vilter - cool compression operation manual

1VPN 35391COctober 2005 Rev. 04Price $45.00

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Important Note:

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

The following instructions have been prepared to assist in installation, operation and removal of Vilter SingleScrew Compressors. Following these instructions will result in a long life of the compressor with satisfactoryoperation.

The entire manual should be reviewed before attempting to install, service or repair the compressor.

A refrigeration compressor is a positive displacement machine. It is designed to pump superheated vapor. Thecompressor must not be subjected to liquid carry over. Care must be exercised in properly designing andmaintaining the system to prevent conditions that could lead to liquid carry over. Vilter ManufacturingCorporation is not responsible for the system or the controls needed to prevent liquid carry over and as suchVilter Manufacturing Corporation cannot warrant equipment damaged by improperly protected or operatingsystems.

Vilter screw compressor components are thoroughly inspected at the factory, assuring the shipment of amechanically perfect piece of equipment. Damage can occur in shipment, however. For this reason, the unitsshould be thoroughly inspected upon arrival. Any damage noted should be reported immediately to the Trans-portation Company. This way, an authorized agent can examine the unit, determine the extent of damage andtake necessary steps to rectify the claim with no serious or costly delays. At the same time, the local Vilterrepresentative or the home office should be notified of any claim made.

All inquires should include the Vilter order number, compressor serial and model number. These can be found onthe compressor name plate on the compressor.

All requests for information, services and or parts should be directed to:

Vilter Manufacturing CorporationCustomer Service Department

5555 South Packard AveP.O. Box 8904

Cudahy, WI 53110-8904 USATelephone: 1-414-744-0111

Fax:1-414-744-3483e-mail: [email protected]

Equipment Identification Numbers:

Vilter Order Number: __________________________Serial Number: _____________Vilter Order Number: __________________________Serial Number: _____________Vilter Order Number: __________________________Serial Number: _____________

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Table of Contents

IMPORTANT NOTE .............................................................................................................................................................. 3

LONG TERM STORAGE REQUIREMENTS .......................................................................................................................... 7

DOMESTIC TERMS AND CONDITIONS .............................................................................................................................. 8EXPORT TERMS AND CONDITIONS ................................................................................................................................. 10

STANDARD VILTER WARRANTY STATEMENT ............................................................................................................. 12VILTER 5/15 EXTENDED WARRANTY STATEMENT ....................................................................................................... 13

WARNING SYMBOLS AND MEANINGS ........................................................................................................................... 15

INSTALLATION INSTRUCTIONS............................................................................................................ 16UNIT WEIGHTS .................................................................................................................................................................. 16FOUNDATIONS .................................................................................................................................................................. 16PLACEMENT OF UNIT ....................................................................................................................................................... 16SYSTEM PIPING .................................................................................................................................................................. 16ELECTRICAL CONNECTIONS ............................................................................................................................................ 17TESTING REFRIGERATION SYSTEM FOR LEAKS ........................................................................................................... 17AMMONIA SYSTEMS ........................................................................................................................................................ 17EVACUATING THE SYSTEM .............................................................................................................................................. 18

UNIT OIL CHARGING ......................................................................................................................................................... 20OIL CHARGE ....................................................................................................................................................................... 20OIL FOR SINGLE SCREW COMPRESSORS UNITS ............................................................................................................ 20SYSTEM REFRIGERANT CHARGING ................................................................................................................................ 20LOW SIDE EQUIPMENT ..................................................................................................................................................... 20COMPRESSORS .................................................................................................................................................................. 21CONDENSERS AND COOLING TOWERS .......................................................................................................................... 21CONTROLS SEE VISSION/VANTAGE MANUAL .................................................................................................................................................... 21INITIAL CHARGING – HIGH SIDE CHARGING ................................................................................................................. 21

SLIDE VALVE ACTUATOR INSTALLATION INSTRUCTIONS ......................................................................................... 22SLIDE VALVE ACTUATOR THEORY OF OPERATION ...................................................................................................... 24SLIDE VALVE ACTUATOR TROUBLESHOOTING NEXT 2 PAGES. .................................................................................. 25

MAINTENANCE SUGGESTIONS ............................................................................................................. 28DAILY .................................................................................................................................................................................. 28WEEKLY .............................................................................................................................................................................. 28MONTHLY ........................................................................................................................................................................... 28TRIMONTHLY ..................................................................................................................................................................... 28YEARLY ............................................................................................................................................................................... 28SYSTEM LEAKS ................................................................................................................................................................. 29YEAR ROUND OPERATION ............................................................................................................................................... 29SERVICE INTERVALS REQUIREMENTS ............................................................................................................................. 30

UNIT DESCRIPTION ......................................................................................................................................................... 31DESCRIPTION OF OPERATION ......................................................................................................................................... 31

OPERATING INSTRUCTIONS .................................................................................................................. 31START UP ............................................................................................................................................................................ 32GAS FLOW .......................................................................................................................................................................... 32LIQUID AMMONIA SUPPLY .............................................................................................................................................. 32

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Table of ContentsSEPARATION ...................................................................................................................................................................... 32LIQUID AND OIL LEVEL MONITORING ............................................................................................................................ 33COMPRESSOR LUBRICATION AND COOLING................................................................................................................. 33COMPRESSOR SHUT DOWN ............................................................................................................................................. 33

OIL SYSTEM ....................................................................................................................................................................... 33CHECKING THE OIL LEVEL ................................................................................................................................................ 33SEPARATOR OIL LEVEL ..................................................................................................................................................... 34ADDING OIL ....................................................................................................................................................................... 34CHANGING AND CLEANING FILTER (SEE PAGE 61) ....................................................................................................... 35OIL FILTER ELEMENT ........................................................................................................................................................ 35LIQUID INJECTION OIL COOLING ..................................................................................................................................... 36

CONTROL SYSTEM ............................................................................................................................................................ 36SCREW COMPRESSOR CONTROL AND OPERATION ..................................................................................................... 36STARTING, STOPPING AND RESTARTING THE COMPRESSOR’ ..................................................................................... 36SLIDE VALVE CONTROL COMMAND SHAFT ROTATION ............................................................................................. 36ACTUATOR LOCATION..................................................................................................................................................... 37OIL SEPARATOR HEATER ................................................................................................................................................. 37

SAFETY SETPOINTS .......................................................................................................................................................... 38DISCHARGE PRESSURE ..................................................................................................................................................... 38SUCTION PRESSURE .......................................................................................................................................................... 38OIL FILTER DIFFERENTIAL PRESSURE ............................................................................................................................ 38OIL TEMPERATURE ........................................................................................................................................................... 38DISCHARGE TEMPERATURE SUPERHEAT ...................................................................................................................... 38HIGH LIQUID LEVEL ........................................................................................................................................................... 38SETTING OF CONTROLS .................................................................................................................................................... 38VALVE SETTINGS ............................................................................................................................................................... 38

INITIAL START UP ............................................................................................................................................................. 39COMPRESSOR PRE START-UP CHECK LISTS ................................................................................................................... 39FIELD PIPING AND MECHANICAL REQUIREMENTS ...................................................................................................... 40FIELD WIRING REQUIREMENTS ....................................................................................................................................... 41

GENERAL COMMENTS ...................................................................................................................................................... 42

SERVICE SECTION ...................................................................................................................................... 42PREPARATION OF UNIT FOR SERVICING ........................................................................................................................ 42REMOVAL OF COMPRESSOR FROM THE UNIT .............................................................................................................. 42INSTALLATION OF THE COMPRESSOR ........................................................................................................................... 43LEAK CHECKING UNIT ...................................................................................................................................................... 43ANNUAL INSPECTION ...................................................................................................................................................... 44MAXIMUM BEARING FLOAT ........................................................................................................................................... 44

GATE ROTOR FLOAT ......................................................................................................................................................... 45GATE ROTOR ASSEMBLY .................................................................................................................................................. 46GATE ROTOR REMOVAL ................................................................................................................................................... 46GATE ROTOR INSTALLATION .......................................................................................................................................... 47GATE ROTOR BLADE REMOVAL ...................................................................................................................................... 47GATE ROTOR THRUST BEARING REMOVAL ................................................................................................................... 48GATE ROTOR THRUST BEARING INSTALLATION ......................................................................................................... 48GATE ROTOR ROLLER BEARING REMOVAL.................................................................................................................... 49

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Table of Contents

GATE ROTOR ROLLER BEARING INSTALLATION .......................................................................................................... 49

INPUT SHAFT SEAL REPLACEMENT ............................................................................................................................... 50INPUT SHAFT SEAL REMOVAL ........................................................................................................................................ 50SHAFT SEAL INSTALLATION ........................................................................................................................................... 50

MAIN ROTOR ASSEMBLY ................................................................................................................................................. 51CAPACITY AND VARIABLE ............................................................................................................................................... 52VOLUME RATIO CONTROL ASSEMBLY ........................................................................................................................... 52

OPTICAL SLIDE VALVE ACTUATOR REMOVAL .............................................................................................................. 52OPTICAL SLIDE VALVE ACTUATOR INSTALLATION ..................................................................................................... 53

COMMAND SHAFT ASSEMBLY REMOVAL .................................................................................................................... 54COMMAND SHAFT ASSEMBLY INSTALLATION ........................................................................................................... 54COMMAND SHAFT BEARING AND O-RING SEAL REPLACEMENT ............................................................................. 55COMMAND SHAFT BEARING AND O-RING SEAL REASSEMBLY ................................................................................ 55

DISCHARGE MANIFOLD REMOVAL ................................................................................................................................ 55DISCHARGE MANIFOLD INSTALLATION ....................................................................................................................... 56

SLIDE VALVE GEAR AND RACK ........................................................................................................................................ 56INSPECTION RACK CLEARANCE VALUES ...................................................................................................................... 56REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS ................................................................................................ 56INSTALLATION OF CAPACITY OR VOLUME CROSS SHAFTS ...................................................................................... 57

TROUBLE SHOOTING GUIDE ............................................................................................................................................ 58ADDING OIL AND INSTALLTION OF OIL FILTER ............................................................................................................ 61DUAL FILTER VALVE SEAL REPLACEMENT ................................................................................................................... 62

VSM COOL COMPRESSION SPARE PARTS LIST ....................................................................................................... 63GATE ROTOR ASSEMBLY .................................................................................................................................................. 65SHAFT SEAL ....................................................................................................................................................................... 66ACTUATING MOTOR WITH OPTICAL SENSOR AND COMMAND SHAFT .................................................................. 67SLIDE VALVE CARRIAGE ASSEMBLY .............................................................................................................................. 68MICELLANEOUS FRAME COMPONENTS 201-401 ONLY ................................................................................................ 70MICELLANEOUS FRAME COMPONENTS 501-701 ONLY ................................................................................................ 72MAIN ROTOR, SLIDE VALVE CROSS SHAFTS AND END PLATE 201-401 ONLY ........................................................... 74MAIN ROTOR, SLIDE VALVE CROSS SHAFTS AND END PLATE 501-701 ONLY ........................................................... 76REPLMAIN ROTOR, SLIDE VALVE CROSS SHAFTS AND END PLATE .......................................................................... 77HOUSING ACCESSIORES ................................................................................................................................................... 78C-FLANGE ASSEMBLY ....................................................................................................................................................... 79TOOLS ................................................................................................................................................................................. 80

SPORLAN THERMOSTATIC EXPANSION VALVE ........................................................................................................... 86“STOP CHECK” OPERATION ............................................................................................................................................. 92“STOP CHECK” INSTALLATION ....................................................................................................................................... 93HANSEN TECHNOLOGIES PRODUCT ............................................................................................................................... 94

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Long Term StorageRequirements

1. The compressor(s) must be stored in a heated building, preferably air conditioned to control moisture, toprevent corrosion of the main rotor shaft/crankshaft and (for screw comp.) The slide valve (volumeratio& capacity) motors and gears.

2. The main rotor shaft/crankshaft must be coated with light grease to prevent rusting.

3. (For Screw Compressors) The volume and capacity slide valve motor enclosures will have corrosioninhibitors installed in them and the enclosures will be sealed. On a six month basis (depending on relativehumidity), 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, to5 psig. Pressure must be monitored with the gauge (provided by Vilter) and checked on a regular basis (atleast monthly).

5. The rotor shaft/crankshaft must be rotated every 3 months to prevent flat spots from developing on thebearing 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. Forreciprocating compressors this is done manually through the oil pressure gauge port.

C. Notify the Vilter Warranty Department when the compressor is started.

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Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms andconditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly rejected,and do not form a part of this Agreement unless Seller agrees to such terms in writing.

Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind Sellerunless this Agreement and any purported change are signed by a home office Officer of Seller.

Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyer’sbinding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unlessagreed otherwise in writing, all payments are due in full within 30 days of Seller shipping the products or providing theservices. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the maximumallowed by law.

Security Agreement. This Agreement shall be considered a security agreement to the maximum extent allowed by law.Seller shall have, retain, and possess a security interest in all products sold to Buyer until Seller is paid in full. Buyergrants to Seller a power of attorney to complete, sign on Buyer’s behalf, and file all forms reasonably necessary toperfect Seller’s security interest. If Buyer defaults, or Seller deems itself insecure of receiving payment, the full unpaidbalance shall become immediately due and payable at the option of the Seller, and Seller may retake possession of theproducts without Court order.

Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. Alldelivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’sOrder Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment deliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a periodof eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from date ofinstallation at the initial end users location, whichever occurs first. In addition, Seller provides the following extendedwarranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating parts, (b) two (2)years from the date of shipment on reciprocating compressors and single screw and reciprocating compressor parts, and(c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not apply to ordinary wear andtear. Seller does not warrant that the product complies with any particular law or regulation not explicitly set forth in thespecifications, and Buyer is responsible for ensuring that the product contains all features necessary to safely performin Buyer’s and its customer’s plants and operations. Buyer must notify Seller of any warranty claim within ten (10) daysafter such claim arises, otherwise Buyer waives all rights to such claim. Products supplied by Seller which are manufac-tured by others are not warranted by Seller, but rather Seller merely passes through the manufacturer’s warranty toBuyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, IN-CLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.Unless otherwise agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair of thedefect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not be responsiblefor costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller will not be liable forany other direct, indirect, consequential, incidental, or special damages arising out of a breach of warranty. THESEWARRANTY REMEDIES ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED. Productsor parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory. Any improperuse, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved by Seller, or anyalteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall void all warranties andwarranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be in default of itspayment obligations to Seller under this Agreement or any credit agreement.

DOMESTIC TERMS andCONDITIONS

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Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damagesarising from canceling or changing this Agreement. No returns shall be allowed other than with Seller’s expresspermission, and such returns shall include a reasonable restocking charge to the extent permitted by law.

Resellers and Distributors. Should Buyer resell the product to a third party, then Buyer agrees to provide a copy ofthese Terms and Conditions to such third party prior to the sale, and obtain such third party’s agreement to bebound by the relevant provisions including, but not limited to, the Warranties Section and the Limitation ofLiability Section. Buyer agrees to indemnify Seller against any and all claims, damages, or liability (includingreasonable attorney fees) arising from Buyer’s breach of the obligations set forth in this Section.

Proprietary Rights. All designs and information provided by Seller remain its property, and Buyer shall honor allproprietary legends.

Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyerunderstands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NOLIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARYOR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PROD-UCT LIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN AD-VANCE.

IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER INEXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTYREMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCE-ABLE FOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREE-MENT, THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS WILL NEVERTHELESS RE-MAIN IN EFFECT.

Governing Law. This Agreement shall be governed by the internal laws of the State of Wisconsin, without resortto conflicts of law analysis.

Attorney fees, Collection Costs, and Indemnification. Buyer agrees to defend and indemnify Seller against anyclaims, damages, or liability (including attorney fees) arising out of Buyer’s violation of any law or breach of itsobligations under this Agreement including, but not limited to, personal injury, death, or property damage. Inaddition, Buyer shall reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforceits rights against Buyer under this Agreement.

Manuals and Brochures. Buyer shall communicate to Seller any special needs, pictorials, labels, warning signs,instructions, or language required for the manuals and brochures used for the products. Buyer agrees to pay areasonable surcharge for additional manuals, special manuals, and brochures.

Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining termsand conditions will be enforced as a whole as if such provision had not be inserted herein.

Waiver, Entire Agreement. No waiver by either party of a right under this Agreement shall waive any other rights.These terms and conditions and any other writing signed by Seller constitute the entire agreement, and may not bemodified other than in writing signed by Seller.

DOMESTIC TERMS andCONDITIONS

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Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms andconditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly rejected,and do not form a part of this Agreement unless Seller agrees to such terms in writing.

Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind Sellerunless this Agreement and any purported change are signed by a home office Officer of Seller.

Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyer’sbinding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unlessagreed otherwise in writing, all payments are due in full upon receipt of order or Vilter’s receipt of an acceptable letter ofcredit. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the maximum allowedby law.

Export Transactions. If the products provided under this Agreement are to be shipped or used outside of the UnitedStates, then the following terms apply unless otherwise agreed by Seller in writing: (1) Buyer shall be responsible for allexport and import scheduling and financial arrangements, (2) Buyer shall be responsible for compliance with all export andimport laws and shall comply, and shall cause its agents to comply, with the Foreign Corrupt Practices Act, (3) the UnitedNations Convention on the International Sale of Goods shall not apply or govern the transaction, (4) Buyer accepts allresponsibility for the products complying with any non-United States based laws, regulations, and other legal require-ments, and (5) Seller shall be entitled to condition any shipment upon Buyer obtaining an acceptable Letter of Credit inSeller’s favor confirmed at a United States based bank of Seller’s choosing.

Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. Alldelivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’sOrder Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment deliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a periodof eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from date ofinstallation at the initial end users location, whichever occurs first. In addition, Seller provides the following extendedwarranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating parts, (b) two (2)years from the date of shipment on reciprocating compressors and single screw and reciprocating compressor parts, and(c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not apply to ordinary wear andtear. Seller does not warrant that the product complies with any particular law or regulation not explicitly set forth in thespecifications, and Buyer is responsible for ensuring that the product contains all features necessary to safely perform inBuyer’s and its customer’s plants and operations. Buyer must notify Seller of any warranty claim within ten (10) days aftersuch claim arises, otherwise Buyer waives all rights to such claim. Products supplied by Seller which are manufactured byothers are not warranted by Seller, but rather Seller merely passes through the manufacturer’s warranty to Buyer. SELLEREXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwiseagreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correctionof the service, or the providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of disman-tling, lost refrigerant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct,indirect, consequential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REM-EDIES ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED.

EXPORT TERMS andCONDITIONS

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Products or parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory. Anyimproper use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved bySeller, or any alteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall void allwarranties and warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be indefault of its payment obligations to Seller under this Agreement or any credit agreement.

Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages arisingfrom canceling or changing this Agreement. No returns shall be allowed other than with Seller’s express permission,and such returns shall include a reasonable restocking charge to the extent permitted by law.

Proprietary Rights. All designs and information provided by Seller remain its property, and Buyer shall honor allproprietary legends.

Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyerunderstands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NO LIABIL-ITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARY OR INCIDENTALDAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCT LIABILITY OR OTHER-WISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.

IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER IN EXCESS OF THECONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTY REMEDY FAILS OF ITS ESSEN-TIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCEABLE FOR ANY REASON, IN CONSIDERATIONOF THE OTHER PROVISIONS OF THIS AGREEMENT, THE PARTIES AGREE THAT ALL LIABILITY LIMITA-TIONS WILL NEVERTHELESS REMAIN IN EFFECT.

Governing Law and Dispute Resolution. This Agreement shall be governed by the internal laws of the State ofWisconsin, U.S.A. without resort to conflicts of law analysis. The parties agree the State courts located in Milwaukee,Wisconsin, U.S.A. shall have exclusive venue for any dispute concerning the enforceability, interpretation, or termina-tion of this Agreement, and agree to bring any such action in this venue. The parties further agree to personaljurisdiction in such courts for any such dispute.

Attorney fees, Collection Costs, and Indemnification. Buyer agrees to defend and indemnify Seller against any claims,damages, or liability (including attorney fees) arising out of Buyer’s violation of any law or breach of its obligationsunder this Agreement including, but not limited to, personal injury, death, or property damage. In addition, Buyer shallreimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce its rights against Buyerunder this Agreement.

