Emerson Vilter VSS

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VSS/VSM/VSH/VSSH • Installation, Operation and Maintenance Manual • Emerson • 35391SD

Appendix E • Liquid Injection Valve Station ICF 20-40 Installation Guide

Appendix E

Liquid Injection Valve Station ICF 20-40

Installation Guide

Main Page

Standard Vilter™ Warranty Statement3
Important Message5
EC Declaration of Incorporation6
- Table of Contents7
- Section 1 • General Information15
How to Use this Manual15
Additional Important Notes15
Refrigeration Compressor Unit Model Designations16
System Unit Identification17
Compressor Unit Component Identification18
Figure 1-1. Refrigeration Compressor Unit Components18
Instrument Identification Letters21
Symbols Identification23
Major Component Identification23
Control and Instrument Identification24
Line Type Designations24
Valve and Instrument Tagging25
Equipment Number Identification25
Pipe Line Data Identification26
- Section 2 • Theory of Operation27
Refrigerant Flow27
Oil Life and Oil Flow27
Oil Cooling28
- Water Cooled Oil Cooling28
- Liquid Injection Oil Cooling28
- V-Plus Oil Cooling28
- Thermosyphon Oil Cooling28
Control System29
- Temperature Elements, Pressure Transmitters and Indicators29
- Section 3 • Installation31
Figure 3-1. Rigging and Lifting Points (VSS-2101 Compressor Unit Shown)31
Delivery Inspection31
Rigging and Lifting of Compressor Unit31
Compressor Unit Inspections Prior to Installation32
Recommended On-Site Tools32
Long Term Storage Recommendations33
- Compressor Motor33
- Long Term Storage Log34
Foundation35
- Considerations Prior to Starting35
- Foundation Materials35
- Building the Foundation35
- Compressor Unit Installation36
- Figure 3-2. Concrete Pad with Compressor Unit Dimensions - Side View36
- Leveling and Grouting37
- Figure 3-3. Concrete Pad with Compressor Unit Dimensions - Front View37
- Figure 3-4. Interior Foundation Isolation37
- Additional Information38
- Operation and Performance38
- General Design Requirements38
- Figure 3-5. Foundation with Housekeeping Pads Dimensions - Top View38
- Figure 3-6. Housekeeping Pad Dimension Detail - Top View39
- Figure 3-7. Level Compressor Unit Using Top Surface of Spherical Washers39
- Figure 3-8. Concrete Pad Housekeeping Detail40
Figure 3-9. Stop/Check Valve Orientation41
Stop/Check Valve Installation41
Piping42
Table 3-1. Maximum Allowable Flange Loads43
Figure 3-10. Maximum Allowable Flange Loads43
Flange Loads43
Figure 3-11. Recommended Remote Air Cooled Oil Cooler Piping44
Remote Air-Cooled Oil Cooler Piping44
Electrical Connections45
- Field Wiring Instructions45
Testing Refrigeration System for Leaks48
- Ammonia Systems48
- Halocarbon Refrigerant Systems48
- CO2 Systems49
Evacuating the System49
Notice on Using Non-Vilter Oils50
Unit Oil Charging and Priming50
- Unit Initial Oil Charging51
- Priming Oil Lines and Compressor51
System Refrigerant Charging52
- Low Side Equipment52
- Compressors52
- Condensers52
- Controls52
- Initial High Side Charging52
Notice on Using Non-Vilter Oils55
Operation55
Oil Inspection55
Section 4 • Operation55
Dual Oil Filters56
Control System56
- Calibration56
- Starting, Stopping and Restarting the Compressor56
- Emergency Shutdown57
Slide Valve Actuator Operation57
Calibrate Slide Valve Actuators (for Units Using Vission20/20™)58
Table 4-1. Command Shaft Rotation Specifications62
Calibrate Slide Valve Actuators (for Units Using Compact Logix PLC)64
Compressor Control with Vission20/20™ Micro-Controller (no Slide Operation)69
Coalescing Oil Return Line Setup70
Suction Equalizing Line Setup - for VSS/VSM Compressors71
Dual Oil Filter Setup for Oil Filters with Filter Head Assemblies72
Table 4-2. Stop/Check Valve Open Positions73
Stop/Check Valve Operation73
Maintenance and Service Schedule - for VSS/VSM Unit Only75
Section 5 • Maintenance/Service75
Maintenance and Service Schedule - for VSH/VSSH Unit Only76
Preventive Maintenance, Checks and Services78
- Daily78
- Weekly78
- Monthly78
- Trimonthly78
- Annually78
Compressor Unit Isolation for Maintenance/Service (Compressors with Slide Valves)79
Recommendations When Servicing (Compressors Without Slide Valves)80
Preparation of Unit for Servicing80
Compressor Unit Leak Check after Servicing81
Oil System Components81
- Oil Sampling81
- Oil Draining85
- Oil Charging86
- Filter Element Replacement (Single Oil Filter Assembly) and Oil Pump Strainer Servicing87
