Emerson Vilter VSS Setup guide

VSS/VSR/VSM/VSH/VSSH
Installation, Operation and Service Manual
Single Screw Bare Shaft Compressor

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VSS/VSR/VSM/VSH/VSSH Compressor • Installation, Operation and Service Manual • Emerson • 35391S
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. Vilter Manufacturing is not responsible for the system
or the controls needed to prevent liquid carry over and as such Vilter Manufacturing cannot warrant equipment
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 Vilter 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 USA
Telephone: [phone]; Fax:[phone]
E-mail: [e-mail]; Web: Emerson.com/Vilter
Equipment Identification Numbers:
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________
Vilter Order Number: _______________________Compressor Serial Number: _________________

ii VSS/VSR/VSM/VSH/VSSH Compressor • Installation, Operation and Service Manual • Emerson • 35391S
Seller warrants the products it manufactures to be free from defects in material and workmanship for a period of
eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from
date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the following
extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating
parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and reciprocating
compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not
apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or regula-
tion not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains all
features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Seller
of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.
Products supplied by Seller, which are manufactured by others, are not warranted by Seller, but rather Seller merely
passes through the manufacturer’s warranty to Buyer.
SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Unless otherwise agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair of
the defect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not be
responsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller will
not be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breach of
warranty. THESE WARRANTY REMEDIES ARE EXCLUSIVE AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED.
Products or parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory.
Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved
by Seller, or any alteration or repair by others which, in Seller’s judgement, adversely affects the Product, shall void
all warranties and warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer
be in default of its payment obligations to Seller under this Agreement or any credit agreement.
Standard VILTER™ Warranty Statement

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VSS/VSR/VSM/VSH/VSSH Compressor • Installation, Operation and Service Manual • Emerson • 35391S
The seller extends warranty, from date of shipment, to a period of fifteen (15) years on all compressor bearings, five
(5) years on all internal compressor parts and two (2) years on the remainder of the parts on single screw compressor
units. 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 ex-
clusive remedy hereunder and shall be conditioned upon Seller’s receiving written notice of any alleged defect within
ten (10) days after its discovery and, at Seller’s option, return of such parts to Seller, F.O.B., freight prepaid to Seller’s
factory. Expenses incurred by Buyer in repairing or replacing any defective product or any lost refrigerant will not
be allowed except by written permission of Seller. This warranty is only applicable to products properly maintained
and used according to Seller’s instructions, the use of genuine Vilter replacement parts and recommended oil in all
repairs and replacements has demonstrated adherence to a scheduled maintenance program as detailed in the Single
Screw Compressor operating manual. This warranty does not apply to normal wear and tear, or damage caused by
corrosion, misuse, overloading, neglect, improper operation, accident or alteration, as determined by Seller. Prod-
ucts 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 the Seller may have from the original
manufacturer. Labor and expenses for repair are not covered by warranty.
THE WARRANTY CONTAINED IN THIS SECTION IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND
WARRANTIES (EXCEPT OF TITLE), EXPRESS OR IMPLIED WARRANTY OF MERCHANTABILITY OR IMPLIED WAR-
RANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Any description of the product, 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. The 5/15 Extended Warranty shall be applicable only
if the specific maintenance guidelines as outlined in the technical manual are followed. This includes the compressor
inspections, completing periodic oil analysis and the change out of the oil and oil filters, and related components as
required with only genuine Vilter parts. The customer is required to keep a maintenance log and receipts demon-
strating the use of Genuine Vilter parts for validation of a warranty claim, if requested.
Note: The 5/15 warranty applies to NEW compressors only, and does NOT include used or remanufactured compressors.
Standard VILTER™ 5/15 Warranty Statement

iv VSS/VSR/VSM/VSH/VSSH Compressor • Installation, Operation and Service Manual • Emerson • 35391S
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 / VSH / VSSH / VSG & VSSG Single Screw Compressor
Model Size: 97, 113, 127, 128, 145, 160, 180, 204, 222, 243, 152, 182, 202, 301, 361, 401, 501, 601,
701, 291, 341, 451, 601, 751, 901, 791, 891, 1051, 1201, 1301, 1551, 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
Signed for and on behalf of Vilter Manufacturing, LLC.:
Last update: May 2019
Vilter Manufacturing, LLC.
5555 South Packard Avenue t P.O. Box 8904 t Cudahy, Wisconsin 53110-8904
001-414- 744-0111 t FAX: [phone]

