Manual Vilter
Manual Vilter
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.
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 Transportation Company. This way, an authorized agent can examine the unit, determine the
extent of damage and take necessary steps to rectify the claim with no serious or costly delays. At the
same time, the local Vilter representative or the home office should be notified of any claim made.
All inquires should include the Vilter order number, compressor serial and model number. These can be
found on the compressor name plate on the compressor.
All requests for information, services and or parts should be directed to:
DESCRIPTION ........................................................................................................................................................................................ 16
SYMBOLS AND MEANINGS ............................................................................................................................................................... 18
Installation Section ...................................................................................................... 19
5
Table of Contents
Service Section Cont ..............................................................................................................................................................
6
Table of Contents
PLUG APPLICABILITY ......................................................................................................................................................................... 92
7
Long Term Storage
Requirements
The procedure described is a general recommendation for extended storage (over one month of no operation) of
Vilter Manufacturing packages and compressors. While this procedure is intended to cover most of the commonly
encountered situations, it is the responsibility of the installation firm and end user to address any unusual condi-
tions. We suggest using the accompanying Long Term Storage Log sheet for recording purposes to validate the
appropriate procedures.
Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verification of the
system integrity, a comprehensive evacuation procedure should be completed to ensure a dry system before refriger-
ant is introduced. The oil circuit of any compressor is to be primed at initial start-up through the oil gauge connec-
tion on reciprocating compressors and the pre-lube oil pump on screw compressors.
Warranty of the system remains in effect as described in Section 5, Product Warranty and Procedures.
* If the unit is designed for indoor duty, it must be stored in a heated building.
If the unit is designed for outdoor duty, and is to be stored outdoors, a canvas tarp is recommended for protec-
tion until installation is imminent. Adequate drainage should be provided, by placing wood blocks under the
base skid, so that water does not collect inside the base perimeter or low spots in the tarp.
* All compressor stop valves are to be closed to isolate the compressor from the remainder of the system. All
other valves, except those venting to atmosphere, are to be open. It is essential that the nitrogen holding charge
integrity be maintained.
* Cover all bare metal surfaces (coupling, flange faces, etc.) with rust inhibitor.
* Desiccant is to be installed in the control panel. If the panel is equipped with a space heater, it is to be
energized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light bulb. Use
an approved electrical spray-on corrosion inhibitor for panel components (relays, switches, etc.)
* All pneumatic controllers and valves (Fisher, Taylor, etc.) are to be covered with plastic bags and sealed with
desiccant bags inside.
* System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5 psi above
atmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be necessary to add a gauge
to monitor the system holding charge pressure. If a drop in pressure occurs, the source of leakage must be found
and corrected. The system must be evacuated and recharged with dry nitrogen to maintain the package integ-
rity.
* Motors – (NOTE: The following are general recommendations. Consult the manufacturer of your motor for
specific recommendations.)
8
Long Term Storage
Requirements
1) Remove the condensation drain plugs from those units equipped with them and insert silica-gel into the openings.
Insert one-half pound bags of silica-gel (or other desiccant material) into the air inlets and outlets of drip-proof
type motors.
NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when the
unit is prepared for service.
2) Cover the unit completely to exclude dirt, dust, moisture, and other foreign materials.
3) If the motor can be moved, it is suggested that the entire motor be encased in a strong, transparent plastic bag.
Before sealing this bag, a moisture indicator should be attached to the side of the motor and several bags of
silica-gel desiccant put inside the bag, around the motor. When the moisture indicator shows that the desiccant
has lost its effectiveness, as by a change in color, the bag should be opened and fresh replacement desiccants
installed.
Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F above
the ambient temperature.
NOTE: There is a potential for damage by small rodents and other animals that will inhabit
motors in search of warm surroundings or food. Due to this, a possibility of motor
winding destruction exists. Sealing motor openings should restrict access to the motor.
4) Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate flat spots on
the bearing surfaces. If the compressor unit is installed, wired and charged with oil, open all oil line valves and
run the oil pump for 10 seconds prior to rotating the compressor shaft. Continue running the oil pump while the
compressor shaft is being turned to help lubricate the surfaces of the shaft seal.
9
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 re-
jected, and do not form a part of this Agreement unless Seller agrees to such terms in writing.
Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind
Seller unless this Agreement and any purported change are signed by a home office Officer of Seller.
Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyer’s
binding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unless
agreed otherwise in writing, all payments are due in full within 30 days of Seller shipping the products or providing
the services. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the
maximum allowed by law.
Security Agreement. This Agreement shall be considered a security agreement to the maximum extent allowed by
law. Seller shall have, retain, and possess a security interest in all products sold to Buyer until Seller is paid in full.
Buyer grants to Seller a power of attorney to complete, sign on Buyer’s behalf, and file all forms reasonably necessary
to perfect Seller’s security interest. If Buyer defaults, or Seller deems itself insecure of receiving payment, the full
unpaid balance shall become immediately due and payable at the option of the Seller, and Seller may retake posses-
sion of the products without Court order.
Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. All
delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’s
Order Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment
deliveries.
Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a
period of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months
from date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the
following extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal
rotating parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and recip-
rocating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties
do not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or
regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains
all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Seller
of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.
Products supplied by Seller which are manufactured by others are not warranted by Seller, but rather Seller merely
passes through the manufacturer’s warranty to Buyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WAR-
RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise agreed in writing, Buyer’s
sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or the
providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of dismantling, lost refrig-
erant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect,
consequential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REM-
EDIES ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED. Products or
parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory. Any improper
use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved by Seller, or any
alteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall void all warranties and
warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be in default of its
payment obligations to Seller under this Agreement or any credit agreement.
10
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, PRODUCT
LIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.
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.
11
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 requirements, 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 recipro-
cating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do
not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or
regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains
all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Seller
of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.
Products supplied by Seller which are manufactured by others are not warranted by Seller, but rather Seller merely
passes through the manufacturer’s warranty to Buyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WAR-
RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise agreed in writing, Buyer’s
sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or the
providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of dismantling, lost refriger-
ant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect, conse-
quential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REMEDIES
ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED.
12
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
LIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARY
OR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCT
LIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.
IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER IN
EXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTY
REMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCEABLE
FOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREEMENT,
THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS 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 Milwau-
kee, Wisconsin, U.S.A. shall have exclusive venue for any dispute concerning the enforceability, interpretation, or
termination 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.
13
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 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.
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 transportation
prepaid to Seller’s factory. Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substi-
tution 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.
14
STANDARD VILTER 5/15
WARRANTY STATEMENT
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.
Note; The 5/15 warranty applies to NEW compressors only, and does NOT include used or remanufactured com-
pressors.
15
Description
COMPRESSOR
The Vilter Single Screw Compressor is a positive ing is flooded with gas at suction pressure. The
displacement, capacity and volume controlled, oil gas enters the open end of the main screw flutes at
flooded, rotary compressor which uses a single the driven end, and becomes trapped in the screw
main screw intermeshed by two opposing gate ro- flute as the screw rotates and the gate rotor tooth
tors. Gas compression occurs when the individual enters the end of the flute. At this point, the com-
fingers of each gate rotor sweep through the pression process begins. Directly after the screw
grooves, or flutes, of the main screw as the screw flute is closed off by the gate rotor tooth, oil is in-
rotates. Compression occurs from the time the jected into the groove.
screw flute is first closed off by the gate rotor fin-
ger, until the time when the screw flute has ro- The oil enters the compressor through a connec-
tated to the point of lining up with the discharge tion at the top of the compressor. The purpose of
port in the compressor housing. A labyrinth type the injected oil is to absorb the heat of compres-
seal is used to prevent gas at discharge pressure sion, to seal the gate rotor tooth in the groove, and
from leaking past the end of the screw. Any dis- to lubricate the moving parts.
charge gas leakage past the labyrinth seal is vented
back to suction via four longitudinal holes drilled Additional internal oiling ports are provided at the
through the body of the screw. main and gate rotor bearings to cool and lubricate
the bearings. The mechanical shaft seal housing
By venting the discharge end of the main screw also contains oiling ports to lubricate, cool and pro-
back to suction, forces on each end of the screw vide a sealing film of oil for the mechanical shafts
are equal. This results in zero net axial forces on seal. Excess oil flows through the check valves on
the main bearings. With twin opposing gate ro- the sealing baffle plate. This oil is directed at the
tors, all radial forces are cancelled out also. Main main rotor roller bearing, which cools and lubri-
shaft bearings have no net forces except the weight cates the front roller bearing.
of the screw and the shaft assembly.
As the main screw rotates, the gate rotor is also
The compressors are comprised of three rotating driven, causing the gate rotor tooth to sweep the
assemblies: the main screw assembly and the two groove in the main screw. This sweeping action
gate rotor assemblies. Each of these rotating as- reduces the volume of the groove ahead of the gate
semblies use a common bearing configuration con- rotor tooth and causes the trapped gas and oil to be
sisting of a single, cylindrical rolling element bear- compressed in the reduced volume. As the main
ing at one end, and a pair of angular contact ball screw continues to rotate, the gate rotor tooth con-
bearings at the other end. The pair of angular tinues to reduce the groove volume to a minimum,
contact ball bearings are used to axially fix one thus compressing the trapped gas to a maximum
end of the rotating shafts, and to absorb the small pressure. A labyrinth seal arrangement prevents
amount of thrust loads on the shafts. The inner the compressed gas from leaking past the end of
races of the ball bearings are securely clamped to the screw. As the gate rotor tooth reaches the end
the rotating shafts, while the outer races are se- of the groove, the groove rotates to a position that
curely held in the bearing housing, thus fixing the lines up with the discharge port in the compressor
axial position of the shaft in relation to the bear- housing and the gas/oil mixture is discharged from
ing housings. The cylindrical roller bearings at the screw at high pressure. This completes the com-
the opposite end of the shafts allow for axial growth pression cycle for a single flute of the main screw.
of the shafts while supporting the radial loads from
the shafts. Once the gas is swept from the main screw flute
through the discharge port, it passes into the dis-
The suction gas enters the compressor housing charge manifold of the compressor. From the dis-
through the top inlet flange, at the driven end of charge manifold, the gas/oil exits the compressor
the unit. The driven end of the compressor hous- housing
16
Description
The Vilter compressors feature the exclusive continues until the screw rotates far enough for
Parallex™ Slide System, which consists of a pair the flute to pass the end of the volume ratio slide.
of slides for each gate rotor assembly. These At this point, the screw flute lines up with the
two independently operated slides are referred discharge port and the compressed gas is ex-
to as the capacity slide and the volume ratio slide. pelled from the screw flute. As the volume ra-
On the suction end of the screw, the capacity tio slide is pulled back away from the discharge
slide moves to vary the timing of the beginning end of the screw, the position of the discharge
of the compression process. With the slide port is changed and the gas is allowed to escape
moved all the way out to the suction end of the the screw flute earlier in the compression pro-
screw (the 100% position), the compression pro- cess, at a reduced pressure.
cess begins immediately after the gate rotor tooth
enters the screw flute and closes off the end of The overall volume ratio within the compressor
the groove. In this situation, the maximum vol- is determined by the distance between the front
ume of gas is trapped in the screw flute at the of the capacity slide (the start of compression)
start of the compression process. As the slide is and the back of the volume ratio slide (the
pulled back away from the suction end of the completion of compression). Therefore, the vol-
screw, the start of the compression process is ume ratio slide must respond to changes in the
delayed as some of the suction gas is allowed to downstream pressure measured in the oil sepa-
spill back out of the screw flute until the screw rator and position itself for the required com-
rotates far enough to pass the end of the capac- pression ratio based on the position of the ca-
ity slide and begin compressing. This causes a pacity slide. By only compressing the gas within
reduced volume of gas to be trapped in the screw the screw as far as required to match the pres-
flute when the compression process begins. In sure in the downstream receiver, the compres-
this way, the capacity of the compressor is re- sor efficiency is maximized. Proper position-
duced from 100% down to as low as 10% of the ing of the volume ratio slide prevents either over
full rated capacity. compressing or under compressing of the gas
within the screw flute. This allows the single
The capacity slide provides the means for con- screw compressor to efficiently handle a range
trolling specific process set points. By con- of volume ratios from as low as 1.2 up to 7.0.
tinuously adjusting the flow of gas through the
compressor, either suction or discharge pressure
in a particular process can be controlled. When
coupled with a microprocessor controller, the
adjustable capacity slide allows for precise and
continuous automatic control of any parameter
in the process to a chosen set point.
17
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...........................................................
Prohibition Symbol......................................................
18
Installation
Section
Installation Section ...................................................................................................... 19
19
20
Installation
21
Installation
In making up joints for steel pipe, the following bon piping, only wrought copper fittings should
procedures should be followed: be used. Cast fittings as used for water service
are porous and will allow the refrigerant to es-
For threaded connections, all threads on the pipe cape. Note this exception: In larger pipe sizes,
and fitting should be carefully cleaned to remove wrought fittings are not available. However,
all traces of grease or oil. Threads should then be specially tested cast fittings are available and
wiped dry with a lintless cloth. Only thread fill- these may be used with complete safety.
ing compounds suitable for refrigeration service
should be used for making steel pipe joints. These In larger pipe sizes, wrought fittings are not avail-
compounds should be used sparingly, and on the able. However, specially tested cast fittings are
pipe only. Do not put any on the first two threads available and these may be used with complete
to prevent any of the compound from entering the safety.
piping system. Acetylene or arc welding is fre-
quently used in making steel pipe joints, however, When soldering copper tubing joints, only sil-
only a skilled welder should attempt this kind of ver solder should be used for Refrigerant-22 ser-
work. Take care to see no foreign materials are vice. Soft solder such as “50-50” should never
left in the pipes and remove all burrs formed when be used, as its melting point is to low, lacks me-
cutting pipe. chanical strength, and tends to break down
chemically in the presence of moisture.
It is important to avoid short, rigid pipe lines that
do not allow any degree of flexibility. This must A second method would be to install flex-
be done to prevent vibration being transmitted ible pipe couplings as close to the compressor
through the pipe lines to the buildings. One unit as possible with connections run in two dif-
method of providing the needed flexibility to ab- ferent directions, 90° apart. These flexible con-
sorb the vibration is to provide long lines that are nections should be installed on both the high and
broken by 90° Ells in three directions. low side lines of the compressor unit.
Smaller Halocarbon and Hydroflourocarbon in- Hangers and supports for coils and pipe lines
stallations use copper pipes with solder type fit- should receive careful attention. During pro-
tings where possible. The use of screw type fit- longed operation of the coils, they may become
tings in Halocarbon systems should be held to an coated with ice and frost, adding extra weight to
absolute minimum, as these refrigerants, due to the coil. The hangers must have ample strength
their physical properties, will leak through screw and be securely anchored to withstand the vibra-
type joints. tion from the compressor and adequately sup-
port the pipe lines.
When drawn copper tubing is used for Halocar-
bon lines, type “K” or “L” conforming to ASTM Water supply and drain connections, and equip-
B88 should be used. Soft annealed copper tubing ment using water, should be installed so all the
conforming to ASTM B280 can also be used for water may be drained from the system after the
tube sizes not larger than 1-3/8" in outside diam- plant has been shut down in cold weather. These
eter. These requirements are in accordance with precautions will avoid costly damage to the
the mechanical code for refrigeration ANSI B9.1- equipment due to freezing.
1971. The type of copper tubing to be used for a
given pressure is dependent on the strength of the This information is taken from ASHRAE 15-89
copper at the design temperature. Some local and ANSI B31.5. The installing contractor
codes forbid the use of Type “L”. Therefore, be- should be thoroughly familiar with these codes,
fore installation, be sure to check local require- as well as any local codes.
ments. Never use type “M” as it does not have
adequate wall thickness to withstand the operat-
ing pressures. In selecting fittings for Halocar-
22
Installation
23
Installation
Charge a small amount of ammonia into the sys- condensables from the system before charging it
tem and pressurize the system to its respective with refrigerant. A combination of moisture and
design pressure. Pass a lit sulfur stick around all refrigerant, along with any oxygen in the sys-
joints and connections. Any leaks will be indi- tem, can form acids or other corrosive com-
cated by a heavy cloud of smoke. If any leaks are pounds that corrode internal parts of the system.
observed during this test, they must be repaired
and rechecked before the system can be consid- To properly evacuate the system, and to remove
ered tight and ready for evacuation. all non-condensables, air and water vapor, use a
high vacuum pump capable of attaining a
B. Halocarbon Refrigerant Systems blanked off pressure of 50 microns or less. At-
tach this pump to the system and allow it to op-
“Oil pumped” dry nitrogen, or anhydrous CO2 in erate until system pressure is reduced somewhere
this order of preference may be used to raise the below 1000 microns. Evacuation should not be
pressure to the proper level for testing. done unless the room temperature is 60F or
higher.
When the proper pressure is attained, test for leaks
with the soap mixture previously described. Af- Attach vacuum gauge(s), reading in the 20 to
ter all leaks are found and marked, relieve the 20,000 micron gauge range, to the refrigerant
system pressure and repair the leaks. Never at- system. These gauge(s) should be used in con-
tempt to repair soldered or welded joints while junction with the high vacuum pump. The read-
the system is under pressure. Soldered joints ing from the gauge(s) indicates when the system
should be opened and re soldered. has reached the low absolute pressure required
for complete system evacuation.
Do not simply add more solder to the leaking joint.
After all the joints have been repaired and the Connect the high vacuum pump into the refrig-
system is considered “tight” the system may be eration system by using the manufacturer’s in-
tested with refrigerant. structions. Connect the pump both to the high
side and low side of the system, to insure system
Attach a drum of the refrigerant to be used in the evacuation. Attach the vacuum gauge to the sys-
system and allow the gas to enter until a pressure tem in accordance with the manufacturer’s in-
of 5 psig is reached. structions.
Remove the refrigerant drum and bring the pres- A single evacuation of the system does not satis-
sure to the recommended test level with oil factorily remove all of the non-condensable, air
pumped dry nitrogen or CO2. Then check the and water vapor. To do a complete job, a triple
entire system again for leaks, using a halide torch evacuation is recommended.
or electronic leak detector. Be sure to check all
flanged, welded, screwed and soldered joints, all When the pump is first turned on, bring system
gasketed joints, and all parting lines on castings. pressure to as low a vacuum level as possible,
If any leaks are found, they must be repaired and and continue operation for 5 to 6 hours.
rechecked before the system can be considered
tight again, remembering that no repair should Stop the pump and isolate the system. Allow the
be made to welded or soldered joins while the sys- unit to stand at this vacuum for another 5 to 6
tem is under pressure. hours. After this time, break, the vacuum and
bring the system pressure up to 0 psig with dry
C. Evacuating The System nitrogen.
A refrigeration system operates best when only To begin the second evacuation, allow the pump
refrigerant is present. Steps must be taken to re- to operate and reduce the pressure again to within
move all air, water, vapor, and all other non- 50 to 1000 microns. After this reading is reached,
24
Installation
For the third evacuation, follow the previous pro- VSR 16” 20 to 27
cedure with the pump operating until system pres- VSR 20” 22 to 31
sure is reduced below the 1000 micron level. Run VSM 20” 20 to 25
the pump an additional 6 hours and hold the sys- VSM 30” 30 to 35
tem for approximately 12 hours at low pressure. 20” 30 to 40
After this, again break the vacuum with dry ni- 24” 40 to 50
trogen and allow the pressure in the system to 30” 60 to 75
rise slightly above zero pounds (psig). Install new 36” 95 to 105
drier cartridges and moisture indicators. Charge 42” 145 to 165
the system once more below the 1000 micron level
and use the refrigerant designed for the system.
The oil level may be above the top sight glass at
When properly evacuating the system as outlined this time. Later, when the unit is placed in op-
above, the system is dry, oxygen-free and free of eration, there will be some drop in the oil level
non-condensables. The piping should not be in- as the various oil lines, oil filter and other pip-
sulated before the evacuation process is started. ing becomes charged with the normal amount of
If moisture is in the system before evacuating, it oil that will be in circulation. This drop in oil
condenses in low places and freezes. If this hap- level should bring the level in the oil receiver/
pens, it can be removed by gently heating the trap separator into the normal operating range. Do
farthest away from the vacuum pump. This causes not mix oils.
the ice to melt and water to boil. Water vapor
collects in the next trap towards the vacuum pump. A. Oil For Single Screw Compressors
This process should be repeated until all pockets
of water have been boiled off, and the vacuum Due to the need for adequate lubrication, Vilter
pump has had a chance to remove all the water recommends only the use of Vilter lubricants,
vapor from the system. designed specifically for Vilter compressors.
With the extensive research that has been per-
VII. UNIT OIL CHARGING formed, we are able to offer refrigerant specific
lubricating oils. Use of oil not specified or sup-
The compressor unit is shipped from Vilter with plied by Vilter will void the compressor warranty.
no oil charge. The initial oil charge can be made
through the drain valve at the oil receiver/separa- Please contact your local Vilter representative or
tor. Vilter motor driven and manually operated the Home Office for further information.
oil chargers are available for this purpose. Once
the unit has been started and is operating above VIII. SYSTEM REFRIGERANT
50% capacity, oil may have to be added to bring CHARGING
the oil level to the normal operating point. With
the unit operating, oil should be added through CAUTION
the charging connection at the suction strainer.
The normal operating level is between the (2) sight When charging the system, make sure the com-
glasses on the oil separator. See Table 2 for ap- pressor unit is pressurized from the discharge
proximate oil charge requirements. side of the compressor. Pressurizing the com-
pressor from the suction side may cause rota-
tion of the compressor, without oil supply, which
could lead to internal damage.
25
Installation
1. Fans on air handling equipment running. 1. Connect a full drum of refrigerant to the
2. Pumps on water cooling equipment running. liquid charging valve. This valve is gener-
3. Proper location and attachment of thermo- ally located in the liquid line immediately
static expansion valve bulb to suction line. after the king or liquid line valve. Purge
4. Correct fan and pump rotation. the air from the charging line.
5. Evaporator pressure regulators and solenoid
valves open. 2. Invert the refrigerant drum if the drum is
6. Water pumps and motors correctly aligned. not equipped with “Liquid” and “Vapor”
7. Belt drives correctly aligned and tensioned. valves, and place in such a position so the
8. Proper voltage to motors. liquid refrigerant only can enter the sys-
tem. Close the liquid line or king valve, if
B. Compressors it is not already closed. Open the “Liquid”
charging valve slowly to allow refrigerant
1. Proper oil level. to enter the system. The vacuum in the
2. Voltage agrees with motor characteristics. system will draw in the refrigerant.
3. Properly sized motor fuses and heaters.
4. Direct drivers aligned and couplings tight. It is important that, during this operation,
5. All suction and discharge valves open. air handling units be running and water is
6. All transducers and RTD’s calibrated and circulating through the chillers. The low
reading correctly. pressures on the system can cause the re-
frigerant to boil at low temperature and
C. Condensers possibly freeze the water if it is not kept
circulating.
1. Water available at water cooled condensers
and supply line valve open. Water freezing in a chiller can rupture the
2. Water in receiver of evaporative condenser tubes and cause extensive damage to the
and makeup water available. system. It would be desirable to charge the
3. Correct rotation of pump and fan motors. initial amount of refrigerant without water
4. Belt drives aligned and tensioned correctly. in the shell and tube equipment to elimi-
5. Pump, fans and motors lubricated. nate the possibility of freeze up.
E. Initial Charging – High Side Charg- 4. Continue charging refrigerant into the sys-
ing tem until the proper operating requirements
are satisfied. Then, close the liquid charg-
There are two methods of charging refrigerant into ing connection and open the liquid line
the system, through the “high side” or through valve allowing the system to operate nor-
26
Installation
2. Check all pressure and temperature readings. Check movement of compressor rotor at drive
coupling end to determine bearing float. (Refer
3. Check micronic oil filter inlet and outlet to Service Section.)
pressures for excessive pressure drop.
Change filter when pressure drop exceeds E. Yearly
45 psi or every six months, whichever oc- (Items 1 thru 13 and “D” above plus 14 thru
curs first. For proper procedure for chang- 28)
ing micronic oil filter and for charging oil
into the system, see Operation Section. 14. Check entire system thoroughly for leaks.
4. Clean strainers each time filter cartridge if 15. Remove all rust from equipment, clean and
paint.
27
Installation
16. Flush out sediment, etc. from water circuits. G. Year Round Operation
18. Clean suction strainer – compressors. 1. Guard against liquid slugging of compres-
sor.
19. Check motors and fans for shaft wear and
end play. 2. Maintain unit in clean condition and paint
as necessary.
20. Check operation and general condition of
microprocessor and other electrical controls. 3. Grease valve stems and threads for the valve
caps.
21. Clean all water strainers.
When refrigeration equipment is operated 24
22. Check drains to make sure water will flow hours a day year round, it is highly recommended
away from equipment. that a yearly check of all internal parts be made
(see Service Section). While the highest mate-
23. Drain and clean entire oil system at receiver rial standards are maintained throughout all
drain. Recharge with new clean moisture Vilter compressors, continuous operation and any
free oil. For proper procedure for changing presence of dirt may prove injurious to the ma-
micronic oil filter and charging oil into the chine. To forestall needless shutdowns or pre-
system, see Start-Up and Operation section. vent possible machine breakdowns, the side cov-
ers should be removed yearly, and a visual in-
24. Check compressor coupling. For integrity spection be made of the internal parts. In this
and alignment. way, a small amount of time spent checking
machine conditions once a year may prevent
25. Check oil pump for wear. extensive shutdowns later with subsequent prod-
uct loss and expensive repairs.
26. Check the calibration of the microprocessor
pressure transducers and RTD’s for accuracy.
F. System Leaks
Name
Name
Correct Correct
Wrong
Wrong
Wrong
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.
29
Installation
These instructions are intended to help you to 1. Install key(s) in the shaft. If the hub is an
installand align the coupling. Covered here will interference fit, heat the hub in an oil bath or
be general information, hub mounting, alignment, oven until bore is sufficiently larger than the
assembly, locknut torquing, discpack replacement, shaft. 350º F. is usually sufficient. An open
and part numbers. The coupling as received, may flame is not recommended. However, if flame
or may not be assembled. heating is necessary, use a very large rose bud
*If assembled, the locknuts are not torqued. tip to give even heat distribution. A thermal
*If coupling is assembled, remove the bolts that heat stick will help determine hub tempera-
attach the hubs to the disc packs. Remove both ture. DO NOT SPOT HEAT THE HUB OR
hubs. Leave the disc packs attached to the center DISTORTION MAY OCCUR. With the hubs
member. expanded, slide it up the shaft to the desired
axial position. A pre-set axial stop device can
A. Hub Mounting: be helpful.
1. Clean hub bores and shafts. Remove any NOTE: All DBZ hubs have pressed in bushings.
nicks or burrs. If bore is tapered, check for good Make sure the bushings are facing the disc pack.
contact pattern. If the bore is straight, mea-
sure the bore and shaft diameters to assure
proper fit. The key(s) should have a snug side- C. Taper Bore:
to-side fit with a small clearance over the top.