- Filter Element Replacement (Duplex Oil Filter Assembly)90
  - Removal90
- Filter Element Replacement (Dual Oil Filter Assembly)90
- Oil Separator Coalescing Filter Replacement95
  - Removal95
  - Installation95
- Oil Separator Heater Cartridge Replacement97
Drive Coupling Hub (Form-Flex BPU) Installation98
- Straight Bore Hubs98
- Tapered Bore Hubs98
- Table 5-4. Shaft and Hub Distances98
Table 5-5. Hub Clamp Bolt and Set Screw Torque Specifications99
Table 5-6. Disc Pack Installation Torque Specifications99
Drive Center Member Installation and Alignment99
Drive Coupling Hub (Form-Flex BPU) and Center Member Removal101
Drive Coupling (Type C Sure-Flex) Replacement101
- Removal101
- Installation102
Coupling Guard Replacement103
- Removal103
- Installation103
Compressor Replacement104
- Removal104
- Installation105
Table 5-8. Bareshaft Compressor Component Weights105
Table 5-9. Bareshaft Compressor Component Lifting Hole Sizes105
Bareshaft Compressor Lifting Points and Weights105
Bareshaft Compressor Center of Gravity (Models 291-2101)107
Bareshaft Compressor Center of Gravity (Models 2401-3001)108
Compressor Inspection109
- Compressor Shaft Bearing Clearance Inspections109
- Gaterotor Bearing Inspection111
- Table 5-11. Maximum Gaterotor Bearing Clearance111
- Gaterotor Inspection112
- Additional Inspections116
- Post Inspection116
Gaterotor Assembly Replacement (All Compressors Except VSM 301-701 & VSM 97-127 Compressors)116
- Removal116
- Table 5-14. Gaterotor Tool Kits116
- Installation117
Gaterotor Assembly Replacement (VSM 301-701 Compressors Only)120
- Removal120
- Installation120
Gaterotor Assembly Replacement (VSM 97-127 Compressors Only)122
- Removal122
- Installation122
Gaterotor Disassembly (All Compressors Except VSM 97-127 Compressors)124
- Gaterotor Blade Removal124
- Gaterotor Blade Installation125
- Gaterotor Thrust Bearing Removal125
- Gaterotor Thrust Bearing Installation125
- Gaterotor Roller Bearing Removal126
- Gaterotor Roller Bearing Installation126
Gaterotor Disassembly (VSM 97-127 Compressors Only)127
- Gaterotor Blade Removal127
- Gaterotor Blade Installation127
- Gaterotor Thrust Bearing Removal128
- Gaterotor Thrust Bearing Installation128
- Gaterotor Roller Bearing Removal128
- Gaterotor Roller Bearing Installation128
Compressor Shaft Seal Replacement129
- Shaft Seal Assembly129
- Handling Seal Face with Care129
- Compressor Shaft Seal Replacement - for VSS/VSM Units130
- Compressor Shaft Seal Replacement - for VSH/VSSH Units132
Slide Valve Actuator Assembly Replacement137
- Removal137
- Installation137
- Actuator Installation Using Anti-Rotation Bolts138
Slide Valve Command Shaft Assembly Replacement139
- Removal139
- Installation139
Liquid Injection Control Valve Station140
Table 5-17. Coils for Solenoid Valves (ICFE)141
Table 5-18. Parts for Motorized Valve Station (ICF)141
Table 5-19. Torque Specifications (Ft-Lbs)142
Main Rotor Assembly142
Torque Specifications142
Nord-Lock ® Washers143
Using a Torque Wrench Correctly143
Table 6-1. Slide Valve Actuator Troubleshooting Guide (1 of 3)145
Section 6 • Troubleshooting145
Table 6-2. Slide Valve Actuator LED Blink Codes (1 of 2)148
Table 6-3. Troubleshooting Guide - General Problems & Solutions (1 of 3)150
Slide Valve Actuator Troubleshooting Guide151
Warranty Claim Processing153
Section 7 • Warranty and Parts153
On-Site Service Support155
Remanufactured Bare Shaft Single Screw Compressor Process155
- Explanation of Rebuild Levels155
- Bare Shaft Compressor Description155
Section 8 • Spare Parts List157
- Gaterotor160
- Shaft Seal167
- Main Rotor168
- Slide Valve Cross Shafts and End Plate170
- End Plate (VSS 2401 - VSS 3001 Only)172
- Slide Valve Carriage Assembly174
- Miscellaneous Frame Components178
- Miscellaneous Frame Components Tubing and Fittings181
- Replacement Tools184
- Replacement Parts185
- Gaterotor Assembly188
- Shaft Seal190
- Main Rotor191
- Slide Valve Carriage Assembly194
- Miscellaneous Frame Components197
- Housing Accessories199
- Replacement Tools200
- Kits203
Appendix A Torque Specifications205
Appendix B Vilter Oil207
Appendix C Vibration Measurements - Single Screw Compressor211
- Wiring the ICAD223
- Troubleshooting228
- The Manual Tool228
- Service Parameters228
- Alarms229
- Common Questions230

Emerson Vilter VSS - Page 231

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