Manuals and Brochures. Buyer shall communicate to Seller any special needs, pictorials, labels, warning signs,instructions, or language required for the manuals and brochures used for the products. Buyer agrees to pay areasonable surcharge for additional manuals, special manuals, and brochures.

Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms andconditions will be enforced as a whole as if such provision had not be inserted herein.

Waiver, Entire Agreement. No waiver by either party of a right under this Agreement shall waive any other rights.These terms and conditions and any other writing signed by Seller constitute the entire agreement, and may not bemodified other than in writing signed by Seller.

EXPORT TERMS andCONDITIONS

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STANDARD VILTER WARRANTYSTATEMENT

Seller warrants the products it manufactures to be free from defects in material and workmanship for a period ofeighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months fromdate of installation at the initial end users location, whichever occurs first. In addition, Seller provides the follow-ing extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal rotatingparts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and reciprocatingcompressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties donot apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law orregulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the productcontains all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer mustnotify Seller of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rightsto such claim. Products supplied by Seller, which are manufactured by others, are not warranted by Seller, butrather Seller merely passes through the manufacturer’s warranty to Buyer.

SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED,INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR PURPOSE.

Unless otherwise agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair ofthe defect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not beresponsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Sellerwill not be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breachof warranty. THESE WARRANTY REMEDIES ARE EXCLUSIVE AND ALL OTHER WARRANTY REM-EDIES ARE EXCLUDED. Products or parts for which a warranty claim is made are to be returned transporta-tion prepaid to Seller’s factory. Any improper use, corrosion, neglect, accident, operation beyond rated capacity,substitution of parts not approved by Seller, or any alteration or repair by others which, in Seller’s judgement,adversely affects the Product, shall void all warranties and warranty obligations. Further, Seller shall not be liableunder the above warranties should Buyer be in default of its payment obligations to Seller under this Agreement orany credit agreement.

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The seller extends warranty, from date of shipment, to a period of fifteen (15) years on all compressor bearings, five (5)years on all internal compressor parts and two (2) years on the remainder of the parts on single screw compressor units.If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product shall berepaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation and Buyer’s exclusiveremedy hereunder and shall be conditioned upon Seller’s receiving written notice of any alleged defect within ten (10)days after its discovery and, at Seller’s option, return of such parts to Seller, F.O.B., freight prepaid to Seller’s factory.Expenses incurred by Buyer in repairing or replacing any defective product or any lost refrigerant will not be allowedexcept by written permission of Seller. This warranty is only applicable to products properly maintained and usedaccording to Seller’s instructions, the use of genuine Vilter replacement parts and recommended oil in all repairs andreplacements has demonstrated adherence to a scheduled maintenance program as detailed in the Single ScrewCompressor operating manual. This warranty does not apply to normal wear and tear, or damage caused by corrosion,misuse, overloading, neglect, improper operation, accident or alteration, as determined by Seller. Products supplied byseller hereunder, which are manufactured by someone else, are not warranted by Seller in any way, but Seller agrees toassign to Buyer any warranty rights in such products that the Seller may have from the original manufacturer. Laborand expenses for repair are not covered by warranty.

THE WARRANTY CONTAINED IN THIS SECTION IS EXCLUSIVE AND IN LIEU OF ALL OTHERREPRESENTATIONS AND WARRANTIES (EXCEPT OF TITLE), EXPRESS OR IMPLIED WARRANTYOF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

Any description of the product, whether in writing or made orally by Seller or Seller’s agents, specifications, samples,models, bulletins, drawings, diagrams, engineering sheets or similar materials used in connection with Buyer’sorder are for the sole purpose of identifying the products and shall not be construed as an express warranty. Anysuggestions by seller or Seller’s agents regarding use, application or suitability of the products shall not be construedas an express warranty unless confirmed to be such in writing by Seller.

The 5/15 Extended Warranty shall be applicable only if the specific maintenance guidelines as outlined in thetechnical manual are followed. This includes the compressor inspections, completing periodic oil analysis and thechange out of the oil and oil filters, and related components as required with only genuine Vilter parts. Thecustomer is required to keep a maintenance log and receipts demonstrating the use of Genuine Vilter parts forvalidation of a warranty claim, if requested. The repair or replacement of parts or the performance of service underthis warranty does not extend the life of this warranty beyond its original expiration date.

VILTER 5/15 EXTENDEDWARRANTY STATEMENT

5/15 EXTENDED WARRANTY FOR SINGLE SCREWCOMPRESSORS

(NON-GAS COMPRESSOR APPLICATIONS ONLY)

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Warning Symbols and Meanings

Electrical Hazards........................................................

Misc. Hazards...............................................................

Mechanical Hazards.....................................................

Fire Hazards..................................................................

Heat/Hot Hazards...........................................................

Mandatory Action Sign/Verification -Communicates an action to be taken toAVOID hazard......................................................

Prohibition Symbol......................................................

Note: The symbols that appear on this page, are used throughout themanual to help identify any potential warnings, cautions or hazards and to assist inavoidance of any accidents or injuries.

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DELIVERY INSPECTION

Vilter screw compressor components are thoroughlyinspected at the factory, assuring the shipment of amechanically perfect piece of equipment. Damage canoccur in shipment. For this reason, the units shouldbe thoroughly inspected upon arrival. Any damagenoted should be reported immediately to the transpor-tation company. This way, an authorized agent canexamine the unit, determine the extent of damage andtake necessary steps to rectify the claim with no seri-ous or costly delays. At the same time, the local Vilterrepresentative or the home office should be notifiedof any claim made.

TABLE 1. UNIT WEIGHTS

MODEL SEPARATOR STANDARD SIZE UNIT (LBS)

VSM 201 12” 2,450VSM 301 12” 2,500VSM 361 12” 2,500VSM 401 12” 2,500VSM 501 16” 3,966VSM 601 16” 4,001VSM 701 16” 4,036VSM 701 20” 4,888* Does not include motor.

FOUNDATIONSVilter single screw compressor units are basically vi-bration free machines, therefore, no elaborate founda-tions are necessary. The floor or foundation uponwhich the unit will be placed should be designed tosupport the entire operating weight of the unit. (SeeTable 1 for unit weight).

PLACEMENT OF UNITThe single screw compressor units are shipped withall major components mounted on structural steel.Place the entire unit on the floor on a concrete pad andsecurely bolt in place. Review local codes andASHRAE Safety Code for Mechanical Refrigeration.Bolt holes are located in the unit’s mounting feet.When locating the unit, provide adequate space for

service work. When the compressor unit is in placeon the concrete pad, check both lengthwise and cross-wise to assure it is level. Use shims and wedges asneeded under the mounting feet to adjust the level ofthe unit.

The coupling center section is shipped loose to al-low a check of proper electrical phasing, direction ofrotation of the motor.

Do not check for motor rotation withouthaving coupling disconnected fromcompressor.

SYSTEM PIPINGRefer to the ANSI/ASME B31.5 Code for Refrigera-tion Piping. All compressor oil supply and oil returnpiping has been completed at the factory. Main linerefrigerant suction and discharge connections arealways necessary.

Care must be taken to avoid trapping the lines exceptfor specific purposes. When traps are used, the hori-zontal dimensions should be as short as possible toavoid excessive oil trapping.

Lines for ammonia systems must be of steel pipe withspecially designed ammonia service fittings. Com-mon pipe fittings must NEVER be used as they willnot provide the same service. Steel pipe is generallyused in large installations when joints are welded.

In making up joints for steel pipe, the following pro-cedures should be followed:

For threaded connections, all threads on the pipe andfitting should be carefully cleaned to remove all tracesof grease or oil. Threads should then be wiped drywith a lint free cloth. Only thread filling compounds

Installation Instructions

17

suitable for refrigeration service should be used formaking steel pipe joints. These compounds shouldbe used sparingly, and on the pipe only. Do not putany on the first two threads to prevent any of thecompound from entering the piping system. Acety-lene or arc welding is frequently used in making steelpipe joints, however, only a skilled welder should at-tempt this kind of work. Take care to see no foreignmaterials are left in the pipes and remove all burrsformed when cutting pipe.

It is important to avoid short, rigid pipe lines that donot allow any degree of flexibility. This must be doneto prevent vibration being transmitted through thepipe lines to the buildings. One method of providingthe needed flexibility to absorb the vibration is toprovide long lines that are broken by 90° ells in threedirections.

Hangers and supports pipe lines should receive care-ful attention. The hangers must have ample strengthand be securely anchored to withstand the vibrationfrom the compressor and adequately support the pipelines.

After installation, pipe hangers and supports maybecome loose due to seasonal changes or the build-ing settling. This will lead to vibrations being trans-mitted through the pipe to the compressor unit. Toavoid piping transmitted vibration, hangers and sup-ports should be periodically checked and adjusted.

This information is taken from ASHRAE 15-89 andANSI B31.5. The installing contractor should be thor-oughly familiar with these codes, as well as any localcodes.

ELECTRICAL CONNECTIONS

The single screw compressor units are shipped withall package mounted controls wired. The standardcontrol power is 115 volts 60 Hertz, single phase. If a115 volt supply is not available, a control transformermay be required. The power source must be con-nected to the control panel according to the electricaldiagrams.

The units are shipped without the compressor motorstarter. Field wiring is required between the fieldmounted starters and package mounted motors.

Additional control wiring in the field is also required.Dry contacts are provided in the control panel forstarting the screw compressor motor. These con-tacts are to be wired in series with the starter coils. Acurrent transformer is supplied along with the com-pressor unit, and is located in the motor junction box.This transformer is to be installed on one phase ofthe compressor motor starter. A normally open auxil-iary contact from the compressor motor starter is alsorequired.

Terminal locations for this wiring can be found onthe wiring diagram supplied with this unit. Addi-tional aspects of the electrical operation of the singlescrew units are covered in the start up and operationsection of this manual.

TESTING REFRIGERATIONSYSTEM FOR LEAKS

Vilter equipment is tested for leaks at the factory.One of the most important steps in putting a refrig-eration system into operation is field testing for leaks.This must be done to assure a tight system that willoperate without any appreciable loss of refrigerant.To test for leaks, the system pressure must be builtup. Test pressures for various refrigerants are listedin ANSI B9.1-1971 code brochure entitle “Safety Codefor Mechanical Refrigeration”. These pressures willusually suffice, however, it is advisable to check lo-cal codes as they may differ. Before testing mayproceed, several things must be done.

First, if test pressures exceed the settings of the sys-tem, relief valves or safety devices, they must beremoved and the connection plugged during the test.Second, all valves should be opened except thoseleading to the atmosphere. Then, open all solenoidsand pressure regulators by the manual lifting stems.All bypass arrangements must also be opened.

Ammonia Systems

Dry nitrogen may be used to raise the pressure in anammonia system to the proper level for the test. Thegas may be put into the system through the chargingvalve or any other suitable opening. Adjust the pres-sure regulator on the bottle to prevent over-pressur-


18

ization. Do not exceed the pressure rating on thevessel with the lowest pressure rating.

Carbon Dioxide should NOT be used as a testing gasin an ammonia system. This will cause ammoniumcarbonate to precipitate when the CO2 and ammoniaare combined. If heavy enough, this precipitate willcause the machine to freeze and clog the strainer.

A mixture of four parts water to one part liquid soap,with a few drops of glycerin added, makes a good leaktest solution. Apply this mixture with a one inch roundbrush at all flanges, threaded joints, and welds. Re-pair all visible leaks. If possible, leave the pressureon over night. A small drop in pressure over thisperiod indicates a very tight system.

Remember to note the ambient temperature, as achange in temperature will cause a change in pres-sure.

After the system is thoroughly tested, open all valveson the lowest part of the system so the gas will flowaway from the compressor. This prevents any dirt orforeign particles from entering the compressor andcontaminating the working parts. The oil should thenbe charged into the compressor.

Charge a small amount of ammonia into the systemand pressurize the system with dry nitrogen to itsrespective design pressure. Pass a lit sulfur stickaround all joints and connections. Any leaks will beindicated by a heavy cloud of smoke. If any leaks areobserved during this test, they must be repaired andrechecked before the system can be considered tightand ready for evacuation.

Evacuating The System

A refrigeration system operates best when only re-frigerant is present. Steps must be taken to remove allair, water, vapor, and all other non-condensibles fromthe system before charging it with refrigerant. A com-bination of moisture and refrigerant, along with anyoxygen in the system, can form acids or other corro-sive compounds that corrode internal parts of thesystem.

To properly evacuate the system, and to remove allnon-condensibles, air and water vapor, use a highvacuum pump capable of attaining a blanked off pres-

sure of 50 microns or less. Attach this pump to thesystem and allow it to operate until system pressureis reduced somewhere below 1000 microns. Evacua-tion should not be done unless the room temperatureis 60°F or higher.

Attach vacuum gauge(s), reading in the 20 to 20,000micron gauge range, to the refrigerant system. Thesegauge(s) should be used in conjunction with the highvacuum pump.

The reading from the gauge(s) indicates when thesystem has reached the low absolute pressure re-quired for complete system evacuation.

Connect the high vacuum pump into the refrigerationsystem by using the manufacturer’s instructions.Connect the pump both to the high side and low sideof the system, to insure system evacuation. Attachthe vacuum gauge to the system in accordance withthe manufacturer’s instructions.

A single evacuation of the system does not satisfac-torily remove all of the non-condensibles, air and wa-ter vapor. To do a complete job, a triple evacuation isrecommended. When the pump is first turned on,bring system pressure to as low a vacuum level aspossible, and continue operation for 5 to 6 hours.

Stop the pump and isolate the system. Allow the unitto stand at this vacuum for another 5 to 6 hours.After this time, break the vacuum and bring the sys-tem pressure up to 0 psig with dry nitrogen.

To begin the second evacuation, allow the pump tooperate and reduce the pressure again to within 50 to1000 microns. After this reading is reached, allow thepump to operate 2 or 3 hours. Stop the pump and letthe system stand with this vacuum. Again using drynitrogen, raise the system pressure to zero.

For the third evacuation, follow the previous proce-dure with the pump operating until system pressureis reduced below the 1000 micron level. Run the pumpan additional 6 hours and hold the system for ap-proximately 12 hours at low pressure. Again breakthe vacuum with dry nitrogen and allow the pressurein the system to rise slightly above zero pounds(psig). Charge the system once more below the 1000micron level and use the refrigerant designed for thesystem.


19

When properly evacuating the system as outlinedabove, the system is dry, oxygen-free and free of non-condensibles. The piping should not be insulatedbefore the evacuation process is started. If moistureis in the system before evacuating, it condenses inlow places and freezes. If this happens, it can beremoved by gently heating the trap farthest away fromthe vacuum pump. This causes the ice to melt andwater to boil. Water vapor collects in the next traptowards the vacuum pump. This process should berepeated until all pockets of water have been boiledoff, and the vacuum pump has had a chance to re-move all the water vapor from the system. The read-ing from the gauge(s) indicates when the systemhas reached the low absolute pressure requiredfor complete system evacuation.


20

UNIT OIL CHARGING

The compressor unit is shipped from Vilter with no oilcharge. The initial oil charge can be made throughthe drain valve at the oil receiver/separator. Viltermotor driven and manually operated oil chargers areavailable for this purpose.

The oil level must be checked with the unit off andwithout any liquid ammonia inside of the separator.During normal operation, one will observe the liquidammonia/oil mixture in the bottom sight glass, not theactual oil level.

To remove the liquid from the separator, manuallyclose off the liquid supply line to the compressor whilerunning. The liquid ammonia level will slowly dropand the superheat will increase. The compressor willautomatically unload and once the superheat reaches25ºF, it will shutdown. Wait 30 minutes to allow the oilin the compressor and pipelines to drain into the sepa-rator to check the level of oil in the sight glass. If youdon’t wait the 30 minutes the oil level will be, de-pending on the separator size, approximately 1/4”-1/2” lower than the original level. Oil may now beadded to the unit to bring it up to the operatinglevel. (See Table Below) for approximate (full) oilcharge requirements.

OIL CHARGEOil Separator Size Approximate Oil Charge –GallonsVSM 12” 7VSM 12”w/oil sump 8VSM 16” short (68’) 9VSM 16” long (86”) 10.5VSM 20” 12.5

When the unit is in operation, there will be some dropin the oil level as the compressor oil lines, oil filter andother piping becomes charged with the normal amountof oil that will be in circulation. This drop in oil levelshould bring the level in the oil receiver/separatorinto the normal operating range.

Do not mix oils. Never check the oil level when theunit is running. See Separator Oil Level on page 34for proper level.

Oil For Single Screw Compressors Units

Due to the need for adequate lubrication, Vilter rec-ommends only the use of Vilter lubricants, designedspecifically for Vilter compressors. With the exten-sive research that has been performed, we are able tooffer refrigerant specific lubricating oils. Use of oilnot specified or supplied by Vilter will void the com-pressor warranty.

Please contact your local Vilter representative or theHome Office for further information.

SYSTEM REFRIGERANTCHARGING

When initially charging the system, make sure thecompressor unit is pressurized from the dischargeside of the compressor. Pressurizing the compressorfrom the suction side may cause rotation of the com-pressor, without oil supply, which could lead to in-ternal damage.

After the system is leak-free and evacuation has beencompleted, it is ready for charging. Before actualcharging, however, the entire operation of the refrig-eration system should be inspected as outlined be-low:

Low Side Equipment

1. Fans on air handling equipment running.

2. Pumps on water cooling equipment running.

3. Proper location and attachment of all thermo-static expansion valve bulbs to their respectivesuction lines.

4. Correct fan and pump rotation.

5. Evaporator pressure regulators and solenoidvalves open.

6. Water pumps and motors correctly aligned anddrive couplings correctly positioned and tight.

7. Belt drives correctly aligned and tightened.

8. Proper voltage to motors.


21

Compressors

1. Proper oil level.

2. Voltage agrees with motor characteristics.

3. Properly sized motor fuses and heaters.

4. Direct drive couplings correctly positioned andassembled.

5. All suction and discharge stop/check or sepa-rated stop valves in their respective automaticor open mode.

6. All transducers and RTD’s calibrated and read-ing correctly.

Condensers and Cooling Towers

1. Water available at water cooled condensers orcooling towers and supply line valve open.

2. Water in remote water tank or sump of evapora-tive condenser or cooling tower and make-upwater available.

3. Correct rotation of pump and fan motors.

4. Belt drives aligned and tightened correctly.

5. Direct drive couplings correctly positioned andtight.

6. Pump, fans and motors lubricated.

Controls

Controls should be at the initial set points. SeeVission/Vantage manual for further information.

Initial Charging – High Side Charging

There are two methods of charging refrigerant intothe system, through the “high side” or through the“low side”. High side charging is usually used forinitial charging as filling of the system is much faster.Low side charging is usually reserved for adding onlysmall amounts of refrigerant after the system is in op-

eration. High side charging of refrigerant into thesystem is accomplished as follows:

1. Connect a full drum of refrigerant to the liquidcharging valve. This valve is generally locatedin the liquid line immediately after the king orliquid line valve. Purge the air from the chargingline.

2. Leak check charging line and connections be-fore charging with liquid.

3. Charge liquid refrigerant from the drum. If thedrum is not equipped with “Liquid” and “Va-por” valves, place the drum in a position recom-mended by the refrigerant supplier so that liquidrefrigerant only can enter the system. Close theliquid line or king valve, if it is not already closed.Open the charging valve slowly to allow liquidrefrigerant to enter the system. The vacuum inthe system will draw in the refrigerant.It is important that, during this operation, air han-dling units be running and water is circulatingthrough water cooled condensers and chillers.The low pressures on the system can cause therefrigerant to boil at low temperature and possi-bly freeze the water if it is not kept circulating.

Water freezing in a condenser or chiller can rup-ture the tubes and cause extensive damage tothe system. It would be desirable to charge theinitial amount of refrigerant without water in theshell and tube equipment to eliminate the possi-bility of freeze up.

4. After some refrigerant has entered the system,the compressor unit starting procedure may befollowed. See Start-Up and Operation Sectionof this manual.