1. Put the hub on the shaft without key(s)
NOTE: If the DBZ hub position on the shaft does inplace. Lightly tap hub up the shaft with a
not allow enough room to install the short bolts soft hammer. This will assure a metal-to-metal
in the hub after hub mounting, install the bolts fit between shaft and hub. This is the starting
and disc pack before mounting hub on shaft. point for the axial draw. Record this position
30
Installation
Note: These torques are approximate. Bolt and locknut threads must be coated with molybdenum
disulfide grease.
* Tightening torques are cadmium plated.
between shaft and hub face with a depth mi- This means there is a minimal amount of wavi-
crometer. Mount a dial indicator to read axial ness in the disc pack when viewed from the
hub movement. Set the indicator to “0”. Re- side. This will result in a flexing element that
move hub and install key(s). Remount hub, is centered and parallel to its mating flange
drawing it up the shaft to the “0” set point. faces. Move the connected equipment to ac-
Continue to advance hub up the taper to the complish the above.
desired axial position. Use the indicator as a
guide only. A pre-set axial stop device can be NOTE: The disc pack is designed to an optimal
helpful. Check the final results with a depth thickness and is not to be used for axial adjust-
micrometer. The hub may have to be heated in ments.
order to reach the desired position on the shaft.
DO NOT SPOT HEAT THE HUB OR DIS- As a guide, maximum and minimum values for
TORTION MAY OCCUR. Install shaft lock- dimension “E” are given. These dimensions are
nut to hold hub in place. suggested for initial installation. Additional ca-
pacity is available to compensate for thermal and
D. Shaft Alignment. structural movement. Maximum axial capacity
values for these couplings are also given. See chart
Move equipment into place. above.
a. Soft Foot. The equipment must sit flat on its c. Angular Alignment. Rigidly mount a dial in-
base. Anysoft foot must be corrected now. dicator on one hub or shaft, reading the face of
the other hub flange, as shown on next page.
b. Axial Spacing. The axial spacing of the shafts Rotate both shafts together, making sure the
should be positioned so that the disc packs shaft axial spacing remains constant. Adjust
(flexing elements) are flat when the equipment the equipment by shimming and/or moving so
is running under normal operating conditions. that the indicator reading is within .002 inch
per inch of coupling flange.
31
Installation
Note: If the driver or driven equipment alignment b. Remove the long bolts. Mount the disc packs
specification is tighter than these recommenda- on the hubs with one bolt through the disc pack
tions, the specification should be used. Also, be aligned with a clearance hole in the hub. In-
sure to compensate for thermal movement in the stall the short bolts through the hub, disc pack,
equipment. The coupling is capable of approxi- bevel washer or link, and secure with a lock-
mately four time the above shaft alignment toler- out.
ances. However, close alignment at installation
will provide longer service with smoother opera- NOTE: All bolt threads should be lubricated. A
tion. clean motor oil is recommended. On size 226 and
larger, a link must be put on bolt first. Remove
Note: Alignment of C- the disc pack alignment bolt. Proceed to mount
Flange Units should be
checked when compressor
the second disc pack to the other hub in the same
or motor are replaced. way.
32
Installation
33
Installation & Calibration
34
Installation & Calibration
during the calibration process. To prevent stated earlier, the actuator voltage will
damage to the actuators, do not connect the fluctuate during calibration. After the
yellow power cable or the gray position actuator has been calibrated, 0V output
transmitter cable until instructed to do so will correspond to the minimum position
later on. and 5V to the maximum position.
6. Open the plastic cover of the capacity 14. Note: The “Slide calibration” screen on
motor by removing the four #10 screws. the Vission/Vantage has a “Current”
Caution: there are wires attached to the window, which displays twice the actuator
connector on the plastic cover. Handling output voltage. This value, (the % volume
the cover too aggressively could break and the % capacity) displayed in the
the wires. “Current Vol” and Current Cap” Windows
are meaningless until calibration has been
7. Gently lift the cover and tilt it toward the completed.
Turck connectors. Raise the cover enough
to be able to press the blue calibrate button 15. Use the DEC button on the Vission/
and be able to see the red LED on the top Vantage panel to drive the slide valve to its
of assembly. minimum “mechanical stop” position. Do
not continue to run the actuator in this
8. Press “Menu” on the main screen and then direction after the slide valve has
press the “Slide Calibration” button, to reached the stop. Doing so may cause
enter the slide calibration screen. (Note: damage to the actuator or the slide
you must be in this slide calibration screen valve. When the slide has reached the
before attaching the yellow power cable or mechanical stop position, use the INC
gray position transmitter cable.) button to pulse the actuator to where the
slide is just off of the mechanical stop and
9. Now connect the yellow power cable and there is no tension on the motor shaft.
the gray position transmitter cable to the
actuator. 16. Quickly press and release the blue button
on the actuator again. The red LED will
10. Press INC and DEC to move the slide now flash at a slower rate, indication that
valve and check for the correct rotation. the minimum slide valve position (0V
See Table 1on page 48 for Actuator/ position) has been set.
command shaft rotation specifications.
17. Use the INC button on the Vission/Vantage
11. Note: If the increase and decrease buttons panel to drive the slide to its maximum
do not correspond to increase or decrease “mechanical stop” position. Do not
shaft rotation, swap the blue and brown continue to run the actuator in this
wires of the “yellow power cable”. This direction after the slide valve has
will reverse the rotation of the actuator/ reached the stop. Doing so may cause
command shaft. damage to the actuator or the slide
valve. When the slide valve has reached
12. Quickly press and release the blue push the mechanical stop position, use the DEC
button on the actuator one time. This button to pulse the actuator to where the
places the actuator in calibration mode. slide is just off of its mechanical stop and
The red LED will begin flashing rapidly. there is no tension on the motor shaft.
13. Note: When the actuator is in calibration 18. Quickly press and release the blue button
mode, it outputs 0V when the actuator is on the actuator one more time. The red
running and 5V when it is still. Thus, as LED will stop flashing. The actuator is
35
Installation
now calibrated and knows the minimum calibration and exit the “Slide Calibration”
and maximum positions of the slide valve screen. The controller will automatically
it controls. Now the capacity or volume energize the actuator and drive it back to
channel of the Vission/Vantage can be its minimum position (below 5%) for pre-
calibrated. start-up.
19. Use the Dec button to move the actuator 26. Note: Now the “Current Cap” or the
towards its minimum position while “Current Vol” value will be displayed in
watching the millivolt readout on the the window on the “Main” screen and the
Vission/Vantage screen. Discontinue “Slide Calibration” screen.
pressing the DEC button when the milli-
volt reading in the “Current” window above 27. Gently lower the plastic cover over the top
the “Set Min” button is approximately 500 of the actuator to where it contacts the base
millivolts. and o-ring seal. After making sure the
cover is seated properly, gently tighten the
20. Now use the DEC and INC buttons to four #10 screws. Caution: The plastic
position the slide valve until a value close cover will crack if the screws are over
to 300 millivolts is on the screen. Then, tightened.
press the “Set Min” button for the capacity
or volume slide valve window to tell the 28. Enable the “Slide Non-Movement Alarm”
controller that this is the minimum by going to the “Setup” menu and choosing
millivolt position. Note: The value in the “Alarm Enable” for the “Slide Non-
“Current Cap” or “Current Vol” window Movement Option”.
has no meaning right now.
29. This completes the calibration for this
21. Use the INC button to rotate the actuator channel either capacity or volume. Repeat
towards its maximum position while the same procedure to the other channel.
watching the millivolt readout on the
controller screen. Discontinue pressing the
INC button when the millivolt reading in
the “Current” window is approximately
9200 millivolts (7900 millivolts for the
2783J qualified analog boards). You are
nearing the mechanical stop position.
36
Slide Valve Actuator Troubleshooting Guide
Slide Valve Actuator Theory of Operation the saved motor position is read from EEPROM
memory and the actuators resumes normal function
The slide valve actuator is a gear-motor with a
position sensor. The motor is powered in the for- This scheme is not foolproof. If the motor is moved
ward and reverse directions from the main com- manually while the power is off or the motor brake
puter in the control panel. The position sensor has failed, allowing the motor to free wheel for too
tells the main computer the position of the slide long after the position sensor looses power, the ac-
valve. The main computer uses the position and tuator will become lost.
process information to decide where to move the
slide valve next. A brake failure can sometimes be detected by the po-
sition sensor. If the motor never stops turning after
The position sensors works by optically counting a power loss, the position sensor detects this, knows
motor turns. On the shaft of the motor is a small it will be lost, and goes immediately into calibrate
aluminum “photochopper”. It has a 180 degree mode when power is restored.
fence that passes through the slots of two slotted
optocouplers. The optocouplers have an infra-
red light emitting diode (LED) on one side of the
slot and a phototransistor on the other. The
phototransistor behaves as a light controlled
switch. When the photochopper fence is block-
ing the slot, light from the LED is prevented from
reaching the phototransistor and the switch is
open. When photochopper fence is not blocking
the slot, the switch is closed.
37
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 white calibrate wire in the grey Tape the end of the white wire
Turck cable is grounded in 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
malfunction air.
The calibrate button is stuck down Try to free the stuck button.
Push button is being held down for Depress the button quickly and
more that ¾ second when going then let go. Each ¾ second the
through the calibration procedure button is held down counts as
another press.
The actuator goes into calibra- The white calibrate wire in the grey Tape the end of the white wire
tion mode spontaneously Turck cable is grounding intermit- in the panel and make sure that
tently it cannot touch metal.
38
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 Get the motor brake to where it op-
properly erates freely and then recalibrate.
There is a rapid clicking noise The photochopper is misaligned Try to realign or replace the ac-
with the slotted optocouplers tuator.
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.
The motor operates in one direc- There is a loose connection in the Tighten.
tion only screw terminal blocks
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.
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.
39
Slide Valve Actuator Troubleshooting Guide
The motor runs sporadically Bad thermal switch Replace the actuator.
The motor runs but output shaft Stripped gears inside the gear motor Replace the actuator.
will not turn or the armature has come un-pressed
from the armature shaft
40
Operation
Section
Operation Section ........................................................................................................ 41
41
Notice on using Non -Vilter Oils
Oil and its additives are crucial in refrigeration system performance. Vilter Manufacturing will NOT
APPROVE non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available it is
not possible for us to test all oils offered in the market place, and their effects on our equipment, as we can
with our own lubricants.
We realize that customers may choose compressor lubricants other than Vilter branded oil. This is cer-
tainly within the customers’ right as owners of the equipment. When this choice is made, however, Vilter
is unable to accept responsibility for any detrimental affects those lubricants may have on the equipment
or system performance and durability.
Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warranty
upon evaluation of the issue. This includes any parts’ failure caused by inadequate lubrication.
Certainly, there are many good refrigeration lubricants in the market place. The choice of a lubricant for
a particular application involves consideration of many aspects of the lubricant and how it and its additive
package, will react in the various parts of the entire refrigeration system. It is a complex choice that
depends on a combination of field experience, lab and field-testing, and knowledge of lubricant chosen.
Vilter will not accept those risks other than for our own compressor lubricants.
42
Operation
43
Operation
44
Operation
to follow all Local, State and Federal ordinances re- the cover assembly in place. On units
garding the recovery of refrigerants. equipped with dual element tanks, insert in-
ner element and make sure it fits onto the
Drain the filter bowl or housing in to an appropriate outlet connection. Put the centering piece
container and dispose of the oil in a appropriate on the outer element and slide into tank mak-
manner following all Local, State and Federal ordi- ing sure the center piece fits into the inner
nances regarding the disposal of used refrigeration element. Put spring plate on outer element
oil. and bolt the cover assembly in place.
CAUTION
Unscrew the bolts holding the cover flange to the
When changing filter, discard clogged filter
tank. Remove the cover flange and spring plate.
only. Save and reuse spring plate and center-
Pull out the filter element(s). Before reassembling,
ing piece. This filter MUST be installed with
thoroughly clean the tank and spring plate to
the spring plate. A compressor that is allowed
lengthen the life span of the filter element(s).
to operate without the spring plate is running
with unfiltered oil.
D. Oil Cooling
45
Operation
1/4” Fine
Adjustment Valve
FIGURE 4.
TYPICAL WATER COOLED OIL COOLER FIGURE 5.
DIAGRAM TYPICAL LIQUID INJECTION OIL COOLING
SCHEMATIC DIAGRAM
The solenoid valve provides positive water
shut-off when the compressor is not in opera- Liquid injection cooling on booster compressors is
tion. handled in the following manner. Using high pres-
sure liquid, the point of injection can be the dis-
A temperature of 150°F is considered high in charge line and no horsepower penalty is paid by
most circumstances and the compressor is pro- injecting liquid into the compressor discharge line.
tected by a safety control to prevent operation The high pressure gas source normally used for the
of the compressor above this temperature. pressure regulator would be compressor discharge
Unless otherwise specified, the oil cooler is pressure. Since, on a booster unit, this intermediate
sized for an 85°F water inlet temperature and pressure is very rarely as high as the nominal set-
10°F temperature rise. ting of 70 psig, high stage discharge gas is used.
2. Liquid Injection Oil Cooling. On high stage compressors, the liquid is injected
directly into the compressor. However, there is a
The components are furnished with liquid in- horsepower penalty when the liquid is injected into
jection for a typical system. The liquid sole- the compressor. This will vary with refrigerant and
noid valve opens whenever the compressor is operating condition. The liquid is injected into the
in operation. The thermostatic expansion valve compressor at a point in the compressor cycle that
controls the flow of liquid refrigerant to the minimizes the brake horsepower penalty.
compressor injection port in response to the
discharge temperature. The discharge tempera- 3. V-PLUS Oil Cooling System
ture is maintained at a minimum of 120°F with
a maximum of 140°F. The discharge tempera- This system consists of a liquid pump, shut-off
ture can be adjusted either of two ways. First, valves, motor, solid state variable speed controller
the small outlet pressure regulator can be used and solid state temperature controller. This method
to adjust superheat. Normally, this regulator of oil cooling is not available on the VSM or VSR
should be adjusted to maintain 70 psig pres- compressor units.
sure at the external equalizing port of the ex-
pansion valve. Raising the pressure beyond The pump and solenoid valve cycle on and off in
70 psig tends to raise the discharge tempera- parallel with the compressor drive motor. The tem-
ture, while lowering the pressure lowers the perature controller receives a temperature signal
discharge temperature. Secondly, the standard from the sensor located in the discharge and oil lines
superheat adjusting screw on the thermostatic and in turn, sends a signal to the motor speed con-
expansion valve can be used to adjust the dis- troller. As the oil and desupserheating load varies,
charge temperature.
46
Operation
the temperature controller adjusts the speed sure transducers. To use the block and bleed
of the pump/motor combination to maintain valves to recalibrate the pressure transducers, the
a constant oil temperature. block valve is shut off at the unit and the pressure
is allowed to bleed off by opening the bleed valve
NOTE: near the pressure transducer enclosure. The trans-
ducer can then be calibrated at atmospheric pres-
See separate V-PLUS® instruction manual for
sure (0 psig), or an external pressure source with
detailed start-up and operation.
an accurate gauge may be attached at the bleed
valve.
4. Thermosyphon Oil Cooling
The discharge pressure transducer cannot be iso-
Using a brazed plate or an one pass shell lated from its pressure source, so it is equipped
and tube type vessel, similar to the water with only a valve to allow an accurate pressure
cooled oil cooler, oil is circulated on the shell gauge to be attached and the pressure transducer
side and liquid refrigerant from the receiver calibrated at unit pressure.
is
circulated through the tubes.Thermosyphon Recheck the transducers periodically for any drift
systems use a 3-way temperature sensing of calibration.
control valve to regulate oil at 120°F. Oil is
bypassed around the thermosyphon oil cooler. A. Screw Compressor Control And
When oil is higher than 120°F, the oil is Operation
passed through the thermosyphon oil cooler.
A 1/4” tubing line w/valve adds high pres- 1. Starting, Stopping and Restarting
sure gas to the oil to quiet the sound of injec- the Compressor
tion. Open this valve in small amounts, until
noise subsides. Before the screw compressor unit may start,
certain conditions must be met. All of the
The closed type cooling circuit is free from safety setpoints must be in a normal condi-
the fouling problems associated with open tion, and the suction pressure must be above
circuit water cooling. Since the oil cooling the low suction pressure setpoint to assure
load is rejected in the condenser, this type of that a load is present. When the “On-Off”
cooling is practical. The temperature limits switch or “Manual-Auto” button is pressed,
here are the same as those regarding the the oil pump will start. When sufficient oil
water cooled oil coolers. pressure is built up and the compressor ca-
pacity control and volume ratio slide valves
II. CONTROL SYSTEM are at or below10%, the compressor unit will
start.
Equipped for automatic operation, the screw com-
pressor unit has safety controls to protect it from If the compressor is in the automatic mode,
irregular operating conditions, an automatic start- it will now load and unload and vary the
ing and stopping sequence, capacity and volume volume ratio in response to the system de-
ratio control systems. mands.
Check all pressure controls with a remote pres- Stopping the compressor unit can be accom-
sure source, to assure that all safety and operat- plished a number of ways. Any of the safety
ing control limits operate at the point indicated setpoints will stop the compressor unit if an
on the microprocessor. abnormal operating condition exists. The
compressor unit “On-Off” or stop button will
The unit can be equipped with optional block and turn the compressor unit off as will the low
bleed valves that are used to recalibrate the pres- pressure setpoint. If any of these conditions
47
Operation
COMMAND SHAFT ROTATION NO. OF TURNS / ROTATION ANGLE / SLIDE TRAVEL
COMP. CAPACITY VOLUME CAPACITY VOLUME
MODEL INC DEC INC DEC TURNS/ANGLE/TRAVEL TURNS/ANGLE/TRAVEL
VSR 111 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSR 151 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSR 221 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSR 301 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSS 451 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSS 601 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSS 751 CCW CW CCW CW 1.09 / 392 / 4.283" 0.63 / 227 / 2.473"
VSS 901 CCW CW CCW CW 1.09 / 392 / 4.283" 0.63 / 227 / 2.473"
VSS 1051 CCW CW CCW CW 1.22 / 439 / 4.777" 0.74 / 266 / 2.889"
VSS 1201 CCW CW CCW CW 1.22 / 439 / 4.777" 0.74 / 266 / 2.889"
VSS 1501 CCW CW CCW CW 1.36 / 490 / 5.325" 0.82 / 295 / 3.200"
VSS 1801 CCW CW CCW CW 1.36 / 490 / 5.325" 0.82 / 295 / 3.200"
VSM 71 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 91 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 101 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 151 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 181 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 201 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 301 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 361 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 401 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 501 CCW CW CCW CW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSM 601 CCW CW CCW CW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSM 701 CCW CW CCW CW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
Note:These refer to the old stlye gear motors and DO NOT apply to the optical motors.
Table 1
turns the compressor unit off, the slide valve mo- 2. Slide Valve Control Gear Motors
tors will immediately energize to drive the slide
valves back to 5% limit. The control motors will Capacity and volume ratio control of the
be de-energized when the respective slide valve screw compressor is achieved by movement
moves back below 5%. If there is a power failure, of the respective slide valves, actuated by
the compressor unit will stop. If the manual start electric motors.
on power failure option is selected (see appropri-
ate Microprocessor Instruction Manual), restart- NOTE:
ing from this condition is accomplished by push- The manual operating shaft on the gear motor
ing the reset button to insure positive operator should be turned the opposite direction of the
control. If the auto start on power failure option desired command shaft rotation.
is selected (see appropriate Microprocessor In-
struction Manual), the compressor unit will start The older capacity and volume control mo-
up after a waiting period. With both options, the tors are equipped with a brake. If it is neces-
compressor slide valves must return below their sary to operate the control motors manually,
respective 5% limits before the compressor unit the brake must be disengaged. The brake
can be restarted. can be disengaged by pushing on the motor
shaft on the cone end. The shaft should be
centered in its travel. Do not use excessive
force manually operating the motor or dam-
age may result.
48
Operation
View Capacity
Instruction Manual.)
Note: Optical
Actuators CAN NOT 3. Oil Separator Heater
be manually rotated.
( VSM 501-701 will The oil separator heater keeps the oil in the
have motor locations separator from becoming too viscous and
opposite of figure #6) helps to boil off refrigerant entrained in the
oil in the receiver section of the separator.
4. Econ-O-Mizer Controls
FIGURE 6.
SLIDE VALVE MOTOR LOCATION Econ-O-Mizer® systems are of three types:
direct expansion, flooded or flash. Flash
When viewing the compressor from the dis- systems include a back pressure regulator to
charge end (opposite the drive end), the up- control intermediate pressure.
per motor is for capacity control. The com-
mand shaft turns (see Table 1) to decrease When a direct expansion system is used, a
the capacity to 10% and reverses to increase solenoid valve and thermostatic expansion
the capacity to 100%. The lower motor is valve are furnished to control the degree of
for volume ratio control. The command shaft subcooling. If a flooded subcooler system
turns (see Table 1) to reduce the volume ra- or flash system is supplied, it is equipped
tio to 2.0, and reverses to increase the vol- with a liquid solenoid valve and a float
ume ratio to 5.0. switch to control the liquid level in the ves-
sel.
Actuation of the electric motors can be done
manually or automatically. To actuate the B. Safety Setpoints
motors manually, place the desired mode
selector in the manual position and push the A detailed explanation of all safety setpoints can
manual Increase or Decrease buttons. In the be found in the appropriate Microprocessor In-
automatic mode, the microprocessor deter- struction Manual.
mines the direction to actuate the electric
motors. However, in the automatic mode, 1. Oil Pressure
there is an “On” and “Off” time for the ca-
pacity control motor. The “On” time is the Low oil pressure differential stops the com-
time in which the slide valve moves, and the pressor unit when there is an insufficient
“Off” time is the time in which the system is difference in pressure between the oil mani-
allowed to stabilize before another change fold and suction.
in slide valve position.
2. Discharge Pressure
The Motor Amps Load Limit protects the
compressor from overloading by decreasing High discharge pressure cutout stops the
the compressor capacity if the motor amper- compressor unit, when the discharge pres-
age is at the Maximum Amps setpoint, or pre- sure in the oil separator exceeds the setpoint.
venting an increase in capacity if the motor
amperage is above the Full Load Amps
setpoint. (See appropriate Microprocessor
49
Operation
Low suction pressure cutout stops the 4. Manually open the oil isolating valve at the
compressor unit when the suction pres- oil separator outlet connection.
sure drops below the setpoint.
5. Open the isolating valve(s) before and after
4. Oil Filter Differential the oil filter housings.
High oil filter differential cutout stops 6. On packages with a full time oil pump, make
the compressor unit when the difference sure the manual opening stem on the oil
between the outlet and inlet of the filter regulating valve is in the auto position. See
exceeds the setpoint. manufacturer’s literature for details.
The oil temperature cutout stops the 7. Manually open the stop valve on the oil bleed
compressor unit when the oil tempera- return line from the element section and open
ture is too high or too low. the expansion valve 1/3 of a turn.
50
“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.
CLOSED
In the manually “Closed Postion”, the
stop check is operating as a conven-
tional 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.
52
Pre-Start Up
Check List
53
PRE START-UP CHECKLIST
FIELD PIPING AND MECHANICAL
REQUIREMENTS
NOTE: If start-up service has been purchased, the following items should be completed before the start-up
man arrives. This will help save time and money.
_____ 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 is shipped loose and must be installed in a vertical up f
low 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 the Stop/Check Valve be located to minimize the
quantity of liquid that can accumulate downstream of the valve.
_____ 4. A Dual Safety Relief Valve is shipped loose for field installation. A connection is provided
on the oil separator for the relief valve. Refer to ASHRAE/ANSI Standard 15 (Safety
Code for Refrigeration) for proper sizing and installation of Relief Valves and Vent Lines.
a) Liquid Injection
An adequate, or dedicated, liquid line is required for the Liquid Injection System. A high pressure
liquid source must be piped to the stop valve at the inlet of the Thermostatic Expansion Valve. On
booster units, an additional 3/8” line must be piped to the regulator from high stage discharge gas f
or the Thermostatic Expansion Valve.
b) V-PLUS
A high pressure liquid source must be run to the V-PLUS® inlet. Some subcooling is desirable. A
high pressure float must be installed at the inlet of the pump and a 3/8” vent line must be returned to
a suction trap. Refer to the V-PLUS manual for additional information.
c) External Oil Cooler
On thermosyphon oil coolers, the refrigerant lines must be connected to the front head of the oil
cooler. On water cooled oil coolers, the water lines must be connected to the front head of the oil
cooler. Installation of water regulating and solenoid valves are recommended.
_____ 6. The oil separator should be provided with oil until the oil level is between the (2) sight
glasses. An oil charging connection is provided on the bottom of the oil separator.
_____ 7. The center member of the compressor coupling is shipped loose to help facilitate final f
ield alignment and allow for motor rotation check. The motor alignment should be within
0.004” total indicator reading in all directions.
a) Both the compressor and motor hubs should be checked for concentricity and perpendicularity.
b) The motor should be checked and shimmed for soft foot prior to attempting final alignment.
c) The center section of the coupling should be left out to allow the start-up technician to verify the
final alignment and motor rotations.
_____ 8. The unit should be pressure tested, evacuated and a system load should be available at the
time of start-up.
54
PRE START-UP CHECKLIST
FIELD WIRING REQUIREMENTS
VILTER MANUFACTURING CORPORATION
VRS SCREW COMPRESSOR, VSS/VSM SINGLE SCREW COMPRESSOR UNITS
PRESTART-UP CHECKLIST
FIELD WIRING REQUIREMENTS FOR UNITS WITH FACTORY WIRED VISSION® MICROPROCESSORS
NOTE: If startup service has been purchased, to save time and money, the following items should be completed before
the startup technician arrives.
The unit is pre-wired at the factory. The necessary field wiring connections are described below.
1. Control power of 115 VAC 50/60 HZ must be wired to the left side terminals of the digital I/O board inside the
ViSSion® cabinet. Line power (L1) is brought in to a 10-amp fuse via the terminal marked “L1” on the appro-
priate connector. The neutral (L1A) is brought in and connected to any of the “N” terminals located on left
connectors. Two separate line power feeds for the oil heaters are brought to two additional 10 amp fuses via the
terminals marked “L2” and “L3” on the same connector just below the “L1” terminal. The neutrals for these
circuits (L2A and L3A) are also connected to any of the “N” terminals. For units with V-PLUS® oil cooling, L1
must also be brought to the fuse in the V-PLUS® panel, and L1A must also be brought to the terminal #2B in the
V-PLUS® panel.
