VPN 35391C

March 20111Rev. 05
Price $45.00
2
Important Note:

READ CAREFULLY BEFORE INSTALLINGAND STARTINGYOUR COMPRESSOR.

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

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

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

Vilter screw compressor components are thoroughly inspected at the factory, assuring the shipment of a
mechanically perfect piece of equipment. Damage can occur in shipment, however. For this reason, the units
should 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 and
take necessary steps to rectify the claim with no serious or costly delays. At the same time, the local Vilter
representative or the home office should be notified of any claim made.

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

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

Vilter Manufacturing Corporation

Customer Service Department
5555 South Packard Ave
P.O. Box 8904
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax: 1-414-744-3483
e-mail: [email protected]

Equipment Identification Numbers:

Vilter Order Number: __________________________Serial Number: _____________

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

3
Table of Contents
IMPORTANT NOTE .............................................................................................................................................................. 3

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

DOMESTIC TERMS AND CONDITIONS .............................................................................................................................. 8

EXPORT TERMS AND CONDITIONS ................................................................................................................................. 10

STANDARD VILTER WARRANTY STATEMENT ............................................................................................................. 12

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

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

INSTALLATION INSTRUCTIONS ............................................................................................................ 16

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

UNIT OIL CHARGING ......................................................................................................................................................... 20

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

SLIDE VALVE ACTUATOR INSTALLATION INSTRUCTIONS ......................................................................................... 22

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

MAINTENANCE SUGGESTIONS ............................................................................................................. 28

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

UNIT DESCRIPTION ......................................................................................................................................................... 31

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

OPERATING INSTRUCTIONS .................................................................................................................. 31

START UP ............................................................................................................................................................................ 32
GAS FLOW .......................................................................................................................................................................... 32
LIQUID AMMONIA SUPPLY .............................................................................................................................................. 32

4
Table of Contents
SEPARATION ...................................................................................................................................................................... 32
LIQUID AND OIL LEVEL MONITORING ............................................................................................................................ 33
COMPRESSOR LUBRICATIONAND COOLING ................................................................................................................. 33
COMPRESSOR SHUT DOWN ............................................................................................................................................. 33

OIL SYSTEM ....................................................................................................................................................................... 33

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

CONTROL SYSTEM ............................................................................................................................................................ 36

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

SAFETY SETPOINTS .......................................................................................................................................................... 38

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

INITIAL START UP ............................................................................................................................................................. 39

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

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

SERVICE SECTION ...................................................................................................................................... 42

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

GATE ROTOR FLOAT ......................................................................................................................................................... 45

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

5
Table of Contents

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

INPUT SHAFT SEAL REPLACEMENT ............................................................................................................................... 50

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

MAIN ROTOR ASSEMBLY ................................................................................................................................................. 51

CAPACITY AND VARIABLE ............................................................................................................................................... 52
VOLUME RATIO CONTROLASSEMBLY ........................................................................................................................... 52

OPTICAL SLIDE VALVE ACTUATOR REMOVAL .............................................................................................................. 52

OPTICAL SLIDE VALVE ACTUATOR INSTALLATION ..................................................................................................... 53

COMMAND SHAFT ASSEMBLY REMOVAL .................................................................................................................... 54

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

DISCHARGE MANIFOLD REMOVAL ................................................................................................................................ 55

DISCHARGE MANIFOLD INSTALLATION ....................................................................................................................... 56

SLIDE VALVE GEAR AND RACK ........................................................................................................................................ 56

INSPECTION RACK CLEARANCE VALUES ...................................................................................................................... 56
REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS ................................................................................................ 56
INSTALLATION OF CAPACITY OR VOLUME CROSS SHAFTS ...................................................................................... 57

TROUBLE SHOOTING GUIDE ............................................................................................................................................ 58

ADDING OIL AND INSTALLTION OF OIL FILTER ............................................................................................................ 61
DUAL FILTER VALVE SEAL REPLACEMENT ................................................................................................................... 62

VSM COOL COMPRESSION SPARE PARTS LIST ....................................................................................................... 63

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

SPORLAN THERMOSTATIC EXPANSION VALVE ........................................................................................................... 86

“STOP CHECK” OPERATION ............................................................................................................................................. 92
“STOP CHECK” INSTALLATION ....................................................................................................................................... 93
HANSEN TECHNOLOGIES PRODUCT ............................................................................................................................... 94

6
Long Term Storage
Requirements

1. The compressor(s) must be stored in a heated building, preferably air conditioned to control moisture, to
prevent corrosion of the main rotor shaft/crankshaft and (for screw comp.) The slide valve (volume
ratio& 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 corrosion
inhibitors installed in them and the enclosures will be sealed. On a six month basis (depending on relative
humidity), check and replace inhibitors as necessary, and check for signs of corrosion.

4. Before leaving Vilter Manufacturing the compressor is evacuated and pressurized, with dry nitrogen, to
5 psig. Pressure must be monitored with the gauge (provided by Vilter) and checked on a regular basis (at
least monthly).

5. The rotor shaft/crankshaft must be rotated every 3 months to prevent flat spots from developing on the
bearing surfaces and to keep the shaft seal lubricated.

6. A log should be maintained indicating that the above procedures have been completed.

When the compressor is installed.

A. Look into the suction and discharge connections and inspect for any signs of corrosion on parts.

B. Prelube the compressor with the main oil pump and rotate by hand several revolutions prior to start. For
reciprocating compressors this is done manually through the oil pressure gauge port.

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

7
DOMESTIC TERMS and
CONDITIONS

Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms and
conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly 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 Seller
unless this Agreement and any purported change are signed by a home office Officer of Seller.

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

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

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

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

8
DOMESTIC TERMS and
CONDITIONS

Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages
arising from 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.

Resellers and Distributors. Should Buyer resell the product to a third party, then Buyer agrees to provide a copy of
these Terms and Conditions to such third party prior to the sale, and obtain such third party’s agreement to be
bound by the relevant provisions including, but not limited to, the Warranties Section and the Limitation of
Liability Section. Buyer agrees to indemnify Seller against any and all claims, damages, or liability (including
reasonable 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 all
proprietary legends.

Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyer
understands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NO
LIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARY
OR 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 IN

EXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTY
REMEDY 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 resort
to conflicts of law analysis.

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
obligations under this Agreement including, but not limited to, personal injury, death, or property damage. In
addition, Buyer shall reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce
its 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 a
reasonable surcharge for additional manuals, special manuals, and brochures.

Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms
and 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 be
modified other than in writing signed by Seller.

9
EXPORT TERMS and
CONDITIONS

Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms and
conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly 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 Seller
unless this Agreement and any purported change are signed by a home office Officer of Seller.

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

Export Transactions. If the products provided under this Agreement are to be shipped or used outside of the United
States, then the following terms apply unless otherwise agreed by Seller in writing: (1) Buyer shall be responsible for all
export and import scheduling and financial arrangements, (2) Buyer shall be responsible for compliance with all export and
import laws and shall comply, and shall cause its agents to comply, with the Foreign Corrupt Practices Act, (3) the United
Nations Convention on the International Sale of Goods shall not apply or govern the transaction, (4) Buyer accepts all
responsibility 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 in
Seller’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. All
delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’s
Order Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment deliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a period
of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from date of
installation at the initial end users location, whichever occurs first. In addition, Seller provides the following extended
warranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating parts, (b) two (2)
years from the date of shipment on reciprocating compressors and single screw and reciprocating compressor parts, and
(c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not apply to ordinary wear and
tear. Seller does not warrant that the product complies with any particular law or regulation not explicitly set forth in the
specifications, and Buyer is responsible for ensuring that the product contains all features necessary to safely perform in
Buyer’s and its customer’s plants and operations. Buyer must notify Seller of any warranty claim within ten (10) days after
such claim arises, otherwise Buyer waives all rights to such claim. Products supplied by Seller which are manufactured by
others are not warranted by Seller, but rather Seller merely passes through the manufacturer’s warranty to Buyer. SELLER
EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDINGTHE IM-
PLIED WARRANTIES OF MERCHANTABILITYAND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise
agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction
of the service, or the providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of 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,ANDALL OTHER WARRANTY REMEDIES ARE EXCLUDED.

10
EXPORT TERMS and
CONDITIONS

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

Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages arising
from 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 all
proprietary legends.

Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyer
understands 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 INCIDENTAL
DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCT LIABILITY OR OTHER-
WISE, EVEN IFADVISED OF THE POTENTIAL DAMAGES INADVANCE.

IN NO EVENT SHALLSELLER BE LIABLE TO BUYER FORANY DAMAGES WHATSOEVER IN EXCESS OFTHE

CONTRACT PRICE. IN THE EVENT THATANY WARRANTY OR WARRANTY REMEDY FAILS OF ITS ESSEN-
TIALPURPOSE, OR IS HELD TO BE INVALID OR UNENFORCEABLE FORANY REASON, IN CONSIDERATION
OF THE OTHER PROVISIONS OF THIS AGREEMENT, THE PARTIESAGREE THATALL 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 of
Wisconsin, 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 personal
jurisdiction 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 obligations
under this Agreement including, but not limited to, personal injury, death, or property damage. In addition, Buyer shall
reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce its 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 a
reasonable surcharge for additional manuals, special manuals, and brochures.

Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms and
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 be
modified other than in writing signed by Seller.

11
STANDARD VILTER WARRANTY
STATEMENT

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

SELLER EXPRESSLY DISCLAIMS ALL OTHER 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 of
the defect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not be
responsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller
will not be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breach
of warranty. THESE WARRANTY REMEDIES ARE EXCLUSIVE AND ALL OTHER WARRANTY 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 liable
under the above warranties should Buyer be in default of its payment obligations to Seller under this Agreement or
any credit agreement.

12
VILTER 5/15 EXTENDED
WARRANTY STATEMENT
5/15 EXTENDED WARRANTY FOR SINGLE SCREW
COMPRESSORS
(NON-GAS COMPRESSOR APPLICATIONS ONLY)

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

THE WARRANTY CONTAINED IN THIS SECTION IS EXCLUSIVE AND IN LIEU OF ALL OTHER
REPRESENTATIONS AND WARRANTIES (EXCEPT OF TITLE), EXPRESS OR IMPLIED WARRANTY
OF MERCHANTABILITY OR IMPLIED 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’s
order are for the sole purpose of identifying the products and shall not be construed as an express warranty. Any
suggestions by seller or Seller’s agents regarding use, application or suitability of the products shall not be construed
as an express warranty unless confirmed to be such in writing by Seller.

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

13
14
Warning Symbols and Meanings

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

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

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

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

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

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

Mandatory Action Sign/Verification -

Communicates an action to be taken to
AVOID hazard......................................................

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

15
Installation Instructions

DELIVERY INSPECTION service work. When the compressor unit is in place

on the concrete pad, check both lengthwise and cross-
Vilter screw compressor components are thoroughly wise to assure it is level. Use shims and wedges as
inspected at the factory, assuring the shipment of a needed under the mounting feet to adjust the level of
mechanically perfect piece of equipment. Damage can the unit.
occur in shipment. For this reason, the units should
be thoroughly inspected upon arrival. Any damage The coupling center section is shipped loose to al-
noted should be reported immediately to the transpor- low a check of proper electrical phasing, direction of
tation company. This way, an authorized agent can rotation of the motor.
examine the unit, determine the extent of damage and
take necessary steps to rectify the claim with no seri-
ous or costly delays. At the same time, the local Vilter
representative or the home office should be notified
of any claim made.

TABLE 1. UNIT WEIGHTS

MODEL SEPARATOR STANDARD

SIZE UNIT (LBS) Do not check for motor rotation without
VSM 201 12” 2,450 having coupling disconnected from
VSM 301 12” 2,500 compressor.
VSM 361 12” 2,500
VSM 401 12” 2,500
SYSTEM PIPING
VSM 501 16” 3,966
VSM 601 16” 4,001 Refer to the ANSI/ASME B31.5 Code for Refrigera-
tion Piping. All compressor oil supply and oil return
VSM 701 16” 4,036
piping has been completed at the factory. Main line
VSM 701 20” 4,888 refrigerant suction and discharge connections are
* Does not include motor. always necessary.

FOUNDATIONS Care must be taken to avoid trapping the lines except

for specific purposes. When traps are used, the hori-
Vilter single screw compressor units are basically vi- zontal dimensions should be as short as possible to
bration free machines, therefore, no elaborate founda- avoid excessive oil trapping.
tions are necessary. The floor or foundation upon
which the unit will be placed should be designed to Lines for ammonia systems must be of steel pipe with
support the entire operating weight of the unit. (See specially designed ammonia service fittings. Com-
Table 1 for unit weight). mon pipe fittings must NEVER be used as they will
not provide the same service. Steel pipe is generally
PLACEMENT OF UNIT used in large installations when joints are welded.
The single screw compressor units are shipped with
all major components mounted on structural steel. In making up joints for steel pipe, the following pro-
Place the entire unit on the floor on a concrete pad and cedures should be followed:
securely bolt in place. Review local codes and
ASHRAE Safety Code for Mechanical Refrigeration. For threaded connections, all threads on the pipe and
Bolt holes are located in the unit’s mounting feet. fitting should be carefully cleaned to remove all traces
When locating the unit, provide adequate space for of grease or oil. Threads should then be wiped dry
with a lint free cloth. Only thread filling compounds

16
Installation Instructions

suitable for refrigeration service should be used for

making steel pipe joints. These compounds should Additional control wiring in the field is also required.
be used sparingly, and on the pipe only. Do not put Dry contacts are provided in the control panel for
any on the first two threads to prevent any of the starting the screw compressor motor. These con-
compound from entering the piping system. Acety- tacts are to be wired in series with the starter coils. A
lene or arc welding is frequently used in making steel current transformer is supplied along with the com-
pipe joints, however, only a skilled welder should at- pressor unit, and is located in the motor junction box.
tempt this kind of work. Take care to see no foreign This transformer is to be installed on one phase of
materials are left in the pipes and remove all burrs the compressor motor starter. A normally open auxil-
formed when cutting pipe. iary contact from the compressor motor starter is also
required.
It is important to avoid short, rigid pipe lines that do
not allow any degree of flexibility. This must be done Terminal locations for this wiring can be found on
to prevent vibration being transmitted through the the wiring diagram supplied with this unit. Addi-
pipe lines to the buildings. One method of providing tional aspects of the electrical operation of the single
the needed flexibility to absorb the vibration is to screw units are covered in the start up and operation
provide long lines that are broken by 90° ells in three section of this manual.
directions.

Hangers and supports pipe lines should receive care- TESTING REFRIGERATION
ful attention. The hangers must have ample strength SYSTEM FOR LEAKS
and be securely anchored to withstand the vibration
from the compressor and adequately support the pipe Vilter equipment is tested for leaks at the factory.
lines. One of the most important steps in putting a refrig-
eration system into operation is field testing for leaks.
After installation, pipe hangers and supports may This must be done to assure a tight system that will
become loose due to seasonal changes or the build- operate without any appreciable loss of refrigerant.
ing settling. This will lead to vibrations being trans- To test for leaks, the system pressure must be built
mitted through the pipe to the compressor unit. To up. Test pressures for various refrigerants are listed
avoid piping transmitted vibration, hangers and sup- in ANSI B9.1-1971 code brochure entitle “Safety Code
ports should be periodically checked and adjusted. for Mechanical Refrigeration”. These pressures will
usually suffice, however, it is advisable to check lo-
This information is taken from ASHRAE 15-89 and cal codes as they may differ. Before testing may
ANSI B31.5. The installing contractor should be thor- proceed, several things must be done.
oughly familiar with these codes, as well as any local
codes. First, if test pressures exceed the settings of the sys-
tem, relief valves or safety devices, they must be
ELECTRICAL CONNECTIONS removed and the connection plugged during the test.
Second, all valves should be opened except those
The single screw compressor units are shipped with leading to the atmosphere. Then, open all solenoids
all package mounted controls wired. The standard and pressure regulators by the manual lifting stems.
control power is 115 volts 60 Hertz, single phase. If a All bypass arrangements must also be opened.
115 volt supply is not available, a control transformer
may be required. The power source must be con- Ammonia Systems
nected to the control panel according to the electrical
diagrams. Dry nitrogen may be used to raise the pressure in an
ammonia system to the proper level for the test. The
The units are shipped without the compressor motor gas may be put into the system through the charging
starter. Field wiring is required between the field valve or any other suitable opening. Adjust the pres-
mounted starters and package mounted motors. sure regulator on the bottle to prevent over-pressur-

17
Installation Instructions

ization. Do not exceed the pressure rating on the sure of 50 microns or less. Attach this pump to the
vessel with the lowest pressure rating. system and allow it to operate until system pressure
is reduced somewhere below 1000 microns. Evacua-
Carbon Dioxide should NOT be used as a testing gas tion should not be done unless the room temperature
in an ammonia system. This will cause ammonium is 60°F or higher.
carbonate to precipitate when the CO2 and ammonia
are combined. If heavy enough, this precipitate will Attach vacuum gauge(s), reading in the 20 to 20,000
cause the machine to freeze and clog the strainer. micron gauge range, to the refrigerant system. These
gauge(s) should be used in conjunction with the high
A mixture of four parts water to one part liquid soap, vacuum pump.
with a few drops of glycerin added, makes a good leak
test solution. Apply this mixture with a one inch round The reading from the gauge(s) indicates when the
brush at all flanges, threaded joints, and welds. Re- system has reached the low absolute pressure re-
pair all visible leaks. If possible, leave the pressure quired for complete system evacuation.
on over night. A small drop in pressure over this
period indicates a very tight system. Connect the high vacuum pump into the refrigeration
system by using the manufacturer’s instructions.
Remember to note the ambient temperature, as a Connect the pump both to the high side and low side
change in temperature will cause a change in pres- of the system, to insure system evacuation. Attach
sure. the vacuum gauge to the system in accordance with
the manufacturer’s instructions.
After the system is thoroughly tested, open all valves
on the lowest part of the system so the gas will flow A single evacuation of the system does not satisfac-
away from the compressor. This prevents any dirt or torily remove all of the non-condensibles, air and wa-
foreign particles from entering the compressor and ter vapor. To do a complete job, a triple evacuation is
contaminating the working parts. The oil should then recommended. When the pump is first turned on,
be charged into the compressor. bring system pressure to as low a vacuum level as
possible, and continue operation for 5 to 6 hours.
Charge a small amount of ammonia into the system
and pressurize the system with dry nitrogen to its Stop the pump and isolate the system. Allow the unit
respective design pressure. Pass a lit sulfur stick to stand at this vacuum for another 5 to 6 hours.
around all joints and connections. Any leaks will be After this time, break the vacuum and bring the sys-
indicated by a heavy cloud of smoke. If any leaks are tem pressure up to 0 psig with dry nitrogen.
observed during this test, they must be repaired and
rechecked before the system can be considered tight To begin the second evacuation, allow the pump to
and ready for evacuation. operate and reduce the pressure again to within 50 to
1000 microns. After this reading is reached, allow the
Evacuating The System pump to operate 2 or 3 hours. Stop the pump and let
the system stand with this vacuum. Again using dry
A refrigeration system operates best when only re- nitrogen, raise the system pressure to zero.
frigerant is present. Steps must be taken to remove all
air, water, vapor, and all other non-condensibles from For the third evacuation, follow the previous proce-
the system before charging it with refrigerant. A com- dure with the pump operating until system pressure
bination of moisture and refrigerant, along with any is reduced below the 1000 micron level. Run the pump
oxygen in the system, can form acids or other corro- an additional 6 hours and hold the system for ap-
sive compounds that corrode internal parts of the proximately 12 hours at low pressure. Again break
system. the vacuum with dry nitrogen and allow the pressure
in the system to rise slightly above zero pounds
To properly evacuate the system, and to remove all (psig). Charge the system once more below the 1000
non-condensibles, air and water vapor, use a high micron level and use the refrigerant designed for the
vacuum pump capable of attaining a blanked off pres- system.

