13668843 manual vilter

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VPN 35391SFebruary 2006 Rev. 05Price $ 60.00

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Important Note:

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

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

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

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

Vilter screw compressor components are thoroughly inspected at the factory, assuring the shipment of amechanically perfect piece of equipment. Damage can occur in shipment, however. For this reason, theunits should be thoroughly inspected upon arrival. Any damage noted should be reported immediatelyto the Transportation Company. This way, an authorized agent can examine the unit, determine theextent of damage and take necessary steps to rectify the claim with no serious or costly delays. At thesame 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 befound on the compressor name plate on the compressor.

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

Vilter Manufacturing CorporationCustomer Service Department

5555 South Packard AveP.O. Box 8904

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

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

Equipment Identification Numbers:

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

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Table of ContentsLONG TERM STORAGE REQUIREMENTS ......................................................................................................................................... 8

DOMESTIC TERMS and CONDITIONS .............................................................................................................................................. 10EXPORT TERMS and CONDITIONS ................................................................................................................................................... 12

STANDARD VILTER WARRANTY STATEMENT .............................................................................................................................. 14STANDARD VILTER 5/15 WARRANTY STATEMENT ..................................................................................................................... 15

DESCRIPTION ........................................................................................................................................................................................ 16SYMBOLS AND MEANINGS ............................................................................................................................................................... 18

Installation Section ...................................................................................................... 19

DELIVERY INSPECTION ....................................................................................................................................................................... 21UNIT WEIGHTS ...................................................................................................................................................................................... 21FOUNDATIONS ...................................................................................................................................................................................... 21LOCATING UNIT - DRIVE COUPLING ALIGNMENT ....................................................................................................................... 21SYSTEM PIPING .................................................................................................................................................................................... 21ELECTRICAL CONNECTIONS ............................................................................................................................................................. 23

TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23 Ammonia Systems ........................................................................................................................................................................... 23

Halocarbon Refrigerant Systems ..................................................................................................................................................... 24Evacuating The System .................................................................................................................................................................... 24

UNIT OIL CHARGING ........................................................................................................................................................................... 25Oil For Single Screw Compressors .................................................................................................................................................. 25

SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25Low Side Equipment ................................................................................................................................................................................ 26Compressors ............................................................................................................................................................................................. 26Condensers ............................................................................................................................................................................................... 26Controls .................................................................................................................................................................................................... 26Initial Charging – High Side Charging .................................................................................................................................................... 26

MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27Daily ................................................................................................................................................................................................. 27Weekly .............................................................................................................................................................................................. 27Monthly ............................................................................................................................................................................................ 27Trimonthly ........................................................................................................................................................................................ 27Yearly ................................................................................................................................................................................................ 27System Leaks .................................................................................................................................................................................... 28Year Round Operation ...................................................................................................................................................................... 28

“STOP CHECK” INSTALLATION ......................................................................................................................................................... 29

COUPLINGS INSTALLATION AND ALIGNMENT ............................................................................................................................. 30Hub Mounting .................................................................................................................................................................................. 30Straight Bore .................................................................................................................................................................................... 30Taper Bore ........................................................................................................................................................................................ 30Shaft Alignment. .............................................................................................................................................................................. 31Final assembly . ............................................................................................................................................................................... 32Disc Pack Replacement. ................................................................................................................................................................... 32

SLIDE VALVE ACTUATOR ................................................................................................................................................................... 34

ACTUATOR MOTOR CONTROL MODULE CALIBRATION PROCEDURE .................................................................................... 34

SLIDE VALVE TROUBLE SHOOTING GUIDE ................................................................................................................................... 37

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Table of ContentsOperation Section ........................................................................................................ 41

OIL SYSTEM ........................................................................................................................................................................................... 43Non-Vilter Oil Notice ...................................................................................................................................................................... 42

Oil Charge ....................................................................................................................................................................................... 43Oil Filter ........................................................................................................................................................................................... 43Filter Removal and Installation, all VSR Units. ............................................................................................................................. 43Filter Removal, VSS and VSM Units .............................................................................................................................................. 44Filter Removal, VSS and VSM Units . ........................................................................................................................................... 44Oil Pressure Regulating ................................................................................................................................................................... 45Oil Cooling ....................................................................................................................................................................................... 45Water Cooled Oil Cooler .................................................................................................................................................................. 45Liquid Injection Oil Cooling. ........................................................................................................................................................... 46V-PLUS Oil Cooling System ............................................................................................................................................................ 46Thermosyphon Oil Cooling .............................................................................................................................................................. 47

CONTROL SYSTEM .............................................................................................................................................................................. 47Screw Compressor Control And Operation ..................................................................................................................................... 47Starting, Stopping and Restarting the Compressor ......................................................................................................................... 47Slide Valve Control .......................................................................................................................................................................... 48

Slide Valve Motor Location ............................................................................................................................................................. 49 Oil Separator Heater ......................................................................................................................................................................... 49 Econ-O-Mizer Controls ................................................................................................................................................................... 49

Safety Setpoints ................................................................................................................................................................................ 49Oil Pressure ...................................................................................................................................................................................... 49Discharge Pressure ........................................................................................................................................................................... 49Suction Pressure ............................................................................................................................................................................... 50Oil Filter Differential ....................................................................................................................................................................... 50Oil Temperature ............................................................................................................................................................................... 50Discharge Temperature .................................................................................................................................................................... 50

INITIAL START-UP ................................................................................................................................................................................. 50Setting of Controls ........................................................................................................................................................................... 50Valve Settings ................................................................................................................................................................................... 50Oil Separator .................................................................................................................................................................................... 50V-PLUS Oil Cooling ........................................................................................................................................................................ 51Liquid Injection Oil Cooling ............................................................................................................................................................ 51

Compressor Pre Start-Up Check List .............................................................................................................................................. 51 Stop Check Operation ...................................................................................................................................................................... 52

Pre-Start Up ...................................................................................................................................................................................... 53

PRE START-UP CHECKLIST - FIELD PIPING AND MECHANICAL REQUIREMENTS .............................................................. 54PRE START-UP CHECKLIST - FIELD WIRING REQUIREMENTS ................................................................................................. 55

Service Section ............................................................................................................. 56

GENERAL COMMENTS ........................................................................................................................................................................ 58

PREPARATION OF UNIT FOR SERVICING ........................................................................................................................................ 58REMOVAL OF COMPRESSOR FROM THE UNIT ............................................................................................................................ 58INSTALLATION OF THE COMPRESSOR ............................................................................................................................................ 59LEAK CHECKING UNIT........................................................................................................................................................................ 59ANNUAL INSPECTION ......................................................................................................................................................................... 60NORD-LOCK WASHERS ....................................................................................................................................................................... 61GATE ROTOR ASSEMBLY .................................................................................................................................................................... 62REMOVAL (All VSS and VSR Models) ................................................................................................................................................. 62REMOVAL (ALL VSM MODELS) ......................................................................................................................................................... 64INSTALLATION (All VSS and VSR Models) ........................................................................................................................................ 66INSTALLATION (All VSM Models) ...................................................................................................................................................... 68

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Table of ContentsService Section Cont ..............................................................................................................................................................

GATE ROTOR BLADE REMOVAL ....................................................................................................................................................... 69GATE ROTOR BLADE INSTALLATION .............................................................................................................................................. 69GATE ROTOR THRUST ......................................................................................................................................................................... 70BEARING REMOVAL GATE ROTOR THRUST .................................................................................................................................. 70BEARING INSTALLATION GATE ROTOR ROLLER .......................................................................................................................... 71GATE ROTOR ROLLER BEARING REMOVAL .................................................................................................................................. 72GATE ROTOR ROLLER BEARING INSTALLATION .......................................................................................................................... 72INPUT SHAFT SEAL REPLACEMENT ................................................................................................................................................ 73INPUT SHAFT SEAL REMOVAL .......................................................................................................................................................... 73SHAFT SEAL INSTALLATION .............................................................................................................................................................. 74MAIN ROTOR ASSEMBLY ................................................................................................................................................................... 75INSPECTION OF SLIDE VALVE ASSEMBLIES IN THE COMPRESSOR......................................................................................... 76REMOVAL SLIDE VALVE ..................................................................................................................................................................... 76

CARRIAGE ASSEMBLIES .................................................................................................................................................................... 76INSTALLATION OF SLIDE VALVE CARRIAGE ASSEMBLIES ........................................................................................................ 77CAPACITY AND VARIABLE VOLUME RATIO CONTROL ASSEMBLY ........................................................................................ 78

OPTICAL SLIDE VALVE ACTUATOR REMOVAL .............................................................................................................................. 78OPTICAL SLIDE VALVE ACTUATOR INSTALLATION ..................................................................................................................... 79GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80

CONVERSION, INSTALLATION OF ACTUATOR ............................................................................................................................... 80COMMAND SHAFT ASSEMBLY REMOVAL ..................................................................................................................................... 80COMMAND SHAFT ASSEMBLY INSTALLATION ............................................................................................................................. 81COMMAND SHAFT BEARING AND O-RING SEAL REPLACEMENT ........................................................................................... 81COMMAND SHAFT BEARING AND O-RING SEAL REASSEMBLY .............................................................................................. 82

DISCHARGE MANIFOLD REMOVAL ................................................................................................................................................. 82DISCHARGE MANIFOLD INSTALLATION ......................................................................................................................................... 82

SLIDE VALVE GEAR AND RACK INSPECTION ................................................................................................................................ 83

REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS .............................................................................................................. 83INSTALLATION OF CAPACITY OR VOLUME CROSS SHAFTS ...................................................................................................... 84

REMOVAL AND INSTALLATION OF CAPACITY OR VOLUMERATIO ACTUATORS (PRIOR TO 11-1-01 AND AFTER 5-1-95 .......................................................................................................... 85

POTENTIOMETER REMOVAL ............................................................................................................................................................. 87POTENTIOMETER INSTALLATION .................................................................................................................................................... 88

RETROFIT CAPACITY AND VOLUME RATIO CONTROL ............................................................................................................... 88 ASSEMBLIES ON ALL VSS AND VSR COMPRESSORS MANUFACTURED BEFORE MAY 1, 1995. ............................................................................................................................................................ 88 REMOVAL ................................................................................................................................................................................................................... 88

INSTALLATION OF RETROFIT COMMAND SHAFT BEARINGAND O-RING SEAL ................................................................................................................................................................................ 89

REPLACEMENT FOR RETROFIT CONTROL ASSEMBLIES .......................................................................................................... 89COMMAND SHAFT BEARING AND O-RING SEAL REASSEMBLY .............................................................................................. 90LIQUID INJECTION PLUG REPLACMENT ........................................................................................................................................ 91

REMOVAL OF PLUG ............................................................................................................................................................................. 91INSTALLATION OF PLUG ................................................................................................................................................................... 91

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Table of ContentsPLUG APPLICABILITY ......................................................................................................................................................................... 92

TORQUE SPECIFICATIONS .................................................................................................................................................................. 93OIL FILTER ELEMENTS ........................................................................................................................................................................ 94

VSS, VSM and VSR SINGLE SCREW COMPRESSORS SERVICE INTERVAL REQUIREMENTS........................... 98

Recommended Spare Parts List ................................................................................ 99

VSS and VSR Replacement Parts Section................................................................ 103Gate Rotor ...................................................................................................................................................................................... 104Shaft Seal ....................................................................................................................................................................................... 108Main Rotor ..................................................................................................................................................................................... 110Slide Valve Cross Shafts and End Plate ....................................................................................................................................... 114

Slide Valve Cross Shafts Prior to 5-1-95 .................................................................................................................................... 115Slide Valve Carriage Assembly ..................................................................................................................................................... 120

Capacity Control Actuating Motor and Command Shaft ........................................................................................................... 122Slide Valve Actuating Motor and Command shaft Before 5-1-95 ............................................................................................... 126Volume Ratio Control Actuating Motor and Command Shaft ..................................................................................................... 128Miscellaneous Frame Components ............................................................................................................................................... 132Tubing and Fittings ........................................................................................................................................................................ 132Miscellaneous Frame Components ............................................................................................................................................... 134C-Flange Adapter Components ..................................................................................................................................................... 138Replacement Parts Tools ............................................................................................................................................................... 140

VSM Replacement Parts Section .............................................................................. 143Gaterotor Assembly ....................................................................................................................................................................... 144Shaft Seal ....................................................................................................................................................................................... 147Main Rotor, Slide Valve Cross Shafts and End Plate (Models 71-401) ..................................................................................... 148Main Rotor, Slide Valve Cross Shafts and End Plate (Models 501-701 .................................................................................... 152Slide Valve Carriage Assembly ..................................................................................................................................................... 154Actuating Motor with Optical Sensor and Command Shaft ........................................................................................................ 156Miscellaneous Frame Components ............................................................................................................................................... 158Replacement Parts Accessories ..................................................................................................................................................... 160Replacement Tools ......................................................................................................................................................................... 162

Vendor Assessories Section ........................................................................................ 163HAIGHT PUMPS 10-80 Pumps ................................................................................................................................................................PARKER Inlet Pressure Regulators ..........................................................................................................................................................CARTRIDGE HEATERS .............................................................................................................................................................................SPORLAN Strainers ...................................................................................................................................................................................VIKING PUMP Pumps and Pressure Relief Valves ..................................................................................................................................FLUID POWER ENERGY Thermostatic Valves .....................................................................................................................................SPORLAN Solenoid Valve and Thermostatic Expansion Valve ..............................................................................................................HANSEN HA4AOAS INLET/OUTLET REGULATOR ............................................................................................................................

