Vilter VSS 451-1801 Operation manual

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VPN 35391S
February2006Rev.05
Price $ 60.00

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ImportantNote:
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, service or repair the compressor.
A refrigeration compressor is a positive displacement machine. It is designed to pump superheated
vapor. 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 Corporation is not responsible for the system or the controls needed to prevent liquid
carry over and as such Vilter Manufacturing Corporation cannot warrant equipment damaged by im-
properly protected or operating systems.
Vilter screw compressor components are thoroughly inspected at the factory, assuring the shipment of a
mechanically perfect piece of equipment. Damage can occurin shipment, however. For this reason, the
units 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 order number, compressor serial and model number. These can be
found on the compressor name plate on the compressor.
All requests for information, services and or parts should be directed to:
Vilter Manufacturing Corporation
Customer Service Department
5555 South Packard Ave
P.O. Box 8904
Cudahy, WI 53110-8904 USA
Telephone: [phone]
Fax:[phone]
e-mail: [email protected]
Equipment Identification Numbers:
Vilter Order Number: __________________________Serial Number: _____________
Vilter Order Number: __________________________Serial Number: _____________
Vilter Order Number: __________________________Serial Number: _____________
Vilter Order Number: __________________________Serial Number: _____________
Vilter Order Number: __________________________Serial Number: _____________

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Table of Contents
LONG TERM STORAGE REQUIREMENTS ......................................................................................................................................... 8
DOMESTIC TERMS and CONDITIONS .............................................................................................................................................. 10
EXPORT TERMS and CONDITIONS ................................................................................................................................................... 12
STANDARDVILTER WARRANTY STATEMENT .............................................................................................................................. 14
STANDARD VILTER 5/15 WARRANTY STATEMENT ..................................................................................................................... 15
DESCRIPTION ........................................................................................................................................................................................ 16
SYMBOLSAND MEANINGS ............................................................................................................................................................... 18
InstallationSection ...................................................................................................... 19
DELIVERYINSPECTION....................................................................................................................................................................... 21
UNITWEIGHTS ...................................................................................................................................................................................... 21
FOUNDATIONS ...................................................................................................................................................................................... 21
LOCATING UNIT - DRIVE COUPLINGALIGNMENT ....................................................................................................................... 21
SYSTEM PIPING .................................................................................................................................................................................... 21
ELECTRICAL CONNECTIONS ............................................................................................................................................................. 23
TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23
Ammonia Systems ........................................................................................................................................................................... 23
Halocarbon Refrigerant Systems ..................................................................................................................................................... 24
Evacuating The System .................................................................................................................................................................... 24
UNIT OIL CHARGING ........................................................................................................................................................................... 25
Oil For Single Screw Compressors.................................................................................................................................................. 25
SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25
Low Side Equipment................................................................................................................................................................................ 26
Compressors ............................................................................................................................................................................................. 26
Condensers ............................................................................................................................................................................................... 26
Controls .................................................................................................................................................................................................... 26
Initial Charging – High Side Charging .................................................................................................................................................... 26
MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27
Daily ................................................................................................................................................................................................. 27
Weekly .............................................................................................................................................................................................. 27
Monthly ............................................................................................................................................................................................ 27
Trimonthly ........................................................................................................................................................................................ 27
Yearly................................................................................................................................................................................................ 27
System Leaks.................................................................................................................................................................................... 28
Year Round Operation...................................................................................................................................................................... 28
“STOPCHECK” INSTALLATION......................................................................................................................................................... 29
COUPLINGS INSTALLATIONANDALIGNMENT ............................................................................................................................. 30
Hub Mounting .................................................................................................................................................................................. 30
Straight Bore .................................................................................................................................................................................... 30
Taper Bore ........................................................................................................................................................................................ 30
Shaft Alignment. .............................................................................................................................................................................. 31
Final assembly . ............................................................................................................................................................................... 32
Disc Pack Replacement.................................................................................................................................................................... 32
SLIDE VALVEACTUATOR ................................................................................................................................................................... 34
ACTUATOR MOTOR CONTROL MODULE CALIBRATION PROCEDURE.................................................................................... 34
SLIDE VALVE TROUBLE SHOOTING GUIDE ................................................................................................................................... 37