5. Continue charging refrigerant into the systemuntil the proper operating requirements are sat-isfied. Then, close the liquid charging connec-tion and open the liquid line valve allowing thesystem to operate normally. To check thatenough refrigerant has been added, the liquidsight glass should show no bubbles, and thereshould be a liquid seal in the receiver. If thesetwo conditions are not satisfied, additional re-frigerant must be added.


22

6. When sufficient refrigerant has been chargedinto the system, close the charging and drumvalves. Then remove the drum from the system.

7. During the charging period, observe the gaugescarefully to insure there are no operating diffi-culties. Watch head pressures closely to makesure the condensers are functioning properly.

Since it is usually necessary to use several drumswhen charging a system, follow step# 6, then startback at step#1 of the above description when attach-ing a new drum. After charging, the refrigerant drumsshould be kept nearby for several days as it is some-times necessary to add more refrigerant as the system“settles down”.

SLIDE VALVE ACTUATORINSTALLATIONS INSTRUCTIONS

WHEN INSTALLING THE OPTICAL SLIDEMOTOR, LOOSEN LOCKING COLLAR BEFORESLIDING THE COLLAR DOWN ON THESHAFT. DO NOT USE A SCREWDRIVER TOPRY LOCKING COLLAR INTO POSITION.

OVERVIEW

Calibration of an optical slide valve actuator is atwo step process that must be done for eachactuator installed of the compressor. Briefly, thesteps are as follows.

1) The actuator motor control module, located in-side the actuator housing, is calibrated so that itknows the minimum and maximum rotational po-sitions of the slide valve it controls. The cali-brated actuator will output 0 VDC at the minimumposition and 5 VDC at the maximum position.

2) After the actuator motor control module has beencalibrated for 0-5Volts, the controlling channelcorresponding to the actuator motor (either thecapacity or volume) has to be calibrated. This

instructs the Vission/ Vantage control panel tolearn 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 CONTROLMODULE CALIBRATION PROCEDURE

1. Disable the Slide Non-Movement Alarm bygoing to the “Setup” menu on the Vission/Vantage and choosing “Alarm Disable” forthe Slide Non-Movement Option.

2. Completely shut off the power to the Vission/Vantage control panel completely.

3. If not already done, mount the slide valveactuator per (“Vilter Actuator set up for Ca-pacity and Volume Slide Motors). Next, wirethe actuator per the attached wiring dia-grams, using the already installed electricalconduit to run the cables. The old wiringcan be used to pull the new cables throughthe conduit to the control panel. The cablesmay also be externally tie-wrapped to theconduit. Run the yellow AC power cable(s)and the gray DC position transmittercable(s) in different conduit. This preventsthe DC position transmitter cable from pick-ing up electrical noise from the AC powercable. Do not connect either of the cables tothe actuators yet.

In addition, if the actuators are replacing oldgearmotors on early Vission/Vantage units, you mustremove the capacitors and associated wiring frominside the control panel. This is necessary to pre-vent electrical damage to the new actuator motor.

4. When completing the calibration of thenew actuators, the motors are signaled tomove to below 5%. This may not com-pletely occur when exiting the calibrationscreen due to a “program timer”. HOW-EVER, when the compressor actuallystarts, the motors will travel below 5% andfunction correctly. The user may see that


23

the actuators are not below 5% aftercalibration and try to find the reason. Ifthe calibration screen is re-entered rightaway and then exited, the timer will allowthe actuator to go below the 5% on thescreen. This may be perceived as aproblem; in reality, it is not.

5. Note: The 0 to 5V-position transmitteroutput of the actuator will fluctuate wildlyduring the calibration process. To preventdamage to the actuators, do not connect theyellow power cable or the gray positiontransmitter cable until instructed to do solater on.

6. Open the plastic cover of the capacity motor byremoving the four #10 screws. Caution: thereare wires attached to the connector on theplastic cover. Handling the cover too aggres-sively could break the wires.

7. Gently lift the cover and tilt it toward the Turckconnectors. Raise the cover enough to be ableto press the blue calibrate button and be ableto see the red LED on the top of assembly.

8. Press “Menu” on the main screen and thenpress the “Slide Calibration” button, to enterthe slide calibration screen. (Note: you must bein this slide calibration screen before attachingthe yellow power cable or gray positiontransmitter cable.)

9. Now connect the yellow power cable and thegray position transmitter cable to the actuator.

10. Press INC and DEC to move the slide valve andcheck for the correct rotation. See Table 1 forActuator/command shaft rotation specifica-tions.

11. Note: If the increase and decrease buttons donot correspond to increase or decrease shaftrotation, swap the blue and brown wires of the“yellow power cable”. This will reverse therotation of the actuator/command shaft.

12. Quickly press and release the blue push buttonon the actuator one time. This places the

actuator in calibration mode. The red LED willbegin flashing rapidly.

13. Note: When the actuator is in calibrationmode, it outputs 0V when the actuator isrunning and 5V when it is still. Thus, as statedearlier, the actuator voltage will fluctuateduring calibration. After the actuator has beencalibrated, 0V output will correspond to theminimum position and 5V to the maximumposition.

14. Note: The “Slide calibration” screen on theVission/Vantage has a “Current” window,which displays twice the actuator outputvoltage. This value, (the % volume and the %capacity) displayed in the “Current Vol” andCurrent Cap” Windows are meaningless untilcalibration has been completed.

15. Use the DEC button on the Vission/Vantagepanel to drive the slide valve to its minimum“mechanical stop” position. Do not continueto run the actuator in this direction after theslide valve has reached the stop. Doing so maycause damage to the actuator or the slidevalve. When the slide has reached themechanical stop position, use the INC buttonto pulse the actuator to where the slide is justoff of the mechanical stop and there is notension on the motor shaft.

16. Quickly press and release the blue button onthe actuator again. The red LED will now flashat a slower rate, indication that the minimumslide valve position (0V position) has been set.

17. Use the INC button on the Vission/Vantagepanel to drive the slide to its maximum“mechanical stop” position. Do not continue torun the actuator in this direction after theslide valve has reached the stop. Doing so maycause damage to the actuator or the slidevalve. When the slide valve has reached themechanical stop position, use the DEC buttonto pulse the actuator to where the slide is justoff of its mechanical stop and there is notension on the motor shaft.

18. Quickly press and release the blue button on


24

the actuator one more time. The red LED willstop flashing. The actuator is now calibratedand knows the minimum and maximumpositions of the slide valve it controls. Nowthe capacity or volume channel of the Vission/Vantage can be calibrated.

19. Use the Dec button to move the actuatortowards its minimum position while watchingthe millivolt readout on the Vission/Vantagescreen. Discontinue pressing the DEC buttonwhen the millivolt reading the “Current”window above the “Set Min” button isapproximately 500 millivolts.

20. Now use the DEC and INC buttons to positionthe slide valve until a value close to 300millivolts is on the screen. Then, press the“Set Min” button in the capacity or volumeslide valve window to tell the controller thatthis is the minimum millivolt position. Note:The value in the “Current Cap” or “CurrentVol” window has no meaning right now.

21. Use the INC button to rotate the actuatortowards its maximum position while watchingthe millivolt readout on the controller screen.Discontinue pressing the INC button when themillivolt reading in the “Current” window isapproximately 9200 millivolts (7900 millivoltsfor the 2783J qualified analog boards). You arenearing the mechanical stop position.

22. Pulse the INC button to carefully move theslide valve until the millivolt readout “satu-rates”, or stops increasing. This is around9500 millivolts (8400 millivolts for 2783qualified analog boards).

23. Pulse the DEC button until the millivolts juststart to decrease. (This is the point where thechannel drops put of saturation).

24. Press the “Set Max” button.

25. Press the “Main” button to complete calibra-tion and exit the “Slide Calibration” screen.The controller will automatically energize theactuator and drive it back to its minimumposition (below 5%) for pre-start-up.26. Note: Now the “Current Cap” or the

“Current Vol” value will be displayed in thewindow on the “Main” screen and the “SlideCalibration” screen.

27. Gently lower the plastic cover over the top ofthe actuator to where it contacts the base ando-ring seal. After making sure the cover isseated properly, gently tighten the four #10screws. Caution: The plastic cover will crackif the screws are over tightened.

28. Enable the “Slide Non-Movement Alarm” bygoing to the “Setup” menu and choosing“Alarm Enable” for the “Slide Non-MovementOption”.

29. This completes the calibration for this channeleither capacity or volume. Repeat the sameprocedure to the other channel.

Slide Valve Actuator Theory of Operation

The slide valve actuator is a gear-motor with a posi-tion sensor. The motor is powered in the forward andreverse directions from the main computer in the con-trol panel. The position sensor tells the main com-puter the position of the slide valve. The main com-puter uses the position and process information todecide where to move the slide valve next.

The position sensors works by optically countingmotor turns. On the shaft of the motor is a smallaluminum “photochopper”. It has a 180 degree fencethat passes through the slots of two slottedoptocouplers. The optocouplers have an infraredlight emitting diode (LED) on one side of the slot anda photo transistor on the other. The photo transistorbehaves as a light controlled switch. When thephotochopper fence is blocking the slot, light fromthe LED is prevented from reaching the photo tran-sistor and the switch is open. When photochopperfence is not blocking the slot, the switch is closed.

As the motor turns, the photochopper fence alter-nately blocks and opens the optocoupler slots, gen-erating a sequence that the position sensormicrocontroller can use to determine motor positionby counting. Because the motor is connected to theslide valve by gears, knowing the motor position


25

means knowing the slide valve position.

During calibration, the position sensor records thehigh and low count of motor turns. The operator tellsthe position sensor when the actuator is at the high orlow position with the push button. Refer to the cali-bration instructions for the detailed calibration proce-dure.

The position sensor can get “lost” if the motor ismoved while the position sensor is not powered. Toprevent this, the motor can only be moved electricallywhile the position sensor is powered. When the posi-tion sensor loses power, power is cut to the motor. Acapacitor stores enough energy to keep the positionsensor circuitry alive long enough for the motor tocome to a complete stop and then save the motorposition to nonvolatile EEPROM memory. Whenpower is restored, the saved motor position is readfrom EEPROM memory and the actuators resumesnormal function

This scheme is not foolproof. If the motor is movedmanually while the power is off or the motor brake hasfailed, allowing the motor to free wheel for too longafter the position sensor looses power, the actuatorwill become lost.

A brake failure can sometimes be detected by the po-sition sensor. If the motor never stops turning after apower loss, the position sensor detects this, knows itwill be lost, and goes immediately into calibrate modewhen power is restored.

Slide Valve Actuator Troubleshooting next 2 pages.


26

Slide Valve Actuator Troubleshooting Guide

The actuator cannot be cali-brated

The actuator goes into cali-bration mode spontaneously

The actuator goes into cali-bration mode every timepower is restored after a powerloss

Dirt or debris is blocking one or bothoptocoupler slots

The photochopper fence extends lessthan about half way into theoptocoupler slots

The white calibrate wire in the greyTurck cable is grounded

Dirt and/or condensation on the po-sition sensor boards are causing it tomalfunction

The calibrate button is stuck down

The position sensor has failed

Push button is being held down formore that ¾ second when goingthrough the calibration procedure

The white calibrate wire in the greyTurck cable is grounding intermit-tently

A very strong source of electromag-netic interference (EMI), such as acontactor, is in the vicinity of the ac-tuator or grey cable

There is an intermittent failure of theposition sensor

The motor brake is not working prop-erly (see theory section above.)

Clean the optocoupler slots witha Q-Tip and rubbing alcohol.

Adjust the photochopper so thatthe fence extends further into theoptocoupler slots. Make sure themotor brake operates freely andthe photochopper will not con-tact the optocouplers when theshaft is pressed down.

Tape the end of the white wire inthe panel and make sure that itcannot touch metal

Clean the boards with an elec-tronics cleaner or compressed air.

Try to free the stuck button.

Replace the actuator.

Depress the button quickly andthen let go. Each ¾ second thebutton is held down counts asanother press.

Tape the end of the white wire inthe panel and make sure that itcannot touch metal.

Increase the distance betweenthe EMI source and the actuator.

Install additional metal shieldingmaterial between the EMI sourceand the actuator or cable.


Get the motor brake to where itoperates freely and recalibrate.

Replace the actuator

27

The motor was manually movedwhile the position sensor was notpowered.

The motor brake is not working prop-erly

The position sensor’s EEPROMmemory has failed

The photochopper is misalignedwith the slotted optocouplers

The photochopper is positioned toolow on the motor shaft.

A motor bearing has failed

There is a loose connection in thescrew terminal blocks

There is a loose or dirty connectionin the yellow Turck cable

The position sensor has failed

There is a broken motor lead or wind-ing

The thermal switch has tripped be-cause the motor is overheated

Any of the reasons listed in “Themotor operates in one directiononly”

The command shaft is jammed

Broken gears in the gearmotor

Motor is overheating and the ther-mal switch is tripping

Recalibrate.

Get the motor brake to where it op-erates freely and then recalibrate.


Try to realign or replace the actua-tor.

Adjust the photochopper so thatthe fence extends further into theoptocoupler slots.


Tighten.

Clean and tighten.



The motor will resume operationwhen it cools. This could be causedby a malfunctioning control panel.Consult the factory.

See above.

Free the command shaft.


This could be caused by a malfunc-tioning control panel. Consult thefactory.

Slide Valve Actuator Troubleshooting Guide

The actuator does not transmitthe correct position after a powerloss

There is a rapid clicking noisewhen the motor is operating

The motor operates in one direc-tion only

The motor will not move in ei-ther direction

The motor runs intermittently,several minutes on, several min-utes off

28

MAINTENANCESUGGESTIONS

Careful checking of a refrigeration system for leaksand proper operation of all components upon instal-lation will start the system on its way to a long life ofsatisfactory service. To ensure the desired trouble-free operation, however, a systematic maintenanceprogram is a prerequisite. The following maintenanceschedule is suggested.

A. Daily

1. Check all pressure and temperature readings.2. Check oil pressures for excessive pressure drop.

Clean filter when pressure drop exceeds 10 psi.For proper procedure to change the oil filter andcharge oil into the system. (See Operation Sec-tion).

Note: Clean the system strainers each timethe oil line filter element is cleaned.

3. Check compressor sound for abnormal noises.4. Check shaft seals for excessive oil leakage. A

small amount of oil leakage (approximately 10drops/min) is normal. This allows lubrication ofthe seal faces.

B. Weekly

(Items 1 thru 4 above plus 5 thru 7)

5. Check oil levels with unit off and liquid removedfrom separator.

6. Check oil pressure and review microprocessorlogs and log sheets.

7. Check refrigerant levels in vessels.

C. Monthly

(Items 1 thru 7 above plus 8 thru 10)

8. Lubricate all motors and bearings. Followmanufacturer’s instructions on lubrication.

9. Check calibration and operation of all controls,particularly safety controls.

10. Operate compressor capacity and volume ratiocontrols through their range both automaticallyand manually.( Recalibrate if necessary).

D. Trimonthly

(About 2000 operating hours)

Check movement of compressor rotor at drivecoupling end to determine bearing endfloat. (Re-fer to Service Section.)

E. Yearly

(Items 1 thru 10 and “D” above plus 11 thru 19)

11. Check entire system thoroughly for leaks.12. Remove all rust from equipment, clean and paint.13. Clean all oil strainers.14. Clean suction strainer – compressors.15. Check motors and fans for shaft wear and end

play.

Slide Valve Actuator Troubleshooting Guide Cont.

Bad thermal switch

Any of the reasons listed in “The mo-tor will not move in either direction”

Stripped gears inside the gear motoror the armature has come unpressedfrom the armature shaft


See above.


The motor runs sporadically

The motor runs but output shaftwill not turn

29

16. Check operation and general condition ofMicrocontroller and other electrical controls.

17. Drain and clean entire oil system through theseparator drain. Recharge with new clean mois-ture free oil. For proper procedure for changingthe strainer element and charging oil into thesystem, see Start-Up and Operation section.

18. Check the calibration of the microprocessorpressure transducers and RTD’s for accuracy.

19. Check mounting bolts for compressor and mo-tor.

F. System Leaks

There are any number of reasons why leaks developin a refrigeration system (i.e. drying out of valve pack-ing, yielding of gaskets, improper replacement ofvalve caps and loosening of joints due to vibration).For these reasons, the need for periodic leak testingcannot be over-emphasized. Similarly, when any ser-vice operations are performed on the system, careshould be exercised to insure all opened flanges aretightened, all plugs that were removed are replacedwith a suitable thread filling compound, all packingglands on valve stems are tightened, and all valvecaps are replaced. When operation is restored, alljoints opened or any valves moved during the ser-vicing should be checked for leaks.

G. Year Round Operation

On a continual basis:

1. Guard against liquid slugging of compressor.2. Maintain unit in clean condition and paint as

necessary.3. Grease valve stems and threads for the valve

caps.4. When refrigeration equipment is operated 24

hours a day year round, it is highly recom-mended that a yearly check of all internal partsbe made (see Service Section). While the high-est material standards are maintained through-out all Vilter compressors, continuous opera-tion and any presence of dirt may prove injuri-ous to the machine. To forestall needless shut-downs or prevent possible machine break-downs, the side covers should be removedyearly, and a visual inspection be made of theinternal parts. In this way, a small amount oftime spent checking machine conditions once a

year may prevent extensive shutdowns laterwith subsequent product loss and expensiverepairs.

30

Service Intervals Requirements

The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrigeration oilin VSM Single Screw Cool Compression Compressor units.

Group Inspection/ SERVICE INTERVAL (HOURS)MaintenanceItem

OIL CIRCUITOil Change (1)Oil Analysis (2)Oil Filters (3)Oil Strainer

Suction ScreenLiquid Line StrainersCoupling Alignmentand Integrity

CONTROL CALIBRATIONTransducersRTD’sInspect CompressorBearings

Key I Inspect.C CleanR Replace.S Sample.

25 (4

)50 20

05,

000

10,0

0020

,000

30,0

0040

,000

50,0

0060

,000

70,0

0080

,000

90,0

0010

0,00

011

0,00

012

0,00

0Notes: (1) The oil should be changed at these intervals, unless oil analysis results exceed the

allowable limits. The frequency of changes will depend on the system cleanliness.

(2) Oil analysis should be done at these intervals as a minimum; the frequency of analysiswill depend on system cleanliness.

(3) The oil filter(s) on a minimum must be changed at these intervals or annually if notrun continuously. However, the oil filter(s) must be changed if the oil filterdifferential exceeds 20 psi or oil analysis requires it.

(4) Initially the oil charge on existing system may need to be changed after 25 hoursdependent on the amount of contaminates in the system.

R R R R R R R R RS S S S S S S S S S S S S S

C C C C C C C C C C C C C C C CC C C C C C C C C C C C C C C C

C C C C C C C C C C C C C C C CC C C C C C C C C C C C C C C C

C C C C C C C C C C C C C C

I I I I I I I I I I I I I II I I I I I I I I I I I I I I I I I I I I

I

31

Operating Instructions

UNIT DESCRIPTION

Description of Operation

The Cool Compression operation is similar to the standard single screw packages, except that there is no external coolerto the unit. A blanket of liquid ammonia lies on top of the oil. The cooling occurs through the entire compression andseparation process. The compressor package is greatly simplified whereas there is no oil pump. Instead, the CoolCompression compressors utilize Suction Oil Injection for start-up. The following sections describe the start-up andoperation of a Cool Compression unit and refer to the figure above.

32

Start Up

When the Cool Compression unit is initiated for start-up, Micro-controller returns the slide valves to theirminimum positions. The suction oil injection sole-noid (SV-2) is actuated. The compressor (C100) nowstarts. There is an initial pressure drop in the suctionchamber of the compressor and a corresponding in-crease in pressure on the discharge of the compres-sor. This creates a pressure differential that forcesthe oil and liquid ammonia mixture through the suc-tion oil injection line into the suction chamber of thecompressor. This oil and liquid provides lubricationand cooling until full pressure differential lubricationis attained.

As the differential pressure increases, the oil and liq-uid ammonia is now injected into the screw during thecompression process and the (SV2) will close.