2. An auxiliary contact from the compressor motor starter is required. This isolated contact is connected to the K-
1 input relay using any of the “L” terminals on the strip of connectors, and returned to the terminal marked
“Motor Starter Aux. Safety” at the very top connector.
3. A dry contact from control relay K-22 must be wired to the compressor motor starter coil. This dry contact is
wired to terminals marked “Compressor Start – N.O. #1A” and “Compressor Start – N.O. #1B”. Control power
for this coil should come from a source, which will be de-energized with the compressor disconnect.
4. A dry contact from control relay K-19 must be wired to the oil pump motor starter coil. This dry contact is wired
to the two terminals marked “Oil Pump Starter”. Control power for this coil should come from a source, which
will be de-energized with the compressor disconnect.
5. An auxiliary safety cutout is available to shut down the compressor package using the K-2 input relay. A dry
contact must be supplied and wired to one of the “L” terminals on any of the connectors, and returned to the
terminal marked “Auxiliary #1 Safety” at the top connector. The jumper to the “Auxiliary #1 Safety” terminal
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.
6. Indication of the compressor alarm or shutdown status is also available via two control relays. Relay K-20 is
provided for remote trip indication and relay K-21 is provided for remote alarm indication. Each relay has three
terminals available: a common input, a normally open contact, and a normally closed contact. For both relays,
the energized state represents a “trip” or “alarm” condition. Loss of voltage to the relay coil and the resultant
return to normal state indicates “safe” condition.
7. The current transformer supplied in the compressor motor conduit box should be checked to insure that the
motor leads of one leg are pulled through the transformer. Note that there is a dot on one side of the current
transformer. This dot must face away from the motor. Typically, a wye delta started motor should have leads 1
and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as different
motors and starting methods will require different leads to be used.
55
Service Section
Service Section ............................................................................................................. 56
56
Service Section
57
Operation
* Applies only to units with V-PLUS® oil *** Applies only to units with water cooled oil
cooling. cooler.
Refer to V-PLUS manual for detailed instructions. ***9. The water supply to the cooler should
be opened.
*9. Manually open the stop valve at the inlet and
outlet of the V-PLUS system. ***10. Verify the water solenoid valve does
open with the compressor motor
*10. Open the needle valve in the ¼” oil supply starter.
line to the V-PLUS pump.
***11. Open 1/4” high pressure gas line valve
piped to oil injection line just enough
*11. The manual opening stem on the solenoid to quiet compressor at 100% capacity.
valve should be in the automatic position
(turned counter clockwise or out).
51
Service
When working on the compressor, care must be C) Isolate the unit by manually closing the dis-
taken to ensure that contaminants (i.e. water from charge Stop/Check valve. If the unit is
melting ice, dirt and dust) do not enter the com- equipped with a V-PLUS® or liquid injection
pressor while it is being serviced. It is essential cooling system, close the liquid supply valves
that all dust, oil or ice that has accumulated on and open all solenoid valves to prevent liq-
the outside of the compressor be removed before uid refrigerant from being trapped between
servicing the compressor. the stop valves and solenoid valves. Allow
the unit to equalize to suction pressure be-
When servicing the compressor, all gaskets, O- fore closing the Suction Bypass or Stop/
rings, roll pins and lock washers must be replaced Check valve. After the unit has equalized to
when reassembling the compressor. suction pressure and suction valve closed,
use an acceptable means to depressurize the
It is important that if the refrigerant requires the unit that complies with all Local, State and
use of a Polyolester (POE) refrigeration oil, that Federal Ordinances.
all oil is removed from the compressor unit after
D) Remove drain plugs from the bottom
the unit has been opened to the atmosphere for
ofcompressor housing and the discharge
servicing. POE refrigeration oils are highly
manifold On units equipped with Suction Oil
hydroscopic and will absorb large quantities of
Injection (SOI) manually open the SOI sole-
moisture in a short time, when exposed to the
noid valve below the compressor. Drain the
atmosphere during servicing. Once the moisture
oil into appropriate containers.
is absorbed into the oil it is nearly impossible to
remove the moisture from the oil.
0.02 REMOVAL OF COMPRESSOR
0.01 PREPARATION OF UNIT FOR
FROM THE UNIT
SERVICING
After Preparing the unit for service the following
steps should be followed when removing the com-
pressor from the unit:
A) Disconnect the motor drive coupling from the
compressor input shaft.
B) Disconnect all gas and oil piping which is
attached to the compressor. When removing
A) On Cool Compression units, while the unit is
the suction strainer on VSS/VSM units or the
running, close the main liquid ammonia line
suction line from VSR units, the suction line
(located before the thermostatic expansion
should be supported to prevent it from sag-
valve) and wait for the unit to stop by itself.
ging.
This operation will remove all the liquid am-
monia from the separator. The compressor C) Replace oil drain in compressor housing and
will stop when the superheat at discharge discharge manifold after oil has stopped
reaches 25°F. draining.
B) Shut down the unit, open the electrical dis-
connect switch and pull the fuses for the com-
pressor motor to prevent the unit from start-
ing. Put a lock on the disconnect switch and
tag the switch to indicate that maintenance All Oil must be removed from unit.
is being performed.
58
Service
G) Lift compressor from the base, verify the B) Break the vacuum on the unit using refriger-
amount of room needed for clearance and ant or dry nitrogen and check for leaks. Con-
weight of the bare compressor when the com- centrate on areas where work was done.
pressor is removed from the unit. C) If no leaks are found, the unit can be returned
to service if refrigerant was used for the leak
0.03 INSTALLATION OF THE detection gas.
COMPRESSOR
If dry nitrogen was used for the leak detec-
A) After the work has been completed, reinstall tion gas, the nitrogen must be purged from
the compressor on the base or C-flange the unit and step A and B should be repeated,
adapter (dependent upon compressor model). this time breaking the vacuum with refriger-
ant. The unit may now be returned to ser-
vice.
B) On the VSS units, replace the shims under the
compressor feet. Check for a soft foot. This
is accomplished by tightening down three of
the hold down bolts and checking the clear-
59
Service
CAUTION
MAIN GATE
Bearing Float 0.003” 0.002”
Maximum Force 300 to 500 200 to 300
Lbs. Lbs.
60
Service
C) Gate rotor bearing float. VSR 111 THRU VSS 601 0.045”
VSS 751 & VSS 901 0.055”
1) Remove the side covers and position a VSS 1051 & VSS 1201 0.060”
dial indicator on the gate rotor. VSS 1501 & VSS 1801 0.060”
2) Use a lever arm pivoting on a bolt with a
small block of wood against the gate ro- E) Readings could be higher than 0.020. If
tor blade to protect the blade. readings is greater than 0.030 over table
3) The maximum amount of bearing float tolerance contact Vilter’s home office.
should not exceed 0.002”. F) Inspect the main and gate rotors for
signs of abnormal wear due to dirt or
other contaminants.
G) After the inspection is complete, the
covers, coupling center member and
guard can be reinstalled and the unit can
then be evacuated and leak checked be-
fore starting.
MODEL FLOAT
61
Service
NOTE:
All parts must be kept with their appropriate side
and not mixed when the compressor is reas-
sembled.
62
Service
910
F) Hold the gate rotor support with a suitable
wrench on the flats provided near the roller
bearing housing. Remove the inner retainer 911 Use flats provided
bolts and the retainer. To remove the thrust on gaterotor
bearing housing, install the thrust bearing support to prevent
removal and installation tool with the smaller
901
rotation when
puller shoe. Turn the jacking screw clock- removing bearing
wise. The thrust bearings and housing as- retainer.
sembly will be pulled off the shaft and out of 110
the frame.
G) Remove the bolts on the roller bearing hous-
ing. Thread two bolts into the jack screw
holes provided in the housing to assist in re-
moving it.
H) To remove the gate rotor support, carefully
move the support opposite the direction of 112
rotation and tilt the roller bearing end to-
wards the suction end of the compressor. The
152
compressor input shaft may have to be turned
to facilitate the removal of the gate rotor sup-
port. On dual gate compressor units, repeat
the procedure for the remaining gate rotor
support assembly.
63
Service
64
Service
65
Service
901
66
Service
67
Service
68
Service
69
Service
70
Service
71
Service
72
Service
2.01 INPUT SHAFT SEAL REMOVAL Seal with stationary carbon face (219B) and
rotating mirror face (219C).
A) Prepare the compressor for servicing as out-
lined in section 0.01. Current Shaft Seal and for all Replace-
ment.
B) Remove bolts (281) holding the shaft seal
cover (218). Insert two of the bolts into the
threaded jacking holes to assist in removing 281 219A 219C
the cover. There will be a small amount of
oil drainage as the cover is removed.
C) Remove the rotating portion of the shaft seal
(219C).
73
Service
261
NOTE:
When replacing the stationary members of the
seal on the VSR 111 thru VSR 301, and VSS
451 and VSS 601, the roll pin in the cover is
260 used only with the seal assembly having a sta-
tionary mirror face. If a seal assembly with a
stationary carbon face is installed, the roll pin
must be removed.
CAUTION
265
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.
74
Service
Maintenance Suggestion:
75
Service
76
Service
77
Service
78
Service
79
Service
C) Disconnect the motor and potentiometer F) Slide the collar until it is flush with the end
leads. of the actuator shaft. Check to make sure
the key is fully inserted in the actuator shaft.
D) Remove the four 5/16” hex head cap screws The key should be flush with the end of the
holding the motor support to the mounting actuator shaft.
plate. Remove the gear motor assembly.
G) Tighten the shaft collar ¼” socket head cap
E) Remove the ¼” retaining nut, washer and screw to 16 ft/lbs. (192 in/lbs.). Failure to
plastic gear from the end of the command correctly torque the locking screw may re-
shaft. Loosen the set screw securing the sult in a failure of the actuator.
large drive gear to the command shaft. Re-
tain drive key for possible re-use with new H) Install the side covers to the bracket with
actuator assembly. hex washer head self tapping screws.
B) On certain units with economizer, the ac- The following steps can be used to remove or
tuator bracket may have to be rotated from install either the capacity or volume command
its original position with the motor. To ac- shaft assemblies.
complish this remove the four hex head cap A) Prepare the compressor for servicing as out-
screws holding the bracket to the motor. lined in section 0.01.
Rotate the motor from the original posi-
tion. Make sure the electrical connections B) Follow the appropriate instructions to re-
on the actuator are not to the top position. move control actuator as outlined in sections
This will allow enough clearance between 4.01 or 4.10.
the motor and economizer line.
80
Service
Old Style Motor Plate
446
Vent hole.
436
Reference “Parts
445 Section” for current
Housing
81
Service
spool
A) Install new O-ring seal in housing and lu-
bricate the O-ring with clean compressor oil.
A vent hole is provided in the command shaft
547
bearing housing to allow any refrigerant and
548
oil that may leak past the O-ring seal to vent 540
549
to atmosphere and not into the slide valve 536
550
motor housing. Install snap ring retainer and 551
washer on the command shaft.
B) On VSS and VSR compressors, remove the A) Install (2) guide rods to position the dis-
discharge spool between the manifold and charge manifold. Install a new manifold
separator. Remove one bolt from each side gasket and the discharge manifold. Install
of the discharge manifold and install (2) the dowel pins and bolts, tighten manifold
guide rods approximately 6” long, to sup- bolts to the recommended torque value.
port the manifold. Remove the remaining
bolts (note length and location of bolts) and B) On VSS and VSR compressors install the
take off the discharge manifold. discharge spool or elbow between the dis-
charge manifold and oil separator with new
Note: Mainfold has dowel pins to locate it gaskets. When installing the discharge el-
on the compressor housing. Therefore, re- bow tighten the bolts to the correct torque
move manifold straight back approximately on the manifold flange first before tighten-
1” as not to break dowel pins. ing the separator flange bolts. Install the
drain plug in the bottom of the discharge
manifold.
82
Service
C) On VSM compressors install the bolts in the F) Look for any excessive wear on all moving
discharge flange. Install the drain plug in parts and replace the worn parts.
the bottom of the discharge manifold.
G) Reassemble the manifold and discharge el-
D) Install both command shaft assemblies and bow as outlined in section 4.10.
control actuators as outlined in sections 4.05
and 4.01.
4.12 REMOVAL OF CAPACITY OR
4.11 SLIDE VALVE GEAR AND RACK VOLUME CROSS SHAFTS
INSPECTION
A) Remove the discharge manifold as outlined
A) Remove the discharge manifold as outlined in section 4.09.
in section 4.09
B) To remove the capacity or volume ratio slide
B) Check rack to rack clamp and rack clamp valve racks, remove the two jam nuts and lock
spacer clearance on all four slide valves. washers (361) securing the rack (316) to the
slide valve shafts. The racks can now be
TABLE 4.1 pulled off the slide valve shafts. Repeat the
RACK CLEARANCE VALUES procedure for the remaining pair of slide valve
racks.
MEASUREMENT CLEARANCE
Check
Rack to torque C) To remove the cross shafts, remove socket
clamp on cap head bolts, clamp and spacers from both
spacer screws sides.
Rack to Roll pins
clamp Loose nuts
83
Service
228
268
222
269
268 When installing the slide
228 221 valve racks, both racks
269 must engage the axle
shaft gears at the same
time.
84
Service
NOTE:
The capacity and volume control motors are
equipped with a brake. If it is necessary to oper-
ate the control motors manually, the brake must be
disengaged. The brake can be disengaged by
pushing on the motor shaft on the cone end. The
shaft should be centered in its travel. Do not use B) Remove the six screws from the cover. Re-
excessive force manually operating the motor or move the cover for the slide valve actuator.
damage may result. Mark and disconnect the wires to the slide
valve control actuator and potentiometer.
85
Service
4.22 INSTALLATION
477
465
87
Service
4.31 REMOVAL
4.24 POTENTIOMETER
INSTALLATION To change to the new style optical motors, the
command shaft and mounting plate must be re-
A) Install potentiometer in the bracket. Install placed. This will require the unit to be evacuated
the lock washer and nut on the potentiom- for servicing.
eter. Do not over tighten nut on the potenti-
ometer.
A) Prepare the compressor for servicing as out-
B) Install the potentiometer gear and clamp on lined in section 0.01.
the potentiometer shaft.
88
Service
B) Remove the hex head cap screws (452) from Lock® washers (477) securing it. Tighten the
the cover (418) for the slide valve control bolts to the recommended torque value.
motor, and remove cover. Mark and discon- C) Install the drive key (427) in the command
nect the wires to the slide valve control motor shaft keyway.
and potentiometer (425). Remove the two hex
bolts (453) under the mounting plate (415) that D) Install the new style optical gear motor as
hold the motor bracket (405) in place. The outlined in section 4.02 Optical Slide Valve
motor can now be removed. Actuator Installation.
IMPORTANT
90
Service
A) Electrically lock out and tag out the screw A) Apply refrigerant grade thread sealant to the
compressor package. threads of the replacement plug. Install plug
into compressor frame.
B) Isolate the screw compressor package B) Rotate the compressor input shaft by hand
from the package. to make sure the compressor turns over
freely.
C) Remove the refrigerant from the screw
compressor package in an approved man- C) Pressurize the screw compressor package
ner. and check for leaks.
91
Service
92
Service
Torque Specifications
TYPE BOLT MARKINGS 1/ 4 " 5/16" 3/ 8 " 7/16" 1/ 2 " 9/16" 5/ 8 " 3/ 4 "
93
Service
Usage VSS451 to
VSS 1801
Dates All units
prior to 3-1-00
Length 18”
Diameter 6-1/8”
A) Characteristics;
94
Service
Length 8”
A) Characteristics;
Length 16.8”
A) Characteristics;
95
Service
A) Characteristics;
1) Pleated type element with a screen
covering the surface of the element.
B) Usage;
96
Service
C) Characteristics;
3) Only end cap is removed from the filter Duplex filter housing.
bowl.
D) Usage;
97
VSS, VSM and VSR SINGLE SCREW COMPRESSORS
SERVICE INTERVAL REQUIREMENTS
FOR VILTER EXTENDED WARRANTY
The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrigeration
oil in VSS, VSM and VSR Single Screw Compressor units.
100,000
120,000
110,000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
5,000
200
Group Maintenance
Item
OIL CIRCUIT
Oil Change (1) R R R R R R R
Oil Analysis (2) S S S S S S S S S S S S S
Oil Filters (3) R R R R R R R R R R R R R R
Oil Strainer I I I I I I I I I I I I I I
PACKAGE
Coalescing Elements R R R R
Suction Screen I I I I I I I I I I I I I I
Liquid Line Strainers I I I I I I I I I I I I I I
Coupling Alignment and
Integrity I I I I I I I I I I I I I I
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
COMPRESSOR
Inspect Compressor I I I I I I I
Bearings I
Key I Inspect.
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 12 psi or oil analysis requires it.
98
Recommended
Spare Parts List
99
VSS - VSR - VSM Spare Parts List
100
COMPONENT VSS VSM VSR V.P. # DESCRIPTION QTY DESCRIPTION MULT
Oil Separator X 2923A Defogger/Coelecent Element 1 16" Oil Separator 140A
X 2879C Defogger/Coelecent Element 1 20" Oil Separator 111R
Gaskets X 69203C Cover Gasket 1 16" Oil Separator 140A
X 93559A Cover Gasket 1 20" Oil Separator 112R
Oil Separator X X 1 20" Oil Separator
X X 2 24" Oil Saparator
X X 2879A Defogger/Coelecent Element 3 30" Oil Separator 140A
X 4 36" Oil Separator
X 5 42" Oil Separator
Gaskets: X X 93559A Cover Gasket, 13" x 12" 1 20" Oil Separator 112R
choose separator X 1 24" Oil Separator
size X 1 30" Oil Separator
X 93560A Cover Gasket, 16" x 15" 1 36" Oil Separator 112R
X 1 42" Oil Separator
X KT721 Oil Filter Element 1 Used on VSR compressors 111R
VSR Units manufactured Before 8-8-96
Oil Filter X KT722 Oil Filter Element 1 Used on VSR compressors 111R
+++ manufactured After 8-8-96
X 1833C Oil Filter Element 1 Single Element Filter Tank 112R
VSS Units Before April - 2000 2 Dual Element Filter Tank 112R
Oil Filter X 35197A Filter Tank Cover Gasket 1 Single or Dual Element Filter Tank 112R
+++ (Included with 1833C)
X X 3109A Duplex Housing - 16" Bowl < or = 30" Oil Separator 111R
X 3110A Duplex Housing - 39" Bowl > 30" Oil Separator 111R
VSS/VSM X X 3111A Single Housing - 16" Bowl < or = 30" Oil Separator 111R
Oil Filter X 3112A Single Housing - 39" Bowl > 30" Oil Separator 111R
+++ X X KT773A 16" Oil Filter Element (3109 B-Duplex Housing) 111R
X X KT773B 16" Oil Filter Element (3109 B-Single Housing) 111R
X KT774 39" Oil Filter Element (3110 B Single & Duplex Housing) 111R
Safety Relief X X X 1498C 300 Psig R-717 Relief Valve 2 300 Psig R-717 Dual Relief Valve 2HVF
Valves X X X 1498A 250 Psig R-717 Relief Valve 2 250 Psig R-717 Dual Relief Valve 2HVF
X X X 1528B 300 Psig Halocarbon Relief Valve, 2 300 Psig Halocarbon Dual Relief Valve 2HVF
Safety Relief 1/2"x 5/8"
Valves X X X 1528H 300 Psig Halocarbon Relief Valve, 2 300 Psig Halocarbon Dual Relief Valve 2HVF
3/4"x 3/4"
X X X 1528M 300 Psig Halocarbon Relief Valve, 2 300 Psig Halocarbon Dual Relief Valve 2HVF
1"x 1"
101
Heater(after ’99) X X 3116C 750W/120V Cartridge Heater >> after 1999 on all separators—qty 1 or 2 111R
102
Spare Parts Cont.....
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103
Gate Rotor
104
Gate Rotor
MODEL NUMBER
ITEM DESCRIPTION VSR 111 & VSR 221 VSR 151 & VSR 301 VSS 451 VSS 601
QTY VPN QTY VPN QTY VPN QTY VPN
GATE ROTOR BLADE AND BEARING
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126, 130,
131, 141, 142 & 143. 1 KT712A 1 KT712B 2 KT712A 2 KT712B
GATE ROTOR BLADE REPLACEMENT
KIT, 111, 118, 120A, 120B, 121, 122, 123,
124, 130, 141, 142 & 143. 1 KT713A 1 KT713B 2 KT713A 2 KT713B
100 SUPPORT ASSEMBLY 110 & 135B. 1 A25159BB 1 A25159BA 2 A25159BB 2 A25159BA
102 GATE ROTOR SUPPORT ASSEMBLY
100, 111, 120B, 119 & 130. 1 A25161BB 1 A25161BA 2 A25161BB 2 A25161BA
105 GATE ROTOR GASKET SET 118, 141,
142 & 143. 1 A25164B 1 A25164B 2 A25164B 2 A25164B
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 1 A25165B 1 A25165B 2 A25165B 2 A25165B
110 SUPPORT. 1 25606A 1 25520A 2 25606A 2 25520A
111 GATE ROTOR. 1 25557A 1 25534A 2 25557A 2 25534A
112 SMALL BEARING HOUSING. 1 25518A 1 25518A 2 25518A 2 25518A
113 LARGE BEARING HOUSING. 1 25517A 1 25517A 2 25517A 2 25517A
114 RETAINER. 1 25008A 1 25008A 2 25008A 2 25008A
115 RETAINER. 1 25009A 1 25009A 2 25009A 2 25009A
116 BALL BEARING COVER. 1 25258A 1 25258A 2 25258A 2 25258A
117 GATE ROTOR COVER. 1 25519A 1 25519A 2 25519A 2 25519A
118 GATE ROTOR COVER GASKET. 1 25259A 1 25259A 2 25259A 2 25259A
119 WASHER. 1 25007A 1 25007A 2 25007A 2 25007A
120A BUSHING, SMALL DOWEL PIN. 1 25006A 1 25006A 2 25006A 2 25006A
120B BUSHING, LARGE DOWEL PIN. 1 25760A 1 25760A 2 25760A 2 25760A
121* SHIM 0.002". ar 25010AA ar 25010AA ar 25010AA ar 25010AA
122* SHIM 0.003". ar 25010AB ar 25010AB ar 25010AB ar 25010AB
123* SHIM 0.005". ar 25010AC ar 25010AC ar 25010AC ar 25010AC V
124* SHIM 0.010". ar 25010AD ar 25010AD ar 25010AD ar 25010AD S
125 ROLLER BEARING. 1 2864B 1 2864B 2 2864B 2 2864B S
126 BALL BEARING. 2 2865B 2 2865B 4 2865B 4 2865B
130 RETAINING RING. 1 2866A 1 2866A 2 2866A 2 2866A &
131 RETAINING RING. 1 2867A 1 2867A 2 2867A 2 2867A
135A DOWEL PIN, SMALL, 0.250" O.D.. 1 2868B 1 2868B 2 2868B 2 2868B V
135B DOWEL PIN, LARGE, 0.4375" O.D.. 1 25910A 1 25910A 2 25910A 2 25910A S
141 O-RING ROLLER BRG HSG. 1 2176M 1 2176M 2 2176M 2 2176M R
142 O-RING BALL BRG HSG. 1 2176R 1 2176R 2 2176R 2 2176R
143 O-RING BRG HSG COVER. 1 2176N 1 2176N 2 2176N 2 2176N Parts
150 HEX HEAD CAP SCREW. 6 2796AJ 6 2796AJ 12 2796AJ 12 2796AJ List
151 HEX HEAD CAP SCREW. 3 2796B 3 2796B 6 2796B 6 2796B
152 HEX HEAD CAP SCREW. 20 2796CJ 20 2796CJ 40 2796CJ 40 2796CJ
153 HEX HEAD CAP SCREW. 16 2796E 16 2796E 32 2796E 32 2796E
160 SOCKET HEAD CAP SCREW. 6 2795E 6 2795E 12 2795E 12 2795E
105
Gate Rotor
ITEM DESCRIPTION VSG 751 VSG 901 VSG 1051 VSG 1201
QTY VPN QTY VPN QTY VPN QTY VPN
GATE ROTOR BLADE AND BEARING
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126, 130,
131, 141, 142 & 143. 2 KT712C 2 KT712D 2 KT712E 2 KT712F
GATE ROTOR BLADE REPLACEMENT
KIT, 111, 118, 120A, 120B, 121, 122, 123,
124, 130, 141, 142 & 143. 2 KT713C 2 KT713D 2 KT713E 2 KT713F
100 SUPPORT ASSEMBLY 110 & 135B. 2 A25159CB 2 A25159CA 2 A25159DB 2 A25159DA
102 GATE ROTOR SUPPORT ASSEMBLY
100, 111, 120B, 119 &130 2 A25161CB 2 A25161CA 2 A25161DB 2 A25161DA
105 GATE ROTOR GASKET SET 118, 141,
142 & 143. 2 A25164C 2 A25164C 2 A25164D 2 A25164D
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 2 A25165C 2 A25165C 2 A25165C 2 A25165C
110 SUPPORT. 2 25612A 2 25553A 2 25614A 2 25587A
111 GATE ROTOR. 2 25608A 2 25554A 2 25610A 2 25588A
112 SMALL BEARING HOUSING. 2 25281A 2 25281A 2 25313A 2 25313A
113 LARGE BEARING HOUSING. 2 25282A 2 25282A 2 25333A 2 25333A
114 RETAINER. 2 25084A 2 25084A 2 25084A 2 25084A
115 RETAINER. 2 25085A 2 25085A 2 25085A 2 25085A
116 BALL BEARING COVER. 2 25284A 2 25284A 2 25335A 2 25335A
117 GATE ROTOR COVER. 2 25285A 2 25285A 2 25311A 2 25311A
118 GATE ROTOR COVER GASKET. 2 25088A 2 25088A 2 25132A 2 25132A
119 WASHER. 2 25086A 2 25086A 2 25086A 2 25086A
120A BUSHING, SMALL DOWEL PIN. 2 25087A 2 25087A 2 25104A 2 25104A
120B BUSHING, LARGE DOWEL PIN. 2 25760B 2 25760B 2 25760B 2 25760B
121* SHIM 0.002". ar 25089AA ar 25089AA ar 25089AA ar 25089AA
122* SHIM 0.003". ar 25089AB ar 25089AB ar 25089AB ar 25089AB
123* SHIM 0.005". ar 25089AC ar 25089AC ar 25089AC ar 25089AC
124* SHIM 0.010". ar 25089AD ar 25089AD ar 25089AD ar 25089AD
125 ROLLER BEARING. 2 2864C 2 2864C 2 2864G 2 2864G
126 BALL BEARING. 4 2865A 4 2865A 4 2865A 4 2865A
130 RETAINING RING. 2 2866B 2 2866B 2 2866B 2 2866B
131 RETAINING RING. 2 2867E 2 2867E 2 2867L 2 2867L
135A DOWEL PIN, SMALL, 0.3125" O.D.. 2 2868F 2 2868F 2 2868H 2 2868H
135B DOWEL PIN, LARGE, 0.4375" O.D.. 2 25910B 2 25910B 2 25910B 2 25910B
141 O-RING ROLLER BRG HSG. 2 2176N 2 2176N 2 2176AJ 2 2176AJ
142 O-RING BALL BRG HSG. 2 2176V 2 2176V 2 2176AM 2 2176AM
143 O-RING BRG HSG COVER. 2 2176U 2 2176U 2 2176U 2 2176U
150 HEX HEAD CAP SCREW. 12 2796B 12 2796B 12 2796B 12 2796B
151 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796N 8 2796N
152 HEX HEAD CAP SCREW. 26 2796Q 26 2796Q 26 2796Q 26 2796Q
153 HEX HEAD CAP SCREW. 32 2796R 32 2796R 36 2796R 36 2796R
160 SOCKET HEAD CAP SCREW. 12 2795H 12 2795H 12 2795H 12 2795H
ar = As required
106
Gate Rotor
ar = As required
107
Shaft Seal
Important:
Item # 244- Tappered
ID Faces Outward.