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Table of Contents
OperationSection........................................................................................................ 41
OIL SYSTEM ........................................................................................................................................................................................... 43
Non-Vilter Oil Notice ...................................................................................................................................................................... 42
Oil Charge....................................................................................................................................................................................... 43
Oil Filter ........................................................................................................................................................................................... 43
Filter Removal and Installation, all VSR Units. ............................................................................................................................. 43
Filter Removal, VSS and VSM Units.............................................................................................................................................. 44
Filter Removal, VSS and VSM Units . ........................................................................................................................................... 44
Oil Pressure Regulating ................................................................................................................................................................... 45
Oil Cooling ....................................................................................................................................................................................... 45
Water Cooled Oil Cooler.................................................................................................................................................................. 45
Liquid Injection Oil Cooling. ........................................................................................................................................................... 46
V-PLUS Oil Cooling System............................................................................................................................................................ 46
Thermosyphon Oil Cooling .............................................................................................................................................................. 47
CONTROL SYSTEM .............................................................................................................................................................................. 47
Screw Compressor Control And Operation ..................................................................................................................................... 47
Starting, Stopping and Restarting the Compressor ......................................................................................................................... 47
Slide Valve Control .......................................................................................................................................................................... 48
Slide Valve Motor Location............................................................................................................................................................. 49
Oil Separator Heater ......................................................................................................................................................................... 49
Econ-O-Mizer Controls ................................................................................................................................................................... 49
Safety Setpoints................................................................................................................................................................................ 49
Oil Pressure ...................................................................................................................................................................................... 49
Discharge Pressure ........................................................................................................................................................................... 49
Suction Pressure ............................................................................................................................................................................... 50
Oil Filter Differential....................................................................................................................................................................... 50
Oil Temperature ............................................................................................................................................................................... 50
Discharge Temperature .................................................................................................................................................................... 50
INITIALSTART-UP ................................................................................................................................................................................. 50
Setting of Controls ........................................................................................................................................................................... 50
Valve Settings ................................................................................................................................................................................... 50
Oil Separator .................................................................................................................................................................................... 50
V-PLUS Oil Cooling ........................................................................................................................................................................ 51
Liquid Injection Oil Cooling ............................................................................................................................................................ 51
Compressor Pre Start-Up Check List .............................................................................................................................................. 51
Stop Check Operation...................................................................................................................................................................... 52
Pre-Start Up...................................................................................................................................................................................... 53
PRE START-UP CHECKLIST - FIELD PIPING AND MECHANICAL REQUIREMENTS .............................................................. 54
PRE START-UP CHECKLIST - FIELD WIRING REQUIREMENTS ................................................................................................. 55
Service Section............................................................................................................. 56
GENERAL COMMENTS ........................................................................................................................................................................ 58
PREPARATION OF UNIT FOR SERVICING ........................................................................................................................................ 58
REMOVAL OF COMPRESSOR FROM THE UNIT ............................................................................................................................ 58
INSTALLATION OF THE COMPRESSOR ............................................................................................................................................ 59
LEAK CHECKING UNIT........................................................................................................................................................................ 59
ANNUALINSPECTION ......................................................................................................................................................................... 60
NORD-LOCKWASHERS ....................................................................................................................................................................... 61
GATE ROTOR ASSEMBLY .................................................................................................................................................................... 62
REMOVAL (All VSS and VSR Models)................................................................................................................................................. 62
REMOVAL (ALL VSM MODELS) ......................................................................................................................................................... 64
INSTALLATION (All VSS and VSR Models) ........................................................................................................................................ 66
INSTALLATION (All VSM Models) ...................................................................................................................................................... 68

