Emerson VSG & VSSG Specifications

VSG & VSSG
Single Screw Bare Shaft Compressor
The World’s Best Compressors
For Gas Compression
TM
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Important Message
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, operate, service or repair the compressor.
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.
Vilter 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 Vilter 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
P.O. Box 8904
5555 South Packard Ave
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax:1-414-744-3483
e-mail: info.vilter@emerson.com
Equipment Identification Numbers:
Vilter Order Number:
Vilter Order Number:
Vilter Order Number:
Vilter Order Number:
_______________________Compressor Serial Number: _________________
_______________________Compressor Serial Number: _________________
_______________________Compressor Serial Number: _________________
_______________________Compressor Serial Number: _________________
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Table of Contents
Important Message............................................................................................. 3
VSG STANDARD VILTER WARRANTY STATEMENT................................................. 6
Long Term Storage Requirements........................................................................ 7
Critical Applications Guidelines............................................................................ 8
Instrumentation Requirements....................................................................... 9
Alarm and Shutdown Readings...................................................................... 11
VSG Package Requirements............................................................................... 12
Description................................................................................................... 13
installation.................................................................................................... 16
Installation & Calibration of Slide Valve Actuators.............................................. 18
Slide Valve Operation.................................................................................... 21
Slide Valve Actuator Trouble Shooting Guide................................................. 22
Operation Section............................................................................................. 26
Notice on using Non -Vilter Oils..................................................................... 26
Maintenance................................................................................................. 29
Service.............................................................................................................. 30
Parts Section..................................................................................................... 57
Gate Rotor.................................................................................................... 58
Shaft Seal...................................................................................................... 62
Tandem Shaft Seal......................................................................................... 63
Main Rotor.................................................................................................... 64
Slide Valve Cross Shafts and End Plate........................................................... 66
Slide Valve Carriage Assembly....................................................................... 68
Actuator & Command Shaft.......................................................................... 72
Miscellaneous Frame Components................................................................ 74
Replacement Tools........................................................................................ 78
VSG 301-701 Replacement Parts Section........................................................... 81
Gaterotor Assembly...................................................................................... 82
Shaft Seal...................................................................................................... 85
Main Rotor, Slide Valve Cross Shafts & End Plate............................................ 86
Slide Valve Carriage Assembly....................................................................... 90
Actuator & Command Shaft.......................................................................... 92
Miscellaneous Frame Components................................................................ 94
Replacement Tools........................................................................................ 98
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VSG STANDARD VILTER 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 warranty 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
WARRANTIES, 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 suggestions 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.
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Long Term Storage Requirements
Note: At the time of purchase Vilter Manufacturing must be notified.
1.
The compressor(s) must be stored in a heated building, preferably air conditioned to control moisture, to prevent corrosion of the main rotor shaft and for the compressor. The slide valve (volume ratio& capacity) motors and gears.
2.
The main rotor shaft must be coated with light grease to prevent rusting.
3.
(For Screw Compressors) The volume and capacity slide valve motor enclosures should have corrosion inhibitors installed in them and the enclosures should be sealed. On a six month basis
(depending on relative humidity), check and replace inhibitors as necessary, and check for signs of corrosion.
4.
Before leaving Vilter Manufacturing the compressor is evacuated and pressurized, with dry
nitrogen, to 5 psig. Pressure must be monitored with the gauge (provided by Vilter) and checked
on a regular basis (at least monthly).
5.
The rotor shaft must be rotated every 3 months to prevent flat spots from developing on the bearing surfaces and to keep the shaft seal lubricated.
6.
A log should be maintained indicating that the above procedures have been completed.
When the compressor is installed.
A.
Look into the suction and discharge connections and inspect for any signs of corrosion on parts.
B.
Prelube the compressor with the main oil pump and rotate by hand several revolutions prior to start.
C.
Notify the Vilter Warranty Department when the compressor is started.
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Critical Applications Guidelines
To ensure the successful operation of the VSG compressor, the guidelines described below
should be followed.
1. Proper lubrication is critical to the operation of the VSG compressor. The compressor relies on
the injected oil to absorb and remove the heat of compression, to seal the compression chambers
formed in the flutes of the screw, and to lubricate all moving parts. For this reason, it is imperative that the oil chosen be of correct viscosity, and that sufficient oil flow be provided at all times,
using an auxiliary oil pump when necessary. The oil chosen must be compatible with the process
gas as well, to prevent absorption of the gas into the oil, which would dilute the oil and reduce the
viscosity. Also, oil filtration to 25 micron nominal particle size is required to ensure that only clean
oil is injected into the compressor. For assistance in choosing the correct oil for the application
and in sizing an auxiliary oil pump, consult a Vilter representative.
2. Injection oil temperature must be closely controlled for optimum performance. Oil temperature
must be maintained a minimum of 15 - 20°F above the gas mixture dewpoint at anytime to prevent
condensation or liquid knockout from occurring within the compressor.
Gas composition plays a role in the performance of the VSG compressor as well. While the VSG is
capable of handling a wide variety of gases, it is required that the concentration of H2S in the process gas not exceed 100 PPM. If H2S is present in the process gas in any concentration, special oil
additives are required to protect the compressor from corrosion.
Notice on using Non -Vilter Oils
Oil and its additives are crucial in refrigeration system performance. Vilter Manufacturing will NOT
APPROVE non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available
it is not possible for us to test all oils offered in the market place, and their effects on our equipment,
as we can with our own lubricants.
We realize that customers may choose compressor lubricants other than Vilter branded oil. This is
certainly within the customers’ right as owners of the equipment. When this choice is made, however,
Vilter is unable to accept responsibility for any detrimental affects those lubricants may have on the
equipment or system performance and durability.
Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warranty upon evaluation of the issue. This includes any parts’ failure caused by inadequate lubrication.
Certainly, there are many good refrigeration lubricants in the market place. The choice of a lubricant
for a particular application involves consideration of many aspects of the lubricant and how it and its
additive package, will react in the various parts of the entire refrigeration system. It is a complex choice
that depends on a combination of field experience, lab and field-testing, and knowledge of lubricant
chosen. Vilter will not accept those risks other than for our own compressor lubricants.
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Instrumentation Requirements
Pressure
Temperature
There are four pressure transducers required to read
system pressures as listed below.
There are four temperature readings required for
processor control, as listed below.
1. Suction pressure transducer (-15.0 - 300 PSIG)
measures the gas suction pressure into the compressor housing, which provides the permissive
to start for minimum suction pressure, and is
used for annunciation of low suction pressure
while running and in the capacity control logic.
2. Discharge pressure transducer (-15.0 - 300 PSIG)
measures the discharge pressure of the process
gas in the separator, which provides annunciation for high discharge pressure, and may also
be used for capacity control logic.
3. Oil Filter Inlet pressure transducer (-15.0 - 300
PSIG) measures the oil pressure as it enters the
oil filter canisters and is used to calculate oil filter
differential pressure to provide annunciation of
high filter differential pressure
4. Oil Manifold pressure transducer (-15.0 - 300
PSIG) measures the oil pressure downstream of
the oil filter as the oil is injected into the compressor, and provides annunciation protection
for low prelube oil pressure, and low running oil
injection pressure.
5. Suction temperature RTD measures the temperature of the incoming suction gas, and is
used to provide annunciation for low suction
temperature when the unit is running.
6. Discharge temperature RTD measures the
temperature of the gas/oil mixture as it is discharged from the compressor housing, and provides annunciation for high running discharge
temperature.
7. Oil Separator temperature RTD measures the
temperature of the oil in the separator sump,
and gives the oil temperature start permissive
and low running separator temperature annunciation.
8. Oil Injection temperature RTD measures the
temperature of the oil as it is injected into the
compressor, which provides annunciation for
either high or low running oil injection temperature.
Additional pressure transducers may be required and
installed by the customer for pressure readings at customer specified points such as process gas discharge
pressure from the package boundary, cooling water
pressure to and/or from the oil cooler, etc.
*
Additional RTD’s may be required and installed
by the customer for temperature readings at
customer specified points such as discharge gas
temperature from the package boundary, cooling
water temperature to and/or from the oil cooler,
gas aftercooler temperature, etc.
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Instrumentation Requirements
MOTOR
COMPRESSOR
OIL SEPARATOR
STANDARD SINGLE
OIL FILTER
OPTIONAL DUAL OIL FILTERS
OIL COOLER
STANDARD WATER COOLED OIL COOLER
OPTIONAL REMOTE AIR COOLED OIL COOLER
Miscellaneous: Additional instrumentation devices required are a current transformer mounted around one
phase of the drive motor leads to measure main motor amperage, and two rotary potentiometers to read the
position of the slides. The amperage signal provides annunciation for high motor amperage, and is used in the
capacity control logic. The rotary potentiometers indicate the position of the slides, which is used as a starting permissive and in the capacity control logic. Also, additional input points may be required for customer
connection of remote signals such as Start and Stop commands, and capacity setpoint control.
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Alarm and Shutdown Readings
The control system for the VSG compressor must protect the
machine from damage caused by running outside of normal
operating conditions by providing operators with alarms
when operating parameters have reached an abnormal
condition, and by automatically stopping the compressor
before these conditions can cause a unit failure. Pressures
and temperatures of the process gas and the oil, as well as
motor amperage and slide positions must all be continuously
monitored to ensure the compressor is operating properly.
1. Low Gas Suction Temperature - This point protects
the compressor from suction gas entering the compressor at too low of a temperature, and is activated
by a direct reading from the suction temperature
RTD located in the suction “T”.
2. High Gas Discharge Temperature - This point protects the compressor against high gas
temperature at the discharge of the unit, and is activated
by a direct reading from the RTD located in the
compressor discharge manifold.
3. Low Oil Separator Start Temperature - This point
protects the compressor from starting with low oil
temperature in the separator, and is activated by a
direct reading from the RTD located in the bottom
of the oil separator.
4. Low Oil Separator Run Temperature - Similar to
the Low Oil Separator Start Temperature described
above, however this point only becomes active after
a predetermined period of running time, and uses a
higher setpoint.
5. Low Oil Injection Temperature - This point protects
the compressor from running with cold oil being
injected into the screw housing, and is activated by
a direct reading from the RTD located in the oil injection line. This point is bypassed for a predetermined
period of time after starting to allow the unit time
to start and warm up.
6. High Oil Injection Temperature - This point protects
the compressor from running with hot oil being
injected into the screw housing, and is activated
by a direct reading from the RTD located in the oil
injection line.
7. Low Suction Pressure - This point protects the
compressor from drawing low suction pressure and
is activated by a direct reading from the suction pressure transducer, which reads the pressure from a tap
located in the suction stop/check valve housing.
8. High Discharge Pressure - This point protects the
compressor from developing high discharge pressure and is activated by a direct reading from the
discharge pressure transducer, which reads the
pressure from a tap located in the oil separator. In
addition to this alarm and shutdown, the compressor
package is ultimately protected from damage due to
over pressurization by at least one discharge pressure
relief valve located on the oil separator. The purpose
of this safety setpoint is to allow for a lower setpoint
to conform to a process requirement, and to prevent
the relief valve from opening.
9. Prelube Oil Pressure - This point acts as a permissive
to start the compressor, and protects against the
compressor starting with no oil lubrication. If, during
a start sequence, the prelube oil pressure fails to rise
above 4.0 PSID, the compressor will fail to start. The
prelube oil pressure is a calculated value obtained
by subtracting the discharge pressure reading from
the oil manifold pressure (oil filter outlet pressure)
reading.
10. Low Oil Pressure - This point protects the compressor from running with insufficient lubrication
pressure, and becomes active after a predetermined
period of running, usually sixty seconds. The oil pressure is a calculated value obtained by subtracting the
suction pressure from the oil manifold pressure (oil
filter outlet pressure) reading, which results in the
actual pressure under which the oil is entering the
screw housing.
11. High Running Oil Filter Differential Pressure - This
point alerts operators to clogging oil filters. When
the oil filters develop a high differential pressure
while running at normal operating temperatures,
it is an indication that they are becoming dirty and
must be changed. An alarm initially warns of dirty
filters; if the situation worsens before the filters are
changed a shutdown will stop the compressor.
In most cases, the safety setpoints described above
will have settings which are dictated by process
requirements, and not necessarily mechanical constraints of the compressor. Process pressures and
temperatures may vary considerably depending
on the application of the compressor, and the VSG
compressor is designed to work well in a broad range
of applications.. For this reason, it is impractical
to suggest “initial” setpoints to fit all applications.
Instead, minimum and maximum values for each
safety setpoint are provided, while precise settings
for the safety setpoints must be derived for each
installation.
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VSG Package Requirements
Process Gas Circuit
1.
Suction Gas Stop/Check Valve - The VSG compressor requires a manually operated stop valve on the
suction line to the compressor to allow for isolating the
compressor package from process gas. Also, a check valve
is required in the suction line to limit reverse rotation of
the compressor on shutdown.
2.
Suction Line Strainer - Vilter strongly recommends the use of an inline suction gas strainer to protect
the VSG compressor from foreign material which may
enter the compressor with the suction gas. This strainer
is generally of stainless steel mesh construction. Vilter can
provide assistance in designing a strainer housing specifically suited to VSG applications.
3.
Process Gas/Oil Separator - A separator vessel
capable of removing the oil from the discharge gas stream
with an efficiency down to at least 5 PPM oil carryover is
required. Vilter’s own available horizontal separator is an
ASME-coded vessel which uses five stages of separation to
achieve an oil loss of as little as 3 to 4 PPM.
4.
Discharge Gas Relief Valve - To protect the compressor package from damage due to over pressurization,
a relief valve must be installed inside of any discharge line
hand block valves. The relief valve must be set to open at
a pressure lower than the Maximum Allowable Working
Pressure (MAWP) of the separator.
5.
Oil Prelube Pump - Usually a direct driven gear
type pump, the oil pump is required to prelube the compressor prior to starting and to maintain oil pressure during any
periods of low compression ratio operation.
6.
Oil Cooler/ Temperature Control Valve - An oil
cooler, either air or water cooled, must be used to remove
the heat of compression from the oil stream. A temperature control valve is used to maintain constant oil injection
temperature to the compressor.
7.
Oil Filtration - Large capacity micronic oil filters
are required to filter the oil before injection into the VSG
compressor. Filtration down to 25 microns nominal or less
is generally acceptable. Dual filters are recommended to
allow replacement of one cartridge while the compressor
continues running with the other cartridge in service.
8.
Oil Heater - An oil heater is generally required
and must be sized to maintain oil temperature of at least
90°F when the compressor is not running. For outdoor installations, low ambient temperatures and winds must be
considered when sizing the oil heater. Also, insulating the
separator and oil piping may be required in low temperature
ambient conditions.
Note - Because the oil system on the VSG compressor utilizes discharge gas pressure as the means to move the
injection oil through the system, it must be remembered that all components of the oil system are exposed to full discharge
pressure and must be pressure rated accordingly.
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Description
COMPRESSOR
The Vilter Single Screw Compressor is a positive
displacement, capacity and volume controlled,
oil flooded, rotary compressor which uses a
single main screw intermeshed by two opposing gate rotors. Gas compression occurs when
the individual teeth of each gate rotor sweep
through the grooves, or flutes, of the main screw
as the screw rotates. Compression occurs from
the time the screw flute is first closed off by the
gate rotor finger, until the time when the screw
flute has rotated to the point of lining up with
the discharge port in the compressor housing.