Gas Flow

The low-pressure refrigerant enters the compressorthrough a combination stop/check valve and suctiontee, into the suction of the compressor. The upstreampressure is measured by Pressure Transducer (PT1).The temperature of the refrigerant is measured by re-sistance temperature detector (RTD1). The refriger-ant gas flows into the compressor where a mixture ofoil and liquid refrigerant is added to the gas throughthe compression process. The compressed gas en-trained with liquid ammonia and oil droplets dischargesthe compressor. The discharge pressure and tempera-ture are monitored by pressure transducer (PT2) andresistance temperature detector (RTD2). The mixturedischarges into the separator where the ammonia andoil droplets are separated from the gas. The high-pressure gas discharges from the separator, throughthe discharge flange on the end of the separator.

Please Note

There are no coalescing elements or any other ser-viceable components located inside the separator.To prevent voiding the warranty, the separatorshould not be disassembled under any circum-stances.

Liquid Ammonia Supply

High-pressure liquid Ammonia is supplied to the com-pressor package by the main liquid supply line. Pro-visions must be made to allow an adequate liquid sup-ply to provide a source of liquid for cooling the com-pressor, while the compressor is running at operat-ing conditions. The liquid supply line is connectedto the in-line strainer to ensure that no debris entersthe solenoid (SV1) and level master control valveslocated downstream of the strainer. The solenoidvalve (SV1), is open during start-up and operation toallow the high pressure liquid ammonia to be fed tothe Level Master Control Valve. The Level MasterControl valve controls the amount of liquid refriger-ant entering the compressor based on level of theliquid refrigerant in the separator.

The Level Master Control sensing bulb and heaterare installed in the end of the separator. The sensingbulb monitors the height of ammonia in the separator.If the ammonia level in the separator is low, the sens-ing bulb is heated by the heater H2, which opens theLevel Master Control Valve. When the liquid level ishigh in the separator the heater H2 cannot heat thesensing bulb and the Level Master Control Valve willclose until the liquid level drops in the separator. Theoutlet of the Level Master Control is connected andallows liquid to be injected into the compressor. De-pending on the operating conditions and model ofthe compressor, the liquid injection could be througheither SV3 and or SV4.

Separation

The mixture of compressed gas, liquid ammonia andoil droplets is discharged from the compressor intothe separator. As the mixture moves through the sepa-rator, the oil and liquid refrigerant droplets separateout and fall to the bottom of the separator. A liquidblanket of ammonia, of approximately 2 inches indepth, remains on top of the oil within the separator.

The last stage of oil separation is completed with awire mesh element. This element does not requiremaintenance and is not a serviceable item. A drainline from the final stage of separation is attached tothe discharge end of the separator. A sight glass andadjustment valve is provided to visually and physi-cally monitor the flow. The drain line is connected to


33

the compressor to allow reinjection of the oil/ammo-nia mixture.

The dry compressed gas is discharged from the sepa-rator at 0º to 2º above the saturated discharge tem-perature. The oil temperature in the separator is moni-tored by RTD3.

Liquid and Oil Level Monitoring

The level of oil within the separator is monitored by afloat mounted within the separator, (LSL3). If the levelof oil falls below that level of (LSL3), an alarm is dis-played on the Vission/Vantage. When the level re-turns to a normal level above (LSL3), the alarm willautomatically be rest.

Should the level remain below (LSL3) for an extendedperiod of time, the compressor will eventually fail on aLO OIL Level failure.

If the ammonia level within the separator is too high,the Liquid Switch (LSH1) will open. If the liquid switchremains open for an extended period, the compressorwill eventually fail on HI LIQ Ammonia Level failure.The compressor failure can not be rest until the HILIQ Ammonia Level returns to normal operating level.In the case that an excess amount of liquid ammonia isinjected into the separator, the separator will also au-tomatically carry the liquid in droplet form out of theseparator and into the system.

Note: The Liquid Switch (LSH1) has been removed onthe on the new models. ( After August 2004)

There are two or three (depending on the size of theseparator) sight glasses in the end of the separator.True oil level will only be seen while the unit is shut-down and all liquid is removed from separator. Duringoperation, a mixture of oil and liquid ammonia will beviewed in the bottom sight glass. The Vission/Van-tage will monitor for low oil level during operation ofthe unit.

The Vission/Vantage monitors the compressor whileoperating. During start-up, the initial superheat maybe high. As long as the superheat continues to de-crease, indicating that there is liquid ammonia beingadded to the separator the unit will continue to oper-ate and load.

If the superheat on the discharge of the compressorduring normal operation reaches 5º F, this signifiesthere is not enough liquid ammonia being fed to thesystem. Solenoid SV3 (see note below) will then openallowing an increased amount of liquid ammonia to beinjected into the compressor system. If the superheatreaches 8º F, the unit begins to unload. If the super-heat continues to increase and reaches 20ºF, the unitwill activate an alarm . At 25ºF, the unit will shutdown.

Note: The solenoid (SV3) has been removed on theon the new models. ( After August 2004)

Compressor Lubrication and Cooling

While the unit is running a mixture of oil and liquidammonia is injected into the compressor during thecompression process. This mixture not only suppliesthe necessary lubrication, but it cools the internalcomponents during the entire compression process.The mixture is injected from the separator, through astrainer and Flow Switch FS1 to assure liquid flow,into the bottom of the compressor. The connectionfor Suction Oil Injection is also branched off this linesupplying liquid to the suction of the compressor forstartup.

Compressor Shut Down

When the CC compressor unit shuts down, the CCunit compressor unit has been designed to remain atdischarge pressure and not bleed down to suction.This will allow the liquid blanket to remain within theseparator under normal circumstances.

OIL SYSTEM

Checking The Oil Level

The oil level must be checked with the unit off for at-least 30 minutes and without any liquid ammonia in-side of the separator. During normal operation, onewill observe the liquid ammonia mixture in the bottomsight glass, not the actual oil level.

To remove the liquid from the separator, manuallyclose off the liquid supply line to the compressor while


34

running. The liquid ammonia level will slowly dropand the superheat will increase. The compressor willautomatically unload and once the superheat reaches25ºF, will shutdown. The user can now visually ob-serve the level of oil in the sight glass. The normaloperating level of the oil is observed in the lower sightglass on all CC units.

Separator Oil Level

Separator Initial filling ofDiameter separator

12” 1/3 of bottom sight glass16” 1/2 of bottom sight glass16” w/3 sight glasses 1/3 of the middle sight glass20” 1/3 of bottom sight glass

Please Note: that during the initial oil fill prior to start-ing the unit for the first time, the oil level will be slightlyhigher. Checking the oil level after a few hours, someof the oil will remain in the compressor on shutdownthus reducing the height of the oil in the separator.

If the unit is equipped with a heater in the separator,it is imperative you charge the oil into the separatorprior to energizing the control panel to prevent burn-ing out the immersion heater.

During the operation of the compressor the oil levelmay not show in the bottom sight glass. This is nor-mal during operation. The package is equipped withhigh and low oil level safeties to prevent the unit fromoperating with too high or low of an oil level. The oillevel should be checked with the unit off, the oil levelshould be half way up the bottom sight glass.

Adding Oil

The unit must be shutdown and should have the liq-uid ammonia removed prior to adding oil.

During shut down, the unit will be at discharge pres-sure. If this pressure is too high, causing an issueregarding the addition of oil, the pressure should bebled down to suction-SLOWLY.

Note: If you bled the separator to suction pressuretoo fast you might carry oil with it.

Use the valve at the bottom of the separator to con-nect the line to add oil. Start to add the oil and monitorthe level as you are adding.

Note: If the oil level is below the normal operatinglevel, fill to the initial filling level of the separator.(See: Separator Oil Level Table)


35

CHANGING ANDCLEANING FILTER

See page 61 for instructions on changing oil andfilters.

Oil Filter Element

The earlier style dual filter (Figure “B”) design allowsfor operation of either filter independently. This willallow changing/cleaning of the filters without shut-ting down the compressor by closing the appropri-ate valves.

Figure “A” is the current version of the dual filterassembly, which incorporates a selector level tochoose either or both filters for use. Figure “B” is theearlier style filter assembly that utilized two singlefilters assembled back to back.

When servicing any of these filters, isolate the as-sembly. Be sure to “Vent” the filter tank then drainthe oil from the canister using the drain plug on thebottom of the assembly. Remove the tank and ele-ment, use all appropriate refrigeration handling andventilation procedures. In order to isolate (Figure“A”) either filter, you must turn handle either CW toclose the left side filter and CCW to close the rightside filter. Note: the pin must be properly seated inthe hole. Although the selector lever on the current(Figure “A”) filter assembly can isolate one filter forservice, if an o-ring leak occurs on the valve, thesystem may need to have all liquid removed for ser-vice/cleaning of filter. The o-rings on the lever shouldbe changed, if this occurs.

In order to isolate (Figure “B”) you must close bothinlet and outlet valves for that filter by turning thehandles CW.

Clean the oil filter element as needed during the first25 hours, depending on the cleanliness of the sys-tem and after the first 50 and 200 hours of operation.This is noted on the microprocessor hour meter.Thereafter, clean the filter every three months or whenthe oil pressure drops (see: Vission/ Vantage Manualset point section), whichever occurs first.

Remove the filter element from the tank. Clean itthoroughly with “brake cleaning” fluid or similar.Before reassembling, clean the tank to lengthen the


Outlet ValveInlet Valve

Drain Plugs

Inlet ValveOutlet Valve

Fig.B Earlier Style DualFilter

HandleCW

To Close

Oil Filter Element

Handle

Drain Plugs

Fig.A Dual Filter

CW CCW

36

life span of the element. Strainer element end caps,and attached gaskets and springs can be re-used (withnew strainer canister gasket).

Replace canister gasket before reassembling strainertank. Place end caps on strainer element and placeinside tank with spring side to bottom of tank. Refillthe tank about 3/4 full of oil, attach it to the head andtighten the (4) bolts.

Liquid Injection Oil Cooling

The units are furnished with liquid injection for a typi-cal system. The liquid solenoid valve opens when-ever the compressor is in operation. The level masterexpansion valve controls the flow of liquid refrigerantto the compressor injection port in response to theliquid level in the separator. The discharge tempera-ture is always maintained at saturation. If the dis-charge is superheated, refer to the TroubleshootingSection.

CONTROL SYSTEM

Equipped for automatic operation, the screw compres-sor unit has safety controls to protect it from irregularoperating conditions, an automatic starting and stop-ping sequence, capacity and volume ratio control sys-tems.

Check all pressure controls with a remote pressuresource to assure that all safety and operating controllimits operate at the point indicated on the micropro-cessor. The unit can be equipped with optional blockand bleed valves that are used to re-calibrate the pres-sure transducers. To use the block and bleed valvesto re-calibrate the pressure transducers, the blockvalve is shut off at the unit and the pressure is al-lowed to bleed off by opening the bleed plug near thepressure transducer enclosure. The transducer canthen be calibrated at atmospheric pressure (0 PSIG),or an external pressure source with an accurate gaugemay be attached at the bleed plug.

The discharge pressure transducer cannot be isolatedfrom its pressure source, so it is equipped with only avalve to allow an accurate pressure gauge to be at-tached and the pressure transducer calibrated at unitpressure.

Recheck the transducer periodically for any drift ofcalibration.

Screw Compressor ControlAnd Operation

Starting, Stopping and RestartingThe Compressor

Before the screw compressor unit may start, certainconditions must be met. All of the safety setpointsmust be in a normal condition, and the suction pres-sure must be above the low suction pressure setpointto assure that a load is present. When the “On-Off”switch or “Manual-Auto” but on is pressed, theheater of the expansion valve bulb will be energizedand heated for 30 seconds before the compressor isallowed to start.

If the compressor is in the automatic mode, it will nowload and unload and vary the volume ratio inresponse to system demands.

Stopping the compressor unit can be accomplished anumber of ways. Any of the safety set points willstop the compressor unit if abnormal operating con-ditions exists. The compressor unit “On-Off” or stopbutton will turn the compressor unit off as will thelow pressure set point. If any of these conditionsturns the compressor unit off, the slide valve motorswill immediately energize to drive the slide valves backto 10% limit.

The control motors will be de-energized when therespective slide valve moves back below 10%. If thereis a power failure, the compressor unit will stop. Ifthe manual start on power failure option is selected(see appropriate Microprocessor Instruction Manual),restarting from this condition is accomplished by push-ing the reset button to insure positive operator con-trol. If the auto start on power failure option is se-lected (see appropriate Microprocessor InstructionManual), the compressor unit will start up after a wait-ing period. With both options, the compressor slidevalves must return below their respective 10% limitsbefore the compressor unit can be restarted.

Slide Valve Control

Capacity and volume ratio control of the screwcompressor is achieved by movement of the respec-tive slide valves, actuated by electric motors.


37

INC DEC INC DECVSM 201 CW CCW CW CCWVSM 301 CW CCW CW CCWVSM 361 CW CCW CW CCWVSM 401 CW CCW CW CCWVSM 501 CCW CW CCW CWVSM 601 CCW CW CCW CWVSM 701 CCW CW CCW CW

Actuator Location

View Capacity

ViewVolume Ratio

VSM 501CW Thru VSM701CW

View Capacity

ViewVolume Ratio

VSM 201 CCW Thru VSM 401CCW

When viewing the compressor from the dischargeend (opposite of the drive end) – on VSM 201-401capacity, is upper right and volume is lower left. Onthe Vsm 501-701, capacity is upper left and volume islower right. The table for command shaft rotation(above) indicates the direction of command shaft ro-tation required to increase or decrease the capacityor volume ratio. The range of capacity adjustment isfrom 10% to 100%, the range of volume ratio adjust-ment is from 2.0 to 7.0.

Actuation of the electric motors can be done auto-matically by the micro-controller or they can be manu-ally actuated through pop-up buttons on the touchscreen display when the micro-controller is put intothe manual mode.

In the automatic mode, the micro-controller deter-mines the direction that the motors will move in re-sponse to system conditions. In addition, there areon and off settings for the capacity motor that con-trols the increase and decrease cycles for the motor.This is done to prevent the control from overshoot-ing and allow the system to stabilize between slidevalve changes.

The Motor Amps Load Limit protects the compressorfrom overloading by decreasing the compressor ca-pacity if the motor amperage is above the Full LoadAmps set point. (See appropriate Vission/VantageOperating Manual.)

Oil Separator Heater

The oil separator heater keeps the oil in the separatorfrom becoming too viscous. The heater is turned ononly when the compressor is off. The separator heateris supplied with an integral temperature control.

Econ-O-Mizer Controls

Econ-O-Mizer® systems are of three types: direct ex-pansion, flooded or flash. Flash systems include aback pressure regulator to control intermediate pres-sure. When a direct expansion system is used,a sole-noid valve and thermostatic expansion valve are fur-nished to control the degree of subcooling. If aflooded subcooler system or flash system is supplied,it is equipped with a liquid solenoid valve and a floatswitch to control the liquid level in the vessel.


CompressorModel Number

Command Shaft RotationCapacity Volume Ratio

38

SETTING OF CONTROLS

Refer to the Vission / Vantage Instruction Manual fora list of initial settings.

Valve Settings

1. The suction stop/check valve is designed tooperate as a stop valve (manually open orclosed) or a check valve. The valve is normallypositioned in the automatic mode during unitoperation. Please refer to the tag on the valveto set it in the automatic position.

2. The discharge stop/check valve is designed tooperate as a stop valve (manually open orclosed) or a check valve. The valve is normallypositioned in the automatic mode during unitoperation. Please refer to the tag on the valveto set it in the automatic position.

3. Open the isolating valve(s) before and after theoil filter housings.

4. Open the oil return valve from oil separator 3/4turn.

SAFETY SETPOINTS

A detailed explanation of all safety setpoints can befound in the Vission / Vantage Instruction Manual forthe following:

Discharge Pressure

High discharge pressure cutout stops the compres-sor unit, when the discharge pressure in the oil sepa-rator exceeds the setpoint.

Suction Pressure

Low suction pressure cutout stops the compressorunit when the suction pressure drops below thesetpoint.

Oil Filter Differential Pressure

High oil filter differential cutout stops the compres-sor unit when the pressure difference between theoutlet and inlet of the filter exceeds the setpoint.

Oil Temperature

The oil temperature cutout stops the compressor unitwhen the oil temperature is too high or too low.

Discharge Temperature Superheat

The high discharge superheat temperature cutoutstops the compressor unit when the discharge tem-perature exceeds the setpoint.

See section Oil Instructions for instructions on add-ing oil to unit.

High Liquid Level

High liquid level alarm goes on when the liquid am-monia level in the separator is too high.


39

COMPRESSOR PRE START-UPCHECK LISTS

Before proceeding with the actual starting of the compressor, the items listed on the “PreStart-Up Check Lists (next 2 pages) must be verified. Time and money will be saved if theitems on the pre start-up check lists are completed before the Vilter Technician arrives.

Initial Start Up

40

Note: If start-up service has been purchased to save time and money the following items should be completedbefore the start-up person arrives.

____1. The unit should be leveled and secured to the mounting pad or floor.

____2. The suction and discharge line must be piped and properly supported independent of the unit.

____3. The discharge Stop/Check valve (if used) is shipped loose and must be installed in a vertical up-flowdirection or in a horizontal line with the valve stem pointing upward at a 45° angle. During off periodsrefrigerant can condense in the line downstream of the Discharge Stop/Check Valve. It is recommendedthat the Stop/Check valve be located to minimize the quantity of liquid that can accumulate downstreamof the valve.

____4. The Discharge and Suction Stop/Check valve must be set to the automatic position. Failure todo so could damage the compressor during the stop. (Reverse rotation)

____5. Piping for oil cooling:

A properly sized high-pressure liquid source (preferably a dedicated line) must be piped to the stop valveat the inlet of the thermostatic expansion valve.

____6. Initial Oil Charge: 12” Separator – 7 gallons – ½ bottom sight glass16” Separator (short 68”)– 9 gallons – 1/2 bottom sight glass*16” Separator (long 86”)–10.5 gallons –1/2 bottom sight glass** note: when using three sight glasses the oil level should be 1/3 of middle glass20” Separator 12.5 gallons – 1/3 bottom sight glass

____7. Before installing the center member, the motor directional rotation should be checked. Then, verify themotor hub is properly spaced to accommodate the center member.

____8. The unit should be pressure tested. Care should be taken to not pressurize excessively from the suctionend of the compressor, as this will drive the compressor in a forward motion without lubrication and maycause damage.

____9. Proper ammonia refrigerant charge should be in the system. Necessary equipment for installation of anyadditional refrigerant should be present at the job-site prior to the startup person’s arrival. In addition, anyrefrigerant handling equipment necessary to comply with local ordinances should also be at the job-site.

____10. Have a qualified electrician present to verify wiring during startup.

____11. A system load should be available at the time of the startup.

____12. Liquid Ammonia Supply (see Liquid Supply Section of manual).

Pre Start-Up Check ListField Piping and Mechanical Requirements

(Cool Compression)

41

NOTE: If start up service has been purchased, the following items should be completed before the start-up technicianarrives. This will help save time and money.

Note: Units with factory-wired microprocessor. The necessary field wiring is listed as below.

Vission_____ 1. Control power of 115 VAC 50/60 HZ must be wired to the connector. L1 is brought to connector 5, terminal 1 and

L2 is brought to connector 5, terminal 5. The fuses are part of the relay board. The neutral can be connected toany of the “N’s” located on the board.

Vission_____ 2. A dry contact from control relay K-22 must be wired to the compressor motor coil. This dry contact is wired to

connector 7, terminal 1 and connector 7, terminal 2. Control power for this coil should come from a source thatwill be de-energized with the compressor disconnect.

Vission_____ 3. A dry contact from control relay K-19 must be wired to the suction oil injection solenoid. This dry contact is wired

to connector 6, terminal 1 and connector 6, terminal 2. Control power for this coil should come from a sourcethat will be de-energized with the compressor disconnect.

Vission_____ 4. An auxiliary safety cutout is available to shut down the compressor package. A dry contact must be supplied and

wired to a L and connector 1, terminal 2. The jumper on the terminal strip between L and connector 1, terminal2 must be removed to use this cutout. The contact, if closed, will allow the compressor to run. If this contactopens at any time, the compressor will shut down.