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The procedure described is a general recommendation for extended storage (over one month of no operation) ofVilter Manufacturing packages and compressors. While this procedure is intended to cover most of the commonlyencountered 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 theappropriate procedures.

Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verification of thesystem 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 thebase 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. Allother valves, except those venting to atmosphere, are to be open. It is essential that the nitrogen holding chargeintegrity 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 beenergized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light bulb. Usean 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 withdesiccant bags inside.

* System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5 psi aboveatmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be necessary to add a gaugeto monitor the system holding charge pressure. If a drop in pressure occurs, the source of leakage must be foundand 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 forspecific recommendations.)

Long Term StorageRequirements

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Long Term StorageRequirements

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-prooftype motors.

NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when theunit 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 ofsilica-gel desiccant put inside the bag, around the motor. When the moisture indicator shows that the desiccanthas lost its effectiveness, as by a change in color, the bag should be opened and fresh replacement desiccantsinstalled.

Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F abovethe ambient temperature.

NOTE: There is a potential for damage by small rodents and other animals that will inhabitmotors in search of warm surroundings or food. Due to this, a possibility of motorwinding 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 onthe bearing surfaces. If the compressor unit is installed, wired and charged with oil, open all oil line valves andrun the oil pump for 10 seconds prior to rotating the compressor shaft. Continue running the oil pump while thecompressor shaft is being turned to help lubricate the surfaces of the shaft seal.

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Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms andconditions. 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 bindSeller 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’sbinding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unlessagreed otherwise in writing, all payments are due in full within 30 days of Seller shipping the products or providingthe services. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) themaximum allowed by law.

Security Agreement. This Agreement shall be considered a security agreement to the maximum extent allowed bylaw. 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 necessaryto perfect Seller’s security interest. If Buyer defaults, or Seller deems itself insecure of receiving payment, the fullunpaid 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. Alldelivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’sOrder Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installmentdeliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for aperiod of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) monthsfrom date of installation at the initial end users location, whichever occurs first. In addition, Seller provides thefollowing extended warranties: (a) three (3) years from the date of shipment on single screw compressor internalrotating 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 warrantiesdo not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law orregulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product containsall features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Sellerof 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 merelypasses 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’ssole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or theproviding 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 orparts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory. Any improperuse, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved by Seller, or anyalteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall void all warranties andwarranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be in default of itspayment obligations to Seller under this Agreement or any credit agreement.

DOMESTIC TERMS andCONDITIONS

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

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

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

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

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

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

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

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

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

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

DOMESTIC TERMS andCONDITIONS

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

Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bindSeller 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’sbinding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unlessagreed otherwise in writing, all payments are due in full upon receipt of order or Vilter’s receipt of an acceptable letterof credit. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the maximumallowed by law.

Export Transactions. If the products provided under this Agreement are to be shipped or used outside of the UnitedStates, then the following terms apply unless otherwise agreed by Seller in writing: (1) Buyer shall be responsible forall export and import scheduling and financial arrangements, (2) Buyer shall be responsible for compliance with allexport 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, andother legal requirements, and (5) Seller shall be entitled to condition any shipment upon Buyer obtaining an acceptableLetter 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. Alldelivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’sOrder Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installmentdeliveries.

Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for aperiod of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) monthsfrom date of installation at the initial end users location, whichever occurs first. In addition, Seller provides thefollowing extended warranties: (a) three (3) years from the date of shipment on single screw compressor internalrotating 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 donot apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law orregulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product containsall features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Sellerof 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 merelypasses 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’ssole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or theproviding 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 REMEDIESARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED.

EXPORT TERMS andCONDITIONS

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Products or parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory.Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approvedby Seller, or any alteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall voidall warranties and warranty obligations. Further, Seller shall not be liable under the above warranties should Buyerbe 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 damagesarising from canceling or changing this Agreement. No returns shall be allowed other than with Seller’s expresspermission, and such returns shall include a reasonable restocking charge to the extent permitted by law.

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

Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyerunderstands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NOLIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARYOR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCTLIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER INEXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTYREMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCEABLEFOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREEMENT,THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS WILL NEVERTHELESS REMAIN INEFFECT.

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

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

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

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

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

EXPORT TERMS andCONDITIONS

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STANDARD VILTERWARRANTY STATEMENT

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

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

Unless otherwise agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair ofthe defect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not beresponsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller willnot be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breach ofwarranty. 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 transportationprepaid 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, adverselyaffects the Product, shall void all warranties and warranty obligations. Further, Seller shall not be liable under theabove warranties should Buyer be in default of its payment obligations to Seller under this Agreement or any creditagreement.

15

STANDARD VILTER 5/15WARRANTY 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 compressorunits. If within such period any such product shall be proved to Seller’s satisfaction to be defective, such productshall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation andBuyer’s exclusive remedy hereunder and shall be conditioned upon Seller’s receiving written notice of any allegeddefect within ten (10) days after its discovery and, at Seller’s option, return of such parts to Seller, F.O.B., freightprepaid to Seller’s factory. Expenses incurred by Buyer in repairing or replacing any defective product or any lostrefrigerant will not be allowed except by written permission of Seller. This warranty is only applicable to productsproperly maintained and used according to Seller’s instructions, the use of genuine Vilter replacement parts andrecommended oil in all repairs and replacements has demonstrated adherence to a scheduled maintenance programas detailed in the Single Screw Compressor operating manual. This warranty does not apply to normal wear andtear, or damage caused by corrosion, misuse, overloading, neglect, improper operation, accident or alteration, asdetermined by Seller. Products supplied by seller hereunder, which are manufactured by someone else, are notwarranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products that theSeller 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 OTHERREPRESENTATIONS AND WARRANTIES (EXCEPT OF TITLE), EXPRESS OR IMPLIED WARRANTYOF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.

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

The 5/15 Extended Warranty shall be applicable only if the specific maintenance guidelines as outlined in thetechnical manual are followed. This includes the compressor inspections, completing periodic oil analysis and thechange out of the oil and oil filters, and related components as required with only genuine Vilter parts. Thecustomer is required to keep a maintenance log and receipts demonstrating the use of Genuine Vilter parts forvalidation of a warranty claim, if requested.

Note; The 5/15 warranty applies to NEW compressors only, and does NOT include used or remanufactured com-pressors.

16

COMPRESSOR

The Vilter Single Screw Compressor is a positivedisplacement, capacity and volume controlled, oilflooded, rotary compressor which uses a singlemain screw intermeshed by two opposing gate ro-tors. Gas compression occurs when the individualfingers of each gate rotor sweep through thegrooves, or flutes, of the main screw as the screwrotates. Compression occurs from the time thescrew flute is first closed off by the gate rotor fin-ger, until the time when the screw flute has ro-tated to the point of lining up with the dischargeport in the compressor housing. A labyrinth typeseal is used to prevent gas at discharge pressurefrom leaking past the end of the screw. Any dis-charge gas leakage past the labyrinth seal is ventedback to suction via four longitudinal holes drilledthrough the body of the screw.

By venting the discharge end of the main screwback to suction, forces on each end of the screware equal. This results in zero net axial forces onthe main bearings. With twin opposing gate ro-tors, all radial forces are cancelled out also. Mainshaft bearings have no net forces except the weightof the screw and the shaft assembly.

The compressors are comprised of three rotatingassemblies: the main screw assembly and the twogate rotor assemblies. Each of these rotating as-semblies use a common bearing configuration con-sisting of a single, cylindrical rolling element bear-ing at one end, and a pair of angular contact ballbearings at the other end. The pair of angularcontact ball bearings are used to axially fix oneend of the rotating shafts, and to absorb the smallamount of thrust loads on the shafts. The innerraces of the ball bearings are securely clamped tothe rotating shafts, while the outer races are se-curely held in the bearing housing, thus fixing theaxial position of the shaft in relation to the bear-ing housings. The cylindrical roller bearings atthe opposite end of the shafts allow for axial growthof the shafts while supporting the radial loads fromthe shafts.

The suction gas enters the compressor housingthrough the top inlet flange, at the driven end ofthe unit. The driven end of the compressor hous-

ing is flooded with gas at suction pressure. Thegas enters the open end of the main screw flutes atthe driven end, and becomes trapped in the screwflute as the screw rotates and the gate rotor toothenters the end of the flute. At this point, the com-pression process begins. Directly after the screwflute is closed off by the gate rotor tooth, oil is in-jected into the groove.

The oil enters the compressor through a connec-tion at the top of the compressor. The purpose ofthe injected oil is to absorb the heat of compres-sion, to seal the gate rotor tooth in the groove, andto lubricate the moving parts.

Additional internal oiling ports are provided at themain and gate rotor bearings to cool and lubricatethe bearings. The mechanical shaft seal housingalso contains oiling ports to lubricate, cool and pro-vide a sealing film of oil for the mechanical shaftsseal. Excess oil flows through the check valves onthe sealing baffle plate. This oil is directed at themain rotor roller bearing, which cools and lubri-cates the front roller bearing.

As the main screw rotates, the gate rotor is alsodriven, causing the gate rotor tooth to sweep thegroove in the main screw. This sweeping actionreduces the volume of the groove ahead of the gaterotor tooth and causes the trapped gas and oil to becompressed in the reduced volume. As the mainscrew continues to rotate, the gate rotor tooth con-tinues to reduce the groove volume to a minimum,thus compressing the trapped gas to a maximumpressure. A labyrinth seal arrangement preventsthe compressed gas from leaking past the end ofthe screw. As the gate rotor tooth reaches the endof the groove, the groove rotates to a position thatlines up with the discharge port in the compressorhousing and the gas/oil mixture is discharged fromthe screw at high pressure. This completes the com-pression cycle for a single flute of the main screw.

Once the gas is swept from the main screw flutethrough the discharge port, it passes into the dis-charge manifold of the compressor. From the dis-charge manifold, the gas/oil exits the compressorhousing

Description

17

continues until the screw rotates far enough forthe flute to pass the end of the volume ratio slide.At this point, the screw flute lines up with thedischarge port and the compressed gas is ex-pelled from the screw flute. As the volume ra-tio slide is pulled back away from the dischargeend of the screw, the position of the dischargeport is changed and the gas is allowed to escapethe screw flute earlier in the compression pro-cess, at a reduced pressure.

The overall volume ratio within the compressoris determined by the distance between the frontof the capacity slide (the start of compression)and the back of the volume ratio slide (thecompletion of compression). Therefore, the vol-ume ratio slide must respond to changes in thedownstream pressure measured in the oil sepa-rator and position itself for the required com-pression ratio based on the position of the ca-pacity slide. By only compressing the gas withinthe screw as far as required to match the pres-sure in the downstream receiver, the compres-sor efficiency is maximized. Proper position-ing of the volume ratio slide prevents either overcompressing or under compressing of the gaswithin the screw flute. This allows the singlescrew compressor to efficiently handle a rangeof volume ratios from as low as 1.2 up to 7.0.

The Vilter compressors feature the exclusiveParallex™ Slide System, which consists of a pairof slides for each gate rotor assembly. Thesetwo independently operated slides are referredto as the capacity slide and the volume ratio slide.On the suction end of the screw, the capacityslide moves to vary the timing of the beginningof the compression process. With the slidemoved all the way out to the suction end of thescrew (the 100% position), the compression pro-cess begins immediately after the gate rotor toothenters the screw flute and closes off the end ofthe groove. In this situation, the maximum vol-ume of gas is trapped in the screw flute at thestart of the compression process. As the slide ispulled back away from the suction end of thescrew, the start of the compression process isdelayed as some of the suction gas is allowed tospill back out of the screw flute until the screwrotates far enough to pass the end of the capac-ity slide and begin compressing. This causes areduced volume of gas to be trapped in the screwflute when the compression process begins. Inthis way, the capacity of the compressor is re-duced from 100% down to as low as 10% of thefull rated capacity.

The capacity slide provides the means for con-trolling specific process set points. By con-tinuously adjusting the flow of gas through thecompressor, either suction or discharge pressurein a particular process can be controlled. Whencoupled with a microprocessor controller, theadjustable capacity slide allows for precise andcontinuous automatic control of any parameterin the process to a chosen set point.