108
Shaft Seal
MODEL NUMBER
ITEM DESCRIPTION VSR 111 & VSR 151& VSS 751-1201 VSS 1501-1801
VSR 221 VSR 301
VSS 451 VSS 601
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Main Rotor
VSS
110
Main Rotor
VSS
MODEL NUMBER
ITEM DESCRIPTION VSS 451 VSS601 VSS751 VSS901 VSS1051 VSS1201 VSS1501 VSS1801
QTY PART# QTY PART# QTY PART# QTY PART# QTY PART# QTY PART# QTY PART# QTY PART#
201 ROTOR ASSY 1 A25168BB 1 A25168BA 1 A25168CB 1 A25168CA 1 A25168DB 1 A25168DA 1 A25168EB 1 A25168AE
111
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Main Rotor
VSR
112
Main Rotor
VSR
MODEL NUMBER
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113
Slide Valve Cross Shafts and End Plate
114
Slide Valve Cross Shafts and End Plate
MODEL NUMBER
VSR111-221 VSR 151-301 VSS 451 VSS 601
ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN
V
221 SHAFT. 2 25031A 2 25031A 2 25031A 2 25031A S
222 GEAR. 2 25027A 2 25027A 2 25027A 2 25027A S
223 GEAR. 2 25028A 2 25028A 2 25028A 2 25028A
228 SPACER. 2 25033C 2 25033C 2 25033C 2 25033C &
229 SPACER. 0 n/a 0 n/a 0 n/a 0 n/a
268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D V
269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA S
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115
Slide Valve Cross Shafts and End Plate
MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201
QTY VPN QTY VPN QTY VPN QTY VPN
220 END PLATE 1 25543A 1 25543A 1 25593A 1 25593A
221 SHAFT. 2 25844A 2 25844A 2 25845A 2 25845A
222 GEAR. 4 25027A 4 25027A 4 25027A 4 25027A
226 RACK CLAMP. 4 25913C 4 25913C 4 25913C 4 25913C
228 SPACER. 4 25033C 4 25033C 4 25033C 4 25033C
267 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B
268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D
269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA
270 PIPE PLUG. 2 2606E 2 2606E 2 2606E 2 2606E
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F 8 2795F
297 SET SCREW 2 2060J 2 2060J 2 2060J 2 2060J
298 SET SCREW 2 2060H 2 2060H 2 2060H 2 2060H
NOTE: Three piece rack spacers and clamp are obsolete, use VPN 25913C instead.
116
Slide Valve Cross Shafts and End Plate
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS1801
QTY VPN QTY VPN
220 END PLATE 1 25661A 1 25661A
221 SHAFT. 2 25793A 2 25793A
222 GEAR. 4 25027A 4 25027A
226 RACK CLAMP. 4 25913C 4 25913C
228 SPACER. 4 25033C 4 25033C
267 DOWEL PIN. 2 2868B 2 2868B
268 EXPANSION PIN. 4 1193D 4 1193D
269 EXPANSION PIN. 4 2981AA 4 2981AA
270 PIPE PLUG. 2 2606A 2 2606A
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F
297 SET SCREW 2 2060J 2 2060J
298 SET SCREW 2 2060H 2 2060H
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117
118
Volume Slide
Capacity Slide
Carriage Assembly
Slide Valve Carriage Assembly
Slide Valve Carriage Assembly
MODEL NUMBER
&
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List
119
Slide Valve Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201
QTY VPN QTY VPN QTY VPN QTY VPN
300 CARRIAGE ASSEMBLY. 2 A25179C 2 A25179C 2 A25179D 2 A25179D
304 CAPACITY PISTON 340, 341, 350 & 355. 2 A25183C 2 A25183C 2 A25183D 2 A25183D
305 VOLUME PISTON 340, 342, 350 & 355. 2 A25184C 2 A25184C 2 A25184D 2 A25184D
307 GASKET SET 345B & 378**. 2 A25200C 2 A25200C 2 A25200D 2 A25200D
316 RACK. 2 25080A 2 25080A 2 25080C 2 25080C
323 RACK. 2 25080B 2 25080B 2 25080D 2 25080D
340 PISTON. 4 25076A 4 25076A 4 25138A 4 25138A
341 CAPACITY PISTON SHAFT. 2 25078A 2 25078A 2 25078E 2 25078E
342 VOLUME PISTON SHAFT. 2 25078B 2 25078B 2 25078F 2 25078F
343A COVER, SEPARATE VOL. & CAP. 2 25123B 2 25123B 4 25123C 4 25123C
343B COVER, ONE PIECE CAST. 2 25279A 2 25279A 2 25401A 2 25401A
344 COVER, SEPARATE VOL. & CAP. 2 25123A 2 25123A n/a n/a n/a n/a
345A GASKET, SEPARATE VOL. &
CAP COVERS. 2 25124B 2 25124B 4 25124C 4 25124C
345B GASKET ONE PIECE CAST COVER. 2 25902A 2 25902A 2 25901A 2 25901A
346 GASKET, SEPARATE VOL. & CAP
COVERS. 2 25124A 2 25124A n/a n/a n/a n/a
347 PISTON SLEEVE. 2 25079A 2 25079A n/a n/a n/a n/a
350 PISTON RING SET. 4 2953AB 4 2953AB 4 2953AC 4 2953AC
355 EXPANSION PIN. 4 1193PP 4 1193PP 4 1193PP 4 1193PP
359 PIPE PLUG. 6 2606D 6 2606D 6 2606E 6 2606E
360 LOCK WASHER (PAIR). 4 3004C 4 3004C 4 3004C 4 3004C
361 WASHER. 4 13265B 4 13265B 4 13265B 4 13265B
363 NUT. 8 2797A 8 2797A 8 2797A 8 2797A
366A HEX HEAD CAP SCREW. 12 2796B 12 2796B 24 2796B 24 2796B
366B HEX HEAD CAP SCREW. 12 2796P 12 2796P 24 2796P 24 2796P
367 HEX HEAD CAP SCREW. 12 2796BN 12 2796BN n/a n/a n/a n/a
373 SOCKET HEAD CAP SCREW. 6 2795N 6 2795N 6 2795P 6 2795P
374 LOCK WASHER (PAIR). 6 3004C 6 3004C 6 3004D 6 3004D
378 0-RING. 2 2176Y 2 2176Y n/a n/a n/a n/a
380 RETAINER RING. 2 2866C 2 2866C n/a n/a n/a n/a
120
Slide Valve Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN
300 CARRIAGE ASSEMBLY. 2 A25179E 2 A25179E
304 CAPACITY PISTON 340, 341, 350 & 355. 2 A25183E 2 A25183E
305 VOLUME PISTON 340, 342, 350 & 355. 2 A25184E 2 A25184E
307 GASKET SET 345 & 378. 2 A25200E 2 A25200E
316 RACK. 2 25779A 2 25779A
323 RACK. 2 25780A 2 25780A
325 SHAFT. 2 25778A 2 25778A
340 PISTON. 4 25782A 4 25782A
341 CAPACITY PISTON SHAFT. 2 25784A 2 25784A
342 VOLUME PISTON SHAFT. 2 25783A 2 25783A
343B COVER. 2 25690A 2 25690A
345B GASKET. 2 25384A 2 25384A
347 PISTON SLEEVE. 4 25786A 4 25786A
350 PISTON RING SET. 4 2953AD 4 2953AD
355 EXPANSION PIN. 4 1193PP 4 1193PP
359 PIPE PLUG. 6 2606E 6 2606E
360 LOCK WASHER (PAIR). 4 3004C 4 3004C
361 WASHER. 4 13265B 4 13265B
363 NUT. 8 2797A 8 2797A
366B HEX HEAD CAP SCREW. 28 2796BL 28 2796BL
373 SOCKET HEAD CAP SCREW. 6 2795AG 6 2795AG
374 LOCK WASHER (PAIR). 6 3004D 6 3004D
378 0-RING. 4 2176AG 4 2176AG
380 RETAINER RING. 4 2755AG 4 2755AG
V
S
S
&
V
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R
Parts
List
121
Capacity Control Actuating Motor and
Command Shaft
Optical Actuator
See note
above
122
Capacity Control Actuating Motor and
Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS601
QTY VPN QTY VPN QTY VPN QTY VPN
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to
new style gear drive potentiometer. Less items 416, 429 & 466.
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to
new style gear drive potentiometer. Less items 416, 429 & 466.
124
Capacity Control Actuating Motor and
Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN
GEAR MOTOR REPLACEMENT
(410, 440, 455, 475). 1 KT720A 1 KT720A
GEAR MOTOR REPLACEMENT
(DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B
410 GEAR MOTOR. 1 25380A 1 25380A
410A GEAR MOTOR (DIV. 2). 1 25868A 1 25868A
411 MOTOR MOUNT. 1 25374A 1 25374A
412 BEARING HOUSING. 1 25364A 1 25364A
413 COMMAND SHAFT. 1 25369A 1 25369A
415 MOUNTING PLATE. 1 25805A 1 25805A
416 COVER PLASTIC. 1 25697A 1 25697A
416A COVER STEEL (DIV. 2). 1 25535A 1 25535A
419 POTENTIOMETER. 1 2935D 1 2935D
420 MOTOR SHAFT GEAR. 1 25029A 1 25029A
421 COMMAND SHAFT GEAR. 1 25806A 1 25806A
422 GEAR. 1 25832A 1 25832A
424 GEAR. 1 2107B 1 2107B
426 KEY. 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A
432 CLAMP FOR ITEM 424. 1 2013A 1 2013A
433 BUSHING (DIV. 2). 1 25853A 1 25853A
435 BALL BEARING. 1 2908A 1 2908A
436** SLEEVE BEARING. 1 25853A 1 25853B
440 PUSH-ON RETAINER. 1 2866F 1 2866F
445 O-RING. 1 2176W 1 2176W
445A O-RING (DIV. 2). 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 V
455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN S
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ
S
457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M
465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE
466 HEX HEAD CAP SCREW. 6 2583C 6 2583C &
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT V
475 LOCK WASHER (PAIR). 4 3004A 4 3004A S
476 LOCK WASHER (PAIR). 3 3004B 3 3004B R
477 LOCK WASHER (PAIR). 8 3004C 8 3004C
480 WASHER. 1 2906AA 1 2906AA
Parts
485 JAM NUT. 1 13283A 1 13283A
492 DOWEL PIN. 1 2868J 1 2868J List
497 PIPE PLUG. 1 2606E 1 2606E
125
Slide Valve Actuating Motor
and Command shaft
Before 5-1-95
418
408 452
425
408
451
463
459
407
450
403
458
405
416
404 420 OR 421
419 443
463 454
458
443
417
455
419
415
429
453 435
439
438
440
411
446
447
410 2 O-RINGS ONLY
IF SPECIFIED.
430
431
412
126
Slide Valve Actuating Motor
and Command shaft
Before 5-1-95
MODEL NUMBER
ITEM DESCRIPTION
VSR 111-301 VSS 451-601 VSS 751-901 VSS 1201
QTY VPN QTY VPN QTY VPN QTY VPN
403 GEAR MOTOR. n/a n/a n/a n/a n/a n/a n/a n/a
404 MOUNTING BLOCK. n/a n/a n/a n/a n/a n/a n/a n/a
405 MOTOR BRACKET. n/a n/a n/a n/a n/a n/a n/a n/a
406 CLIP. n/a n/a n/a n/a n/a n/a n/a n/a
407 COLLAR. n/a n/a n/a n/a n/a n/a n/a n/a
408 LOCKING TAB. n/a n/a n/a n/a n/a n/a n/a n/a
410 BEARING HOUSING. n/a n/a n/a n/a n/a n/a n/a n/a
411 SHAFT. n/a n/a n/a n/a n/a n/a n/a n/a
412 COUPLING. 2 25032A 2 25032A 2 25032A 2 25032A
415 PLATE. n/a n/a n/a n/a n/a n/a n/a n/a
416 GEAR. 2 25029A 2 25029A 2 25029A 2 25029A
417 GEAR. n/a n/a n/a n/a n/a n/a n/a n/a
418 COVER. 2 25697A 2 25697A 2 25697A 2 25697A
419 KEY. 4 25039BC 4 25039BC 4 25039BC 4 25039BC
420 POSITION INDICATOR, CAPACITY. n/a n/a n/a n/a n/a n/a n/a n/a
421 POSITION INDICATOR, VOLUME. n/a n/a n/a n/a n/a n/a n/a n/a
425 POTENTIOMETER. n/a n/a n/a n/a n/a n/a n/a n/a
429 GASKET. 2 25757A 2 25757A 2 25757A 2 25757A
430 O-RING. 2 2176W 2 2176W 2 2176W 2 2176W
431 O-RING. 2 2176X 2 2176X 2 2176X 2 2176X
435 BALL BEARING. 2 2908A 2 2908A 2 2908A 2 2908A
438 RETAINER RING. 2 2866D 2 2866D 2 2866D 2 2866D
439 RETAINER RING. 2 2867C 2 2867C 2 2867C 2 2867C
440 WASHER. 2 2906AA 2 2906AA 2 2906AA 2 2906AA
443 PUSH ON RETAINER. 4 2866F 4 2866F 4 2866F 4 2866F
446 EXPANSION PIN. 2 1193D 2 1193D 2 1193D 2 1193D
V
447 EXPANSION PIN. 2 2981AA 2 2981AA 2 2981AA 2 2981AA
S
450 NUT. 4 1393E 4 1393E 4 1393E 4 1393E
S
451 SOCKET HEAD CAP SCREW. 8 2795Z 8 2795Z 8 2795Z 8 2795Z
452 HEX HEAD CAP SCREW. 12 2583C 12 2583C 12 2583C 12 2583C
&
453 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE
454 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB 4 2795AB 4 2795AB
V
455 SOCKET HEAD CAP SCREW. 8 2795L 8 2795L 8 2795L 8 2795L
S
458 SOCKET HEAD SET SCREW. 4 2060F 4 2060F 4 2060F 4 2060F
R
459 SOCKET HEAD SET SCREW. 2 2060E 2 2060E 2 2060E 2 2060E
463 WASHER. 8 2880E 8 2880E 8 2880E 8 2880E
Parts
List
NOTE: * Not pictured.
n/a No longer available, contact Home Office.
127
Volume Ratio Control Actuating Motor
and Command Shaft
Optical Actuator
See Note
above
128
Volume Ratio Control Actuating Motor
and Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS 601
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to new
style gear drive potentiometer. Less items 416, 429 & 466.
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer
to new style gear drive potentiometer. Less items 416, 429 & 466.
130
Volume Ratio Control Actuating Motor
and Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN
GEAR MOTOR REPLACEMENT
(410, 440, 455, 475). 1 KT720C 1 KT720C
GEAR MOTOR REPLACEMENT
(DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D
410 GEAR MOTOR. 1 25379A 1 25379A
410A GEAR MOTOR (DIV. 2). 1 25867A 1 25867A
411 MOTOR MOUNT. 1 25374A 1 25374A
412 BEARING HOUSING. 1 25364A 1 25364A
413 COMMAND SHAFT. 1 25369A 1 25369A
415 MOUNTING PLATE. 1 25805A 1 25805A
416 COVER. 1 25697A 1 25697A
416A COVER STEEL (DIV. 2). 1 25535A 1 25535A
419 POTENTIOMETER. 1 2935D 1 2935D
420 MOTOR SHAFT GEAR. 1 25029A 1 25029A
421 COMMAND SHAFT GEAR. 1 25806A 1 25806A
423 GEAR. 1 25831A 1 25831A
425 GEAR. 1 2107A 1 2107A
426 KEY. 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A
432 CLAMP FOR ITEM 424. 1 2013A 1 2013A
433 BUSHING (DIV. 2). 1 25853A 1 25853A
435 BALL BEARING. 1 2908A 1 2908A
436** SLEEVE BEARING. 1 25853B 1 25853B
440 PUSH-ON RETAINER. 1 2866F 1 2866F
445 O-RING. 1 2176W 1 2176W
445A O-RING (DIV. 2). 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
455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ V
457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M
S
465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE
466 HEX HEAD CAP SCREW. 6 2583C 6 2583C S
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT &
475 LOCKWASHER (PAIR). 4 3004A 4 3004A
476 LOCKWASHER (PAIR). 3 3004B 3 3004B V
477 LOCKWASHER (PAIR). 8 3004C 8 3004C S
480 WASHER. 1 2906AA 1 2906AA R
485 JAM NUT. 1 13283A 1 13283A
492 DOWEL PIN. 1 2868J 1 2868J
497 PIPE PLUG. 1 2606E 1 2606E Parts
List
** Note: Item 412 was modified to remove the sleeve bearing.
131
Miscellaneous Frame Components
Tubing and Fittings
556 OR 555
567
568 555
558
558
555
567
555 555
564
555 566
565 563
555
555
132
Miscellaneous Frame Components
Tubing and Fittings
MODEL NUMBER
ITEM DESCRIPTION VSR 111-VSR 221 VSR 151-VSR 301 VSS 451 VSS 601
QTY VPN QTY VPN QTY VPN QTY VPN
555 ELBOW . 2 13375D 2 13375D 5 13375D 5 13375D
556 STRAIGHT. n/a n/a n/a n/a 1 13229D 1 13229D
557 TEE, RUNNING. n/a n/a n/a n/a 1 1509A 1 1509A
558 HEX BUSHING. 1 13231AA 1 13231AA 1 13231AA 1 13231AA
560 ELBOW. n/a n/a n/a n/a 1 13375Z 1 13375Z
561 ELBOW. n/a n/a n/a n/a 1 13375F 1 13375F
562 PLUG. n/a n/a n/a n/a 1 2606E 1 2606E
MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201
QTY VPN QTY VPN QTY VPN QTY VPN
555 ELBOW. 5 13375D 5 13375D 3 13375D 3 13375D
556 STRAIGHT. 1 13229D 1 13229D 2 13229D 2 13229D
557 TEE, RUNNING. 1 1509A 1 1509A 1 1509A 1 1509A
558 HEX BUSHING. 1 13231AA 1 13231AA 1 1101H 1 1101H
559 HEX BUSHING. 0 n/a 0 n/a 1 1101K 1 1101K
560 ELBOW. 1 13375Z 1 13375Z 1 13375Z 1 13375Z
561 ELBOW. 1 13375F 1 13375F 1 13375F 1 13375F
562 PLUG. 1 2606E 1 2606E 1 2606A 1 2606A
563 TEE. n/a n/a n/a n/a 2 13376D 2 13376D
564 TEE. n/a n/a n/a n/a 1 13239C 1 13239C V
565 TEE. 2 1884A 2 1884A n/a n/a n/a n/a S
566 NIPPLE. 2 13181D 2 13181D n/a n/a n/a n/a S
&
V
S
MODEL NUMBER R
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN Parts
555 ELBOW. 2 13375D 2 13375D List
557 TEE, RUNNING. 1 13376D 1 13376D
558 HEX BUSHING. 1 13231AA 1 13231AA
559 HEX BUSHING. 1 1101H 1 1101H
560 ELBOW. 1 13375Z 1 13375Z
567 CONNECTOR. 1 13299C 1 13299C
568 REDUCING BUSHING. 1 1101M 1 1101M
133
Miscellaneous Frame Components
134
Miscellaneous Frame Components
MODEL NUMBER
135
Miscellaneous Frame Components
MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201
QTY VPN QTY VPN QTY VPN QTY VPN
GASKET AND O-RING KIT; 1 KT710B 1 KT710B 1 KT710C 1 KT710C
504 FLANGE SET 513, 514 & 547. 1 A25190A 1 A25190A 1 A25190B 1 A25190B
504 FLANGE SET 513A, 514A & 547
ECON-O-MIZER PORT. 2 A25190B 2 A25190B 2 A25190B 2 A25190B
511 DISCHARGE MANIFOLD. 1 25540A 1 25540A 1 25597A 1 25597A
512 MANIFOLD GASKET. 1 25541A 1 25541A 1 25324A 1 25324A
513 FLANGE OIL. 1 25058A 1 25058A 1 25058B 1 25058B
513A FLANGE ECON-O-MIZER. 2 25058A 2 25058A 2 25058B 2 25058B
514 FLANGE GASKET OIL. 1 11323D 1 11323D 1 11323E 1 11323E
514A FLANGE GASKET ECON-O-MIZER. 2 11323D 2 11323D 2 11323E 2 11323E
515 KEY. 1 13396S 1 13396S 1 13396S 1 13396S
518 SUCTION FLANGE GASKET. 1 25199C 1 25199C 1 25199D 1 25199D
519 DISCHARGE FLANGE GASKET. 1 25199B 1 25199B 1 25199C 1 25199C
522 LOCKING WASHER. 1 25004A 1 25004A 1 25004A 1 25004A
523 LOCKING TAB. 1 25005A 1 25005A 1 25005A 1 25005A
526 ORIFICE PLATE. 1 25223CB 1 25223CA 1 25223DB 1 25223DB
529 WAVE SPRING. 1 2912E 1 2912E 1 2912E 1 2912E
530 O-RING 2 2176J 2 2176J 2 2176J 2 2176J
535 PIPE PLUG 3/8" MPT. 2 2606D 2 2606D 2 2606D 2 2606D
536 PIPE PLUG 1/2" MPT. 8 2606E 8 2606E 4 2606E 4 2606E
537 PIPE PLUG 1-1/4" MPT. 2 13163G 2 13163G 2 13163G 2 13163G
538 PIPE PLUG 3/4" MPT. 6 2606A 6 2606A
540 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B
541 SET SCREW. 1 13298G 1 13298G 1 13298G 1 13298G
545 HEX HEAD CAP SCREW FOR OIL
SUPPLY FLANGE. 2 2796C 2 2796C 2 2796C 2 2796C
545 HEX HEAD CAP SCREW FOR
ECON-O-MIZER FLANGE. 4 2796C 4 2796C 4 2796C 4 2796C
547 HEX HEAD CAP SCREW. 21 2796GP 21 2796GP 24 2796GP 24 2796GP
548 HEX HEAD CAP SCREW. 2 2796GAB 2 2796GAB 2 2796GAB 2 2796GAB
549 HEX HEAD CAP SCREW. 2 2796GAE 2 2796GAE 2 2796GAE 2 2796GAE
554 HEX HEAD CAP SCREW. 1 2796U 1 2796U 1 2796U 1 2796U
569 PIPE PLUG 1/4" MPT. 2 2606C 2 2606C 2 2606C 2 2606C
136
Miscellaneous Frame Components
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN
GASKET AND O-RING KIT; 1 KT710D 1 KT710D
504 FLANGE SET 513, 514 & 547. 1 A25190C 1 A25190C
504 FLANGE SET 513A, 514A & 547
ECON-O-MIZER PORT. 2 A25190D 2 A25190D
511 DISCHARGE MANIFOLD. 1 25663A 1 25663A
512 MANIFOLD GASKET. 1 25676A 1 25676A
513 FLANGE OIL. 1 12477C 1 12477C
513A FLANGE ECON-O-MIZER.
514 FLANGE GASKET OIL. 1 11323F 1 11323F
514A FLANGE GASKET ECON-O-MIZER.
515 KEY. 1 25039AC 1 25039AC
518 SUCTION FLANGE GASKET. 1 25199D 1 25199D
519 DISCHARGE FLANGE GASKET. 1 25199C 1 25199C
522 LOCKING WASHER. 1 25004C 1 25004C
523 LOCKING TAB. 1 25005C 1 25005C
530 O-RING 2 2176J 2 2176J
536 PIPE PLUG 1/2" MPT. 3 2606E 3 2606E
537 PIPE PLUG 1-1/4" MPT. 2 13163G 2 13163G
538 PIPE PLUG 3/4" MPT. 3 2606A 3 2606A
540 DOWEL PIN. 2 2868K 2 2868K
541 SET SCREW. 1 13298G 1 13298G
542 PIPE PLUG 3/4" MPT. 1 13163F 1 13163F
545 HEX HEAD CAP SCREW FOR
OIL SUPPLY FLANGE. 4 11397E 4 11397E
545 HEX HEAD CAP SCREW FOR
ECON-O-MIZER FLANGE.