Vantage_____ 1. Control power of 115 VAC 50/60 HZ must be wired to the connector. L1 is brought to connector 8, terminal 8 and L2 is

brought to connector 8, terminal 8. The fuse are part of the combo board. the neutral can be connected to any of the “N’s”located on the board.

Vantage_____ 2. A dry contact from control relay K-3 must be wired to the compressor motor coil. This dry contact is wired to connector

9, terminal 2 and connector 9, terminal 3. Control power for this coil should come from a source that will be de-energizedwith the compressor disconnect.

Vantage_____ 3. A dry contact from control relay K-5 must be wired to the suction oil injection solenoid. This dry contact is wired to

connector 8, terminal 1 and connector 8, terminal 1 and connector 8, terminal 2. Control power for this coil should comefrom a source that will be de-energized with the compressor disconnect.

Vantage_____ 4. An auxiliary safety cutout is available to shut down the compressor package. A dry contact must be supplied and wired to

L and connector 12, terminal 2. The jumper on the terminal strip between L and connector 12 terminal 2 must be removedto use this cutout. The contact, if closed, will allow the compressor to run. If this contact opens at any time, the compressorwill shut down.

Note: Vission has separate alarm and trip contact, Vantage has a combined trip and alarm contact.

Vission and Vantage

_____ 5. Indication of the compressors’ alarm or shutdown status is also available. To monitor the alarm status, wire to the alarmrelay on the board. It will have a 0 VAC potential when the compressor is operating normally, and go to 115 VAC whenin an alarm condition. To monitor the shutdown status, wire to trip relay on board. It will have a 0 VAC potential whenthe compressor is operating normally, and go to 115 VAC when in a shutdown condition.

Vission and Vantage

_____ 6. The current transformer supplied in the compressor motor conduit box should be checked to insure the motor leads of oneleg are pulled through the transformer. However, this should always be checked as different motors and starting methodswill require different leads to be used.

Pre Start-Up Check ListField Wiring Requirements

(Cool Compression)

42

GENERAL COMMENTS

When working on the compressor, care must be takento ensure that contaminants (i.e. water from meltingice, dirt and dust) do not enter the compressor while itis being serviced. It is essential that all dust, oil or icethat has accumulated on the outside of the compres-sor be removed before servicing the compressor.

When servicing the compressor, all gaskets, O-rings,roll pins and lock washers must be replaced whenreassembling the compressor.

PREPARATION OF UNIT FOR SERVICING

A) On Cool Compression units, while the unit is run-ning, close the main liquid ammonia line (locatedbefore the thermostatic expansion valve) and waitfor the unit to stop by itself. This operation willremove all the liquid ammonia from the separator.The compressor will stop when the superheat atdischarge reaches 25°F.

B) Shut down the unit, open the electrical discon-nect switch and pull the fuses for the compres-sor motor to prevent the unit from starting. Put alock on the disconnect switch and tag the switchto indicate that maintenance is being performed.

C) Isolate the unit by manually closing the dischargeStop/Check valve. If the unit is equipped with aV-PLUS® or liquid injection cooling system, closethe liquid supply valves and open all solenoidvalves to prevent liquid refrigerant from beingtrapped between the stop valves and solenoidvalves. Allow the unit to equalize to suction pres-sure before closing the Suction Bypass or Stop/Check valve. After the unit has equalized to suc-

tion pressure and suction valves closed. Use anacceptable means to depressurize the unit thatcomplies with all Local, State and Federal Ordi-nances.

D) Remove drain plugs from the bottom of compres-sor housing and the discharge manifold. On unitsequipped with Suction Oil Injection (SOI) manu-ally open the SOI solenoid valve below the com-pressor. Drain the oil into appropriate contain-ers.

REMOVAL OF COMPRESSORFROM THE UNIT

After Preparing the unit for service the following stepsshould be followed when removing the compressorfrom the unit:

A) Disconnect the motor drive coupling from thecompressor input shaft.

B) Disconnect all gas and oil piping which is at-tached to the compressor. When removing thesuction strainer on VSM units, the suction lineshould be supported to prevent it from sagging.

C) Replace oil drain plug in compressor housingand discharge manifold after oil has stoppeddraining.

All Oil must be removed from unit.

D) Remove all electrical connections to the com-pressor.

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43

On VSM with C- flange the motor/C-flange/com-pressor assembly must be supported with a chainfall or other lifting device, before the bolts hold-ing the compressor to the C-flange adapter canbe removed.

F) Install appropriate lifting eye into a threaded holeon the top of the compressor.

Verify unit is properly secured to avoidcompressor from falling.

Re-verify all piping and electrical are properlydisconnected prior to lifting unit.

G) Remove compressor from the unit, verify ad-equate amount of room needed for clearance andweight of the bare compressor when the com-pressor is removed from the unit.

INSTALLATION OF THE COMPRESSOR

A) After the work has been completed, reinstall thecompressor on the base or C-flange adapter (de-pendent upon compressor model).

B) On VSM units, the compressor should be boltedonto the C-flange adapter and the coupling rein-stalled.

C) Replace all electrical, gas, liquid and oil connec-tions removed when servicing the compressor.

LEAK CHECKING UNIT

Note: Unit must be leak checked before evacua-tion.

CAUTION

Slowly pressurize the unit from the discharge sideof the compressor. Pressurizing the compressor fromthe suction side may cause rotation of the compres-sor without oil supply, which could lead to internaldamage.

A) Use a vacuum pump to evacuate the unit.

B) Break the vacuum on the unit using refrigerantor dry nitrogen and check for leaks. Concentrateon areas where work was done.

C) If no leaks are found, the unit can be returned toservice if refrigerant was used for the leak detec-tion gas.

If dry nitrogen was used for the leak detectiongas, the nitrogen must be purged from the unitand step A and B should be repeated, this timebreaking the vacuum with refrigerant. The unitmay now be returned to service.

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44

ANNUAL INSPECTION

The Vilter Single Screw Compressor is designed forlong periods of trouble free operation with a mini-mum of maintenance. However, a yearly inspectionis recommended so any irregular wear is noted andrectified. At this time, the bearing float is measuredfor the main rotor and gate rotors.

The following are the procedures used in measuringthe main rotor and gate rotor bearing float.

CAUTION

When taking the measurements, do not exceed 300to 500 Lbs. of force at point of contact or damagemay result to the bearings.

A) Shut down and de-pressurize the unit, as out-lined in section 0.01.

B) Main rotor bearing float.

1) Remove the coupling guard, then removethe center member from the coupling.

2) Attach a dial indicator to the compressorframe as shown and zero indicator. Place alever arm and fulcrum behind the compres-sor coupling half and push the coupling to-wards the motor (note measurement).

TABLE 0.1 MAXIMUM BEARING FLOAT

MAIN GATEBearing Float 0.003” 0.002”Maximum Force 300 to 500 200 to 300

Lbs. Lbs.

3) Re-Zero indicator, now position the fulcrumon the motor and use the lever arm to pushthe input shaft towards the compressor(note measurement).

4) Add both readings, the total indicator move-ment is the bearing float and this shouldnot exceed 0.003”.

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45

C) Gate rotor bearing float.

1) Remove the side covers (see: Gaterotor Re-moval Section) and position a dial indicatoron the gate rotor.

2) Use a lever arm pivoting on a bolt with asmall block of wood against the gate rotorblade to protect the blade.

3) The maximum amount of bearing floatshould not exceed 0.002”.

D) Measure the gate rotor to blade float. Somemovement between blade and support is neces-sary to prevent damage to the compressor blade,however at no time should the blade uncoverthe support.

1) Position the blade with the gate rotor damperpin and 90º to the main rotor.

2) Position a dial indicator at the tip of the sup-port. The total movement of the damper pinin the bushing is the gate rotor float. Referto table 0.2 to find the maximum blade tosupport float (on new compressor parts).

TABLE 0.2. GATE ROTOR FLOAT

MODEL FLOATVSM 71 THRU 401 0.045”VSM 501 THRU 701 0.045”

E) Readings could be higher than 0.2. Ifreadings is greater than 0.30 on tablecontact Vilter’s home office.

F) Inspect the main and gate rotors forsigns of abnormal wear due to dirt orother contaminants from the system.

G) After the inspection is complete, thecovers, coupling center member andguard can be reinstalled and the unit canthen be evacuated and leak checked be-fore starting.

0.06 NORD-LOCK WASHERS

A) Nord-Lock® lock washer sets are used in manyareas on the Single Screw Compressor that re-quires a vibration proof lock washer.

B) The lock washer set is assembled so the courseserrations that resemble ramps are mated together.

C) Once the lock washer set is tightened down, ittakes more force to loosen the bolt then it didto tighten it. This is caused by the washersriding up the opposing serrations.

ramp.

Fine serrations face out.

Coarse serrationsmate together.

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Coarse Serrationsmate together

46

D) Turn the main rotor so the driving edge of thegroove is between the top of the shelf or slightlybelow the back of the gate rotor support. At thispoint install the gate rotor stabilizing tool.

E) Remove plug on the thrust bearing housing.Loosen the socket head cap screw that is lo-cated underneath the plug. This secures the in-ner races of the thrust bearings to the spindle.

F) Remove bolts that hold the thrust bearing hous-ing to the compressor. Insert two of the boltsinto the threaded jacking holes to assist in re-moving the bearing housing from the compres-sor. When the housing is removed, there will beshims between the spindle and thrust bearings.These control the clearance between the shelfand gate rotor blades. These must be kept withtheir respective parts for that side of the com-pressor.

G) Remove the bolts from the roller bearing hous-ing. After the bolts have been removed, the hous-ing can be removed from the compressor.

H) To remove the gate rotor support tool, carefullymove the support opposite the direction of rota-tion and tilt the roller bearing end towards thesuction end of the compressor. The compressorinput shaft may have to be turned to facilitatethe removal of the gate rotor support. On dualgate versions, repeat the procedure for the re-maining gate rotor support assembly.

Service Section

GATE ROTOR ASSEMBLY

GATE ROTOR REMOVAL

Note: The thrust bearing outer races are not securedin a stationary bearing housing on the compressors.On VSM compressors the thrust bearings are locatedin the gate rotor support and rotate with the supportwhen the compressor is in operation. The inner racesare secured to the stationary bearing spindle.

A) Prepare the compressor for servicing as outlinedin section: Preparation of Unit.

B) Remove the upper bolt from the side cover andinstall a guide stud in the hole. Remove the re-maining bolts and side cover. There will be someoil drainage when the cover is removed.

C) The side cover that contains the suction strainershould have the suction line properly supportedbefore the bolts securing the line to the covercan be removed. After the line is removed, thecover can be removed per paragraph B.

47

GATE ROTOR INSTALLATION

A) Install the gate rotor support. Carefully tilt theroller bearing end of the gate rotor support to-wards the suction end of the compressor. Thecompressor input shaft may have to be rotatedto facilitate the installation of the gate rotor sup-port.

B) Install the roller bearing housing with a new O-ring. Tighten the bolts to the recommendedtorque value.

C) Install the spindle with shims, tighten the boltsto the recommended torque value, measure theclearance between the shelf and blade.

D) Check the clearance between the entire gate ro-tor blade and the shelf, rotate the gate rotor tofind the tightest spot. It should be between 0.003”-0.004”. Make adjustments, if necessary. It ispreferable to shim the gate rotor blade looserrather than tighter against the shelf.

E) Once the clearance is set remove the spindle.Install new o-ring, apply Loctite 242 thread lockerto the socket head cap screw clamping the thrustbearings to the spindle. Torque all bolts to therecommended torque values.

F) Install side covers and or remove suction tee withnew gaskets. Tighten bolts to the recommendedtorque value. The unit can now be evacuatedand leak checked as outlined in section 0.03.

GATE ROTOR BLADE REMOVAL

A) Remove the gate rotor assembly. Refer to sec-tion: Gate Rotor Removal.

B) Remove the snap ring and washer from the gaterotor assembly. Lift gate rotor blade assemblyoff the gate rotor support.

C) Check damper pin and dampener bushing for ex-cessive wear. Replace if necessary.

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Gaterotor for C-flange Models

48

GATE ROTOR BLADE REMOVAL

A) Install damper bushing (120) in gate rotorblade (111) from the back side of the blade.Be sure the bushing is fully seated.

B) Place the blade assembly on the gate rotor sup-port. Locating damper over bushing pin.

C) Install washer (119) and snap ring (130) on gaterotor assembly. The bevel on the snap ring mustface away from the gate rotor blade. After thegate rotor blade and support are assembled, thereshould be a small amount of rotational move-ment between the gate rotor and support.

D) For installation of the gate rotor assembly andsetting of gate rotor clearance, refer to section1.02.

GATE ROTOR THRUST BEARINGREMOVAL

1) Remove retaining ring that holds thrust bear-ings in gate rotor support.

2) Remove bearings from support.

3) Remove bearing retainer from inner race.

GATE ROTOR THRUST BEARINGINSTALLATION

1) Install retainer in the back of the inner raceof one of the thrust bearings. The back ofthe inner race is the narrower of the two sides.

2) The bearing with the retainer should beplaced in the housing first, retainer towardsthe support. Install the second bearing. Thebearings should be positioned face to face.This means that the larger sides of the innerraces are placed together. A light applica-tion of clean compressor lubricating oilshould be used to ease the installation ofthe bearings into the gate rotor support.

Service Section

Top of Blade

Back of B lade

Lip on gaterotor bladeis positioned up and awayfrom the support.

120

111

49

Inner Retainer

Ball BearingsRetaining Ring

3) Install the bearing retaining snap ring.

4) For installation of the bearing housing andthe setting of the gate rotor blade clearance,refer to section: Gate Rotor Installation.

GATE ROTOR ROLLER BEARINGREMOVAL

A) Refer to section: Removal of the Gate Rotor Bear-ing housings and gate rotor supports.

B) Remove the snap ring (131), which retains theroller bearing in the bearing housing.

C) Remove the roller bearing (125) from the bearinghousing (112).

D) Use a bearing puller to remove the roller bearingrace (125) from the gate rotor support (110).

GATE ROTOR ROLLERBEARING INSTALLATION

A) Match up the part numbers on the inner race tothe part numbers outer race, first install shim (155)on support. Press the bearing race (numbers vis-ible) onto the gate rotor support.

B) Install the outer bearing into the bearing hous-ing so the numbers match the numbers on theinner race. Install the snap ring retainer in thehousing. The bevel on the snap ring must faceaway from the roller bearing.

C) For installation of the bearing housing, refer tosection Gate Rotor Installation.

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Numbered Side

50

INPUT SHAFT SEALREPLACEMENT

On Vilter VSM compressors the type of seal utilizedhas a stationary carbon and a rotating mirror face.

INPUT SHAFT SEAL REMOVAL

A) Prepare the compressor for servicing as outlinedin section 0.01.

B) Remove bolts (281) holding the shaft seal cover(218). Insert two of the bolts into the threadedjacking holes to assist in removing the cover.There will be a small amount of oil drainage asthe cover is removed.

C) Remove the rotating portion of the shaft seal(219C) off shaft.

D) Remove oil seal (230) from cover.

E) Remove the carbon cartridge portion of the shaftseal (219B) from the seal cover using a brassdrift and hammer to tap it out from the back sideof the seal cover.

SHAFT SEAL INSTALLATION

A) Install new oil seal in clean cover.

CAUTION

Care must be taken when handling the shaft sealand mirror face so it is not damaged. Do not touchthe carbon or mirror face as body oil and sweat willcause the mirror face to corrode.

B) To install the carbon cartridge part of the seal in

230 218 265 260 219B

219C219A281

Roll pin # 265 only usedon VSS 751 and larger.

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260

261

Stationary seal265

51

the seal cover; remove protective wrap from thecarbon cartridge, do not wipe or touch the carbonface. Lubricate the sealing O-ring with clean com-pressor lubricating oil. Install cartridge using sealinstallation tool or similar.

C) Wipe clean, the compressor input shaft and theshaft seal cavity in the compressor housing.Apply clean compressor oil to the shaft seal seat-ing area on input shaft.

D) Lubricate the inside area of the rotating seal withclean compressor lubricating oil, do not wipe ortouch the face of the rotating portion of the seal.Align the slot in the rotating seal with the drivepin on the compressor input shaft. Carefully pushthe seal on, holding onto the outside area of theseal until the seal seats against the shoulder onthe input shaft. Make sure the seal is seatedagainst the shoulder. If the seal is not fully seatedagainst the shoulder, the shaft seal carbon willbe damaged when the seal cover is installed.

Maintenance Suggestion:

A spray bottle filled with clean compressor oil may beused to lubricate the faces of the seals without touch-ing the seal.

E) Install a new O-ring on the seal cover, makingsure the O-ring is placed in the proper O-ringgroove and not the oil gallery groove. Lubricateboth seal faces with clean compressor lubricat-ing oil.

F) Carefully install the seal cover on the compres-sor shaft, evenly tightening the bolts to the re-commended torque values.

G) Install the coupling and coupling guard. Theunit can then be evacuated and leak checked, asoutlined in section 0.03.

MAIN ROTOR ASSEMBLY

Due to the procedures and tools involved in the dis-assembly and reassembly, the main rotor assemblymust be performed by qualified individuals. Pleaseconsult the factory if maintenance is required.

Service Section

Align slot in sealwith dowel pin orkey in shaft.

Make sure that seal isbottomed against shoulder on shaft.

265

Align slot in sealwith dowel pin orkey in shaft.

52

CAPACITY AND VARIABLEVOLUME RATIO CONTROLASSEMBLY

A) The following instructions are applicable for mostunits equipped with optical gear motors builtafter 11-1-01.

B) On VSS units and dual gate VSM units, each pairof volume or capacity slide valves are mechani-cally connected and actuated to move as a bal-anced pair.

Note: Models VSM 501-701 capacity and volume motorlocation is opposite.

OPTICAL SLIDE VALVEACTUATOR REMOVAL

A) Follow appropriate lock out tag out proceduresto shut off the electricity to the microprocessor.Disconnect cables from actuator.

B) Remove the side covers from the bracket to gainaccess to the shaft collar.

C) Loosen shaft collar locking screw. Slide the col-lar onto the actuator shaft. Lightly tighten lock-ing screw to hold it in place.

D) Remove the (4) #10 socket head cap screws hold-ing the bracket to the base plate.

E) Remove slide valve actuator from the unit. Re-move key from command shaft.

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53

OPTICAL SLIDE VALVEACTUATOR INSTALLATION

A) Install the key in the command shaft keyway.

B) Slide the actuator assembly on to the commandshaft. While aligning one of the two key slots inthe actuator shaft with the key on the commandshaft. Make sure that the collar remained on theactuator shaft. Due to the position of the slidevalve in the compressor, use of the other key slotmay be required to align the bracket holes withthe threaded mounting plate holes.

C) Slide the collar until it is flush with the end of theactuator shaft. Check to make sure the key isfully inserted in the actuator shaft. The key shouldbe flush with the end of the actuator shaft.

D) Tighten the shaft collar ¼” socket head cap screwto 16 ft/lbs. (192 in/lbs.). Failure to correctlytorque the locking screw may result in a failureof the actuator.

E) Install the side covers to the bracket with hexwasher head self tapping screws.

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54

Service Section

OPTICAL SLIDE ACTUATOR INSTALLATION

A) Remove the four self tapping screws that securethe side covers to the actuator bracket. This willallow access to the actuator shaft.

B) Install the key in the command shaft keyway.

C) Slide the actuator assembly on to the commandshaft. Align one of the two key slots in the ac-tuator shaft with the key on the command shaft.Make sure that the collar remained on the actua-tor shaft. Due to the position of the slide valve inthe compressor, use of the other key slot may berequired to align the bracket holes with thethreaded mounting plate holes.

D) Slide the collar until it is flush with the end of theactuator shaft. Check to make sure the key isfully inserted in the actuator shaft. The key shouldbe flush with the end of the actuator shaft.

E) Tighten the shaft collar ¼” socket head cap screwto 16 ft/lbs. (192 in/lbs.). Failure to correctly torquethe locking screw may result in a failure of theactuator.

F) Install the side covers to the bracket with hexwasher head self tapping screws.

G) Refer to the slide valve actuator calibration in-structions in the Vission/Vantage manual or theinstructions packed with actuators on calibra-tion procedures.