18
Installation Instructions

When properly evacuating the system as outlined

above, the system is dry, oxygen-free and free of non-
condensibles. The piping should not be insulated
before the evacuation process is started. If moisture
is in the system before evacuating, it condenses in
low places and freezes. If this happens, it can be
removed by gently heating the trap farthest away from
the vacuum pump. This causes the ice to melt and
water to boil. Water vapor collects in the next trap
towards the vacuum pump. This process should be
repeated until all pockets of water have been boiled
off, 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 system
has reached the low absolute pressure required
for complete system evacuation.

19
Installation Instructions

UNIT OIL CHARGING Oil For Single Screw Compressors Units

The compressor unit is shipped from Vilter with no oil Due to the need for adequate lubrication, Vilter rec-
charge. The initial oil charge can be made through ommends only the use of Vilter lubricants, designed
the drain valve at the oil receiver/separator. Vilter specifically for Vilter compressors. With the exten-
motor driven and manually operated oil chargers are sive research that has been performed, we are able to
available for this purpose. offer refrigerant specific lubricating oils. Use of oil
not specified or supplied by Vilter will void the com-
The oil level must be checked with the unit off and pressor warranty.
without any liquid ammonia inside of the separator.
During normal operation, one will observe the liquid Please contact your local Vilter representative or the
ammonia/oil mixture in the bottom sight glass, not the Home Office for further information.
actual oil level.
SYSTEM REFRIGERANT
To remove the liquid from the separator, manually CHARGING
close off the liquid supply line to the compressor while
running. The liquid ammonia level will slowly drop
and the superheat will increase. The compressor will
automatically unload and once the superheat reaches
25ºF, it will shutdown. Wait 30 minutes to allow the oil When initially charging the system, make sure the
in the compressor and pipelines to drain into the sepa- compressor unit is pressurized from the discharge
rator to check the level of oil in the sight glass. If you side of the compressor. Pressurizing the compressor
don’t wait the 30 minutes the oil level will be, de- from the suction side may cause rotation of the com-
pending on the separator size, approximately 1/4”- pressor, without oil supply, which could lead to in-
1/2” lower than the original level. Oil may now be ternal damage.
added to the unit to bring it up to the operating
level. (See Table Below) for approximate (full) oil After the system is leak-free and evacuation has been
charge requirements. completed, it is ready for charging. Before actual
charging, however, the entire operation of the refrig-
OILCHARGE eration system should be inspected as outlined be-
low:
Oil Separator Size Approximate Oil
Charge –Gallons
VSM 12” 7 Low Side Equipment
VSM 12”w/oil sump 8
VSM 16” short (68’) 9 1. Fans on air handling equipment running.
VSM 16” long (86”) 10.5
VSM 20” 12.5 2. Pumps on water cooling equipment running.

3. Proper location and attachment of all thermo-

When the unit is in operation, there will be some drop static expansion valve bulbs to their respective
in the oil level as the compressor oil lines, oil filter and suction lines.
other piping becomes charged with the normal amount 4. Correct fan and pump rotation.
of oil that will be in circulation. This drop in oil level
should bring the level in the oil receiver/separator 5. Evaporator pressure regulators and solenoid
into the normal operating range. valves open.

6. Water pumps and motors correctly aligned and

drive couplings correctly positioned and tight.
Do not mix oils. Never check the oil level when the 7. Belt drives correctly aligned and tightened.
unit is running. See Separator Oil Level on page 34
for proper level. 8. Proper voltage to motors.
20
Installation Instructions

Compressors eration. High side charging of refrigerant into the

system is accomplished as follows:
1. Proper oil level.

2. Voltage agrees with motor characteristics. 1. Connect a full drum of refrigerant to the liquid
charging valve. This valve is generally located
3. Properly sized motor fuses and heaters. in the liquid line immediately after the king or
liquid line valve. Purge the air from the charging
4. Direct drive couplings correctly positioned and line.
assembled.
2. Leak check charging line and connections be-
5. All suction and discharge stop/check or sepa- fore charging with liquid.
rated stop valves in their respective automatic
or open mode. 3. Charge liquid refrigerant from the drum. If the
drum is not equipped with “Liquid” and “Va-
6. All transducers and RTD’s calibrated and read- por” valves, place the drum in a position recom-
ing correctly. mended by the refrigerant supplier so that liquid
refrigerant only can enter the system. Close the
Condensers and Cooling Towers liquid line or king valve, if it is not already closed.
Open the charging valve slowly to allow liquid
1. Water available at water cooled condensers or refrigerant to enter the system. The vacuum in
cooling towers and supply line valve open. the system will draw in the refrigerant.
It is important that, during this operation, air han-
2. Water in remote water tank or sump of evapora- dling units be running and water is circulating
tive condenser or cooling tower and make-up through water cooled condensers and chillers.
water available. The low pressures on the system can cause the
refrigerant to boil at low temperature and possi-
3. Correct rotation of pump and fan motors. bly freeze the water if it is not kept circulating.
Water freezing in a condenser or chiller can rup-
4. Belt drives aligned and tightened correctly. ture the tubes and cause extensive damage to
the system. It would be desirable to charge the
5. Direct drive couplings correctly positioned and initial amount of refrigerant without water in the
tight. shell and tube equipment to eliminate the possi-
bility of freeze up.
6. Pump, fans and motors lubricated.
4. After some refrigerant has entered the system,
the compressor unit starting procedure may be
Controls followed. See Start-Up and Operation Section
of this manual.
Controls should be at the initial set points. See
5. Continue charging refrigerant into the system
Vission/Vantage manual for further information.
until the proper operating requirements are sat-
isfied. Then, close the liquid charging connec-
tion and open the liquid line valve allowing the
Initial Charging – High Side Charging system to operate normally. To check that
enough refrigerant has been added, the liquid
There are two methods of charging refrigerant into sight glass should show no bubbles, and there
the system, through the “high side” or through the should be a liquid seal in the receiver. If these
“low side”. High side charging is usually used for two conditions are not satisfied, additional re-
initial charging as filling of the system is much faster. frigerant must be added.
Low side charging is usually reserved for adding only
small amounts of refrigerant after the system is in op-

21
Installation Instructions

6. When sufficient refrigerant has been charged instructs the Vission/ Vantage control panel to
into the system, close the charging and drum learn the rotational 0% position & rotational 100%
valves. Then remove the drum from the system. position of the slide valve travel.

7. During the charging period, observe the gauges PLEASE NOTE:

carefully to insure there are no operating diffi- Because there is an optical sensor on this motor,
culties. Watch head pressures closely to make do not attempt calibration in direct sunlight.
sure the condensers are functioning properly.

Since it is usually necessary to use several drums ACTUATOR MOTOR CONTROL

when charging a system, follow step# 6, then start MODULE CALIBRATION PROCEDURE
back at step#1 of the above description when attach-
ing a new drum. After charging, the refrigerant drums 1. Disable the Slide Non-Movement Alarm by
should be kept nearby for several days as it is some- going to the “Setup” menu on the Vission/
times necessary to add more refrigerant as the system Vantage and choosing “Alarm Disable” for
“settles down”. the Slide Non-Movement Option.

2. Completely shut off the power to the Vission/

Vantage control panel completely.
SLIDE VALVE ACTUATOR
INSTALLATIONS INSTRUCTIONS 3. If not already done, mount the slide valve
actuator per (“Vilter Actuator set up for Ca-
pacity and Volume Slide Motors). Next, wire
the actuator per the attached wiring dia-
grams, using the already installed electrical
WHEN INSTALLING THE OPTICAL SLIDE conduit to run the cables. The old wiring
MOTOR, LOOSEN LOCKING COLLAR BEFORE can be used to pull the new cables through
SLIDING THE COLLAR DOWN ON THE the conduit to the control panel. The cables
SHAFT. DO NOT USE A SCREWDRIVER TO may also be externally tie-wrapped to the
PRY LOCKING COLLAR INTO POSITION. conduit. Run the yellow AC power cable(s)
and the gray DC position transmitter
cable(s) in different conduit. This prevents
OVERVIEW the DC position transmitter cable from pick-
ing up electrical noise from the AC power
Calibration of an optical slide valve actuator is a cable. Do not connect either of the cables to
two step process that must be done for each the actuators yet.
actuator installed of the compressor. Briefly, the
steps are as follows. In addition, if the actuators are replacing old
gearmotors on early Vission/Vantage units, you must
1) The actuator motor control module, located in- remove the capacitors and associated wiring from
side the actuator housing, is calibrated so that it inside the control panel. This is necessary to pre-
knows the minimum and maximum rotational po- vent electrical damage to the new actuator motor.
sitions of the slide valve it controls. The cali-
brated actuator will output 0 VDC at the minimum 4. When completing the calibration of the
position and 5 VDC at the maximum position. new actuators, the motors are signaled to
move to below 5%. This may not com-
2) After the actuator motor control module has been pletely occur when exiting the calibration
calibrated for 0-5Volts, the controlling channel screen due to a “program timer”. HOW-
corresponding to the actuator motor (either the EVER, when the compressor actually
capacity or volume) has to be calibrated. This starts, the motors will travel below 5% and
function correctly. The user may see that

22
Installation Instructions

the actuators are not below 5% after actuator in calibration mode. The red LED will
calibration and try to find the reason. If begin flashing rapidly.
the calibration screen is re-entered right
away and then exited, the timer will allow 13. Note: When the actuator is in calibration
the actuator to go below the 5% on the mode, it outputs 0V when the actuator is
screen. This may be perceived as a running and 5V when it is still. Thus, as stated
problem; in reality, it is not. earlier, the actuator voltage will fluctuate
during calibration. After the actuator has been
5. Note: The 0 to 5V-position transmitter calibrated, 0V output will correspond to the
output of the actuator will fluctuate wildly minimum position and 5V to the maximum
during the calibration process. To prevent position.
damage to the actuators, do not connect the
yellow power cable or the gray position 14. Note: The “Slide calibration” screen on the
transmitter cable until instructed to do so Vission/Vantage has a “Current” window,
later on. which displays twice the actuator output
voltage. This value, (the % volume and the %
6. Open the plastic cover of the capacity motor by capacity) displayed in the “Current Vol” and
removing the four #10 screws. Caution: there Current Cap” Windows are meaningless until
are wires attached to the connector on the calibration has been completed.
plastic cover. Handling the cover too aggres-
sively could break the wires. 15. Use the DEC button on the Vission/Vantage
panel to drive the slide valve to its minimum
7. Gently lift the cover and tilt it toward the Turck “mechanical stop” position. Do not continue
connectors. Raise the cover enough to be able to run the actuator in this direction after the
to press the blue calibrate button and be able slide valve has reached the stop. Doing so may
to see the red LED on the top of assembly. cause damage to the actuator or the slide
valve. When the slide has reached the
8. Press “Menu” on the main screen and then mechanical stop position, use the INC button
press the “Slide Calibration” button, to enter to pulse the actuator to where the slide is just
the slide calibration screen. (Note: you must be off of the mechanical stop and there is no
in this slide calibration screen before attaching tension on the motor shaft.
the yellow power cable or gray position
transmitter cable.) 16. Quickly press and release the blue button on
the actuator again. The red LED will now flash
9. Now connect the yellow power cable and the at a slower rate, indication that the minimum
gray position transmitter cable to the actuator. slide valve position (0V position) has been set.

10. Press INC and DEC to move the slide valve and 17. Use the INC button on the Vission/Vantage
check for the correct rotation. See Table 1 for panel to drive the slide to its maximum
Actuator/command shaft rotation specifica- “mechanical stop” position. Do not continue to
tions. run the actuator in this direction after the
slide valve has reached the stop. Doing so may
11. Note: If the increase and decrease buttons do cause damage to the actuator or the slide
not correspond to increase or decrease shaft valve. When the slide valve has reached the
rotation, swap the blue and brown wires of the mechanical stop position, use the DEC button
“yellow power cable”. This will reverse the to pulse the actuator to where the slide is just
rotation of the actuator/command shaft. off of its mechanical stop and there is no
tension on the motor shaft.
12. Quickly press and release the blue push button
on the actuator one time. This places the 18. Quickly press and release the blue button on

23
Installation Instructions

the actuator one more time. The red LED will “Current Vol” value will be displayed in the
stop flashing. The actuator is now calibrated window on the “Main” screen and the “Slide
and knows the minimum and maximum Calibration” screen.
positions of the slide valve it controls. Now
the capacity or volume channel of the Vission/ 27. Gently lower the plastic cover over the top of
Vantage can be calibrated. the actuator to where it contacts the base and
o-ring seal. After making sure the cover is
19. Use the Dec button to move the actuator seated properly, gently tighten the four #10
towards its minimum position while watching screws. Caution: The plastic cover will crack
the millivolt readout on the Vission/Vantage if the screws are over tightened.
screen. Discontinue pressing the DEC button
when the millivolt reading the “Current” 28. Enable the “Slide Non-Movement Alarm” by
window above the “Set Min” button is going to the “Setup” menu and choosing
approximately 500 millivolts. “Alarm Enable” for the “Slide Non-Movement
Option”.
20. Now use the DEC and INC buttons to position
the slide valve until a value close to 300 29. This completes the calibration for this channel
millivolts is on the screen. Then, press the either capacity or volume. Repeat the same
“Set Min” button in the capacity or volume procedure to the other channel.
slide valve window to tell the controller that
this is the minimum millivolt position. Note:
The value in the “Current Cap” or “Current Slide Valve Actuator Theory of Operation
Vol” window has no meaning right now.
The slide valve actuator is a gear-motor with a posi-
21. Use the INC button to rotate the actuator tion sensor. The motor is powered in the forward and
towards its maximum position while watching reverse directions from the main computer in the con-
the millivolt readout on the controller screen. trol panel. The position sensor tells the main com-
Discontinue pressing the INC button when the puter the position of the slide valve. The main com-
millivolt reading in the “Current” window is puter uses the position and process information to
approximately 9200 millivolts (7900 millivolts decide where to move the slide valve next.
for the 2783J qualified analog boards). You are
nearing the mechanical stop position. The position sensors works by optically counting
motor turns. On the shaft of the motor is a small
22. Pulse the INC button to carefully move the aluminum “photochopper”. It has a 180 degree fence
slide valve until the millivolt readout “satu- that passes through the slots of two slotted
rates”, or stops increasing. This is around optocouplers. The optocouplers have an infrared
9500 millivolts (8400 millivolts for 2783 light emitting diode (LED) on one side of the slot and
qualified analog boards). a photo transistor on the other. The photo transistor
behaves as a light controlled switch. When the
23. Pulse the DEC button until the millivolts just photochopper fence is blocking the slot, light from
start to decrease. (This is the point where the the LED is prevented from reaching the photo tran-
channel drops put of saturation). sistor and the switch is open. When photochopper
fence is not blocking the slot, the switch is closed.
24. Press the “Set Max” button.
As the motor turns, the photochopper fence alter-
25. Press the “Main” button to complete calibra- nately blocks and opens the optocoupler slots, gen-
tion and exit the “Slide Calibration” screen. erating a sequence that the position sensor
The controller will automatically energize the microcontroller can use to determine motor position
actuator and drive it back to its minimum by counting. Because the motor is connected to the
position (below 5%) for pre-start-up. slide valve by gears, knowing the motor position
26. Note: Now the “Current Cap” or the

24
Installation Instructions

means knowing the slide valve position.

During calibration, the position sensor records the

high and low count of motor turns. The operator tells
the position sensor when the actuator is at the high or
low position with the push button. Refer to the cali-
bration instructions for the detailed calibration proce-
dure.