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VSS/VSR/VSM/VSH/VSSH Compressor • Installation, Operation and Service Manual • Emerson • 35391S
Table of Contents
Section Title Page Number
Important Message.........................................................................................................................................i
Standard Vilter™ Warranty Statement ...........................................................................................................ii
Standard Vilter™ 5/15 Warranty Statement ..................................................................................................iii
EC Declaration of Incorporation ....................................................................................................................iv
Section 1 • General Information
How To Use This Manual............................................................................................................................. 1-1
Additional Important Notes ....................................................................................................................... 1-1
System Unit Identification ......................................................................................................................... 1-2
Bare Shaft Refrigeration and Heat Pump Compressor Model Designations ................................................. 1-3
Section 2 • Theory Of Operation
Compressor ............................................................................................................................................... 2-1
Capacity and Volume Control..................................................................................................................... 2-1
Refrigerant and Oil System......................................................................................................................... 2-2
Refrigerant Flow............................................................................................................................. 2-2
Oil Life and Oil Flow........................................................................................................................ 2-2
Control System .......................................................................................................................................... 2-4
Temperature Elements, Pressure Transmitters and Indicators......................................................... 2-4
Critical Application Guidelines ................................................................................................................... 2-4
Alarm and Shutdown Readings .................................................................................................................. 2-5
Single Screw Package Requirements .......................................................................................................... 2-6
Section 3 • Installation
Delivery Inspection .................................................................................................................................... 3-1
Rigging and Lifting of the Compressor ....................................................................................................... 3-1
Bareshaft Compressor Lifting Points and Weights ...................................................................................... 3-1
Bareshaft Compressor Center of Gravity (Models 291-2101) ...................................................................... 3-3
Bareshaft Compressor Center of Gravity (Models 2401-3001) .................................................................... 3-4
Compressor Inspections Prior to Installation .............................................................................................. 3-5
Recommended On-site Tools ..................................................................................................................... 3-5
Compressor Mounting ............................................................................................................................... 3-5
Notice on Using Non-Vilter Oils.................................................................................................................. 3-5
Long Term Storage Recommendations....................................................................................................... 3-6
Long Term Storage Log................................................................................................................... 3-7
Stop/Check Valve Installation..................................................................................................................... 3-8
Piping ........................................................................................................................................................ 3-9
Flange Loads............................................................................................................................................ 3-10
Slide Valve Actuator Installations Instructions.......................................................................................... 3-11
Installation................................................................................................................................... 3-11
Overview...................................................................................................................................... 3-11
Actuator Motor Control Module Calibration Procedure................................................................. 3-11
Instrumentation Requirements................................................................................................................ 3-12
Pressure ....................................................................................................................................... 3-12
Temperature ................................................................................................................................ 3-12
Miscellaneous............................................................................................................................... 3-13
Testing Refrigeration System For Leaks .................................................................................................... 3-13
Ammonia Systems ....................................................................................................................... 3-13
Halocarbon Refrigerant Systems .................................................................................................. 3-13
CO2 Systems ................................................................................................................................ 3-14