A labyrinth type seal is used to prevent gas at
discharge pressure from leaking past the end
of the screw. Any discharge gas leakage past
the labyrinth seal is vented back to suction via
four longitudinal holes drilled through the body
of the screw.
By venting the discharge end of the main screw
back to suction, forces on each end of the screw
are equal. This results in zero net axial forces on
the main bearings. With twin opposing gate
rotors, all radial forces are cancelled out also.
Main shaft bearings have no net forces except
the weight of the screw and the shaft assembly.
The VSG compressors are comprised of three
rotating assemblies: the main screw assembly
and the two gate rotor assemblies. Each of these
rotating assemblies use a common bearing
configuration consisting of a single, cylindrical
rolling element bearing at one end, and a pair
of angular contact ball bearings at the other
end. The pair of angular contact ball bearings
are used to axially fix one end of the rotating
shafts, and to absorb the small amount of thrust
loads on the shafts. The inner races of the ball
bearings are securely clamped to the rotating
shafts, while the outer races are securely held
in the bearing housing, thus fixing the axial
position of the shaft in relation to the bearing
housings. The cylindrical roller bearings at the
opposite end of the shafts allow for axial growth
of the shafts while supporting the radial loads
from the shafts.
The suction gas enters the compressor housing
through the top inlet flange, at the driven end of
the unit. The driven end of the compressor housing is flooded with gas at suction pressure. The
gas enters the open end of the main screw flutes
at the driven end, and becomes trapped in the
screw flute as the screw rotates and the gate rotor
tooth enters the end of the flute. At this point, the
compression process begins. Directly after the
screw flute is closed off by the gate rotor tooth,
oil is injected into the groove.
The oil enters the compressor through a connection at the top of the compressor. The purpose of
the injected oil is to absorb the heat of compression, to seal the gate rotor tooth in the groove,
and to lubricate the moving parts.
Additional internal oiling ports are provided at the
main and gate rotor bearings to cool and lubricate
the bearings. The mechanical shaft seal housing
also contains oiling ports to lubricate, cool and
provide a sealing film of oil for the mechanical
shafts seal. Excess oil flows through the check
valves on the sealing baffle plate. This oil is directed at the main rotor roller bearing, which cools
and lubricates the front roller bearing.
As the main screw rotates, the gate rotor is also
driven, causing the gate rotor tooth to sweep the
groove in the main screw. This sweeping action
reduces the volume of the groove ahead of the
gate rotor tooth and causes the trapped gas and
oil to be compressed in the reduced volume. As
the main screw continues to rotate, the gate rotor
tooth continues to reduce the groove volume to a
minimum, thus compressing the trapped gas to a
maximum pressure. A labyrinth seal arrangement
prevents the compressed gas from leaking past the
end of the screw. As the gate rotor tooth reaches
the end of the groove, the groove rotates to a
position that lines up with the discharge port in
the compressor housing and the gas/oil mixture is
discharged from the screw at high pressure. This
completes the compression cycle for a single flute
of the main screw.
Once the gas is swept from the main screw flute
through the discharge port, it passes into the
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Description
discharge manifold of the compressor. From
the discharge manifold, the gas/oil exits the
compressor housing
The Vilter VSG compressors feature the
exclusive Parallex™ Slide System, which
consists of a pair of slides for each gate rotor
assembly. These two independently operated slides are referred to as the capacity
slide and the volume ratio slide. On the
suction end of the screw, the capacity slide
moves to vary the timing of the beginning
of the compression process. With the
slide moved all the way out to the suction
end of the screw (the 100% position), the
compression process begins immediately
after the gate rotor tooth enters the screw
flute and closes off the end of the groove.
In this situation, the maximum volume of
gas is trapped in the screw flute at the start
of the compression process. As the slide
is pulled back away from the suction end
of the screw, the start of the compression
process is delayed as some of the suction
gas is allowed to spill back out of the screw
flute until the screw rotates far enough to
pass the end of the capacity slide and begin
compressing. This causes a reduced volume
of gas to be trapped in the screw flute when
the compression process begins. In this way,
the capacity of the compressor is reduced
from 100% down to as low as 10% of the full
rated capacity.
The capacity slide provides the means for
controlling specific process set points.
By continuously adjusting the flow of gas
through the compressor, either suction or
discharge pressure in a particular process
can be controlled. When coupled with a
microprocessor controller, the adjustable
capacity slide allows for precise and continuous automatic control of any parameter in
the process to a chosen set point.
The second slide for each gate rotor is the
volume ratio slide. The purpose of the
volume ratio slide is to maximize the efficiency of the compressor by matching
the gas pressure within the screw flute at
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the point of discharge to the downstream
process requirements. The volume ratio slide
operates at the discharge end of the screw,
and acts to vary the position of the discharge
port. When the slide is extended fully to the
discharge end of the screw (the 100% position), the compression process within the
screw flute continues until the screw rotates
far enough for the flute to pass the end of the
volume ratio slide. At this point, the screw
flute lines up with the discharge port and the
compressed gas is expelled from the screw
flute. As the volume ratio slide is pulled back
away from the discharge end of the screw,
the position of the discharge port is changed
and the gas is allowed to escape the screw
flute earlier in the compression process, at a
reduced pressure.
The overall volume ratio within the compressor is determined by the distance between
the front of the capacity slide (the start of
compression) and the back of the volume
ratio slide (the completion of compression).
Therefore, the volume ratio slide must
respond to changes in the downstream
pressure measured in the oil separator and
position itself for the required compression
ratio based on the position of the capacity
slide. By only compressing the gas within
the screw as far as required to match the
pressure in the downstream receiver,
the compressor efficiency is maximized.
Proper positioning of the volume ratio slide
prevents either over compressing or under
compressing of the gas within the screw
flute. This allows the single screw compressor to efficiently handle a range of volume
ratios from as low as 1.2 up to 7.0.
Description
DESCRIPTION OF GAS SYSTEM FOR A STANDARD
COMPRESSOR SET
DESCRIPTION OF OIL SYSTEM FOR A STANDARD
COMPRESSOR SET
The gas passes through a stop valve and a check
valve and then through a mesh strainer mounted
directly to the inlet flange. The check valve is necessary to prevent reverse rotation and potential
damage or oil loss at shut down. The suction gas
enters the compressor housing through the top inlet
flange, at the driven end of the unit.
At start oil at is drawn from the oil separator tank by the
oil pump, and passes through a oil cooler and micronic
filters to the oil supply inlet on the compressor frame.
From there it internally lubricates all points internal to
the compressor. After start-up when the compressor
develops sufficient differential pressure the oil pump
can be shut down and the oiling can take place without
the use of the oil pump. On units with low pressure differentials such as booster and low pressure differential
high stage compressors, the oil pump must remain on
whenever the unit is running to maintain sufficient oil
flow.
After compression the gas is discharged from the
discharge manifold directly into a oil separator tank.
On the discharge of the oil separator tank another
check valve is positioned to prevent the entry of
gas or liquid refrigerant in to the separator when
the compressor is shut down. The separator should
be allowed to equalize slowly to suction pressure
through a small bypass line around the suction check
or combination stop/check valve. This will allow the
compressor to start without a pressure differential
across it, reducing the starting power requirements.
From the discharge manifold, the gas/oil exits the
compressor housing and passes into the oil separator through a pipe elbow. The separator vessel
serves to separate the oil from the gas as the gas
stream moves from one end of the separator to
the other. The majority of the oil is separated from
the gas in the primary chamber of the vessel due to
changes in direction and velocity reduction. Any remaining oil mist is separated from the gas stream as
the stream passes through the coalescing elements
and into the secondary chamber of the vessel. The
gas at discharge pressure then exits at the far end
of the separator.
Oil collected in the bottom of the separator is
drained off to be recirculated in the oil injection
system. The injection oil temperature is controlled
by several means the first of which is a three-way
mixing valve, which mixes hot oil directly from the
separator with oil which has passed through the
oil cooler to obtain oil at the desired temperature.
This oil then passes through a filter to remove any
contaminants, which may have been picked up
from the process gas, and is injected back into the
compressor.
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Installation
PIPING
Before installing piping, the compressor inlet and
outlet ports should be inspected to ensure no dirt
is present.
Piping should be supported so that no piping loads
are transmitted to the compressor casings.
All piping should be inspected for cleanliness before
installation. As each pipe is connected to the compressor, the coupling alignment should be checked
to ensure that no alteration has taken place.
If alignment has altered, the compressor is being
strained and the piping supports must be adjusted.
It is not sufficient merely to re-align the drive coupling, as this will not correct the cause of the strain.
Compressors must have an inlet strainer permanently fitted to the compressor inlet.
Care must be taken to avoid trapping the lines except for specific purposes. When traps are used, the
horizontal dimensions should be as short as possible
to avoid excessive oil trapping.
Steel pipe is generally used in large installations
when joints are welded.
In making up joints for steel pipe, the following
procedures should be followed:
For threaded connections, all threads on the pipe
and fitting should be carefully cleaned to remove
all traces of grease or oil. Threads should then be
wiped dry with a lintless cloth. Only thread filling
compounds suitable for service should be used for
making steel pipe joints. These compounds should
be used sparingly, and on the pipe only. Do not put
any on the first two threads to prevent any of the
thread sealing compound from entering the piping
system. Acetylene or arc welding is frequently used
in making steel pipe joints, however, only a skilled
welder should attempt this kind of work. Take care
to see no foreign materials are left in the pipes and
remove all burrs formed when cutting pipe.
16
For halocarbon piping, only wrought copper fittings should be used. Cast fittings as used for water
service are porous and will allow the refrigerant to
escape. Note this exception: In larger pipe sizes,
wrought fittings are not available. However, specially tested cast fittings are available and these may
be used with complete safety.
It is important to avoid short, rigid pipe lines that do
not allow any degree of flexibility. This must be done
to prevent vibration being transmitted through the
pipe lines to the buildings. One method of providing the needed flexibility to absorb the vibration is
to provide long lines that are broken by 90° Ells in
three directions.
A second method would be to install flexible pipe
couplings as close to the compressor unit as possible
with connections run in two different directions,
90° apart. These flexible connections should be
installed on both the high and low side lines of the
compressor unit.
Hangers and supports for coils and pipe lines should
receive careful attention. During prolonged operation of the coils, they may become coated with
ice and frost, adding extra weight to the coil. The
hangers must have ample strength and be securely
anchored to withstand the vibration from the compressor and adequately support the pipe lines.
This information is taken from and ANSI B31.3. The
installing contractor should be thoroughly familiar
with these codes, as well as any local codes.
Installation
TESTING SYSTEM
FOR LEAKS
Vilter equipment is tested for leaks at the factory.
One the most important steps in putting the system
into operation is field testing for leaks. This must
be done to assure a tight system that will operate
without any appreciable loss of gas.
First, if test pressures exceed the settings of the
system, relief valves or safety devices, they must
be removed and the connection plugged during the
test. Secondly, all valves should be opened except
those leading to the atmosphere. Then, open all
solenoids and pressure regulators by the manual
lifting stems. All bypass arrangements must also
be opened.
OIL FOR SINGLE SCREW
COMPRESSORS
Due to the need for adequate lubrication, Vilter recommends only the use of Vilter lubricants, designed
specifically for Vilter compressors. With the extensive
research that has been performed, we are able to offer specific lubricating oils. Use of oil not specified or
supplied by Vilter will void the compressor warranty.
HYDROCARBON SYSTEMS
“Oil pumped” dry nitrogen, or anhydrous CO2 in
this order of preference may be used to raise the
pressure to the proper level for testing.
When the proper pressure is attained, test for leaks
with the soap mixture previously described. After
all leaks are found and marked, relieve the system
pressure and repair the leaks. Never attempt to
repair soldered or welded joints while the system is
under pressure. Soldered joints should be opened
and re soldered.
Do not simply add more solder to the leaking
joint. After all the joints have been repaired and the
system is considered “tight”.
Remove the drum and bring the pressure to the recommended test level with oil pumped dry nitrogen
or CO2. Then check the entire system again for leaks,
using a halide torch or electronic leak detector.
Be sure to check all flanged, welded, screwed and
soldered joints, all gasketed joints, and all parting
lines on castings. If any leaks are found, they must
be repaired and rechecked before the system can be
considered tight again, remembering that no repair
should be made to welded or soldered joins while
the system is under pressure.
17
Installation & Calibration of Slide Valve Actuators
Slide Valve Actuator Installation Instructions
Caution
WHEN INSTALLING THE OPTICAL SLIDE MOTOR,
LOOSEN LOCKING COLLAR BEFORE SLIDING THE
COLLAR DOWN ON THE SHAFT. DO NOT USE A
SCREWDRIVER TO PRY LOCKING COLLAR INTO
POSITION.
OVERVIEW
Calibration of an optical slide valve actuator is a two
step process that must be done for each actuator
installed of the compressor. Briefly, the steps are as
follows.
1) The actuator motor control module, located
inside the actuator housing, is calibrated so
that it knows the minimum and maximum rotational positions of the slide valve it controls.
The calibrated actuator will output 0 VDC at the
minimum position and 5 VDC at the maximum
position.
2) After the actuator motor control module has been
calibrated for 0-5Volts, the controlling channel
corresponding to the actuator motor (either the
capacity or volume) has to be calibrated. This
instructs the control panel to learn the rotational
0% position & rotational 100% position of the slide
valve travel.
PLEASE NOTE:
Because there is an optical sensor on this motor, do
not attempt calibration in direct sunlight.
ACTUATOR MOTOR CONTROL
MODULE CALIBRATION PROCEDURE
1. Disable the Slide Non-Movement Alarm by going to the “Setup” menu on the control panel
and choosing “Alarm Disable” for the Slide NonMovement Option. (If applicable).
2. Completely shut off the power to the control
panel completely.
18
3. If not already done, mount the slide valve actuator per (“Vilter Actuator set up for Capacity and
Volume Slide Motors). Next, wire the actuator
per the attached wiring diagrams, using the
already installed electrical conduit to run the
cables. The old wiring can be used to pull the
new cables through the conduit to the control panel. The cables may also be externally
tie-wrapped to the conduit. Run the yellow
AC power cable(s) and the gray DC position
transmitter cable(s) in different conduit. This
prevents the DC position transmitter cable from
picking up electrical noise from the AC power
cable. Do not connect either of the cables to
the actuators yet.
In addition, if the actuators are replacing old gearmotors on early units, you must remove the capacitors and associated wiring from inside the control
panel. This is necessary to prevent electrical damage
to the new actuator motor.
4. When completing the calibration of the new
actuators, the motors are signaled to move
to below 5%. This may not completely occur
when exiting the calibration screen due to a
“program timer”. HOWEVER, when the compressor actually starts, the motors will travel
below 5% and function correctly. The user may
see that the actuators are not below 5% after
calibration and try to find the reason. If the
calibration screen is re-entered right away and
then exited, the timer will allow the actuator
to go below the 5% on the screen. This may
be perceived as a problem; in reality,it is not.
5. Note:The 0 to 5V-position transmitter
output of the actuator will fluctuate wildly
during the calibration process. To prevent
damage to the actuators, do not connect the
yellow power cable or the gray position
transmitter cable until instructed to do so
later on.
6. Open the plastic cover of the capacity motor by
removing the four #10 screws.
Installation & Calibration of Slide Valve Actuators
Caution: there are wires attached to the connector on the plastic cover. Handling the
cover too aggressively could break the wires.
