Emerson VILTER VSG Setup guide

The World's Best CompressorsTM
For Gas Compression
VSG & VSSG Single Screw
Installation, Operation and Service Manual
Bare Sha Compressor

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VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
Important Message
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.
The following instructions have been prepared to assist in installation, operation and removal of VilterTM 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.
Only qualified personnel shall operate, install and maintain the equipment.
Qualified personnel shall be accredited by a local regulatory agency, which requires that they are continually scruti-
nized by an organization whose sole mission is to establish, maintain and assure that the highest industry standards
are set and met in a continuous and ongoing basis. The credentials shall address topics ranging from plant safety,
operating concepts and principles and operations through the basics of refrigeration compliance and PSM (Process
Safety Management) requirements.
Follow local workplace occupational safety and health regulations.
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. 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 systems.
VilterTM screw compressor components are thoroughly inspected at the factory. However, damage can occur
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 VilterTM representative or the home office should be notified of any claim made.
All inquires should include the VilterTM 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
5555 South Packard Ave
Cudahy, WI 53110-8904 USA
Telephone: [phone], Fax:[phone]
E-mail: [e-mail], Website: Emerson.com/Vilter
Equipment Identification Numbers:
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________

ii VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
VSG STANDARD VILTERTM 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 war-
ranty 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 WAR-
RANTIES, 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 sugges-
tions 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.

iii
VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
EC Declaration of Incorporation
We hereby declare that the following machinery is intended to be incorporated into other machinery, and must
not be put into service until the relevant machinery into which it is to be incorporated has been declared in con-
formity with the essential requirements of the Machinery Directive 2006/42/EC.
Machine Description: Industrial Compressor
Make: Vilter
Type: VSM / VSS / VSR /VSH / VSSH / VSG & VSSG Single Screw Compressor
Model Size: 71, 91, 97, 101, 111, 113, 127, 128, 145, 151, 160, 180, 204, 221, 222, 243, 152, 182, 202,
301, 361, 401, 501, 601, 701, 291, 341, 451, 601, 751, 901, 791, 891, 1051, 1201, 1301, 1501,
1551, 1801, 1851, 2101, 2401, 2601, 2801, 3001.
Manufactured by: Vilter Manufacturing, LLC.
The following transposed harmonised European Standards 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 design.
IEC/EN60204-1 (2016) - Safety of Machinery - Electrical equipment of machines - Specication for general
requirements.
A technical construction le for this machinery is retained at the following address:
Vilter Manufacturing, LLC.
5555 South Packard Avenue
P.O. Box 8904, Cudahy
Wisconsin 53110-8904, USA
Vilter’s Authorized Representative in Europe is Emerson S.R.L., company No J12/88/2006, Emerson 4 Street, Parcul
Industrial Tetarom II, Cluj-Napoca 400638, Romania. For product compliance destination sales questions in Europe,
contact the Regulatory Compliance Department: [e-mail] ([phone]).
In Great Britain, it is Emerson Process Management Ltd., Company No 00671801, Meridian East, Leicester, LE19
1UX, United Kingdom. For product compliance destination sales questions contact the Regulatory Compliance
Department: ukproductcomplianc[email protected] ([phone]).
Signed for and on behalf of Vilter Manufacturing, LLC.:
Last update: September 2021
Vilter Manufacturing, LLC.
5555 South Packard Avenue t P.O. Box 8904 t Cudahy, Wisconsin 53110-8904
001-414- 744-0111 t FAX: [phone]