548 HEX HEAD CAP SCREW. 26 2796HR 26 2796HR
549 HEX HEAD CAP SCREW. 2 2796HAB 2 2796HAB
550 HEX HEAD CAP SCREW. 2 2796HAF 2 2796HAF V
554 HEX HEAD CAP SCREW. 1 2796U 1 2796U S
569 PIPE PLUG 1/4" MPT. 2 2606C 2 2606C S
Parts
List
137
C-Flange Adapter Components
630
620
610 601
641 640
640
650
641
651
642
138
C-Flange Adapter Components
MODEL NUMBER
ITEM DESCRIPTION VSR 111 & VSR 221 VSR 151 & VSR 301
QTY VPN QTY VPN
601 C-FLANGE ADAPTER.
610 KEY. 1 25039AA 1 25039AA
620 HEX HEAD CAP SCREW. 8 2796C 8 2796C
630 LOCKWASHER (PAIR). 8 3004H 8 3004H
640 CONNECTOR. 1 13229C 1 13229C
641 TUBE 1/4" O.D. x 6" LONG. 0.5 Ft. S1589AA 0.5 Ft. S1589AA
642 PIPE PLUG. 1 2606C 1 2606C
650 O-RING. 2 2176AZ 2 2176AZ
651 O-RING. 1 2176AB 1 2176AB
V
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&
V
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R
Parts
List
139
Replacement Parts
Tools
140
Replacement Parts
Tools
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS 601
QTY VPN QTY VPN QTY VPN QTY VPN
900 GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917). 1 A25205B 1 A25205B 1 A25205B 1 A25205B
901 GATEROTOR STABILIZER SET
(901A, 901B & 901C). 1 A25698A 1 A25698A 1 A25698A 1 A25698A
901A GATEROTOR STABILIZER. 1 A25698B 1 A25698B 1 A25698B 1 A25698B
901B HEX HEAD CAP SCREW. 4 2796A 4 2796A 4 2796A 4 2796A
901C RAIL, SIDE. 2 25698A 2 25698A 2 25698A 2 25698A
910 PULLER BAR. 1 25204A 1 25204A 1 25204A 1 25204A
911 PULLER SHOE. 1 25157A 1 25157A 1 25157A 1 25157A
912 PUSHER SHOE. 1 25157B 1 25157B 1 25157B 1 25157B
913 JACKING SCREW. 1 A25156B 1 A25156B 1 A25156B 1 A25156B
914 GUIDE STUD. 1 25908A 1 25908A 1 25908A 1 25908A
915 GUIDE STUD. 2 25908B 2 25908B 2 25908B 2 25908B
916 STUD. 3 25908C 3 25908C 3 25908C 3 25908C
917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W 2 2795W 2 2795W
918 HEX NUT 3 13228F 3 13228F 3 13228F 3 13228F
MODEL NUMBER V
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201 S
QTY VPN QTY VPN QTY VPN QTY VPN S
900 GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917). 1 A25205C 1 A25205C 1 A25205C 1 A25205C &
901 GATEROTOR STABILIZER SET
(901A, 901B & 901C). 1 A25698A 1 A25698A 1 A25698A 1 A25698A V
901A GATEROTOR STABILIZER. 1 A25698B 1 A25698B 1 A25698B 1 A25698B S
901B HEX HEAD CAP SCREW. 4 2796A 4 2796A 4 2796A 4 2796A R
901C RAIL, SIDE. 2 25698A 2 25698A 2 25698A 2 25698A
910 PULLER BAR. 1 25204B 1 25204B 1 25204B 1 25204B Parts
911 PULLER SHOE. 1 25157C 1 25157C 1 25157C 1 25157C List
912 PUSHER SHOE. 1 25157D 1 25157D 1 25157D 1 25157D
913 JACKING SCREW. 1 A25156B 1 A25156B 1 A25156B 1 A25156B
914 GUIDE STUD. 1 25908A 1 25908A 1 25908A 1 25908A
915 GUIDE STUD. 2 25908B 2 25908B 2 25908B 2 25908B
916 STUD. 2 25908C 2 25908C 2 25908C 2 25908C
917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W 2 2795W 2 2795W
918 HEX NUT 2 13228F 2 13228F 2 13228F 2 13228F
141
Replacement Parts
Tools
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN
900 GATEROTOR TOOLS (901, 910,
911, 912, 913, 914, 915, 916 & 917). 1 A25205E 1 A25205E
901 GATEROTOR STABILIZER SET (
901A, 901B, 901C & 901D). 1 A25699A 1 A25699A
901A GATEROTOR STABILIZER. 1 A25699B 1 A25699B
901B HEX HEAD CAP SCREW. 4 2796A 4 2796A
901C RAIL, SIDE. 2 25698C 2 25698C
901D LOCK WASHER. 4 13165B 4 13165B
910 PULLER BAR. 1 25204C 1 25204C
911 PULLER SHOE. 1 25157E 1 25157E
912 PUSHER SHOE. 1 25157F 1 25157F
913 JACKING SCREW. 1 A25156B 1 A25156B
914 GUIDE STUD. 1 25908A 1 25908A
915 GUIDE STUD. 2 25908B 2 25908B
916 STUD. 2 25908C 2 25908C
917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W
918 HEX NUT 2 13228F 2 13228F
142
VSM Replacement
Parts Section
V
S
M
Parts
List
143
Gaterotor Assembly
144
Gaterotor Assembly
Part totals indicated are for one gate rotor assembly, machines with two gate rotors will require double the
components listed below.
MODEL NUMBER
ITEM DESCRIPTION VSM-71, 151, 301 VSM-91, 181, 361 VSM-101, 201, 401
QTY VPN QTY VPN QTY VPN
100 SUPPORT ASSEMBLY 110 & 135B. 1 A25222AB 1 A25222AA 1 A25222AC
101 GATE ROTOR & DAMPER ASSEMBLY
111,120. 1 A25160AB 1 A25160AA A25160AC
102 GATE ROTOR SUPPORT ASSEMBLY
100, 101, 119 & 130. 1 A25161AB 1 A25161AA A25161AC
105 GATE ROTOR GASKET SET
141 & 143. 1 A25164A 1 A25164A A25164A
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 1 A25165A 1 A25165A A25165A
110 SUPPORT. 1 25723D 1 25723C 1 25723B
111 GATE ROTOR. 1 25718B 1 25718C 1 25718D
112 SMALL BEARING HOUSING. 1 25407B 1 25407B 1 25407B
114 SNAP RING. 1 2867L 1 2867L 1 2867L
115 RETAINER BALL BEARING 1 25935A 1 25935A 1 25935A
116 BALL BEARING SUPPORT. 1 25408B 1 25408B 1 25408B
117 GATE ROTOR COVER. 1 25416B 1 25416B 1 25416B
118 GATE ROTOR COVER GASKET. 1 25259B 1 25259B 1 25259B
119 WASHER WAVE SPRING. 1 3203A 1 3203A 1 3203A
120 DAMPER. 1 25760A 1 25760A 1 25760A
121* SHIM 0.002". ar 25921AA ar 25921AA ar 25921AA
122* SHIM 0.003". ar 25921AB ar 25921AB ar 25921AB
123* SHIM 0.005". ar 25921AC ar 25921AC ar 25921AC
124* SHIM 0.010". ar 25921AD ar 25921AD ar 25921AD
125 ROLLER BEARING. 1 2864F 1 2864F 1 2864F
126 BALL BEARING. 2 2865L 2 2865L 2 2865L
130 RETAINING RING. 1 2866H 1 2866H 1 2866H
131 RETAINING RING. 1 2867S 1 2867S 1 2867S
132 RETAINING RING. 1 2866J 1 2866J 1 2866J
135 DOWEL PIN 1 25910A 1 25910A 1 25910A
141 O-RING ROLLER BRG HSG. 1 2176L 1 2176L 1 2176L
143 O-RING BALL BRG SUPPORT. 1 2176F 1 2176F 1 2176F
151 SOC HEAD CAP SCREW. 1 2795AP 1 2795AP 1 2795AP
152 HEX HEAD CAP SCREW. 11 2796CG 11 2796CG 11 2796CG
155 SHIM ar 25977D ar 25977D ar 25977D
156 SHIM ar 25977C ar 25977C ar 25977C
170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C
176 PIPE PLUG. 1 2606D 1 2606D 1 2606D
ar = As required
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Gaterotor Assembly
Part totals indicated are for one gate rotor assembly, dual gate machines will require double the components.
MODEL NUMBER
ITEM DESCRIPTION VSM-501 VSM-601 VSM-701
QTY VPN QTY VPN QTY VPN
100 SUPPORT ASSEMBLY 110 & 135B. 1 A26011BB 1 A26011BA 1 A26011BA
101 GATE ROTOR & DAMPER ASSEMBLY
111,120. 1 A26002BB 1 A26002BA 1 A26002BC
102 GATE ROTOR SUPPORT ASSEMBLY
100, 101, 119 & 130. 1 A26003BB 1 A26003BA 1 A26003BC
105 GATE ROTOR GASKET SET 118,
141 & 143. 1 A26005B 1 A26005B 1 A26005B
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 1 A26035B 1 A26035B 1 A26035B
110 SUPPORT. 1 26030BB 1 26030BA 1 26030BA
111 GATE ROTOR. 1 26032A 1 26031A 1 26033A
112 SMALL BEARING HOUSING. 1 25518B 1 25518B 1 25518B
114 SNAP RING. 1 2867U 1 2867U 1 2867U
115 RETAINER BALL BEARING 1 25935B 1 25935B 1 25935B
116 BALL BEARING SUPPORT. 1 26019B 1 26019B 1 26019B
117 GATE ROTOR COVER. 1 26021B 1 26021B 1 26021B
118 GATE ROTOR COVER GASKET. 1 25259C 1 25259C 1 25259C
119 WASHER. 1 25007A 1 25007A 1 25007A
120 DAMPER. 1 25760A 1 25760A 1 25760A
121* SHIM 0.002". ar 26027AA ar 26027AA ar 26027AA
122* SHIM 0.003". ar 26027AB ar 26027AB ar 26027AB
123* SHIM 0.005". ar 26027AC ar 26027AC ar 26027AC
124* SHIM 0.010". ar 26027AD ar 26027AD ar 26027AD
125 ROLLER BEARING. 1 2864B 1 2864B 1 2864B
126 BALL BEARING. 1 2865B 1 2865B 1 2865B
130 RETAINING RING. 1 2866A 1 2866A 1 2866A
131 RETAINING RING. 1 2867A 1 2867A 1 2867A
132 RETAINING RING. 1 2866K 1 2866K 1 2866K
135 DOWEL PIN 1 25910A 1 25910A 1 25910A
141 O-RING ROLLER BRG HSG. 1 2176M 1 2176M 1 2176M
143 O-RING BALL BRG SUPPORT. 1 2176R 1 2176R 1 2176R
151 SOC HEAD CAP SCREW. 1 2795AAA 1 2795AAA 1 2795AAA
152 HEX HEAD CAP SCREW. 12 2796CG 12 2796CG 12 2796CG
155 SHIM ar 25977G ar 25977G ar 25977G
156 SHIM ar 25977H ar 25977H ar 25977H
170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C
176 PIPE PLUG. 1 2606D 1 2606D 1 2606D
146
Shaft Seal
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71- 401 ALL VSM 501-701
QTY VPN QTY VPN
* SHAFT SEAL KIT Ammon Kit
219, 230, & 260. 1 KT709D 1 KT709A
* SHAFT SEAL KIT Halo Kit
219, 230 & 260. 1 KT781D 1 KT781A
218 SEAL HOUSING. 1 25410B 1 25269A
219 SHAFT SEAL. 1 A 1 A
230 OIL SEAL. 1 2930C 1 25040A
244- TEFLON SEAL 1 25939A 1 25939A
252- RETAINER RING 1 2928M 1 2928M
260 O-RING 1 2176U 1 2176F
261 O-RING. (205 Only) 1 2176AE n/a
264 ROLL PIN. 1 1193RR 1 1193RR
281 HEX HEAD CAP
SCREW. 6 2796N 8 2796B
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List
147
Main Rotor, Slide Valve Cross Shafts
and End Plate
(Models 71-401 Only Counter-clockwise)
148
Main Rotor, Slide Valve Cross Shafts
and End Plate
(Models 71-201 Only CounterClockwise)
MODEL NUMBER
ITEM DESCRIPTION VSM 71 AND 151 VSM 91 AND 181 VSM 101 AND 201
QTY VPN QTY VPN QTY VPN
201 MAIN ROTOR ASSEMBLY. 1 A25266AB 1 A25266AA 1 A25266AC
203 OIL BAFFLE ASSEMBLY (1) 217,
(1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA
207 SHIM ASSORTMENT (2) 240,
(2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A
217 OIL BAFFLE PLATE. 1 25719D 1 25719D 1 25719D
220 END PLATE. 1 25719B 1 25719B 1 25719B
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. 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. (See item 271) 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
271** PLUG SOLID 1 25422A 1 25422A 1 25422A
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
286 SOCKET HEAD CAP SCREW. 4 2795F 4 2795F 4 2795F
297 SET SCREW. 2 2060J 2 2060J 2 2060J
298 SET SCREW. 2 2060H 2 2060H 2 2060H
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Main Rotor, Slide Valve Cross Shafts
and End Plate
(Models 301-401 Only Counter-clockwise)
MODEL NUMBER
ITEM DESCRIPTION VSM 301 VSM 361 VSM 401
QTY VPN QTY VPN QTY VPN
201 MAIN ROTOR ASSEMBLY. 1 A25226AB 1 A25226AA 1 A25226AC
203 OIL BAFFLE ASSEMBLY (1)
217, (1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA
207 SHIM ASSORTMENT (2) 240,
(2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A
217 OIL BAFFLE PLATE . 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. 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. (See item 271) 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
271** PLUG SOLID 1 25422A 1 25422A 1 25422A
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
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
150
See Next Page for Models 501-701
Main Rotor, Slide Valve Cross Shafts
and End Plate
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151
Main Rotor, Slide Valve Cross Shafts
and End Plate
(Model 501-701 Only Clockwise)
152
Main Rotor, Slide Valve Cross Shafts
and End Plate
(Model 501-701 Only Clockwise)
MODEL NUMBER
ITEM DESCRIPTION VSM 501 VSM 601 VSM 701
QTY VPN QTY VPN QTY VPN
201 MAIN ROTOR ASSEMBLY. 1 A26010BB 1 A26010BA 1 A26010BC
203 OIL BAFFLE ASSEMBLY (1) 217,
(1) 244, (1) 248, (1) 249, (1) 252. 1 A26034B 1 A26034B 1 A26034B
207 SHIM ASSORTMENT (2) 240,
(2) 241, (1) 242, (1) 243 1 A25177B 1 A25177B 1 A25177B
217 OIL BAFFLE PLATE. 1 A26034B 1 A26034B 1 A26034B
220 END PLATE. 1 26025B 1 26025B 1 26025B
221 SHAFT. 2 25843A 2 25843A 2 25843A
222 GEAR. 4 25027A 4 25027A 4 25027A
228 SPACER. 4 25847A 4 25847A 4 25847A
240 SHIM 0.002” A 25255AA A 25255AA A 25255AA
241 SHIM 0.003” A 25255AB A 25255AB A 25255AB
242 SHIM 0.005” A 25255AC A 25255AC A 25255AC
243 SHIM 0.010” A 25255AD A 25255AD A 25255AD
244 TEFLON RING. 1 25929B 1 25929B 1 25929B
248 CHECK VALVE. 1 3120A 1 3120A 1 3120A
249 CHECK VALVE. 1 3120B 1 3120B 1 3120B
250 RETAINING RING. 2 2867B 2 2867B 2 2867B
252 RETAINING RING 1 2928N 1 2928N 1 2928N
255 WASHER 2 25977E 2 25977E 2 25977E
256 WASHER 2 25977F 2 25977F 2 25977F
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 HEX HEAD CAP SCREW. 2 2796CL 2 2796CL 2 2796CL
278 HEX HEAD CAP SCREW. 2 2796CT 2 2796CT 2 2796CT
279 HEX HEAD CAP SCREW. 2 2796CZ 2 2796CZ 2 2796CZ
280 HEX HEAD CAP SCREW. 6 2796EL 6 2796EL 6 2796EL
281 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796B
282 SOCKET HEAD CAP SCREW 2 2795D 2 2795D 2 2795D
297 SET SCREW. 2 2060J 2 2060J 2 2060J
298 SET SCREW. 2 2060H 2 2060H 2 2060H
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154
Volume Ratio
Capacity Slide
Slide Valve Carriage Assembly
Carriage Assembly
Slide Valve Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501 - 701
QTY VPN QTY VPN
300 CARRIAGE ASSEMBLY. 1 A25179A 1 A26012B
304 CAPACITY PISTON 340, 341, 350 & 355. 1 A25183A 1 A25183B
305 VOLUME PISTON 340, 342, 350 & 355. 1 A25184A 1 A25184B
316 CAPACITY RACK. 1 25023D 1 25024A
318 CAPACITY RACK SHAFT. 1 25772C 1 25772A
323 VOLUME RATIO RACK. 1 25023C 1 25023A
325 VOLUME RATIO RACK SHAFT. 1 25772D 1 25772B
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
372* SOCKET HEAD CAP SCREW. N/A 1 2795M
373 SOCKET HEAD CAP SCREW. 3 2795A 3 2795N
374 LOCK WASHER (PAIR). 3 3004C 3 3004C
Notes: There are two slide valve carriages per compressor. Each one each has its own Volume
Ratio and Capacity slide valves. The above totals are per side of the compressor, double
the quantities if both slide valve carriages are being worked on.
*. Not Pictured.
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155
Actuating Motor with Optical Sensor
and Command Shaft
156
Actuating Motor with Optical Sensor
and Command Shaft
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501- 701
QTY VPN QTY VPN
Notes: 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 quantities above.
* Bearing changed to steel until 10/25/04, then removed due to housing being modified.
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Miscellaneous Frame Components
158
Miscellaneous Frame Components
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71-401 ALL VSM 501 - 701
QTY VPN QTY VPN
511 DISCHARGE MANIFOLD. 1 25734B n/a
511 240 mm DISCHARGE MANIFOLD
WITH DOWN DISCHARGE. n/a 1 25024BC
511 240 mm DISCHARGE MANIFOLD
WITH HORIZONTAL DISCHARGE. n/a 1 25024BB
511 240 mm DISCHARGE MANIFOLD
WITH UP DISCHARGE. n/a 1 25024BA
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 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
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160
Housing Accessories
C-Flange Assembly
Replacement Parts Accessories
Replacement Parts Accessories
Housing Accessories
MODEL NUMBER
ITEM DESCRIPTION VSM 71 - 701
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
C-Flange Assembly
MODEL NUMBER
ITEM DESCRIPTION VSM 71 - 401 VSM 501 - 701
QTY VPN QTY VPN
1 C-FLANGE. 1 A 1 A
2 ADAPTER. 1 A 1 A
3 HEX HEAD CAP SCREW. 8 2796F 8 2796F
4 HEX HEAD CAP SCREW. 4 2796EL 4 A
5 LOCKWASHER (PAIR). 8 3004H 8 3004H
6 LOCKWASHER (PAIR). 4 3004F 4 A
7 PORT COVER. 2 25685A 2 25685B
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 2 2176BG
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Replacement Tools
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501 - 701
QTY VPN QTY VPN
901 GATEROTOR STABILIZER. 1 25742A 1 25742B
902 SEAL INSTALLATION TOOL 1 25455A 1 25455B
162
Vendor Assessories
Section
163
Haight Pumps
10-80 GPM OIL PUMPS face of the seal will need to be inspected for crack-
VILTER PART NUMBER ing or excessive wear. If they are damaged the seal
3022UB, EU and HU must be replaced at this time.
HAIGHT MODEL 10-80U Series
3. Replace cap "o"-ring (3) at this time.
4. Make sure that the electricity is turned 5. Install the new stationary portion of the
off to the oil pump motor and remove the 4 bolts seal in the cap with the polished surface faces the
and washers from the oil pump mounting face (25 rotating portion of the seal when assembled. Lu-
and 26), remove bolts securing the motor to the bricate the "o''-ring of the stationary portion of the
unit and slide the oil pump motor from the oil pump. seal with clean compressor oil to facilitate the in-
stallation.
5. Remove the set screw from the coupling
half and slide the coupling off of the oil pump shaft. 6. Remove the rotating portion of the seal
Remove the key (1) from shaft. from the oil pump shaft Oil the shaft to aid in the
removal of the seal. The bellows may stick to the
6. Using fine emery paper remove any burrs shaft, this is a normal, this wilt require a little pres-
from the key way area and the end of the sure to start it moving. After the rotating portion
shaft. of the seal is removed, inspect the shaft (22) for
damage and replacd if necessary.
SHAFT SEAL INSPECTION.
REMOVAL AND INSTALLATION. 7. Lubricate the shaft with dean com-
pressor oil and push the replacement seal on to the
1. Prepare the pump for servicing as stated shaft taking care not to touch the carbon face of the
in the previous paragraph. seal.
2. Remove the seal housing by unscrewing 8. Screw the cap back on to the pump hous-
the cap (2) using care as the seal in compressed ing and torque 40 to 60 ft.lbs.
with a spring, therefore the cap may release towards
the key way as the cap is unscrewed. With the cap 9. Re-install the key and coupling, tighten
unscrewed, slide it off of the shaft. The seal (21) the set screw after it is determined that the cou-
will now be visible, but possibly under compres- plings mate up correctly. Pressurize and leak check
sion as the bellows of the the unit concentrating on areas that repairs were
seal may be sticking to the shaft. made.
Carefully, rotate the shaft and inspect the bellows 10. It is normal for the seal to weep a small
of the seal for damage. If it is damaged the seal amount of oil on start-up until the bellows takes a
must be replaced at this time. If the bellows is in set on the shaft.
good shape, then the carbon face and the matting
164
Haight Pumps
Note:
Effective 2002, the ‘D” Series has been discontinued and upgraded to the “U” series.
When placing an order for a new pump and had the “D” (old) series pump you will be
required to upgrade to an “U” and a new Hub will also need to be purchased.
165
Haight Pumps
166
10U through 40U Haight Pump w/o Relief Valve
10U through 40U Haight Pump with Relief Valve
12
CHECK VALVE BULLETIN 50-16C
Type CK4A
Port Size 13 - 100mm (1/2” - 4”)
FOR AMMONIA, R12, R22, R502
AND OTHER COMMON REFRIGERANTS
FEATURES
• UL Listed (Thru 3" Size)
September 1990
• Installs in any position Installation, Service and Parts Information
• Compact
• Lightweight
Purpose
• In-Line The Type CK4A Check Valves prevent backward flow of fluid
• Design Pressure (MRP): 34.5 bar (500 psi) in refrigerant suction, hot gas or liquid lines. The most frequent
use for these valves is in recirculating (overfeed) systems.
They are especially suited for high speed compressor
discharge, pump discharge, suction - down to -50°C (-60°F)
and hot gas lines (pan to evaporator).
Description Certain refrigerant flows pulsate sufficiently or with a
These compact valves are spring closing with a lapped, frequency in harmony with the valve’s natural frequency,
stainless steel or chrome plated seat for positive closing which can cause “slapping” or even wholesale failure. These
action and low leakage. A minimum pressure difference of valves are not recommended for slow speed compressor
0.05 bar (0.75 psi) is required to hold the valve in the open discharge lines (See CK-1, Bulletin 50-10B) or for any
position. Removable seat plate with combination O-ring and compressor discharge where a low speed machine
metal-to-metal knife edge seal allows the valve to be discharges into the same downstream header, or for use on
disassembled for maintenance. They may be ordered with side-port suction lines on a screw compressor installation.
male adapter rings for close-coupling to other Refrigerating
Specialties valves and may be installed in any position. Operation
These are light spring-closing check valves. An increase in
the pressure drop across the valve overcomes the force of
the closing spring and the disc is forced away from its seat
permitting flow. As the flow decreases, the disc is forced
back against its seat by the expansion of the closing spring.
Flow is then stopped.
Installation
Keep dirt from entering the valve. Do not remove protective
packaging until ready to install.
Install the valve where it can be serviced easily. DO NOT
INSTALL AT THE INLET OF A SOLENOID VALVE, OR A
REGULATOR WITH AN ELECTRIC SHUT-OFF FEATURE; DO
NOT INSTALL AT THE INLET OF AN OUTLET PRESSURE
REGULATOR IN A SYSTEM WHERE LIQUID MAY BE
TRAPPED BETWEEN TWO VALVES. Check Valves when used
with such valves should always be installed at the outlet of
the valves.
NOTE: THE ODS COPPER FLANGES AVAILABLE ARE ONLY
FOR INSTALLATIONS WHERE R-12, R-22, AND R-502 OR
OTHER HALOCARBON REFRIGERANTS ARE USED. DO
NOT USE THESE FLANGES FOR AMMONIA. FOR
INSTALLATIONS USING AMMONIA THE FPT, SOCKET WELD
OR WELD NECK FLANGES SHOULD BE USED.
The Type CK4A Valves may be installed in any position. The
valve must be installed with the arrow pointing in the direction
of flow. After installing the valve, tighten the flange bolts evenly.
Fig. 1
The CK4A Check Valves may be closed-coupled to
Refrigerating Specialties Refrigerant Valves and most hand
valves by using a Refrigerating Specialties Male Adapter Ring.
Dimensional Data
PORT SIZE
Dimension 13mm 20-25mm 32mm 50mm 65mm 75mm 100m
(1/2”) (3/4 - 1”) (1-1/4”) (2”) (2-1/2”) (3”) (4”)
mm 75 113 95 114 148 148 179
A
inch 29.3 4.43 3.75 4.50 5.81 5.81 7.06
mm 38 62 95 114 148 148 179
B
inch 1.50 2.43 3.75 4.50 5.81 5.81 7.06
mm 27 32 50 60 70 81 89
C
inch 1.06 1.25 2 2.37 2.75 3.19 3.50
D mm 63 59 79 114 145 157 177
(FPT, SW) inch 2.47 2.32 3.10 4.47 5.72 6.16 6.97
Conn.
Size 3/8, 1/2, 3/4 3/4” 1” 1-1/4” 1-1/4” 1-1/2” 1-1/2” 2” 2-1/2” 3” 4”
mm 82 97 117 117 126 136 171 177 215 245 298
E
inch 3.22 3.82 4.61 4.61 4.97 5.35 6.72 6.97 8.47 9.66 11.72
Conn.
Size 1/2 5/8 7/8 7/8 1-1/8 1-3/8 1-5/8 1-3/8 1-5/8 2-1/8 1-5/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 4-1/8
mm 76 82 98 99 193 99.5 111 119 130 159 193 177 205 203 250 228 248 285
F
inch 2.98 3.22 3.85 3.88 4.07 3.91 4.36 4.69 5.12 6.26 7.57 6.95 8.08 7.98 9.82 8.95 9.76 11.2
mm 9 13 29 20 24 25 28 25 28 34 28 34 37 37 42 42 48 55
N
inch .37 .50 .75 .75 .93 .96 1.09 .96 1.09 1.34 1.09 1.34 1.46 1.46 1.65 1.65 1.90 2.15
mm 13 13 15 15 25 29 32
P
inch .50 .50 .60 .60 1.0 1.1 1.3
FEATURES
• Pilot operated characterized Modulating Plug
for precise control
• Suitable for all common refrigerants and oil
• 27.6 bar (400 psig) design pressure (MRP)
• Flanges for threaded or welded steel pipe and
copper tube (copper not for ammonia)
A4A, A4AE
• Interchangeable parts
• Easy to service
• Close coupled strainers, optional
• Many control variations are possible with the
use of a few Modules and kits. (See
Adaptomode Pressure Regulator Bul. 23-06)
• Stainless Steel Diaphragm
• Chrome Plated Pilot Seat
• Manual Opening Stem
PILOT SEAT
Description
GAUGE PORT
These compact, heavy duty, pilot operated, iron alloy
DIAPHRAGM
(ASTM A126 Class B) Inlet Pressure Regulators are
suitable for Ammonia, R-12, R-22, R-502 and other
POWER PISTON common refrigerants and fluids approved for use in
refrigeration systems.