7. Gently lift the cover and tilt it toward the Turck
connectors. Raise the cover enough to be able
to press the blue calibrate button and be able
to see the red LED on the top of assembly.
8. Press “Menu” on the main screen and then press
the “Slide Calibration” button, to enter the slide
calibration screen. (Note: you must be in this slide
calibration screen before attaching the yellow
power cable or gray position transmitter cable.)
9. Now connect the yellow power cable and the
gray position transmitter cable to the actuator.
10. Press INC and DEC to move the slide valve and check
for the correct rotation. See Table 1on page 48 for
Actuator/command shaft rotation specifications.
11. Note: If the increase and decrease buttons do
not correspond to increase or decrease shaft
rotation, swap the blue and brown wires of
the “yellow power cable”. This will reverse
the rotation of the actuator/command shaft.
12. Quickly press and release the blue push button on the actuator one time. This places the actuator in calibration mode. The
r e d L E D w i l l b e g i n f l a s h i n g r a p i d l y.
13. Note: When the actuator is in calibration mode, it outputs 0V when the actuator is running
and 5V when it is still. Thus, as stated earlier, the
actuator voltage will fluctuate during calibration. After the actuator has been calibrated,
0V output will correspond to the minimum
position and 5V to the maximum position.
14. Note: The “Slide calibration” screen on the control panel has a “Current” window, which displays
twice the actuator output voltage. This value,
(the % volume and the % capacity) displayed in
the “Current Vol” and Current Cap” Windows are
meaningless until calibration has been completed.
15. Use the DEC button on the control panel to
drive the slide valve to its minimum “mechanical stop” position. Do not continue to run the
actuator in this direction after the slide valve
has reached the stop. Doing so may cause damage to the actuator or the slide valve. When
the slide has reached the mechanical stop position, use the INC button to pulse the actuator
to where the slide is just off of the mechanical
stop and there is no tension on the motor shaft.
16. Quickly press and release the blue button on
the actuator again. The red LED will now flash
at a slower rate, indication that the minimum
slide valve position (0V position) has been set.
17. Use the INC button on the control panel to drive
the slide to its maximum “mechanical stop” position. Do not continue to run the actuator in this
direction after the slide valve has reached the
stop. Doing so may cause damage to the actuator or the slide valve. When the slide valve has
reached the mechanical stop position, use the
DEC button to pulse the actuator to where the
slide is just off of its mechanical stop and there
is no tension on the motor shaft.
18. Quickly press and release the blue button on the
actuator one more time. The red LED will stop
flashing. The actuator is now calibrated and knows
the minimum and maximum positions of the slide
valve it controls. Now the capacity or volume
channel of the control panel can be calibrated.
19. Use the Dec button to move the actuator towards
its minimum position while watching the millivolt readout on the control panel screen. Discontinue pressing the DEC button when the millivolt
reading in the “Current” window above the “Set
Min” button is approximately 500 millivolts.
20. Now use the DEC and INC buttons to position the
slide valve until a value close to 300 millivolts is on
the screen. Then, press the “Set Min” button for
the capacity or volume slide valve window to tell
the controller that this is the minimum millivolt
position. Note: The value in the “Current Cap” or
“Current Vol” window has no meaning right now.
19
Installation & Calibration of Slide Valve Actuators
21. Use the INC button to rotate the actuator towards its maximum position while watching
the millivolt readout on the controller screen.
Discontinue pressing the INC button when
the millivolt reading in the “Current” window
is approximately 9200 millivolts (7900 millivolts for the 2783J qualified analog boards).
You are nearing the mechanical stop position.
22. Pulse the INC button to carefully move the slide
valve until the millivolt readout “saturates”, or
stops increasing. This is around 9500 millivolts
(8400 millivolts for 2783 qualified analog boards).
23. Pulse the DEC button until the millivolts just
start to decrease. (This is the point where
the channel drops out of saturation).Adjust millivolt value to 300 millivolts below
recorded maximum millivolts in step #22.
24. Press the “Set Max” button.
25. Press the “Main” button to complete calibration and exit the “Slide Calibration” screen.
The controller will automatically energize
the actuator and drive it back to its minimum position (below 5%) for pre-start-up.
26. Note: Now the “Current Cap” or the “Current
Vol” value will be displayed in the window on the
“Main” screen and the “Slide Calibration” screen.
27. Gently lower the plastic cover over the top
of the actuator to where it contacts the base
and o-ring seal. After making sure the cover
is seated properly, gently tighten the four
#10 screws. Caution: The plastic cover
will crack if the screws are over tightened.
28. Enable the “Slide Non-Movement Alarm” by going to the “Setup” menu and choosing “Alarm
Enable” for the “Slide Non-Movement Option”.
29. This completes the calibration for this channel either capacity or volume. Repeat the
same procedure to the other channel.
20
Slide Valve Operation
Slide Valve Actuator Operation
The slide valve actuator is a gear-motor with a position sensor. The motor is powered in the forward
and reverse directions from the main computer in
the control panel. The position sensor tells the main
computer the position of the slide valve. The main
computer uses the position and process information
to decide where to move the slide valve next.
The position sensors works by optically counting motor turns. On the shaft of the motor is a small aluminum “photochopper”. It has a 180 degree fence that
passes through the slots of two slotted optocouplers.
The optocouplers have an infrared light emitting diode (LED) on one side of the slot and a phototransistor
on the other. The phototransistor behaves as a light
controlled switch. When the photochopper fence
is blocking the slot, light from the LED is prevented
from reaching the phototransistor and the switch is
open. When photochopper fence is not blocking the
slot, the switch is closed.
This scheme is not foolproof. If the motor is moved
manually while the power is off or the motor brake
has failed, allowing the motor to free wheel for too
long after the position sensor looses power, the actuator will become lost.
A brake failure can sometimes be detected by the
position sensor. If the motor never stops turning after
a power loss, the position sensor detects this, knows
it will be lost, and goes immediately into calibrate
mode when power is restored.
As the motor turns, the photochopper fence alternately blocks and opens the optocoupler slots,
generating a sequence that the position sensor microcontroller can use to determine motor position by
counting. Because the motor is connected to the slide
valve by gears, knowing the motor position means
knowing the slide valve position.
During calibration, the position sensor records the
high and low count of motor turns. The operator tells
the position sensor when the actuator is at the high
or low position with the push button. Refer to the
calibration instructions for the detailed calibration
procedure.
The position sensor can get “lost” if the motor is
moved while the position sensor is not powered. To
prevent this, the motor can only be moved electrically
while the position sensor is powered. When the position sensor loses power, power is cut to the motor. A
capacitor stores enough energy to keep the position
sensor circuitry alive long enough for the motor to
come to a complete stop and then save the motor
position to non-volatile EEPROM memory. When
power is restored, the saved motor position is read
from EEPROM memory and the actuators resumes
normal function
21
Slide Valve Actuator Trouble Shooting Guide
Problem
The actuator cannot be calibrated
Reason
Dirt or debris is blocking one or
both optocoupler slots
Clean the optocoupler slots
with a Q-Tip and rubbing alcohol.
The photochopper fence extends
less than about half way into the
optocoupler slots
Adjust the photochopper so
that the fence extends further
into the optocoupler slots.
Make sure the motor brake
operates freely and the photochopper will not contact the
optocouplers when the shaft is
pressed down.
The white calibrate wire in the grey
Turck cable is grounded
Dirt and/or condensation on the
position sensor boards are causing
it to malfunction
The actuator goes into calibration mode spontaneously
22
Tape the end of the white wire
in the panel and make sure that
it cannot touch metal
Clean the boards with an electronics cleaner or compressed
air.
The calibrate button is stuck
down
Try to free the stuck button.
The position sensor has failed
Replace the actuator.
Push button is being held down for
more that ¾ second when going
through the calibration procedure
Depress the button quickly and
then let go. Each ¾ second the
button is held down counts as
another press.
The white calibrate wire in the grey
Turck cable is grounding intermittently
Tape the end of the white wire
in the panel and make sure that
it cannot touch metal.
A very strong source of electromagnetic interference (EMI), such as a
contactor, is in the vicinity of the
actuator or grey cable
Increase the distance between
the EMI source and the actuator.
There is an intermittent failure of
the position sensor
The actuator goes into calibration mode every time
power is restored after a
power loss
Solution
Install additional metal shielding material between the EMI
source and the actuator or
cable.
Replace the actuator.
The motor brake is not working properly (see theory section
above.)
Get the motor brake to where it
operates freely and recalibrate.
Slide Valve Actuator Trouble Shooting Guide
Problem
The actuator does not transmit the correct position after
a power loss
There is a rapid clicking noise
when the motor is operating
The motor operates in one
direction only
The motor will not move in
either direction
The motor runs intermittently,
several minutes on, several
minutes off
Reason
The motor was manually moved
while the position sensor was not
powered.
The motor brake is not working
properly
Solution
Recalibrate.
Get the motor brake to where it
operates freely and then recalibrate.
The position sensor’s EEPROM
memory has failed
Replace the actuator.
The photochopper is misaligned
with the slotted optocouplers
Try to realign or replace the actuator.
The photochopper is positioned
too low on the motor shaft.
Adjust the photochopper so that
the fence extends further into
the optocoupler slots.
A motor bearing has failed
Replace the actuator.
There is a loose connection in the
screw terminal blocks
Tighten.
There is a loose or dirty connection in the yellow Turck cable
Clean and tighten.
The position sensor has failed
Replace the actuator.
There is a broken motor lead or
winding
Replace the actuator.
The thermal switch has tripped
because the motor is overheated
The motor will resume operation when it cools. This could be
caused by a malfunctioning control panel. Consult the factory.
Any of the reasons listed in “The
motor operates in one direction
only”
See above.
The command shaft is jammed
Free the command shaft.
Broken gears in the gearmotor
Replace the actuator.
Motor is overheating and the
thermal switch is tripping
This could be caused by a malfunctioning control panel. Consult the factory.
23
Slide Valve Actuator Trouble Shooting Guide
Problem
Reason
Solution
The motor runs sporadically
Bad thermal switch
Replace the actuator.
Any of the reasons listed in “The
motor will not move in either direction”
See above.
The motor runs but output
shaft will not turn
Stripped gears inside the gear motor or the armature has come unpressed from the armature shaft
Replace the actuator.
Slide Valve Actuators communicate problems discovered by internal diagnostics via LED blink codes. Only one blink
code is displayed, even though it is possible that more than one problem has been detected.
Flash Pattern
Meaning
*=ON
_=OFF
*_*_*_*_*_*_*_*_*_*_*_
Calibration step 1
*___*___*___*___*___
Calibration step 2
*__*________________
This indicates a zero span. This error can only occur during calibration. The typical
cause is forgetting to move the actuator when setting the upper limit of the span.
If this is the case, press the blue button to restart the calibration procedure. This
error can also occur if either or both of the slotted optocouplers are not working. If
this is the case, the slide valve actuator will have to be replaced.
The operation of the slotted optocouplers is tested as follows:
1. Manually rotate the motor shaft until the aluminum photochopper fence is not
blocking either of the optocoupler slots.
2. Using a digital multi-meter, measure the DC voltage between terminal 3 of
the small terminal block and TP1 on the circuit board (see Note 1). You should
measure between 0.1 and 0.2 Volts.
3. Next, measure the DC voltage between terminal 3 and TP2 on the circuit
board. You should measure between 0.1 and 0.2 Volts.
24
Slide Valve Actuator Trouble Shooting Guide
*__________________
This indicates a skipped state in the patterns generated by the optocouplers as the
motor moves. This error means that the slide valve actuator is no longer transmitting accurate position information. The actuator should be recalibrated as soon as
possible. This code will not clear until the actuator is recalibrated.
This code can be caused by:
1. The motor speed exceeding the position sensors ability to measure it at some
time during operation. A non-functioning motor brake is usually to blame.
2. The actuator is being operated where strong infrared light can falsely trigger
the slotted optocouplers, such as direct sunlight. Shade the actuator when the
cover is off for service and calibration. Do not operate the actuator with the
cover off.
*__*__*____________
The motor has overheated. The actuator motor will not run until it cools. Once the
motor cools, the actuator will resume normal operation.
Motor overheating is sometimes a problem in hot and humid environments when
process conditions demand that the slide valve reposition often. Solutions are
available; consult your Vilter authorized distributor for details.
Another possible cause for this error is a stuck motor thermal switch. The thermal switch can be tested by measuring the DC voltage with a digital multi-meter
between the two TS1 wire pads (see Note 2). If the switch is closed (normal operation) you will measure 0 Volts.
********************
The 24V supply is voltage is low. This will occur momentarily when the actuator is
powered up and on power down.
If the problem persists, measure the voltage using a digital multi-meter between
terminals 3 and 4 of the small terminal block. If the voltage is >= 24V, replace the
actuator.
_*******************
The EEPROM data is bad. This is usually caused by loss of 24V power before the
calibration procedure was completed. The actuator will not move while this error
code is displayed. To clear the error, calibrate the actuator. If this error has occurred and the cause was not the loss of 24V power during calibration, possible
causes are:
1. The EEPROM memory in the micro-controller is bad.
2. The large blue capacitor is bad or has a cracked lead.
*****____*__________
Micro-controller program failure. Replace the actuator.
Note 1: TP1 and TP2 are plated-thru holes located close to the slotted optocouplers on the board. They are clearly
marked on the board silkscreen legend.
Note 2: The TS1 wire pads are where the motor thermal switch leads solder into the circuit board. They are clearly
marked on the board silkscreen legend and are oriented at a 45 degree angle.
25
Operation Section
Notice on using Non -Vilter Oils
Oil and its additives are crucial in system performance. Vilter Manufacturing will NOT APPROVE non-Vilter oils
for use with Vilter compressors. Due to the innumerable choices available it is not possible for us to test all oils
offered in the market place, and their effects on our equipment.
We realize that customers may choose lubricants other than Vilter branded oil. This is certainly within the
customers’ right as owners of the equipment. When this choice is made, however, Vilter is unable to accept
responsibility for any detrimental affects those lubricants may have on the equipment or system performance
and durability.
Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warranty upon
evaluation of the issue. This includes any parts’ failure caused by inadequate lubrication.
Certainly, there are many good lubricants in the market place. The choice of a lubricant for a particular application involves consideration of many aspects of the lubricant and how it and its additive package will
react in the various parts of the entire system. It is a complex choice that depends on a combination of field
experience, lab and field-testing, and knowledge of lubricant chosen. Vilter will not accept those risks other
than for our own lubricants.
26
Operation
CONTROL SYSTEM
A. Screw Compressor Control And Operation
Note:
Optical Actuators CAN NOT
be manually rotated.
View Capacity
1. Starting, Stopping and Restarting the Compressor.
Before the screw compressor unit may start, certain
conditions must be met. All of the safety setpoints
must be in a normal condition, and the suction pressure must be above the low suction pressure setpoint
to assure that a load is present. When the “On-Off”
switch or “Manual-Auto” button is pressed, the oil
pump will start. When sufficient oil pressure is built
up and the compressor capacity control and volume
ratio slide valves are at or below 10%, the compressor
unit will start.
If the compressor is in the automatic mode, it will
now load and unload and vary the volume ratio in
response to the system demands.