The position sensor can get “lost” if the motor is

moved while the position sensor is not powered. To
prevent this, the motor can only be moved electrically
while the position sensor is powered. When the posi-
tion sensor loses power, power is cut to the motor. A
capacitor stores enough energy to keep the position
sensor circuitry alive long enough for the motor to
come to a complete stop and then save the motor
position to nonvolatile EEPROM memory. When
power is restored, the saved motor position is read
from EEPROM memory and the actuators resumes
normal function

This scheme is not foolproof. If the motor is moved

manually while the power is off or the motor brake has
failed, allowing the motor to free wheel for too long
after the position sensor looses power, the actuator
will become lost.

A brake failure can sometimes be detected by the po-

sition sensor. If the motor never stops turning after a
power loss, the position sensor detects this, knows it
will be lost, and goes immediately into calibrate mode
when power is restored.

Slide Valve Actuator Troubleshooting next 2 pages.

25
Slide Valve Actuator Troubleshooting Guide

The actuator cannot be cali- Dirt or debris is blocking one or both Clean the optocoupler slots with
brated optocoupler slots a Q-Tip and rubbing alcohol.

The photochopper fence extends less Adjust the photochopper so that

than about half way into the the fence extends further into the
optocoupler slots optocoupler slots. Make sure the
motor brake operates freely and
the photochopper will not con-
tact the optocouplers when the
shaft is pressed down.

The white calibrate wire in the grey Tape the end of the white wire in
Turck cable is grounded the panel and make sure that it
cannot touch metal

Dirt and/or condensation on the po- Clean the boards with an elec-
sition sensor boards are causing it to tronics cleaner or compressed air.
malfunction
Try to free the stuck button.
The calibrate button is stuck down
Replace the actuator.
The position sensor has failed
Depress the button quickly and
Push button is being held down for then let go. Each ¾ second the
more that ¾ second when going button is held down counts as
through the calibration procedure another press.

Tape the end of the white wire in

The actuator goes into cali- The white calibrate wire in the grey the panel and make sure that it
bration mode spontaneously Turck cable is grounding intermit- cannot touch metal.
tently
Increase the distance between
A very strong source of electromag- the EMI source and the actuator.
netic interference (EMI), such as a
contactor, is in the vicinity of the ac- Install additional metal shielding
tuator or grey cable material between the EMI source
and the actuator or cable.

Replace the actuator.

There is an intermittent failure of the Get the motor brake to where it

position sensor operates freely and recalibrate.

The actuator goes into cali- Replace the actuator

The motor brake is not working prop-
bration mode every time erly (see theory section above.)
power is restored after a power
loss

26
Slide Valve Actuator Troubleshooting Guide

The actuator does not transmit The motor was manually moved Recalibrate.
the correct position after a power while the position sensor was not
loss powered.

The motor brake is not working prop- Get the motor brake to where it op-
erly erates freely and then recalibrate.

The position sensor’s EEPROM Replace the actuator.

memory has failed

There is a rapid clicking noise The photochopper is misaligned Try to realign or replace the actua-
with the slotted optocouplers tor.
when the motor is operating
The photochopper is positioned too Adjust the photochopper so that
low on the motor shaft. the fence extends further into the
optocoupler slots.

A motor bearing has failed Replace the actuator.

The motor operates in one direc- There is a loose connection in the Tighten.
tion only screw terminal blocks

There is a loose or dirty connection Clean and tighten.

in the yellow Turck cable

The position sensor has failed Replace the actuator.

There is a broken motor lead or wind- Replace the actuator.

ing

The motor will not move in ei- The thermal switch has tripped be- The motor will resume operation
ther direction cause the motor is overheated when it cools. This could be caused
by a malfunctioning control panel.
Consult the factory.

Any of the reasons listed in “The See above.

motor operates in one direction
only”

The command shaft is jammed Free the command shaft.

Broken gears in the gearmotor Replace the actuator.

The motor runs intermittently, Motor is overheating and the ther- This could be caused by a malfunc-
several minutes on, several min- mal switch is tripping tioning control panel. Consult the
utes off factory.

27
Slide Valve Actuator Troubleshooting Guide Cont.

The motor runs sporadically Bad thermal switch Replace the actuator.

Any of the reasons listed in “The mo- See above.

tor will not move in either direction”

The motor runs but output shaft Stripped gears inside the gear motor Replace the actuator.
will not turn or the armature has come unpressed
from the armature shaft

MAINTENANCE
SUGGESTIONS

Careful checking of a refrigeration system for leaks 6. Check oil pressure and review microprocessor
and proper operation of all components upon instal- logs and log sheets.
lation will start the system on its way to a long life of 7. Check refrigerant levels in vessels.
satisfactory service. To ensure the desired trouble-
free operation, however, a systematic maintenance C. Monthly
program is a prerequisite. The following maintenance
schedule is suggested. (Items 1 thru 7 above plus 8 thru 10)

A. Daily 8. Lubricate all motors and bearings. Follow

manufacturer’s instructions on lubrication.
1. Check all pressure and temperature readings. 9. Check calibration and operation of all controls,
2. Check oil pressures for excessive pressure drop. particularly safety controls.
Clean filter when pressure drop exceeds 10 psi. 10. Operate compressor capacity and volume ratio
For proper procedure to change the oil filter and controls through their range both automatically
charge oil into the system. (See Operation Sec- and manually.( Recalibrate if necessary).
tion).
D. Trimonthly
Note: Clean the system strainers each time
the oil line filter element is cleaned. (About 2000 operating hours)
Check movement of compressor rotor at drive
3. Check compressor sound for abnormal noises. coupling end to determine bearing endfloat. (Re-
4. Check shaft seals for excessive oil leakage. A fer to Service Section.)
small amount of oil leakage (approximately 10
drops/min) is normal. This allows lubrication of
E. Yearly
the seal faces.
(Items 1 thru 10 and “D” above plus 11 thru 19)
B. Weekly 11. Check entire system thoroughly for leaks.
12. Remove all rust from equipment, clean and paint.
(Items 1 thru 4 above plus 5 thru 7) 13. Clean all oil strainers.
14. Clean suction strainer – compressors.
5. Check oil levels with unit off and liquid removed
15. Check motors and fans for shaft wear and end
from separator.
play.

28
16. Check operation and general condition of year may prevent extensive shutdowns later
Microcontroller and other electrical controls. with subsequent product loss and expensive
17. Drain and clean entire oil system through the repairs.
separator drain. Recharge with new clean mois-
ture free oil. For proper procedure for changing
the strainer element and charging oil into the
system, see Start-Up and Operation section.
18. Check the calibration of the microprocessor
pressure 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 develop

in a refrigeration system (i.e. drying out of valve pack-
ing, yielding of gaskets, improper replacement of
valve caps and loosening of joints due to vibration).
For these reasons, the need for periodic leak testing
cannot be over-emphasized. Similarly, when any ser-
vice operations are performed on the system, care
should be exercised to insure all opened flanges are
tightened, all plugs that were removed are replaced
with a suitable thread filling compound, all packing
glands on valve stems are tightened, and all valve
caps are replaced. When operation is restored, all
joints 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 parts
be 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 removed
yearly, and a visual inspection be made of the
internal parts. In this way, a small amount of
time spent checking machine conditions once a

29
Service Intervals Requirements

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

Group Inspection/ SERVICE INTERVAL (HOURS)

Maintenance

100,000

120,000
110,000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
25 (4)

5,000
Item

200
50
OIL CIRCUIT
Oil Change (1) R R R R R R R R R
Oil Analysis (2) S S S S S S S S S S S S S S
Oil Filters (3) C C C C C C C C C C C C C C C C
Oil Strainer C C C C C C C C C C C C C C C C

Suction Screen C C C C C C C C C C C C C C C C
Liquid Line Strainers C C C C C C C C C C C C C C C C
Coupling Alignment C C C C C C C C C C C C C C
and Integrity

CONTROL CALIBRATION
Transducers I I I I I I I I I I I I I I
RTD’s I I I I I I I I I I I I I I
Inspect Compressor I I I I I I I
Bearings I

Key I Inspect.
C Clean
R Replace.
S Sample.

Notes: (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 analysis
will depend on system cleanliness.

(3) The oil filter(s) on a minimum must be changed at these intervals or annually if not
run continuously. However, the oil filter(s) must be changed if the oil filter
differential exceeds 20 psi or oil analysis requires it.

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

30
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 cooler
to the unit. A blanket of liquid ammonia lies on top of the oil. The cooling occurs through the entire compression and
separation process. The compressor package is greatly simplified whereas there is no oil pump. Instead, the Cool
Compression compressors utilize Suction Oil Injection for start-up. The following sections describe the start-up and
operation of a Cool Compression unit and refer to the figure above.

31
Operating Instructions

Start Up Liquid Ammonia Supply

When the Cool Compression unit is initiated for start- High-pressure liquid Ammonia is supplied to the com-
up, Micro-controller returns the slide valves to their pressor package by the main liquid supply line. Pro-
minimum positions. The suction oil injection sole- visions must be made to allow an adequate liquid sup-
noid (SV-2) is actuated. The compressor (C100) now ply to provide a source of liquid for cooling the com-
starts. There is an initial pressure drop in the suction pressor, while the compressor is running at operat-
chamber of the compressor and a corresponding in- ing conditions. The liquid supply line is connected
crease in pressure on the discharge of the compres- to the in-line strainer to ensure that no debris enters
sor. This creates a pressure differential that forces the solenoid (SV1) and level master control valves
the oil and liquid ammonia mixture through the suc- located downstream of the strainer. The solenoid
tion oil injection line into the suction chamber of the valve (SV1), is open during start-up and operation to
compressor. This oil and liquid provides lubrication allow the high pressure liquid ammonia to be fed to
and cooling until full pressure differential lubrication the Level Master Control Valve. The Level Master
is attained. Control valve controls the amount of liquid refriger-
ant entering the compressor based on level of the
As the differential pressure increases, the oil and liq- liquid refrigerant in the separator.
uid ammonia is now injected into the screw during the
compression process and the (SV2) will close. The Level Master Control sensing bulb and heater
are installed in the end of the separator. The sensing
Gas Flow bulb monitors the height of ammonia in the separator.
If the ammonia level in the separator is low, the sens-
The low-pressure refrigerant enters the compressor ing bulb is heated by the heater H2, which opens the
through a combination stop/check valve and suction Level Master Control Valve. When the liquid level is
tee, into the suction of the compressor. The upstream high in the separator the heater H2 cannot heat the
pressure is measured by Pressure Transducer (PT1). sensing bulb and the Level Master Control Valve will
The temperature of the refrigerant is measured by re- close until the liquid level drops in the separator. The
sistance temperature detector (RTD1). The refriger- outlet of the Level Master Control is connected and
ant gas flows into the compressor where a mixture of allows liquid to be injected into the compressor. De-
oil and liquid refrigerant is added to the gas through pending on the operating conditions and model of
the compression process. The compressed gas en- the compressor, the liquid injection could be through
trained with liquid ammonia and oil droplets discharges either SV3 and or SV4.
the compressor. The discharge pressure and tempera-
ture are monitored by pressure transducer (PT2) and Separation
resistance temperature detector (RTD2). The mixture
discharges into the separator where the ammonia and The mixture of compressed gas, liquid ammonia and
oil droplets are separated from the gas. The high- oil droplets is discharged from the compressor into
pressure gas discharges from the separator, through the separator. As the mixture moves through the sepa-
the discharge flange on the end of the separator. rator, the oil and liquid refrigerant droplets separate
out and fall to the bottom of the separator. A liquid
blanket of ammonia, of approximately 2 inches in
Please Note depth, remains on top of the oil within the separator.

There are no coalescing elements or any other ser- The last stage of oil separation is completed with a
viceable components located inside the separator. wire mesh element. This element does not require
To prevent voiding the warranty, the separator maintenance and is not a serviceable item. A drain
should not be disassembled under any circum- line from the final stage of separation is attached to
stances. the discharge end of the separator. A sight glass and
adjustment valve is provided to visually and physi-
cally monitor the flow. The drain line is connected to

32
Operating Instructions

the compressor to allow reinjection of the oil/ammo- If the superheat on the discharge of the compressor
nia mixture. during normal operation reaches 5º F, this signifies
there is not enough liquid ammonia being fed to the
The dry compressed gas is discharged from the sepa- system. Solenoid SV3 (see note below) will then open
rator at 0º to 2º above the saturated discharge tem- allowing an increased amount of liquid ammonia to be
perature. The oil temperature in the separator is moni- injected into the compressor system. If the superheat
tored by RTD3. reaches 8º F, the unit begins to unload. If the super-
heat continues to increase and reaches 20ºF, the unit
Liquid and Oil Level Monitoring will activate an alarm . At 25ºF, the unit will shutdown.

The level of oil within the separator is monitored by a Note: The solenoid (SV3) has been removed on the
float mounted within the separator, (LSL3). If the level on the new models. ( After August 2004)
of 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 will Compressor Lubrication and Cooling
automatically be rest.
While the unit is running a mixture of oil and liquid
Should the level remain below (LSL3) for an extended ammonia is injected into the compressor during the
period of time, the compressor will eventually fail on a compression process. This mixture not only supplies
LO OIL Level failure. the necessary lubrication, but it cools the internal
components during the entire compression process.
If the ammonia level within the separator is too high, The mixture is injected from the separator, through a
the Liquid Switch (LSH1) will open. If the liquid switch strainer and Flow Switch FS1 to assure liquid flow,
remains open for an extended period, the compressor into the bottom of the compressor. The connection
will eventually fail on HI LIQ Ammonia Level failure. for Suction Oil Injection is also branched off this line
The compressor failure can not be rest until the HI supplying liquid to the suction of the compressor for
LIQ Ammonia Level returns to normal operating level. startup.
In the case that an excess amount of liquid ammonia is
injected into the separator, the separator will also au-
Compressor Shut Down
tomatically carry the liquid in droplet form out of the
separator and into the system.
When the CC compressor unit shuts down, the CC
unit compressor unit has been designed to remain at
Note: The Liquid Switch (LSH1) has been removed on
discharge pressure and not bleed down to suction.
the on the new models. ( After August 2004)
This will allow the liquid blanket to remain within the
separator under normal circumstances.
There are two or three (depending on the size of the
separator) 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. During OIL SYSTEM
operation, a mixture of oil and liquid ammonia will be
viewed in the bottom sight glass. The Vission/Van- Checking The Oil Level
tage will monitor for low oil level during operation of
the unit. The oil level must be checked with the unit off for at-
least 30 minutes and without any liquid ammonia in-
The Vission/Vantage monitors the compressor while side of the separator. During normal operation, one
operating. During start-up, the initial superheat may will observe the liquid ammonia mixture in the bottom
be high. As long as the superheat continues to de- sight glass, not the actual oil level.
crease, indicating that there is liquid ammonia being
added to the separator the unit will continue to oper- To remove the liquid from the separator, manually
ate and load. close off the liquid supply line to the compressor while

33
Operating Instructions

running. The liquid ammonia level will slowly drop Adding Oil
and the superheat will increase. The compressor will
automatically unload and once the superheat reaches The unit must be shutdown and should have the liq-
25ºF, will shutdown. The user can now visually ob- uid ammonia removed prior to adding oil.
serve the level of oil in the sight glass. The normal
operating level of the oil is observed in the lower sight During shut down, the unit will be at discharge pres-
glass on all CC units. sure. If this pressure is too high, causing an issue
regarding the addition of oil, the pressure should be
Separator Oil Level bled down to suction-SLOWLY.

Separator Initial filling of Note: If you bled the separator to suction pressure
Diameter separator too fast you might carry oil with it.

12” 1/3 of bottom sight glass Use the valve at the bottom of the separator to con-
16” 1/2 of bottom sight glass nect the line to add oil. Start to add the oil and monitor
16” w/3 sight glasses 1/3 of the middle sight glass the level as you are adding.
20” 1/3 of bottom sight glass
Note: If the oil level is below the normal operating
level, fill to the initial filling level of the separator.
(See: Separator Oil Level Table)
Please Note: that during the initial oil fill prior to start-
ing the unit for the first time, the oil level will be slightly
higher. Checking the oil level after a few hours, some
of the oil will remain in the compressor on shutdown
thus 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 separator
prior to energizing the control panel to prevent burn-
ing out the immersion heater.

During the operation of the compressor the oil level

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

34
Operating Instructions

Oil Filter Element

CHANGING AND
CLEANING FILTER

See page 61 for instructions on changing oil and

filters.

Oil Filter Element

The earlier style dual filter (Figure “B”) design allows

for operation of either filter independently. This will
allow changing/cleaning of the filters without shut-
CW CCW ting down the compressor by closing the appropri-
ate valves.

Handle Figure “A” is the current version of the dual filter

assembly, which incorporates a selector level to
choose either or both filters for use. Figure “B” is the
earlier style filter assembly that utilized two single
Drain Plugs filters assembled back to back.

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

Handle In order to isolate (Figure “B”) you must close both

CW inlet and outlet valves for that filter by turning the
To Close handles CW.