The second slide for each gate rotor is the vol-ume ratio slide. The purpose of the volume ra-tio slide is to maximize the efficiency of the com-pressor by matching the gas pressure within thescrew flute at the point of discharge to the down-stream process requirements. The volume ratioslide operates at the discharge end of the screw,and acts to vary the position of the dischargeport. When the slide is extended fully to thedischarge end of the screw (the 100% position),the compression process within the screw flute

Description

18

Symbols and Meanings

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

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

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

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

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

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

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

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

19

InstallationSection

Installation Section ...................................................................................................... 19

DELIVERY INSPECTION....................................................................................................................................................................... 21UNIT WEIGHTS ...................................................................................................................................................................................... 21FOUNDATIONS ...................................................................................................................................................................................... 21LOCATING UNIT - DRIVE COUPLING ALIGNMENT ....................................................................................................................... 21SYSTEM PIPING .................................................................................................................................................................................... 21ELECTRICAL CONNECTIONS ............................................................................................................................................................. 23

TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23 Ammonia Systems ........................................................................................................................................................................... 23

Halocarbon Refrigerant Systems ..................................................................................................................................................... 24Evacuating The System .................................................................................................................................................................... 24

UNIT OIL CHARGING ........................................................................................................................................................................... 25Oil For Single Screw Compressors .................................................................................................................................................. 25

SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25Low Side Equipment ................................................................................................................................................................................ 26Compressors ............................................................................................................................................................................................. 26Condensers ............................................................................................................................................................................................... 26Controls .................................................................................................................................................................................................... 26Initial Charging – High Side Charging .................................................................................................................................................... 26

MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27Daily ................................................................................................................................................................................................. 27Weekly .............................................................................................................................................................................................. 27Monthly ............................................................................................................................................................................................ 27Trimonthly ........................................................................................................................................................................................ 27Yearly ................................................................................................................................................................................................ 27System Leaks .................................................................................................................................................................................... 28Year Round Operation ...................................................................................................................................................................... 28

“STOP CHECK” INSTALLATION ......................................................................................................................................................... 29

COUPLINGS INSTALLATION AND ALIGNMENT ............................................................................................................................. 30Hub Mounting .................................................................................................................................................................................. 30Straight Bore .................................................................................................................................................................................... 30Taper Bore ........................................................................................................................................................................................ 30Shaft Alignment. .............................................................................................................................................................................. 31Final assembly . ............................................................................................................................................................................... 32Disc Pack Replacement. ................................................................................................................................................................... 32

SLIDE VALVE ACTUATOR ................................................................................................................................................................... 34

ACTUATOR MOTOR CONTROL MODULE CALIBRATION PROCEDURE .................................................................................... 34

SLIDE VALVE TROUBLE SHOOTING GUIDE ................................................................................................................................... 37

21

Installation

I. DELIVERY INSPECTION

Vilter screw compressor components are thor-oughly inspected at the factory, assuring the ship-ment of a mechanically perfect piece of equip-ment. Damage can occur in shipment, however.For this reason, the units should be thoroughlyinspected upon arrival. Any damage noted shouldbe reported immediately to the transportation com-pany. This way, an authorized agent can exam-ine the unit, determine the extent of damage andtake necessary steps to rectify the claim with noserious or costly delays. At the same time, thelocal Vilter representative or the home officeshould be notified of any claim made.

TABLE 1. UNIT WEIGHTSMODEL STANDARD ECON-O-MIZER UNIT (LBS)* UNIT (LBS)*

VSM 71 2,750 2,750VSM 91 2,750 2,750VSM 101 2,750 2,750VSM 151 2,750 2,750VSM 181 2,750 2,750VSM 201 2,750 2,750VSM 301 2,850 2,850VSM 361 2,850 2,850VSM 401 2,850 2,850VSM 501 4,000 4,000VSM 601 4,500 4,500VSM 701 5,000 5,000VSS 451 4,000 4,000VSS 601 4,500 4,500VSS 751 5,300 5,300VSS 901 5,300 5,300VSS 1051 6,600 6,600VSS 1201 6,700 6,700VSS 1501 10,010 10,010VSS 1801 10,010 10,010

* Does not include motor.

II. FOUNDATIONS

Vilter single screw compressor units are basicallyvibration free machines, therefore, no elaboratefoundations are necessary. The floor or founda-tion upon which the unit will be placed should bedesigned to support the entire operating weightof the unit. See Table 1 for unit weights.

III. LOCATING UNIT - DRIVECOUPLING ALIGNMENT

The single screw compressor units are shippedwith all major components mounted on struc-tural steel. Place the entire unit on the floor on aconcrete pad and securely bolt in place. Reviewlocal codes and ASHRAE Safety Code for Me-chanical Refrigeration. Bolt holes are locatedin the unit’s mounting feet. When locating theunit, provide adequate space for service work.When the compressor unit is in place on the con-crete pad, check both lengthwise and crosswiseto assure it is level. Use shims and wedges asneeded under the mounting feet to adjust the levelof the unit.

On single screw units, the motor and compres-sor have been roughly aligned at the factory. Thecoupling center section was shipped loose to al-low a check of proper electrical phasing, direc-tion of rotation of the motor and final couplingalignment. The dial indicator alignment methodis recommended. Final alignment should bewithin 0.004 inches total indicator reading inall direction for the VSS models and 0.010 inchesfor the VSM models.

IV. SYSTEM PIPING

Refer to the ANSI/ASME B31.5 Code for Re-frigeration Piping. All compressor oil supply andoil return piping has been completed at the fac-tory. The necessary connections to be made tothe screw compressor unit will vary dependingon the type of oil cooling method purchased.Main line refrigerant suction and discharge con-nections are always necessary.

Care must be taken to avoid trapping the linesexcept for specific purposes. When traps areused, the horizontal dimensions should be asshort as possible to avoid excessive oil trapping.

Lines for ammonia systems must be of steel pipewith specially designed ammonia service fittings.Common pipe fittings must NEVER be used asthey will not provide the same service. Steel pipeis generally used in large installations when jointsare welded.

22

Installation

In making up joints for steel pipe, the followingprocedures should be followed:

For threaded connections, all threads on the pipeand fitting should be carefully cleaned to removeall traces of grease or oil. Threads should then bewiped dry with a lintless cloth. Only thread fill-ing compounds suitable for refrigeration serviceshould be used for making steel pipe joints. Thesecompounds should be used sparingly, and on thepipe only. Do not put any on the first two threadsto prevent any of the compound from entering thepiping system. Acetylene or arc welding is fre-quently used in making steel pipe joints, however,only a skilled welder should attempt this kind ofwork. Take care to see no foreign materials areleft in the pipes and remove all burrs formed whencutting pipe.

It is important to avoid short, rigid pipe lines thatdo not allow any degree of flexibility. This mustbe done to prevent vibration being transmittedthrough the pipe lines to the buildings. Onemethod of providing the needed flexibility to ab-sorb the vibration is to provide long lines that arebroken by 90° Ells in three directions.

Smaller Halocarbon and Hydroflourocarbon in-stallations use copper pipes with solder type fit-tings where possible. The use of screw type fit-tings in Halocarbon systems should be held to anabsolute minimum, as these refrigerants, due totheir physical properties, will leak through screwtype joints.

When drawn copper tubing is used for Halocar-bon lines, type “K” or “L” conforming to ASTMB88 should be used. Soft annealed copper tubingconforming to ASTM B280 can also be used fortube sizes not larger than 1-3/8" in outside diam-eter. These requirements are in accordance withthe mechanical code for refrigeration ANSI B9.1-1971. The type of copper tubing to be used for agiven pressure is dependent on the strength of thecopper at the design temperature. Some localcodes forbid the use of Type “L”. Therefore, be-fore installation, be sure to check local require-ments. Never use type “M” as it does not haveadequate wall thickness to withstand the operat-ing pressures. In selecting fittings for Halocar-

bon piping, only wrought copper fittings shouldbe used. Cast fittings as used for water serviceare porous and will allow the refrigerant to es-cape. Note this exception: In larger pipe sizes,wrought fittings are not available. However,specially tested cast fittings are available andthese may be used with complete safety.

In larger pipe sizes, wrought fittings are not avail-able. However, specially tested cast fittings areavailable and these may be used with completesafety.

When soldering copper tubing joints, only sil-ver solder should be used for Refrigerant-22 ser-vice. Soft solder such as “50-50” should neverbe used, as its melting point is to low, lacks me-chanical strength, and tends to break downchemically in the presence of moisture.

A second method would be to install flex-ible pipe couplings as close to the compressorunit as possible with connections run in two dif-ferent directions, 90° apart. These flexible con-nections should be installed on both the high andlow side lines of the compressor unit.

Hangers and supports for coils and pipe linesshould receive careful attention. During pro-longed operation of the coils, they may becomecoated with ice and frost, adding extra weight tothe coil. The hangers must have ample strengthand be securely anchored to withstand the vibra-tion from the compressor and adequately sup-port the pipe lines.

Water supply and drain connections, and equip-ment using water, should be installed so all thewater may be drained from the system after theplant has been shut down in cold weather. Theseprecautions will avoid costly damage to theequipment due to freezing.

This information is taken from ASHRAE 15-89and ANSI B31.5. The installing contractorshould be thoroughly familiar with these codes,as well as any local codes.

23

Installation

V. ELECTRICAL CONNECTIONS

The single screw compressor units are shippedwith all package mounted controls wired. Thestandard control power is 115 volts 60 Hertz,single phase. If a 115 volt supply is not available,a control transformer may be required. The powersource must be connected to the control panel ac-cording to the electrical diagrams.

The units are shipped without the compressormotor starter. Field wiring is required betweenthe field mounted starters and package mountedmotors.

Additional control wiring in the field is also re-quired. Dry contacts are provided in the controlpanel for starting the screw compressor motor.These contacts are to be wired in series with thestarter coils. A current transformer is suppliedalong with the compressor unit, and is located inthe motor junction box. This transformer is to beinstalled around one phase of the compressormotor starter. A normally open auxiliary contactfrom the compressor motor starter is also required.

Terminal locations for this wiring can be foundon the wiring diagram supplied with this unit.Additional aspects of the electrical operation ofthe single screw units are covered in the start upand operation section of this manual.

VI. TESTING REFRIGERATIONSYSTEM FOR LEAKS

Vilter equipment is tested for leaks at the factory.One the most important steps in putting a refrig-eration system into operation is field testing forleaks. This must be done to assure a tight systemthat will operate without any appreciable loss ofrefrigerant. To test for leaks, the system pressuremust be built up. Test pressures for various re-frigerants are listed in ANSI B9.1-1971 code bro-chure entitle “Safety Code for Mechanical Refrig-eration”. These pressures will usually suffice,however, it is advisable to check local codes asthey may differ. Before testing may proceed, sev-eral things must be done.

First, if test pressures exceed the settings of thesystem, relief valves or safety devices, they mustbe removed and the connection plugged duringthe test. Secondly, all valves should be openedexcept those leading to the atmosphere. Then,open all solenoids and pressure regulators by themanual lifting stems. All bypass arrangementsmust also be opened. Because of differences incharacteristics of the various refrigerants, twodifferent testing methods are necessary.

A. Ammonia Systems

Dry nitrogen may be used to raise the pressurein an ammonia system to the proper level for thetest. The gas may be put into the system throughthe charging valve or any other suitable open-ing. Adjust the pressure regulator on the bottleto prevent over-pressurization. Do not exceedthe pressure rating on the vessel with the lowestpressure rating.

Carbon Dioxide should NOT be used as a test-ing gas in a system where ammonia is alreadydissolved in any moisture remaining. This willcause ammonium carbonate to precipitate whenthe CO2 is added. If heavy enough, this precipi-tate may cause the machine to freeze and clogthe strainer.

A mixture of four parts water to one part liquidsoap, with a few drops of glycerin added, makesa good solution. Apply this mixture with a oneinch round brush at all flanges, threaded joints,and welds. Repair all visible leaks. If possible,leave the pressure on over night. A small pres-sure drop of 5 lbs. Over this period indicates avery tight system.Remember to note the ambient temperature, as achange in temperature will cause a change inpressure.

After the system is thoroughly tested, open allvalves on the lowest part of the system so the gaswill float away from the compressor. This pre-vents any dirt or foreign particles from enteringthe compressor and contaminating the workingparts. The oil should then be charged into thecompressor.

24

Installation

Charge a small amount of ammonia into the sys-tem and pressurize the system to its respectivedesign pressure. Pass a lit sulfur stick around alljoints and connections. Any leaks will be indi-cated by a heavy cloud of smoke. If any leaks areobserved during this test, they must be repairedand rechecked before the system can be consid-ered tight and ready for evacuation.

B. Halocarbon Refrigerant Systems

“Oil pumped” dry nitrogen, or anhydrous CO2 inthis order of preference may be used to raise thepressure to the proper level for testing.

When the proper pressure is attained, test for leakswith the soap mixture previously described. Af-ter all leaks are found and marked, relieve thesystem pressure and repair the leaks. Never at-tempt to repair soldered or welded joints whilethe system is under pressure. Soldered jointsshould be opened and re soldered.

Do not simply add more solder to the leaking joint.After all the joints have been repaired and thesystem is considered “tight” the system may betested with refrigerant.

Attach a drum of the refrigerant to be used in thesystem and allow the gas to enter until a pressureof 5 psig is reached.

Remove the refrigerant drum and bring the pres-sure to the recommended test level with oilpumped dry nitrogen or CO2. Then check theentire system again for leaks, using a halide torchor electronic leak detector. Be sure to check allflanged, welded, screwed and soldered joints, allgasketed joints, and all parting lines on castings.If any leaks are found, they must be repaired andrechecked before the system can be consideredtight again, remembering that no repair shouldbe made to welded or soldered joins while the sys-tem is under pressure.

C. Evacuating The System

A refrigeration system operates best when onlyrefrigerant is present. Steps must be taken to re-move all air, water, vapor, and all other non-

condensables from the system before charging itwith refrigerant. A combination of moisture andrefrigerant, along with any oxygen in the sys-tem, can form acids or other corrosive com-pounds that corrode internal parts of the system.

To properly evacuate the system, and to removeall non-condensables, air and water vapor, use ahigh vacuum pump capable of attaining ablanked off pressure of 50 microns or less. At-tach this pump to the system and allow it to op-erate until system pressure is reduced somewherebelow 1000 microns. Evacuation should not bedone unless the room temperature is 60F orhigher.

Attach vacuum gauge(s), reading in the 20 to20,000 micron gauge range, to the refrigerantsystem. These gauge(s) should be used in con-junction with the high vacuum pump. The read-ing from the gauge(s) indicates when the systemhas reached the low absolute pressure requiredfor complete system evacuation.

Connect the high vacuum pump into the refrig-eration system by using the manufacturer’s in-structions. Connect the pump both to the highside and low side of the system, to insure systemevacuation. Attach the vacuum gauge to the sys-tem in accordance with the manufacturer’s in-structions.