Stopping the compressor unit can be accomplished
a number of ways. Any of the safety setpoints will
stop the compressor unit if an abnormal operating
condition exists. The compressor unit “On-Off” or
stop button will turn the compressor unit off as will
the low pressure setpoint. If any of these conditions
turns the compressor unit off, the slide valve motors
will immediately energize to drive the slide valves
back to 5% limit. The control motors will be deenergized when the respective slide valve moves back
below 5%. If there is a power failure, the compressor
unit will stop. If the manual start on power failure
option is selected (see appropriate Microprocessor
Instruction Manual), restarting from this condition is
accomplished by pushing the reset button to insure
positive operator control. If the auto start on power
failure option is selected (see appropriate Microprocessor Instruction Manual), the compressor unit will
start up after a waiting period. With both options,
the compressor slide valves must return below their
respective 5% limits before the compressor unit can
be restarted.
View Volume
Ratio
SLIDE VALVE ACTUATOR LOCATION:
VSG 401 CCW
When viewing the compressor from the discharge
end (opposite the drive end), the upper motor is
for capacity control. The command shaft turns (see
Table 1) to decrease the capacity to 10% and reverses
to increase the capacity to 100%. The lower motor is
for volume ratio control. The command shaft turns
(see Table 1) to reduce the volume ratio to 2.0, and
reverses to increase the volume ratio to 5.0.
Actuation of the electric motors can be done manually or automatically. To actuate the motors manually, place the desired mode selector in the manual
position and push the manual Increase or Decrease
buttons. In the automatic mode, the microprocessor determines the direction to actuate the electric
motors. However, in the automatic mode, there is an
“On” and “Off” time for the capacity control motor.
The “On” time is the time in which the slide valve
moves, and the “Off” time is the time in which the
system is allowed to stabilize before another change
in slide valve position.
View Capacity
View Volume
Ratio
2. Slide Valve Control Actuators
Capacity and volume ratio control of the screw compressor is achieved by movement of the respective
slide valves, actuated by electric motors.
SLIDE VALVE ACTUATOR LOCATION:
VSG 501 CW Thru VSG 701 CW
27
Operation
Table 1
COMP.
MODEL
COMMAND SHAFT ROTATION
CAPACITY
VOLUME INC
DEC
INC
DEC
VSSG 291 CW
VSSG 341 CW
VSSG 451 CW
VSSG 601 CW
VSG 751 CCW
VSG 901 CCW
VSG 1051 CCW
VSG 1201 CCW
VSG 1551 CCW
VSG 1851 CCW
VSG 2101 CCW
VSG 301 CW
VSG 361 CW
VSG 401 CW
VSG 501 CCW
VSG 601 CCW
VSG 701 CCW
CCW
CCW
CCW
CCW
CW
CW
CW
CW
CW
CW
CW
CCW
CCW
CCW
CW
CW
CW
CW
CW
CW
CW
CCW
CCW
CCW
CCW
CCW
CCW
CCW
CW
CW
CW
CCW
CCW
CCW
CCW
CCW
CCW
CCW
CW
CW
CW
CW
CW
CW
CW
CCW
CCW
CCW
CW
CW
CW
NO. OF TURNS / ROTATION
ANGLE / SLIDE TRAVEL
CAPACITY
VOLUME
TURNS/DEGREES/TRAVEL TURNS/DEGREES/TRAVEL
0.91
0.91
0.91
0.91
1.09
1.09
1.22
1.22
1.36
1.36
1.36
0.80
0.80
0.80
0.91
0.91
0.91
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
328
328
328
328
392
392
439
439
490
490
490
288
288
288
328
328
328
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
3.568”
3.568”
3.568”
3.568”
4.283”
4.283”
4.777”
4.777”
5.325”
5.325”
5.325”
3.141”
3.141”
3.141”
3.568”
3.568”
3.568”
0.52
0.52
0.52
0.52
0.63
0.63
0.74
0.74
0.82
0.82
0.82
0.45
0.45
0.45
0.52
0.52
0.52
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
187
187
187
187
227
227
266
266
295
295
295
162
162
162
187
187
187
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
2.045”
2.045”
2.045”
2.045”
2.473”
2.473”
2.889”
2.889”
3.200”
3.200”
3.200”
1.767”
1.767”
1.767”
2.045”
2.045”
2.045”
NOTE: These refer to the old style gear motors and DO NOT apply to the new optical motors. Rotation for the
optical motors is the OPPOSITE of what is shown in the chart.
4. Oil Filter Differential
B. Safety Setpoints
A detailed explanation of all safety setpoints can be found
in the Compact Logix PLC manual, p/n 35391CL.
1. Oil Pressure
Low oil pressure differential stops the compressor unit
when there is an insufficient difference in pressure
between the oil manifold and suction.
High oil filter differential cutout stops the compressor unit when the difference between the outlet and
inlet of the filter exceeds the setpoint.
5. Oil Temperature
The oil temperature cutout stops the compressor
unit when the oil temperature is too high or too low.
6. Discharge Temperature
2. Discharge Pressure
High discharge pressure cutout stops the compressor
unit, when the discharge pressure in the oil separator
exceeds the setpoint.
3. Suction Pressure
Low suction pressure cutout stops the compressor
unit when the suction pressure drops below the
setpoint.
28
The high discharge temperature cutout stops the
compressor unit when the discharge temperature
exceeds the setpoint.
Inspect Compressor
Bearings
Key:
Transducers
RTD's
Coalescing Elements
Suction Screen
Coupling Alignment
and Integrity
Oil Change
Oil Analysis (1)
Oil Filters
Oil Strainer
200
(I)
Inspect.
I
I
I
I
I
I
I
I
I
R
I
5,000
R
S
R
I
I
I
I
I
I
R
S
R
I
I
I
I
I
I
I
I
I
R
S
R
I
40,000
R
I
S
R
I
50,000
(S)
I
I
I
I
S
R
I
60,000
Sample.
I
I
I
I
R
I
R
S
R
I
70,000
I
I
I
I
S
R
I
I
I
I
I
I
R
S
R
I
80,000
BASED ON DRY CLEAN GAS
30,000
(R) Replace.
I
I
I
I
S
R
I
10,000
SERVICE INTERVAL (HOURS)
90,000
I
I
I
R
I
S
R
I
100,000
I
I
I
I
I
R
S
R
I
110,000
I
I
I
I
S
R
I
I
I
I
I
I
R
I
R
S
R
I
120,000
NOTE: See Motor Manual for proper lubrication procedures and service intervals.
(2) Note: The life of the compressor will be increased by purging the compressor unit with dry nitrogen or sweet, dry natural gas at
shutdown.
The life of the oil is directly affected by the quality of the gas. Proper separation of any liquids must be accomplished to prevent
droplets of liquid at the compressor suction. The discharge temperature of the compressor must be kept a minimum of 30°F above
the discharge gas dew point to prevent the condensing of liquids in the oil separator. The oil separator shell and legs must be
insulated when the gas stream has a high probability of having condensables.
(1) Note: Oil Analysis/Sampling is based on the gas stream. It is at the customer's discretion to increase the time period between oil
sampling if contamination of oil is unlikely, and to decrease the time period between oil sampling if oil contamination is likely or
evident. An oil sample must be taken when there is reason to believe the oil is contaminated anytime during operation. In landfill,
corrosive, and wet gas conditions, oil sampling is recommended every 3-4 months.
COMPRESSOR (2)
CONTROL
CALIBRATION
PACKAGE
OIL CIRCUIT
GROUP
INSPECTION
OR
MAINTENANCE
ITEM
20,000
Gas Compression "Maintenance and Inspection Schedule"
4/29/2009
Maintenance
Gas Compression Maintenance and Inspection Schedule
29
Service
GENERAL COMMENTS
When working on the compressor, care must be taken
to ensure that contaminants (i.e. water from melting
ice, dirt and dust) do not enter the compressor while
it is being serviced. It is essential that all dust, oil or
ice that has accumulated on the outside of the compressor be removed before servicing the compressor.
When servicing the compressor, all gaskets, O-rings,
roll pins and lock washers must be replaced when
reassembling the compressor.
PREPARATION OF UNIT FOR SERVICING
A) Shut down the unit, open the electrical disconnect switch and pull the fuses for the compressor
motor to prevent the unit from starting. Put a
lock on the disconnect switch and tag the switch
to indicate that maintenance is being performed.
B) Isolate the unit by manually closing the discharge
Stop valve. Allow the unit to equalize to suction
pressure before closing the Suction Bypass. After
the unit has equalized to suction pressure and
suction valve closed, use an acceptable means to
depressurize the unit that complies with all Local,
State and Federal Ordinances.
C) Remove drain plugs from the bottom of compressor housing and the discharge manifold On
units equipped with Suction Oil Injection (SOI)
manually open the SOI solenoid valve below the
compressor. Drain the oil into appropriate containers.
30
Service
Top View
Rotor Being Pushed By
Use Of Lever
Direction of rotor movement.
Axial force at coupling
to be 300-500lbs.
Rigidly attach dial indicator.
Position it on the axis of the
compressor.
Force to be determined
by length of level arm.
COMPRESSOR INSPECTION
The Vilter Single Screw Compressor is designed for
long periods of trouble free operation with a minimum of maintenance. However, a yearly inspection
is recommended so any irregular wear is noted and
rectified. At this time, the bearing float is measured
for the main rotor and gate rotors.
Small wooden block or fulcrum.
The following are the procedures used in measuring
the main rotor and gate rotor bearing float.
BEARING CHECK
CAUTION
Top View
Rotor Being Pushed in the
opposite direction by use of a lever.
Direction of rotor movement.
Axial force at coupling
to be 300-500lbs.
When taking the measurements, do not exceed 300 to
500 Lbs. of force at point of contact or damage may
result to the bearings
A) Shut down and de-pressurize the unit.
Rigidly attach dial
indicator.
Position it on the
axis of the
compressor.
B) Main rotor bearing float.
1) Remove the coupling guard, then remove the
center member from the coupling.
Small wooden block
or fulcrum.
Force to be determined
by length of level arm.
Side View
Showing gate rotor bearing float
being measured.
Direction of rotor movement.
Axial force at gate rotor to be
200 to 300 lbs.
Wooden block to prevent
damge to gate rotor blade.
Force to be determined
Rigidly attach
by length of level arm.
dial indicator.
Use bolt for fulcrum.
2) Attach a dial indicator to the compressor
frame as shown and zero indicator. Place a
lever arm and fulcrum behind the compressor
coupling half and push the coupling towards
the motor (note measurement).
TABLE.1 MAXIMUM BEARING FLOAT
MAIN
GATE
Bearing Float
0.003”
0.002”
Maximum Force 300 to 500 200 to 300
Lbs.
Lbs.
3) Re-Zero indicator, now position the fulcrum
on the motor and use the lever arm to push
the input shaft towards the compressor (note
measurement).
31
Service
TABLE 2. GATE ROTOR FLOAT
4) Add both readings, the total indicator movement is the bearing float and this should not
exceed 0.003”.
C) Gate rotor bearing float.
1) Remove the side covers and position a dial
indicator on the gate rotor.
2) Use a lever arm pivoting on a bolt with a
small block of wood against the gate rotor
blade to protect the blade.
3) The maximum amount of bearing float
should not exceed 0.002”.
MODEL
VSG 301 THRU 401
VSG 501 THRU 701
VSSG 291 THRU VSSG 601
VSG 751 & VSG 901
VSG 1051 & VSG 1201
VSG 1551 THRU VSG 2101 FLOAT
0.045”
0.045”
0.045”
0.055”
0.060”
0.060”
E) Readings could be higher than 0.020. If readings is greater than 0.030 over table tolerance
contact Vilter’s home office.
F) Inspect the main and gate rotors for signs of abnormal wear due to dirt or other contaminants.
G) After the inspection is complete, the covers,
coupling center member and guard can be
reinstalled and the unit can then be evacuated
and leak checked before starting.
D) Measure the gate rotor to blade float. Some
movement between blade and support is necessary to prevent damage to the compressor blade,
however at no time should the blade uncover the
support.
1) Position the blade with the gate rotor
damper pin and 90º to the main rotor.
2) Position a dial indicator at the tip of the support. The total movement of the damper pin
in the bushing is the gate rotor float. Refer
to table 0.2 to find the maximum blade to
support float (on new compressor parts
only).
32
Service
GATE ROTOR ASSEMBLY CAUTION
Gate rotor removal and assembly is divided into distinct instructions, instructions for all VSG and VSSG
models and different instructions for all VSM models.
Please follow the appropriate set of instructions.
For VSG 451 thru 601
compressors, do not
use side rails.
REMOVAL ( All VSG)
90 1A
A) Prepare the compressor for servicing.
For VSSG 751/901 & VSG 1051/1201
compressors, use side rails and
assemble to gaterotor stablizer
as stamped.
90 1B
90 1C
NOTE: All parts must be kept with their appropriate side and not mixed when the compressor is reassembled.
B) Remove two upper bolts from the side cover,
and install guide studs in the holes. Remove the
remaining bolts and side cover. There will be
some oil drainage when the cover is removed.
C) Turn the main rotor so a driving edge of any one
of the main rotor grooves is even with the back
of the gate rotor support.
Drive End
D) Insert the gate rotor stabilizer. The side rails
are not required on VSSG 291 thru 601. For the
VSG 751 thru 901 and VSG 1051 thru 1201
compressors, use the side rails and assemble to
the gate rotor stabilizer as stamped. For the VSG
1551 thru 2101, use the side rails and assemble
to the gate rotor stabilizer.
The gate rotor stabilizer is designed to hold the
gate rotor support in place and prevent damage
to the gate rotor blade as the thrust bearings and
housing is being removed.
33
Service
E) Remove the hex head and socket head bolts from
the thrust bearing cover. Insert two of the bolts
into the threaded jacking holes to assist in removing the cover. Retain the shim pack and keep it
with the bearing housing cover.
F) Hold the gate rotor support with a suitable wrench
on the flats provided near the roller bearing housing. Remove the inner retainer bolts and the
retainer. To remove the thrust bearing housing,
install the thrust bearing removal and installation
tool with the smaller puller shoe. Turn the jacking
screw clockwise. The thrust bearings and housing
assembly will be pulled off the shaft and out of the
frame.
G) Remove the bolts on the roller bearing housing.
Thread two bolts into the jack screw holes provided in the housing to assist in removing it.
H) To remove the gate rotor support, carefully move
the support opposite the direction of rotation and
tilt the roller bearing end towards the suction end
of the compressor. The compressor input shaft
may have to be turned to facilitate the removal of
the gate rotor support. On dual gate compressor
units, repeat the procedure for the remaining gate
rotor support assembly.
34
Service
REMOVAL (ALL VSG 301-701 MODELS)
The removal of the gate rotor assembly for the VSG
301-701 compressors is similar for the VSG 9012101 compressors. The inner races are secured to
the stationary bearing spindle.
A) Prepare the compressor for servicing.
B) Remove the upper bolt from the side cover and
install a guide stud in the hole. Remove the
remaining bolts and side cover. There will be
some oil drainage when the cover is removed.
C) The side cover that contains the suction strainer
should have the suction line properly supported
before the bolts securing the line to the cover
can be removed. After the line is removed, the
cover can be removed per paragraph B.
D) Turn the main rotor so the driving edge of the
groove is between the top of the shelf or slightly
below the back of the gate rotor support. At
this point install the gate rotor stabilizing tool.
35
Service
E) Remove plug on the thrust bearing housing.
Loosen the socket head cap screw that is located
underneath the plug. This secures the inner races
of the thrust bearings to the spindle.