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Table of Contents
Section Title Page Number
Section 4 • Operation
Notice on Using Non-Vilter Oils.................................................................................................................. 4-1
Operation .................................................................................................................................................. 4-1
Control System ......................................................................................................................................... 4-1
Starting, Stopping and Restarting The Compressor ........................................................................ 4-1
Emergency Shutdown .................................................................................................................... 4-2
Capacity and Volume Ration Control through Slide Valve Actuators ............................................... 4-2
Slide Valve Actuator Operation .................................................................................................................. 4-3
Calibrate Slide Valve Actuators (For Units Using Vission20/20™) ................................................................ 4-4
Calibrate Slide Valve Actuators (For Units Using Compact Logix PLC)........................................................ 4-10
Compressor Control with Vission20/20™ Micro-Controller (No Slide Operation)...................................... 4-15
Suction Equalizing Line Setup - For VSS/VSM Compressors....................................................................... 4-16
Stop/Check Valve Operation .................................................................................................................... 4-17
Section 5 • Maintenance/Service
Maintenance and Service Schedule - For VSS/VSM Unit Only ...................................................................... 5-1
Maintenance and Service Schedule - For VSH/VSSH Unit Only..................................................................... 5-2
Preventive Maintenance, Checks and Services............................................................................................ 5-4
Daily............................................................................................................................................... 5-4
Weekly........................................................................................................................................... 5-4
Monthly ......................................................................................................................................... 5-4
Trimonthly ..................................................................................................................................... 5-4
Annually......................................................................................................................................... 5-4
Compressor Unit Isolation For Maintenance/Service (Compressors With Slide Valves)................................ 5-5
Recommendations When Servicing (Compressors Without Slide Valves) ................................................... 5-6
Preparation of Unit For Servicing................................................................................................................ 5-6
Compressor Unit Leak Check After Servicing .............................................................................................. 5-7
Oil Sampling .............................................................................................................................................. 5-7
Recommendations ......................................................................................................................... 5-7
Installation of The Oil Sampler Valve............................................................................................... 5-8
Pre-Sampling ................................................................................................................................. 5-8
Sampling Procedure....................................................................................................................... 5-8
Oil Sample Analysis Report........................................................................................................... 5-10
Compressor Replacement ........................................................................................................................ 5-11
Removal....................................................................................................................................... 5-11
Installation................................................................................................................................... 5-12
Compressor Inspection ............................................................................................................................ 5-13
Compressor Shaft Bearing Clearance Inspections ......................................................................... 5-13
Determine Maximum Applied Force.................................................................................. 5-13
Main Rotor Bearing Axial Clearance Inspection.................................................................. 5-13
Main Rotor Bearing Radial Clearance Inspection................................................................ 5-14
Gaterotor Bearing Inspection ....................................................................................................... 5-15
Gaterotor Inspection .................................................................................................................... 5-16
A) Gaterotor - Main Housing Shelf Clearance..................................................................... 5-16
B) Gaterotor Float Measurement....................................................................................... 5-17
C) Gaterotor Backlash Inspection ...................................................................................... 5-18
Important Notes............................................................................................................... 5-19
Additional Inspections.................................................................................................................. 5-20
Post Inspection............................................................................................................................. 5-20
Gaterotor Assembly Replacement
(All Compressors Except VSM 301-701 and VSM 97-127 Compressors) .................................................... 5-20
Removal....................................................................................................................................... 5-20
Installation................................................................................................................................... 5-21

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VSS/VSR/VSM/VSH/VSSH Compressor • Installation, Operation and Service Manual • Emerson • 35391S
Table of Contents
Section Title Page Number
Gaterotor Assembly Replacement (VSM 301-701 Compressors Only)....................................................... 5-24
Removal....................................................................................................................................... 5-24
Installation................................................................................................................................... 5-24
Gaterotor Assembly Replacement (VSM 97-127 Compressors Only)......................................................... 5-26
Removal....................................................................................................................................... 5-26
Installation................................................................................................................................... 5-26
Gaterotor Disassembly (All Compressors Except VSM 97-127 Compressors)............................................. 5-28
Gaterotor Blade Removal.............................................................................................................. 5-28
Gaterotor Blade Installation.......................................................................................................... 5-29
Gaterotor Thrust Bearing Removal................................................................................................ 5-29
Gaterotor Thrust Bearing Installation............................................................................................ 5-29
Gaterotor Roller Bearing Removal................................................................................................. 5-30
Gaterotor Roller Bearing Installation............................................................................................. 5-30
Gaterotor Disassembly (VSM 97-127 Compressors Only) ......................................................................... 5-31
Gaterotor Blade Removal.............................................................................................................. 5-31
Gaterotor Blade Installation.......................................................................................................... 5-31
Gaterotor Thrust Bearing Removal................................................................................................ 5-32
Gaterotor Thrust Bearing Installation............................................................................................ 5-32
Gaterotor Roller Bearing Removal................................................................................................. 5-32
Gaterotor Roller Bearing Installation............................................................................................. 5-32
Compressor Shaft Seal Replacement ........................................................................................................ 5-33
Shaft Seal Assembly ..................................................................................................................... 5-33
Handling Seal Face with Care........................................................................................................ 5-33
Compressor Shaft Seal Replacement - For VSS/VSM Units ............................................................. 5-34
Tools ................................................................................................................................ 5-34
Removal ........................................................................................................................... 5-34
Installation ....................................................................................................................... 5-34
Compressor Shaft Seal Replacement - For VSH/VSSH Units ........................................................... 5-36
Shaft Seal Removal Shaft Seal Removal - For Part# 25985Y and 25985YA .......................... 5-36
Shaft Seal Removal Shaft Seal Removal - For Part# 28985W and 28985WA ....................... 5-37
Prior to Shaft Seal Installation ........................................................................................... 5-38
Shaft Seal Installation - For Part# 25985Y and 25985Y ...................................................... 5-39
Shaft Seal Installation - For Part# 28985W and 28985WA ................................................. 5-40
Slide Valve Actuator Assembly Replacement ............................................................................................ 5-41
Removal....................................................................................................................................... 5-41
Installation................................................................................................................................... 5-41
Actuator Installation Using Anti-Rotation Bolts............................................................................. 5-42
Slide Valve Command Shaft Assembly Replacement................................................................................. 5-43
Removal....................................................................................................................................... 5-43
Installation................................................................................................................................... 5-43
Liquid Injection Control Valve Station (Danfoss ICF 20-40 Valve Station)................................................... 5-44
Main Rotor Assembly ............................................................................................................................... 5-46
Torque Specifications............................................................................................................................... 5-46
Using A Torque Wrench Correctly............................................................................................................. 5-47
Nord-Lock®Washers ................................................................................................................................ 5-47
Section 6 • Troubleshooting
Slide Valve Actuator Troubleshooting Guide............................................................................................... 6-1
Slide Valve Actuator LED Blink Codes.......................................................................................................... 6-4
Troubleshooting Guide - General Problems & Solutions.............................................................................. 6-6