A single evacuation of the system does not satis-factorily remove all of the non-condensable, airand water vapor. To do a complete job, a tripleevacuation is recommended.

When the pump is first turned on, bring systempressure to as low a vacuum level as possible,and continue operation for 5 to 6 hours.

Stop the pump and isolate the system. Allow theunit to stand at this vacuum for another 5 to 6hours. After this time, break, the vacuum andbring the system pressure up to 0 psig with drynitrogen.

To begin the second evacuation, allow the pumpto operate and reduce the pressure again to within50 to 1000 microns. After this reading is reached,

25

Installation

allow the pump to operate 2 or 3 hours. Stop thepump and let the system stand with this vacuum.Again using dry nitrogen, raise the system pres-sure to zero.

For the third evacuation, follow the previous pro-cedure with the pump operating until system pres-sure is reduced below the 1000 micron level. Runthe pump an additional 6 hours and hold the sys-tem for approximately 12 hours at low pressure.After this, again break the vacuum with dry ni-trogen and allow the pressure in the system torise slightly above zero pounds (psig). Install newdrier cartridges and moisture indicators. Chargethe system once more below the 1000 micron leveland use the refrigerant designed for the system.

When properly evacuating the system as outlinedabove, the system is dry, oxygen-free and free ofnon-condensables. The piping should not be in-sulated before the evacuation process is started.If moisture is in the system before evacuating, itcondenses in low places and freezes. If this hap-pens, it can be removed by gently heating the trapfarthest away from the vacuum pump. This causesthe ice to melt and water to boil. Water vaporcollects in the next trap towards the vacuum pump.This process should be repeated until all pocketsof water have been boiled off, and the vacuumpump has had a chance to remove all the watervapor from the system.

VII. UNIT OIL CHARGING

The compressor unit is shipped from Vilter withno oil charge. The initial oil charge can be madethrough the drain valve at the oil receiver/separa-tor. Vilter motor driven and manually operatedoil chargers are available for this purpose. Oncethe unit has been started and is operating above50% capacity, oil may have to be added to bringthe oil level to the normal operating point. Withthe unit operating, oil should be added throughthe charging connection at the suction strainer.The normal operating level is between the (2) sightglasses on the oil separator. See Table 2 for ap-proximate oil charge requirements.

TABLE 2. OIL CHARGE

Oil Separator Size Approximate OilCharge – Gallons

VSR 16” 20 to 27VSR 20” 22 to 31VSM 20” 20 to 25VSM 30” 30 to 3520” 30 to 4024” 40 to 5030” 60 to 7536” 95 to 10542” 145 to 165

The oil level may be above the top sight glass atthis time. Later, when the unit is placed in op-eration, there will be some drop in the oil levelas the various oil lines, oil filter and other pip-ing becomes charged with the normal amount ofoil that will be in circulation. This drop in oillevel should bring the level in the oil receiver/separator into the normal operating range. Donot mix oils.

A. Oil For Single Screw Compressors

Due to the need for adequate lubrication, Vilterrecommends only the use of Vilter lubricants,designed specifically for Vilter compressors.With the extensive research that has been per-formed, we are able to offer refrigerant specificlubricating oils. Use of oil not specified or sup-plied by Vilter will void the compressor warranty.

Please contact your local Vilter representative orthe Home Office for further information.

VIII. SYSTEM REFRIGERANTCHARGING

CAUTION

When charging the system, make sure the com-pressor unit is pressurized from the dischargeside of the compressor. Pressurizing the com-pressor from the suction side may cause rota-tion of the compressor, without oil supply, whichcould lead to internal damage.

26

Installation

After the system is leak-free and evacuation hasbeen completed, it is ready for charging. Beforeactual charging, however, the entire operation ofthe refrigeration system should be inspected asoutlined below:

A. Low Side Equipment

1. Fans on air handling equipment running.2. Pumps on water cooling equipment running.3. Proper location and attachment of thermo-

static expansion valve bulb to suction line.4. Correct fan and pump rotation.5. Evaporator pressure regulators and solenoid

valves open.6. Water pumps and motors correctly aligned.7. Belt drives correctly aligned and tensioned.8. Proper voltage to motors.

B. Compressors

1. Proper oil level.2. Voltage agrees with motor characteristics.3. Properly sized motor fuses and heaters.4. Direct drivers aligned and couplings tight.5. All suction and discharge valves open.6. All transducers and RTD’s calibrated and

reading correctly.

C. Condensers

1. Water available at water cooled condensersand supply line valve open.

2. Water in receiver of evaporative condenserand makeup water available.

3. Correct rotation of pump and fan motors.4. Belt drives aligned and tensioned correctly.5. Pump, fans and motors lubricated.

D. Controls

Controls should be at the initial set points. Seemicroprocessor manual for further information.

E. Initial Charging – High Side Charg-ing

There are two methods of charging refrigerant intothe system, through the “high side” or through

the “low side”. High side charging is usuallyused for initial charging as filling of the system ismuch faster. Low side charging is usually reservedfor adding only small amounts of refrigerant afterthe system is in operation.

High side charging of refrigerant into the sys-tem is accomplished as follows:

1. Connect a full drum of refrigerant to theliquid charging valve. This valve is gener-ally located in the liquid line immediatelyafter the king or liquid line valve. Purgethe air from the charging line.

2. Invert the refrigerant drum if the drum isnot equipped with “Liquid” and “Vapor”valves, and place in such a position so theliquid refrigerant only can enter the sys-tem. Close the liquid line or king valve, ifit is not already closed. Open the “Liquid”charging valve slowly to allow refrigerantto enter the system. The vacuum in thesystem will draw in the refrigerant.

It is important that, during this operation,air handling units be running and water iscirculating through the chillers. The lowpressures on the system can cause the re-frigerant to boil at low temperature andpossibly freeze the water if it is not keptcirculating.

Water freezing in a chiller can rupture thetubes and cause extensive damage to thesystem. It would be desirable to charge theinitial amount of refrigerant without waterin the shell and tube equipment to elimi-nate the possibility of freeze up.

3. After some refrigerant has entered the sys-tem, the compressor unit starting proceduremay be followed. See Start-Up and Opera-tion Section of this manual.

4. Continue charging refrigerant into the sys-tem until the proper operating requirementsare satisfied. Then, close the liquid charg-ing connection and open the liquid linevalve allowing the system to operate nor-

27

Installation

mally. To check that enough refrigerant hasbeen added, the liquid sight glass shouldshow no bubbles, and there will be a liquidseal in the receiver. If these two conditionsare not satisfied, additional refrigerant mustbe added.

5. When sufficient refrigerant has been chargedinto the system, close the charging and drumvalves. Then remove the drum from the sys-tem.

6. During the charging period, observe thegauge carefully to insure no operating diffi-culties. Watch head pressures closely tomake sure the condensers are functioningproperly.

Since it is usually necessary to use several drumswhen charging a system, follow the procedures inparagraphs E1 and E2 of the above descriptionwhen attaching a new drum. After charging, therefrigerant drums should be kept nearby for sev-eral days as it is sometimes necessary to add morerefrigerant as the system “settles down”.

IX. MAINTENANCE SUGGESTIONS

Careful checking of a refrigeration system forleaks and proper operation of all components uponinstallation will start the system on its way to along life of satisfactory service. To ensure thedesired trouble-free operation, however, a system-atic maintenance program is a prerequisite. Thefollowing maintenance schedule is suggested.

A. Daily

1. Check oil levels.

2. Check all pressure and temperature readings.

3. Check micronic oil filter inlet and outletpressures for excessive pressure drop.Change filter when pressure drop exceeds45 psi or every six months, whichever oc-curs first. For proper procedure for chang-ing micronic oil filter and for charging oilinto the system, see Operation Section.

4. Clean strainers each time filter cartridge if

replaced.

5. Check compressor sound for abnormalnoises.

6. Check shaft seals for excessive oil leakage.A small amount of oil leakage (approxi-mately 10 drops/min) is normal. This al-lows lubrication of the seal faces.

B. Weekly(Items 1 thru 6 above plus 7 thru 9)

7. Check the refrigeration system for leakswith a suitable leak detector.

8. Check oil pressures and review micropro-cessor log and log sheets.

9. Check refrigerant levels in vessels.

C. Monthly(Items 1 thru 8 above plus 9 thru 13)

10. Oil all motors and bearings. Followmanufacturer’s instructions on lubrication.

11. Check calibration and operation of all con-trols, particularly safety controls.

12. Check oil cooler for any evidence of corro-sion, scaling or other fouling.

13. Operate compressor capacity and volumeratio controls through their range both au-tomatically and manually.

D. Trimonthly(About 2000 operating hours)

Check movement of compressor rotor at drivecoupling end to determine bearing float. (Referto Service Section.)

E. Yearly(Items 1 thru 13 and “D” above plus 14 thru28)

14. Check entire system thoroughly for leaks.

15. Remove all rust from equipment, clean andpaint.

28

Installation

16. Flush out sediment, etc. from water circuits.

17. Clean all oil strainers.

18. Clean suction strainer – compressors.

19. Check motors and fans for shaft wear andend play.

20. Check operation and general condition ofmicroprocessor and other electrical controls.

21. Clean all water strainers.

22. Check drains to make sure water will flowaway from equipment.

23. Drain and clean entire oil system at receiverdrain. Recharge with new clean moisturefree oil. For proper procedure for changingmicronic oil filter and charging oil into thesystem, see Start-Up and Operation section.

24. Check compressor coupling. For integrityand alignment.

25. Check oil pump for wear.

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

27. Check mounting bolts for compressor andmotor.

F. System Leaks

There are any number of reasons why leaks de-velop in a refrigeration system (i.e. such as dry-ing out of valve packing, yielding of gaskets, im-proper replacement of valve caps and looseningof joints due to vibration). For these reasons, theneed for periodic leak testing cannot be over-em-phasized. Similarly, when any service operationsare performed on the system, care should be exer-cised to insure all opened flanges are tightened,all plugs that were removed are replaced with asuitable thread filling compound, all packingglands on valve stems are tightened, and all valvecaps are replaced. When operation is restored,all joints opened or any valves moved during theservicing should be checked for leaks.

G. Year Round Operation

On a continual basis:

1. Guard against liquid slugging of compres-sor.

2. Maintain unit in clean condition and paintas necessary.

3. Grease valve stems and threads for the valvecaps.

When refrigeration equipment is operated 24hours a day year round, it is highly recommendedthat a yearly check of all internal parts be made(see Service Section). While the highest mate-rial standards are maintained throughout allVilter compressors, continuous operation and anypresence of dirt may prove injurious to the ma-chine. To forestall needless shutdowns or pre-vent possible machine breakdowns, the side cov-ers should be removed yearly, and a visual in-spection be made of the internal parts. In thisway, a small amount of time spent checkingmachine conditions once a year may preventextensive shutdowns later with subsequent prod-uct loss and expensive repairs.

29

“Stop Check” Installation

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

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

See Operation Section on Stop Check Operation.

Correct

Wrong

Correct

Wrong

Verify the location of Spring andnote the Vilter name

Name

Name

Wrong

Stem should always bepositioned upwards.

30

Installation

IIV. COUPLINGS INSTALLATIONAND ALIGNMENT

These instructions are intended to help you toinstalland align the coupling. Covered here willbe general information, hub mounting, alignment,assembly, locknut torquing, discpack replacement,and part numbers. The coupling as received, mayor may not be assembled.*If assembled, the locknuts are not torqued.*If coupling is assembled, remove the bolts thatattach the hubs to the disc packs. Remove bothhubs. Leave the disc packs attached to the centermember.

A. Hub Mounting:

1. Clean hub bores and shafts. Remove anynicks or burrs. If bore is tapered, check for goodcontact pattern. If the bore is straight, mea-sure the bore and shaft diameters to assureproper fit. The key(s) should have a snug side-to-side fit with a small clearance over the top.

NOTE: If the DBZ hub position on the shaft doesnot allow enough room to install the short boltsin the hub after hub mounting, install the boltsand disc pack before mounting hub on shaft.

B. Straight Bore:

1. Install key(s) in the shaft. If the hub is aninterference fit, heat the hub in an oil bath oroven until bore is sufficiently larger than theshaft. 350º F. is usually sufficient. An openflame is not recommended. However, if flameheating is necessary, use a very large rose budtip to give even heat distribution. A thermalheat stick will help determine hub tempera-ture. DO NOT SPOT HEAT THE HUB ORDISTORTION MAY OCCUR. With the hubsexpanded, slide it up the shaft to the desiredaxial position. A pre-set axial stop device canbe helpful.

NOTE: All DBZ hubs have pressed in bushings.Make sure the bushings are facing the disc pack.

C. Taper Bore:

1. Put the hub on the shaft without key(s)inplace. Lightly tap hub up the shaft with asoft hammer. This will assure a metal-to-metalfit between shaft and hub. This is the startingpoint for the axial draw. Record this position

31

Installation

This means there is a minimal amount of wavi-ness in the disc pack when viewed from theside. This will result in a flexing element thatis centered and parallel to its mating flangefaces. Move the connected equipment to ac-complish the above.

NOTE: The disc pack is designed to an optimalthickness and is not to be used for axial adjust-ments.

