models.

Gaterotor Assembly Replacement (VSM 301-701 Compressors ONLY)

Procedure for removing and installing the gaterotor assembly specifically for VSM 301-701 compressors.

Gaterotor Assembly Replacement (VSM 97-127 Compressors ONLY)

Procedure for removing and installing the gaterotor assembly specifically for VSM 97-127 compressors.

Gaterotor Disassembly (All VSS & VSM Compressors Except VSM 97-127 Compressors)

Procedure for disassembling the gaterotor for VSS and VSM compressors, excluding VSM 97-127.

Gaterotor Disassembly (VSM 97-127 Compressors ONLY)

Procedure for disassembling the gaterotor specifically for VSM 97-127 compressors.

Compressor Shaft Seal Replacement

Overview of the shaft seal assembly and precautions for handling seal faces.

Compressor Shaft Seal Replacement - For VSS/VSM Units

Procedure for replacing the compressor shaft seal for VSS/VSM units, including removal and installation steps.

Compressor Shaft Seal Replacement - For VSH/VSSH Units

Procedure for replacing the compressor shaft seal for VSH/VSSH units, including parts and pressure ranges.

Shaft Seal Installation - For Part# 25985Y and 25985YA

Procedure for installing the shaft seal, including fitting components, lubricating, and tightening bolts.

Shaft Seal Installation – For Part# 28985W and 28985WA

Procedure for installing the shaft seal for specific part numbers, including fitting components and tightening.

Slide Valve Actuator Assembly Replacement

Procedure for replacing the slide valve actuator assembly, including removal and installation steps.

Slide Valve Command Shaft Assembly Replacement

Procedure for replacing the capacity or volume command shaft assemblies, including removal and installation.

Maintenance and Service Schedule - For VSH/VSSH Compressor Only

Provides a table of inspection and maintenance tasks for VSH/VSSH compressors based on discharge and differential pressure.

Preparation of Unit For Servicing

Steps to prepare the unit for servicing, including electrical lockout and depressurization.

Gaterotor Float Measurement

Procedure for measuring gaterotor float using a dial indicator and comparing to table values.

Main Rotor Bearing Axial Clearance Inspection

Procedure for inspecting the axial clearance of the main rotor bearings using a dial indicator.

Handling Seal Face with Care

Crucial instructions for handling seal faces to avoid contamination and damage during installation.

Section 6: Troubleshooting

Slide Valve Actuator Troubleshooting Guide

Guide to diagnosing and resolving issues with the slide valve actuator, including calibration problems.

Slide Valve Actuator Troubleshooting Guide (2 of 3)

Troubleshooting common problems like spontaneous calibration mode and motor issues.

Slide Valve Actuator Troubleshooting Guide (3 of 3)

Troubleshooting guide covering motor issues, intermittent operation, and output shaft problems.

Slide Valve Actuator LED Blink Codes

Explanation of LED blink codes displayed by slide valve actuators for diagnostic purposes.

Troubleshooting Guide - General Problems & Solutions (1 of 3)

Guide to general problems and solutions, including low oil pressure, oil flow issues, and faulty readings.

Troubleshooting Guide - General Problems & Solutions (2 of 3)

Troubleshooting for oil loss issues, high oil temperature (liquid injection), and slide valve actuator alarms.

Troubleshooting Guide - General Problems & Solutions (3 of 3)

Troubleshooting for high amp draw, vibration, and excessive motor backspin.

Section 7: Warranty and Parts

Warranty Claim Processing

Explains the process for submitting and processing warranty claims.

Section 8: Spare Parts List

Appendix A: Torque Specifications

Appendix C: Vibration Measurements - Single Screw Compressor

Appendix F: Hand-Held Slide Valve Calibration Tool

Calibration Procedure

Step-by-step procedure for calibrating slide valve actuators using the hand-held tool.

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