iv / Blank VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB

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Table of Contents
Section Title Page Number
VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
Important Message................................................................................................................................i
VSG Standard Vilter Warranty Statement ...............................................................................................ii
EC Declaration of Incorporation .............................................................................................................iii
Section 1 • General Information
How To Use This Manual ........................................................................................................................1-1
Additional Important Notes ...................................................................................................................1-1
Bare Shaft Gas Compressor Model Designations ....................................................................................1-2
System Unit Identification......................................................................................................................1-3
Bare Shaft Compressor...............................................................................................................1-3
Compressor Unit ........................................................................................................................1-3
Package Unit ..............................................................................................................................1-3
Section 2 • Theory of Operation
Compressor ...........................................................................................................................................2-1
Capacity and Volume Control.................................................................................................................2-1
Description of a Gas System for a Standard Compressor Set ...................................................................2-2
Description of an Oil System for a Standard Compressor Set...................................................................2-3
Critical Applications Guidelines ..............................................................................................................2-3
Notice on using Non-Vilter Oils ..............................................................................................................2-3
Alarm and Shutdown Readings ..............................................................................................................2-3
VSG Package Requirements ...................................................................................................................2-5
Process Gas Circuit .....................................................................................................................2-5
Section 3 • Installation
Long Term Storage Requirements ..........................................................................................................3-1
Long Term Storage Log...............................................................................................................3-2
Instrumentation Requirements ..............................................................................................................3-3
Pressure .....................................................................................................................................3-3
Temperature ..............................................................................................................................3-3
Miscellaneous.............................................................................................................................3-3
Piping 3-5
Recommended Header Piping ....................................................................................................3-5
Compressor Suction Piping ........................................................................................................3-5
Compressor Discharge Piping.....................................................................................................3-7
Oil Line and Aftercooler Piping ...................................................................................................3-9
Air Cooled Condenser Piping ......................................................................................................3-10
Allowable Flange Loads ..............................................................................................................3-11
Testing System For Leaks........................................................................................................................3-12
Hydrocarbons Systems...............................................................................................................3-12
Notice on Using Non-Vilter Oils .............................................................................................................. 3-12
Oil for Single Screw Compressors ...........................................................................................................3-12
Installation and Calibration of Slide Valve Actuators ..............................................................................3-13
Slide Valve Actuator Installation Instructions..............................................................................3-13
Actuator Motor Control Module Calibration Procedure...............................................................3-13
Slide Valve Operation.............................................................................................................................3-15

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Section Title Page Number
VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
Section 4 • Operation
Notice on Using Non-Vilter Oils .............................................................................................................. 4-1
Safety Setpoints.....................................................................................................................................4-1
Control System .....................................................................................................................................4-2
Calibration .................................................................................................................................4-2
Starting, Stopping and Restarting The Compressor ....................................................................4-2
Emergency Shutdown ................................................................................................................4-2
Slide Valve Actuator Calibration (25972XP)............................................................................................4-3
Slide Calibration Screen Overview ..............................................................................................4-3
Calibrate Slide Valve Actuators (25972XP)..................................................................................4-3
Slide Valve Actuators Calibration (For VPN 25972D Only).......................................................................4-6
Section 5 • Maintenance/Service
Maintenance and Service Schedule ........................................................................................................5-1
Additional Notes ........................................................................................................................5-2
Recommendations When Servicing........................................................................................................5-2
Preparation of Unit For Servicing............................................................................................................5-2
Compressor Inspection ..........................................................................................................................5-3
Bearing Check ............................................................................................................................5-3
Gaterotor Assembly Replacement ..........................................................................................................5-5
Removal (All VSG Models) ..........................................................................................................5-5
Removal (All VSG 301-701 Models)............................................................................................. 5-6
Installation (All VSG Models) ......................................................................................................5-8
Installation (All VSG 301-701 Models).........................................................................................5-10
Gate Rotor Blade Removal ..........................................................................................................5-11
Gate Rotor Blade Installation ......................................................................................................5-11
Gate Rotor Thrust Bearing Removal ............................................................................................5-11
Gate Rotor Thrust Bearing Installation ........................................................................................5-11
Gate Rotor Roller Bearing Removal .............................................................................................5-12
Gate Rotor Roller Bearing Installation .........................................................................................5-12
Compressor Shaft Seal Replacement ......................................................................................................5-13
Compressor Shaft Seal Removal .................................................................................................5-13
Compressor Shaft Seal Installation .............................................................................................5-13
Maintenance Suggestion............................................................................................................5-13
Inspection of Slide Valve Assemblies In The Compressor ........................................................................5-15
Prepare The Compressor For Servicing .......................................................................................5-15
Removal of Slide Valve Carriage Assemblies...............................................................................5-15
Installation of Slide Valve Carriage Assemblies............................................................................5-16
Slide Valve Actuator Assembly Replacement ..........................................................................................5-17
Removal.....................................................................................................................................5-17
Installation.................................................................................................................................5-17
Actuator Installation Using Anti-Rotation Bolts...........................................................................5-18
Slide Valve Command Shaft Assembly Replacement...............................................................................5-19
Removal.....................................................................................................................................5-19
Installation.................................................................................................................................5-19
Slide Valve Command Shaft Assembly Replacement (For the Design Before June 2006)..........................5-20
Removal.....................................................................................................................................5-20
Installation.................................................................................................................................5-20
Slide Valve Command Shaft Bearing and O-Ring Seal Replacement (For the Design Before June 2006) ... 5-20
Removal.....................................................................................................................................5-20
Reassembly ................................................................................................................................5-21