As a guide, maximum and minimum values fordimension “E” are given. These dimensions aresuggested for initial installation. Additional ca-pacity is available to compensate for thermal andstructural movement. Maximum axial capacityvalues for these couplings are also given. See chartabove.

c. Angular Alignment. Rigidly mount a dial in-dicator on one hub or shaft, reading the face ofthe other hub flange, as shown on next page.Rotate both shafts together, making sure theshaft axial spacing remains constant. Adjustthe equipment by shimming and/or moving sothat the indicator reading is within .002 inchper inch of coupling flange.

between shaft and hub face with a depth mi-crometer. Mount a dial indicator to read axialhub movement. Set the indicator to “0”. Re-move hub and install key(s). Remount hub,drawing it up the shaft to the “0” set point.Continue to advance hub up the taper to thedesired axial position. Use the indicator as aguide only. A pre-set axial stop device can behelpful. Check the final results with a depthmicrometer. The hub may have to be heated inorder to reach the desired position on the shaft.DO NOT SPOT HEAT THE HUB OR DIS-TORTION MAY OCCUR. Install shaft lock-nut to hold hub in place.

D. Shaft Alignment.

Move equipment into place.

a. Soft Foot. The equipment must sit flat on itsbase. Anysoft foot must be corrected now.

b. Axial Spacing. The axial spacing of the shaftsshould be positioned so that the disc packs(flexing elements) are flat when the equipmentis running under normal operating conditions.

Coupling Total Indicator Dimension “E” TorqueSize Reading (T.I.R.) Ft.-Lbs.

Angle Parrallel Min Max (In.-Lbs.)

50 .004 .003 1.36 1.37 (24)62 .005 .003 1.74 1.75 (36)75 .005 .003 1.77 1.78 (36)101 .006 .004 2.08 2.10 (96)126 .007 .005 2.46 2.48 (156)163 .009 .005 2.46 2.48 (156)201 .010 .006 2.96 2.98 25226 .012 .007 3.83 3.83 30263 .014 .009 4.33 4.35 40301 .016 .010 4.90 4.93 95351 .018 .012 5.90 5.93 175401 .020 .013 6.71 6.75 150*451 .024 .014 7.27 7.31 190*

Note: These torques are approximate. Bolt and locknut threads must be coated with molybdenumdisulfide grease.* Tightening torques are cadmium plated.

32

Installation

d. Parallel Offset. Rigidly mount a dial indi-cator on one hubor shaft, reading the other hubflange outside diameter, as shown in Figure 3.Indicator set-up sag must be compensated for.Rotate both shafts together. Adjust the equip-ment by shimming and/or moving so that theindicator reading is within .002 inch per inchof the axial length between flex elements. Seedrawing below.

Note: If the driver or driven equipment alignmentspecification is tighter than these recommenda-tions, the specification should be used. Also, besure to compensate for thermal movement in theequipment. The coupling is capable of approxi-mately four time the above shaft alignment toler-ances. However, close alignment at installationwill provide longer service with smoother opera-tion.

E. Final assembly .

With the coupling in good alignment the boltswill fit through the holes in the flanges and thedisc packs more easily.

a. If the coupling arrived assembled, the discpacks are still attached to the center ring. Be-fore taking the discs packs off, first install onehub bolt through each disc pack and securewith lock out. This will help when the pack isreinstalled late. If the coupling was shippeddisassembled, the bolt through the pack is notrequired as the discs in the pack are factorytaped together.

b. Remove the long bolts. Mount the disc packson the hubs with one bolt through the disc packaligned with a clearance hole in the hub. In-stall the short bolts through the hub, disc pack,bevel washer or link, and secure with a lock-out.

NOTE: All bolt threads should be lubricated. Aclean motor oil is recommended. On size 226 andlarger, a link must be put on bolt first. Removethe disc pack alignment bolt. Proceed to mountthe second disc pack to the other hub in the sameway.

C.Position one set of short bolts in each hubon top. Now slide the center ring down intoplace straddling the short bolts with the cen-ter ring bushings. If coupling is dynam-icallybalanced, the center ring match marks mustlineup with both hub match marks. When onebushing is in-line with the hole in the disc pack,slide one long bolt through washer or link, discpack, center ring, disc pack, washer or link,and then secure with a locknut. The long boltrequires a minimum clearance “R” for instal-lation between back side of coupling flangeand stationary equipment. See Figure 1 andTable l for value of “R.” On size 226 and largera link must be put on the bolt first. Now in-stall the rest of the long bolts in the same man-ner.

D.Torque the long bolt locknuts at this time.See Table on page 31 for torque values.

NOTE: With the coupling in good alignment, thebolts will fit through the holes in the flanges andthe disc pack more easily. It is recommended thatall locknuts be retightened after several hours of

Note: Alignment of C-Flange Units should bechecked when compressoror motor are replaced.

33

Installation

initial operation. E.For further help with the installa-tion or alignment, consult Rexnord.

F. Disc Pack Replacement.

If it becomes necessary to replace the disc pack, itcan be done as follows:

A. Remove all the long bolts and lower the cen-ter ring by sliding it our from between the twodisc packs.

B. Remove one short bolt from the disc pack/hubconnection and reinstall it through a hub clear-ance hole and into the hole in the disc pack. Putthe nut on. This will keep the discs together andmaintains the disc orientation for later reinstal-lation. Remove the rest of the short bolts andtakeoff the disc pack. Repeat for the second discpack.

C. Replace the pack(s) if required. Recheck align-ment per Section D. Reassemble per Section E.

34

Installation & Calibration

SLIDE VALVE ACTUATORINSTALLATIONS INSTRUCTIONS

Caution

WHEN INSTALLING THE OPTICAL SLIDEMOTOR, LOOSEN LOCKING COLLARBEFORE SLIDING THE COLLAR DOWNON THE SHAFT. DO NOT USE A SCREW-DRIVER TO PRY LOCKING COLLAR INTOPOSITION.

OVERVIEW

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

1) The actuator motor control module, locatedinside the actuator housing, is calibrated sothat it knows the minimum and maximumrotational positions of the slide valve it con-trols. The calibrated actuator will output 0VDC at the minimum position and 5 VDCat the maximum position.

2) After the actuator motor control module hasbeen calibrated for 0-5Volts, the controllingchannel corresponding to the actuator mo-tor (either the capacity or volume) has to becalibrated. This instructs the Vission/ Van-tage control panel to learn the rotational 0%position & rotational 100% position of theslide valve travel.

PLEASE NOTE:Because there is an optical sensor on thismotor, do not attempt calibration in directsunlight.

ACTUATOR MOTOR CONTROLMODULE CALIBRATION PROCEDURE

1. Disable the Slide Non-Movement Alarmby going to the “Setup” menu on theVission/Vantage and choosing “AlarmDisable” for the Slide Non-MovementOption. (If applicable).

2. Completely shut off the power to theVission/Vantage control panel com-pletely.

3. If not already done, mount the slidevalve actuator per (“Vilter Actuator setup for Capacity and Volume Slide Mo-tors). Next, wire the actuator per theattached wiring diagrams, using the al-ready installed electrical conduit to runthe cables. The old wiring can be usedto pull the new cables through the con-duit to the control panel. The cablesmay also be externally tie-wrapped tothe conduit. Run the yellow AC powercable(s) and the gray DC positiontransmitter cable(s) in different con-duit. This prevents the DC positiontransmitter cable from picking up elec-trical noise from the AC power cable.Do not connect either of the cables tothe actuators yet.

In addition, if the actuators are replacing oldgearmotors on early Vission/Vantage units, youmust remove the capacitors and associated wir-ing from inside the control panel. This is neces-sary to prevent electrical damage to the new ac-tuator motor.

4. When completing the calibration ofthe new actuators, the motors aresignaled to move to below 5%. Thismay not completely occur whenexiting the calibration screen due to a“program timer”. HOWEVER, whenthe compressor actually starts, themotors will travel below 5% andfunction correctly. The user may seethat the actuators are not below 5%after calibration and try to find thereason. If the calibration screen is re-entered right away and then exited,the timer will allow the actuator to gobelow the 5% on the screen. Thismay be perceived as a problem; inreality,it is not.

5. Note:The 0 to 5V-position transmitteroutput of the actuator will fluctuate wildly

35

Installation & Calibration

during the calibration process. To preventdamage to the actuators, do not connect theyellow power cable or the gray positiontransmitter cable until instructed to do solater on.

6. Open the plastic cover of the capacitymotor by removing the four #10 screws.Caution: there are wires attached to theconnector on the plastic cover. Handlingthe cover too aggressively could breakthe wires.

7. Gently lift the cover and tilt it toward theTurck connectors. Raise the cover enoughto be able to press the blue calibrate buttonand be able to see the red LED on the topof assembly.

8. Press “Menu” on the main screen and thenpress the “Slide Calibration” button, toenter the slide calibration screen. (Note:you must be in this slide calibration screenbefore attaching the yellow power cable orgray position transmitter cable.)

9. Now connect the yellow power cable andthe gray position transmitter cable to theactuator.

10. Press INC and DEC to move the slidevalve and check for the correct rotation.See Table 1on page 48 for Actuator/command shaft rotation specifications.

11. Note: If the increase and decrease buttonsdo not correspond to increase or decreaseshaft rotation, swap the blue and brownwires of the “yellow power cable”. Thiswill reverse the rotation of the actuator/command shaft.

12. Quickly press and release the blue pushbutton on the actuator one time. Thisplaces the actuator in calibration mode.The red LED will begin flashing rapidly.

13. Note: When the actuator is in calibrationmode, it outputs 0V when the actuator isrunning and 5V when it is still. Thus, as

stated earlier, the actuator voltage willfluctuate during calibration. After theactuator has been calibrated, 0V outputwill correspond to the minimum positionand 5V to the maximum position.

14. Note: The “Slide calibration” screen onthe Vission/Vantage has a “Current”window, which displays twice the actuatoroutput voltage. This value, (the % volumeand the % capacity) displayed in the“Current Vol” and Current Cap” Windowsare meaningless until calibration has beencompleted.

15. Use the DEC button on the Vission/Vantage panel to drive the slide valve to itsminimum “mechanical stop” position. Donot continue to run the actuator in thisdirection after the slide valve hasreached the stop. Doing so may causedamage to the actuator or the slidevalve. When the slide has reached themechanical stop position, use the INCbutton to pulse the actuator to where theslide is just off of the mechanical stop andthere is no tension on the motor shaft.

16. Quickly press and release the blue buttonon the actuator again. The red LED willnow flash at a slower rate, indication thatthe minimum slide valve position (0Vposition) has been set.

17. Use the INC button on the Vission/Vantagepanel to drive the slide to its maximum“mechanical stop” position. Do notcontinue to run the actuator in thisdirection after the slide valve hasreached the stop. Doing so may causedamage to the actuator or the slidevalve. When the slide valve has reachedthe mechanical stop position, use the DECbutton to pulse the actuator to where theslide is just off of its mechanical stop andthere is no tension on the motor shaft.

18. Quickly press and release the blue buttonon the actuator one more time. The redLED will stop flashing. The actuator is

36

Installation

now calibrated and knows the minimumand maximum positions of the slide valveit controls. Now the capacity or volumechannel of the Vission/Vantage can becalibrated.

19. Use the Dec button to move the actuatortowards its minimum position whilewatching the millivolt readout on theVission/Vantage screen. Discontinuepressing the DEC button when the milli-volt reading in the “Current” window abovethe “Set Min” button is approximately 500millivolts.

20. Now use the DEC and INC buttons toposition the slide valve until a value closeto 300 millivolts is on the screen. Then,press the “Set Min” button for the capacityor volume slide valve window to tell thecontroller that this is the minimummillivolt position. Note: The value in the“Current Cap” or “Current Vol” windowhas no meaning right now.

21. Use the INC button to rotate the actuatortowards its maximum position whilewatching the millivolt readout on thecontroller screen. Discontinue pressing theINC button when the millivolt reading inthe “Current” window is approximately9200 millivolts (7900 millivolts for the2783J qualified analog boards). You arenearing the mechanical stop position.

22. Pulse the INC button to carefully move theslide valve until the millivolt readout“saturates”, or stops increasing. This isaround 9500 millivolts (8400 millivolts for2783 qualified analog boards).

23. Pulse the DEC button until the millivoltsjust start to decrease. (This is the pointwhere the channel drops out ofsaturation).Adjust millivolt value to 300millivolts below recorded maximum milli-volts in step #22.

24. Press the “Set Max” button.

25. Press the “Main” button to complete

calibration and exit the “Slide Calibration”screen. The controller will automaticallyenergize the actuator and drive it back toits minimum position (below 5%) for pre-start-up.

26. Note: Now the “Current Cap” or the“Current Vol” value will be displayed inthe window on the “Main” screen and the“Slide Calibration” screen.

27. Gently lower the plastic cover over the topof the actuator to where it contacts the baseand o-ring seal. After making sure thecover is seated properly, gently tighten thefour #10 screws. Caution: The plasticcover will crack if the screws are overtightened.

28. Enable the “Slide Non-Movement Alarm”by going to the “Setup” menu and choosing“Alarm Enable” for the “Slide Non-Movement Option”.

29. This completes the calibration for thischannel either capacity or volume. Repeatthe same procedure to the other channel.

37

Slide Valve Actuator Troubleshooting Guide

Slide Valve Actuator Theory of Operation

The slide valve actuator is a gear-motor with aposition sensor. The motor is powered in the for-ward and reverse directions from the main com-puter in the control panel. The position sensortells the main computer the position of the slidevalve. The main computer uses the position andprocess information to decide where to move theslide valve next.

The position sensors works by optically countingmotor turns. On the shaft of the motor is a smallaluminum “photochopper”. It has a 180 degreefence that passes through the slots of two slottedoptocouplers. The optocouplers have an infra-red light emitting diode (LED) on one side of theslot and a phototransistor on the other. Thephototransistor behaves as a light controlledswitch. When the photochopper fence is block-ing the slot, light from the LED is prevented fromreaching the phototransistor and the switch isopen. When photochopper fence is not blockingthe slot, the switch is closed.