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Table of Contents
Section Title Page Number
Section 7 • Warranty And Parts
Warranty Claim Processing ........................................................................................................................ 7-1
Motor Warranty Procedure ........................................................................................................................ 7-2
On-Site Service Support............................................................................................................................. 7-3
Remanufactured 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
VSH/VSSH Recommended Spare Parts List ................................................................................................. 8-1
VSS Recommended Spare Parts List ........................................................................................................... 8-3
Gaterotor ....................................................................................................................................... 8-5
Shaft Seal ..................................................................................................................................... 8-11
Main Rotor ................................................................................................................................... 8-13
Slide Valve Cross Shafts and End Plate........................................................................................... 8-14
End Plate (VSS 2401 - VSS 3001 Only)........................................................................................... 8-16
Slide Valve Carriage Assembly ...................................................................................................... 8-18
Actuator and Command Shaft ...................................................................................................... 8-21
Miscellaneous Frame Components ............................................................................................... 8-22
Miscellaneous Frame Components Tubing and Fittings................................................................. 8-25
Replacement Tools ....................................................................................................................... 8-28
Replacement Parts ....................................................................................................................... 8-29
VSM 301-701 Recommended Spare Parts List .......................................................................................... 8-31
Gaterotor Assembly ..................................................................................................................... 8-32
Shaft Seal ..................................................................................................................................... 8-34
Main Rotor ................................................................................................................................... 8-35
Slide Valve Cross Shafts and End Plate........................................................................................... 8-36
Slide Valve Carriage Assembly ...................................................................................................... 8-38
Actuator and Command Shaft ...................................................................................................... 8-40
Miscellaneous Frame Components ............................................................................................... 8-41
Housing Accessories..................................................................................................................... 8-43
Replacement Tools ....................................................................................................................... 8-44
VSM 97-127 Recommended Spare Parts List ............................................................................................ 8-46
Kits................................................................................................................................................ 8-47
Appendices
Appendix A Torque Specifications.............................................................................................................. A-1
Appendix B Vilter Oil.................................................................................................................................B -1
Appendix C Vibration Measurements - Single Screw Compressor...............................................................C-1
Appendix D Liquid Injection Valve Setup Instructions and ICM/ICAD Motorized Valve Quick Start Guide...D-1
Appendix E Liquid Injection Valve Station ICF 20-40 Installation Guide .......................................................E-1
Appendix F Hand-Held Slide Valve Calibration Tool ....................................................................................F-1