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Table of Contents
Service Section Cont..............................................................................................................................................................
GATE ROTOR BLADE REMOVAL ....................................................................................................................................................... 69
GATE ROTOR BLADE INSTALLATION .............................................................................................................................................. 69
GATE ROTOR THRUST ......................................................................................................................................................................... 70
BEARING REMOVAL GATE ROTOR THRUST .................................................................................................................................. 70
BEARING INSTALLATION GATE ROTOR ROLLER.......................................................................................................................... 71
GATE ROTOR ROLLER BEARING REMOVAL .................................................................................................................................. 72
GATE ROTOR ROLLER BEARING INSTALLATION.......................................................................................................................... 72
INPUT SHAFT SEAL REPLACEMENT ................................................................................................................................................ 73
INPUT SHAFT SEAL REMOVAL .......................................................................................................................................................... 73
SHAFT SEALINSTALLATION .............................................................................................................................................................. 74
MAIN ROTOR ASSEMBLY ................................................................................................................................................................... 75
INSPECTION OF SLIDE VALVE ASSEMBLIES IN THE COMPRESSOR......................................................................................... 76
REMOVAL SLIDE VALVE ..................................................................................................................................................................... 76
CARRIAGE ASSEMBLIES .................................................................................................................................................................... 76
INSTALLATION OF SLIDE VALVE CARRIAGEASSEMBLIES ........................................................................................................ 77
CAPACITYAND VARIABLE VOLUME RATIO CONTROL ASSEMBLY ........................................................................................ 78
OPTICAL SLIDE VALVEACTUATOR REMOVAL .............................................................................................................................. 78
OPTICALSLIDE VALVEACTUATOR INSTALLATION ..................................................................................................................... 79
GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80
GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80
CONVERSION, INSTALLATION OF ACTUATOR............................................................................................................................... 80
COMMAND SHAFTASSEMBLY REMOVAL ..................................................................................................................................... 80
COMMAND SHAFTASSEMBLY INSTALLATION ............................................................................................................................. 81
COMMAND SHAFT BEARINGAND O-RING SEAL REPLACEMENT ........................................................................................... 81
COMMAND SHAFT BEARINGAND O-RING SEALREASSEMBLY .............................................................................................. 82
DISCHARGE MANIFOLD REMOVAL ................................................................................................................................................. 82
DISCHARGE MANIFOLD INSTALLATION ......................................................................................................................................... 82
SLIDE VALVE GEAR AND RACK INSPECTION ................................................................................................................................ 83
REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS .............................................................................................................. 83
INSTALLATION OF CAPACITYOR VOLUME CROSS SHAFTS...................................................................................................... 84
REMOVALAND INSTALLATION OF CAPACITYOR VOLUME
RATIO ACTUATORS (PRIOR TO 11-1-01AND AFTER 5-1-95 .......................................................................................................... 85
POTENTIOMETER REMOVAL ............................................................................................................................................................. 87
POTENTIOMETER INSTALLATION .................................................................................................................................................... 88
RETROFIT CAPACITYAND VOLUME RATIO CONTROL ............................................................................................................... 88
ASSEMBLIES ONALLVSSAND VSR COMPRESSORS
MANUFACTURED BEFORE MAY 1, 1995. ............................................................................................................................................................ 88
REMOVAL................................................................................................................................................................................................................... 88
INSTALLATION OF RETROFIT COMMAND SHAFT BEARING
AND O-RING SEAL ................................................................................................................................................................................ 89
REPLACEMENT FOR RETROFIT CONTROL ASSEMBLIES .......................................................................................................... 89
COMMAND SHAFT BEARINGAND O-RING SEALREASSEMBLY .............................................................................................. 90
LIQUID INJECTION PLUG REPLACMENT ........................................................................................................................................ 91
REMOVAL OF PLUG ............................................................................................................................................................................. 91
INSTALLATION OF PLUG ................................................................................................................................................................... 91

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Table of Contents
PLUG APPLICABILITY......................................................................................................................................................................... 92
TORQUE SPECIFICATIONS .................................................................................................................................................................. 93
OIL FILTER ELEMENTS ........................................................................................................................................................................ 94
VSS, VSM and VSR SINGLE SCREW COMPRESSORS SERVICE INTERVAL REQUIREMENTS........................... 98
Recommended Spare Parts List ................................................................................ 99
VSS and VSR Replacement Parts Section................................................................ 103
Gate Rotor ...................................................................................................................................................................................... 104
Shaft Seal ....................................................................................................................................................................................... 108
Main Rotor ..................................................................................................................................................................................... 110
Slide Valve Cross Shafts and End Plate ....................................................................................................................................... 114
Slide Valve Cross Shafts Prior to 5-1-95 .................................................................................................................................... 115
Slide Valve Carriage Assembly ..................................................................................................................................................... 120
Capacity Control Actuating Motor and Command Shaft ........................................................................................................... 122
Slide Valve Actuating Motor and Command shaft Before 5-1-95............................................................................................... 126
Volume Ratio Control Actuating Motor and Command Shaft ..................................................................................................... 128
Miscellaneous Frame Components ............................................................................................................................................... 132
Tubing and Fittings........................................................................................................................................................................ 132
Miscellaneous Frame Components ............................................................................................................................................... 134
C-Flange Adapter Components ..................................................................................................................................................... 138
Replacement Parts Tools ............................................................................................................................................................... 140
VSM Replacement Parts Section .............................................................................. 143
Gaterotor Assembly ....................................................................................................................................................................... 144
Shaft Seal ....................................................................................................................................................................................... 147
Main Rotor, Slide Valve Cross Shafts and End Plate (Models 71-401) ..................................................................................... 148
Main Rotor, Slide Valve Cross Shafts and End Plate (Models 501-701 .................................................................................... 152
Slide Valve Carriage Assembly ..................................................................................................................................................... 154
Actuating Motor with Optical Sensor and Command Shaft ........................................................................................................ 156
Miscellaneous Frame Components ............................................................................................................................................... 158
Replacement Parts Accessories ..................................................................................................................................................... 160
Replacement Tools......................................................................................................................................................................... 162
VendorAssessories Section ........................................................................................ 163
HAIGHT PUMPS 10-80 Pumps ................................................................................................................................................................
PARKER Inlet Pressure Regulators ..........................................................................................................................................................
CARTRIDGE HEATERS .............................................................................................................................................................................
SPORLAN Strainers...................................................................................................................................................................................
VIKING PUMP Pumps and Pressure Relief Valves ..................................................................................................................................
FLUID POWER ENERGY Thermostatic Valves.....................................................................................................................................
SPORLAN Solenoid Valve and Thermostatic Expansion Valve ..............................................................................................................
HANSEN HA4AOAS INLET/OUTLET REGULATOR ............................................................................................................................