F) Remove bolts that hold the thrust bearing housing to the compressor. Insert two of the bolts into
the threaded jacking holes to assist in removing
the bearing housing from the compressor. When
the housing is removed, there will be shims between the spindle and thrust bearings. These
control the clearance between the shelf and
gate rotor blades. These must be kept with their
respective parts for that side of the compressor.
G) Remove the bolts from the roller bearing housing.
After the bolts have been removed, the housing
can be removed from the compressor.
H) To remove the gate rotor support, carefully move
the support opposite the direction of rotation
and tilt the roller bearing end towards the suction end of the compressor. The compressor
input shaft may have to be turned to facilitate the
removal of the gate rotor support. On dual gate
versions, repeat the procedure for the remaining
gate rotor support assembly.
36
Service
INSTALLATION (All VSG Models)
A) Install the gate rotor support by carefully tilting
the roller bearing end of the gate rotor support
towards the suction end of the compressor. The
compressor input shaft may have to be rotated
to facilitate the installation of the gate rotor support.
Install gate rotor stabilizer. The gate rotor stabilizer (901) will hold the gate rotor support
in place as the thrust bearing housing is being
installed. If the gate rotor support is not restricted from moving, the gate rotor blade may
be damaged.
B) Install the roller bearing housing (112) with a
new O-ring (141). Tighten the bolts (152) to the
recommended torque value.
C) When installing the thrust bearing housing
(113), a new O-ring (142) must be used when
the housing is installed. Lubricate the outside of
the housing and bearings with clean compressor
oil to aid in the installation. Due to the fit of the
bearings on the gate rotor shaft, the thrust bearing removal and installation tool with the pusher
shoe must be used. Turn the jacking screw clockwise. This will push the thrust bearings onto the
shaft and push the housing assembly into the
frame. Install the inner retainer (115) and bolts
(151) using Loctite® 242 thread locker. Tighten
the bolts to the recommended torque value.
37
Service
D) Set the clearance between the gate rotor blade
and the shelf.
1.
Place a piece of 0.003”-0.004” shim stock
between the gate rotor blade and the shelf.
2.
Measure the depth from the top of the compressor case to the top of the thrust bearing
housing. This determines the amount of
shims needed for the correct clearance.
3.
Use factory installed shim pack (106) and
bearing housing cover (116) without the Oring (143). Check the clearance between the
entire gate rotor blade and the shelf, rotate
the gate rotor to find the tightest spot. It
should be between 0.003”-0.004”. Make
adjustments, if necessary. It is preferable to
shim the gate rotor blade looser rather than
tighter against the shelf.
Note: Replacement blades are precisely the same
dimensionally as blades installed originally at factory: Therefore, the same amount of shims will be
required for replacement blades.
E) After clearance has been set install a new O-ring
(143) on bearing housing cover, install cover and
tighten the bolts to the recommended torque
value.
F) Install side cover with a new gasket. Tighten the
bolts to the recommended torque value. The
unit can then be evacuated and leak checked as
outlined in section 0.03.
38
Service
INSTALLATION (All VSG 301-701 Models)
A) Install the gate rotor support. Carefully tilt the
roller bearing end of the gate rotor support towards the suction end of the compressor. The
compressor input shaft may have to be rotated
to facilitate the installation of the gate rotor
support.
B) Install the roller bearing housing with a new
O-ring. Tighten the bolts to the recommended
torque value.
C) Install the spindle with shims and o-ring, tighten
the bolts to the recommended torque value,
measure the clearance between the shelf and
blade.
Gaterotor for C-flange Models
D) Check the clearance between the entire gate
rotor blade and the shelf, rotate the gate rotor
to find the tightest spot. It should be between
0.003”-0.004”. Make adjustments, if necessary.
It is preferable to shim the gate rotor blade
looser rather than tighter against the shelf.
E) Once the clearance is set remove the spindle.
Install new o-ring, apply Loctite 242 thread
locker to the socket head cap screw clamping
the thrust bearings to the spindle. Torque all
bolts to the recommended torque values.
F) Install side covers with new gaskets. Tighten
bolts to the recommended torque value. The
unit can now be evacuated and leak checked as
outlined in section 0.03.
39
Service
GATE ROTOR BLADE REMOVAL
A) Remove the gate rotor assembly.
B) Remove the snap ring and washer from the gate
rotor assembly. Lift gate rotor blade assembly off
the gate rotor support.
C) Check damper pin and bushing for excessive wear.
Replace if necessary.
TOP of assembly
Relief area faces TOP of assembly.
40
Service
GATE ROTOR BLADE INSTALLATION
(with Relief)
A) Install damper pin bushing (120) in gate rotor
blade (111) from the back side of the blade. Be
sure the bushing is fully seated.
B) Place the blade assembly on the gate rotor support. Locating Damper over pin.
C) Install washer (119) and snap ring (130) on gate
rotor assembly. The bevel on the snap ring must
face away from the gate rotor blade. After the
gate rotor blade and support are assembled,
there should be a small amount of rotational
movement between the gate rotor and support.
D) For installation of the gate rotor assembly and
setting of gate rotor clearance, refer to section
INSTALLATION (All VSG 301-701 Models).
GATE ROTOR THRUST BEARING REMOVAL
A) Refer to section INSTALLATION (All VSG Models)
for removal of the gate rotor bearing housings
and gate rotor supports.
B) For removal of thrust bearings on VSG units:
1) Remove bolts (150) from the clamping ring
(114).
2) Remove thrust bearing clamping ring.
3) Remove thrust bearings (126) from housing
(113).
C) For removal of thrust bearings on VSSG units:
1) Remove retaining ring from gate rotor support.
2) Remove bearings from support.
3) Remove bearing retainer from inner race.
41
Service
GATE ROTOR THRUST BEARING INSTALLATION
A) For installation of thrust bearings on VSG and
VSSG units:
1) Install bearings (126) in the housing so the
bearings are face to face.
The larger sides of the inner races are
placed together. A light application of
clean compressor lubricating oil should
be used to ease the installation of the
bearings into the housing.
2) Center the bearing retainer ring on housing, use Loctite® 242-thread locker and
evenly tighten the bolts to the recommended torque value.
3) For installation of the bearing housing and
the setting of the gate rotor blade clearance, refer to section INSTALLATION (All
VSG Models).
B) For installation of thrust bearings on VSG 301701 units:
Inner Retainer
1) Install retainer in the back of the inner race
of one of the thrust bearings. The back of
the inner race is the narrower of the two
sides.
2) The bearing with the retainer should
be placed in the housing first, retainer
towards the support. Install the second
bearing. The bearings should be positioned face to face. This means that the
larger sides of the inner races are placed
together. A light application of clean compressor lubricating oil should be used to
ease the installation of the bearings into
the gate rotor support.
3) Install the bearing retaining snap ring.
4) For installation of the bearing housing and
the setting of the gate rotor blade clearance, refer to section INSTALLATION (All
VSG Models).
42
Retaining Ring
Ball Bearings
Service
GATE ROTOR ROLLER BEARING REMOVAL
A) Refer to section REMOVAL ( All VSG) for removal
of the gate rotor bearing housings and gate rotor
supports.
B) Remove the snap ring (131), which retains the
roller bearing in the bearing housing.
C) Remove the roller bearing (125) from the bearing
housing (112).
D) Use a bearing puller to remove the roller bearing
race (125) from the gate rotor support (110).
GATE ROTOR ROLLER BEARING INSTALLATION
A) Match up the part numbers on the inner race to
the part numbers outer race. Press the bearing
race (numbers visible) onto the gate rotor support.
B) Install the outer bearing into the bearing housing
so the numbers match the numbers on the inner
race. Install the snap ring retainer in the housing.
The bevel on the snap ring must face away from
the roller bearing.
C) For installation of the bearing housing, refer to
section INSTALLATION (All VSG Models).
43
Service
COMPRESSOR SHAFT SEAL REPLACEMENT
Seal with stationary mirror face (219B) and
rotating carbon face (219C).
Seal with stationary carbon face (219B)
and rotating mirror face (219C).
COMPRESSOR SHAFT SEAL REMOVAL
A) Prepare the compressor for servicing as outlined
in section REMOVAL ( All VSG) .
B) Remove bolts (281) holding the shaft seal cover
(218). Insert two of the bolts into the threaded
jacking holes to assist in removing the cover.
There will be a small amount of oil drainage as
the cover is removed.
C) Remove the rotating portion of the shaft seal
(219C).
D) Remove oil seal (230) from cover.
E) Remove the stationary portion of the shaft seal
(219B) from the seal cover using a brass drift and
hammer to tap it out from the back side of the
seal cover.
44
Current Shaft Seal and for all Replacement.
Service
COMPRESSOR SEAL INSTALLATION
NOTE:
When replacing the stationary members of the seal on
the VSSG 291 thru VSSG 601 the roll pin in the cover
is used only with the seal assembly having a stationary mirror face. If a seal assembly with a stationary
carbon face is installed, the roll pin must be removed.
A) Install new oil seal in cover.
CAUTION
Care must be taken when handling the shaft seal and
mirror face so it is not damaged. Do not touch the
carbon or mirror face as body oil and sweat will cause
the mirror face to corrode.
B) To install the carbon cartridge part of the seal
in the seal cover; clean the seal cover, remove
protective plastic from the carbon cartridge, do
not wipe or touch the carbon face. Lubricate the
sealing O-ring with clean compressor lubricating
oil. If applicable, align the hole on the back of
the carbon cartridge with the dowel pin in the
seal cover. Install cartridge using seal installation
tool or similar (see tool lists).
C) Wipe clean, the compressor input shaft and the
shaft seal cavity in the compressor housing. Apply clean compressor oil to the shaft seal seating
area on input shaft.
D) Lubricate the inside area of the rotating seal with
clean compressor lubricating oil, do not wipe
or touch the face of the rotating portion of the
seal. Align the slot in the rotating seal with the
drive pin on the compressor input shaft. Carefully push the seal on, holding onto the outside
area of the seal until the seal seats against the
45
Service
shoulder on the input shaft. Make sure the seal
is seated against the shoulder. If the seal is not
fully seated against the shoulder, the shaft seal
carbon will be damaged when the seal cover is
installed.
Maintenance Suggestion:
A spray bottle filled with clean compressor oil
may be used to lubricate the faces of the seals
without touching the seal.
E) Install a new O-ring on the seal cover, making
sure the O-ring is placed in the O-ring groove
and not the oil gallery groove. Lubricate both
seal faces with clean compressor lubricating oil.
F) Carefully install the seal cover on the compressor
shaft, evenly tightening the bolts to the recommended torque values.
G) Install the coupling and coupling guard. The unit
can then be evacuated and leak checked.
46
MAIN ROTOR ASSEMBLY
Due to the procedures and tools involved in the disassembly and reassembly, the main rotor assembly must
be performed by qualified individuals.
Please consult the factory if maintenance is required.
Service
INSPECTION OF SLIDE VALVE ASSEMBLIES IN
THE COMPRESSOR
Prepare the compressor for servicing.
A) Remove the gate rotor access covers. Using a
mirror and flashlight, visually inspect the slide
valve carriage through the gas bypass opening.
Look for any significant signs of wear on the slide
valve carriage.
B) To check the clearance of the slide valve clamps,
the gate rotor support must be removed. Refer
to removal of the gate rotor support.
C) Using a feeler gauge, inspect the clearance between capacity and volume slide valve clamps
and slide valve carriage through the gas bypass
opening. The clearance should be less than
0.002”.
D) If the slide valves are worn in excess of the tolerances, the factory should be contacted.
REMOVAL SLIDE VALVE CARRIAGE ASSEMBLIES
A) Prepare the compressor for servicing.
B) If only one of the slide valve carriages is removed
only the corresponding gate rotor support
needs to be removed. If both carriages are
removed both gate rotors must be removed.
Remove the gate rotor assemblies.
C) Remove the capacity and volume actuators.
Remove the discharge manifold, capacity and
volume cross shafts and the slide valve racks.
47
Service
D) Locate and remove the socket head plugs above
the slide valve carriage attachment bolts. Remove the bolts located under the plugs.
E) The slide valve carriage may now be removed.
On newer carriages there is a threaded hole in
the back of the slide valve carriage to aid in its
removal. Use a threaded tip slide hammer to aid
in the removal of the carriage.
Note: Slide Valves may be re-positioned to aid in
removal of assembly.
INSTALLATION OF SLIDE VALVE CARRIAGE ASSEMBLIES
A) Position the slide valves to the center of the carriage. Place the slide valve assembly in the bore of
frame and use the slide hammer to slowly tap the
carriage into position. Re-positioning slide valves
once inside bore may aid installation. Adjust the
carriage so that the 3-holes line up.
B) Install the 3 socket head cap screws with new
Nord-Lock washers beneath the heads, but do
not tighten them.
C) Work a piece of 0.005”shim stock between the
slide valves and the main rotor to help position
the carriage.
D) Tighten, to the correct torque the hold down
bolts to secure the carriage in the frame. The
edges of the slide valves themselves should be
at or slightly below the main rotor bore.
E) Re- Install the capacity and volume slide valve
cross shafts, slide valve racks and discharge
manifold.
F) Re-install the gate rotor assemblies.
48
Service
COMMAND SHAFT ASSEMBLY REMOVAL
The following steps can be used to remove or install
either the capacity or volume command shaft assemblies.
A) Prepare the compressor for servicing.
B) Follow the appropriate instructions to remove
control actuator.
.
C) Remove four socket head cap screws (457) and
Nord-Lock washers (477) securing mounting
plate (415) to manifold.
D) The command shaft and mounting plate may
now be removed from the compressor.
457 477
415
B) Install the actuator mounting plate with the four
socket head cap screws and Nord-Lock washers
securing it with proper torque.
C) The unit can now be leak checked.
COMMAND SHAFT BEARING AND O-RING SEAL
REPLACEMENT
A) Remove command shaft assembly.
B) Remove snap ring retainer (451) from command
shaft housing (412). Push the command shaft assembly out of the housing.
COMMAND SHAFT ASSEMBLY INSTALLATION
A) Install the command shaft assembly with a new
o-ring (446) on the manifold. Make sure that the
command shaft tongue is engaged in the cross
shaft slot. Rotate the bearing housing so the
vent holes point down, this will prevent water
and dust from entering the vents.
49
Service
C) The command shaft bearing (435) is a press
fit on the command shaft (413). Remove the
command shaft bearing with a suitable press.
Ven t ho le.
436
445
Reference “Parts
Section” for current
Housing
DISCHARGE MANIFOLD REMOVAL
A) Remove both control actuators and command
shaft assemblies.
B) On VSG751-2101 and VSSG 291-601 compressors, remove the discharge spool between the
manifold and separator. Remove one bolt from
each side of the discharge manifold and install
(2) guide rods approximately 6” long, to support
the manifold. Remove the remaining bolts (note
length and location of bolts) and take off the
discharge manifold.
D) Remove the O-ring seal (445) from the command shaft housing. The command shaft bushing (433 and 436) might have to be removed to
gain access to o-rings. Replace bushing if the
bore is deeply scored or excessively worn.
Note: Mainfold has dowel pins to locate it on the
compressor housing. Therefore, remove manifold
straight back approximately 1” as not to break
dowel pins.
COMMAND SHAFT BEARING AND O-RING
SEAL REASSEMBLY
A) Install new O-ring seal in housing and lubricate
the O-ring with clean compressor oil. A vent
hole is provided in the command shaft bearing
housing to allow any refrigerant and oil that may
leak past the O-ring seal to vent to atmosphere
and not into the slide valve motor housing.