COMMAND SHAFT ASSEMBLY REMOVAL

The following steps can be used to remove or installeither the capacity or volume command shaft assem-blies.

A) Prepare the compressor for servicing as outlinedin section: Preparation of Unit for Service.

B) Follow the appropriate instructions to removecontrol actuator as outlined in sections: Capac-ity and Variable Ratio Control Assembly.

457 477 415

C) Remove four socket head cap screws (457) andNord-Lock washers (477) securing mountingplate (415) to manifold.

D) The command shaft and mounting plate may nowbe removed from the compressor.

COMMAND SHAFT ASSEMBLYINSTALLATION

A) Install the command shaft assembly with a newo-ring (446) on the manifold. Make sure that thecommand shaft tongue is engaged in the crossshaft slot. Rotate the bearing housing so thevent holes point down, this will prevent waterand dust from entering the vents.

Command shaftassembly.

Align the tongue of the command shaft with the groove in the cross shaft.

446

Rotate bearing housingso vent hole points down.

B) Install the actuator mounting plate with the foursocket head cap screws and Nord-Lock washerssecuring it with proper torque.

55

COMMAND SHAFT BEARING AND O-RINGSEAL REASSEMBLY

A) Install new O-ring seal in housing and lubricatethe O-ring with clean compressor oil. A vent holeis provided in the command shaft bearing hous-ing to allow any refrigerant and oil that may leakpast the O-ring seal to vent to atmosphere andnot into the slide valve motor housing.

B) Remove any burrs from the command shaft toprevent damage to the O-ring when assembling.Install snap ring retainer and washer on the com-mand shaft. Press the command shaft bearingonto the command shaft. Insert the commandshaft into the housing applying pressure on outerrace of bearing. Make sure the bearing is fullyseated in the command shaft housing. Install thesnap ring retainer (451) in the command shafthousing.

C) Install command shaft assembly as outlined insection: Optical Slide Actuator Installation.

DISCHARGE MANIFOLD REMOVAL

A) Remove both control actuators and commandshaft assemblies as outlined in sections: OpticalActuator Removal and Command Shaft Removal.

Note: Manifold has dowel pins to locate it on thecompressor housing. Therefore, remove manifoldstraight back approximately 1” as not to breakdowel pins.

547

548

549

550

551

540

536

512511

519

Guide rodsDischargespool

C) The unit can now be leak checked as outlined insection: Leak Check Unit.

COMMAND SHAFT BEARING AND O-RINGSEAL REPLACEMENT

A) Remove command shaft assembly as outlined insection 4.05.

B) Remove snap ring retainer (451) from commandshaft housing (412). Push the command shaftassembly out of the housing.

C) The command shaft bearing (435) is a press fit onthe command shaft (413). Remove the commandshaft bearing with a suitable press.

436

445

Vent hole.

D) Remove the O-ring seal (445) from the commandshaft housing. The command shaft bushing (433and 436) might have to be removed to gain ac-cess to o-rings. Replace bushing if the bore isdeeply scored or excessively worn, using bush-ing (vpn 25853B).

Service Section

On divison 2only

56

NOTE:When removing the discharge manifold on VSM com-pressor the compressor must be properly supportedto keep the compressor from moving when the mani-fold is removed.

B) On VSM compressors unbolt the discharge flangefrom the discharge manifold.

C) Remove one bolt from each side of the dischargemanifold and install (2) guide rods approximately6” long, to support the manifold. Remove theremaining bolts (note length and location of bolts)and take off the discharge manifold.

DISCHARGE MANIFOLD INSTALLATION

A) Install (2) guide rods to position the dischargemanifold. Install a new manifold gasket and thedischarge manifold. Align the dowel pins andbolts, tighten manifold bolts to the recommendedtorque value.

B) On VSM compressors install the bolts in the dis-charge flange. Install the drain plug in the bot-tom of the discharge manifold.

C) Install both command shaft assemblies and con-trol actuators as outlined in sections; Optical SlideValve Actuator Removal and Command ShaftRemoval.

SLIDE VALVE GEAR AND RACKINSPECTION

A) Remove the discharge manifold as outlined insection: Discharge Manifold Removal.

B) Check rack to rack clamp and rack clamp spacerclearance on slide valves.

Note Models 501-701 DO NOT have Rack Clamps.RACK CLEARANCE VALUES

MEASUREMENT CLEARANCE

Rack to clamp. 0.005 to 0.010”Rack to clamp spacer. 0.003 to 0.005”

C) Check torque of socket heat cap screws.

D) Check for excessive movement between the slidevalve rack shafts and the rack. The jam nuts onthe end of the slide valve rack shaft should betight.

E) Check for loose or broken roll pins in gears.

Loose nuts Roll pinsRack toclamp

Rack to

spacerclamp

Check

on captorque

screws

F) Look for any excessive wear on all moving partsand replace the worn parts.

G) Reassemble the manifold and discharge elbowas outlined in section: Discharge Manifold In-stallation.

REMOVAL OF CAPACITY ORVOLUME CROSS SHAFTS

A) Remove the discharge manifold as outlined insection: Discharge Manifold Removal.

B) To remove the capacity or volume ratio slidevalve racks, remove the two jam nuts and lockwashers (361) securing the rack (316) to the slidevalve shafts. The racks can now be pulled offthe slide valve shafts. Repeat the procedure forthe remaining pair of slide valve racks.

Service Section

57

286 363323220

226

225

222

361316224

C) To remove the cross shafts, remove sockethead bolts, clamp and spacers from both sides.

VSM compressors cross shafts.

D) Loosen either set-screws (297 or 298) to be ableto remove roll-pins. Drive the roll pins from pin-ion gear from one side. Remove pinion gear. Slidethe cross shaft with the remaining pinion gear orspacers out from the opposite side. Repeat theprocedure for the remaining cross shaft.

INSTALLATION OF CAPACITY ORVOLUME CROSS SHAFTS

A) To reassemble either set of capacity or volumeratio slide valve racks, install the cross shaft withthe pinion gear onto the end plate, place the re-maining pinion gear on the shaft and drive in theroll pins. Install clamps, spacers and bolts onboth sides. Tighten the bolts to the recommendedtorque values.

B) The slide valve sets must be synchronized ondual gate VSM units. Both slide valve racks foreither the volume ratio or capacity slide valvesmust engage the cross shaft gears at the sametime. Push the slides all the way towards thesuction end of the compressor until they stop.Engage matching slide racks with gears for ei-ther capacity or volume and install them com-pletely on slide valve shafts. Install washers andjam nuts on the slide valve shafts. Repeat theprocedure for the remaining set of slide valveracks.

must engage the axleshaft gears at the same time.

When installing the slidevalve racks, both racks

C) Install (2) guide rods to position the dischargemanifold. Install a new manifold gasket and thedischarge manifold. Install the dowel pins andbolts, tighten manifold bolts to the recommendedtorque value.

D) Install the discharge as outlined in section: SlideValve Gear and Rack Inspection.

Service Section

58

Trouble Shooting Guide

Overheating / Dischargesuperheat too high.

Not enough liquid before theexpansion valve.

Solenoid before the expansion valve will not open.

Expansion valve is notsupplying enough liquid.

Heater in the expansionvalve bulb does not work.

Heater in the expansionvalve bulb in not inserteddeep enough into the well.

Too much oil in the separa-tor.

Oil injection strainer

Liquid injection strainersdirty.

Discharge temperature RTDoff calibration.

Main oil injection filter /strainer clogged.

Check the sight glass to see if this is full ofliquid. If there is no or foamy liquid in sightglass check for proper liquid supply.

1. Check if solenoid coil is energized. Ifthere is voltage being supplied to thecoil, replace solenoid coil.

2. If there is no voltage being supplied tothe coil, check output module ofMicroprocessor.

3. Manually open solenoid to check for proper operation of solenoid

Change the superheat adjustment of thevalve by turning the superheat-adjustingstem on the valve..

Remove the heater from the bulb to check ifit is warm. (Make sure to insert it back tothe end of the bulb bore)

Check the heater for continuity withOhmmeter. If reading is infinite or shorted,replace coil. Heater resistance should bebetween 960 and 1000 ohms.

Check the position of heater in well andreadjust it accordingly.

See: Checking Oil Level Instructions

Remove and clean strainer, reinstall.

Remove and clean expansion valve andliquid line strainers, reinstall.

Recalibrate discharge RTD.

When this filter is clogged, the compressorwill overheat only when the liquidexpansion valve is closed. As soon as thevalve reopens the compressor will runnormally. If you have this intermittentoverheating problems stop the compressorimmediately and clean the filter/strainer.

59


High liquid level.

Low liquid level.

Low oil level.

Expansion valve not set upproperly.

Too much, oil in the separa-tor.

Liquid level too high at lowratio, waves in the separatorare too high causing a falseindication.

Check for proper operationof the expansion valve.

High superheat adjustment ofthe expansion valve.

Heater malfunctioning.

Liquid line strainer plugged.

Expansion valve power heador sensor bulb faulty.

Checking oil while unit isrunning.

Unit shuts down.

Low oil level alarm at start.

Too much liquid beingsupplied to separator.

Foaming of liquid and oil inseparator.

Adjust the superheat setting of theexpansion valve to maintain proper liquidlevel.

The oil will cover the bulb and theexpansion valve will stay open.

Reset the valve to drop the level (1/4”) ofliquid in the separator.

Observe the liquid flow in the sight glassbefore the expansion valve on the liquidline. If there is no apparent flow, rapidlyclose and open the hand service valve tocheck if the liquid is flowing to thecompressor.

Adjust the expansion valve superheat settingto maintain proper liquid level.

Check resistance of heater. Heaterresistance should be between 960 and 1000ohms.

Liquid line strainer plugged.

Replace expansion valve power headassembly.

The running oil level is below the sightglass. Check oil level after unit has beenshut down at least 30 minutes with thesuction oil injection valve on. This allowsthe oil in the compressor to migrate back tothe separator.

6 hours after displaying a low oil levelalarm the unit will shut down, if no oil isadded during this time

Low oil level alarm due to large volume ofoil being supplied to compressor at start,alarm should end within a few minuteswhen the oil level stabilizes.

Excessive amounts of liquid will allow theseparator to operate inefficiently. Lowerliquid level by adjusting expansion valvesuperheat setting.

Foaming of liquid and oil in separator.Large variations in discharge pressure willallow flashing of the liquid in the separator.Adjust head pressure controls to maintain amore stable head pressure.

60


Low oil level.

(Continued).

Excessive oil foam.

Liquid line overheating tocompressor..

¼” drain line from separatornot open enough.

Not enough oil in separator.

Not enough liquid beingsupplied to the separator.Loss of or low liquid supplyfrom expansion valveLoss of or low liquid supplyfrom expansion valve

Depending on operating condi-tions, the line may need to befully open.

Check for proper level in theseparator.

1. Check if expansion valve isoperating, observe the sightglass.

2. Check the adjustment of theexpansion valve.

3. Check the heater.4. Check the liquid line and

expansion valve strainers.5. Replace the expansion valve power head assembly.6. Check if expansion valve is

operating, observe the sightglass.

7. Check the adjustment of theexpansion valve.

8. Check the heater.9. Check the liquid line and

expansion valve strainers.10. Replace the expansion valve power head assembly.

62

Dual Filter Valve Seal Replacement

INSTRUCTIONS – VALVE SEAL REPLACEMENT

Follow these step by step instructions when valve seal replacement becomes necessary. Warranty on thevalve will be voided, if these instructions are not followed.

WARNING: DO NOT TWIST THE VALVE PLUG DURING REMOVAL OR INSTALLATION. THIS WILLCAUSE PERMANENT DAMAGE TO THE VALVE PLUG AND/OR VALVE BODY MACHINED SURFACES.

DISASSEMBLY:

1. Bring the handle to the center (down) position.

2. Clean the front and back of the valve assembly of all possible contaminants.

CAUTION: THE RETAINING RINGS ARE IN A HONED VALVE BODY AND REQUIRE SPE-CIAL CARE WHILE REMOVING. IMPROPER HANDLING COULD CAUSE PERMANENTDAMAGE TO THE VALVE BODY AND COULD VOID THE WARRANTY.

3. Remove front retaining ring and pull out the valve plug assembly. If required, lightly push ortap on the back at the center of the plug.

DO NOT twist the plug while removing (see above warning). Caution must be observed whileremoving the plug assembly to avoid losing the ball and spring they will become loose items.

4. Check for any damage to the valve plug and valve body. Do not attempt to repair any partswithout consulting the factory. These parts are machined to close tolerances.

5. Remove the (seals) two O-Rings(1) from the plug and one O-Ring(2) from the valve bore rear.

CLEANLINESS:

Cleanliness is important for proper sealing and long seal life. Every precaution must be taken to insurethat all parts are clean prior to assembly. Foreign particles, dirt, metal chips, etc. in the valve may causeleakage and can damage the seals, thus reducing their life.

HandleShaft

O-Ring2176AU (2)

O-Ring2176X (1)

Front View Inside View of Valve PlugAssembly (located in housing)

1 2

63

VSM Cool Compression Spare Parts List

ITEMDESCRIPTION Separator Size

12” 16” 20”QTY VPN QTY VPN QTY VPN

RTD w/ turck connector 1 2611 G 1 2611 G 1 2611 GPressure Transducer 1 2783J 1 2783J 1 2783JHeater 1 3116 A 1 3116 A 1 3116 ARTD Transducer cordset 1 3122 B 1 3122B 1 3122 B

Oil Filter strainer basket(20” canister) inc’s all gasketsSingle Filter Assembly 1 3150D 1 3150D 1 3150DDUPLEX Canister Kit 1 3150S 1 3150S 1 3150SOil Filter strainer basket assemblywith magnets for 20” canister 1 3150F 1 3150F 1 3150FFilter Canister Gasket (Only) 1 1448B 1 1448B 1 1448BPleated Filter 10 micron 1 3150M 1 3150M 1 3150MPleater Filter 20 micron 1 3150N 1 3150N 1 3150NSuction Oil Injection Solenoid 115V 1 3035 BABBF 1 3035 BABBF 1 3035 BABBFSuction Oil Injection Solenoid 1 3035 BBBBF 1 3035 BBBBF 1 3035 BBBBF208/230VReplacement solenoid coil - 115V 1 3035U 1 3035U 1 3035UReplacement solenoid coil 1 3035V 1 3035V 1 3035V208/230VSuction Oil Strainer ¾” FPT 1 3144 A 1 3144 A 1 3144 AHigh Liquid Level Switch 1 3152 A 1 3152 A 1 3152 ALow Level Oil Float Switch 1 3147 A 1 3147 A 1 3147 A20 Ton TXV Liquid Injection Valve 1 A27565A 1 A27565A 1 A27565A30 Ton “ 1 A27565B 1 A27565B 1 A27565B50 Ton “ 1 A27565C 1 A27565C 1 A27565C75 Ton “ 1 A27565D 1 A27565D 1 A27565D100 Ton “ 1 A27565E 1 A27565E 1 A27565ELMC Heater Assembly 120 v/15watt 1 3208A 1 3208A 1 3208ALMC Powerhead assy 20-100TR 1 A27565F 1 A27565F 1 A27565F20 Ton -Liquid Injection strainer 1 2875 G 1 2875 G 1 2875 G30 Ton – 100 Ton “ 1 2875 H 1 2875 H 1 2875 HLiquid Injection Solenoid 120V 1 2875 F 1 2875 F 1 2875 F120V – Replacement Coil 1 2562 J 1 2562 J 1 2562 J240V – Replacement Coil 1 2562 K 1 2562 K 1 2562 KOil, Vilter R717, 5 gal. 1 2939 A 1 2939 A 1 2939 AOil, Vilter R717, 55 gal. 1 2939 B 1 2939 B 1 2939 BDisch. Manifold to Sep. flg. gskt.201 thru 401 1 1548 CA 1 1548 CA 1 1548 CADisch. manifold to Sep. flg. gskt.501 thru 701 1 1548 DA 1 1548 DA 1 1548 DASuction Tee to Comp. gskt.201 thru 401 1 1548 CA 1 1548 CA 1 1548 CASuction Tee to Comp. gskt. 501 thru 701 1 25404 A 1 25404 A 1 25404 AEconomizer 1” flg. gasket 1 1548 LA 1 1548 LA 1 1548 LAEconomizer comp. flg. gskt. 1 11323 D 1 11323 D 1 11323 D

64

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66

Replacement PartsShaft Seal

MODEL NUMBERITEM DESCRIPTION ALL VSM 201 ALL VSM 501 THROUGH

THROUGH 401 THROUGH 701QTY VPN QTY VPN

* SHAFT SEAL KIT AMMONIA; 1 KT-709D 1 KT-709A219, 230 & 260.

218 SEAL HOUSING. 1 25410B 1 25269A219 SHAFT SEAL. A A230 OIL SEAL. 1 2930C 1 25040A260 O-RING. 1 2176AE 1 2176F281 HEX HEAD CAP SCREW. 6 2796N 8 2796B

NOTE * Not pictured.Seal sold only as a kit. Cool Compression is ammonia only.

67

400 Assembly(446 not included)

Replacement PartsActuating Motor with

Optical Sensor and Command Shaft

MODEL NUMBERITEM DESCRIPTION ALL VSM 201 VSM 501


*400 COMMAND SHAFT ASSEMBLY 1 A25975A 1 A25975B

412, 413, 427, 435, 436, 445, 450, 451, 480.401 SLIDE VALVE MOTOR COMPLETE 1 25972A 1 25972A

WITH CABLES412 BEARING HOUSING. 1 25364A 1 25364A413 COMMAND SHAFT. 1 25417A 1 25375A415 MOUNTING PLATE. 1 25805B 1 25805B427 KEY. 1 25039BC 1 25039BC435 BALL BEARING. 1 2908A 1 2908A436 SLEEVE BEARING. 1 25853A 1 25853A445 O-RING. 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M466 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB475 LOCKWASHER (PAIR). 4 3004A 4 3004A477 LOCKWASHER (PAIR). 4 3004C 4 3004C480 WASHER. 1 2906AA 1 2906AA

Note: There are two slide valve actuators per compressor. One each for the control of the VolumeRatio and Capacity slide valves. If both actuators or parts are to be replaced double the quan-tities above.

401

68

Replacement PartsSlide Valve Carriage Assembly

304 Assembly

305Assembly

Volume Ratio Slide Valve Components

Capacity Slide Valve Components

Slide Valve Carriage Assembly

69

Replacement PartsSlide Valve Carriage Assembly

MODEL NUMBERITEM DESCRIPTION ALL VSM 201 ALL VSM 501


300* CARRIAGE ASSEMBLY. 1 A25179A 1 A26012B304 CAPACITY PISTON 1 A25183A 1 A25183B

340, 341, 350 & 355.305 VOLUME PISTON . 1 A25184A 1 A25184B

340, 342, 350 & 355311 WASHER 1 25020A 1 25020A316 CAPACITY RACK. 1 25023D 1 25024A318 CAPACITY RACK SHAFT. 1 25772C 1 25772A323 VOLUME RATIO RACK. 1 25023C 1 25023A325 VOLUME RATIO RACK SHAFT. 1 25772D 1 25772B331 SPAVER-CAPACITY 1 25924A 1 25929A332 SPACER-VOLUME 1 25924B 1 25929B340 PISTON. 2 25017B 2 25017A341 CAPACITY PISTON SHAFT. 1 25018B 1 25019A342 VOLUME PISTON SHAFT. 1 25018C 1 25018A350 PISTON RING SET. 2 2953AE 2 2953AA355 EXPANSION PIN. 2 1193PP 2 1193PP359 PIPE PLUG. 3 2606D 3 2606D360 LOCK WASHER (PAIR). 2 3004C 2 3004C361 WASHER. 2 13265B 2 13265B363 NUT. 4 2797A 4 2797A364 WASHER 1 13265C 1 13265C372* SOCKET HEAD CAP SCREW. 1 2795M373 SOCKET HEAD CAP SCREW. 3 2795A 3 2795N374 LOCK WASHER (PAIR). 3 3004C 3 3004C

Note: There are two slide valve carriages per gaterotor. Each one each has its ownVolume Ratio and Capacity slide valves. The above totals are per side of thecompressor, double the quantities if both slide valve carriages are being worked on.*Not Pictured.