As the motor turns, the photochopper fence al-ternately blocks and opens the optocoupler slots,generating a sequence that the position sensormicrocontroller can use to determine motor posi-tion by counting. Because the motor is connectedto the slide valve by gears, knowing the motorposition means knowing the slide valve position.

During calibration, the position sensor records thehigh and low count of motor turns. The operatortells the position sensor when the actuator is atthe high or low position with the push button.Refer to the calibration instructions for the de-tailed calibration procedure.

The position sensor can get “lost” if the motor ismoved while the position sensor is not powered.To prevent this, the motor can only be moved elec-trically while the position sensor is powered.When the position sensor loses power, power iscut to the motor. A capacitor stores enough en-ergy to keep the position sensor circuitry alivelong enough for the motor to come to a completestop and then save the motor position to non-vola-tile EEPROM memory. When power is restored,

the saved motor position is read from EEPROMmemory and the actuators resumes normal function

This scheme is not foolproof. If the motor is movedmanually while the power is off or the motor brakehas failed, allowing the motor to free wheel for toolong after the position sensor looses power, the ac-tuator will become lost.

A brake failure can sometimes be detected by the po-sition sensor. If the motor never stops turning aftera power loss, the position sensor detects this, knowsit will be lost, and goes immediately into calibratemode when power is restored.

38


The actuator cannot be cali-brated

The actuator goes into calibra-tion mode spontaneously

The actuator goes into calibra-tion mode every time power isrestored after a power loss

Dirt or debris is blocking one or bothoptocoupler slots

The photochopper fence extends lessthan about half way into theoptocoupler slots

The white calibrate wire in the greyTurck cable is grounded

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

The calibrate button is stuck down

The position sensor has failed

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

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

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

There is an intermittent failure of theposition sensor

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

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

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

Tape the end of the white wirein the panel and make sure thatit cannot touch metal

Clean the boards with an elec-tronics cleaner or compressedair.

Try to free the stuck button.

Replace the actuator.

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

Tape the end of the white wirein the panel and make sure thatit cannot touch metal.

Increase the distance betweenthe EMI source and the actua-tor.

Install additional metal shield-ing material between the EMIsource and the actuator or cable.


Get the motor brake to where itoperates freely and recalibrate.

Replace the actuator

39

The motor was manually movedwhile the position sensor was notpowered.

The motor brake is not workingproperly

The position sensor’s EEPROMmemory has failed

The photochopper is misalignedwith the slotted optocouplers

The photochopper is positioned toolow on the motor shaft.

A motor bearing has failed

There is a loose connection in thescrew terminal blocks

There is a loose or dirty connectionin the yellow Turck cable

The position sensor has failed

There is a broken motor lead orwinding

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

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

The command shaft is jammed

Broken gears in the gearmotor

Motor is overheating and the ther-mal switch is tripping

Recalibrate.

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


Try to realign or replace the ac-tuator.

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


Tighten.

Clean and tighten.



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

See above.

Free the command shaft.


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


The actuator does not transmitthe correct position after a powerloss

There is a rapid clicking noisewhen the motor is operating

The motor operates in one direc-tion only

The motor will not move in ei-ther direction

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

40


Bad thermal switch

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

Stripped gears inside the gear motoror the armature has come un-pressedfrom the armature shaft


See above.


The motor runs sporadically

The motor runs but output shaftwill not turn

41

OperationSection

Operation Section ........................................................................................................ 41

OIL SYSTEM ........................................................................................................................................................................................... 43Oil Charge ........................................................................................................................................................................................ 43Oil Filter ........................................................................................................................................................................................... 43Filter Removal and Installation, all VSR Units. ............................................................................................................................. 43Filter Removal, VSS and VSM Units .............................................................................................................................................. 44Filter Removal, VSS and VSM Units . ........................................................................................................................................... 44Oil Pressure Regulating ................................................................................................................................................................... 45Oil Cooling ....................................................................................................................................................................................... 45Water Cooled Oil Cooler .................................................................................................................................................................. 45Liquid Injection Oil Cooling. ........................................................................................................................................................... 46V-PLUS Oil Cooling System ............................................................................................................................................................ 46Thermosyphon Oil Cooling .............................................................................................................................................................. 47

CONTROL SYSTEM .............................................................................................................................................................................. 47Screw Compressor Control And Operation ..................................................................................................................................... 47Starting, Stopping and Restarting the Compressor ......................................................................................................................... 47Slide Valve Control .......................................................................................................................................................................... 48

Slide Valve Motor Location ............................................................................................................................................................. 49 Oil Separator Heater ......................................................................................................................................................................... 49 Econ-O-Mizer Controls ................................................................................................................................................................... 49

Safety Setpoints ................................................................................................................................................................................ 49Oil Pressure ...................................................................................................................................................................................... 49Discharge Pressure ........................................................................................................................................................................... 49Suction Pressure ............................................................................................................................................................................... 50Oil Filter Differential ....................................................................................................................................................................... 50Oil Temperature ............................................................................................................................................................................... 50Discharge Temperature .................................................................................................................................................................... 50

INITIAL START-UP ................................................................................................................................................................................. 50Setting of Controls ........................................................................................................................................................................... 50Valve Settings ................................................................................................................................................................................... 50Oil Separator .................................................................................................................................................................................... 50V-PLUS Oil Cooling ........................................................................................................................................................................ 51Liquid Injection Oil Cooling ............................................................................................................................................................ 51

Compressor Pre Start-Up Check List .............................................................................................................................................. 51 Stop Check Operation ...................................................................................................................................................................... 52

Pre-Start Up ...................................................................................................................................................................................... 53

PRE START-UP CHECKLIST - FIELD PIPING AND MECHANICAL REQUIREMENTS .............................................................. 54PRE START-UP CHECKLIST - FIELD WIRING REQUIREMENTS ................................................................................................. 55

42

Notice on using Non -Vilter Oils

Oil and its additives are crucial in refrigeration system performance. Vilter Manufacturing will NOTAPPROVE non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available it isnot possible for us to test all oils offered in the market place, and their effects on our equipment, as we canwith 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, Vilteris unable to accept responsibility for any detrimental affects those lubricants may have on the equipmentor system performance and durability.

Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warrantyupon 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 fora particular application involves consideration of many aspects of the lubricant and how it and its additivepackage, will react in the various parts of the entire refrigeration system. It is a complex choice thatdepends 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.

43

Operation

I. OIL SYSTEM

A. Oil Charge

Charge the combination oil receiver/separatorwith the proper quantity of lubricating oil (seeInstallation Section).

CAUTIONIt is imperative you charge the oil into thereceiver/separator prior to energizing the con-trol panel to prevent burning out the immer-sion heater in the separator/receiver.

During operation, maintain the receiver/sepa-rator oil level in the normal operating rangebetween the two bullseye sight glasses. If theoil level is visible only in the lowest sight glass,add oil to the operating compressor through theconnection located at the compressor suctioninlet. Pump oil into the compressor until theoil level in the separator is between the twobullseye sight glasses. Watch this level care-fully to maintain proper operation. Never al-low the oil to reach a level higher than indi-cated on the highest sight glass, since this mayimpair the operation and efficiency of the oilseparator portion of this combination vessel.

B. Oil Filter

Change the oil filter after the first 200 hours ofoperation, as noted on the hour meter. There-after, replace the filter every six months, orwhen the oil pressure drop through the filterreaches 45 psi, whichever occurs first. Thepressure drop across the filter is read on themicroprocessor panel. Check the pressure dropand record it daily.

To prepare for the removal of the filter, shutdown the compressor. Isolate the filter housingappropriate. If unit is equipped with duplex fil-ter housings the unit does not have to be shutdown, however the filter to be serviced must beisolated before the tank or bowl can be opened.

1. Filter Removal and installation, allVSR Units.

Release the pressure in the oil filter housing byopening the bleed valves at the stop valve inthe block and bleed assembly, or at the bleedvalve for the oil filter housing. Be sure to fol-low all Local, State and Federal ordinances re-garding the recovery of refrigerants.

FIGURE 1.TYPICAL CANISTER TYPE FILTER

CROSS SECTION

Drain the filter bowl or housing in to an appro-priate container and dispose of the oil in a ap-propriate manner following all Local, State andFederal ordinances regarding the disposal ofused refrigeration oil.

Loosen and remove the locking ring on filtertank by turning in a counter clockwise direc-tion. Remove filter tank with the used element.

Remove the filter element from the tank. Be-fore reassembling, thoroughly clean the tankto lengthen the life span of the filter element.

Wet the threads and O-ring on the head andthe O-ring in the new element with clean re-frigeration oil.

44

Operation

CAUTION

Do not use a pipe wrench, hammer or any othertool to tighten the locking ring.

Insert new element into the filter tank withthe open end visible. Attach tank to headand HAND TIGHTEN the locking ring.

The filter housing can be evacuated and thenslowly pressurized to check for leaks beforereturning to service.

2. Filter Removal, VSS and VSM Units(after 5/1/00) when using Vilter PartNumbers 3111A (16” Simplex), or3112A (39” Simplex) oil filterhousings.

Release the pressure in the oil filter housingby opening the bleed valves at the stop valvein the block and bleed assembly, or at thebleed valve for the oil filter housing. Be sureto follow all Local, State and Federal ordi-nances regarding the recovery of refrigerants.

Drain the filter bowl or housing in to an ap-propriate container and dispose of the oil ina appropriate manner following all Local,State and Federal ordinances regarding thedisposal of used refrigeration oil.

Loosen and remove the cover on the bowl ofthe filter tank by turning it in a counter clock-wise direction. Remove the used element.

Wet the O-ring in the new element with cleanrefrigeration oil. Insert the new element intothe filter tank with the closed end visible andattach the cover to the bowl. HANDTIGHTEN the cover.


3. Filter Removal, VSS and VSMUnits (after 5/1/00) when usingVilter Part Numbers 3109A (16”Duplex), or 3110A (39” Duplex) oilfilter housings.

Isolate the bowl to be worked on by turninghandle. The handle will cover the drainvalve of active element. Close commutervalve in center of handle. Release the pres-sure in the isolated bowl by bleeding throughthe stop valve on the oil filter cover for Du-plex (Vilter Part #3109A or 3110A), orthrough the stop valve for the oil filter hous-ing. Be sure to follow all Local, State andFederal ordinances regarding the recoveryof refrigerants.

Drain the filter bowl or housing in to an ap-propriate container and dispose of the oil ina appropriate manner following all Local,State and Federal ordinances regarding thedisposal of used refrigeration oil.

Loosen and remove the cover on the bowl ofthe filter tank by turning it in a counter clock-wise direction. Remove the used element.

Wet the O-ring in the new element with cleanrefrigeration oil. Insert the new element intothe filter tank with the close end visible andattach the cover to the bowl. HANDTIGHTEN the cover.

The filter housing can be evacuated and thenslowly pressurized by opening the commutervalve on handle. This will pressurize thehousing. Check for leaks. The filter cannow be returned to service. Repeat for otherfilter bowl if needed.

4. Filter Removal, VSS Units usingVilter Part Number1833C oil filterelements.

Release the pressure in the oil filter housingby opening the bleed valves at the stop valvein the block and bleed assembly, or at thebleed valve for the oil filter housing. Be sure

45

Operation

to follow all Local, State and Federal ordinances re-garding the recovery of refrigerants.

Drain the filter bowl or housing in to an appropriatecontainer and dispose of the oil in a appropriatemanner following all Local, State and Federal ordi-nances regarding the disposal of used refrigerationoil.

Unscrew the bolts holding the cover flange to thetank. Remove the cover flange and spring plate.Pull out the filter element(s). Before reassembling,thoroughly clean the tank and spring plate tolengthen the life span of the filter element(s).

FIGURE 3.1833C FILTER ELEMENT TANKS

To replace the filter element(s), on single elementtanks, insert the element and make sure it fits ontothe outlet connection. Install spring plate, and bolt

the cover assembly in place. On unitsequipped with dual element tanks, insert in-ner element and make sure it fits onto theoutlet connection. Put the centering pieceon the outer element and slide into tank mak-ing sure the center piece fits into the innerelement. Put spring plate on outer elementand bolt the cover assembly in place.

CAUTIONWhen changing filter, discard clogged filteronly. Save and reuse spring plate and center-ing piece. This filter MUST be installed withthe spring plate. A compressor that is allowedto operate without the spring plate is runningwith unfiltered oil.


C. Oil Pressure Regulating

On units with a full time oil pump, the back pres-sure regulator, in the oil supply line from the sepa-rator, controls upstream pressure to the compres-sor bearings and should be adjusted to hold theoil pressure at 50 psig above suction pressure.Excess oil not required for bearing lubrication ispassed through the regulator and flows into theseparator.

D. Oil Cooling

1. Water Cooled Oil Cooler

In lieu of the three way oil temperature valveto control the temperature of the oil used forlubrication and cooling of the compressor,it is required to install a water regulatingvalve and solenoid valve combination to con-trol the water supply to the oil cooler. Thewater inlet connection should be made onthe bottom and the outlet connection on thetop. The water supply is controlled by thewater regulating valve to maintain the oiltemperature at approximately 120°F.

46

Operation

FIGURE 4.TYPICAL WATER COOLED OIL COOLER

DIAGRAM

The solenoid valve provides positive watershut-off when the compressor is not in opera-tion.

A temperature of 150°F is considered high inmost circumstances and the compressor is pro-tected by a safety control to prevent operationof the compressor above this temperature.Unless otherwise specified, the oil cooler issized for an 85°F water inlet temperature and10°F temperature rise.