All A4 Regulators are pilot operated using upstream
pressure for the opening force and requires a minimum
0.14 bar (2 psig) pressure drop to fully open.
These valves are generally ordered with close coupled
upstream strainer to prevent entrance of foreign material
into the valve and the rest of the system. (See current Bul
MODULATING
PLUG 00-10 for strainer information.)
CLOSING Purpose
SPRING
Modulates flow of refrigerant gas or liquid to maintain
DIRT WIPER constant upstream (or inlet) pressure as set-for, despite
load fluctuations. The A4AR is a main valve only and will
MANUAL
control pressures as determined by the remote pilot(s)
OPENING piped to it.
STEM
The fluid temperature range for the A4 Series of
Fig. 1 Regulators is -45°C to 105°C (-50°F to 220°F).
Fig. 2
(**) All Plug Kits and Bottom Assembly Kits for 1-5/8" Port Size Valves can be used in the 2 “ Port Size Valves for reducing capacity.
Remote pilot piping should not exceed 6m (20 ft.) in total Where cold refrigerant liquid lines are used, it is necessary
length and should be 3/8" pipe or equivalent tube size. that certain precautions be taken to avoid damage which
The remote piping must originate in the upstream pipe, could result from liquid expansion. Temperature increase
not at the A4AR valve itself. in a piping section full of solid liquid will cause high
pressure due to the expanding liquid which can possibly
See current issue of Bul. 21-02 for details of A2B Inlet rupture a gasket, pipe or valve. All hand valves isolating
Pressure Pilot. Use A2B2 with 20-50mm (3/4" - 2") A4AR. such sections should be marked, warning against
Use A2B Inlet Pressure Pilot with 65-100mm (2-1/2"- 4") accidental closing, and must not be closed until the liquid
A4AR. is removed. Check valves must never be installed
If main valve is to perform as an Outlet Pressure upstream of solenoid valves, or regulators with electric
Regulator, use Outlet Pressure Pilots A2BO2E for shut-off, nor should hand valves upstream of solenoid
20-50mm (3/4" - 2") A4AR, or A2BO4E for 65-100mm valves or downstream of check valves be closed until the
(2-1/2" - 4") A4AR. liquid has been removed. It is advisable to properly install
relief devices in any section where liquid expansion could
For positive electric shut-off, for all sizes A4AR Main Valve,
take place.
use direct operated pilot solenoid Type S6N. See Bul.
30-90C for details. Avoid all piping or control arrangements which might
produce thermal or pressure shock.
Maintenance and Service For the protection of people and products, all refrigerant
GENERAL PROCEDURE: must be removed from the section to be worked on before
Dirt in the system is the greatest single cause of regulator a valve, strainer, or other device is opened or removed.
malfunction. All screens or filters must be cleaned or
Flanges with ODS connections are not suitable for
replaced when they become dirty. At start up it is especially
ammonia service.
important that these items are cleaned or changed
frequently. When the RSF close-coupled companion
A4A, A4AE
Fig. 3
A4AR
Fig. 4
À FPT: Internal NPT (USA Standard Taper Pipe Thread). Flange Bolt Torque Requirements
Á NW: Metric equivalent nominal size for steel tubing. Bolt Diameter Valve Port Size Torque
 Metric copper tubing used for refrigeration. 11 mm (7/16") 13mm (1/2 ") 3.9 mkg (28 ft lb)
à ODS connections to fit copper tubing of given outside
16m m (5/8") 20-50mm (3/4 "- 2") 11.8 mkg (85 ft lb)
diameter. (Not for use with ammonia)
19m m (3/4") 65-75mm (2-1/2 "- 3") 14.5 mkg (105 ft lb)
Definitions: 22mm (7/8") 100mm (4") 22.1 mkg (150 ft lb)
ODS - Outside Diameter Sweat
I.D. - Inside Diameter
O.D. - Outside Diameter
N.A. - Not Available
Warranty
All Refrigerating Specialties Products are warranted including any warranty of merchantability or warranty
against defect in workmanship and materials for a period of fitness for a particular purpose and in no event is
of one year from date of shipment from factory. This Refrigerating Specialties responsible for any
warranty is in force only when products are properly consequential damages of any nature whatsoever. No
installed, field assembled, maintained and operated in use employee, agent, dealer or other person is authorized to
and service as specifically stated in Refrigerating give any warranties on behalf of Refrigerating Specialties,
Specialties Catalogs or Bulletins for normal refrigeration nor to assume, for Refrigerating Specialties, any other
applications, unless otherwise approved in writing by liability in connection with any of its products.
Refrigerating Specialties Division. Defective products, or
parts thereof, returned to the factory with transportation
charges prepaid and found to be defective by factory Factory Repair and Rebuilding
inspection will be replaced or repaired at Refrigerating For the convenience of our customers, we have a standard
Specialties’ option, free of charge, F.O.B. factory. Warranty factory repair and rebuilding service. Repairable returned
does not cover products which have been altered or Regulators are disassembled, cleaned, sandblasted, worn
repaired in the field; damaged in transit, or have suffered parts replaced, reassembled and re-painted. For quickest
accidents, misuse, or abuse. Products disabled by dirt, service, it is advisable that this be done during the off
or other foreign substances will not be considered peak season.
defective.
The express warranty above constitutes the only warranty
of Refrigerating Specialties products, and is in lieu of all
other warranties, expressed of implied, written or oral,
®
CARTRIDGE
HEATERS
HI-TEMP OPEN AIR TEST WATT DENSITY CALCULATIONS: The subtraction of 3/4” from the overall
length in the above equations is a general
This test was conducted using a 5/8” dia. x 6” Watt density of a Hi-Temp Cartridge is
allowance for the watt density calculations
(15.8 mm x 152 mm) long, 750 watt 240 volt simply the total heater wattage divided by
on Standard Cartridge heaters only.
Hi-Temp Cartridge heater. The test was con- the heated area of the cartridge in square
ducted in ambient air 70º F (21º C). A type ‘J’ inches. Hi-Temp Cartridge heaters, heated length
thermocouple was attached to the heater at varies depending upon heater diameter
the center of the sheath. The voltage was Watt Total Heater Wattage and length.
=
varied through a variac to obtain proper Density
(Heated Length) x Cartridge Dia. x 3.14 For specific unheated sections contact
power input for corresponding watt density. Fast Heat.
Heated Length = OAL – Unheated Sections
(OAL - Overall Length)
1600º F (871º C)
APPROXIMATE TEMPERATURE IN DEGREES AT THE
1500º F (815º C)
1400º F (760º C)
CENTER OF THE HEATER
1300º F (704º C)
1200º F (649º C)
1100º F (593º C)
1000º F (538º C)
900º F (482º C)
800º F (427º C)
WATTS PER SQUARE INCH / WATTS PER SQUARE CM SHEATH; HI-TEMP CARTRIDGE
HEATER (THIS GRAPH FOR REFERENCE ONLY)
STANDARD CARTRIDGES MATERIAL AND CONSTRUCTION • U.L. approved and C.S.A. certified flexible
nickel conductor with fiberglass insulated
Our Standard Cartridge heaters are • Computer designed specifications.
lead wire 482º F, (250º C) is standard.
designed as an economical, quality heater • 304 stainless steel sheath for oxidation Mica tape/fiberglass insulated 842º F,
for lower temperature use (typically 40 resistance. (450º C) available when requested
watts per square inch, depending on the
• Ceramic insulator spaces helically wound as dictated by the application.
application). Standard Cartridges can meet
U.L./C.S.A. approval, use the chart on page resistor inside the sheath. • Disc end of the heater rests on a mica
151 for reference and consult factory. • Helically wound nickel chromium resistor insulator and is held in position when
is of a conservative design for each the sheath is rolled over onto it. This is a
The Standard Cartridge Heater is made to
application and evenly stretched through standard assembly procedure unless the
withstand internal temperatures of up to
the ceramic insulators. application requires moisture or water-
1000º F (538º C) and features a stainless
proof sealing, at which time the end cap
steel sheath for resistance to oxidation. • Fine grain high purity magnesium oxide can be sealed by brazing or welding.
High-purity magnesium oxide (MgO) fills (MgO) fills any voids around the resistor
any space around the resistor wire in order wire to optimize heat transfer, dielectric • Ceramic cap standard; cement, epoxy or
to optimize heat transfer and increase the strength and life of the heater. RTV seal also available.
life of the heater.
• Resistor wire is joined to the leads by
For faster shipment, Standard Cartridges are placing each end into nickel chromium
available through our Fast Track delivery which, upon crimping, affords a positive
program. Refer to page 2 for a complete and consistent junction.
description of these rapid delivery programs. Crimped tubing
Core
APPLICATIONS MgO
Standard Cartridge heaters can be used in
virtually any application involving lower
temperatures and relatively little vibration or Spacer
impact. Some examples include sealing bars,
heating platens, heating fluids and forming.
Standard Cartridges can also be modified to
meet the demands of special applications.
Our engineers can utilize a variety of alterna- Ceramic cap
tive features and options to customize the
heater to your specific needs.
Lead wire
Standard
Standard
STRAIGHT LEADS W/SILK AND PAINT Repairable silk and paint leads for Standard
Cartridges.
Overall length Hi-Temp
Hi-Temp Cartridges are provided with
approx. 1” (25.4 mm) sleeving as standard.
Silk and paint leads are optional on
Hi-Temps.
10” (25.4 cm) leads standard, other lengths
are available.
Standard
Standard
Standard
BRAID OVER PAIR OF LEADS Stainless steel braid over lead wires.
For applications requiring small radius
Overall length Hi-Temp
bending and lead wire abrasion protection.
10” (25.4 cm) braid standard, other lengths
are available.
Standard
SQUARE-LOCK ARMOR STRAIN RELIEF Straight stainless steel armor cable protects
leads from abrasion.
Overall length Hi-Temp
Armor sizes include:
Square-lock - 1/4”, 5/16”, 1/2”, and 5/8”.
Convoluted - 3/8”, and 5/8” only.
(Moisture-resistant)
10” (25.4 cm) standard, other lengths
are available.
Standard
CONVOLUTED ARMOR STRAIN RELIEF
?
POTTING SYSTEMS AVAILABLE
Overall length Hi-Temp
1. Cement 1000º F (538º C)
2. Epoxy 300º F (149º C)
3. RTV® 500º F (260º C)
4. Teflon® Cap 500º F (260º C)
• Cement seal can be wiped with a
Silicon® varnish to inhibit moisture
penetration.
CONVOLUTED ARMOR Standard • Teflon® Cap requires an extended
• Used in situations that require moisture resistant armor.
• Available in most instances in which armor is utilized. lead time.
• Some size restrictions apply.
Armor length
Standard
BUSHING, ARMOR AND PLUG Hex head N.P.T. bushing and armor cable
with power plug attached.
Insert length Hi-Temp
Sheath material types: stainless steel, cold
rolled or steel.
Must specify insert length, bushing material,
armor length and Hubbell® power plug
number.
Moisture-resistant armor available.
Armor length
Standard
BOLT HEATER Fast Heat bolt heaters are designed to
heat drilled metal surfaces quickly while
Insert length minimizing heat loss to surrounding areas.
Each is designed to expand drilled bolts or
studs while maintaining a uniform heat
throughout its heated length. Typically, after
a bolt is heated (expanded) the holding nut
is tightened. The shrink tightness is obtained
when the heater is removed and the bolt
cools. This process is frequently used in the
Standard assembly and/or servicing of heavy duty
equipment such as compressors, steam
turbines, pressure vessels, etc.
RIGHT ANGLE ELBOW Hi-Temp Right angle copper elbow for applications
requiring right angle lead exit.
B Insert length
Moisture-resistant seal is optional.
A
10” (25.4 cm) leads standard, other lengths
are available.
C Both Hi-Temp and Standard Cartridges are
also available with stainless steel braid over
the leads (See Standard at left).
Standard
Standard leads
ELBOW DIMENSIONS
A B C
Standard IN MM IN MM IN MM
3/8 9.5 1 25.4 1 25.4
1/2 12.8 1 1⁄4 31.8 1 1⁄4 31.8
5/8 15.9 1 1⁄4 31.8 1 1⁄2 38.1
3/4 19.1 1 5⁄8 41.3 1 1⁄2 38.1
Standard
Standard
90º LEADS W/S. ST. BRAID Hi-Temp Braided leads exit at 90º angle for applica-
D tions requiring small radius bends, lead wire
Overall length
protection and where space is limited.
A 10” (25.4 cm) braid standard, other lengths
are available.
Order by overall length.
Standard
90º S. ST. ARMOR Hi-Temp Armor cable exit at 90º angle for applications
D where space is limited and lead wire
Overall length abrasion protection is required.
A 10” (25.4 cm) armor standard, other lengths
are available.
Order by overall length.
A D (min.)
Standard IN MM IN MM
Standard
1/2” -
5/8”
Standard
Standard
BOTTOM UNGROUNDED
Where circumstances are such that an
ungrounded thermocouple is required.
Hi-Temp
CENTER UNGROUNDED
The thermocouple is positioned internally
and ungrounded to monitor the heater
temperature.
Generally used in research and
Hi-Temp
development applications.
Convoluted Armor
WIDTH
SIZE TOLERANCE DIM. A MAX.
FITTING CHART
FEATURES
• Handwheel or Seal Cap
• Replaceable PTFE seat disc
• Full-ported angular seat allows washing action
• Positive shut-off
• Low pressure drop
• 50 & 100 mesh stainless steel screen
• Stainless steel stem with positive back seating
• Drain connection for safe cleaning
• Maximum Safe Working Pressure 400 PSIG March 2003
• Fluid Temperature Range -65°F to +350°F Installation, Service and Parts Information
Description
Safe Operation (See also Bulletin RSB)
The Refrigerating Specialties combination stop/strainer People doing any work on a refrigeration system must be qualified
shut-off valves are designed to provide all the benefits of a and completely familiar with the system and the Refrigerating
typical valve and strainer assembly within a single valve Specialties Division valves involved, or all other precautions will
be meaningless. This includes reading and understanding
body. This unique combination valve decreases the pertinent Refrigerating Specialties Division product Bulletins and
effects of pressure drop in a system by eliminating the Safety Bulletin RSB prior to installation or servicing work.
need for a separate strainer, while reducing system and
Where cold refrigerant liquid lines are used, it is necessary that certain
installation costs. precautions be taken to avoid damage that could result from liquid
expansion. Temperature increase in a piping section full of solid liquid
will cause high pressure due to the expanding liquid that can possibly
rupture a gasket, pipe or valve. All hand valves isolating such sections
should be marked, warning against accidental closing, and must not be
HANDWHEEL SEAL CAP closed until the liquid is removed. Check valves must never be installed
upstream of solenoid valves, or regulators with electric shut-off, nor
should hand valve upstream of solenoid valves or downstream of check
valves be close until the liquid has been removed. It is advisable to
properly install relief devices in any section where liquid expansion
could take place.
310604
SPARE PARTS
ITEM DESCRIPTION PORT SIZE
1/2 & 3/4 * 1/2 & 3/4 1* 1 1-1/4 1-1/2 2 2-1/2 3
20-24 Handwheel 204268 204268 204268 204268 204269 204269 204269 204269 204270
Seal Cap 204273 204273 204273 204273 204274 204274 204274 204274 204275
10-13 Packing Kit 204471 204471 204471 204471 204472 204472 204472 204472 204473
5-14 Bonnet Asm 206865 206865 206866 206866 206867 206868 206869 206870 206871
15, 18 Screen Asm 206873 206873 206874 206874 206874 206875 206876 206877 206878
6-8 Disc Kit 204321 204322 204323 204324 204325
2 Gasket Pkg Bonnet 204281 204281 204282 204282 204283 204283 204284 204285 204286
Gasket Pkg Seal Cap 204292 204292 204292 204292 204292 204292 204292 204292 204293
5 9
7 6
8
1
15
16 17
18
19
20
OV E RA LL V A LV E DIM E NS IONS
1/2" & 3/4"* 1/2" & 3/4" 1"* 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
(13 & 20 (13 & 20
P ORT S IZE (25 M M ) (25 M M ) (32 M M ) (40 M M ) (50 M M ) (65 M M ) (75 M M ) (100 M M )
MM) MM)
M M INCH M M INCH M M INCH M M INCH M M INCH M M INCH M M INCH M M INCH MM INCH MM INCH
Aw 197 7.75 197 7.75 235 9.25 235 9.25 200 7.87 204 8.03 233 9.18 231 9.12 290 11.43 231 13.03
As 216 8.50 216 8.50 230 9.03 230 9.03 212 8.37 220 8.68 231 9.12 324 12.75 324 12.75 354 13.93
B 57 2.25 57 2.25 82 3.25 82 3.25 89 3.50 108 4.25 125 4.93 149 5.87 162 6.37 212 8.37
C 85 3.37 165 6.50 108 4.25 192 7.56 216 8.50 235 9.25 260 10.25 260 10.25 324 12.75 406 16.00
W 85 3.37 85 3.37 108 4.25 98 3.87 104 4.12 109 4.31 113 4.56 130 5.12 180 7.12 238 9.37
STRAINERS
TYPE 8000 SERIES
for REFRIGERANTS / BRINE / WATER / OIL
TYPE 6000 STRAINER suitable for brine and water applications, and other
liquids where a strainer made of nonferrous material is desirable.
These strainers have a forged brass body, and stainless steel wire cloth
screen. Types 6022 through 6088 have a knife edge seal plug. The maxi-
mum safe working pressure is 500 psig.
Bulletin 50-10, June 2000 supersedes Bulletin 50-10 dated July 1996 and all prior publications.
© Copyright 2000 By Sporlan Valve Company, Washington, Missouri.
Page 2 / Bulletin 50-10
Semi-cast steel body with FPT inlet and flanged outlet connections. Strainer screen
is stainless steel with a seal plug for screen removal. Complete unit is zinc plated
and painted. The maximum safe working pressure is 500 psig.
CONNECTIONS
SCREEN WEIGHT - Lbs. DIMENSIONS - Inches
TYPE Inches MESH
NO. AREA PART SIZE SHIP-
INLET *OUTLET NET A B C E F G H K L
Sq. In. NO. PING
XD 074 2 FPT Flange 6.6 635-3 100 1-w 3 4.19 1.50 2.25 2.88 2.00 0.78 1.09 0.50 0.13
* Strainers are supplied with female companion flange. Available without flange when so ordered.
WEIGHT
SCREEN DIMENSIONS - Inches
TYPE CONNECTION MESH Lbs.
NO. Inches AREA PART SIZE SHIP-
NET A B C D E F G H K L
Sq. In. NO. PING
8004 2 FPT*
15 4097-3 80 5 7 5.69 2.75 5.06 2.06 3.81 2.69 1.28 1.75 0.56
8006 w FPT*
0.13
9008 1 FPT** 11
23 4110-3 60 13 7.56 3.13 7.50 2.44 3.75 1.81 2.31 0.75
9010 1-4 FPT** 10-2
* Strainers are supplied without companion flange. Female companion flange, bolts, and gasket can be supplied when ordered.
** Strainers are supplied without companion flange. Male companion flange, bolts and gasket can be supplied when ordered.
HANSEN TECHNOLOGIES
CORPORATION
Specifications, Applications,
Service Instructions & Parts
HCK4 IN-LINE
CHECK VALVES
5 / 8 " thru 4" PORT
Flanged
3 8
/ " thru 4"
FPT, SW, WN, ODS
for refrigerants
ADVANTAGES
These compact check valves offer reliable operation
regardless of position. Corrosion resistant stainless
steel seat disc. Metal-to-metal seats facilitate durable,
tight closing of valves.
APPLICATIONS
These in-line check valves are designed to provide
refrigerant flow control to hot gas lines, liquid lines, ADDITIONAL FEATURES
compressor discharge lines, suction lines, and hot Mounts in any position
gas heated drain pans. Less than 1 PSID wide opening pressure
Can be close-coupled
These valves are not recommended for use with Low bubble leakage tolerance
pulsating loads such as low speed compressor For Ammonia, R22, R134a, and other approved
discharge and screw compressor side port refrigerants
applications. For applications such as these, use Dimensionally replaces R/S CK4A-2, -3, -4, -8, & -1
Hansen HCK1 piston type check valves. U.L. Listed
MATERIAL SPECIFICATIONS INSTALLATION
Body: Valve may be located in any position. Arrow on
5 / 8 " thru 1¼": Steel, ASTM A108, zinc chromate valve body should match direction of flow. Secure
plated valve with gaskets between flanges and tighten
1½" thru 4": Ductile iron, ASTM A536, zinc bolts evenly. Do not use this valve or any component
chromate plated to align pipes or tighten gap between flanges.
Seat Disc: Stainless steel
Seat Cartridge: Do not install on inlet side of solenoid valves or
5 / 8 " thru 1¼": Stainless steel, ASTM A582 control valves with electric shut-off or shut-off valves
1½" thru 4": Steel, ASTM A108, zinc chromate unless a relief valve is used from therein between
plated piping. Do not install on inlet side of outlet pressure
Spring: Stainless steel regulators where liquid may become trapped.
Safe Working Pressure: 400 PSIG (27 bar) Instead, check valves should be located on outlet
Operating Temperature: -60F to 240F (-50 to 115°C) side of these valves. Check valves can be close-
coupled to other matching solenoid valves, pressure
regulators, or strainers by using a Male Adapter
Ring and longer bolts supplied when so specified
on order.
INSTALLATION DIMENSIONS
5 8
/ "
2.50" 3.25" 3.25" 3.25" 5.06" 5.06" 6.06" 6.06" 6.39"
A
(64 mm) (83 mm) (83 mm) (83 mm) (129 mm) (129 mm) (154 mm) (154 mm) (162 mm)
3.19" 4.50" 4.50" 4.50" 4.56" 4.56" 6.00" 6.00" 7.13"
B
(81 mm) (114 mm) (114 mm) (114 mm) (116 mm) (116 mm) (152 mm) (152 mm) (181 mm)
3.50" 4.50" 4.50" 4.50" 6.38" 6.38" 7.50" 7.50" 8.00"
C
(89 mm) (114 mm) (114 mm) (114 mm) (162 mm) (162 mm) (191 mm) (191 mm) (203 mm)
0.38" 0.50" 0.50" 0.50" 0.75" 0.75" 1.00" 1.00" 1.00"
D
(10 mm) (13 mm) (13 mm) (13 mm) (19 mm) (19 mm) (25 mm) (25 mm) (25 mm)
1.03" 1.22" 1.22" 1.22" 2.56" 2.56" 2.92" 2.92" 3.50"
E=
(26 mm) (31 mm) (31 mm) (31 mm) (65 mm) (65 mm) (74 mm) (74 mm) (89 mm)
1.50" 2.37" 2.37" 2.37" 3.62" 3.62" 4.84" 4.84" 6.06"
F
(38 mm) (60 mm) (60 mm) (60 mm) (92 mm) (92 mm) (123 mm) (123 mm) (154 mm)
1.56" 2.50" 2.50" 2.50" 4.56" 4.56" 6.00" 6.00" 7.13"
G
(40 mm) (64 mm) (64 mm) (64 mm) (116 mm) (116 mm) (152 mm) (152 mm) (181 mm)
2.19" 3.12" 3.12" 3.12" 3.06" 3.06" 4.00" 4.12" 5.00"
H
(56 mm) (79 mm) (79 mm) (79 mm) (78 mm) (78 mm) (102 mm) (105 mm) (127 mm)
3.26" 4" 4" 4" 6.06" 6.06" 7.06" 7.06" 9.89"
J
(83 mm) (102 mm) (102 mm) (102 mm) (154 mm) (154 mm) (179 mm) (179 mm) (251 mm)
0.33" 0.49" 0.59" 0.62" 0.71" 0.87" 0.96" 1.08" 1.40"
K
(8 mm) (12 mm) (15 mm) (16 mm) (18 mm) (22 mm) (24 mm) (27 mm) (36 mm)
Valve Cv (Kv) 5.8 (5) 8.2 (7) 11.7 (10) 14.0 (12) 39 (33) 50 (43) 74 (63) 93 (80) 210 (180)
Pipe Size ½", ¾" ¾" 1" 1¼" 1½" 2" 2½" 3" 4"
*Dimensionally replaces R/S check valve models CK4A-2, -3, -4, -8, and -1. = "E" dimension is check valve body outside
edge to outside edge. Flange groove depth: nominal 0.12" each of two; gasket thickness: nominal 0.06" each of two.
2
PARTS LIST
HCK4-2 (2-BOLT) HCK4-2 (2-BOLT)
SIZING
Check valves are normally selected on the basis of HCK4-2* 5 8
/" (16) ½" 3 8
/ ", ¾" 5 8
/ "
line size. However, for gas flow applications at low HCK4-3* ¾" (20) ¾" 1", 1¼" 7 8
/ "
load conditions, a minimum of 1 psid across the 1 8
HCK4-4* 1" (25) 1" ¾", 1¼" 1 /"
valve is essential. This will maintain valve at full
open position. Valve Cv (Kv) is listed in the HCK4-5 1¼" (32) 1¼" ¾", 1" 1 3/ 8"
installation dimension table on page 2. Factory valve HCK4-7 1½" (40) 1½" 2" 1 5/ 8"
sizing assistance is available. HCK4-8* 2" (50) 2" 1½" 2 1/ 8"
HCK4-9 2½" (65) 2½" 3" 2 5/ 8"
HCK4-0 3" (80) 3" -- 3 1/ 8"
SERVICE AND MAINTENANCE HCK4-1* 4" (100) 4" -- 4 1/ 8"
These valves are a reliable part of a refrigeration
system. However, if valve does not appear to be * Replaces R/S CK4A-2, CK4A-3, CK4A-4, CK4A-8, & CK4A-1.
HCK4-2 close-couples to HS6 & HS8 Solenoid Valves.
operating satisfactorily, isolate it from the refrigeration
HCK4-3, -4, & -5 close-couples to HS7 Solenoid Valve.
system. Remove all refrigerant from associated piping FPT available only 3/ 8" to 1¼".
and valves. Follow the guidelines in the caution
section. Loosen each flange nut on the check valve. TO ORDER: Specify valve type, connection style and
Break each flange gasket seal. Carefully loosen size, and close-coupling information if needed.
flange bolts one at a time, being cautious to avoid
any refrigerant which still may be present. Remove
check valve from flanges and inspect. Lapped seating TYPICAL SPECIFICATIONS
surfaces should be smooth and free of pits or
"Refrigeration in-line check valves shall have steel
scratches.
or ductile iron bodies, stainless steel seat discs,
To confirm valve operation, move seat disc with stainless steel closing springs, and be suitable for
eraser end of pencil. Movement should be free from a safe working pressure of 400 PSIG, as manufactured
friction. If not, disassemble and visually inspect for by Hansen Technologies Corporation type HCK4 or
dirt in valve or burrs on seat disc. Clean or replace approved equal."
parts as necessary. Valve discs and seats can be
restored by lapping on a flat plate. Typical close-coupling to solenoid valve.