70

Replacement PartsMicellaneous Frame Components

201-401 Only

71


201-401 Only

MODEL NUMBERITEM DESCRIPTION ALL VSM 201 ALL VSM 501


511 DISCHARGE MANIFOLD 1 25734B n/a511 240 mm DISCHARGE MANIFOLD 1 25024BC

WITH DOWN DISCHARGE n/a511 240 mm DISCHARGE MANIFOLD 1 25024BB

WITH HORIZONTAL DISCHARGE n/a511 240 mm DISCHARGE MANIFOLD 1 25024BA

WITH UP DISCHARGE n/a512 MANIFOLD GASKET 1 25737A 1 26037A514 ECON-O-MIZER GASKET 2 11323GG 2 11323D515 KEY 1 13396R 1 13396R522 COUPLING LOCK PLATE n/a 1 25004D523 LOCK WASHER n/a 1 3004H528 ECON-O-MIZER PLUG 2 25419A 2 25397K530 O-RING (501-701 only) n/a 2 2176BF535 PIPE PLUG 7 2606E 2 2606D536 PIPE PLUG 1 13163F 6 2606E537 PIPE PLUG 1 13163G 1 13163G538 PIPE PLUG 9 2606B 2 2606B540 DOWEL PIN 2 2868B 2 2868B542 PIPE PLUG 3 2606C 10 2606B545 HEX HEAD CAP SCREW 4 2796EL 4 2796C546 SOCKET HEAD CAP SCREW 7 2795AK 6 2795GD547 HEX HEAD CAP SCREW 3 2796EN 4 2796F548 SOCKET HEAD CAP SCREW n/a 3 2795GH549 CAP SCREW 3 2796EY 1 2795GP550 CAP SCREW 2 2796AB 2 2795GS551 HEX HEAD CAP SCREW n/a 2 2796C570 BEARING OIL PLUG 1 25978A n/a571 PLUG 1 25979A n/a572 SPRING 1 3148A n/a

Note: *. Not Pictured.

72


501-701 Only

73


501-701 Only

MODEL NUMBERITEM DESCRIPTION ALL VSM 501

THROUGH 401 THROUGH 701QTY VPN

511 DISCHARGE MANIFOLD n/a511 240 mm DISCHARGE MANIFOLD 1 25024BC

WITH DOWN DISCHARGE511 240 mm DISCHARGE MANIFOLD 1 25024BB

WITH HORIZONTAL DISCHARGE511 240 mm DISCHARGE MANIFOLD 1 25024BA

WITH UP DISCHARGE512 MANIFOLD GASKET 1 26037A514 ECON-O-MIZER GASKET 2 11323D515 KEY 1 13396R522 COUPLING LOCK PLATE 1 25004D523 LOCK WASHER 1 3004H528 ECON-O-MIZER PLUG 2 25397K530 O-RING 2 2176BF535 PIPE PLUG 2 2606D536 PIPE PLUG 6 2606E537 PIPE PLUG 1 13163G538 PIPE PLUG 2 2606B540 DOWEL PIN 2 2868B542 PIPE PLUG 10 2606B545 HEX HEAD CAP SCREW 4 2796C546 SOCKET HEAD CAP SCREW 6 2795GD547 HEX HEAD CAP SCREW 4 2796F548 SOCKET HEAD CAP SCREW 3 2795GH549 CAP SCREW 1 2795GP550 CAP SCREW 2 2795GS551 HEX HEAD CAP SCREW 2 2796C570 BEARING OIL PLUG n/a571 PLUG n/a572 SPRING n/a

Note: *Not Pictured.

74

Replacement PartsMain Rotor, Slide Valve Cross Shafts and End Plate

(Counter Clockwise Rotation)201-401 ONLY

75


201-401 Only

MODEL NUMBER VSM 201ITEM DESCRIPTION VSM 301 VSM 361 VSM 401

QTY VPN QTY VPN QTY VPN

201 MAIN ROTOR ASSEMBLY. 1 A25266AB 1 A25266AA 1 A25266AC203 OIL BAFFLE ASSEMBLY. 1 A25942AA 1 A25942AA 1 A25942AA

(1)217,(1) 244, (1) 248, (1) 249,(1) 252207 SHIM ASSORTMENT 1 A25177A 1 A25177A 1 A25177A

(2) 240, (2) 241, (1) 242, (1) 243217 OIL BAFFLE . 1 25938A 1 25938A 1 25938A220 END PLATE. 1 25719D 1 25719D 1 25719D221 SHAFT. 2 25941A 2 25941A 2 25941A222 GEAR. 4 25027A 4 25027A 4 25027A227 CLAMP. 4 25913A 4 25913A 4 25913A228 SPACER. 4 25847A 4 25847A 4 25847A240 SHIM 0.002” A 25409AA A 25409AA A 25409AA241 SHIM 0.003” A 25409AB A 25409AB A 25409AB242 SHIM 0.005” A 25409AC A 25409AC A 25409AC243 SHIM 0.010” A 25409AD A 25409AD A 25409AD244 TEFLON RING.(Baffle) 1 25939A 1 25939A 1 25939A248 CHECK VALVE. 1 3120A 1 3120A 1 3120A249 CHECK VALVE. 1 3120B 1 3120B 1 3120B250 RETAINING RING. 2 2867T 2 2867T 2 2867T252 RETAINING RING 1 2829M 1 2829M 1 2829M254 WAVE SPRING. 1 2912G 1 2912G 1 2912G267 DRILL BUSHING. 2 3121A 2 3121A 2 3121A268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 3 2606B 3 2606B 3 2606B277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N282 SOCKET HEAD CAP SCREW.286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F297 SET SCREW. 2 2060J 2 2060J 2 2060J298 SET SCREW. 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.A As required.

Does Not Apply

76


(Clockwise Rotation)501-701 Only

77


501-701 Only

MODEL NUMBERITEM DESCRIPTION VSM 301 VSM 361 VSM 401

QTY VPN QTY VPN QTY VPN

201 MAIN ROTOR ASSEMBLY. 1 A25266AB 1 A25266AA 1 A25266AC203 OIL BAFFLE ASSEMBLY. 1 A25942AA 1 A25942AA 1 A25942AA

(1)217,(1) 244, (1) 248, (1) 249,(1) 252207 SHIM ASSORTMENT 1 A25177A 1 A25177A 1 A25177A

(2) 240, (2) 241, (1) 242, (1) 2431 25938A 1 25938A 1 25938A

220 END PLATE. 1 25719D 1 25719D 1 25719D221 SHAFT. 2 25941A 2 25941A 2 25941A222 GEAR. 4 25027A 4 25027A 4 25027A

228 SPACER. 4 25847A 4 25847A 4 25847A240 SHIM 0.002” A 25409AA A 25409AA A 25409AA241 SHIM 0.003” A 25409AB A 25409AB A 25409AB242 SHIM 0.005” A 25409AC A 25409AC A 25409AC243 SHIM 0.010” A 25409AD A 25409AD A 25409AD244 TEFLON RING. 1 25939A 1 25939A 1 25939A248 CHECK VALVE. 1 3120A 1 3120A 1 3120A249 CHECK VALVE. 1 3120B 1 3120B 1 3120B250 RETAINING RING. 2 2867T 2 2867T 2 2867T252 RETAINING RING 1 2829M 1 2829M 1 2829M254 WAVE SPRING. (205 only) 1 2912G 1 2912G 1 2912G267 DRILL BUSHING. 2 3121A 2 3121A 2 3121A268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 3 2606B 3 2606B 3 2606B277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N282 SOCKET HEAD CAP SCREW.286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F297 SET SCREW. 2 2060J 2 2060J 2 2060J298 SET SCREW. 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.A As required.

Does Not Apply

VSM501 VSM601 VSM 701QTY VPN QTY VPN QTY VPN

1 A26010BB 1 A26010BA 1 A26010BC

1 A26034B 1 A26034B 1 A26034B

1 A25177B 1 A25177B 2 A25177B

1 26025B 1 26025B 1 26025B2 25843A 2 25843A 2 25843A4 25027A 4 25027A 4 25027A

2 25847A 2 25847A 2 25847AA 25255AA A 25255AA A 25255AAA 25255AB A 25255AB A 25255ABA 25255AC A 25255AC A 25255ACA 25255AD A 25255AD A 25255AD1 25929B 1 25929B 1 25929B1 3120A 1 3120A 1 3120A1 3120B 1 3120B 1 3120B2 2867B 2 2867B 2 2867B1 2928N 1 2928N 1 2928N

2 3121A 2 3121A 2 3121A4 1193D 4 1193 4 1193D4 2981AA 4 2981AA 4 2981AA3 2606B 3 2606B 3 2606B2 2796CL 2 2796CL 2 2796CL2 2796CT 2 2796CT 2 2796CT2 2796CZ 2 2796CZ 2 2796CZ6 2796EL 6 2796EL 6 2796EL8 2796B 8 2796B 8 2796B2 2795D 2 2795D 2 2795D

2 2060J 2 2060J 2 2060J2 2060H 2 2060H 2 2060H

78

Replacement Parts Housing Accessiores

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GA

SKET

.1

1132

3T15

3H

EX H

EAD

CA

P SC

REW

.32

2796

DC

154

HEX

HEA

D C

AP

SCR

EW.

811

39B

E17

1LO

CK

WA

SHER

(PA

IR).

830

04J

180

INLE

T SC

REE

N.

125

920A

190

PIPE

PLU

G.

226

06C

191

PIPE

PLU

G.

126

06E

343

PIST

ON

CO

VER

. *1

2572

4B

79

MODEL NUMBERITEM DESCRIPTION VSM201 VSM 501


1 C-FLANGE. 1 A 1 A2 ADAPTER. 1 A3 HEX HEAD CAP SCREW. 8 2796F 8 2796F4 HEX HEAD CAP SCREW. 4 2796EL A5 LOCKWASHER (PAIR). 8 3004H 8 3004H6 LOCKWASHER (PAIR). 4 3004F A7 PORT COVER. 2 25685A 2 25685A8 HEX HEAD CAP SCREW. 2 2796AC 2 2796AC9 CONNECTOR 1 13229C 1 13229C10 TUBE (CUT TO )LENGTH 1 S1589A 1 S1589A345 O-RING. 4 2176BX 4 2176CA346 O-RING. 2 2176BG 4 2176BG

NOTE: A. Contact Home Office for part number.

Replacement PartsC-Flange Assembly

80

Replacement PartsTools

MODEL NUMBERITEM DESCRIPTION VSM 201 VSM501

THRU VSM 401 THRU 701QTY VPN QTY VPN

901 GATEROTOR STABILIZER. 1 25742A 1 25742B902 SEAL INSTALLATION TOOL 1 25455A 1 25455B

81

Sporlan Level Master

Complete Control Valve and Element:

1. Liquid Injection Assembly parts are found in the SPARE PARTS LISTS (page 39).

2. Connection sizes and tubing lengths, if other than standard, contact Vilter Manufacturing.

ELECTRICAL SPECIFICATION

Standard 15 watt, 120v.

STANDARD CAPILLARY TUBING LENGTH ---- 10 FEET

HEATER ELEMENT ASSEMBLY

Consists of heater element lead wire, protective thermostatic switch, and moisture proof seal. The standard leadwire length is two feet.

Heater Element Level Master Control

Sight Glass

Solenoid Valve

Strainer

Two Conductor Rubber CoveredElectrical Cord

1/2” Male ConduitConnection

82

Sporlan Thermostatic Expansion Valve

HOW THE THERMOSTATICEXPANSION VALVE WORKS

Basically, Thermostatic Expansion Valve Opera-tion determined by three fundamental pressures:

P1 Bulb pressure acts on one side of the diaphragm,tends to open the valve.

P2 Evaporator pressure acts on the opposite side,tends to close the valve.

P3 Spring pressure — which also assists in the clos-ing action — is applied to the pin carrier and istransmitted through push rods to a buffer plateon the evaporator side of the diaphragm.

When the valve is modulating, bulb pressure is bal-anced by the evaporator pressure plus the spring pres-sure:

p1 = p2 + p3

When the same refrigerant is used in both the thermo-static element and refrigeration system, each will exertthe same pressure if their temperatures are identical.After evaporation of the liquid refrigerant in the evapo-rator the suction gas is superheated — its temperaturewill increase. However, the evaporator pressure, neglect-ing pressure drop, is unchanged. This warmer vaporflowing through the suction line increases the bulb tem-perature.

Since the bulb contains both vapor and liquid refriger-ant (not superheated vapor alone as in the suction line)its temperature and pressure increases. This higher bulbpressure acting on the top (bulb side) of the diaphragmis greater than the opposing evaporator pressure plusspring pressure, causing the valve pin to be moved awayfrom the seat. The valve is opened until the spring pres-sure — combined with the evaporator pressure — issufficient to balance the bulb pressure. Figure-i illus-trates a system with the same refrigerant in both thebulb and evaporator. Bulb pressure is shown in red,evaporator pressure in blue, and spring pressure in black.The total closing pressure (evaporator plus spring) isshown by a blue and black dash curve.

If the valve does not feed enough refrigerant, the evapo-rator pressure drops or the bulb temperature is increasedby the warmer vapor leaving the evaporator (or both)and the valve opens, admitting more refrigerant untilthe three pressures are again in balance. Conversely, ifthe valve feeds too much refrigerant, the bulb tempera-ture is decreased, or the evaporator pressure increases(or both) and the spring pressure tends to close thevalve until the three pressures are in balance.

With an increase in evaporator load, the liquid refriger-ant evaporates at a faster rate — moving the point ofcomplete vaporization further from the outlet of the coil.This action leaves more coil surface for superheatingthe refrigerant which increases the bulb temperatureAND pressure. With the increased pressure exerted ontop of the diaphragm, the valve moves to a more openposition to handle the new load condition with a slightchange in superheat.

The thermostatic expansion valve will maintain a fullyactive evaporator under all load conditions.

Fixed restrictions and other expansion devices canoffer only a corn promise in system performance whenoperating conditions change.

SPORLAN SELECTIVE CHARGES

For the most efficient system performance, Sporlan in-troduced Selective Charges for thermostatic expansionvalves over 40 years ago. Their present universal accept-ance throughout the refrigeration industry is evidenceof the many operational advantages not possible withconventional charges.

An explanation of the characteristics, design features,and advantages of each selective charge follows:

Bulb T empera ture

Bulb Pressure(Opening Force)

Spring Press ure

CLOSINGFORCE

Fi g u r e 1

Superheat

RefrigCurve

EvapPressu re

Evap T emp

Bulb Temp=Saturat ion Temp

+ Superheat

Bulb Pressu re1

2

3

83


Design Characteristics:

1 Employs same refrigerant in thermostatic elementas used within system.

2 Bulb volume and amount of charge it contains issuch that sufficient liquid will remain in the bulb un-der all temperature conditions of the diaphragm caseand capillary’ tubing.

Advantages:

Bulb will always control refrigerant flow despite acolder valve or diaphragm case.

Disadvantages:

1 When the compressor is started, the suction andevaporator pressures drop. But since the valve bulb isnot imniediately cooled, the comparatively high bulbpressure opens the valve too much resulting in:

a Low superheat and possible floodback to thecompressor.

b Delayed suction pressure pulldown and possi-ble overloading of the compressor motor.

2 With the same valve adjustment, the superheat in-creases at lower evaporator temperatures where highsuperheats are more detrimental to system capacity.

3 During off-cycle, if bulb is in a comparatively warmlocation, the bulb pressure may be great enough to

open the valve, filling the evaporator with liquid. Thisis another possible cause of flood-back at start-up.

4 Conventional liquid charged valves have no inherentanti-hunt features.

Application:

Because of definite operating advantages obtained withthe use of other Selective Charges, the use of the TypeL charge is generally confined to large capacity ammo-nia systems and a few unusual application.

Design Characteristics:

1 Pressure limit or maximum operating pressure (MOP)feature. The Sporlan P charge is a patented modifica-tion of the conventional limited liquid charge (gascharge). The constituents of this charge are such that ata predetermined valve bulb temperature a maximumbulb pressure is reached. Any increase in bulb tempera-ture above this point also results in virtually no increasein bulb pressure, causing the valve to throttle.

2 Sporlan Type P air conditioning charge makes use ofthe Flow-Master element originally patented by Sporlanwhich is effective in stabilizing valve control and inmaterially reducing system hunt.

Type P Air Condit ioning Chargewi t h t he Sp o r lan F L O W M A S T E R E le men t

No L i qu i dPre se n t (Ga s)

i n B u lb

P o i n t O fC o m p l e t e

V a p o r i z a t i o nS pr i ng P re ssu re(Co ns ta n t )

R e f r i g e r a n t

PRESSURE

F i g u r e 3

T e mp er at u re

Conventional L iquid Chargewi t h T y pe L Ch arge

T e mp er at ur e

RefrigerantPressure- Temperature

CharacteristicS pr i ng P re s su re(Co ns t an t )

R e f r i g e r a n t

PRESSURE

F i g u r e 2

84


Type L liquid charges are also available for most com-monly used refrigerants in most element sizes.

THERMOSTATIC EXPANSION VALVE withRAPID PRESSURE BALANCER FEATUREU.S. Patent Na. 3,252,297

Sporlan developed and patented a totally new type of“bleed valve” for use with air conditioning PSC (Per-manent split capacitor — low starting torque) motorcompressors. This development was prompted by re-quests from manufacturers of air conditioning equipmentfor a thermostatic expansion valve which would equal-ize high and low side pressures more rapidly than a con-ventional permanent bleed design. The RPB valve pre-sents a major breakthrough in the design of thermostaticexpansion valves. These valves generally reduce theequalization time by about 50% over that obtained withthe permanent bleed type.

The RPB feature should allow the system pressures toequalize in about two minutes; however, the amount ofsystem charge and high side volume can affect this time.As shown in Figure-7 the RPB bleed is actuated only onthe off cycle. Immediately after shut down the evapo-rator pressure rises and the pin carrier moves to the closedposition as in a conventional valve. However, with theRPB design the pin carrier continues its motion andopens the secondary spring loaded bleed port allowingrapid equalization of high and low side pressures. Uponrestarting the compressor the secondary bleed port closesand the valve functions in the normal manner.

The RPB feature is currently available in valve Types Cand S up to and including 4 tons Refrigerant 22 nomi-nal capacity for air conditioning and heat pump (indoorcoil only) applications.

For proper operation, foreign material must be kept outof the valve. A Catch-All Filter-Drier should be in-stalled as close as possible to the valve inlet.On systems utilizing compressors that have startingtorques higher than the PSC motor, on outdoor coils ofheat pumps, or on refrigeration systems, the RPB shouldnot be used because of possible start-up problems. Whena “bleed valve” is required on one of these systems, thepermanent bleed type valve is available. To determinethe proper bleed port size, sufficient testing must bedone by the manufacturer.

Normally, it is advisable to replace a valve with one ofthe same specification. However, a valve with the RPBfeature can replace a permanent bleed type except onoutdoor coils of heat pumps or on refrigeration systems.If electrical “hard-start” components have been addedto the system, it is not necessary nor advisable to usethe bleed port or RPB type thermostatic expansion valve.

12

22

500

502

FCP60

VCP100AND VGA

FC

VC

DC

RC

FZFZPVZVZP

RZRZP

VX

RX

DCP70

RC9115

Refri

gera

nt

Air C

ondi

tioni

ngor He

at Pu

mp

Com

mer

cial

Refri

gera

tion

+50 F

to -

10 F

Low

Tem

pera

ture

Refri

gera

tion

0 F to

- 40

F]

Extre

me L

owTe

mpe

ratu

reRe

frige

ratio

n-0

F to

- 10

0 F

85


THE EXTERNAL EQUALIZER

The operation of the thermostatic expansion valve isdependent upon the relationship of the three funda-mental pressures. See Figure-i. Bulb pressure actingon top of the diaphragm must always equal the sum ofevaporator (or suction pressure) and spring pressureapplied to the under-side of the diaphragm.