Clean the oil filter element as needed during the first

25 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.
Drain Plugs Thereafter, clean the filter every three months or when
the oil pressure drops (see: Vission/ Vantage Manual
set point section), whichever occurs first.
Fig.B Earlier Style Dual
Filter Remove the filter element from the tank. Clean it
thoroughly with “brake cleaning” fluid or similar.
Before reassembling, clean the tank to lengthen the

35
Operating Instructions

life span of the element. Strainer element end caps, Screw Compressor Control
and attached gaskets and springs can be re-used (with And Operation
new strainer canister gasket).
Starting, Stopping and Restarting
Replace canister gasket before reassembling strainer
The Compressor
tank. Place end caps on strainer element and place
inside tank with spring side to bottom of tank. Refill
Before the screw compressor unit may start, certain
the tank about 3/4 full of oil, attach it to the head and
conditions must be met. All of the safety setpoints
tighten the (4) bolts.
must be in a normal condition, and the suction pres-
sure must be above the low suction pressure setpoint
to assure that a load is present. When the “On-Off”
Liquid Injection Oil Cooling
switch or “Manual-Auto” but on is pressed, the
heater of the expansion valve bulb will be energized
The units are furnished with liquid injection for a typi-
and heated for 30 seconds before the compressor is
cal system. The liquid solenoid valve opens when-
allowed to start.
ever the compressor is in operation. The level master
expansion valve controls the flow of liquid refrigerant
If the compressor is in the automatic mode, it will now
to the compressor injection port in response to the
load and unload and vary the volume ratio in
liquid level in the separator. The discharge tempera-
response to system demands.
ture is always maintained at saturation. If the dis-
charge is superheated, refer to the Troubleshooting
Stopping the compressor unit can be accomplished a
Section.
number of ways. Any of the safety set points will
stop the compressor unit if abnormal operating con-
CONTROL SYSTEM ditions exists. The compressor unit “On-Off” or stop
button will turn the compressor unit off as will the
Equipped for automatic operation, the screw compres- low pressure set point. If any of these conditions
sor unit has safety controls to protect it from irregular turns the compressor unit off, the slide valve motors
operating conditions, an automatic starting and stop- will immediately energize to drive the slide valves back
ping sequence, capacity and volume ratio control sys- to 10% limit.
tems.
The control motors will be de-energized when the
Check all pressure controls with a remote pressure respective slide valve moves back below 10%. If there
source to assure that all safety and operating control is a power failure, the compressor unit will stop. If
limits operate at the point indicated on the micropro- the manual start on power failure option is selected
cessor. The unit can be equipped with optional block (see appropriate Microprocessor Instruction Manual),
and bleed valves that are used to re-calibrate the pres- restarting from this condition is accomplished by push-
sure transducers. To use the block and bleed valves ing the reset button to insure positive operator con-
to re-calibrate the pressure transducers, the block trol. If the auto start on power failure option is se-
valve is shut off at the unit and the pressure is al- lected (see appropriate Microprocessor Instruction
lowed to bleed off by opening the bleed plug near the Manual), the compressor unit will start up after a wait-
pressure transducer enclosure. The transducer can ing period. With both options, the compressor slide
then be calibrated at atmospheric pressure (0 PSIG), valves must return below their respective 10% limits
or an external pressure source with an accurate gauge before the compressor unit can be restarted.
may be attached at the bleed plug.
Slide Valve Control
The discharge pressure transducer cannot be isolated
from its pressure source, so it is equipped with only a Capacity and volume ratio control of the screw
valve to allow an accurate pressure gauge to be at- compressor is achieved by movement of the respec-
tached and the pressure transducer calibrated at unit tive slide valves, actuated by electric motors.
pressure.

Recheck the transducer periodically for any drift of

calibration.

36
Operating Instructions

Command Shaft Rotation When viewing the compressor from the discharge
Compressor Capacity Volume Ratio end (opposite of the drive end) – on VSM 201-401
Model Number INC DEC INC DEC capacity, is upper right and volume is lower left. On
VSM 201 CW CCW CW CCW the Vsm 501-701, capacity is upper left and volume is
VSM 301 CW CCW CW CCW lower right. The table for command shaft rotation
VSM 361 CW CCW CW CCW
(above) indicates the direction of command shaft ro-
VSM 401 CW CCW CW CCW
VSM 501 CCW CW CCW CW tation required to increase or decrease the capacity
VSM 601 CCW CW CCW CW or volume ratio. The range of capacity adjustment is
VSM 701 CCW CW CCW CW from 10% to 100%, the range of volume ratio adjust-
ment is from 2.0 to 7.0.
Actuator Location
Actuation of the electric motors can be done auto-
matically by the micro-controller or they can be manu-
View Capacity ally actuated through pop-up buttons on the touch
screen display when the micro-controller is put into
the 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 are
on 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 slide
valve changes.

View The Motor Amps Load Limit protects the compressor

Volume Ratio from overloading by decreasing the compressor ca-
pacity if the motor amperage is above the Full Load
Amps set point. (See appropriate Vission/Vantage
Operating Manual.)
VSM 501CW Thru VSM701CW

View Capacity
Oil Separator Heater

The oil separator heater keeps the oil in the separator

from becoming too viscous. The heater is turned on
only when the compressor is off. The separator heater
is 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 a
back pressure regulator to control intermediate pres-
View sure. When a direct expansion system is used,a sole-
Volume Ratio noid valve and thermostatic expansion valve are fur-
nished to control the degree of subcooling. If a
flooded subcooler system or flash system is supplied,
VSM 201 CCW Thru VSM 401CCW
it is equipped with a liquid solenoid valve and a float
switch to control the liquid level in the vessel.
37
Operating Instructions

SAFETY SETPOINTS SETTING OF CONTROLS

A detailed explanation of all safety setpoints can be Refer to the Vission / Vantage Instruction Manual for
found in the Vission / Vantage Instruction Manual for a list of initial settings.
the following:
Valve Settings
Discharge Pressure
1. The suction stop/check valve is designed to
High discharge pressure cutout stops the compres- operate as a stop valve (manually open or
sor unit, when the discharge pressure in the oil sepa- closed) or a check valve. The valve is normally
rator exceeds the setpoint. positioned in the automatic mode during unit
operation. Please refer to the tag on the valve
Suction Pressure to set it in the automatic position.

Low suction pressure cutout stops the compressor 2. The discharge stop/check valve is designed to
unit when the suction pressure drops below the operate as a stop valve (manually open or
setpoint. closed) or a check valve. The valve is normally
positioned in the automatic mode during unit
Oil Filter Differential Pressure operation. Please refer to the tag on the valve
to set it in the automatic position.
High oil filter differential cutout stops the compres-
sor unit when the pressure difference between the 3. Open the isolating valve(s) before and after the
outlet and inlet of the filter exceeds the setpoint. oil filter housings.

Oil Temperature 4. Open the oil return valve from oil separator 3/4
turn.
The oil temperature cutout stops the compressor unit
when the oil temperature is too high or too low.

Discharge Temperature Superheat

The high discharge superheat temperature cutout

stops 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.

38
Initial Start Up

COMPRESSOR PRE START-UP

CHECK LISTS

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

39
Pre Start-Up Check List
Field Piping and Mechanical Requirements
(Cool Compression)

Note: If start-up service has been purchased to save time and money the following items should be completed
before 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-flow
direction or in a horizontal line with the valve stem pointing upward at a 45° angle. During off periods
refrigerant can condense in the line downstream of the Discharge Stop/Check Valve. It is recommended
that the Stop/Check valve be located to minimize the quantity of liquid that can accumulate downstream
of the valve.

____4. The Discharge and Suction Stop/Check valve must be set to the automatic position. Failure to
do 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 valve
at the inlet of the thermostatic expansion valve.

____6. Initial Oil Charge: 12” Separator – 7 gallons – ½ bottom sight glass
16” 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 glass
20” Separator 12.5 gallons – 1/3 bottom sight glass

____7. Before installing the center member, the motor directional rotation should be checked. Then, verify the
motor 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 suction
end of the compressor, as this will drive the compressor in a forward motion without lubrication and may
cause damage.

____9. Proper ammonia refrigerant charge should be in the system. Necessary equipment for installation of any
additional refrigerant should be present at the job-site prior to the startup person’s arrival. In addition, any
refrigerant 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).

40
Pre Start-Up Check List
Field Wiring Requirements
(Cool Compression)

NOTE: If start up service has been purchased, the following items should be completed before the start-up technician
arrives. 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 to
any 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 that
will 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 source
that 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, terminal
2 must be removed to use this cutout. The contact, if closed, will allow the compressor to run. If this contact
opens 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-energized
with 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 come
from 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 removed
to use this cutout. The contact, if closed, will allow the compressor to run. If this contact opens at any time, the compressor
will 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 alarm
relay on the board. It will have a 0 VAC potential when the compressor is operating normally, and go to 115 VAC when
in an alarm condition. To monitor the shutdown status, wire to trip relay on board. It will have a 0 VAC potential when
the 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 one
leg are pulled through the transformer. However, this should always be checked as different motors and starting methods
will require different leads to be used.

41
Service Section

GENERAL COMMENTS tion pressure and suction valves closed. Use an

acceptable means to depressurize the unit that
When working on the compressor, care must be taken complies with all Local, State and Federal Ordi-
to ensure that contaminants (i.e. water from melting nances.
ice, dirt and dust) do not enter the compressor while it
is being serviced. It is essential that all dust, oil or ice D) Remove drain plugs from the bottom of compres-
that has accumulated on the outside of the compres- sor housing and the discharge manifold. On units
sor be removed before servicing the compressor. equipped with Suction Oil Injection (SOI) manu-
ally open the SOI solenoid valve below the com-
When servicing the compressor, all gaskets, O-rings, pressor. Drain the oil into appropriate contain-
roll pins and lock washers must be replaced when ers.
reassembling the compressor.

REMOVAL OF COMPRESSOR
FROM THE UNIT
PREPARATION OF UNIT FOR SERVICING
After Preparing the unit for service the following steps
should be followed when removing the compressor
from the unit:
A) Disconnect the motor drive coupling from the
compressor input shaft.
B) Disconnect all gas and oil piping which is at-
tached to the compressor. When removing the
suction strainer on VSM units, the suction line
A) On Cool Compression units, while the unit is run- should be supported to prevent it from sagging.
ning, close the main liquid ammonia line (located
before the thermostatic expansion valve) and wait C) Replace oil drain plug in compressor housing
for the unit to stop by itself. This operation will and discharge manifold after oil has stopped
remove all the liquid ammonia from the separator. draining.
The compressor will stop when the superheat at
discharge 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 a All Oil must be removed from unit.
lock on the disconnect switch and tag the switch
to indicate that maintenance is being performed.
D) Remove all electrical connections to the com-
C) Isolate the unit by manually closing the discharge pressor.
Stop/Check valve. If the unit is equipped with a
V-PLUS® or liquid injection cooling system, close
the liquid supply valves and open all solenoid
valves to prevent liquid refrigerant from being
trapped between the stop valves and solenoid
valves. 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-

42
Service Section

INSTALLATION OF THE COMPRESSOR

A) After the work has been completed, reinstall the

compressor on the base or C-flange adapter (de-
pendent upon compressor model).
B) On VSM units, the compressor should be bolted
On VSM with C- flange the motor/C-flange/com-
onto the C-flange adapter and the coupling rein-
pressor assembly must be supported with a chain
stalled.
fall or other lifting device, before the bolts hold-
ing the compressor to the C-flange adapter can C) Replace all electrical, gas, liquid and oil connec-
be removed. tions removed when servicing the compressor.

F) Install appropriate lifting eye into a threaded hole

on the top of the compressor. LEAK CHECKING UNIT

Note: Unit must be leak checked before evacua-

tion.

Verify unit is properly secured to avoid

compressor from falling. CAUTION
Re-verify all piping and electrical are properly
disconnected prior to lifting unit.
Slowly pressurize the unit from the discharge side
of the compressor. Pressurizing the compressor from
G) Remove compressor from the unit, verify ad-
the suction side may cause rotation of the compres-
equate amount of room needed for clearance and
sor without oil supply, which could lead to internal
weight of the bare compressor when the com-
damage.
pressor is removed from the unit.

A) Use a vacuum pump to evacuate the unit.

B) Break the vacuum on the unit using refrigerant
or dry nitrogen and check for leaks. Concentrate
on areas where work was done.
C) If no leaks are found, the unit can be returned to
service if refrigerant was used for the leak detec-
tion gas.
If dry nitrogen was used for the leak detection
gas, the nitrogen must be purged from the unit
and step A and B should be repeated, this time
breaking the vacuum with refrigerant. The unit
may now be returned to service.

43
Service Section

ANNUAL INSPECTION

The Vilter Single Screw Compressor is designed for

long periods of trouble free operation with a mini-
mum of maintenance. However, a yearly inspection
is recommended so any irregular wear is noted and
rectified. At this time, the bearing float is measured
for the main rotor and gate rotors.
The following are the procedures used in measuring
the main rotor and gate rotor bearing float.

CAUTION

When taking the measurements, do not exceed 300

to 500 Lbs. of force at point of contact or damage
may result to the bearings.

A) Shut down and de-pressurize the unit, as out-

lined in section 0.01.
B) Main rotor bearing float.
1) Remove the coupling guard, then remove
the center member from the coupling.
2) Attach a dial indicator to the compressor
frame as shown and zero indicator. Place a
lever 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 GATE
Bearing Float 0.003” 0.002”
Maximum Force 300 to 500 200 to 300
Lbs. Lbs.

3) Re-Zero indicator, now position the fulcrum

on the motor and use the lever arm to push
the input shaft towards the compressor
(note measurement).

4) Add both readings, the total indicator move-

ment is the bearing float and this should
not exceed 0.003”.

44
Service Section

C) Gate rotor bearing float.

E) Readings could be higher than 0.2. If
1) Remove the side covers (see: Gaterotor Re- readings is greater than 0.30 on table
moval Section) and position a dial indicator contact Vilter’s home office.
on the gate rotor.
F) Inspect the main and gate rotors for
2) Use a lever arm pivoting on a bolt with a
signs of abnormal wear due to dirt or
small block of wood against the gate rotor
other contaminants from the system.
blade to protect the blade.
3) The maximum amount of bearing float G) After the inspection is complete, the
should not exceed 0.002”. covers, coupling center member and
guard can be reinstalled and the unit can
then be evacuated and leak checked be-
fore starting.

0.06 NORD-LOCK WASHERS

A) Nord-Lock® lock washer sets are used in many

areas on the Single Screw Compressor that re-
quires a vibration proof lock washer.
B) The lock washer set is assembled so the course
serrations that resemble ramps are mated together.
C) Once the lock washer set is tightened down, it
takes more force to loosen the bolt then it did
to tighten it. This is caused by the washers
riding up the opposing serrations.

Fine serrations face out.

D) Measure the gate rotor to blade float. Some

movement between blade and support is neces-
sary to prevent damage to the compressor blade,
however at no time should the blade uncover
the support.
1) Position the blade with the gate rotor damper Coarse Serrations
pin and 90º to the main rotor. mate together
rampCoarse
. serrations
2) Position a dial indicator at the tip of the sup-
mate together.
port. The total movement of the damper pin
in the bushing is the gate rotor float. Refer
to table 0.2 to find the maximum blade to
support float (on new compressor parts).

TABLE 0.2. GATE ROTOR FLOAT

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

45
Service Section

D) Turn the main rotor so the driving edge of the

groove is between the top of the shelf or slightly
below the back of the gate rotor support. At this
point install the gate rotor stabilizing tool.

E) Remove plug on the thrust bearing housing.

Loosen the socket head cap screw that is lo-
GATE ROTOR ASSEMBLY cated underneath the plug. This secures the in-
ner races of the thrust bearings to the spindle.
GATE ROTOR REMOVAL
F) Remove bolts that hold the thrust bearing hous-
ing to the compressor. Insert two of the bolts
Note: The thrust bearing outer races are not secured into the threaded jacking holes to assist in re-
in a stationary bearing housing on the compressors. moving the bearing housing from the compres-
On VSM compressors the thrust bearings are located sor. When the housing is removed, there will be
in the gate rotor support and rotate with the support shims between the spindle and thrust bearings.
when the compressor is in operation. The inner races These control the clearance between the shelf
are secured to the stationary bearing spindle. and gate rotor blades. These must be kept with
their respective parts for that side of the com-
pressor.
A) Prepare the compressor for servicing as outlined
in section: Preparation of Unit. G) Remove the bolts from the roller bearing hous-
ing. After the bolts have been removed, the hous-
B) Remove the upper bolt from the side cover and ing can be removed from the compressor.
install a guide stud in the hole. Remove the re-
maining bolts and side cover. There will be some H) To remove the gate rotor support tool, carefully
oil drainage when the cover is removed. move the support opposite the direction of rota-
tion and tilt the roller bearing end towards the
C) The side cover that contains the suction strainer suction end of the compressor. The compressor
should have the suction line properly supported input shaft may have to be turned to facilitate
before the bolts securing the line to the cover the removal of the gate rotor support. On dual
can be removed. After the line is removed, the gate versions, repeat the procedure for the re-
cover can be removed per paragraph B. maining gate rotor support assembly.

46
Service Section

GATE ROTOR INSTALLATION

A) Install the gate rotor support. Carefully tilt the

roller bearing end of the gate rotor support to-
wards the suction end of the compressor. The
compressor input shaft may have to be rotated
to 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 recommended
torque value.
C) Install the spindle with shims, tighten the bolts
to the recommended torque value, measure the
clearance between the shelf and blade.
D) Check the clearance between the entire gate ro-
tor blade and the shelf, rotate the gate rotor to
find the tightest spot. It should be between 0.003”-
0.004”. Make adjustments, if necessary. It is
preferable to shim the gate rotor blade looser
rather than tighter against the shelf.
E) Once the clearance is set remove the spindle.
Install new o-ring, apply Loctite 242 thread locker
to the socket head cap screw clamping the thrust
bearings to the spindle. Torque all bolts to the
recommended torque values.
F) Install side covers and or remove suction tee with
new gaskets. Tighten bolts to the recommended
torque value. The unit can now be evacuated Gaterotor for C-flange Models
and 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 gate
rotor assembly. Lift gate rotor blade assembly
off the gate rotor support.
C) Check damper pin and dampener bushing for ex-
cessive wear. Replace if necessary.

47
Service Section

GATE ROTOR BLADE REMOVAL

Lip on gaterotor blade A) Install damper bushing (120) in gate rotor

is positioned up and away blade (111) from the back side of the blade.
from the suppor t. Be sure the bushing is fully seated.
111 Top of Blade
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 gate
120 rotor assembly. The bevel on the snap ring must
Back of B lade
face away from the gate rotor blade. After the
gate rotor blade and support are assembled, there
should be a small amount of rotational move-
ment between the gate rotor and support.
D) For installation of the gate rotor assembly and
setting of gate rotor clearance, refer to section
1.02.

GATE ROTOR THRUST BEARING

REMOVAL

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 BEARING

INSTALLATION

1) Install retainer in the back of the inner race

of one of the thrust bearings. The back of
the inner race is the narrower of the two sides.