CAUTION
Hansen check valves are only for refrigeration
systems. These instructions and related safety
precautions must be completely read and understood
before selecting, using, or servicing these valves.
Only knowledgeable, trained refrigeration mechanics
should install, operate, or service these valves. Stated
temperature and pressure limits should not be
exceeded. Valves should not be removed unless
system has been evacuated to zero pressure. See ISO 9002
Hansen Technologies Corp.
also Safety Precautions in current List Price Bulletin Burr Ridge, IL Cert. # 000472
Orlando, FL Cert. # 001523
and Safety Precautions Sheet supplied with product.
Escaping refrigerant might cause personal injury, HANSEN TECHNOLOGIES
particularly to the eyes and lungs. CORPORATION
6827 High Grove Boulevard
Burr Ridge, Illinois 60527 U.S.A.
Telephone: (708) 325-1565 FAX: (708) 325-1572
Toll-free: 1-800-426-7368
© 1995 Hansen Technologies Corporation Printed in U.S.A.
TECHNICAL SERVICE MANUAL
HEAVY DUTY PUMPS SECTION TSM 144
SERIES 4195 and 495 PAGE 1 OF 9
SERIES GG - AL ISSUE B
CONTENTS
Introduction 1
Special Information 2
Special Mechanical Seals 2
Maintenance 2
Disassembly 3
Assembly 5
Thrust Bearing Adjustment 7
Installation of Carbon Graphite Bushings 7 FIGURE 1
Pressure Relief Valve Instructions 7 GG. HJ and HL 4195 SERIES
Foot Type Unmounted Pump with Tapped
INTRODUCTION
The illustrations used in this manual are for identification
purposes only and cannot be used for ordering parts. Obtain
a parts list from the factory or a Viking® representative.
Always give complete name of part, part number and
material with model number and serial number of pump
when ordering repair parts. The unmounted pump or pump
unit model number and serial number are on the nameplate
secured to the pump.
In the Viking model number system, basic size letters are
combined with series number (4195 and 495), indicating both
the unmounted or mounted pump units.
This manual deals only with Series 4195 and 495 Heavy
Duty Pumps. Refer to Figures 1 thru 14 for general
configuration and nomenclature used in this manual. Pump
specifications and recommendations are listed in Catalog
Section 144, Series 4195 and 495 Heavy Duty Pumps.
FIGURE 4
AS, AK and AL SIZE 495 SERIES
VIKING PUMP INC. • Unmounted Pump with Tapped Ports
A Unit of IDEX Corporation •
SPECIAL INFORMATION SPECIAL MECHANICAL SEALS
This bulletin illustrates the mechanical seal which is
standard in the catalog pump. A Seal Installation
DANGER Drawing will be furnished with a pump fitted with a non-
standard mechanical seal. Consult this Seal Installation
BEFORE OPENING ANY VIKING PUMP LIQUID Drawing before disassembling pump.
CHAMBER (PUMPING CHAMBER,
Modifications are required to install Teflon seals in
RESERVOIR, RELIEF VALVE ADJUSTING CAP
these pumps. Contact factory for specific information.
FITTING ETC.) BE SURE:
1. THAT ANY PRESSURE IN CHAMBER RELIEF VALVE ADJUSTING SCREW CAP
HAS BEEN COMPLETELY VENTED
THROUGH SUCTION OR DISCHARGE
LINES OR OTHER APPROPRIATE
OPENINGS OR CONNECTIONS.
2. THAT THE DRIVING MEANS (MOTOR,
TURBINE, ENGINE, ETC.) HAS BEEN SUCTION DISCHARGE
“LOCKED OUT” OR MADE NON-
OPERATIONAL SO THAT IT CANNOT BE
STARTED WHILE WORK IS BEING DONE
ON PUMP.
3. THAT YOU KNOW WHAT LIQUID THE FIGURE 5
PUMP HAS BEEN HANDLING AND THE
PRECAUTIONS NECESSARY TO SAFELY MAINTENANCE
HANDLE THE LIQUID. OBTAIN A
Series 4195 and 495 pumps are designed for long, trouble-
MATERIAL SAFETY DATA SHEET
free service life under a wide variety of application
(MSDS) FOR THE LIQUID TO BE SURE
conditions with a minimum of maintenance. The points
THESE PRECAUTIONS ARE
SPECIAL INFORMATION
UNDERSTOOD.
listed below will help provide long service life.
CLEANING PUMP: Keep pump as clean as possible. This
FAILURE TO FOLLOW ABOVE LISTED will facilitate inspection, adjustment and repair work and
PRECAUTIONARY MEASURES MAY RESULT help prevent overlooking a dirt covered grease fitting.
IN SERIOUS INJURY OR DEATH.
STORAGE: If pump is to be stored, or not used for six
months or more, pump must be drained and a light coat of
non-detergent SAE 30 weight oil must be applied to all
ROTATION: Viking pumps operate equally well in a internal pump parts. Lubricate fittings and apply grease to
clockwise or counterclockwise rotation. Shaft rotation pump shaft extension. Viking suggests rotating pump shaft
determines which port is suction and which is discharge. by hand one complete revolution every 30 days to circulate
Suction Port is where pumping elements (gear teeth) come the oil.
out of mesh.
SUGGESTED REPAIR TOOLS: The following tools must
PRESSURE RELIEF VALVES: be available to properly repair Series 4195 and 495 pumps.
1. Viking pumps are positive displacement pumps and These tools are in addition to standard mechanics’ tools
such as open end wrenches, pliers, screw drivers, etc.
must be provided with some sort of pressure protection.
Most of the items can be obtained from an industrial supply
This may be a relief valve mounted directly on the
house.
pump, an inline pressure relief valve, a torque limiting
device or a rupture disk. 1. Soft Headed hammer
2. There are relief valve options available on those pump 2. AlIen wrenches (set screws & special mechanical seals)
models designed to accept a relief valve. Options may 3. Snap Ring Pliers
include a return to tank relief valve and a jacketed relief INTERNAL – Viking Part No. 2-810-047-999
valve. Pumps equipped with a jacketed head plate are GG-HJ-HL 4195-495
generally not available with a relief valve. EXTERNAL – Viking Part No. 2-810-029-375
3. If pump rotation is reversed during operation, pressure GG-HJ-HL 4195-495
protection must be provided on both sides of pump. 4. Mechanical Seal Installation Sleeve
2-751-001-900 for 0.75 inch seal; GG 4195-495
4. Relief valve adjusting screw cap must always point
2-751-004-900 for 1.25 inch seal; AS-AL 4195-495
towards suction side of pump. If pump rotation is
reversed, remove pressure relief valve and turn end for 5. Bearing Locknut Spanner Wrench
end. Refer to Figure 5. (Source: #471 J.H. Williams & Co. or equal)
5. Pressure relief valves should not be used to control 6. Spanner Wrench, adjustable pin type for use on bearing
housing end cap.
pump flow or regulate discharge pressure.
(Source: #482 J.H. Williams & Co. or equal)
For additional information on pressure relief valves, refer to 7. Brass bar
Technical Service Manual TSM 000 and Engineering
8. Arbor press
Service Bulletin ESB-31.
MECHANICAL SEAL
SHAFT
SNAP RINGS
IDLER PIN
CASING
HEAD GASKET
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART
1 Locknut 7 Ball Bearing, Inner 12 Idler Bushing 18 Gasket for Relief Valve
2 Snap Ring, Outer 8 Casing (4195) 13 Idler and Bushing 19 Relief Valve
3 Ball Bearing, Outer 8A Casing (495) 14 Head Gasket 20 Capscrew for Valve
4 Snap Ring for Shaft * 9 Pipe Plug 15 Idler Pin
5 Bearing Housing 10 Mechanical Seal 16 Head and Idler Pin
6 Snap Ring, Inner 11 Rotor and Shaft 17 Capscrew for Head
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART
LOCKNUT
BEARING HOUSING
BALL BEARING
NYLON INSERT
END CAP
LIP SEAL
LOCKNUT
BEARING HOUSING
SETSCREW
10. The rotor and shaft can now be removed by tapping on 13. GG, HJ, HL: Remove inner snap ring and single row
end of shaft with a lead hammer or, if using a regular ball bearing from casing.
hammer, use a piece of hardwood between shaft and AS, AK, AL: Remove single row ball bearing from
hammer. The rotary member of the seal will come out casting.
with rotor and shaft.
14. Remove seal seat or stationary part of seal from casing.
11. AS,AK,AL: Remove bearing retainer washer. The
15. Disassemble thrust bearing assembly.
washer may have stayed with Rotor and
Shaft when removed or is against ball GG, HJ, HL: Remove outer snap ring from bearing
bearing. See Figure 10. housing and remove ball bearing. See
12. Remove the mechanical seal rotary member and spring Figure 9.
AS, AK, AL: Loosen two set screws in flange outside
from rotor and shaft assembly.
diameter. Rotate end cap and lip seal
counterclockwise and remove. Remove
ball bearing. See Figure 10.
ASSEMBLY
Assembly Notes On Standard Mechanical Seal
(Synthetic Rubber Bellows Type) FIGURE 12
Prior to installing rotary portion of mechanical seal, prepare 5. Place seal spring on shaft against rotor hub. Refer to
and organize rotor shaft, head and idler assemblies and Figure 12.
appropriate gaskets for quick assembly. 6. Slide rotary member, lapped contact surface facing away
Once rotary portion of mechanical seal is installed on rotor from spring, over installation sleeve on shaft until just
shaft, it is necessary to assemble parts as quickly as contacting the spring. Do not compress spring. Remove
possible to insure the seal does not stick to shaft in wrong installation sleeve.
axial position. The seat will stick to the shaft after several 7. Coat rotor shaft with non-detergent SAE 30 weight oil.
minutes setting time. Install shaft slowly pushing until the ends of rotor teeth
Never touch sealing faces with anything except clean are just below the face of the casing.
hands or clean cloth. Minute particles can scratch the seal 8. Leave the rotor in this position. Withdrawal of rotor and
faces and cause leakage. shaft may displace the carbon seal rotating face and
1. Coat idler pin with non-detergent SAE 30 weight result in damage to the seal.
oil and place idler and bushing on idler pin in 9. Place O-ring gasket on head and install head and idler
head. If replacing a carbon graphite bushing, refer assembly on pump. Pump head and casing were marked
to Installation of Carbon Graphite Bushings, page before disassembly to insure proper reassembly. If not,
7. be sure idler pin, which is offset in pump head, is
2. Clean rotor hub and casing seal housing bore. positioned up and equal distance between port
Make sure both are free from dirt and grit. Coat connections to allow for proper flow of liquid through
outer diameter of seal seat and inner diameter of pump.
seal housing bore with non-detergent SAE 30 10. Tighten head capscrews evenly.
weight oil.
11. If pump was equipped with a relief valve and was
3. Start seal seat in seal housing bore. If force is removed during disassembly, install on head with new
necessary protect seal face with a clean gaskets. Relief valve adjusting screw cap must always
cardboard disc and gently tap i1 in place with a point towards suction port. Refer to Figure 5 page 2. For
piece of wood. Be sure seal seat is completely relief valve repair or adjustments, see PRESSURE
seated in the bore. RELIEF VALVE INSTRUCTIONS, Page 7.
FIGURE 14 ASSEMBLY
VALVE – AS, AK and AL SIZES
Reverse procedures outlined under Disassembly. If valve
is removed for repairs, be sure to replace in same
VALVE - LIST OF PARTS position. Relief valve adjusting screw cap must always
1. Valve Cap 6. Valve Body point towards suction side of pump. If pump rotation is
2. Adjusting Screw 7. Valve Spring reversed, remove relief valve and turn end for end. Refer
to Figures 5, page 2.
3. Lock Nut 8. Poppet
4. Spring Guide 9. Cap Gasket
5. Bonnet 10. Bonnet
DANGER
2010 2” NPT
2010-1 1 1/2” NPT
2010J24 1 1/2” SAE O-Ring
A2010J32 2” SAE O-Ring
F2010 2” 125# FF Flange
SF2010 2” 150# RF Flange
SF2010X 2” 300# RF Flange
When used in a diverting application, on start-up the total fluid flow is rout- Heavy Duty
ed back to the main system. As fluid temperature rises to the control
range, some fluid is diverted to the cooling system. As fluid temperature Self-Contained
continues to increase, more flow is diverted. When the thermostat is in a
fully stroked condition, all fluid flow is directed to the cooling system. FPE Replaceable Element
Thermostatic Valves may also be used in a mixing application.
In a mixing application, hot fluid enters the “B” port and colder fluid enters Non-Adjustable
the “C” port. The flows mix and the thermostat adjusts to reach the desired
temperature, exiting the “A” port. Rugged Construction
Standard FPE thermostatic valve housings are made from aluminum and Tamper-Proof
grey iron castings, however, ductile iron, bronze, steel and stainless steel
housings are available.
Operate in Any Position
Available Connections: NPT, SAE O-Ring, 125# FF Flange, 150# and
300# RF Flange. Compact
Optional features: High over temperature element, plated element. Other Available for Refrigeration Service
options available upon request.
* (Replace * with body material type; A=Cast Iron, B=Bronze, D=Ductile, S=Steel, SS=Stainless Steel)
PRESSURE RATINGS
MATERIAL PSI
A, B 150
D 250
S, SS 500
SF, SSF 275
SFX, SSFX 720
To Order
FLUID POWER ENERGY, INC. Specify Model Number, nominal
temperature desired, and housing
W229 N591 Foster Court • Waukesha, WI 53186 material. For Model coding information,
visit our website or consult your
262 • 548 • 6220 Fax 262 • 548 • 6239 factory representative.
www.fpevalves.com
FPE-2010-050803
August 2003 / BULLETIN 30-11
SOLENOID VALVES
Installation and Servicing Instructions
■ When changing from the old KC model coils to the current Types B6, B9, B10, B14, B19, B25 Series (Brass Connections)
MKC molded model coils, discard the coil housing, coil 1. Remove the coil assembly, enclosing tube and nut, all internal
housing bottom plate, two coil sleeves (not used with KC-1 parts, and manual lift stem assembly.
coil) AND THE SPACER. 2. Locate the word IN or the directional arrow on the valve body.
3. Place the valve in the line in the proper direction of flow and
■ The OMKC-2 coil fits the OB9, OE9, OB10, OE10, OB14, OE14, solder.
OB19, OE19, OB25, OE25, OB33, OE33, OE34, OE42 series
normally open solenoid valves and the XRN, XRM, XPO
series rapid cycle solenoid valves.
■ Figure 1
Enclosing
■ Other Sporlan Valve products using a molded coil are as Tube Locknut
follows: Enclosing Tube
MKC-1 — OM-1, SORIT, 8D, 12D, 10G, SORIT-PI, 5D, SHGB(E)-8. Enclosing
MKC-2 — 16D, DDR-20, SHGB(E)-15, OLDR-15 and OLDR-20. Kickoff Spring Tube Gasket
OMKC-2 — LDR-15, LDR-20, XTM and XTO. Stem and Plunger
To insure peak performance, solenoid valves must be selected and Valve Body Seat Disc
applied correctly; however, proper installation procedures are equally
important. The following instructions list the essential points for
correct installation.
Manual Lift Stem
An exploded view of a typical solenoid valve is illustrated in Figures (if required)
5, 5A and 6, page 4.
Position — All standard solenoid valves may be mounted 4. Re-assemble as follows, see Figures 1, 5, and 5A:
horizontal, on its side or in a vertical line with the exception of the a. Place the seat disc into the valve body with the smaller
following: A3 dated 6-86 or before, MA32, B33, OB33, MA42, diameter end facing up.
MA50, MA5A, MA17A, XWG, XUP, XRN, XRM and XPO series. b. Place the enclosing tube gasket onto the valve body above the
These valves MUST be installed in horizontal lines with the coil threads.
housing no more than 45° from vertical, see table on page 2. The c. Hold the plunger with one hand so that the pointed end is
direction of flow is indicated by an arrow or the word IN on the inlet resting in the pilot port of the disk. Make sure the small spring
of the valve body. For heat pump applications, valve types C(M)E is in place on the top of the plunger. (NOTE: Does not
and C(M)B are typically installed with the directional arrow pointing apply to normally open and rapid cycle series.)
toward the outdoor coil. Or, the IN connection toward the indoor coil. d. With the other hand, place the enclosing tube over the plunger,
making sure the enclosing tube gasket is in position.
NOTE: Solenoid valves having a type number starting with the letter e. Replace the enclosing tube locknut and tighten. (See
"X" are Special Solenoid Valves (non-standard). Contact Sporlan recommended torque in the table on page 2.) Do not over
Valve Company, Washington, MO if valve mounting is in question. tighten.
f. Replace manual lift stem. Tighten lift stem assembly and seal cap.
SOLDER CONNECTIONS g. Replace the coil assembly. (NOTE: For normally open and
Because of possible damage to valve components due to the high rapid cycle valves replace spacer and spacer cup
temperatures of soldering and brazing, "B" Series Solenoid Valves with coil assembly.)
with brass connections are shipped handtight to facilitate
disassembly, with the exception of the (M)B33S2 & OB33S2. It is NOTE: Excessive tightening of the enclosing tube locknut can
necessary to completely disassemble these valves before any heat is damage the valve body bore. Please observe the torques listed on
applied to the valve body. The following steps outline recommended page 2.
procedures when installing these valves.
Types: All E Series (Extended Copper Connections)
Soldering Precautions — Solder connections on Sporlan Solenoid Brazed into the line without disassembly because the valve contains
Valves are either copper or brass. Any of the commonly used types of extended connections. Use caution by placing a wet cloth or chill
solder are satisfactory with these materials. Regardless of the type of block on the extensions at the body to prevent excessive overheating.
solder used, it is important to avoid overheating the valve. Follow Type A3S1 installation instructions.
© COPYRIGHT 2003 BY SPORLAN VALVE COMPANY, WASHINGTON, MISSOURI
BULLETIN 30-11, AUGUST 2003 SUPERSEDES BULLETIN 30-11, NOVEMBER 2000 AND ALL PRIOR PUBLICATIONS.
Page 2 / BULLETIN 30-11
PIPE CONNECTIONS These valves have male flange connections on the inlet of the valve;
therefore, the flange and bushing for the inlet must be the female pair.
Types A3, W3, B6, W6, B9, B10, B14, W14, B19, W19, B25,
W25, (K)(B)R183, (K)(B)R184, (K)(B)R246 Series
These valves can be installed without disassembly. Avoid excessive INSTALLATION—ALL VALVES
amounts of pipe sealing compounds. It will interfere with the valve Mounting — A Type 1216-1 universal mounting bracket, Figure 2,
operation if it comes in contact with the valve's internal parts. is available, when ordered. It fits all standard Sporlan Solenoid
Valves except the Types W3, MA32, B33, E33, E34, E42, MA42,
NOTE: When pipe type solenoid valves are installed with pipe to MA50, (K)(B)R183, (K)(B)R184, (K)(B)R246 series and the Type
ODF adaptors, the valve must be disassembled prior to brazing the 180 Solenoid Pilot Control. The slots in the bracket match the tapped
ODF adaptors. holes in the standard solenoid valves so that they may be secured by
two screws supplied with the bracket. A locknut is also furnished for
use with Types MA5A3 and MA17A3. Both types of installations are
FLANGED CONNECTIONS— shown in Figure 2. The manual lift stem seal cap is replaced after the
PIPE or SOLDER locknut is tightened against the bracket.
Solenoid valves with flanged connections may be installed without
disassembly. In most cases the flanges are packed disassembled from 1.50 1.50
the valve body. Therefore, they may be installed in the line before the ■ Figure 2 Hole through
which solenoid
valve is installed. Be certain that the correct flange is installed on the is screwed to
inlet line in order to properly match the flow direction of the valve. If bracket
1.75 2.16
the valve is installed backwards, it will not function properly.
1.16
Types MA5A3, MA17A3, MA32P3, MA42P3, MA50P3
1.
06
Coil
Plunger
Assembly
Enclosing
Tube
Spacer Diaphragm
(normally open & Assembly
Typical View of rapid cycle only) Enclosing
E34 & E42 Series Tube O-Ring
Solenoid Valves Enclosing Enclosing
Tube Tube O-Ring Plunger
Lock Nut Assembly
Pilot Assembly
Enclosing Tube Enclosing Tube Body
or (normally open & Body
(normally closed)
rapid cycle)
Body
(A & B Coil Housing
Series)
Body
(E Series)
Body
(E34 & E42 Coil Sleeve
Series)
Manual Lift Stem Assembly
(if required) Coil Spring
*Tetraseal
*B and E Series Solenoid Valves have been redesigned. The new design can be easily identified as a thin, synthetic Gasket
coated metal gasket, known as a Wolverine gasket. The old gasket is a thicker type of O-ring with a square cross or
section, known as a tetraseal. See the partial cross sections of the valve body at right. The gaskets and the
enclosing tubes of the two designs are not interchangeable. The new enclosing tube assembly is included in the
*Wolverine
Gasket Coil
replacement parts kits.
Thermostatic
Expansion Valves
Installation, Field Service, and Assembly
Installation While not always convenient or possible, valve Types BI, F, FB, and
O are easier to service if mounted in a vertical and upright position.
Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
If mounted in a horizontal position, the internal parts must be
Solder Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
carefully reassembled to prevent damage to them. Also, some consid-
Bulb Location and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
eration should be taken in mounting larger sized expansion valves.
External Equalizer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
They must be adequately supported since system vibration and the
Driers, Strainers, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 4
weight of the valve may cause valve connections to fracture.
Test Pressures and Dehydration Temperatures . . . . . . . . . . . . . . . 4
Expansion Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
If a hand valve is located on the outlet side of the TEV it should have
How to Determine Superheat Correctly . . . . . . . . . . . . . . . . . . . . 5
a full sized port. No restrictions should appear between the TEV and
How to Change the Superheat Setting . . . . . . . . . . . . . . . . . . . . . 5
the evaporator, except a refrigerant distributor if one is used.
For peak performance, it is important to select a Sporlan Occasionally, TEVs are located in corrosive atmospheric conditions
Thermostatic Expansion Valve (TEV) with correct capacity, selective that can damage the valve and/or the element assembly. Due to this
charge, external or internal equalizer, etc. See Bulletins 10-9 and 10-10 possibility, the valve must be protected with appropriate materials to
for complete application information. Equally important is the proper prevent premature failure. Consult specialists in protective coatings.
installation, which can determine the success or failure of the entire
system.
Precautions:
When the evaporator and TEV are located above the
Valve Location receiver, there is a static pressure loss in the liquid line. This is due
TEVs may be mounted in any position, but they should be installed to the weight of the column of liquid refrigerant, and this weight may
as close to the evaporator as possible. If a refrigerant distributor is be interpreted in terms of pressure loss in pounds per square inch as
used with the expansion valve, best performance is obtained if the shown in Table 3, Bulletin 10-9. If the vertical lift is great enough,
distributor is mounted directly to the valve outlet. If the distributor vapor or flash gas will form in the liquid line causing a serious
cannot be mounted directly to the valve outlet, the distance between reduction in the capacity of the TEV.
the valve outlet and distributor should not exceed 24 inches or refrig-
erant distribution problems may occur. Also, the tube connecting the When an appreciable vertical lift is unavoidable, precautions should
valve outlet and distributor can be sized smaller to maintain refrig- be taken to prevent the accompanying pressure loss from producing
erant velocity and better distribution. Elbows located between the liquid line vapor. This can be accomplished by providing enough
expansion valve and distributor will hinder proper distribution and subcooling to the liquid refrigerant, either in the condenser or after
therefore, are not recommended. the liquid leaves the receiver. Subcooling is determined by
subtracting the actual liquid temperature from the condensing
Best distribution is usually obtained if the expansion valve feeds temperature (corresponding to the condensing pressure). A
vertically up or down into the distributor. System manufacturers, subcooling calculation example is provided in the "subcooling"
however, have successfully applied distributors in other orientations. section of Bulletin 10-9.
This precaution will prevent overheating the valve body which could
damage the superheat spring and result in flood back problems. In
addition, the Type O, EBF/SBF, and EBS valve contain synthetic
parts which can be damaged due to overheating, resulting in poor
valve performance.
Receiver
Main Suction Line Accepted principles of good suction line piping should be followed
to provide a bulb location that will give the best possible valve
To Compressor control. When system manufacturers have piping recommendations
that differ from the general industry recommendations and Sporlan’s
Figure 1 suggestions shown in this section, those recommendations should be
used. When specific recommendations are not available, the sugges-
Ordinarily the conventional suction-liquid heat exchanger is installed tions below should be used.
near the evaporator, where the suction vapor is the coldest, to re-
condense any vapor in the liquid line. When the primary purpose of The bulb should be attached to a horizontal suction line at the
the heat exchanger is to prevent the formation of flash gas – particu- evaporator outlet (See Figures 3, 4, and 5) If the bulb cannot be
larly on systems that have a long liquid line or excessive vertical lift located in that manner, it may be located on a descending vertical
– install the heat exchanger near the receiver before the vertical line only (as shown in Figure 5 for “pumpdown control”). The bulb
lift occurs. (This also applies to the special devices described in should never be located in a trap or downstream of a trap in the
Method 3). Because vapor in the liquid line considerably increases suction line. Liquid refrigerant or mixture of liquid refrigerant and oil
friction losses, the total pressure drop available across the expansion boiling out of the trap will falsely influence the temperature of the
device on these types of systems is reduced. Also, the suction line and bulb and result in poor valve control.
liquid line should be carefully insulated to minimize heat gain if
subcooled below ambient temperature. On suction lines 7/8” OD and larger, the surface temperature may
vary slightly around the circumference of the line. On these lines, it
Important is generally recommended that the bulb be installed at 4 or 8 o’clock
Preventing the formation of vapor in liquid lines having high pressure on the side of the horizontal line, and parallel with respect to the
losses does not eliminate the requirement that an adequate pressure direction of flow. On smaller lines the bulb may be mounted at any
drop must be available across the TEV. The capacity tables show point around the circumference, however locating the bulb on the
valve capacities at pressure drops lower than normal. For TEV bottom of the line is not recommended as an oil-refrigerant mixture
application data and capacities at pressure drops below those listed, is generally present at that point. Certain conditions peculiar to a
consult Sporlan Valve Company. particular system may require a different bulb location than normally
BULLETIN 10-11 / Page 3
On brine tanks and water coolers, the bulb should be below the liquid
Short as possible to minimize amount of oil. surface where it will be at the same temperature as the evaporator
during the off-cycle. When locating the bulb in a brine tank, paint it
and the capillary tubing with pitch or other corrosion resistant paint.