On an internally equalized valve, the pressure at thevalve outlet (or evaporator inlet) is transmitted to theunder-side of the diaphragm via a passageway withinthe valve or through clearance around the push rods.On an externally equalized valve the under-side of thediaphragm is isolated from valve outlet pressure bypacking around the push rods or by closely fitted rodsmaking a metal-to-metal seal. See Figure-8. Suctionpressure is transmitted to the under-side of the dia-phragm by a line usually connected between the suc-tion line near the evaporator outlet (generally down-stream of the bulb) and an external fitting on the valve.

While internally equalized valves may be used with evapo-rators that have a low pressure drop, valves with an ex-ternal equalizer must be used when there is an appre-ciable pressure drop between the valve outlet and bulblocation. This is illustrated in Figures-9, 10, and 11. Therefrigerant in the system is assumed to be R12.

Figure-9 shows an internally equalized valve feeding anevaporator — which, for purpose of illustration, has nopressure drop. The pressure at the valve outlet and at thebulb location is 27 psig. So, the under-side of the valve

diaphragm senses the evaporator pressure of 27 psig— which acts to close the valve. A spring pressureof 7 psi also assists the evaporator pressure in at-tempting to close the valve. The valve consequentlyadjusts its flow rate until the suction line vapor be-comes sufficiently superheated to create a bulb tem-perature of 37 F. which develops a pressure of 34psig — assuming the same refrigerant in the bulbas in the system — balancing the evaporator andspring pressure. The resulting superheat is 90 F.

V a l ue w i th I n t er na l E qu a l i z e r Va l ue w i t h E x t e r na l E qu a l i z e r

P u s hR o d s

In te r na lE qu a l i z er

P u s hR o d s

P u s hR o d

P a c k i n g

Ex t e r n a lE qu a l i z er

F i t t i n g

E v a p o r a t o rO u t l e t

Pr e s s u reV a l v eO ut l e t

P r e s s u re

Fi g u r e 8

Spring Pr ess ure7 psi

F i g u r e 9

Diagram

Bulb Pressu re34 psi Conver ted t o Temper at ure = 37*

Evapo ratorOutl et Pressure

27 psi

C lo s i n g P r es s ur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . =2 7 + 7 =3 4 p s i( e v a po r at or i n l e t p r e s su r e p l u s s p r i n g p r e ss u r e )

Bu l b Pr e s s u r e N ec e ss ar y t o o pe n va l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 ps iBu lb t e mpe r a t u r e e q u i va l e nt t o 3 4 p s i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 * FSa t u r at e d t em p er a t u r e e qu i v al en t t o ev ap o r at o r ou t l e t p r e s s u r e . . 2 8 * F

S UPE RHE AT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 * F( B l u b t e m pe r a t ur e m i n us s a t u r a e d e v a p o r a t o r t e mp e r a t u r e )

27 27

Spring Press ure7 ps i

F i g u r e 10

D iagram

Bul b Pr essu re40 ps i Converted t o Temperature = 43*

Evapo ratorOutle t P ressure

27 ps i

C l o s i ng P re ss ur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 33+ 7= 4 0 p s i( ev ap o r at o r i n l e t pr e s s u r e p l u s s p ri n g p r e s su r e )

Bu l b Pr e ss ur e N ec es s a ry t o o pe n v a l v e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ps iBu l b t e m per a t ur e e qu i v a l en t t o 4 0 p s i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 * F

Sa t u r at e d t e m p er a t u r e e qu i va l ent t o ev ap o r at o r o ut l e t pr e s s u r e. . 2 8 * F

SUPE RHEA T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5* F( B l ub t em pe r at ur e m i nu s s a t u r a e d e va p or a t o r t em p er a t u r e)

3 327

43

86


If this same internally equalized valve with the samespring adlustment is installed on an evaporator ofequivalent nominal capacity but with a 6 psi pressuredrop, the operating superheat will increase to 15~ F.as shown in Figure-b. Now the valve senses a com-paratively high pressure of 33 psig at the valve outlet.The total closing pressure is 33 + 7 or 40 psig. Sincethe bulb pressure must equal the total closing pres-sure, the valve reduces its flow rate to create the nec-essary s~perheat and bulb pressure. Consequently,excessive evaporator pressure drop causes an in-ternally equalized valve to operate at abnormallyhigh superheat, and serious loss of evaporator ca-pacity results.

The problem of improper valve control illustrated inFigure-b may be corrected by applying a thermostaticvalve with an external equalizer. Figure-li shows thesame system, but with an externally equalized valve.The suction pressure at the bulb location is transmit-ted to the under-side of the diaphragm via the exter-nal equalizer line. Valve operation is now identical tothat shown in Figure-9, and the superheat returns to9* F.

WHEN TO USE THE EXTERNALEQUALIZER

As evaporating temperature drops the maximumpressure drop that can be tolerated between the valveOutlet and the bulb location without serious capac-ity loss for an internally equalized valve also de-creases. This is shown in Table 1 below. There are,of course, applications which may satisfactorilyemploy the internal equalizer when higher pres-sure drop is present, but this should usually be veri-fied by laboratory tests. The general recommenda-tions given in Table 1 are suitable for most fieldinstalled systems. Use External Equalizer whenpressure drop between valve outlet and bulb lo-cation exceeds values shown in Table 1.

When the expansion valve is equipped with an Ex-ternal Equalizer, it must be connected—nevercapped—or the valve may flood, starve, or regulateerratically.

There is no operational disadvantage in using anExternal Equalizer even if the evaporator has alow pressure drop.

Evaporating TemperatureDegress F.

Refrigerant

12,50022502717

2333

1.522.52

11.51.751.5

.751.01.251.0

.5

.751.0.75

40 20 0 -20 -40Pressure Drop-psi

Ammonia

Spr ing Press ure7 psi

F ig u r e 11

Diag ram

Bulb P ressu re34 ps i Conver ted to Temperature = 37*

Evaporato rOutlet P ressure

27 psi

C los ing P re ssu r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .= 2 7+ 7= 34 ps i(ev apo ra t o r in l e t p r e ssu r e p lu s s p r i ng p re ssu re )

Bu l b P r ess u r e N ec ess a r y t o o pe n va l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 ps iBu l b t em pera t u re e qu iva l en t t o 34 p s i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 7 *F

Sa tu ra t ed t em per a tu r e equ iva l en t t o ev apo ra t o r ou t le t p r e ssu re . .28 * F

SUPE RHEA T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 * F( B l u b t em per a t u re m i nu s sa tu r ae d e vap or a to r t em p era t u r e )

3327

37

88

“Stop Check” Operation

AUTO

In the “Auto Position”, the stop valve isoperating as a check valve, allowingflow in the directions of the arrows.

To set the valve to the automatic position,fully close the valve, and turn the stemout as indicated by the chart below.

CLOSED

In the manually “Closed Postion”, thestop check is operating as aconvientional stop valve, not allowingflow in either direction.

OPEN

In the manually ” Open Position”, withthe valve stem fully back seated, the valvedisc is lifted slightly, allowing flow in ei-ther direction.

Valve Size 1.5” 2” 2.5” 3” 4” 5” 6” 8”Number of Turns 2 2.25 2.75 3.25 4.5 3.75 5.75 7.75

89

“Stop Check” Installation

Installation: The new design will apply only to the 2” thru 4” stop valves. Retrofitting a fieldinstallation will require replacing the bonnet assembly.

The bonnet must be installed with the spring towards the bottom (seeillustrations above). The drill fixture is designed so that the hole for the springwill always be drilled on the opposite side from the cast-in Vilter name on thebonnet. From the outside of the valve, the casting numbers must always betowards the top of the valve.

Correct

Wrong

Correct

Wrong

Verify the location of Spring and notethe Vilter name

Name

Name

Wrong

90

Hansen TechnologiesProduct

INTRODUCTIONThe redesigned, heavy-duty HS8A refrigerationsolenoid valve is flanged, compact, and pilot-oper-ated. It is now more dirt resistant, erosion resistant,and corrosion resistant. A dirt controlling Teflonpiston seal prevents sticking. The valve body hasimproved, erosion resistant flow passages. And aproprietary coating on the valve body gives un-matched corrosion protection. The HS8A is used toprovide on-off control of refrigerant flow. When thecoil is energized, a pressure difference across the pis-ton opens the valve seat. When the coil is de-ener-gized, a spring closes the main Teflon seat to stop allflow.

APPLICATIONSThe HS8A is ideal as a liquid line solenoidvalve.While primarily for ammonia, this valve is alsosuitable for R22, R134a, and other compatible re-frigerants. The most common use of this valve is tocontrol flow to: expansion devices, recirculating liq-uid overfeed evaporators, hot gas defrost, and smallcapacity evaporator suction. In addition, the HS8Amakes an ideal noncondensible gas (air) purge pointsolenoid valve, and is recommended for use withHansen AUTO-PURGERs.

MAXIMUM RATINGS, AMMONIALiquid, Receiver Pressure: 110 Tons (387 kW)Recirculation, 4 to 1: 36 Tons (127 kW)Hot Gas: 10 Tons (35 kW)Suction: 5.0 Tons (18 kW)Flow Factor: Cv = 3.3 (2.9 Kv)

ADDITIONAL FEATURESDimensionally replaces RIS S8F and Hansen HS8Low-wattage coil300 psig (20.7 bar) MOPDTeflon main & pilot seatsClose-couples to STO5O (100 mesh) strainerHeavy-duty constructionCSA certified

MATERIAL SPECIFICATIONSBody: Cast ductile iron, corrosion-resistantcoatedBonnet Cartridge: Steel, platedPiston: Stainless steel, Teflon sealPlunger: Stainless steelPilot Orifice: Stainless SteelSeats: Teflon, pilot and mainMOPD: 300 psig (20.7 bar) AC coils onlySafe Working Pressure: 400 psig (27 bar)Operating Temperature: -600F to +2400F (-50”C to +11 5”C)

Bulletin S119dOctober, 1999

HANSEN TECHNOLOGIESCORPORATION

HS8A with Close-Coupled STO5O Strainer

HSBASOLENOID VALVE

1/211 (13 MM) PORT

Specifications, ApplicationService Instructions & Parts.

Flanged3/8” through ¾”

FPT, SW, WN, ODSfor refrigerants

Key FeaturesWatertightEncapsulatedCoil

CorrosionProtection ForCoil Housing

Ductile Iron BodyWith CorrosionProtectionLarge DiameterStable StainlessSteel Closing SpringDirt ControllingTeflon Piston SealPrevents StickingImproved Teflon Seat

Improved, ErosionResistant Flow Passages

Stainless Steel Stem

Corrosion Proof Seal Cap

91

1alblcld234

567834

791011121314a14b1920

15

1617

18

2114b

2223

2526a26b

24

27

28

29

*NOTE: All parts also fit HS8.

1 70-02711 70-02861 70-02841 FACTORY1 70-10601 70-02891 70-0281

70-1059

1 70-02951 70-02981 70-03014 70-02971 70-02891 70-0281

70-10051 70-03011 70-00091 70-00113 70-00651 70-00101 70-00251 70-00081 70-00111 70-00261 70-0019

70-1001

1 70-01441 70-1 0051 70-1059

70-1002

1 70-04971 70-04941 70-1 005

70-10031 70-00041 70-1005

70-10751 75-079817 0-0011

78-1 0011 78-00051 78-0016

70-100670-1007

2 70-00552 70-00732 70-0076

1 78-0002

HSSAII

78-1002

FACTORY

Above Std. Coil Kits Consist of:Bare Coil, 1 iSV 50160Hz, wire leadsBare Coil, 230V 50/60Hz, wire leadsBare Coil, 24V 50160Hz, wire leadsOther Voltage CoilsCoil Housing Assembly KitCoil WasherCoil Nut

Solenoid Tube/Plunger KitAbove Kit Consists of:PlungerSolenoid TubeSolenoid Tube GasketTube ScrewsCoil WasherCoil Nut

Gasket Kit Consists ofSolenoid Tube GasketUpper Body 0-ringLower Body 0-ringFlange GasketStem 0-ringPackingSeal Cap Gasket (prior to 1998Seal Cap 0-ringPacking WasherPacking Nut

Bonnet Cartridge KitAbove Kit Consists of:Cartridge AssemblyGasket KitSolenoid Tube/Plunger Kit

Piston Assembly KitAbove Kit Consists of:Piston AssemblyClosing SpringGasket Kit

Stem Kit Consists of:StemGasket Kit

Seal Cap Kit Consists of:Seal CapSeal Cap 0-ring

Strainer Screen Kit Consists of:Screen Assembly, 100 meshStrainer Cap Gasket

Bolt and Nut KitFor HS8A less Strainer (a)For HS8A with Strainer (b)

Consists of:Nut 7/16-14Bolt, 7/16—14 x 33/4Bolt, 7/16—14 x 51/2

Strainer Cap

Assembled BodyReplacement KitComplete Valve less Coil Kit and Flanges

Assembled StrainerReplacement Kit

Flange Kit (FPT,SW,WN,ODS)Includes (2) Flanges only;Specify Style and Size

ELECTRICALThe solenoid is a normally-closed (NC) device. Onestandard coil fits all Hansen valves. The coil draws 16watts and operates properly between 85% and 110%of rated voltage (24V coil draws 19 watts).The stan-dard coil connection is a 1/2’ fitting (NPSM) for con-duit. DIN plug, quick disconnect, and junction boxcoils are available. Pilot lights are also available Con-tact the factory for details. Coils have a rustproofedsteel housing which meets NEMA 3R (rainproof)and NEMA 4 (sptashproof) requirements. The junc-tion box version is considered NEMA 1.

The coil should only be energized while installed onthe solenoid tube. Otherwise, the coil may quicklyburn-out. To avoid bending the solenoid tube, removethe coil from the valve before tightening any flexibleconduit connection.

INSTALLATIONProtect the interior of the valve from dirt before andduring installation. A close-coupled inlet strainer isnormally installed and recommended. Allow 2” (50mm) above the valve for coil removal and 3” (76 mm)below the strainer for screen removal. The arrow onthe valve body must point in the direction of systemflow. If a pressure reversal can occur use a check valveon the outlet side of the HS8A. The check valve can beclose coupled directly to the HS8A outlet.

INSTALLATION DIMENSIONs

DESCRIPTION ITEM

QNTY PRT#

Std. Coil Kit (11 5V) l/2•’ FittingStd. Coil Kit (230V) ~/2” FittingStd. Coil Kit (24V) 1/2’~ FittingStd. Coil Kit (Other Voltages)DIN Plug Coil KitsQuick Disconnect Coil KitsCoil with Junction Box Kits

70-1 05770-105670-1058FACTORYFACTORYFACTORYFACTORY

3.63"(92mm)

5.25(133mm)

2.88"(133mm)

1.5"(38mm)

3.25"(83mm)

5.00"(127mm)

3.00"(76mm) without strainer

Note:

All ow " (50mm) forCoil removal

Al low 3" (75mm)for Strainer Basket removal

92

Hansen TechnologiesProduct

Parts List

6 43

2

1

5

8

15

7

16

25

11

29

12

13

20

14

21191124

23

28

22

29

26

11

27

10

9

18

17

Standard 1/2" Coil Fitting shown above. Other coil options also availble are:

DIN Plug Coil Quick Disconnect Coil Coil Juction With Box

93

SERVICE AND MAINTENANCE

Failure to open: Wrong coil voltage; low linevoltage; electric controlling device is not switching;coil is burned-out; inlet/outlet pressure differentialis too high; piston or solenoid coil plunger is jammed closedwith dirt.

Failure to close: Electric controlling device is notswitching; manual-opening stem is turned in; pistonor solenoid coil plunger is jammed open by dirt;damage or dirt at main valve seat or pilot valve seat.

Before opening the valve for service, be sure it isisolated from the system and all refrigerant ispumped out to zero pressure. Disconnect electricalpower from the coil (1). To remove the coil (1), unscrew thecoil nut (4) and remove the washer (3).Then, remove the coil (1) from the solenoid tube (6). Toremove internal parts, use a large wrench to slowly unscrewthe bonnet cartridge (15), proceeding cautiously to detectany remaining refrigerant insidethe valve. Then, remove theclosing spring (17) and piston (16). Check for dirt on thepiston (16), Teflon piston seal, and seat. Clean and reinstallor install new parts. Check the upper (9) and lower (10)body 0-rings and replace if necessary. Use refrigerant oil orgrease when installing the 0-rings.

To check the pilot section of the valve, first loosen the foursolenoid tube screws (8). Then, break the seal between thesolenoid tube (6) and bonnet cartridge (15), being careful toavoid any refrigerant which may remain. Check the face ofthe Teflon seat in the plunger (5), the plunger spring, andthe pilot seat orifice on the bonnet cartridge (15). Clean,polish, or replace parts as necessary. The pilot seat is inte-gral with the bonnet cartridge. Install a new solenoid tubegasket (7) and oil lightly. Reassemble the bonnetcartridge(15) to the valve body (27), using 75 ft-lbs (102 N-rn) torqueto tighten the secondary, metal, knife-edge seal.Carefullycheck the valve for leaks before restoring to service.

CAUTION

Hansen valves are for refrigeration systems only. These in-structions must be read completely and understood beforeselecting, using, or servicing these valves. Only knowledge-able, trained refrigeration technicians should install, oper-ate, or service these valves. Stated temperature and pres-sure limits should not be exceeded. Bonnets, solenoid tubes,etc., should not be removed from valves unless the systemhas been evacuated to zero pressure. See also Safety Pre-cautions in the current List Price Bulletin and the SafetyPrecautions sheet supplied with product. Escaping refriger-ant can cause injury, especially to the eyes and lungs.

WARRANTY

Hansen valves are warranted against defects in workman-ship and materials for a period of one year F.O.B. our plant.No consequential damages or field labor is included.

ORDERING INFORMATION,HS8A SOLENOID VALVE

FLANGE CONNECTION STYLE & SIZESFPT, SW, WN ODS

STD ALSO STD 1/2 3/4”, 3/8” 5/8”

FPT: Female Pipe Thread (American National Standard)SW: Socket Weld to accommodate American and API pipeWN: Weld Neck to match American pipe ODS: OutsideDiameter Sweat, for American copper tubes

Standard encapsulated solenoid coil is included for 115V,230V, or 24V; 50/60Hz; other voltages are available. Stan-dard coil connection is a 1/2” fitting (NPSM). Coils withDIN plug, quick disconnect, or junction box are available.Pilot lights are also available. Contact the factory.

TO ORDER: Specify type, connection style and size, volts,and strainer if required. Unless otherwise specified, the stan-dard coil with ½” fitting will be supplied.

TYPICAL SPECIFICATIONS “Refrigerant solenoid valves shall have encapsulated, wa-tertight coils, Teflon seats, ductile iron or steel bodies, stain-less steel pistons, spring closing pilot and main valve seats,and must be suitable for a safe working pressure of 400 psig(27 bar), as manufactured by Hansen Technologies Corpora-tion or approved equal.”

OTHER PRODUCTSModular Pressure RegulatorsSolenoid ValvesGas-Powered ValvesShut-Off Valves, 3/~’ to 16’Hand Expansion Valves (Regulators)Level Pulse Control Systems (Pulse Width Valves)Thermostatic Expansion Valves (TXV)Inline and Piston-Type Check ValvesGauge, Purge, and Needle ValvesStrainers and Filter SystemsAUTO-PURGER®sLiquid Refrigerant PumpsFloat Drain RegulatorsVan-Level® Adjustable Level ControlsTechni~Level®Transducer ProbesFloat SwitchesSEE-LEVEL® Liquid IndicatorsFrost Master® Defrost ControllersPressure-Relief ValvesRupture Disc Assemblies

HANSEN TECHNOLOGIES CORPORATION

6827 High Grove Boulevard Burr Ridge, Illinois 60521 USA

Telephone: 630-325-1565 Toll-free: 800-426-7368

Fax: 630-325-1572 E-mail: [email protected]

Web site: www.hantech.com

Hansen Continued.............

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If service is required, first contact your equipment distributor or contactA Vilter Technical Service Representative at:

Note: It will be necessary to have your Vilter order number availablewhen contacting Vilter Manufacturing Corporation for service support.

Vilter Manufacturing Corporation5555 South Packard Ave.

PO Box 8904Cudahy, WI 53110-8904Telephone: 414-744-0111

Fax: 414-744-1769e-mail: [email protected]

vilter - cool compression operation manual

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