2) The bearing with the retainer should be

placed in the housing first, retainer towards
the support. Install the second bearing. The
bearings should be positioned face to face.
This means that the larger sides of the inner
races are placed together. A light applica-
tion of clean compressor lubricating oil
should be used to ease the installation of
the bearings into the gate rotor support.

48
Service Section

3) Install the bearing retaining snap ring.

4) For installation of the bearing housing and

the setting of the gate rotor blade clearance,
refer to section: Gate Rotor Installation.
Inner Retainer

GATE ROTOR ROLLER BEARING

REMOVAL

A) Refer to section: Removal of the Gate Rotor Bear-

ing housings and gate rotor supports.

B) Remove the snap ring (131), which retains the

roller bearing in the bearing housing. Retaining Ring
Ball Bearings
C) Remove the roller bearing (125) from the bearing
housing (112).

D) Use a bearing puller to remove the roller bearing

race (125) from the gate rotor support (110).

GATE ROTOR ROLLER

BEARING INSTALLATION Numbered Side
A) Match up the part numbers on the inner race to
the 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 the
inner race. Install the snap ring retainer in the
housing. The bevel on the snap ring must face
away from the roller bearing.

C) For installation of the bearing housing, refer to

section Gate Rotor Installation.

49
Service Section

INPUT SHAFT SEAL

REPLACEMENT

281 219A 219C

On Vilter VSM compressors the type of seal utilized

has a stationary carbon and a rotating mirror face.

INPUT SHAFT SEAL REMOVAL

A) Prepare the compressor for servicing as outlined

in section 0.01.

230 218 265 260 219B B) Remove bolts (281) holding the shaft seal cover
(218). Insert two of the bolts into the threaded
Roll pin # 265 only used jacking holes to assist in removing the cover.
on VSS 751 and larger. There will be a small amount of oil drainage as
the 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 shaft

Stationary seal seal (219B) from the seal cover using a brass
drift and hammer to tap it out from the back side
265
of the seal cover.

SHAFT SEAL INSTALLATION

261
A) Install new oil seal in clean cover.

CAUTION

260 Care must be taken when handling the shaft seal

and mirror face so it is not damaged. Do not touch
the carbon or mirror face as body oil and sweat will
cause the mirror face to corrode.

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

50
Service Section

the seal cover; remove protective wrap from the Align slot in seal
carbon cartridge, do not wipe or touch the carbon with dowel pin or
key in shaft.
face. Lubricate the sealing O-ring with clean com-
pressor lubricating oil. Install cartridge using seal
installation tool or similar. 265

C) Wipe clean, the compressor input shaft and the

shaft 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 with

clean compressor lubricating oil, do not wipe or
touch the face of the rotating portion of the seal.
Align the slot in the rotating seal with the drive
Make sure that seal is
pin on the compressor input shaft. Carefully push bottomed against
the seal on, holding onto the outside area of the shoulder on shaft.
Align slot in seal
seal until the seal seats against the shoulder on with dowel pin or
key in shaft.
the input shaft. Make sure the seal is seated
against the shoulder. If the seal is not fully seated
against the shoulder, the shaft seal carbon will
be damaged when the seal cover is installed.

Maintenance Suggestion:

A spray bottle filled with clean compressor oil may be

used to lubricate the faces of the seals without touch-
ing the seal.

E) Install a new O-ring on the seal cover, making

sure the O-ring is placed in the proper O-ring
groove and not the oil gallery groove. Lubricate
both 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. The

unit can then be evacuated and leak checked, as
outlined in section 0.03.

MAIN ROTOR ASSEMBLY

Due to the procedures and tools involved in the dis-

assembly and reassembly, the main rotor assembly
must be performed by qualified individuals. Please
consult the factory if maintenance is required.

51
Service Section

CAPACITY AND VARIABLE

VOLUME RATIO CONTROL
ASSEMBLY

A) The following instructions are applicable for most

units equipped with optical gear motors built
after 11-1-01.

B) On VSS units and dual gate VSM units, each pair

of 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 motor

location is opposite.

OPTICAL SLIDE VALVE

ACTUATOR REMOVAL

A) Follow appropriate lock out tag out procedures

to shut off the electricity to the microprocessor.
Disconnect cables from actuator.

B) Remove the side covers from the bracket to gain

access 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.

52
Service Section

OPTICAL SLIDE VALVE

ACTUATOR INSTALLATION

A) Install the key in the command shaft keyway.

B) Slide the actuator assembly on to the command

shaft. While aligning one of the two key slots in
the actuator shaft with the key on the command
shaft. Make sure that the collar remained on the
actuator shaft. Due to the position of the slide
valve in the compressor, use of the other key slot
may be required to align the bracket holes with
the threaded mounting plate holes.

C) Slide the collar until it is flush with the end of the

actuator shaft. Check to make sure the key is
fully inserted in the actuator shaft. The key should
be flush with the end of the actuator shaft.

D) Tighten the shaft collar ¼” socket head cap screw

to 16 ft/lbs. (192 in/lbs.). Failure to correctly
torque the locking screw may result in a failure
of the actuator.

E) Install the side covers to the bracket with hex

washer head self tapping screws.

53
Service Section

B) Follow the appropriate instructions to remove

control actuator as outlined in sections: Capac-
ity and Variable Ratio Control Assembly.

457 477 415

OPTICAL SLIDE ACTUATOR IN
STALLATION

A) Remove the four self tapping screws that secure

the side covers to the actuator bracket. This will
allow access to the actuator shaft.

B) Install the key in the command shaft keyway.

C) Slide the actuator assembly on to the command

shaft. Align one of the two key slots in the ac-
tuator shaft with the key on the command shaft. C) Remove four socket head cap screws (457) and
Make sure that the collar remained on the actua- Nord-Lock washers (477) securing mounting
tor shaft. Due to the position of the slide valve in plate (415) to manifold.
the compressor, use of the other key slot may be
required to align the bracket holes with the D) The command shaft and mounting plate may now
threaded mounting plate holes. be removed from the compressor.

D) Slide the collar until it is flush with the end of the COMMAND SHAFT ASSEMBLY
actuator shaft. Check to make sure the key is INSTALLATION
fully inserted in the actuator shaft. The key should
be flush with the end of the actuator shaft. A) Install the command shaft assembly with a new
o-ring (446) on the manifold. Make sure that the
E) Tighten the shaft collar ¼” socket head cap screw command shaft tongue is engaged in the cross
to 16 ft/lbs. (192 in/lbs.). Failure to correctly torque shaft slot. Rotate the bearing housing so the
the locking screw may result in a failure of the vent holes point down, this will prevent water
actuator. and dust from entering the vents.

F) Install the side covers to the bracket with hex Rotate bearing housing
so vent hole points down.
washer head self tapping screws. Command shaft
assembly.
Align the tongue of
G) Refer to the slide valve actuator calibration in- the command shaft
with the groove in the
structions in the Vission/Vantage manual or the cross shaft.

instructions packed with actuators on calibra-

tion procedures. 446

COMMAND SHAFT ASSEMBLY REMOVAL

The following steps can be used to remove or install

either the capacity or volume command shaft assem-
blies.
A) Prepare the compressor for servicing as outlined
in section: Preparation of Unit for Service. B) Install the actuator mounting plate with the four
socket head cap screws and Nord-Lock washers
securing it with proper torque.
54
Service Section

C) The unit can now be leak checked as outlined in COMMAND SHAFT BEARING AND O-RING
section: Leak Check Unit. SEAL REASSEMBLY

A) Install new O-ring seal in housing and lubricate

COMMAND SHAFT BEARING AND O-RING the O-ring with clean compressor oil. A vent hole
SEAL REPLACEMENT is provided in the command shaft bearing hous-
ing to allow any refrigerant and oil that may leak
A) Remove command shaft assembly as outlined in past the O-ring seal to vent to atmosphere and
section 4.05. not into the slide valve motor housing.

B) Remove snap ring retainer (451) from command

B) Remove any burrs from the command shaft to
shaft housing (412). Push the command shaft
prevent damage to the O-ring when assembling.
assembly out of the housing.
Install snap ring retainer and washer on the com-
mand shaft. Press the command shaft bearing
onto the command shaft. Insert the command
shaft into the housing applying pressure on outer
race of bearing. Make sure the bearing is fully
seated in the command shaft housing. Install the
snap ring retainer (451) in the command shaft
housing.

C) Install command shaft assembly as outlined in

section: Optical Slide Actuator Installation.

DISCHARGE MANIFOLD REMOVAL

On divison 2
only
A) Remove both control actuators and command
shaft assemblies as outlined in sections: Optical
Actuator Removal and Command Shaft Removal.

C) The command shaft bearing (435) is a press fit on Note: Manifold has dowel pins to locate it on the
the command shaft (413). Remove the command compressor housing. Therefore, remove manifold
shaft bearing with a suitable press. straight back approximately 1” as not to break
dowel pins.

511 512 Guide rods

Vent hole.
Discharge 519

436 spool

445
547

548
D) Remove the O-ring seal (445) from the command 540
549
shaft housing. The command shaft bushing (433 536
550
and 436) might have to be removed to gain ac- 551
cess to o-rings. Replace bushing if the bore is
deeply scored or excessively worn, using bush-
ing (vpn 25853B).

55
Service Section

NOTE:
When removing the discharge manifold on VSM com-
C) Check torque of socket heat cap screws.
pressor the compressor must be properly supported
to keep the compressor from moving when the mani-
D) Check for excessive movement between the slide
fold is removed.
valve rack shafts and the rack. The jam nuts on
the end of the slide valve rack shaft should be
B) On VSM compressors unbolt the discharge flange tight.
from the discharge manifold.
E) Check for loose or broken roll pins in gears.
C) Remove one bolt from each side of the discharge
manifold and install (2) guide rods approximately
6” long, to support the manifold. Remove the
remaining bolts (note length and location of bolts)
and take off the discharge manifold.

DISCHARGE MANIFOLD INSTALLATION Check

Rack to torque
clamp on cap
A) Install (2) guide rods to position the discharge spacer screws
manifold. Install a new manifold gasket and the
Rack to Roll pins
discharge manifold. Align the dowel pins and clamp Loose nuts
bolts, tighten manifold bolts to the recommended
torque value.

B) On VSM compressors install the bolts in the dis-

charge flange. Install the drain plug in the bot- F) Look for any excessive wear on all moving parts
tom of the discharge manifold. and replace the worn parts.

C) Install both command shaft assemblies and con- G) Reassemble the manifold and discharge elbow
trol actuators as outlined in sections; Optical Slide as outlined in section: Discharge Manifold In-
Valve Actuator Removal and Command Shaft stallation.
Removal.

REMOVAL OF CAPACITY OR
SLIDE VALVE GEAR AND RACK VOLUME CROSS SHAFTS
INSPECTION
A) Remove the discharge manifold as outlined in
A) Remove the discharge manifold as outlined in section: Discharge Manifold Removal.
section: Discharge Manifold Removal.
B) To remove the capacity or volume ratio slide
B) Check rack to rack clamp and rack clamp spacer valve racks, remove the two jam nuts and lock
clearance on slide valves. washers (361) securing the rack (316) to the slide
valve shafts. The racks can now be pulled off
Note Models 501-701 DO NOT have Rack Clamps. the slide valve shafts. Repeat the procedure for
RACK CLEARANCE VALUES the remaining pair of slide valve racks.

MEASUREMENT CLEARANCE

Rack to clamp. 0.005 to 0.010”

Rack to clamp spacer. 0.003 to 0.005”

56
Service Section

INSTALLATION OF CAPACITY OR
220 323 286 363 VOLUME CROSS SHAFTS

A) To reassemble either set of capacity or volume

ratio slide valve racks, install the cross shaft with
226 the pinion gear onto the end plate, place the re-
maining pinion gear on the shaft and drive in the
225 roll pins. Install clamps, spacers and bolts on
both sides. Tighten the bolts to the recommended
torque values.
222
B) The slide valve sets must be synchronized on
dual gate VSM units. Both slide valve racks for
either the volume ratio or capacity slide valves
must engage the cross shaft gears at the same
time. Push the slides all the way towards the
224 316 361 suction 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 and
jam nuts on the slide valve shafts. Repeat the
procedure for the remaining set of slide valve
C) To remove the cross shafts, remove socket racks.
head bolts, clamp and spacers from both sides.

When installing the slide

valve racks, both racks
must engage the axle
shaft gears at the same
time.

VSM compressors cross shafts. C) Install (2) guide rods to position the discharge
manifold. Install a new manifold gasket and the
D) Loosen either set-screws (297 or 298) to be able discharge manifold. Install the dowel pins and
to remove roll-pins. Drive the roll pins from pin- bolts, tighten manifold bolts to the recommended
ion gear from one side. Remove pinion gear. Slide torque value.
the cross shaft with the remaining pinion gear or
spacers out from the opposite side. Repeat the D) Install the discharge as outlined in section: Slide
procedure for the remaining cross shaft. Valve Gear and Rack Inspection.

57
Trouble Shooting Guide

Not enough liquid before the Check the sight glass to see if this is full of
liquid. If there is no or foamy liquid in sight
expansion valve. glass check for proper liquid supply.

Solenoid before the expan 1. Check if solenoid coil is energized. If

sion valve will not open. there is voltage being supplied to the
coil, replace solenoid coil.
2. If there is no voltage being supplied to
the coil, check output module of
Microprocessor.
3. Manually open solenoid to check for
proper operation of solenoid

Expansion valve is not Change the superheat adjustment of the

valve by turning the superheat-adjusting
supplying enough liquid. stem on the valve..

Heater in the expansion Remove the heater from the bulb to check if
valve bulb does not work. it is warm. (Make sure to insert it back to
the end of the bulb bore)
Check the heater for continuity with
Ohmmeter. If reading is infinite or shorted,
replace coil. Heater resistance should be
between 960 and 1000 ohms.
Overheating / Discharge
superheat too high. Check the position of heater in well and
Heater in the expansion readjust it accordingly.
valve bulb in not inserted
deep enough into the well.

Too much oil in the separa- See: Checking Oil Level Instructions
tor.

Oil injection strainer

Remove and clean strainer, reinstall.

Remove and clean expansion valve and

Liquid injection strainers liquid line strainers, reinstall.
dirty.

Discharge temperature RTD Recalibrate discharge RTD.

off calibration.
When this filter is clogged, the compressor
will overheat only when the liquid
Main oil injection filter /
expansion valve is closed. As soon as the
strainer clogged. valve reopens the compressor will run
normally. If you have this intermittent
overheating problems stop the compressor
immediately and clean the filter/strainer.

58
Trouble Shooting Guide

Expansion valve not set up Adjust the superheat setting of the

properly. expansion valve to maintain proper liquid
High liquid level. level.
Too much, oil in the separa- The oil will cover the bulb and the
tor. expansion valve will stay open.

Liquid level too high at low Reset the valve to drop the level (1/4”) of
ratio, waves in the separator liquid in the separator.
are too high causing a false
indication.

Observe the liquid flow in the sight glass

Check for proper operation before the expansion valve on the liquid
of the expansion valve. line. If there is no apparent flow, rapidly
close and open the hand service valve to
check if the liquid is flowing to the
compressor.

High superheat adjustment of Adjust the expansion valve superheat setting

Low liquid level. the expansion valve.
to maintain proper liquid level.

Check resistance of heater. Heater

Heater malfunctioning.
resistance should be between 960 and 1000
ohms.
Liquid line strainer plugged.
Liquid line strainer plugged.

Expansion valve power head

Replace expansion valve power head
or sensor bulb faulty. assembly.
The running oil level is below the sight
Checking oil while unit is glass. Check oil level after unit has been
shut down at least 30 minutes with the
running. suction oil injection valve on. This allows
the oil in the compressor to migrate back to
the separator.
6 hours after displaying a low oil level
alarm the unit will shut down, if no oil is
Unit shuts down.
Low oil level. added during this time
Low oil level alarm due to large volume of
oil being supplied to compressor at start,
Low oil level alarm at start. alarm should end within a few minutes
when the oil level stabilizes.
Excessive amounts of liquid will allow the
Too much liquid being separator to operate inefficiently. Lower
supplied to separator. liquid level by adjusting expansion valve
superheat setting.
Foaming of liquid and oil in separator.
Foaming of liquid and oil in Large variations in discharge pressure will
separator. allow flashing of the liquid in the separator.
Adjust head pressure controls to maintain a
more stable head pressure.

59
Trouble Shooting Guide

Depending on operating condi-

Low oil level. ¼” drain line from separator tions, the line may need to be
not open enough. fully open.
(Continued).

Not enough oil in separator. Check for proper level in the

separator.

Excessive oil foam. Not enough liquid being 1. Check if expansion valve is
supplied to the separator. operating, observe the sight
Liquid line overheating to Loss of or low liquid supply glass.
compressor.. from expansion valve 2. Check the adjustment of the
Loss of or low liquid supply expansion valve.
from expansion 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 sight
glass.
7. Check the adjustment of the
expansion valve.
8. Check the heater.
9. Check the liquid line and
expansion valve strainers.
10. Replace the expansion valve
power head assembly.

60
61
Dual Filter Valve Seal Replacement

1 O-Ring 2
2176AU (2)
O-Ring
2176X (1)

Shaft
Handle

Front View Inside View of Valve Plug

Assembly (located in housing)

INSTRUCTIONS – VALVE SEAL REPLACEMENT

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

WARNING: DO NOT TWIST THE VALVE PLUG DURING REMOVAL OR INSTALLATION. THIS WILL
CAUSE 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 PERMANENT
DAMAGE 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 or
tap on the back at the center of the plug.

DO NOT twist the plug while removing (see above warning). Caution must be observed while
removing 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 parts
without 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 insure
that all parts are clean prior to assembly. Foreign particles, dirt, metal chips, etc. in the valve may cause
leakage and can damage the seals, thus reducing their life.