Install snap ring retainer and washer on the
command shaft.
B) Remove any burrs from the command shaft to
prevent damage to the O-ring when assembling.
Press the command shaft bearing onto the
command shaft. Insert the command shaft into
the housing applying pressure on outer race of
bearing. Make sure the bearing is fully seated
in the command shaft housing. Install the snap
ring retainer in the command shaft housing.
C) Install command shaft assembly.
50
NOTE:
When removing the discharge manifold on VSG 301-701
compressor the compressor must be properly supported
to keep the compressor from moving when the manifold
is removed.
C) On VSG 301-701 compressors unbolt the discharge flange from the discharge manifold.
D) Remove one bolt from each side of the discharge
manifold and install (2) guide rods approximately
6” long, to support the manifold. Remove the
remaining bolts (note length and location of bolts)
and take off the discharge manifold.
Service
DISCHARGE MANIFOLD INSTALLATION
A) Install (2) guide rods to position the discharge
manifold. Install a new manifold gasket and
the discharge manifold. Install the dowel pins
and bolts, tighten manifold bolts to the recommended torque value.
B) On VSG 751-2101 and VSSG 291-601 compressors install the discharge spool or elbow between the discharge manifold and oil separator
with new gaskets. When installing the discharge
elbow tighten the bolts to the correct torque on
the manifold flange first before tightening the
separator flange bolts. Install the drain plug in
the bottom of the discharge manifold.
C) On VSG 301-701 compressors install the bolts
in the discharge flange. Install the drain plug in
the bottom of the discharge manifold.
D) Install both command shaft assemblies and
control actuators.
SLIDE VALVE GEAR AND RACK INSPECTION
A) Remove the discharge manifold.
B) Check rack to rack clamp and rack clamp spacer
clearance on all four slide valves.
F) Look for any excessive wear on all moving parts
and replace the worn parts.
G) Reassemble the manifold and discharge elbow.
REMOVAL OF CAPACITY OR VOLUME CROSS
SHAFTS
A) Remove the discharge manifold.
B) To remove the capacity or volume ratio slide
valve racks, remove the two jam nuts and lock
washers (361) securing the rack (316) to the slide
valve shafts. The racks can now be pulled off the
slide valve shafts. Repeat the procedure for the
remaining pair of slide valve racks.
TABLE 4.1
RACK CLEARANCE VALUES
MEASUREMENT
Rack to clamp.
Rack to clamp spacer.
CLEARANCE
0.005 to 0.010”
0.003 to 0.005”
C) Check torque of socket heat cap screws.
D) Check for excessive movement between the
slide valve rack shafts and the rack. The jam nuts
on the end of the slide valve rack shaft should be
tight.
E) Check for loose or broken roll pins in gears.
51
Service
C) To remove the cross shafts, remove socket head
bolts, clamp and spacers from both sides.
VSG 751-2101 compressors cross shafts.
INSTALLATION OF CAPACITY OR VOLUME
CROSS SHAFTS
A) To reassemble either set of capacity or volume
ratio slide valve racks, install the cross shaft with
the pinion gear onto the back plate, place the
remaining pinion gear on the shaft and drive in
the roll pins. Install clamps, spacers and bolts
on both sides. Tighten the bolts to the recommended torque values.
VSSG 291-601 compressors cross shafts
Volume control cross shaft.
B) The slide valve sets must be synchronized on VSG
751-2101 and dual gate VSG 301-701 units. Both
slide valve racks for either the volume ratio or
capacity slide valves must engage the cross shaft
gears at the same time. Push the racks all the way
towards the suction end of the compressor until
they stop. Install washers and jam nuts on the
slide valve shafts. Repeat the procedure for the
remaining set of slide valve racks.
Capacity control cross shaft.
D) Drive the roll pins from pinion gear from one
side. Remove pinion gear. Slide the cross shaft
with the remaining pinion gear or spacers out of
the opposite side. Repeat the procedure for the
remaining cross shaft.
52
C) Install (2) guide rods to position the discharge
manifold. Install a new manifold gasket and
the discharge manifold. Install the dowel pins
and bolts, tighten manifold bolts to the recommended torque value.
D) On VSG 751-2101 and VSSG 291-601 and VSG
301-701 compressors install the discharge.
Service
TORQUE SPECIFICATIONS (ALL UNITS IN FT.-LBS)
TYPE BOLT
HEAD
MARKINGS
1
/4”
5
OUTSIDE DIAMETER OF BOLT SHANK
3
7
1
9
5
/16”
/8”
/16”
/2”
/16”
/8”
3
/4”
SAE GRADE 2
6
12
20
32
47
69
96
155
SAE GRADE 5
10
19
33
54
78
114
154
257
SAE GRADE 8
14
29
47
78
119
169
230
380
SOCKET HEAD CAP SCREW
16
33
54
84
125
180
250
400
TORQUE SPECIFICATION FOR 17-4 STAINLESS STEEL FASTENERS (FT-LBS)
TYPE ¼”
5/16” 3/8” 7/16” ½”
9/16” 5/8” ¾”
HEX & SOCKET
HEAD CAP
SCREW
8
14
101
NUT
8
25
40
60
137
245
NOTE: CONTINUE USE OF RED LOCTITE ON CURRENTLY APPLIED LOCATIONS. USE BLUE
LOCTITE ON ALL REMAINING LOCATIONS.
53
Service
USING A TORQUE WRENCH CORRECTLY
TORQUE WRENCHES
USING A TORQUE WRENCH CORRECTLY INVOLVES FOUR PRIMARY CONCERNS:
A. A smooth even pull to the break point is required. Jerking the wrench can cause the pivot point
to break early leaving the bolt at a torque value lower then required. Not stopping when the
break point is reached results in an over torque condition.
B. When more than one bolt holds two surfaces together there is normally a sequence that
should be used to bring the surfaces together in an even manner. Generally bolting is tightened incrementally in a diametrically staggered pattern. Some maintenance manuals specify
a tightening scheme. If so, the manual scheme shall be followed. Just starting on one side and
tightening in a circle can cause the part to warp, crack, or leak.
C. In some cases threads are required to be lubricated prior to tightening the bolt/nut. Whether
a lubricant is used or not has considerable impact on the amount of torque required to achieve
the proper preload in the bolt/stud. Use a lubricant, if required, or not if so specified.
D. Unlike a ratchet wrench a torque wrench is a calibrated instrument that requires care. Recalibration is required periodically to maintain accuracy. If you need to remove a bolt/nut do not
use the torque wrench. The clockwise/counterclockwise switch is for tightening right hand or
left hand threads not for loosening a fastener. Store the torque wrench in a location where it
will not be bumped around.
54
Service
A. The Nord-Lock® lock washer sets are used in many
areas in both the VSG & VSSG screw compressors that
require a vibration proof lock washer.
B. The lock washer set is assembled so the course
serrations that resemble ramps are mated together.
C. Once the lock washer set is tightened down, it
takes more force to loosen the bolt that it did to
tighten it. This is caused by the washers riding up
the opposing ramps.
55
56
Parts Section
Recommended
Spare Parts List
Refer to the Custom Manual
Spare Parts Section for Specific Applications
Please have your Model # and Sales Order # available when ordering.
These are found on the compressor’s Name Plate.
57
Gate Rotor
58
Gate Rotor
MODEL NUMBER
ITEM DESCRIPTION
VSSG 451
VSSG 601
QTY VPN
QTY VPN
GATE ROTOR BLADE AND BEARING
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126,
130, 131, 141, 142 & 143.
GATE ROTOR BLADE REPLACE
KIT, 111, 118, 120A, 120B, 121, 122,
123, 124, 130, 141, 142 & 143.
GATE ROTOR SUPPORT ASSEMBLY
100, 111, 120B, 119 & 130.
GATE ROTOR GASKET SET 118, 141,
142 & 143.
SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124.
SUPPORT.
GATE ROTOR.
2
2
2
A25165B
25606A
25557A
2
2
2
112
113
114
115
116
117
118
119
120A
120B
121
122
123
124
125
126
130
131
135A
135B
141
142
143
150
151
152
153
160
SMALL BEARING HOUSING.
LARGE BEARING HOUSING.
RETAINER.
RETAINER.
BALL BEARING COVER.
GATE ROTOR COVER.
GATE ROTOR COVER GASKET.
WASHER.
BUSHING, SMALL DOWEL PIN.
BUSHING, LARGE DOWEL PIN.
SHIM 0.002”.
SHIM 0.003”.
SHIM 0.005”.
SHIM 0.010”.
ROLLER BEARING.
BALL BEARING.
RETAINING RING.
RETAINING RING.
DOWEL PIN, SM, 0.250” O.D..
DOWEL PIN, LG, 0.4375” O.D..
O-RING ROLLER BRG HSG.
O-RING BALL BRG HSG.
O-RING BRG HSG COVER.
HEX HEAD CAP SCREW.
HEX HEAD CAP SCREW.
HEX HEAD CAP SCREW.
HEX HEAD CAP SCREW.
SOCKET HEAD CAP SCREW.
2
2
2
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
12
6
40
32
12
25518A
25517A
25008A
25009A
25258A
25519A
25259A
25007A
25006A
25760A
25010AA
25010AB
25010AC
25010AD
2864B
2865B
2866A
2867A
2868B
25910A
2176M
2176R
2176N
2796AJ
2796B
2796CJ
2796E
2795E
2
2
2
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
12
6
40
32
12
102
105
106
110
111
2
KT712A
2
KT712B
2
KT713A
2
KT713B
2
A25161BB 2
A25161BA
2
A25164B
2
A25164B
A25165B
25520A
25534A
25518A
25517A
25008A
25009A
25258A
25519A
25259A
25007A
25006A
25760A
25010AA
25010AB
25010AC
25010AD
2864B
2865B
2866A
2867A
2868B
25910A
2176M
2176R
2176N
2796AJ
2796B
2796CJ
2796E
2795E
NOTE: ar = As Required
59
Gate Rotor
ITEM DESCRIPTION
GATE ROTOR BLADE AND BEARING
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126,
130,131, 141, 142 & 143.
GATE ROTOR BLADE REPLACE
KIT, 111, 118, 120A, 120B, 121, 122,
123, 124, 130, 141, 142 & 143.
102
GATE ROTOR SUPPORT ASSEMBLY
100, 111, 120B, 119 &130
105
GATE ROTOR GASKET SET 118, 141,
142 & 143.
SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124.
110
SUPPORT.
111
GATE ROTOR.
118
GATE ROTOR COVER GASKET.
119
WASHER.
120A BUSHING, SMALL DOWEL PIN.
120B BUSHING, LARGE DOWEL PIN.
121*
SHIM 0.002”.
122*
SHIM 0.003”.
123*
SHIM 0.005”.
124*
SHIM 0.010”.
125
ROLLER BEARING.
126
BALL BEARING.
130
RETAINING RING.
131
RETAINING RING.
135A DOWEL PIN, SMALL, 0.3125” O.D..
135B DOWEL PIN, LARGE, 0.4375” O.D..
141
O-RING ROLLER BRG HSG.
142
O-RING BALL BRG HSG.
143
O-RING BRG HSG COVER.
ar = As Required
60
VSG 751
QTY VPN
VSG 901
QTY VPN
VSG 1051
QTY VPN
VSG 1201
QTY VPN
2
KT712C
2
KT712D
2
KT712E
2
KT712F
2
KT713C
2
KT713D
2
KT713E
2
KT713F
2
A25161CB 2
A25161CA 2
A25161DB 2
A25161DA
2
A25164C
2
A25164C
2
A25164D
2
A25164D
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
A25165C
25612A
25608A
25088A
25086A
25087A
25760B
25089AA
25089AB
25089AC
25089AD
2864C
2865A
2866B
2867E
2868F
25910B
2176N
2176V
2176U
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
A25165C
25553A
25554A
25088A
25086A
25087A
25760B
25089AA
25089AB
25089AC
25089AD
2864C
2865A
2866B
2867E
2868F
25910B
2176N
2176V
2176U
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
A25165C
25614A
25610A
25132A
25086A
25104A
25760B
25089AA
25089AB
25089AC
25089AD
2864G
2865A
2866B
2867L
2868H
25910B
2176AJ
2176AM
2176U
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
A25165C
25587A
25588A
25132A
25086A
25104A
25760B
25089AA
25089AB
25089AC
25089AD
2864G
2865A
2866B
2867L
2868H
25910B
2176AJ
2176AM
2176U
Gate Rotor
ITEM
DESCRIPTION
VSG 1551
QTY
VPN
GATE ROTOR BLADE AND BEARING
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126, 130,
131, 141, 142 & 143.
2
KT712M
GATE ROTOR BLADE REPLACEMENT
KIT, 111, 118, 120A, 120B, 121, 122, 123,
124, 130, 141, 142 & 143.
2
KT713N
101
GATE ROTOR ASSEMBLY 111 & 120.
2
A25160EB
102
GATE ROTOR SUPPORT ASSEMBLY
100, 111, 120B, 119 &130.
2
A25161EB
105
GATE ROTOR GASKET SET 118, 141,
142 & 143.
2
A25164E
SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124.
2
A25165E
110
SUPPORT.
2
25687A
111
GATE ROTOR.
2
25647A
112
SMALL BEARING HOUSING.
2
25667A
113
LARGE BEARING HOUSING.
2
25669A
114
RETAINER.
2
25141A
115
RETAINER.
2
25789A
116
BALL BEARING COVER.
2
25351A
117
GATE ROTOR COVER.
2
25354A
118
GATE ROTOR COVER GASKET.
2
25790A
119
WASHER.
2
25788A
120A
BUSHING, SMALL DOWEL PIN.
2
25104A
120B
BUSHING, LARGE DOWEL PIN.
2
25760C
121*
SHIM 0.002”.
ar
25791AA
122*
SHIM 0.003”.
ar
25791AB
123*
SHIM 0.005”.
ar
25791AC
124*
SHIM 0.010”.
ar
25791AD
125
ROLLER BEARING.
2
2864K
126
BALL BEARING.
4
2865K
130
RETAINING RING.
2
2866G
131
RETAINING RING.
2
2867R
135A
DOWEL PIN, SMALL, 0.375” O.D..
2
2868H
135B
DOWEL PIN, LARGE, 0.500” O.D..
2
25910C
141
O-RING ROLLER BRG HSG.
2
2176U
142
O-RING BALL BRG HSG.
2
2176BD
143
O-RING BRG HSG COVER.
2
2176P
150
HEX HEAD CAP SCREW.
12
2796CJ
151
HEX HEAD CAP SCREW.
8
2796N
152
HEX HEAD CAP SCREW.
32
2796CJ
153
HEX HEAD CAP SCREW.
44
2796R
160
SOCKET HEAD CAP SCREW.