Figure 3
recommended. In these cases the proper bulb location may be If, for practical reasons, the bulb must be located where its tempera-
determined by trial. ture will be higher than the evaporator during the off-cycle, a
solenoid valve must be used ahead of the TEV.
For satisfactory expansion valve control, good thermal contact
between the bulb and suction line is essential. The bulb should be
securely fastened with two bulb straps, supplied with each expansion Compressor BELOW
valve, to a clean straight section of the suction line.
Evaporator
Recommended suction line piping usually includes a horizontal line
leaving the evaporator to which the TEV bulb is attached. This line is Without
pitched slightly downward, and when a vertical riser follows, a short Pumpdown
trap is placed immediately ahead of the vertical line, see Figure 3.
The trap will collect any liquid refrigerant or oil passing through the
suction line and prevent it from influencing the bulb temperature.
Multiple Evaporators
Pumpdown
Above and Below Main Suction Line Control
Figure 5
Free draining. The equalizer connection should be made at a point that will most
accurately reflect the pressure existing in the suction line at the bulb
location. See Figure 6. Generally, the connection is immediately
downstream of the bulb. However, equipment manufacturers
Figure 4 sometimes locate them in return bends or suction headers that are
Page 4 / BULLETIN 10-11
Excessive test pressures can shorten the life of the TEV diaphragm.
Table 1 lists the maximum pressure that can safely be applied with
the expansion valve connected to the evaporator. These maximum
pressures are well above the minimum field leak test pressures for
low sides, listed by the ANSI/ASHRAE Standard 15-2001 or latest
revision.
It must be connected - NEVER CAPPED!
Must be free of crimps, solder, etc. The external equalizer line should be disconnected if there is any
possibility of exceeding the recommended maximum pressures
listed below.
Figure 6
If elevated temperatures are used to assist in dehydrating the system,
compatible with their specific design requirements. The difference
the TEV should not be exposed to temperatures exceeding those
between the pressure at the equalizer connection and the suction
shown in Table 2.
pressure at the bulb location should not exceed reasonable pressure
drop values. The values shown in Table 1 of Bulletin 10-9 can be Table 2 refers to the maximum dehydration temperatures when the
used as a guide in determining the value. bulb and valve body are subjected to the same temperature. On L, C,
Z, and X charges, 250°F maximum valve body temperature is
If any evaporator pressure or temperature control valves are located permissible if the bulb temperature does not exceed those
in the suction line at or near the evaporator outlet, the equalizer must shown in the table.
be connected on the evaporator side of these valves.
Table 2
Maximum Dehydration Temperatures – Degrees F
Figure 7 Thermostatic Charge
Refrigerant
L C Z X VGA P Type, ZP Series
Moisture and smaller particles of foreign materials are equally
harmful to the system and must be removed for peak system perfor- 12, 134a 190 190 250 - --
mance. Field experience has proven that, without a doubt, most 22 160 160 185 210 250 250
expansion valve failures are due to the presence of dirt, sludge, and
404A, 502, 507 150 150 170 ---
moisture in the system. Furthermore, the performance and life of
other system components are also seriously affected by these foreign 717 (Ammonia) 150 190 235 --- - -- ---
materials. The Sporlan Catch-All Filter-Drier® removes dirt,
moisture, acids, and sludge, and insures the circulation of clean, dry
refrigerant through the system at all times.
Expansion Valve Adjustment
For all refrigeration and air conditioning applications we recommend Each Sporlan TEV is thoroughly tested and set at the factory before
that a Sporlan Catch-All Filter-Drier be installed in the liquid line shipment. This factory superheat setting will be correct and no
ahead of the TEV. See Bulletin 40-10 for complete Catch-All Filter- further adjustment is required for the majority of applications.
Drier specifications. However, there are many factors which can affect the performance of
a TEV. These factors are independently variable and all of them
Further system protection is easily and inexpensively provided with cannot be compensated for in the design of a valve. When the
the installation of a Sporlan See-All®. The See-All is a combination application or operating conditions require a different valve setting
liquid and moisture indicator that visually indicates if there is a due to one or more of the factors listed below, the valve may be
shortage of refrigerant in the liquid line, or if the moisture content of adjusted to obtain the required operating superheat. Therefore, an
the refrigerant is at a dangerous level. See Bulletin 70-10 for adjusting stem is provided on all standard valves. The valve should
complete See-All specifications. be set with the system as near as possible to design conditions.
BULLETIN 10-11 / Page 5
Factors which affect valve performance and may make it necessary the estimated pressure drop will equal the approximate
to adjust the valve are: suction line pressure at the bulb.
1. Low temperature difference (TDs) between the refrigerant and 3. Convert the pressure obtained in 2a or 2b above to saturated
the air evaporator temperature by using a temperature-pressure chart.
2. TEV bulb location 4. Subtract the two temperatures obtained in 1 and 3 – the differ-
3. Balance between compressor and evaporator ence is superheat.
4. Ratio of load to TEV capacity Figure 8 illustrates a typical example of superheat measurement on
5. Condenser capacity an air conditioning system using Refrigerant 22. The temperature of
6. Operation of several fixtures on multiple installation the suction line at the bulb location is read at 52°F. The suction
pressure at the compressor is 66 psig and the estimated suction line
7. Seasonal variation in head pressure caused by extreme changes in pressure drop is 2 psi …66 psig + 2 psig = 68 psig at the bulb, which
ambient air temperature. is equivalent to a 40°F saturation temperature. (Use dew point
temperature for refrigerant blends.) 40°F subtracted from 52°F =
Note: Valve Types F, (E)BF/SBF, Q, A, M, V, K, and W have non- 12°F superheat.
rising adjusting stems and a change in adjustment does not change
the stem position. Note: Refrigerated case manufacturers frequently use a “tempera-
ture difference” method to approximate superheat. This procedure
When setting valves on multi-evaporator refrigeration systems with consists of measuring the temperature of a location on the evaporator
pressure or temperature sensitive evaporator control valves, the which is representative of saturated vapor temperature; and, then
following procedure is recommended: subtracting that temperature from the outlet evaporator temperature
1. Evaporator Pressure Regulating Valve (ORI Type): the ORI valve which is measured at the bulb location.
is set first at the minimum load condition. Then, if necessary, the
expansion valve is adjusted to the desired superheat setting while While this method of reading “superheat” is acceptable on those
under the normal operating load condition. manufacturer’s cases where the pressure drop through the evaporator
is low, Sporlan does not recommend the “temperature difference”
2. Temperature Sensitive Evaporator Regulating Valves (CDS
method for other types of systems.
Type): The CDS valve is forced into a fully open position first.
Then the expansion valve is adjusted to the desired superheat
setting at full load condition. Finally, the controller for the CDS
is set to the desired temperature. Contact Sporlan Valve
Company, or the case manufacturer, for additional details on What's Your
setting the CDS controller. Superheat?
When the adjustment is completed on the TEV, always tighten the
adjusting stem packing nut and replace the seal cap tightly.
Temperature
Many expansion valves are made non-adjustable for use on here reads
Original Equipment Manufacturer’s units, particularly those valves 52°
used on residential air conditioning and heat pump systems. These
valves are set at a superheat predetermined by the manufacturer’s OBTAIN SUCTION PRESSURE 40°
laboratory tests and cannot be adjusted in the field. 68 PSIG (at bulb) 12°
SUPERHEAT
Some non-adjustable models are modifications of standard
adjustable type valves. This is done by using a solid bottom cap
instead of one equipped with an adjusting stem and seal cap. These
valves can be identified by an N preceding the standard valve designa-
tion. Adjustable bottom cap assemblies are available for converting
most non-adjustable valves to the adjustable type. However, this is Figure 8
rarely required. If symptoms indicate that a valve adjustment is
needed, carefully check the other possible causes of incorrect
superheat, pages 6 through 10, before attempting an adjustment. How to Change the Superheat
Setting
How to Determine Superheat Note: There are some valve bodies (G, EG, C, S, EBS
and EMC) that have a packing nut around the adjust-
Correctly ment stem. It may be necessary to loosen the packing
1. Measure the temperature of the suction line at the bulb location. nut slightly to turn the adjusting stem. Do not forget
2. Obtain the suction pressure that exists in the suction line at the to retighten the nut after the superheat is set.
bulb location by either of the following methods:
a. If the valve is externally equalized, a gauge in the external To reduce the superheat, turn the adjusting stem counter-
equalizer line will indicate the desired pressure directly and clockwise. To increase the superheat, turn the adjusting stem
accurately. clockwise. When adjusting the valve, make no more than one turn
b. Read the gauge pressure at the suction valve of the of the stem at a time and observe the change in superheat closely to
compressor. To the pressure add the estimated pressure drop prevent over-shooting the desired setting. As much as 30 minutes
through the suction line between bulb location and may be required for the new balance to take place after an adjust-
compressor suction valve. The sum of the gauge reading and ment is made.
Page 6 / BULLETIN 10-11
If in doubt about the correct superheat setting for a particular system, The primary cause of difficulty with either the BP or RPB feature is
consult the equipment manufacturer. As a general rule, the proper dirt and other foreign materials that restrict or plug them. And if the
superheat setting will depend on the amount of temperature differ- system purpose intended for either feature is not being satisfied, the
ence (TD) between refrigerant temperature and the temperature of the valve probably needs cleaning or replacing.
air or other substance being cooled. Where high TD’s exist, such as
on air conditioning applications, the superheat setting can be made as As stated in Bulletin 10-9, the RPB type valve is not to be applied on
high as 15°F without noticeable loss in evaporator capacity. Where systems using high starting torque compressors or “hard-start”
low TD’s exist, such as in low temperature blower coil applications, electrical components, on outdoor coils of heat pumps, or on any
a superheat setting of 10°F or below is usually recommended for refrigeration system, and it should not be used to replace BP type
maximum evaporator capacity. It is these applications that the TEV valves that are applied on those types of systems. On systems other
will more than likely need to be adjusted. than those described above, the RPB type valve can replace the BP
type valve when necessary. Usually it is advisable to replace a valve
For the correct valve setting on factory built equipment, manufac- with one of the same specification unless advised differently. Consult
turers’ recommendations should be followed. Some manufacturers with the system manufacturer for assistance.
specify the superheat directly; others may recommend valve adjust-
ment to a given suction pressure at certain operating conditions, or
until a certain frost line is observed. Such recommendations, however
they are stated, represent the results of extensive laboratory testing to
Complaint "A"
determine the best possible operation. “Valve does not feed enough refrigerant.”
SYMPTOMS:
■ Load temperature (air or water leaving
* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
BULLETIN 10-11 / Page 7
3. Wax — Certain systems are contaminated with small amounts 7. Insufficient pressure drop across valve — One of the
of wax which will precipitate at low temperatures in systems factors that influence expansion valve capacity is the pressure
with Refrigerants 22 or 502. Since the TEV represents the first drop that exists between the inlet and outlet. Anything
cold point in the refrigeration cycle, wax is most likely to form contributing to a reduction in this pressure drop will reduce valve
at the valve port. capacity. Abnormally low condensing pressures, excessive liquid
It is sometimes difficult to observe the wax in a valve because it line pressure losses (even with adequate subcooling), undersized
may exist in solid form only at very low temperatures. By the distributor nozzle or distributor tubes may also be responsible for
time the valve has been taken apart, the temperature has a very low net pressure drop across the valve port.
increased enough to cause the wax to melt and thus become Remedy — Remove source of pressure loss, or install valve
difficult to detect. When wax is suspected, it can usually be with adequate capacity at the reduced pressure drop. If inlet
detected on the pin and seat by packing the valve in dry ice pressure to valve is low due to low condensing pressure, raise
while disassembling. pressure.
Remedy — Clean the valve with solvent before reassembling If the refrigerant distributor nozzle is undersized replace with
the valve. The Sporlan HH style Catch-All Filter-Driers have a correct size. See Bulletin 20-10.
special activated charcoal desiccant that is designed to remove
wax in the liquid line before it causes trouble. Therefore, to 8. Dead thermostatic element or wrong thermo-
prevent wax problems, use these HH style driers (e.g., C-415- static charge — If the element has partially or completely
S-HH) on all low temperature systems using Refrigerants 22 or lost its thermostatic charge, the valve will be unable to feed
502. sufficient refrigerant or will remain closed. A wrong charge may
cause insufficient feed also.
4. Refrigerant shortage — See•All or sight glass in the Remedy — Replace the element if it is dead. If charge is
liquid line will show bubbles when the system is short of refrig- incorrect, replace with proper selective charge. See Bulletin 10-9.
erant charge. Before adding more refrigerant however, be sure
the bubbles are not produced by other causes (See Paragraphs 9. Charge migration (CP series, ZP series, and VGA
A-2 and A-5). charges only) — In order for valves with these charges to
A lack of refrigerant charge may also be detected by a hissing maintain control at the bulb, the bulb must be kept at a lower
sound at the TEV. Some systems not equipped with a liquid line temperature than the element (diaphragm case). If the thermo-
sight glass will have test cocks or other devices for checking the static charge does migrate to the element because of a lower
refrigerant level in the receiver. element temperature, the valve will throttle.
Remedy — Add enough refrigerant to obtain desired result. Detection — Warm the element with a cloth saturated with
hot water. If this produces more refrigerant feed and reduces the
5. Gas in the liquid line — As explained in Paragraphs A-2 superheat to normal, charge migration is responsible for the
and A-4, liquid line vapor can be produced by a partially starved evaporator.
plugged strainer or drier and by a shortage of refrigerant charge. Causes —
In addition, gas in the liquid line can be caused by air or other ■ Insufficient pressure drop between the valve outlet and bulb
non-condensable gases in the system or by excessive pressure location, possibly due to an oversized distributor nozzle or no
losses in the liquid line as a result of: nozzle at all.
■ Long or undersized line. ■ Excessive pushrod leakage, which allows the leaking refrig-
■ Liquid line vertical lift. erant to cool the diaphragm case before passing into the
Remedy — Verify the correct liquid line size for the equiva- equalizer line. This is a rare occurrence and should be
carefully checked before arriving at this conclusion.
lent length and system tonnage. Consult liquid line sizing data
■ Cold location of TEV, or condensate drippage on the
published in many manufacturers’ catalogs and in textbooks. If
diaphragm case.
undersized, repipe with the correct size.
Remedies —
Determine amount of vertical lift, and obtain the resulting
pressure loss from Table 3, Bulletin 10-9. Using the subcooling
■ Install distributor nozzle correctly sized in accordance with
calculation example provided in the "subcooling" section of nozzle sizing procedure given in Sporlan Bulletin 20-10.
■ On valves with packed pushrod construction, remove element
Bulletin 10-9, find required subcooling necessary to prevent
gasification with the existing pressure losses. Provide the and tighten the pushrod packing nuts.
■ Relocate the TEV away from cold outlet air, or condensate
necessary subcooling by using one of the methods described on
Page 1. drippage.
flowing through the evaporator, check the piping for possible Disassemble the valve to be certain that dirt or foreign material
refrigerant flow from another evaporator affecting the bulb. Re- is not responsible (see B-2). If the pin and seat are worn or
pipe if necessary. See Figure 4. damaged and an internal parts kit is available, replace the parts.
When parts are not available, the valve must be replaced.
13. High pressure drop through evaporator
Remedy — Check the pressure at the evaporator inlet and 4. Oversized valve — Check valve ratings considering all the
outlet with gauges. If pressure difference is greater than the factors which affect its capacity. See Page 16, Bulletin 10-9, or
values shown in Table 1, Bulletin 10-9, use an externally Page 3, Bulletin 10-10.
equalized valve. Remedy — Install correctly sized valve.
14. Restricted, plugged, or capped external equalizer — 5. Incorrect bulb installation — The bulb should be securely
If the pressure under the diaphragm builds up due to pushrod fastened to a straight, clean, section of the suction line using two
leakage and cannot escape through the external equalizer line, bulb straps for good thermal contact. Also, the temperature of the
the valve will remain closed. bulb should not be influenced by ambient temperature — an
Remedy — Check the external equalizer line to be sure it is external heat source such as a steam pipe or heating coil.
open or not capped. Remedy — Install bulb correctly. See Bulb Location and
Installation, Page 2.
for this purpose. Another corrective measure is to install a suction 3. Low load— Low evaporator load may be caused by insuffi-
line solenoid valve that is de-energized during the off-cycle. cient air over the coil as a result of an undersized blower, dirty
air filters, or an obstruction in the air stream. In addition, frost
3. Restricted or plugged external equalizer — A formation on the coil or low entering air temperatures will
momentary flood can occur when the load increases suddenly, reduce the evaporator load.
such as at start-up because the higher suction pressure cannot
Remedy — Correct the condition responsible.
reach the underside of the diaphragm and help close the valve.
If the pressure under the diaphragm increases due to any
4. Flow from one coil affecting TEV bulb of another
pressure leakage around the pushrods, the valve will eventually
(Multiple evaporator systems only) — The tempera-
throttle.
ture of the bulb may be falsely influenced by flow from another
Remedy — Remove the restriction or plugged portion of the evaporator usually because of incorrect piping.
external equalizer.
Remedy — Correct the piping. See Figure 4, Page 3.
4. Liquid line solenoid valve seat leak or interrupted
5. Improper compressor-evaporator balance — If the
pumpdown — Liquid refrigerant can continue to feed the
compressor is too large for the load and evaporator capacity, the
TEV and/or remain in evaporator upon shut-down causing
low suction pressure which results will cause poor system
flood-back to the compressor upon start-up.
performance.
Remedy — Disassemble and clean solenoid valve and/or
Remedy — Consult with the manufacturer or consulting
replace damaged internal parts if seat leakage is the problem. If
engineer, or the ASHRAE Handbook on component balancing.
the pumpdown cycle isn’t completed before the compressor
cycles off, or the thermostat calls for cooling and reopens the If necessary, change or correct the improperly sized component.
liquid line solenoid before the evaporator has been properly Hot gas bypass may be used to balance properly.
evacuated, check the low pressure cut-off setting or the
electrical controls for possible causes. 6. Evaporator oil-logged — Poor heat transfer occurs and
unpredictable performance takes place. If erratic performance is
observed over a period of time, and other causes are omitted
from consideration, review the amount of oil in the system.
Complaint "D" Turbulent compressor oil level with little or no return to the
“Valve doesn't feed properly.” compressor sump indicates oil problems.
SYMPTOMS: Remedy — Remove excessive oil from evaporator and
■ Poor system performance. connecting piping. Many times the evaporator temperature will
■ Superheat normal or lower than normal. be too low for the oil to be removed. Therefore, the system must
■ Suction pressure lower than normal with be allowed to warm sufficiently to get cold oil to drain. Analyze
compressor unloaders locked out or hot gas system components for possible causes of oil problem before
bypass shut off.* restarting the system. Consult with the compressor manufacturer
for specific details on their compressor.
enter the suction line and throttle the valve. This will cause ■ Superheat fluctuates.
normally loaded circuits to be deprived of their share of ■ Valve does not feed enough, and then too much
* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
Page 10 / BULLETIN 10-11
tions are not necessary. If hunting is severe with floodback to 5. System is hunting or cycling. See Section E on Page 9.
the compressor, check the possible remedies shown in
paragraphs below. 6. The TEV has been physically abused in an effort
to make the valve work properly. This is usually the
2. Valve size — An over-sized valve usually aggravates hunting. result of a mistaken analysis. It is frequently assumed that if a
Carefully check the valve rating considering all the factors valve does not feed properly, it is stuck (either opened or
affecting its capacity. See Bulletin 10-9, or Bulletin 10-10. closed). Beating the valve body with a hammer will only distort
Remedy — Replace valve with one correctly sized. On the body and make it impossible for the valve to work once the
multiple circuit evaporators using a refrigerant distributor, the real cause is determined.
capacity of the valve can be reduced, within certain limits, by If a valve “sticks,” it is usually due to moisture freezing in the
installing a smaller distributor nozzle. See Bulletin 20-10. port, dirt and other foreign material restricting or plugging the
internal parts, wax forming on the internal parts at low temper-
3. Bulb location — If the bulb is located in a suction line trap, atures, or the valve has been physically abused so it cannot
its temperature will be affected by liquid oil and refrigerant function.
alternately collecting and evaporating at this point. This Remedy — Inspect the valve and its internal parts, including
condition frequently results in severe hunting. the inlet strainer. If plugged or restricted in any way, clean the
Remedy — As a temporary measure relocate the bulb away parts thoroughly, oil the parts with a good grade of refrigerant
from the trap, and any turbulent areas created by elbows, tees, oil, and reassemble the parts. Complete details on this subject
etc. Also remove the bulb from the air stream or insulate. Re- are found on Pages 10 through 12.
pipe if necessary. Sometimes another position around the If the valve is beyond normal cleaning processes, or if it is
circumference of the suction line will minimize hunting. Follow physically damaged in any way, replace the valve with its proper
the Bulb Location and Installation instructions given on Page 2 replacement model.
for the best TEV control.
Seat
Complaint "F"
Pin Carrier
“System won't perform properly.”
SYMPTOM:
■ Cannot get valve to react or regulate at all. Spring
Spring Guide
THE CAUSE MAY BE: Bottom Cap
1. No refrigerant being fed to evaporator. See Section Assembly
A on Pages 6 & 7.
Note: These Field Assembly Instructions apply in part to all Sporlan exerting too much pressure in tightening the element or in
TEVs. See Figure 9 for an “exploded” view of those models that can clamping the body in the vise. Also, do not use a wrench on the
be completely disassembled. When a TEV is to be disassembled for outer welded edge of the element.
inspection and cleaning, or for replacement of the thermostatic
element or the internal parts, the following information should be 4. Inspect parts, element, and body for any foreign materials or
reviewed for assistance. physical damage.
Types F dated approximately C84 or earlier and Types I, BI, NI, RI, 5. On valves with replaceable elements and/or internal parts,
FB manufactured prior to 1994 do not have replaceable elements nor replace any items that appear damaged.
internal parts kits, but can be disassembled for inspection and
cleaning. Type F dated D84 or later, Type S valves dated B69 or later, 6. Clean all parts with solvent, preferably by applying and then
Type C valves dated C70 or later, and ALL Type G, X, (E)BF/SBF blowing off with clean dry compressed air.
and EBS valves employ packless pushrod construction and internal
parts are NOT available for use with them. However, their elements
can be replaced and they can be disassembled for inspection and
cleaning. Due to the single pushrod construction of the Type RIGHT WRONG
(E)BF/SBF and EBS valves, only the bottom cap assembly, pin
guide, and superheat spring may be removed for inspection and
cleaning.
STRAINERS
NOTES:
1. TO ORDER, SPECIFY CATALOG NO AND IF STRAINER WILL BE CLOSED-COUPLED TO
VALVE OR INSTALLED AS SEPERATE UNIT. (IF SEPERATE UNIT, SPECIFY FLANGE
CONN. STYLE AND SIZE)
2. WHEN ORDERING; SPECIFY “WITH COMPANION FLANGES, BOLTS & GASKETS”.
3. MATERIAL: BODY: DUCTILE IRON A536 65,000 PSI TENSILE
SCREEN: STAINLESS STEEL 60 MESH (ST050 IS 100 MESH)
4. MANUFACTURER: HANSEN TECHNOLOGIES CORPORATION
Revisions:
R0: NEW ISSUE. SDP 11/27/02 ECN: M020087
Drawn By: JDA Date: 6-14-04
5555 S. Packard Ave.
Redrawn By: Approved By: RPK
3214 R0
Cudahy, WI 53110
NOTE:
PORT A IS FOR THE OUTLET
PORT B IS FOR THE HOT INLET
PORT C IS FOR THE COLD INLET
SPARE/REPLACEMENT NOTES:
THERMOSTAT 49qC/120qF AND GASKET + GUIDE RING -FLAMMABLE HYDROCARBONS ARE NOT
VILTER RECOMMENDED.
SPARE PARTS FOR CODE NO. -CAN BE MOUNTED IN ANY DIRECTION
PART NO.
ORV 25 AND ORV 40 H1 148H3243 3214X -DESIGNED FOR MAX WORKING PRESSURE 580 PSIG
ORV 40 AND ORV 50 H2 148H3244 3214Y -STAINLESS STEEL NICKEL PLATED THERMOSTATIC
ORV 65 AND ORV 80 H3 148H3245 3214Z ELEMENT
Revisions
HA4AOAS - Inlet/Outlet Economizer Port / Side Load Pressure
Regulator
Purpose: To maintain an operating pressure in the economizer or side load vessel, while providing a means
of protecting the compressor motor from overloading from high economizer loads during start-up, or from
high side loads.
Construction: This valve is made up of an Outlet Pressure Regulator Base, an Inlet Pressure Regulator
Module, and a Shut Off Solenoid.
Operation: The Shut Off Solenoid must be energized to activate the HA4AOAS valve. For a flash type or
shell & coil type economizer, or for side load applications, the solenoid must be activated when the
compressor starts. For a direct expansion type, the solenoid is generally activated when the compressor
reaches 30% to 70% compressor capacity, depending on the system.
The estimated economizer operating pressure of the valve will be as shown on the performance printout for
the compressor unit. Side load pressure settings would be set as required for the system. By means of a
pressure gauge, the actual economizer operating pressure can be determined by placing the Inlet Pressure
Regulator module range spring at minimum force (control module stem should be fully turned counter-
clockwise). Leaving the regulator in this position, the actual economizer compressor port pressure can be
read. NOTE: The compressor must be at 100% capacity and at normal operating suction and discharge
pressures before the actual port pressure can be determined. Once this pressure is known, the module stem
should be turned clockwise until there is a slight increase in pressure shown on the gauge. Increasing the
turns on the module stem will raise the inlet pressure.
The Outlet Pressure setting is a maximum pressure setting that will allow the compressor to load to 100%.
If too much economizer or side port gas flow occurs, port pressure increases resulting in a motor amperage
increase, which may result in amp limiting and the compressor will not load to 100%. In order to adjust the
Outlet Pressure Module, its range spring should be set near maximum force (control module stem should be
fully turned clockwise). If the compressor is not able to fully load because of Amp limiting, the outlet
pressure needs to be decreased by turning the stem counter-clockwise until there is a decrease in pressure
shown on the gauge. Reduce outlet pressure until motor amperage drops and the compressor is able to load
to 100% capacity. Make sure that the Outlet Pressure setting is at least 10 psig higher than the inlet pressure
to prevent a conflict in operation of the inlet and outlet features of the valve. NOTE: There must be
abnormally high gas flow to set the outlet feature. It may not be necessary to use the outlet feature if the
compressor motor has been sized large enough so that the unit does not amp limit on high economizer or
side load gas flow.
Hansen HA4AOAS
Inlet/Outlet Regulator for Screw Compressor Economizer
(Controls Pressure of accumulator or other types of vessels that is economized and controls
outlet pressure to economizer port on screw compressor)
M3E25
168