62
VSM Cool Compression Spare Parts List

ITEM
DESCRIPTION Separator Size
12” 16” 20”
QTY VPN QTY VPN QTY VPN

RTD w/ turck connector 1 2611 G 1 2611 G 1 2611 G

Pressure Transducer 1 2783J 1 2783J 1 2783J
Heater 1 3116 A 1 3116 A 1 3116 A
RTD Transducer cordset 1 3122 B 1 3122B 1 3122 B

Oil Filter strainer basket

(20” canister) inc’s all gaskets
Single Filter Assembly 1 3150D 1 3150D 1 3150D
DUPLEX Canister Kit 1 3150S 1 3150S 1 3150S
Oil Filter strainer basket assembly
with magnets for 20” canister 1 3150F 1 3150F 1 3150F
Filter Canister Gasket (Only) 1 1448B 1 1448B 1 1448B
Pleated Filter 10 micron 1 3150M 1 3150M 1 3150M
Pleater Filter 20 micron 1 3150N 1 3150N 1 3150N
Suction Oil Injection Solenoid 115V 1 3035 BABBF 1 3035 BABBF 1 3035 BABBF
Suction Oil Injection Solenoid 1 3035 BBBBF 1 3035 BBBBF 1 3035 BBBBF
208/230V
Replacement solenoid coil - 115V 1 3035U 1 3035U 1 3035U
Replacement solenoid coil 1 3035V 1 3035V 1 3035V
208/230V
Suction Oil Strainer ¾” FPT 1 3144 A 1 3144 A 1 3144 A
High Liquid Level Switch 1 3152 A 1 3152 A 1 3152 A
Low Level Oil Float Switch 1 3147 A 1 3147 A 1 3147 A
20 Ton TXV Liquid Injection Valve 1 A27565A 1 A27565A 1 A27565A
30 Ton “ 1 A27565B 1 A27565B 1 A27565B
50 Ton “ 1 A27565C 1 A27565C 1 A27565C
75 Ton “ 1 A27565D 1 A27565D 1 A27565D
100 Ton “ 1 A27565E 1 A27565E 1 A27565E
LMC Heater Assembly 120 v/15watt 1 3208A 1 3208A 1 3208A
LMC Powerhead assy 20-100TR 1 A27565F 1 A27565F 1 A27565F
20 Ton -Liquid Injection strainer 1 2875 G 1 2875 G 1 2875 G
30 Ton – 100 Ton “ 1 2875 H 1 2875 H 1 2875 H
Liquid Injection Solenoid 120V 1 2875 F 1 2875 F 1 2875 F
120V – Replacement Coil 1 2562 J 1 2562 J 1 2562 J
240V – Replacement Coil 1 2562 K 1 2562 K 1 2562 K
Oil, Vilter R717, 5 gal. 1 2939 A 1 2939 A 1 2939 A
Oil, Vilter R717, 55 gal. 1 2939 B 1 2939 B 1 2939 B
Disch. Manifold to Sep. flg. gskt.
201 thru 401 1 1548 CA 1 1548 CA 1 1548 CA
Disch. manifold to Sep. flg. gskt.
501 thru 701 1 1548 DA 1 1548 DA 1 1548 DA
Suction Tee to Comp. gskt.
201 thru 401 1 1548 CA 1 1548 CA 1 1548 CA
Suction Tee to Comp. gskt.
501 thru 701 1 25404 A 1 25404 A 1 25404 A
Economizer 1” flg. gasket 1 1548 LA 1 1548 LA 1 1548 LA
Economizer comp. flg. gskt. 1 11323 D 1 11323 D 1 11323 D

63
Replacement Parts

64
Gate Rotor Assembly
Part totals indicated are for one gate rotor assembly, dual gate machines will require double the components.

MODEL NUMBER
ITEM DESCRIPTION VSM- 301 VSM- 361 VSM- 201&401 VSM- 501 VSM- 601 VSM- 701
QTY VPN QTY VPN QTY VPN QTY VPN QTY VPN QTY VPN

100 SUPPORT ASSEMBLY 110 & 135. 1 A25222AB 1 A25222AA 1 A25222AC 1 A26001BB 1 A26001BA 1 A26001BA
101 GATE ROTOR & DAMPER KIT. 1 A25160AB 1 A25160AA 1 A25160AC 1 A26002BB 1 A26002BA 1 A26002BC
120 and 111
102 GATE ROTOR SUPPORT ASM. 1 A25161AB 1 A25161AA 1 A25161AC 1 A26003BB 1 A26003BA 1 A26003BC
100,101,119 &130
105 GATE ROTOR GASKET SET 1 A25164A 1 A25164A 1 A25164A 1 A26005B 1 A26005B 1 A26005B
141,&143
106 SHIM PACK SET 1 A25165A 1 A25165A 1 A25165A 1 A 26035B 1 A26035B 1 A26035B
(2) 121, (2) 122, (1) 123, (1) 124.
110 SUPPORT. 1 25723D 1 25723C 1 25723B 1 26030BB 1 26030BA 1 26030BA
111 GATE ROTOR. 1 25910A 1 25910A 1 25910A 1 26032A 1 26031A 1 26033A
112 SMALL BEARING HOUSING. 1 25407B 1 25407B 1 25407B 1 25518B 1 25518B 1 25518B
114 SNAP RING. 1 2867L 1 2867L 1 2867L 1 2867U 1 2867U 1 2867U
115 RETAINER BALL BEARING 1 25935A 1 25935A 1 25935A 1 25935B 1 25935B 1 25935B
116 BALL BEARING SUPPORT. 1 25408B 1 25408B 1 25408B 1 26019B 1 26019B 1 26019B
117 GATE ROTOR COVER. 1 25416B 1 25416B 1 25416B 1 26021B 1 26021B 1 26021B
118 GATE ROTOR COVER GASKET. 1 25259B 1 25259B 1 25259B 1 25259C 1 25259C 1 25259C
119 WASHER. 1 3203A 1 3203A 1 3203A 1 25007A 1 25007A 1 25007A
120 DAMPER. 1 25760A 1 25760A 1 25760A 1 25760A 1 25760A 1 25760A
121* SHIM 0.002". 25921AA 25921AA 25921AA 1 26027AA 1 26027AA 1 26027AA
122* SHIM 0.003". 25921AB 25921AB 25921AB 1 26027AB 1 26027AB 1 26027AB
123* SHIM 0.005". 25921AC 25921AC 25921AC 1 26027AC 1 26027AC 1 26027AC
124* SHIM 0.010". 25921AD 25921AD 25921AD 1 26027AD 1 26027AD 1 26027AD
125 ROLLER BEARING. 1 2864F 1 2864F 1 2864F 1 2864B 1 2864B 1 2864B
126 BALL BEARING. 2 2865L 1 2865L 1 2865L 1 2865B 1 2865B 1 2865B
130 RETAINING RING. 1 2906AB 2 2906AB 1 2906AB 1 2866A 1 2866A 1 2866A
131 RETAINING RING. 1 2867S 1 2867S 1 2867S 1 2867A 1 2867A 1 2867A
132 RETAINING RING. 1 2866J 1 2866J 1 2866J 1 2866K 1 2866K 1 2866K
135 DOWEL PIN 1 25910A 1 25910A 1 25910A 1 25910A 1 25910A 1 25910A
141 O-RING ROLLER BRG HSG. 1 2176L 1 2176L 1 2176L 1 2176M 1 2176M 1 2176M
143 O-RING BALL BRG SUPPORT. 1 2176F 1 2176F 1 2176F 1 2176R 1 2176R 1 2176R
151 SOC HEAD CAP SCREW. 1 2795AP 1 2795AP 1 2795AP 1 2795AAA 1 2795AAA 1 2795AAA
152 HEX HEAD CAP SCREW. 11 2796CG 11 2796CG 11 2796CG 12 2796CG 12 2796CG 12 2796CG
155 SHIM 25977D 25977D 25977D 25977G 25977G 25977G
156 SHIM 25977C 25977C 25977C 25977H 25977H 25977H
170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C 1 3004C 1 3004C 1 3004C
176 PIPE PLUG. 1 2606D 1 2606D 1 2606D 1 2606D 1 2606D 1 2606D

NOTE: * Not pictured

Replacement Parts
Gate Rotor Assembly

65
Replacement Parts
Shaft Seal

MODEL NUMBER
ITEM DESCRIPTION ALL VSM 201 ALL VSM 501 THROUGH
THROUGH 401 THROUGH 701
QTY VPN QTY VPN
* SHAFT SEAL KIT AMMONIA; 1 KT-709D 1 KT-709A
219, 230 & 260.
218 SEAL HOUSING. 1 25410B 1 25269A
219 SHAFT SEAL. A A
230 OIL SEAL. 1 2930C 1 25040A
260 O-RING. 1 2176AE 1 2176F
281 HEX HEAD CAP SCREW. 6 2796N 8 2796B

NOTE * Not pictured.

Seal sold only as a kit. Cool Compression is ammonia only.

66
Replacement Parts
Actuating Motor with
Optical Sensor and Command Shaft

400 Assembly
(446 not included)

401

MODEL NUMBER
ITEM DESCRIPTION ALL VSM 201 VSM 501
THROUGH 401 THROUGH 701
QTY VPN QTY VPN
*
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 CABLES
412 BEARING HOUSING. 1 25364A 1 25364A
413 COMMAND SHAFT. 1 25417A 1 25375A
415 MOUNTING PLATE. 1 25805B 1 25805B
427 KEY. 1 25039BC 1 25039BC
435 BALL BEARING. 1 2908A 1 2908A
436 SLEEVE BEARING. 1 25853A 1 25853A
445 O-RING. 1 2176W 1 2176W
446 O-RING. 1 2176X 1 2176X
450 RETAINING RING. 1 2866D 1 2866D
451 RETAINING RING. 1 2867C 1 2867C
457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M
466 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB
475 LOCKWASHER (PAIR). 4 3004A 4 3004A
477 LOCKWASHER (PAIR). 4 3004C 4 3004C
480 WASHER. 1 2906AA 1 2906AA

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

67
Replacement Parts
Slide Valve Carriage Assembly

Volume Ratio Slide Valve Components 304 Assembly

305
Capacity Slide Valve Components Assembly

Slide Valve Carriage Assembly

68
Replacement Parts
Slide Valve Carriage Assembly

MODEL NUMBER
ITEM DESCRIPTION ALL VSM 201 ALL VSM 501
THROUGH 401 THROUGH 701
QTY VPN QTY VPN
300* CARRIAGE ASSEMBLY. 1 A25179A 1 A26012B
304 CAPACITY PISTON 1 A25183A 1 A25183B
340, 341, 350 & 355.
305 VOLUME PISTON . 1 A25184A 1 A25184B
340, 342, 350 & 355
311 WASHER 1 25020A 1 25020A
316 CAPACITY RACK. 1 25023D 1 25024A
318 CAPACITY RACK SHAFT. 1 25772C 1 25772A
323 VOLUME RATIO RACK. 1 25023C 1 25023A
325 VOLUME RATIO RACK SHAFT. 1 25772D 1 25772B
331 SPAVER-CAPACITY 1 25924A 1 25929A
332 SPACER-VOLUME 1 25924B 1 25929B
340 PISTON. 2 25017B 2 25017A
341 CAPACITY PISTON SHAFT. 1 25018B 1 25019A
342 VOLUME PISTON SHAFT. 1 25018C 1 25018A
350 PISTON RING SET. 2 2953AE 2 2953AA
355 EXPANSION PIN. 2 1193PP 2 1193PP
359 PIPE PLUG. 3 2606D 3 2606D
360 LOCK WASHER (PAIR). 2 3004C 2 3004C
361 WASHER. 2 13265B 2 13265B
363 NUT. 4 2797A 4 2797A
364 WASHER 1 13265C 1 13265C
372* SOCKET HEAD CAP SCREW. 1 2795M
373 SOCKET HEAD CAP SCREW. 3 2795A 3 2795N
374 LOCK WASHER (PAIR). 3 3004C 3 3004C

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

69
Replacement Parts
Micellaneous Frame Components
201-401 Only

70
Replacement Parts
Micellaneous Frame Components
201-401 Only

MODEL NUMBER
ITEM DESCRIPTION ALL VSM 201 ALL VSM 501
THROUGH 401 THROUGH 701
QTY VPN QTY VPN

511 DISCHARGE MANIFOLD 1 25734B n/a

511 240 mm DISCHARGE MANIFOLD 1 25024BC
WITH DOWN DISCHARGE n/a
511 240 mm DISCHARGE MANIFOLD 1 25024BB
WITH HORIZONTAL DISCHARGE n/a
511 240 mm DISCHARGE MANIFOLD 1 25024BA
WITH UP DISCHARGE n/a
512 MANIFOLD GASKET 1 25737A 1 26037A
514 ECON-O-MIZER GASKET 2 11323GG 2 11323D
515 KEY 1 13396R 1 13396R
522 COUPLING LOCK PLATE n/a 1 25004D
523 LOCK WASHER n/a 1 3004H
528 ECON-O-MIZER PLUG 2 25419A 2 25397K
530 O-RING (501-701 only) n/a 2 2176BF
535 PIPE PLUG 7 2606E 2 2606D
536 PIPE PLUG 1 13163F 6 2606E
537 PIPE PLUG 1 13163G 1 13163G
538 PIPE PLUG 9 2606B 2 2606B
540 DOWEL PIN 2 2868B 2 2868B
542 PIPE PLUG 3 2606C 10 2606B
545 HEX HEAD CAP SCREW 4 2796EL 4 2796C
546 SOCKET HEAD CAP SCREW 7 2795AK 6 2795GD
547 HEX HEAD CAP SCREW 3 2796EN 4 2796F
548 SOCKET HEAD CAP SCREW n/a 3 2795GH
549 CAP SCREW 3 2796EY 1 2795GP
550 CAP SCREW 2 2796AB 2 2795GS
551 HEX HEAD CAP SCREW n/a 2 2796C
570 BEARING OIL PLUG 1 25978A n/a
571 PLUG 1 25979A n/a
572 SPRING 1 3148A n/a

Note: *. Not Pictured.

71
Replacement Parts
Micellaneous Frame Components
501-701 Only

72
Replacement Parts
Micellaneous Frame Components
501-701 Only

MODEL NUMBER
ITEM DESCRIPTION ALL VSM 501
THROUGH 401 THROUGH 701
QTY VPN

511 DISCHARGE MANIFOLD n/a

511 240 mm DISCHARGE MANIFOLD 1 25024BC
WITH DOWN DISCHARGE
511 240 mm DISCHARGE MANIFOLD 1 25024BB
WITH HORIZONTAL DISCHARGE
511 240 mm DISCHARGE MANIFOLD 1 25024BA
WITH UP DISCHARGE
512 MANIFOLD GASKET 1 26037A
514 ECON-O-MIZER GASKET 2 11323D
515 KEY 1 13396R
522 COUPLING LOCK PLATE 1 25004D
523 LOCK WASHER 1 3004H
528 ECON-O-MIZER PLUG 2 25397K
530 O-RING 2 2176BF
535 PIPE PLUG 2 2606D
536 PIPE PLUG 6 2606E
537 PIPE PLUG 1 13163G
538 PIPE PLUG 2 2606B
540 DOWEL PIN 2 2868B
542 PIPE PLUG 10 2606B
545 HEX HEAD CAP SCREW 4 2796C
546 SOCKET HEAD CAP SCREW 6 2795GD
547 HEX HEAD CAP SCREW 4 2796F
548 SOCKET HEAD CAP SCREW 3 2795GH
549 CAP SCREW 1 2795GP
550 CAP SCREW 2 2795GS
551 HEX HEAD CAP SCREW 2 2796C
570 BEARING OIL PLUG n/a
571 PLUG n/a
572 SPRING n/a

Note: *Not Pictured.

73
Replacement Parts
Main Rotor, Slide Valve Cross Shafts and End Plate
(Counter Clockwise Rotation)
201-401 ONLY

74
Replacement Parts
Main Rotor, Slide Valve Cross Shafts and End Plate
201-401 Only

MODEL NUMBER VSM 201

ITEM DESCRIPTION VSM 301 VSM 361 VSM 401
QTY VPN QTY VPN QTY VPN

201 MAIN ROTOR ASSEMBLY. 1 A25266AB 1 A25266AA 1 A25266AC

203 OIL BAFFLE ASSEMBLY. 1 A25942AA 1 A25942AA 1 A25942AA
(1)217,(1) 244, (1) 248, (1) 249,(1) 252
207 SHIM ASSORTMENT 1 A25177A 1 A25177A 1 A25177A
(2) 240, (2) 241, (1) 242, (1) 243
217 OIL BAFFLE . 1 25938A 1 25938A 1 25938A
220 END PLATE. 1 25719D 1 25719D 1 25719D
221 SHAFT. 2 25941A 2 25941A 2 25941A
222 GEAR. 4 25027A 4 25027A 4 25027A
227 CLAMP. 4 25913A 4 25913A 4 25913A
228 SPACER. 4 25847A 4 25847A 4 25847A
240 SHIM 0.002” A 25409AA A 25409AA A 25409AA
241 SHIM 0.003” A 25409AB A 25409AB A 25409AB
242 SHIM 0.005” A 25409AC A 25409AC A 25409AC
243 SHIM 0.010” A 25409AD A 25409AD A 25409AD
244 TEFLON RING.(Baffle) 1 25939A 1 25939A 1 25939A
248 CHECK VALVE. 1 3120A 1 3120A 1 3120A
249 CHECK VALVE. 1 3120B 1 3120B 1 3120B
250 RETAINING RING. 2 2867T 2 2867T 2 2867T
252 RETAINING RING 1 2829M 1 2829M 1 2829M
254 WAVE SPRING. 1 2912G 1 2912G 1 2912G
267 DRILL BUSHING. 2 3121A 2 3121A 2 3121A
268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D
269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA
270 PIPE PLUG. 3 2606B 3 2606B 3 2606B
277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ
278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR
279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A
280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q
281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N
282 SOCKET HEAD CAP SCREW. Does Not Apply
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F
297 SET SCREW. 2 2060J 2 2060J 2 2060J
298 SET SCREW. 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.