2. Liquid Injection Oil Cooling.

The components are furnished with liquid in-jection for a typical system. The liquid sole-noid valve opens whenever the compressor isin operation. The thermostatic expansion valvecontrols the flow of liquid refrigerant to thecompressor injection port in response to thedischarge temperature. The discharge tempera-ture is maintained at a minimum of 120°F witha maximum of 140°F. The discharge tempera-ture can be adjusted either of two ways. First,the small outlet pressure regulator can be usedto adjust superheat. Normally, this regulatorshould be adjusted to maintain 70 psig pres-sure at the external equalizing port of the ex-pansion valve. Raising the pressure beyond70 psig tends to raise the discharge tempera-ture, while lowering the pressure lowers thedischarge temperature. Secondly, the standardsuperheat adjusting screw on the thermostaticexpansion valve can be used to adjust the dis-charge temperature.

FIGURE 5.TYPICAL LIQUID INJECTION OIL COOLING

SCHEMATIC DIAGRAM

Liquid injection cooling on booster compressors ishandled in the following manner. Using high pres-sure liquid, the point of injection can be the dis-charge line and no horsepower penalty is paid byinjecting liquid into the compressor discharge line.The high pressure gas source normally used for thepressure regulator would be compressor dischargepressure. Since, on a booster unit, this intermediatepressure is very rarely as high as the nominal set-ting of 70 psig, high stage discharge gas is used.

On high stage compressors, the liquid is injecteddirectly into the compressor. However, there is ahorsepower penalty when the liquid is injected intothe compressor. This will vary with refrigerant andoperating condition. The liquid is injected into thecompressor at a point in the compressor cycle thatminimizes the brake horsepower penalty.

3. V-PLUS Oil Cooling System

This system consists of a liquid pump, shut-offvalves, motor, solid state variable speed controllerand solid state temperature controller. This methodof oil cooling is not available on the VSM or VSRcompressor units.

The pump and solenoid valve cycle on and off inparallel with the compressor drive motor. The tem-perature controller receives a temperature signalfrom the sensor located in the discharge and oil linesand in turn, sends a signal to the motor speed con-troller. As the oil and desupserheating load varies,

1/4” FineAdjustment Valve

47

Operation

the temperature controller adjusts the speedof the pump/motor combination to maintaina constant oil temperature.

NOTE:See separate V-PLUS® instruction manual fordetailed start-up and operation.

4. Thermosyphon Oil Cooling

Using a brazed plate or an one pass shelland tube type vessel, similar to the watercooled oil cooler, oil is circulated on the shellside and liquid refrigerant from the receiveriscirculated through the tubes.Thermosyphonsystems use a 3-way temperature sensingcontrol valve to regulate oil at 120°F. Oil isbypassed around the thermosyphon oil cooler.When oil is higher than 120°F, the oil ispassed through the thermosyphon oil cooler.A 1/4” tubing line w/valve adds high pres-sure gas to the oil to quiet the sound of injec-tion. Open this valve in small amounts, untilnoise subsides.

The closed type cooling circuit is free fromthe fouling problems associated with opencircuit water cooling. Since the oil coolingload is rejected in the condenser, this type ofcooling is practical. The temperature limitshere are the same as those regarding thewater cooled oil coolers.

II. CONTROL SYSTEM

Equipped for automatic operation, the screw com-pressor unit has safety controls to protect it fromirregular operating conditions, an automatic start-ing and stopping sequence, capacity and volumeratio control systems.

Check all pressure controls with a remote pres-sure source, to assure that all safety and operat-ing control limits operate at the point indicatedon the microprocessor.

The unit can be equipped with optional block andbleed valves that are used to recalibrate the pres-

sure transducers. To use the block and bleedvalves to recalibrate the pressure transducers, theblock valve is shut off at the unit and the pressureis allowed to bleed off by opening the bleed valvenear the pressure transducer enclosure. The trans-ducer can then be calibrated at atmospheric pres-sure (0 psig), or an external pressure source withan accurate gauge may be attached at the bleedvalve.

The discharge pressure transducer cannot be iso-lated from its pressure source, so it is equippedwith only a valve to allow an accurate pressuregauge to be attached and the pressure transducercalibrated at unit pressure.

Recheck the transducers periodically for any driftof calibration.

A. Screw Compressor Control AndOperation

1. Starting, Stopping and Restartingthe Compressor

Before the screw compressor unit may start,certain conditions must be met. All of thesafety setpoints must be in a normal condi-tion, and the suction pressure must be abovethe low suction pressure setpoint to assurethat a load is present. When the “On-Off”switch or “Manual-Auto” button is pressed,the oil pump will start. When sufficient oilpressure is built up and the compressor ca-pacity control and volume ratio slide valvesare at or below10%, the compressor unit willstart.

If the compressor is in the automatic mode,it will now load and unload and vary thevolume ratio in response to the system de-mands.

Stopping the compressor unit can be accom-plished a number of ways. Any of the safetysetpoints will stop the compressor unit if anabnormal operating condition exists. Thecompressor unit “On-Off” or stop button willturn the compressor unit off as will the lowpressure setpoint. If any of these conditions

48

Operation

2. Slide Valve Control Gear Motors

Capacity and volume ratio control of thescrew compressor is achieved by movementof the respective slide valves, actuated byelectric motors.

NOTE:The manual operating shaft on the gear motorshould be turned the opposite direction of thedesired command shaft rotation.

The older capacity and volume control mo-tors are equipped with a brake. If it is neces-sary to operate the control motors manually,the brake must be disengaged. The brakecan be disengaged by pushing on the motorshaft on the cone end. The shaft should becentered in its travel. Do not use excessiveforce manually operating the motor or dam-age may result.

Table 1

COMMAND SHAFT ROTATION NO. OF TURNS / ROTATION ANGLE / SLIDE TRAVELCOMP. CAPACITY VOLUME CAPACITY VOLUMEMODEL INC DEC INC DEC TURNS/ANGLE/TRAVEL TURNS/ANGLE/TRAVELVSR 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.

turns the compressor unit off, the slide valve mo-tors will immediately energize to drive the slidevalves back to 5% limit. The control motors willbe de-energized when the respective slide valvemoves back below 5%. If there is a power failure,the compressor unit will stop. If the manual starton power failure option is selected (see appropri-ate Microprocessor Instruction Manual), restart-ing from this condition is accomplished by push-ing the reset button to insure positive operatorcontrol. If the auto start on power failure optionis selected (see appropriate Microprocessor In-struction Manual), the compressor unit will startup after a waiting period. With both options, thecompressor slide valves must return below theirrespective 5% limits before the compressor unitcan be restarted.

49

Operation

FIGURE 6. SLIDE VALVE MOTOR LOCATION

When viewing the compressor from the dis-charge end (opposite the drive end), the up-per motor is for capacity control. The com-mand shaft turns (see Table 1) to decreasethe capacity to 10% and reverses to increasethe capacity to 100%. The lower motor isfor volume ratio control. The command shaftturns (see Table 1) to reduce the volume ra-tio to 2.0, and reverses to increase the vol-ume ratio to 5.0.

Actuation of the electric motors can be donemanually or automatically. To actuate themotors manually, place the desired modeselector in the manual position and push themanual Increase or Decrease buttons. In theautomatic mode, the microprocessor deter-mines the direction to actuate the electricmotors. However, in the automatic mode,there is an “On” and “Off” time for the ca-pacity control motor. The “On” time is thetime in which the slide valve moves, and the“Off” time is the time in which the system isallowed to stabilize before another changein slide valve position.

The Motor Amps Load Limit protects thecompressor from overloading by decreasingthe compressor capacity if the motor amper-age is at the Maximum Amps setpoint, or pre-venting an increase in capacity if the motoramperage is above the Full Load Ampssetpoint. (See appropriate Microprocessor

Instruction Manual.)

3. Oil Separator Heater

The oil separator heater keeps the oil in theseparator from becoming too viscous andhelps to boil off refrigerant entrained in theoil in the receiver section of the separator.

The heater is turned on only when the com-pressor is off. The separator heater is sup-plied with an integral temperature control.

4. Econ-O-Mizer Controls

Econ-O-Mizer® systems are of three types:direct expansion, flooded or flash. Flashsystems include a back pressure regulator tocontrol intermediate pressure.

When a direct expansion system is used, asolenoid valve and thermostatic expansionvalve are furnished to control the degree ofsubcooling. If a flooded subcooler systemor flash system is supplied, it is equippedwith a liquid solenoid valve and a floatswitch to control the liquid level in the ves-sel.

B. Safety Setpoints

A detailed explanation of all safety setpoints canbe found in the appropriate Microprocessor In-struction Manual.

1. Oil Pressure

Low oil pressure differential stops the com-pressor unit when there is an insufficientdifference in pressure between the oil mani-fold and suction.

2. Discharge Pressure

High discharge pressure cutout stops thecompressor unit, when the discharge pres-sure in the oil separator exceeds the setpoint.

View Capacity

ViewVolume Ratio

Note: OpticalActuators CAN NOTbe manually rotated.

( VSM 501-701 willhave motor locationsopposite of figure #6)

50

Operation

3. Suction Pressure

Low suction pressure cutout stops thecompressor unit when the suction pres-sure drops below the setpoint.

4. Oil Filter Differential

High oil filter differential cutout stopsthe compressor unit when the differencebetween the outlet and inlet of the filterexceeds the setpoint.

5. Oil Temperature

The oil temperature cutout stops thecompressor unit when the oil tempera-ture is too high or too low.

6. Discharge Temperature

The high discharge temperature cutoutstops the compressor unit when the dis-charge temperature exceeds the setpoint.

III. INITIAL START-UP

A. Setting of Controls

Refer to the appropriate Microprocessor Instruc-tion Manual for a list of initial settings.

B. Valve Settings

1. The suction stop/check valve is designed tooperate as a stop valve (manually open orclosed) or a check valve. The valve is nor-mally positioned in the automatic mode dur-ing unit operation. Please refer to the tag onthe valve to set it in the automatic position.

2. The ¼” valve should be open during opera-tion. The valve enables the unit to slowlyequalize to low side pressure during off peri-ods. This valve must be adjusted to minimizeoil loss when compressor stops.

3. The discharge stop/check valve is designedto operate as a stop valve (manually open orclosed) or a check valve. The valve is nor-mally positioned in the automatic mode dur-ing unit operation. Please refer to the tag on

the valve to set it in the automatic position.

4. Manually open the oil isolating valve at theoil separator outlet connection.

5. Open the isolating valve(s) before and afterthe oil filter housings.

6. On packages with a full time oil pump, makesure the manual opening stem on the oilregulating valve is in the auto position. Seemanufacturer’s literature for details.

C. Oil Separator

7. Manually open the stop valve on the oil bleedreturn line from the element section and openthe expansion valve 1/3 of a turn.

NOTE:The purpose of the oil bleed return assemblyis to collect any oil that passes through the oilseparating element and returns that oil to thecompressor. The hand expansion valve shouldbe adjusted to prevent an oil level from form-ing in the sight glass when the compressor isat 100% capacity. Generally 1/3 to 1 turn openis satisfactory.

8. A second oil bleed return valve is located inthe mid section of the oil separator. Thisvalve should be opened about 1/2 of a turnto meter oil back to the compressor.

FIGURE 7.OIL SEPARATOR BLEED LINE

Stop Valve

52

“Stop Check” Operation

AUTO

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

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

CLOSED

In the manually “Closed Postion”, thestop check is operating as a conven-tional stop valve, not allowing flow ineither direction.

OPEN

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

Valve Size 1.5” 2” 2.5” 3” 4” 5” 6” 8”Number of TurnsOpen 2 2.25 2.75 3.25 4.5 3.75 5.75 7.75(from closed position)

53

Pre-Start UpCheck List

54

PRE START-UP CHECKLISTFIELD PIPING AND MECHANICAL

REQUIREMENTS

NOTE: If start-up service has been purchased, the following items should be completed before the start-upman 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 theunit

_____ 3. The Discharge Stop/Check Valve is shipped loose and must be installed in a vertical up flow direction or in a horizontal line with the valve stem pointing upward at a 45° angle.During off periods, refrigerant can condense in the line downstream of the Discharge Stop/Check Valve. It is recommended the Stop/Check Valve be located to minimize thequantity of liquid that can accumulate downstream of the valve.

_____ 4. A Dual Safety Relief Valve is shipped loose for field installation. A connection is providedon the oil separator for the relief valve. Refer to ASHRAE/ANSI Standard 15 (SafetyCode for Refrigeration) for proper sizing and installation of Relief Valves and Vent Lines.

_____ 5. Piping For Oil Cooling

a) Liquid InjectionAn adequate, or dedicated, liquid line is required for the Liquid Injection System. A high pressureliquid source must be piped to the stop valve at the inlet of the Thermostatic Expansion Valve. Onbooster units, an additional 3/8” line must be piped to the regulator from high stage discharge gas for the Thermostatic Expansion Valve.

b) V-PLUSA high pressure liquid source must be run to the V-PLUS® inlet. Some subcooling is desirable. Ahigh pressure float must be installed at the inlet of the pump and a 3/8” vent line must be returned toa suction trap. Refer to the V-PLUS manual for additional information.

c) External Oil CoolerOn thermosyphon oil coolers, the refrigerant lines must be connected to the front head of the oilcooler. On water cooled oil coolers, the water lines must be connected to the front head of the oilcooler. 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) sightglasses. 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 field alignment and allow for motor rotation check. The motor alignment should be within0.004” 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 thefinal alignment and motor rotations.