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The procedure described is a general recommendation for extended storage (over one month of no operation) of
Vilter Manufacturing packages and compressors. While this procedure is intended to cover most of the commonly
encountered situations, it is the responsibility of the installation firm and end user to address any unusual condi-
tions. We suggest using the accompanying Long Term Storage Log sheet for recording purposes to validate the
appropriate procedures.
Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verification of the
system integrity, a comprehensive evacuation procedure should be completed to ensure a dry system before refriger-
ant is introduced. The oil circuit of any compressor is to be primed at initial start-up through the oil gauge connec-
tion on reciprocating compressors and the pre-lube oil pump on screw compressors.
Warranty of the system remains in effect as described in Section 5, Product Warranty and Procedures.
* If the unit is designed for indoor duty, it must be stored in a heated building.
If the unit is designed for outdoor duty, and is to be stored outdoors, a canvas tarp is recommended for protec-
tion until installation is imminent. Adequate drainage should be provided, by placing wood blocks under the
base skid, so that water does not collect inside the base perimeter or low spots in the tarp.
* All compressor stop valves are to be closed to isolate the compressor from the remainder of the system. All
other valves, except those venting to atmosphere, are to be open. It is essential that the nitrogen holding charge
integrity be maintained.
* Cover all bare metal surfaces (coupling, flange faces, etc.) with rust inhibitor.
* Desiccant is to be installed in the control panel. If the panel is equipped with a space heater, it is to be
energized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light bulb. Use
an approved electrical spray-on corrosion inhibitor for panel components (relays, switches, etc.)
* All pneumatic controllers and valves (Fisher, Taylor, etc.) are to be covered with plastic bags and sealed with
desiccant bags inside.
* System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5 psi above
atmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be necessary to add a gauge
to monitor the system holding charge pressure. If a drop in pressure occurs, the source of leakage must be found
and corrected. The system must be evacuated and recharged with dry nitrogen to maintain the package integ-
rity.
* Motors – (NOTE: The following are general recommendations. Consult the manufacturer of your motor for
specific recommendations.)
Long Term Storage
Requirements

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Long Term Storage
Requirements
1) Remove the condensation drain plugs from those units equipped with them and insert silica-gel into the openings.
Insert one-half pound bags of silica-gel (or other desiccant material) into the air inlets and outlets of drip-proof
type motors.
NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when the
unit is prepared for service.
2) Cover the unit completely to exclude dirt, dust, moisture, and other foreign materials.
3) If the motor can be moved, it is suggested that the entire motor be encased in a strong, transparent plastic bag.
Before sealing this bag, a moisture indicator should be attached to the side of the motor and several bags of
silica-gel desiccant put inside the bag, around the motor. When the moisture indicator shows that the desiccant
has lost its effectiveness, as by a change in color, the bag should be opened and fresh replacement desiccants
installed.
Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F above
the ambient temperature.
NOTE: There is a potential for damage by small rodents and other animals that will inhabit
motors in search of warm surroundings or food. Due to this, a possibility of motor
winding destruction exists. Sealing motor openings should restrict access to the motor.
4) Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate flat spots on
the bearing surfaces. If the compressor unit is installed, wired and charged with oil, open all oil line valves and
run the oil pump for 10 seconds prior to rotating the compressor shaft. Continue running the oil pump while the
compressor shaft is being turned to help lubricate the surfaces of the shaft seal.

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Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms and
conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly re-
jected, and do not form a part of this Agreement unless Seller agrees to such terms in writing.
Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind
Seller unless this Agreement and any purported change are signed by a home office Officer of Seller.
Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyer’s
binding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unless
agreed otherwise in writing, all payments are due in full within 30 days of Seller shipping the products or providing
the services. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the
maximum allowed by law.
Security Agreement. This Agreement shall be considered a security agreement to the maximum extent allowed by
law. Seller shall have, retain, and possess a security interest in all products sold to Buyer until Seller is paid in full.
Buyer grants to Seller a power of attorney to complete, sign on Buyer’s behalf, and file all forms reasonably necessary
to perfect Seller’s security interest. If Buyer defaults, or Seller deems itself insecure of receiving payment, the full
unpaid balance shall become immediately due and payable at the option of the Seller, and Seller may retake posses-
sion of the products without Court order.
Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. All
delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’s
Order Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment
deliveries.
Warranties. 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 recip-
rocating 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
regulation 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 WAR-
RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-
CHANTABILITYAND FITNESS FORAPARTICULARPURPOSE. 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 refrig-
erant, 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 REM-
EDIES 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 judgment, 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.
DOMESTIC TERMS and
CONDITIONS