A As required.

75
Replacement Parts
Main Rotor, Slide Valve Cross Shafts and End Plate
(Clockwise Rotation)
501-701 Only

76
Replacement Parts
Main Rotor, Slide Valve Cross Shafts and End Plate
501-701 Only

MODEL NUMBER
ITEM DESCRIPTION VSM501
VSM 301 VSM601
VSM 361 VSM VSM
401 701
QTY
QTY VPN VPN QTY QTY
VPN VPN QTYQTYVPN VPN

201 MAIN ROTOR ASSEMBLY. 11 A26010BB

A25266AB 1 1A25266AA
A26010BA
1 1 A25266AC
A26010BC
203 OIL BAFFLE ASSEMBLY. 1 A25942AA 1 A25942AA 1 A25942AA
(1)217,(1) 244, (1) 248, (1) 249,(1) 252 1 A26034B 1 A26034B 1 A26034B
207 SHIM ASSORTMENT 1 A25177A 1 A25177A 1 A25177A
(2) 240, (2) 241, (1) 242, (1) 243 1 A25177B 1 A25177B 2 A25177B
1 25938A 1 25938A 1 25938A
220 END PLATE. 11 26025B
25719D 1 125719D
26025B 1 1 25719D
26025B
221 SHAFT. 22 25843A
25941A 2 225941A
25843A 2 2 25941A
25843A
222 GEAR. 44 25027A
25027A 4 425027A
25027A 4 4 25027A
25027A

228 SPACER. 24 25847A

25847A 4 225847A
25847A 4 2 25847A
25847A
240 SHIM 0.002” AA 25255AA A
25409AA A25409AA
25255AAA A 25255AA
25409AA
241 SHIM 0.003” AA 25255AB A
25409AB A25409AB
25255ABA A 25255AB
25409AB
242 SHIM 0.005” AA 25255AC A
25409AC A25409AC
25255ACA A 25255AC
25409AC
243 SHIM 0.010” AA 25255AD A
25409AD A25409AD
25255ADA A 25255AD
25409AD
244 TEFLON RING. 11 25929B
25939A 1 125939A
25929B 1 1 25929B
25939A
248 CHECK VALVE. 11 3120A
3120A 1 13120A3120A 1 1 3120A
3120A
249 CHECK VALVE. 11 3120B
3120B 1 13120B3120B 1 1 3120B
3120B
250 RETAINING RING. 22 2867B
2867T 2 22867T2867B 2 2 2867B
2867T
252 RETAINING RING 11 2928N
2829M 1 12829M2928N 1 1 2928N
2829M
254 WAVE SPRING. (205 only) 1 2912G 1 2912G 1 2912G
267 DRILL BUSHING. 22 3121A
3121A 2 23121A3121A 2 2 3121A
3121A
268 EXPANSION PIN. 44 1193D
1193D 4 4 1193D1193 4 4 1193D
1193D
269 EXPANSION PIN. 44 2981AA
2981AA 4 42981AA2981AA4 4 2981AA
2981AA
270 PIPE PLUG. 33 2606B
2606B 3 32606B2606B 3 3 2606B
2606B
277 SOCKET HEAD CAP SCREW. 22 2796CL
2795AQ 2 22795AQ2796CL 2 2 2796CL
2795AQ
278 SOCKET HEAD CAP SCREW. 22 2796CT
2795AR 2 22795AR2796CT2 2 2796CT
2795AR
279 SOCKET HEAD CAP SCREW. 24 2796CZ
2795A 4 2 2795A2796CZ4 2 2796CZ
2795A
280 HEX HEAD CAP SCREW. 68 2796EL
2796Q 8 62796Q 2796EL 8 6 2796EL
2796Q
281 HEX HEAD CAP SCREW. 86 2796B
2796N 6 82796N 2796B 6 8 2796B
2796N
Does Not Apply
282 SOCKET HEAD CAP SCREW. 2 2795D 2 2795D 2 2795D
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F
297 SET SCREW. 22 2060J
2060J 2 22060J 2060J 2 2 2060J
2060J
298 SET SCREW. 22 2060H
2060H 2 22060H2060H 2 2 2060H
2060H

NOTE: * Not pictured.

A As required.

77
78
Replacement Parts
Housing Accessiores

MODEL NUMBER
ITEM DESCRIPTION VSM 201 THROUGH 401
QTY VPN
117 GATE ROTOR COVER. 1 25416B
118 COVER GASKET. 2 25259B
127 SUCTION TEE. 1 25735B
128 BLIND FLANGE WITH TAP. 1 25967A
129 GASKET. 1 11323T
153 HEX HEAD CAP SCREW. 32 2796DC
154 HEX HEAD CAP SCREW. 8 1139BE
171 LOCKWASHER (PAIR). 8 3004J
180 INLET SCREEN. 1 25920A
190 PIPE PLUG. 2 2606C
191 PIPE PLUG. 1 2606E
343 PISTON COVER. * 1 25724B
Replacement Parts
C-Flange Assembly

MODEL NUMBER
ITEM DESCRIPTION VSM201 VSM 501
THROUGH 401 THROUGH 701
QTY VPN QTY VPN
1 C-FLANGE. 1 A 1 A
2 ADAPTER. 1 A
3 HEX HEAD CAP SCREW. 8 2796F 8 2796F
4 HEX HEAD CAP SCREW. 4 2796EL A
5 LOCKWASHER (PAIR). 8 3004H 8 3004H
6 LOCKWASHER (PAIR). 4 3004F A
7 PORT COVER. 2 25685A 2 25685A
8 HEX HEAD CAP SCREW. 2 2796AC 2 2796AC
9 CONNECTOR 1 13229C 1 13229C
10 TUBE (CUT TO )LENGTH 1 S1589A 1 S1589A
345 O-RING. 4 2176BX 4 2176CA
346 O-RING. 2 2176BG 4 2176BG

NOTE: A. Contact Home Office for part number.

79
Replacement Parts
Tools

MODEL NUMBER
ITEM DESCRIPTION VSM 201 VSM501
THRU VSM 401 THRU 701
QTY VPN QTY VPN
901 GATEROTOR STABILIZER. 1 25742A 1 25742B
902 SEAL INSTALLATION TOOL 1 25455A 1 25455B

80
Sporlan Level Master

Heater Element Level Master Control Solenoid Valve

Sight Glass
Strainer

1/2” Male Conduit

Connection

Two Conductor Rubber Covered

Electrical Cord

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 lead
wire length is two feet.

81
Sporlan Thermostatic Expansion Valve

HOW THE THERMOSTATIC Since the bulb contains both vapor and liquid refriger-
ant (not superheated vapor alone as in the suction line)
EXPANSION VALVE WORKS its temperature and pressure increases. This higher bulb
pressure acting on the top (bulb side) of the diaphragm
Basically, Thermostatic Expansion Valve Opera- is greater than the opposing evaporator pressure plus
tion determined by three fundamental pressures: spring pressure, causing the valve pin to be moved away
P1 Bulb pressure acts on one side of the diaphragm, from the seat. The valve is opened until the spring pres-
tends to open the valve. sure — combined with the evaporator pressure — is
sufficient to balance the bulb pressure. Figure-i illus-
P2 Evaporator pressure acts on the opposite side, trates a system with the same refrigerant in both the
tends to close the valve. bulb and evaporator. Bulb pressure is shown in red,
evaporator pressure in blue, and spring pressure in black.
P3 Spring pressure — which also assists in the clos- The total closing pressure (evaporator plus spring) is
ing action — is applied to the pin carrier and is shown by a blue and black dash curve.
transmitted through push rods to a buffer plate
on the evaporator side of the diaphragm. If the valve does not feed enough refrigerant, the evapo-
rator pressure drops or the bulb temperature is increased
When the valve is modulating, bulb pressure is bal- by the warmer vapor leaving the evaporator (or both)
anced by the evaporator pressure plus the spring pres- and the valve opens, admitting more refrigerant until
sure: the three pressures are again in balance. Conversely, if
the valve feeds too much refrigerant, the bulb tempera-
p1 = p2 + p3 ture is decreased, or the evaporator pressure increases
(or both) and the spring pressure tends to close the
valve 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 of
1 complete vaporization further from the outlet of the coil.
Bulb P re ssu re
This action leaves more coil surface for superheating
Bulb Temp =
Satur at ion Te mp the refrigerant which increases the bulb temperature
+ Super h eat 2 AND pressure. With the increased pressure exerted on
top of the diaphragm, the valve moves to a more open
3 S pring P ress ur e position to handle the new load condition with a slight
Refrig
C Curve change in superheat.
L
O
S
I Bulb Pressure The thermostatic expansion valve will maintain a fully
N (Opening Force)
G Evap active evaporator under all load conditions.
F Pressu re
O Evap T emp
R Superheat Fixed restrictions and other expansion devices can
C
E
offer only a corn promise in system performance when
Bulb T empera ture
operating conditions change.
Fi g ur e 1

SPORLAN SELECTIVE CHARGES

When the same refrigerant is used in both the thermo- For the most efficient system performance, Sporlan in-
static element and refrigeration system, each will exert troduced Selective Charges for thermostatic expansion
the same pressure if their temperatures are identical. valves over 40 years ago. Their present universal accept-
After evaporation of the liquid refrigerant in the evapo- ance throughout the refrigeration industry is evidence
rator the suction gas is superheated — its temperature of the many operational advantages not possible with
will increase. However, the evaporator pressure, neglect- conventional charges.
ing pressure drop, is unchanged. This warmer vapor
flowing through the suction line increases the bulb tem- An explanation of the characteristics, design features,
perature. and advantages of each selective charge follows:

82
Sporlan Thermostatic Expansion Valve

Conventional Liquid Charge Type P Air Conditioning Charge

w i t h T y pe L C h ar g e w i t h t he Sp o r l an FLOW M ASTER E l e m en t

N o L i qu i d
P r e s e n t (G a s )
P Refrigerant P i n Bulb

R Pressure- Temperature R Poi nt Of

E C om p le te
E S pr i ng P r e s s u r e
( C o ns t a n t )
Characteristic
Vaporization
S Refri gerant S S pr i ng P re s s u r e
( C o ns t a n t )
S S Refri gerant
U U
R R
E E

T e m p er at ur e T e m p er at u r e

Figure 2 F igure 3

Design Characteristics:

1 Employs same refrigerant in thermostatic element open the valve, filling the evaporator with liquid. This
as used within system. is another possible cause of flood-back at start-up.

2 Bulb volume and amount of charge it contains is 4 Conventional liquid charged valves have no inherent
such that sufficient liquid will remain in the bulb un- anti-hunt features.
der all temperature conditions of the diaphragm case
and capillary’ tubing. Application:
Advantages: Because of definite operating advantages obtained with
the use of other Selective Charges, the use of the Type
Bulb will always control refrigerant flow despite a L charge is generally confined to large capacity ammo-
colder valve or diaphragm case. nia systems and a few unusual application.

Disadvantages: Design Characteristics:

1 When the compressor is started, the suction and
evaporator pressures drop. But since the valve bulb is 1 Pressure limit or maximum operating pressure (MOP)
not imniediately cooled, the comparatively high bulb feature. The Sporlan P charge is a patented modifica-
pressure opens the valve too much resulting in: tion of the conventional limited liquid charge (gas
charge). The constituents of this charge are such that at
a Low superheat and possible floodback to the a predetermined valve bulb temperature a maximum
compressor. bulb pressure is reached. Any increase in bulb tempera-
b Delayed suction pressure pulldown and possi- ture above this point also results in virtually no increase
ble overloading of the compressor motor. in bulb pressure, causing the valve to throttle.

2 With the same valve adjustment, the superheat in- 2 Sporlan Type P air conditioning charge makes use of
creases at lower evaporator temperatures where high the Flow-Master element originally patented by Sporlan
superheats are more detrimental to system capacity.
which is effective in stabilizing valve control and in
3 During off-cycle, if bulb is in a comparatively warm materially reducing system hunt.
location, the bulb pressure may be great enough to

83
Sporlan Thermostatic Expansion Valve

Low Temperature
Air Conditioning

+50 F to - 10 F

-0 F to - 100 F
Extreme Low
Refrigeration

Refrigeration

Refrigeration
0 F to - 40 F]

Temperature
Commercial
Heat Pump
Refrigerant

or

FZ
12 FCP60 FC FZP
22 VCP100 VZ
VC VX
AND VGA VZP
500 DCP70 DC
502 RC9115 RC RZ RX
RZP

Type L liquid charges are also available for most com-

monly used refrigerants in most element sizes.

THERMOSTATIC EXPANSION VALVE with

RAPID PRESSURE BALANCER FEATURE
U.S. Patent Na. 3,252,297

Sporlan developed and patented a totally new type of For proper operation, foreign material must be kept out
“bleed valve” for use with air conditioning PSC (Per- of the valve. A Catch-All Filter-Drier should be in-
manent split capacitor — low starting torque) motor stalled as close as possible to the valve inlet.
compressors. This development was prompted by re- On systems utilizing compressors that have starting
quests from manufacturers of air conditioning equipment torques higher than the PSC motor, on outdoor coils of
for a thermostatic expansion valve which would equal- heat pumps, or on refrigeration systems, the RPB should
ize high and low side pressures more rapidly than a con- not be used because of possible start-up problems. When
ventional permanent bleed design. The RPB valve pre- a “bleed valve” is required on one of these systems, the
sents a major breakthrough in the design of thermostatic permanent bleed type valve is available. To determine
expansion valves. These valves generally reduce the the proper bleed port size, sufficient testing must be
equalization time by about 50% over that obtained with done by the manufacturer.
the permanent bleed type.
Normally, it is advisable to replace a valve with one of
The RPB feature should allow the system pressures to the same specification. However, a valve with the RPB
equalize in about two minutes; however, the amount of feature can replace a permanent bleed type except on
system charge and high side volume can affect this time. outdoor coils of heat pumps or on refrigeration systems.
As shown in Figure-7 the RPB bleed is actuated only on If electrical “hard-start” components have been added
the off cycle. Immediately after shut down the evapo- to the system, it is not necessary nor advisable to use
rator pressure rises and the pin carrier moves to the closed the bleed port or RPB type thermostatic expansion valve.
position as in a conventional valve. However, with the
RPB design the pin carrier continues its motion and
opens the secondary spring loaded bleed port allowing
rapid equalization of high and low side pressures. Upon
restarting the compressor the secondary bleed port closes
and the valve functions in the normal manner.

The RPB feature is currently available in valve Types C

and S up to and including 4 tons Refrigerant 22 nomi-
nal capacity for air conditioning and heat pump (indoor
coil only) applications.

84
Sporlan Thermostatic Expansion Valve

THE EXTERNAL EQUALIZER B ul b P re ssu re

34 p si Co n ver te d t o Te mp er at ure = 3 7 *

The operation of the thermostatic expansion valve is D ia g ra m

dependent upon the relationship of the three funda-

mental pressures. See Figure-i. Bulb pressure acting
on top of the diaphragm must always equal the sum of
evaporator (or suction pressure) and spring pressure
applied to the under-side of the diaphragm. Sp rin g Pr ess u re 27 27
7 psi

On an internally equalized valve, the pressure at the

valve outlet (or evaporator inlet) is transmitted to the Eva po ra to r
Ou tl et P re ssu re
2 7 psi
under-side of the diaphragm via a passageway within
Cl o s i n g P r es s ur e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 2 7 + 7 = 3 4 p s i
the valve or through clearance around the push rods. ( e v a p o r a t o r 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 )
B u l b P r e s s u r e N e c e ss a r y t o o p e n va l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4 p s i
On an externally equalized valve the under-side of the B u l b t e m p e r a t u r e e q u i va l e n t t o 3 4 p s i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7 * F
Sa 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
diaphragm is isolated from valve outlet pressure by
S UPE RHE AT ....... . ....... . ....... .. ...... .. ...... .. ...... .. .....9 * F
packing around the push rods or by closely fitted rods ( B l u b t e m pe r a t ur e mi 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 )

making a metal-to-metal seal. See Figure-8. Suction Fi g u r e 9

pressure is transmitted to the under-side of the dia-

phragm by a line usually connected between the suc-
diaphragm senses the evaporator pressure of 27 psig
tion line near the evaporator outlet (generally down-
— which acts to close the valve. A spring pressure
stream of the bulb) and an external fitting on the valve.
of 7 psi also assists the evaporator pressure in at-
tempting to close the valve. The valve consequently
adjusts its flow rate until the suction line vapor be-
Fi g u r e 8 comes sufficiently superheated to create a bulb tem-
V a l u e w i th I n t er n a l E q u a l i z e r Va l u e w i t h E x t e r n a l E q u a li z e r perature of 37 F. which develops a pressure of 34
psig — assuming the same refrigerant in the bulb
as in the system — balancing the evaporator and
spring pressure. The resulting superheat is 90 F.
Pu s h Ex t e r n a l
Rod E qu a l i z er
I n t e r na l Pac king Fitt ing
E qu a l i z er

Pu s h Pu s h B ul b P r es su re
Ro d s 4 0 ps i C on ve rte d t o T emp era tu re = 43 *
Ro d s
Val ve Evaporator
O ut l e t O utl et
Pr e ssu re Pr e s s u r e D ia g ra m

33
27
Sp rin g P res s ure
While internally equalized valves may be used with evapo- 7 ps i
43

rators that have a low pressure drop, valves with an ex-

ternal equalizer must be used when there is an appre- Ev a po rato r
Ou tle t P re ss u re
ciable pressure drop between the valve outlet and bulb 27 psi

location. This is illustrated in Figures-9, 10, and 11. The C l o s i n g P re s s u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . = 3 3 + 7 = 4 0 p s i