16
2795G
VSG1851
QTY
VPN
VSG 2101
QTY
VPN
2
KT712L
2
KT712K
2
2
KT713M
A25160EA
2
2
KT713L
A25160EA
2
A25161EA
2
A25161EL
2
A25164E
2
A25164E
2
2
2
2
2
2
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
12
8
32
44
16
A25165E
25665A
25645A
25667A
25669A
25141A
25789A
25351A
25354A
25790A
25788A
25104A
25760C
25791AA
25791AB
25791AC
25791AD
2864K
2865K
2866G
2867R
2868H
25910C
2176U
2176BD
2176P
2796CJ
2796N
2796CJ
2796R
2795G
2
2
2
2
2
2
2
2
2
2
2
2
2
ar
ar
ar
ar
2
4
2
2
2
2
2
2
2
12
8
32
44
16
A25165E
25495D
25744D
25667A
25669A
25141A
25789A
25351A
25354A
25790A
25788A
25104A
25760C
25791AA
25791AB
25791AC
25791AD
2864K
2865K
2866G
2867R
2868H
25910C
2176U
2176BD
2176P
2796CJ
2796N
2796CJ
2796R
2795G
ar = As required
61
Shaft Seal
Shaft Seal With Stationary Carbon Face
62
ITEM DESCRIPTION
SHAFT SEAL VITON KIT, 219, 260, 230
MODEL NUMBER
VSSG 291-601
VSG 751-1201
VSG 1551 thru 2101
QTY VPN
QTY VPN
QTY VPN
1
KT709AG 1
KT709BG 1
KT709CG
230
260
1
1
OIL SEAL.
O-RING.
25040A
2176F
1
1
25064A
2176AC
1
1
2930B
2176BH
Tandem Shaft Seal
DESCRIPTION
TANDEM SHAFT SEAL
2.25”
QTY VPN
1
25713A
1
25713B
SHAFT DIAMETER
2.5”
QTY VPN
QTY
1
25713A
1
1
25713B
1
2.875”
VPN
25713A
25713B
63
Main Rotor
64
65
207
SHIM PACK 1 A25177B
1 A25177B
ITEM DESCRIPTION
VSSG 451
VSSG 601
QTY PART#
QTY PART#
201
ROTOR ASSY 1 A25168BB 1 A25168BA
(DOES NOT INCLUDE
SHIM PACK #207)
MODEL NUMBER
A25168CB
1 A25177C
1
1
1
A25177C
A25168CA
VSG 751
VSG 901
QTY PART# QTY PART#
1 A25177D
1 A25168DB
VSG 1051 QTY PART#
1 A25177D 1
A25177E
1 A25168DA 1 A25168EB
VSG 1201 VSG 1551
QTY PART# QTY PART#
1
1
A25177E
A25168AE
VSG 1851
QTY PART#
1
1
A25177E
A25225EE
VSG 2101
QTY PART#
Slide Valve Cross Shafts and End Plate
66
Slide Valve Cross Shafts and End Plate
ITEM DESCRIPTION
221
SHAFT.
222
GEAR.
226
RACK CLAMP.
227
RACK CLAMP.
228
SPACER.
268
EXPANSION PIN.
269
EXPANSION PIN.
286
SOCKET HEAD CAP SCREW.
297
SET SCREW
298
SET SCREW
ITEM DESCRIPTION
220
END PLATE
221
SHAFT.
222
GEAR.
226
RACK CLAMP.
228
SPACER.
267
DOWEL PIN.
268
EXPANSION PIN.
269
EXPANSION PIN.
270
PIPE PLUG.
286
SOCKET HEAD CAP SCREW.
297
SET SCREW
298
SET SCREW
MODEL NUMBER
VSSG 291-601
QTY
VPN
2
25843A
4
25027A
2
25913A
2
25913B
2
25847A
4
1193D
4
2981AA
8
2795F
2
2060J
2
2060H
MODEL NUMBER
VSG 751 & VSG 901
VSG 1051 & VSG 1201
QTY VPN
QTY
VPN
1
25543A
1
25593A
2
25844A
2
25845A
4
25027A
4
25027A
4
25913C
4
25913C
4
25033C
4
25033C
2
2868B
2
2868B
4
1193D
4
1193D
4
2981AA
4
2981AA
2
2606E
2
2606E
8
2795F
8
2795F
2
2060J
2
2060J
2
2060H
2
2060H
MODEL NUMBER
ITEM DESCRIPTION
VSG 1551Thru VSG 2101
QTY
VPN
220
END PLATE
1
25661A
221
SHAFT.
2
25793A
222
GEAR.
4
25027A
226
RACK CLAMP.
4
25913C
228
SPACER.
4
25033C
267
DOWEL PIN.
2
2868B
268
EXPANSION PIN.
4
1193D
269
EXPANSION PIN.
4
2981AA
270
PIPE PLUG.
2
2606A
286
SOCKET HEAD CAP SCREW.
8
2795F
297
SET SCREW
2
2060J
298
SET SCREW
2
2060H
67
68
Capacity Slide
Volume Slide
Carriage Assembly
Slide Valve Carriage Assembly
Slide Valve Carriage Assembly
ITEM DESCRIPTION
300
CARRIAGE ASSEMBLY.
304
CAPACITY PISTON 340, 341, 350 & 355
305
VOLUME PISTON 340, 342, 350 & 355
307
GASKET SET 345B.
316
RACK.
323
RACK.
343A COVER, SEPARATE VOL. & CAP.
343B COVER, ONE PIECE CAST.
345A GASKET, SEPARATE VOL. & n/a
CAP COVERS.
345B GASKET, ONE PIECE CAST COVER.
350
PISTON RING SET.
355
EXPANSION PIN.
359
PIPE PLUG.
360
LOCK WASHER (PAIR).
361
WASHER.
363
NUT.
366A HEX HEAD CAP SCREW, SEPARATE
VOL. & CAP COVERS.
366B HEX HEAD CAP SCREW, ONE PIECE
CAST COVER.
MODEL NUMBERVSSG 291 Thru VSSG 601
QTY
2
2
2
2
2
2
4
2
VPN
A25179B
A25183B
A25184B
A25200B
25024A
25023A
25022A
25399A
4
2
4
4
6
4
4
8
25021A
25900A
2953AA
1193PP
2606D
3004C
13265B
2797A
24
2796N
24
2796B
69
Slide Valve Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION
VSG 751
QTY VPN
300
CARRIAGE ASSEMBLY.
2
A25179C
304
CAPACITY PISTON 340, 341, 350 & 355.2
A25183C
305
VOLUME PISTON 340, 342, 350 & 355. 2
A25184C
307
GASKET SET 345B & 378**.
2
A25200C
316
RACK.
2
25080A
323
RACK.
2
25080B
340
PISTON.
4
25076A
341
CAPACITY PISTON SHAFT.
2
25078A
342
VOLUME PISTON SHAFT.
2
25078B
343A COVER, SEPARATE VOL. & CAP.
2
25123B
343B COVER, ONE PIECE CAST.
2
25279A
344
COVER, SEPARATE VOL. & CAP.
2
25123A
345A GASKET, SEPARATE VOL. &
CAP COVERS.
2
25124B
345B GASKET ONE PIECE CAST COVER. 2
25902A
346
GASKET, SEPARATE VOL. & CAP
COVERS.
2
25124A
347
PISTON SLEEVE.
2
25079A
350
PISTON RING SET.
4
2953AB
355
EXPANSION PIN.
4
1193PP
359
PIPE PLUG.
6
2606D
360
LOCK WASHER (PAIR).
4
3004C
361
WASHER.
4
13265B
363
NUT.
8
2797A
366A HEX HEAD CAP SCREW.
12
2796B
366B HEX HEAD CAP SCREW.
12
2796P
367
HEX HEAD CAP SCREW.
12
2796BN
373
SOCKET HEAD CAP SCREW.
6
2795N
374
LOCK WASHER (PAIR).
6
3004C
378
0-RING.
2
2176Y
380
RETAINER RING.
2
2866C
70
VSG 901
QTY VPN
2
A25179C
2
A25183C
2
A25184C
2
A25200C
2
25080A
2
25080B
4
25076A
2
25078A
2
25078B
2
25123B
2
25279A
2
25123A
VSG 1051
QTY VPN
2
A25179D
2
A25183D
2
A25184D
2
A25200D
2
25080C
2
25080D
4
25138A
2
25078E
2
25078F
4
25123C
2
25401A
n/a
n/a
VSG 1201
QTY VPN
2
A25179D
2
A25183D
2
A25184D
2
A25200D
2
25080C
2
25080D
4
25138A
2
25078E
2
25078F
4
25123C
2
25401A
n/a
n/a
2
2
25124B
25902A
4
2
25124C
25901A
4
2
25124C
25901A
2
2
4
4
6
4
4
8
12
12
12
6
6
2
2
25124A
25079A
2953AB
1193PP
2606D
3004C
13265B
2797A
2796B
2796P
2796BN
2795N
3004C
2176Y
2866C
n/a
n/a
4
4
6
4
4
8
24
24
n/a
6
6
n/a
n/a
n/a
n/a
2953AC
1193PP
2606E
3004C
13265B
2797A
2796B
2796P
n/a
2795P
3004D
n/a
n/a
n/a
n/a
4
4
6
4
4
8
24
24
n/a
6
6
n/a
n/a
n/a
n/a
2953AC
1193PP
2606E
3004C
13265B
2797A
2796B
2796P
n/a
2795P
3004D
n/a
n/a
Slide Valve Carriage Assembly
ITEM DESCRIPTION
300
CARRIAGE ASSEMBLY.
304
CAPACITY PISTON 340, 341, 350 & 355
305
VOLUME PISTON 340, 342, 350 & 355
307
GASKET SET 345 & 378.
316
RACK.
323
RACK.
325
SHAFT.
340
PISTON.
341
CAPACITY PISTON SHAFT.
342
VOLUME PISTON SHAFT.
343B COVER.
345B GASKET.
347
PISTON SLEEVE.
350
PISTON RING SET.
355
EXPANSION PIN.
359
PIPE PLUG.
360
LOCK WASHER (PAIR).
361
WASHER.
363
NUT.
366B HEX HEAD CAP SCREW.
373
SOCKET HEAD CAP SCREW.
374
LOCK WASHER (PAIR).
378
0-RING.
380
RETAINER RING.
MODEL NUMBER
VSG 1551 to 2101
QTY VPN
2
A25179E
2
A25183E
2
A25184E
2
A25200E
2
25779A
2
25780A
2
25778A
4
25782A
2
25784A
2
25783A
2
25690A
2
25384A
4
25786A
4
2953AD
4
1193PP
6
2606E
4
3004C
4
13265B
8
2797A
28
2796BL
6
2795AG
6
3004D
4
2176AG
4
2755AG
71
Actuator & Command Shaft
72
Actuator & Command Shaft
ITEM
DESCRIPTION
MODEL NUMBER
VSSG 291 thru
VSSG 601
QTY VPN
VSG 751 thru
VSSG 901
VPN
VSG 1051 thru
VSG 1201
VPN
VSG 1551 thru
VSG 2101
VPN
400
401
446
2
2
2
A25994C
25972D
2176X
A25994D
25972D
2176X
A25994E
25972D
2176X
COMMAND SHAFT ASSEMBLY
SLIDEVALVE ACUATOR
O-RING
A25994B
25972D
2176X
73
Miscellaneous Frame Components
VSG Screw Compressor
74
Miscellaneous Frame Components
MODEL NUMBER
ITEM
DESCRIPTION
GASKET AND O-RING KIT; 504
FLANGE SET 513, 514 & 547A.
VSSG 291 thru
VSSG 601
QTY VPN
1
KT710A1
1
A25190A
506
ECON-O-MIZER PORT.
2
A25190B
512
513
513
514
514A
518
519
524
525
527
528
530
532
535
539
540
545
545
547
552
552
553
650
651
MANIFOLD GASKET.
FLANGE OIL.
AFLANGE ECON-O-MIZER.
FLANGE GASKET OIL.
FLANGE GASKET ECON‑O‑MIZER.
SUCTION FLANGE GASKET.
DISCHARGE FLANGE GASKET.
COVER.
GASKET.
INLET SCREEN.
ECON-O-MIZER PLUG.
O-RING
O-RING
PIPE PLUG 1/4” MPT.
PIPE PLUG.
DOWEL PIN.
HEX HEAD CAP SCREW FOR OIL SUPPLY FLANGE.
HEX HEAD CAP SCREW FOR ECON-O-MIZER FLANGE.
HEX HEAD CAP SCREW.
HEX HEAD CAP SCREW.
HEX HEAD CAP SCREW.
HEX HEAD CAP SCREW.
O-RING.
O-RING.
1
1
2
1
2
1
1
n/a
n/a
n/a
n/a
2
n/a
n/a
n/a
2
n/a
2
n/a
4
8
n/a
n/a
n/a
n/a
n/a
25503A
25058A
25058A
11323D
11323D
25199C
25199B
n/a
n/a
n/a
n/a
2176AB
n/a
n/a
n/an/an/a
2868B
n/a
2796C
n/a
2796C
2796C
n/a
n/a
n/a
n/a
n/a
75
Miscellaneous Frame Components
MODEL NUMBER
ITEM DESCRIPTION
VSG 751
VSG 901
VSG 1051
VSG 1201
QTY VPN
QTY
VPN
QTY
VPN
QTY VPN
GASKET AND O-RING KIT;
1
KT710B
1
KT710B
1
KT710C
1
KT710C
504
FLANGE SET 513, 514 & 547.
1
A25190A
1
A25190A
1
A25190B 1
A25190B
512
MANIFOLD GASKET.
1
25541A
1
25541A
1
25324A
1
25324A
513
FLANGE OIL.
1
25058A
1
25058A
1
25058B
1
25058B
514
FLANGE GASKET OIL.
1
11323D
1
11323D
1
11323E
1
11323E
518
SUCTION FLANGE GASKET.
1
25199C
1
25199C
1
25199D
1
25199D
519
DISCHARGE FLANGE GASKET.
1
25199B
1
25199B
1
25199C
1
25199C
526
ORIFICE PLATE.
1
25223CB
1
25223CA
1
25223DB 1
25223DB
529
WAVE SPRING.
1
2912E
1
2912E
1
2912E
1
2912E
530
O-RING
2
2176J
2
2176J
2
2176J
2
2176J
538
PIPE PLUG 3/4” MPT.
6
2606A
6
2606A
540
DOWEL PIN.
2
2868B
2
2868B
2
2868B
2
2868B
547
HEX HEAD CAP SCREW.
21 2796GP
21
2796GP
24
2796GP
24 2796GP
554
HEX HEAD CAP SCREW.
1
2796U
1
2796U
1
2796U
1
2796U
76
Miscellaneous Frame Components
MODEL NUMBER
ITEM DESCRIPTION
VSG 1551 THRU
VSG 2101
QTY VPN
GASKET AND O-RING KIT;
1
KT710D
504 FLANGE SET 513, 514 & 547.
1
A25190C
504 FLANGE SET 513A, 514A & 547
ECON-O-MIZER PORT.
2
A25190D
512 MANIFOLD GASKET.
1
25676A
513 FLANGE OIL.
1
12477C
513A FLANGE ECON-O-MIZER.
514 FLANGE GASKET OIL.
1
11323F
514A FLANGE GASKET ECON-O-MIZER.
518 SUCTION FLANGE GASKET.
1
25199D
519 DISCHARGE FLANGE GASKET.
1
25199C
530 O-RING
2
2176J
538 PIPE PLUG 3/4” MPT.
3
2606A
540 DOWEL PIN.
2
2868K
542 PIPE PLUG 3/4” MPT.
1
13163F
545 HEX HEAD CAP SCREW FOR
OIL SUPPLY FLANGE.
4
11397E
NOTE:*Not pictured
**For VSS 1801 Serial Numbers 819, 820 & 821 only.
77
78
1551
291
Replacement Tools
Replacement Tools
MODEL NUMBER
ITEM DESCRIPTION
900
GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917).
901
GATEROTOR STABILIZER SET
(901A, 901B & 901C).