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Section Title Page Number
VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
Discharge Manifold Removal..................................................................................................................5-21
Discharge Manifold Installation.............................................................................................................. 5-21
Slide Valve Gear and Rack Inspection...................................................................................................... 5-22
Removal of Capacity or Volume Cross Shafts ..........................................................................................5-22
Installation of Capacity or Volume Cross Shafts ......................................................................................5-23
Main Rotor Assembly .............................................................................................................................5-24
Torque Specifications............................................................................................................................. 5-24
Using A Torque Wrench Correctly...........................................................................................................5-25
Nord-Lock®Washers ..............................................................................................................................5-25
Section 6 • Troubleshooting
Slide Valve Actuator Troubleshooting Guide...........................................................................................6-1
Slide Valve Actuator LED Blink Codes......................................................................................................6-3
Troubleshooting Guide - General Problems and Solutions ......................................................................6-5
Section 7 • Warranty and Parts
Warranty Claim Processing ....................................................................................................................7-1
Process For Returning Products Covered By the Warranty...........................................................7-1
Procedure For Parts Not Manufactured By Vilter.........................................................................7-1
Motor Warranty Procedure ....................................................................................................................7-2
On-Site Service Support.........................................................................................................................7-3
Remanufactured Gas Bare Shaft Single Screw Compressor Process ........................................................7-3
Explanation of Rebuild Levels......................................................................................................7-3
Bare Shaft Compressor Description ............................................................................................7-3
Section 8 • Spare Parts List
How to Read a Parts List and Illustration.................................................................................................8-1
Item Number..............................................................................................................................8-1
Description ................................................................................................................................8-1
Model Number ...........................................................................................................................8-1
VPN 8-1
Quantity.....................................................................................................................................8-1
Assembly and Kit Information ....................................................................................................8-1
Terms and Abbreviation Used.....................................................................................................8-1
Important Notes ........................................................................................................................8-1
VilterTM Aftermarket Parts Contact Information ..........................................................................8-1
Recommended Spare Parts List ..............................................................................................................8-3
Gate Rotor..................................................................................................................................8-4
Shaft Seal ...................................................................................................................................8-8
Tandem Shaft Seal......................................................................................................................8-9
Main Rotor .................................................................................................................................8-10
Slide Valve Cross Shafts and End Plate.........................................................................................8-12
Slide Valve Carriage Assembly ....................................................................................................8-14
Actuator and Command Shaft ....................................................................................................8-18
Miscellaneous Frame Components .............................................................................................8-20
Replacement Tools .....................................................................................................................8-24
VSG 301-701 Replacement Parts Section ...............................................................................................8-27
Gaterotor Assembly ...................................................................................................................8-28
Shaft Seal ...................................................................................................................................8-31
Main Rotor, Slide Valve Cross Shafts and End Plate ......................................................................8-32

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Table of Contents
Section Title Page Number
VSG & VSSG Single Screw Compressor • Installation, Operation and Service Manual • Emerson • 35391SB
Slide Valve Carriage Assembly ....................................................................................................8-36
Actuator and Command Shaft ....................................................................................................8-38
Miscellaneous Frame Components .............................................................................................8-40
Replacement Tools .....................................................................................................................8-44
Appendices
Appendix A Torque Specifications......................................................................................................A-1
Appendix B Vilter Oil .........................................................................................................................B-1
Appendix C Vibration Measurements - Single Screw Compressor.......................................................C-1