( e v a p o r a t o r i n l e t p r e s s u r e p l u s s p ri n g p r e s s u r e )
refrigerant in the system is assumed to be R12. B u l b P r e s s u r e N e c e s s a ry t o o p e n v a l v e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 0 p s i
Bu l b t e mper a t ur e e qu i v a l en t t o 4 0 p si . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3 * F
Sa t u r at e d t e mp 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

Figure-9 shows an internally equalized valve feeding an SUPE RHEA T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5* F

evaporator — which, for purpose of illustration, has no ( Bl ub t em pe r at ur e mi nu s s a t u r a e d e va p or a t o r t emp er a t u r e)

pressure drop. The pressure at the valve outlet and at the Fi g u r e 10

bulb location is 27 psig. So, the under-side of the valve

85
Sporlan Thermostatic Expansion Valve

WHEN TO USE THE EXTERNAL

EQUALIZER
Bul b P r ess u re
34 ps i C onver t ed t o Temper at ure = 37*

Di ag ra m
As evaporating temperature drops the maximum
pressure drop that can be tolerated between the valve
Outlet and the bulb location without serious capac-
ity loss for an internally equalized valve also de-
33 creases. This is shown in Table 1 below. There are,
27
Spr ing Pr ess ure
7 psi
37
of course, applications which may satisfactorily
employ the internal equalizer when higher pres-
Ev apo r ato r
sure drop is present, but this should usually be veri-
Outl et P r ess ure
27 psi fied by laboratory tests. The general recommenda-
Clos ing P re ssur e. . .. .. .. .. . .. .. .. . . .. .. .. .. ... .. .. . . .. .. .. . . .. .. .. .. . .. .= 2 7+ 7= 34 psi
(ev apo rat or in l et pr e ssu r e p lu s s pr i ng pre ssu re )
tions given in Table 1 are suitable for most field
Bul b Pr ess ur e N ec ess ar y t o o pe n val v e.. . . .. .. ... .. .. .. . . .. .. .. .. . .. .. .. .34 psi
Bul b t empera t ure e qu iva l ent t o 34 p si .. .. .. .. . . .. .. . .. .. .. .. .. .. .. .. . . ... .3 7*F
installed systems. Use External Equalizer when
Satu rat ed t em per a tu r e equ ival ent t o ev apo ra t or out let pr e ssu re. .28 * F pressure drop between valve outlet and bulb lo-
S U P E RH E A T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 * F
( Bl u b t em per at ure mi nu s sa tu r ae d e vap or a to r t emp era t ur e )
cation exceeds values shown in Table 1.
Fig ur e 11

If this same internally equalized valve with the same

spring adlustment is installed on an evaporator of Evaporating Temperature
equivalent nominal capacity but with a 6 psi pressure Degress F.
Refrigerant 40 20 0 -20 -40
drop, the operating superheat will increase to 15~ F.
as shown in Figure-b. Now the valve senses a com- Pressure Drop-psi
paratively high pressure of 33 psig at the valve outlet. 12,500 2 1.5 1 .75 .5
The total closing pressure is 33 + 7 or 40 psig. Since 22 3 2 1.5 1.0 .75
the bulb pressure must equal the total closing pres-
sure, the valve reduces its flow rate to create the nec- 502 3 2.5 1.75 1.25 1.0
essary s~perheat and bulb pressure. Consequently, 717 3 2 1.5 1.0 .75
Ammonia
excessive evaporator pressure drop causes an in-
ternally equalized valve to operate at abnormally
high superheat, and serious loss of evaporator ca-
pacity results.
When the expansion valve is equipped with an Ex-
ternal Equalizer, it must be connected—never
The problem of improper valve control illustrated in
capped—or the valve may flood, starve, or regulate
Figure-b may be corrected by applying a thermostatic
valve with an external equalizer. Figure-li shows the erratically.
same system, but with an externally equalized valve.
The suction pressure at the bulb location is transmit- There is no operational disadvantage in using an
ted to the under-side of the diaphragm via the exter- External Equalizer even if the evaporator has a
nal equalizer line. Valve operation is now identical to low pressure drop.
that shown in Figure-9, and the superheat returns to
9* F.

86
87
“Stop Check” Operation

AUTO
In the “Auto Position”, the stop valve is
operating as a check valve, allowing
flow in the directions of the arrows.

To set the valve to the automatic position,

fully close the valve, and turn the stem
out as indicated by the chart below.

CLOSED
In the manually “Closed Postion”, the
stop check is operating as a
convientional stop valve, not allowing
flow in either direction.

OPEN
In the manually ” Open Position”, with
the valve stem fully back seated, the valve
disc 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

88
“Stop Check” Installation

Name

Name

Correct Correct

Wrong
Wrong
Wrong

Verify the location of Spring and note

the Vilter name

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

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

89
Hansen Technologies
Product

Bulletin S119d
October, 1999

HANSEN TECHNOLOGIES
CORPORATION

HS8A with Close-Coupled STO5O Strainer

HSBA
INTRODUCTION
SOLENOID VALVE
The redesigned, heavy-duty HS8A refrigeration
solenoid valve is flanged, compact, and pilot-oper- 1/211 (13 MM) PORT
ated. It is now more dirt resistant, erosion resistant,
and corrosion resistant. A dirt controlling Teflon Specifications, Application
piston seal prevents sticking. The valve body has Service Instructions & Parts.
improved, erosion resistant flow passages. And a
proprietary coating on the valve body gives un-
Flanged
matched corrosion protection. The HS8A is used to
3/8” through ¾”
provide on-off control of refrigerant flow. When the
FPT, SW, WN, ODS
coil is energized, a pressure difference across the pis-
for refrigerants
ton opens the valve seat. When the coil is de-ener-
gized, a spring closes the main Teflon seat to stop all Key Features
flow. Watertight
Encapsulated
Coil
APPLICATIONS Corrosion
Protection For
The HS8A is ideal as a liquid line solenoid Coil Housing
valve.While primarily for ammonia, this valve is also
Ductile Iron Body
suitable for R22, R134a, and other compatible re- With Corrosion
Protection
frigerants. The most common use of this valve is to
Large Diameter
control flow to: expansion devices, recirculating liq- Stable Stainless
Steel Closing Spring
uid overfeed evaporators, hot gas defrost, and small
Dirt Controlling
capacity evaporator suction. In addition, the HS8A Teflon Piston Seal
makes an ideal noncondensible gas (air) purge point Prevents Sticking
Improved Teflon Seat
solenoid valve, and is recommended for use with
Improved, Erosion
Hansen AUTO-PURGERs. Resistant Flow Passages

Stainless Steel Stem

MAXIMUM RATINGS, AMMONIA
Corrosion Proof Seal Cap
Liquid, Receiver Pressure: 110 Tons (387 kW)
Recirculation, 4 to 1: 36 Tons (127 kW) MATERIALSPECIFICATIONS
Hot Gas: 10 Tons (35 kW) Body: Cast ductile iron, corrosion-resistant
Suction: 5.0 Tons (18 kW) coated
Flow Factor: Cv = 3.3 (2.9 Kv) Bonnet Cartridge: Steel, plated
Piston: Stainless steel, Teflon seal
ADDITIONAL FEATURES Plunger: Stainless steel
Dimensionally replaces RIS S8F and Hansen HS8 Pilot Orifice: Stainless Steel
Low-wattage coil Seats: Teflon, pilot and main
300 psig (20.7 bar) MOPD MOPD: 300 psig (20.7 bar) AC coils only
Teflon main & pilot seats Safe Working Pressure: 400 psig (27 bar)
Close-couples to STO5O (100 mesh) strainer Operating Temperature: -600F to +2400F (-
Heavy-duty construction 50”C to +11 5”C)
CSA certified

90
Above Std. Coil Kits Consist of:
ELECTRICAL 1a Bare Coil, 1 iSV 50160Hz, wire leads 1 70-0271
The solenoid is a normally-closed (NC) device. One lb Bare Coil, 230V 50/60Hz, wire leads 1 70-0286
lc Bare Coil, 24V 50160Hz, wire leads 1 70-0284
standard coil fits all Hansen valves. The coil draws 16 Other Voltage Coils 1 FACTORY
ld
watts and operates properly between 85% and 110% 2 Coil Housing Assembly Kit 1 70-1060
of rated voltage (24V coil draws 19 watts).The stan- 3 Coil Washer 1 70-0289
4 Coil Nut 1 70-0281
dard coil connection is a 1/2’ fitting (NPSM) for con-
duit. DIN plug, quick disconnect, and junction box Solenoid Tube/Plunger Kit 70-1059
coils are available. Pilot lights are also available Con- Above Kit Consists of:
5 Plunger 1 70-0295
tact the factory for details. Coils have a rustproofed Solenoid Tube 1 70-0298
6
steel housing which meets NEMA 3R (rainproof) 7 Solenoid Tube Gasket 1 70-0301
and NEMA 4 (sptashproof) requirements. The junc- 8 Tube Screws 4 70-0297
3 Coil Washer 1 70-0289
tion box version is considered NEMA 1. Coil Nut 1 70-0281
4

The coil should only be energized while installed on Gasket Kit Consists of 70-1005
7 Solenoid Tube Gasket 1 70-0301
the solenoid tube. Otherwise, the coil may quickly Upper Body 0-ring 1 70-0009
9
burn-out. To avoid bending the solenoid tube, remove 10 Lower Body 0-ring 1 70-0011
the coil from the valve before tightening any flexible 11 Flange Gasket 3 70-0065
12 Stem 0-ring 1 70-0010
conduit connection. Packing 1 70-0025
13
14a Seal Cap Gasket (prior to 1998 1 70-0008
INSTALLATION 14b Seal Cap 0-ring 1 70-0011
19 Packing Washer 1 70-0026
Protect the interior of the valve from dirt before and Packing Nut 1 70-0019
20
during installation. A close-coupled inlet strainer is
normally installed and recommended. Allow 2” (50 Bonnet Cartridge Kit 70-1001
Above Kit Consists of:
mm) above the valve for coil removal and 3” (76 mm) Cartridge Assembly 1 70-0144
15
below the strainer for screen removal. The arrow on Gasket Kit 1 70-1 005
the valve body must point in the direction of system Solenoid Tube/Plunger Kit 1 70-1059
flow. If a pressure reversal can occur use a check valve Piston Assembly Kit 70-1002
on the outlet side of the HS8A. The check valve can be Above Kit Consists of:
close coupled directly to the HS8A outlet. 16 Piston Assembly 1 70-0497
17 Closing Spring 1 70-0494
Gasket Kit 1 70-1 005
INSTALLATION DIMENSIONs
Stem Kit Consists of: 70-1003
18 Stem 1 70-0004
3.63" Gasket Kit 1 70-1005
(92mm)
Seal Cap Kit Consists of: 70-1075
Note: 21 Seal Cap 1 75-0798
14b Seal Cap 0-ring 17 0-0011
Allow " (50mm) for
Coil removal Strainer Screen Kit Consists of: 78-1 001
5.25 1 78-0005
(133mm) 22 Screen Assembly, 100 mesh
Allow 3" (75mm) 23 Strainer Cap Gasket 1 78-0016
for Strainer Basket removal
Bolt and Nut Kit
For HS8A less Strainer (a) 70-1006
For HS8A with Strainer (b) 70-1007
2.88"
3.25" (133mm) Consists of:
(83mm) 25 Nut 7/16-14 2 70-0055
26a Bolt, 7/16—14 x 33/4 2 70-0073
26b Bolt, 7/16—14 x 51/2 2 70-0076
1.5"
5.00" (38mm)
(127mm) 24 Strainer Cap 1 78-0002
3.00"(76mm) without strainer
27 Assembled Body HSSAII
Replacement Kit
Complete Valve less Coil Kit and Flanges
DESCRIPTION
QNTY PRT#
ITEM 28 Assembled Strainer 78-1002
Std. Coil Kit (11 5V) l/2•’ Fitting 70-1 057 Replacement Kit
Std. Coil Kit (230V) ~/2” Fitting 70-1056
Std. Coil Kit (24V) 1/2’~ Fitting 70-1058 29 Flange Kit (FPT,SW,WN,ODS) FACTORY
Std. Coil Kit (Other Voltages) FACTORY Includes (2) Flanges only;
DIN Plug Coil Kits FACTORY Specify Style and Size
Quick Disconnect Coil Kits FACTORY
Coil with Junction Box Kits FACTORY

*NOTE: All parts also fit HS8. 91

Hansen Technologies
Product

Parts List

6 4
3
2

5
8
9 15
10 7
27 17 16

25
11
11
26 29

12
29
13
22
20
28
18 14
23
21
24 11 19

Standard 1/2" Coil Fitting shown above. Other coil options also availble are:
DIN Plug Coil Quick Disconnect Coil Coil Juction With Box

92
Hansen Continued.............

SERVICE AND MAINTENANCE ORDERING INFORMATION,

HS8A SOLENOID VALVE
Failure to open: Wrong coil voltage; low line
voltage; electric controlling device is not switching; FLANGE CONNECTION STYLE & SIZES
coil is burned-out; inlet/outlet pressure differential FPT, SW, WN ODS
is too high; piston or solenoid coil plunger is jammed closed STD ALSO STD
with dirt. 1/2 3/4”, 3/8” 5/8”

Failure to close: Electric controlling device is not FPT: Female Pipe Thread (American National Standard)
switching; manual-opening stem is turned in; piston SW: Socket Weld to accommodate American and API pipe
or solenoid coil plunger is jammed open by dirt; WN: Weld Neck to match American pipe ODS: Outside
damage or dirt at main valve seat or pilot valve seat. Diameter Sweat, for American copper tubes

Before opening the valve for service, be sure it is Standard encapsulated solenoid coil is included for 115V,
isolated from the system and all refrigerant is 230V, or 24V; 50/60Hz; other voltages are available. Stan-
pumped out to zero pressure. Disconnect electrical dard coil connection is a 1/2” fitting (NPSM). Coils with
power from the coil (1). To remove the coil (1), unscrew the DIN plug, quick disconnect, or junction box are available.
coil nut (4) and remove the washer (3). Pilot lights are also available. Contact the factory.
Then, remove the coil (1) from the solenoid tube (6). To
remove internal parts, use a large wrench to slowly unscrew TO ORDER: Specify type, connection style and size, volts,
the bonnet cartridge (15), proceeding cautiously to detect and strainer if required. Unless otherwise specified, the stan-
any remaining refrigerant insidethe valve. Then, remove the dard coil with ½” fitting will be supplied.
closing spring (17) and piston (16). Check for dirt on the
piston (16), Teflon piston seal, and seat. Clean and reinstall TYPICAL SPECIFICATIONS
or install new parts. Check the upper (9) and lower (10) “Refrigerant solenoid valves shall have encapsulated, wa-
body 0-rings and replace if necessary. Use refrigerant oil or tertight coils, Teflon seats, ductile iron or steel bodies, stain-
grease when installing the 0-rings. less steel pistons, spring closing pilot and main valve seats,
and must be suitable for a safe working pressure of 400 psig
To check the pilot section of the valve, first loosen the four (27 bar), as manufactured by Hansen Technologies Corpora-
solenoid tube screws (8). Then, break the seal between the tion or approved equal.”
solenoid tube (6) and bonnet cartridge (15), being careful to
avoid any refrigerant which may remain. Check the face of OTHER PRODUCTS
the Teflon seat in the plunger (5), the plunger spring, and Modular Pressure Regulators
the pilot seat orifice on the bonnet cartridge (15). Clean, Solenoid Valves
polish, or replace parts as necessary. The pilot seat is inte- Gas-Powered Valves
gral with the bonnet cartridge. Install a new solenoid tube Shut-Off Valves, 3/~’ to 16’
gasket (7) and oil lightly. Reassemble the bonnetcartridge Hand Expansion Valves (Regulators)
(15) to the valve body (27), using 75 ft-lbs (102 N-rn) torque Level Pulse Control Systems (Pulse Width Valves)
to tighten the secondary, metal, knife-edge seal.Carefully Thermostatic Expansion Valves (TXV)
check the valve for leaks before restoring to service. Inline and Piston-Type Check Valves
Gauge, Purge, and Needle Valves
CAUTION Strainers and Filter Systems
AUTO-PURGER®s
Hansen valves are for refrigeration systems only. These in- Liquid Refrigerant Pumps
structions must be read completely and understood before Float Drain Regulators
selecting, using, or servicing these valves. Only knowledge- Van-Level® Adjustable Level Controls
able, trained refrigeration technicians should install, oper- Techni~Level®Transducer Probes
ate, or service these valves. Stated temperature and pres- Float Switches
sure limits should not be exceeded. Bonnets, solenoid tubes, SEE-LEVEL® Liquid Indicators
etc., should not be removed from valves unless the system Frost Master® Defrost Controllers
has been evacuated to zero pressure. See also Safety Pre- Pressure-Relief Valves
cautions in the current List Price Bulletin and the Safety Rupture Disc Assemblies
Precautions sheet supplied with product. Escaping refriger-
ant can cause injury, especially to the eyes and lungs.
HANSEN TECHNOLOGIES
WARRANTY CORPORATION
6827 High Grove Boulevard
Hansen valves are warranted against defects in workman- Burr Ridge, Illinois 60521 USA
ship and materials for a period of one year F.O.B. our plant. Telephone: 630-325-1565
No consequential damages or field labor is included. Toll-free: 800-426-7368
Fax: 630-325-1572
E-mail: [email protected]
Web site: www.hantech.com

93
If service is required, first contact your equipment distributor or contact
A Vilter Technical Service Representative at:

Vilter Manufacturing Corporation

5555 South Packard Ave.
PO Box 8904
Cudahy, WI 53110-8904
Telephone: 414-744-0111
Fax: 414-744-1769
e-mail: [email protected]

Note: It will be necessary to have your Vilter order number available

when contacting Vilter Manufacturing Corporation for service support.

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95
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e-mail: [email protected]