VSSG 291 thru
VSSG 601
QTY VPN
ITEM DESCRIPTION
900
GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917).
901
GATEROTOR STABILIZER SET
(901A, 901B & 901C).
1
A25205B
1
A25698A
MODEL NUMBER
VSG 751
VSG 901
QTY VPN
QTY VPN
VSG 1051
QTY VPN
VSG 1201
QTY VPN
1
A25205C
1
A25205C
1
A25205C
1
A25205C
1
A25698A
1
A25698A
1
A25698A
1
A25698A
79
Replacement Tools
ITEM DESCRIPTION
900
GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917).
901
GATEROTOR STABILIZER SET
(901A, 901B, 901C & 901D).
80
MODEL NUMBER
VSG 1551 thru
VSG 2101
QTY VPN
1
A25205E
1
A25699A
VSG 301-701 Replacement Parts Section
Recommended
Spare Parts List
Refer to the Custom Manual
Spare Parts Section for Specific Applications
Please have your Model # and Sales Order # available when ordering.
These are found on the compressor’s Name Plate.
81
Gaterotor Assembly
82
Gaterotor Assembly
Part totals indicated are for one gate rotor assembly, machines with two gate rotors will require
double the components listed below.
ITEM DESCRIPTION
100
SUPPORT ASSEMBLY 110 & 135B.
101
GATE ROTOR & DAMPER ASSEMBLY
111,120.
102
GATE ROTOR SUPPORT ASSEMBLY
100, 101, 119 & 130.
SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124.
110
SUPPORT.
111
GATE ROTOR.
114
SNAP RING.
115
RETAINER BALL BEARING
118
GATE ROTOR COVER GASKET.
119
WASHER WAVE SPRING.
120
DAMPER.
121*
SHIM 0.002”.
122*
SHIM 0.003”.
123*
SHIM 0.005”.
124*
SHIM 0.010”.
125
ROLLER BEARING.
126
BALL BEARING.
130
RETAINING RING.
131
RETAINING RING.
132
RETAINING RING.
135
DOWEL PIN
141
O-RING ROLLER BRG HSG.
143
O-RING BALL BRG SUPPORT.
155
SHIM
156
SHIM
MODEL NUMBER
VSG 301
VSG 361
VSG 401
QTY VPN
QTY VPN
QTY VPN
1
A25222AB 1
A25222AA 1
A25222AC
1
A25160AB 1
A25160AA
A25160AC
1
A25161AB 1
A25161AA
A25161AC
1
1
1
1
1
1
1
1
ar
ar
ar
ar
1
2
1
1
1
1
1
1
ar
ar
A25165A
25723D
25718B
2867L
25935A
25259B
3203A
25760A
25921AA
25921AB
25921AC
25921AD
2864F
2865L
2866H
2867S
2866J
25910A
2176L
2176F
25977D
25977C
A25165A
25723C
1
25718C
1
2867L
1
25935A
1
25259B
1
3203A
1
25760A
1
25921AA ar
25921AB ar
25921AC ar
25921AD ar
2864F
1
2865L
2
2866H
1
2867S
1
2866J
1
25910A
1
2176L
1
2176F
1
25977D
ar
25977C
ar
A25165A
25723B
25718D
2867L
25935A
25259B
3203A
25760A
25921AA
25921AB
25921AC
25921AD
2864F
2865L
2866H
2867S
2866J
25910A
2176L
2176F
25977D
25977C
1
1
1
1
1
1
1
1
ar
ar
ar
ar
1
2
1
1
1
1
1
1
ar
ar
ar = As required
83
Gaterotor Assembly
Part totals indicated are for one gate rotor assembly, dual gate machines will require double the components.
ITEM DESCRIPTION
100
SUPPORT ASSEMBLY 110 & 135B.
101
GATE ROTOR & DAMPER ASSEMBLY
111,120.
102
GATE ROTOR SUPPORT ASSEMBLY
100, 101, 119 & 130.
SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124.
110
SUPPORT.
111
GATE ROTOR.
114
SNAP RING.
115
RETAINER BALL BEARING
118
GATE ROTOR COVER GASKET.
119
WASHER.
120
DAMPER.
121*
SHIM 0.002”.
122*
SHIM 0.003”.
123*
SHIM 0.005”.
124*
SHIM 0.010”.
125
ROLLER BEARING.
126
BALL BEARING.
130
RETAINING RING.
131
RETAINING RING.
132
RETAINING RING.
135
DOWEL PIN
141
O-RING ROLLER BRG HSG.
143
O-RING BALL BRG SUPPORT.
155
SHIM
156
SHIM
NOTE:
84
*
Not pictured
ar = As Required
MODEL NUMBER
VSG 501
VSG 601
VSG 701
QTY VPN
QTY VPN
QTY VPN
1
A26011BB 1
A26011BA 1
A26011BA
1
A26002BB 1
A26002BA 1
A26002BC
1
A26003BB 1
A26003BA 1
A26003BC
1
1
1
1
1
1
1
1
ar
ar
ar
ar
1
1
1
1
1
1
1
1
ar
ar
A26035B
26030BB
26032A
2867U
25935B
25259C
25007A
25760A
26027AA
26027AB
26027AC
26027AD
2864B
2865B
2866A
2867A
2866K
25910A
2176M
2176R
25977G
25977H
A26035B
26030BA
26031A
2867U
25935B
25259C
25007A
25760A
26027AA
26027AB
26027AC
26027AD
2864B
2865B
2866A
2867A
2866K
25910A
2176M
2176R
25977G
25977H
A26035B
26030BA
26033A
2867U
25935B
25259C
25007A
25760A
26027AA
26027AB
26027AC
26027AD
2864B
2865B
2866A
2867A
2866K
25910A
2176M
2176R
25977G
25977H
1
1
1
1
1
1
1
1
ar
ar
ar
ar
1
1
1
1
1
1
1
1
ar
ar
1
1
1
1
1
1
1
1
ar
ar
ar
ar
1
1
1
1
1
1
1
1
ar
ar
Shaft Seal
ITEM DESCRIPTION
*
SHAFT SEAL KIT Viton Kit
MODEL NUMBER
ALL VSG 301-401
QTY
VPN
ALL VSG 501-701
QTY
VPN
219, 230, & 260.
1
KT709DG
1
219
230
244-
252-
260
261
SHAFT SEAL.
OIL SEAL.
TEFLON SEAL
RETAINER RING
O-RING
O-RING.(205 Only)
1
1
1
1
1
1
A
1
2930C
1
25939A
1
2928M
1
2176U
1
2176AE
KT709AG
A
25040A
25939A
2928M
2176F
n/a
NOTE *
A
-
Not pictured.
Sold only as kit.
See recommended spare parts lists for complete assembly.
85
Main Rotor, Slide Valve Cross Shafts & End Plate
Models VSG301-401 Counter Clockwise ONLY
86
Main Rotor, Slide Valve Cross Shafts & End Plate
Models VSG301-401 Counter Clockwise ONLY
ITEM DESCRIPTION
201
MAIN ROTOR ASSEMBLY. 203
OIL BAFFLE ASSEMBLY (1)
217, (1) 244, (1) 248, (1) 249, (1) 252.
SHIM ASSORTMENT (2) 240,
(2) 241, (1) 242, (1) 243
217
OIL BAFFLE PLATE .
220
END PLATE.
221
SHAFT.
222
GEAR.
227
CLAMP.
228
SPACER.
240
SHIM 0.002”
241
SHIM 0.003”
242
SHIM 0.005”
243
SHIM 0.010”
244
TEFLON RING.
248
CHECK VALVE.
249
CHECK VALVE.
252
RETAINING RING
268
EXPANSION PIN.
269
EXPANSION PIN.
271** PLUG SOLID
281
HEX HEAD CAP SCREW.
286
SOCKET HEAD CAP SCREW.
297
SET SCREW.
298
SET SCREW.
NOTE:
*
**
A
MODEL NUMBER
VSG 301
VSG 361
VSG 401
QTY VPN
QTY VPN
QTY VPN
1
A25226AB 1
A25226AA 1
A25226AC
1
A25942AA 1
A25942AA 1
A25942AA
1
1
1
2
4
4
4
A
A
A
A
1
1
1
1
4
4
1
6
8
2
2
A25177A
25938A
25719D
25941A
25027A
25913A
25847A
25409AA
25409AB
25409AC
25409AD
25939A
3120A
3120B
2829M
1193D
2981AA
25422A
2796N
2795F
2060J
2060H
A25177A
25938A
25719D
25941A
25027A
25913A
25847A
25409AA
25409AB
25409AC
25409AD
25939A
3120A
3120B
2829M
1193D
2981AA
25422A
2796N
2795F
2060J
2060H
A25177A
25938A
25719D
25941A
25027A
25913A
25847A
25409AA
25409AB
25409AC
25409AD
25939A
3120A
3120B
2829M
1193D
2981AA
25422A
2796N
2795F
2060J
2060H
1
1
1
2
4
4
4
A
A
A
A
1
1
1
1
4
4
1
6
8
2
2
1
1
1
2
4
4
4
A
A
A
A
1
1
1
1
4
4
1
6
8
2
2
Not pictured.
Required at top locate single gaterotor only.
As required.
87
Main Rotor, Slide Valve Cross Shafts & End Plate
Models VSG501-701 Clockwise ONLY
88
Main Rotor, Slide Valve Cross Shafts & End Plate
Models VSG501-701 Clockwise ONLY
ITEM DESCRIPTION
201
MAIN ROTOR ASSEMBLY. 203
OIL BAFFLE ASSEMBLY (1) 217,
(1) 244, (1) 248, (1) 249, (1) 252.
SHIM ASSORTMENT (2) 240,
(2) 241, (1) 242, (1) 243
220
END PLATE.
221
SHAFT.
222
GEAR.
228
SPACER.
240
SHIM 0.002”
241
SHIM 0.003”
242
SHIM 0.005”
243
SHIM 0.010”
244
TEFLON RING.
248
CHECK VALVE.
249
CHECK VALVE.
252
RETAINING RING
255
WASHER
256
WASHER
268
EXPANSION PIN.
269
EXPANSION PIN.
281
HEX HEAD CAP SCREW.
282
SOCKET HEAD CAP SCREW
297
SET SCREW.
298
SET SCREW.
NOTE:
*
A
MODEL NUMBER
VSG 501
VSG 601
VSG 701
QTY VPN
QTY VPN
QTY VPN
1
A26010BB 1
A26010BA 1
A26010BC
1
A26034B
1
A26034B
1
A26034B
1
1
2
4
4
A
A
A
A
1
1
1
1
2
2
4
4
8
2
2
2
A25177B
26025B
25843A
25027A
25847A
25255AA
25255AB
25255AC
25255AD
25929B
3120A
3120B
2928N
25977E
25977F
1193D
2981AA
2796B
2795D
2060J
2060H
1
1
2
4
4
A
A
A
A
1
1
1
1
2
2
4
4
8
2
2
2
A25177B
26025B
25843A
25027A
25847A
25255AA
25255AB
25255AC
25255AD
25929B
3120A
3120B
2928N
25977E
25977F
1193D
2981AA
2796B
2795D
2060J
2060H
1
1
2
4
4
A
A
A
A
1
1
1
1
2
2
4
4
8
2
2
2
A25177B
26025B
25843A
25027A
25847A
25255AA
25255AB
25255AC
25255AD
25929B
3120A
3120B
2928N
25977E
25977F
1193D
2981AA
2796B
2795D
2060J
2060H
Not pictured.
As required.
89
90
Assembly Includes Carriage and Slides.
Carriage Assembly
Capacity Slide
Volume Ratio
Slide Valve Carriage Assembly
Slide Valve Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION
ALL VSG 301-401 ALL VSG 501-701
QTY VPN
QTY VPN
300
CARRIAGE ASSEMBLY.
1
A25179A 1
A26012B
304
CAPACITY PISTON 340, 341, 350 & 355.1
A25183A 1
A25183B
305
VOLUME PISTON 340, 342, 350 & 355. 1
A25184A 1
A25184B
316
CAPACITY RACK.
1
25023D
1
25024A
318
CAPACITY RACK SHAFT.
1
25772C
1
25772A
323
VOLUME RATIO RACK.
1
25023C
1
25023A
325
VOLUME RATIO RACK SHAFT.
1
25772D
1
25772B
350
PISTON RING SET.
2
2953AE
2
2953AA
360
LOCK WASHER (PAIR).
2
3004C
2
3004C
361
WASHER.
2
13265B
2
13265B
363
NUT.
4
2797A
4
2797A
372*
SOCKET HEAD CAP SCREW.
N/A
1
2795M
Notes:There are two slide valve carriages per compressor. Each one each has its
own Volume Ratio and Capacity slide valves. The above totals are per side of the
compressor, double the quantities if both slide valve carriages are being worked
on.
*.Not Pictured.
91
Actuator & Command Shaft
92
Actuator & Command Shaft
ITEM
DESCRIPTION
MODEL NUMBER
VSSG 291 thru
VSSG 601
QTY VPN
VSG 751 thru
VSSG 901
VPN
VSG 1051 thru
VSG 1201
VPN
VSG 1551 thru
VSG 2101
VPN
400
401
446
2
2
2
A25994C
25972D
2176X
A25994D
25972D
2176X
A25994E
25972D
2176X
COMMAND SHAFT ASSEMBLY
SLIDEVALVE ACUATOR
O-RING
A25994B
25972D
2176X
93
Miscellaneous Frame Components
Model VSG 301-401
Model VSG 501-701
94
Miscellaneous Frame Components
ITEM DESCRIPTION
512
MANIFOLD GASKET.
514
ECON-O-MIZER GASKET.
522
COUPLING LOCK PLATE
523
LOCK WASHER
528
ECON-O-MIZER PLUG.
530
O-RING
540
DOWEL PIN
542
PIPE PLUG
551
HEX HEAD CAP SCREW
570
BEARING OIL PLUG
571
PLUG
572
SPRING
Notes*.
MODEL NUMBER
ALL VSG 301-401 ALL VSG 501 - 701
QTY VPN
QTY VPN
1
25737A
1
26037A
2
11323GG 2
11323D
n/a
1
25004D
n/a
1
3004H
2
25419A
2
25397K
n/a
2
2176BF
2
2868B
2
2868B
3
2606C
10
2606B
n/a
2
2796C
1
25978A
n/a
1
25979A
n/a
1
3148A
n/a
Not Pictured.
95
Housing Accessories
Miscellaneous Frame Components
96
Miscellaneous Frame Components
Housing Accessories
ITEM DESCRIPTION
117
GATE ROTOR COVER.
118
COVER GASKET.
129
GASKET.
180
INLET SCREEN.
343
PISTON COVER. *
MODEL NUMBER
VSG 301 - 701
QTY
VPN
1
25416B
2
25259B
1
11323T
1
25920A
1
25724B
ITEM DESCRIPTION
MODEL NUMBER
VSG 301 - 401
VSG 501 - 701
QTY VPN
QTY VPN
345
346
4
2
O-RING.
O-RING.
2176BX
2176BG
4
2
2176CA
2176BG
97
Replacement Tools
ITEM DESCRIPTION
901
GATEROTOR STABILIZER.
902
SEAL INSTALLATION TOOL
98
MODEL NUMBER
ALL VSG 301-401 ALL VSG 501-701
QTY VPN
QTY VPN
1
25742A
1
25742B
1
25455A
1
25455B
99
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100
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