_____ 8. The unit should be pressure tested, evacuated and a system load should be available at thetime of start-up.

Order #_______________________________Compressor Serial #________________________

55

PRE START-UP CHECKLISTFIELD WIRING REQUIREMENTS

VILTER MANUFACTURING CORPORATIONVRS 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 beforethe 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 theViSSion® 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 leftconnectors. Two separate line power feeds for the oil heaters are brought to two additional 10 amp fuses via theterminals marked “L2” and “L3” on the same connector just below the “L1” terminal. The neutrals for thesecircuits (L2A and L3A) are also connected to any of the “N” terminals. For units with V-PLUS® oil cooling, L1must also be brought to the fuse in the V-PLUS® panel, and L1A must also be brought to the terminal #2B in theV-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 iswired to terminals marked “Compressor Start – N.O. #1A” and “Compressor Start – N.O. #1B”. Control powerfor 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 wiredto the two terminals marked “Oil Pump Starter”. Control power for this coil should come from a source, whichwill 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 drycontact must be supplied and wired to one of the “L” terminals on any of the connectors, and returned to theterminal marked “Auxiliary #1 Safety” at the top connector. The jumper to the “Auxiliary #1 Safety” terminalmust be removed to use this cutout. The contact, if closed, will allow the compressor to run. If this contactopens at any time, the compressor will shut down.

6. Indication of the compressor alarm or shutdown status is also available via two control relays. Relay K-20 isprovided for remote trip indication and relay K-21 is provided for remote alarm indication. Each relay has threeterminals 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 resultantreturn to normal state indicates “safe” condition.

7. The current transformer supplied in the compressor motor conduit box should be checked to insure that themotor leads of one leg are pulled through the transformer. Note that there is a dot on one side of the currenttransformer. This dot must face away from the motor. Typically, a wye delta started motor should have leads 1and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as differentmotors and starting methods will require different leads to be used.

Order #_______________________________Compressor Serial #________________________

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Service SectionService Section ............................................................................................................. 56

GENERAL COMMENTS ........................................................................................................................................................................ 58

PREPARATION OF UNIT FOR SERVICING ........................................................................................................................................ 58REMOVAL OF COMPRESSOR FROM THE UNIT ............................................................................................................................ 58INSTALLATION OF THE COMPRESSOR ............................................................................................................................................ 59LEAK CHECKING UNIT........................................................................................................................................................................ 59ANNUAL INSPECTION ......................................................................................................................................................................... 60NORD-LOCK WASHERS ....................................................................................................................................................................... 61GATE ROTOR ASSEMBLY .................................................................................................................................................................... 62REMOVAL (All VSS and VSR Models) ................................................................................................................................................. 62REMOVAL (ALL VSM MODELS) ......................................................................................................................................................... 64INSTALLATION (All VSS and VSR Models) ........................................................................................................................................ 66INSTALLATION (All VSM Models) ...................................................................................................................................................... 68

GATE ROTOR BLADE REMOVAL ....................................................................................................................................................... 69GATE ROTOR BLADE INSTALLATION .............................................................................................................................................. 69GATE ROTOR THRUST ......................................................................................................................................................................... 70BEARING REMOVAL GATE ROTOR THRUST .................................................................................................................................. 70BEARING INSTALLATION GATE ROTOR ROLLER .......................................................................................................................... 71GATE ROTOR ROLLER BEARING REMOVAL .................................................................................................................................. 72GATE ROTOR ROLLER BEARING INSTALLATION .......................................................................................................................... 72INPUT SHAFT SEAL REPLACEMENT ................................................................................................................................................ 73INPUT SHAFT SEAL REMOVAL .......................................................................................................................................................... 73SHAFT SEAL INSTALLATION .............................................................................................................................................................. 74MAIN ROTOR ASSEMBLY ................................................................................................................................................................... 75INSPECTION OF SLIDE VALVE ASSEMBLIES IN THE COMPRESSOR......................................................................................... 76REMOVAL SLIDE VALVE ..................................................................................................................................................................... 76

CARRIAGE ASSEMBLIES .................................................................................................................................................................... 76INSTALLATION OF SLIDE VALVE CARRIAGE ASSEMBLIES ........................................................................................................ 77CAPACITY AND VARIABLE VOLUME RATIO CONTROL ASSEMBLY ........................................................................................ 78

OPTICAL SLIDE VALVE ACTUATOR REMOVAL .............................................................................................................................. 78OPTICAL SLIDE VALVE ACTUATOR INSTALLATION ..................................................................................................................... 79GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80

CONVERSION, INSTALLATION OF ACTUATOR ............................................................................................................................... 80COMMAND SHAFT ASSEMBLY REMOVAL ..................................................................................................................................... 80COMMAND SHAFT ASSEMBLY INSTALLATION ............................................................................................................................. 81COMMAND SHAFT BEARING AND O-RING SEAL REPLACEMENT ........................................................................................... 81COMMAND SHAFT BEARING AND O-RING SEAL REASSEMBLY .............................................................................................. 82

DISCHARGE MANIFOLD REMOVAL ................................................................................................................................................. 82DISCHARGE MANIFOLD INSTALLATION ......................................................................................................................................... 82

SLIDE VALVE GEAR AND RACK INSPECTION ................................................................................................................................ 83

REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS .............................................................................................................. 83INSTALLATION OF CAPACITY OR VOLUME CROSS SHAFTS ...................................................................................................... 84

REMOVAL AND INSTALLATION OF CAPACITY OR VOLUMERATIO ACTUATORS (PRIOR TO 11-1-01 AND AFTER 5-1-95 .......................................................................................................... 85

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POTENTIOMETER REMOVAL ............................................................................................................................................................. 87POTENTIOMETER INSTALLATION .................................................................................................................................................... 88

RETROFIT CAPACITY AND VOLUME RATIO CONTROL ............................................................................................................... 88 ASSEMBLIES ON ALL VSS AND VSR COMPRESSORS MANUFACTURED BEFORE MAY 1, 1995. ............................................................................................................................................................ 88 REMOVAL................................................................................................................................................................................................................... 88

INSTALLATION OF RETROFIT COMMAND SHAFT BEARINGAND O-RING SEAL ................................................................................................................................................................................ 89

REPLACEMENT FOR RETROFIT CONTROL ASSEMBLIES .......................................................................................................... 89COMMAND SHAFT BEARING AND O-RING SEAL REASSEMBLY .............................................................................................. 90LIQUID INJECTION PLUG REPLACMENT ........................................................................................................................................ 91

REMOVAL OF PLUG ............................................................................................................................................................................. 91INSTALLATION OF PLUG ..................................................................................................................................................................... 91PLUG APPLICABILITY .......................................................................................................................................................................... 92

TORQUE SPECIFICATIONS .................................................................................................................................................................. 93OIL FILTER ELEMENTS ........................................................................................................................................................................ 94VSS, VSM and VSR SINGLE SCREW COMPRESSORS SERVICE INTERVAL REQUIREMENTS........................... 98

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Operation

D. V-PLUS Oil Cooling

* Applies only to units with V-PLUS® oilcooling.

Refer to V-PLUS manual for detailed instructions.

*9. Manually open the stop valve at the inlet andoutlet of the V-PLUS system.

*10. Open the needle valve in the ¼” oil supplyline to the V-PLUS pump.

*11. The manual opening stem on the solenoidvalve should be in the automatic position(turned counter clockwise or out).

E. Liquid Injection Oil Cooling

** Applies only to units with Liquid InjectionOil Cooling.

**9. Open the stop valve at the inlet of thepressure regulator.

**10. Open the metering valve 1/8 to 1/4 ofa turn.

**11. Adjust the manual opening stem to theliquid line solenoid. (Refer to acces-sory equipment section for details.)

**12. The pressure regulator may require adjustment after the compressor is running.(Refer to the accessory section on de-tails of how to adjust regulator.) The reg-ulator should be adjusted to maintain ap-proximately 70 psig on the external equalizing connection of the TX valve. At thissetting, the controls should maintain theoil temperature at approximately 115°F.

To adjust oil temperature up or down,raise or lower the pressure setting on theregulator. It should not be necessary toadjust the superheat setting on the TXvalve.

F. Water Cooled Oil Cooler

*** Applies only to units with water cooled oilcooler.

***9. The water supply to the cooler shouldbe opened.

***10. Verify the water solenoid valve doesopen with the compressor motorstarter.

***11. Open 1/4” high pressure gas line valvepiped to oil injection line just enoughto quiet compressor at 100% capacity.

G. Compressor Pre Start-Up CheckList

Before proceeding with actual starting of the com-pressor, the items listed on the “Pre Start-UpCheck List” must be verified. Time and moneywill be saved before the Vilter start-up man ar-rives.

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Service

0.00 GENERAL COMMENTS

When working on the compressor, care must betaken to ensure that contaminants (i.e. water frommelting ice, dirt and dust) do not enter the com-pressor while it is being serviced. It is essentialthat all dust, oil or ice that has accumulated onthe outside of the compressor be removed beforeservicing the compressor.

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

It is important that if the refrigerant requires theuse of a Polyolester (POE) refrigeration oil, thatall oil is removed from the compressor unit afterthe unit has been opened to the atmosphere forservicing. POE refrigeration oils are highlyhydroscopic and will absorb large quantities ofmoisture in a short time, when exposed to theatmosphere during servicing. Once the moistureis absorbed into the oil it is nearly impossible toremove the moisture from the oil.

0.01 PREPARATION OF UNIT FORSERVICING

A) On Cool Compression units, while the unit isrunning, close the main liquid ammonia line(located before the thermostatic expansionvalve) and wait for the unit to stop by itself.This operation will remove all the liquid am-monia from the separator. The compressorwill stop when the superheat at dischargereaches 25°F.

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 andtag the switch to indicate that maintenanceis being performed.

C) Isolate the unit by manually closing the dis-charge Stop/Check valve. If the unit isequipped with a V-PLUS® or liquid injectioncooling system, close the liquid supply valvesand open all solenoid valves to prevent liq-uid refrigerant from being trapped betweenthe stop valves and solenoid valves. Allowthe unit to equalize to suction pressure be-fore closing the Suction Bypass or Stop/Check valve. After the unit has equalized tosuction pressure and suction valve closed,use an acceptable means to depressurize theunit that complies with all Local, State andFederal Ordinances.

D) Remove drain plugs from the bottomofcompressor housing and the dischargemanifold On units equipped with Suction OilInjection (SOI) manually open the SOI sole-noid valve below the compressor. Drain theoil into appropriate containers.

0.02 REMOVAL OF COMPRESSORFROM THE UNIT

After Preparing the unit for service the followingsteps should be followed when removing the com-pressor from the unit:

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

B) Disconnect all gas and oil piping which isattached to the compressor. When removingthe suction strainer on VSS/VSM units or thesuction line from VSR units, the suction lineshould be supported to prevent it from sag-ging.

C) Replace oil drain in compressor housing anddischarge manifold after oil has stoppeddraining.

All Oil must be removed from unit.

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

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CAUTION

May cause an electrical shock!

E) On VSG units, loosen and remove bolts holding the compressor to the base.

Keep compressor alignment shims togetherand mark the locations with a permanentmarker. On VSG with C- flange the motor/C-flange/compressor assembly must be sup-ported with a chain fall or other lifting device,before the bolts holding the compressor tothe C-flange adapter can be removed.

F) Install appropriate lifting eye into the threadedhole on the top of the compressor.

Verify unit is properly secured to avoidcompressor from falling.

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

G) Lift compressor from the base, verify theamount of room needed for clearance andweight of the bare compressor when the com-pressor is removed from the unit.

0.03 INSTALLATION OF THECOMPRESSOR

A) After the work has been completed, reinstallthe compressor on the base or C-flangeadapter (dependent upon compressor model).

B) On the VSS units, replace the shims under thecompressor feet. Check for a soft foot. Thisis accomplished by tightening down three ofthe hold down bolts and checking the clear-

ance under the fourth compressor foot. Ifthere is clearance, add the appropriate amountof shims. Tighten down the fourth bolt andloosen either adjacent bolt and check againfor clearance, adding shims accordingly.Align the compressor and motor.

On VSR & VSM units, the compressor can bebolted onto the C-flange adapter and the cou-pling reinstalled.

On VSR compressors the discharge elbowshould be tightened on the separator first,before the compressor manifold flange is tight-ened. This should be done to prevent com-pressor to motor misalignment.

Replace all electrical, gas and oil connectionsremoved when servicing the compressor.

0.03 LEAK CHECKING UNIT

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

CAUTION

Slowly pressurize the unit from the dischargeside of the compressor. Pressurizing the com-pressor from the suction side may cause rota-tion of the compressor without oil supply, whichcould lead to internal damage.

A) Use a vacuum pump to evacuate the unit.

B) Break the vacuum on the unit using refriger-ant or dry nitrogen and check for leaks. Con-centrate on areas where work was done.

C) If no leaks are found, the unit can be returnedto service if refrigerant was used for the leakdetection gas.

If dry nitrogen was used for the leak detec-tion gas, the nitrogen must be purged fromthe unit and step A and B should be repeated,this time breaking the vacuum with refriger-ant. The unit may now be returned to ser-vice.

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Service

0.05 ANNUAL INSPECTION

The Vilter Single Screw Compressor is designedfor long periods of trouble free operation with aminimum of maintenance. However, a yearly in-spection is recommended so any irregular wear isnoted and rectified. At this time, the bearing floatis measured for the main rotor and gate rotors.

The following are the procedures used in measur-ing the main rotor and gate rotor bearing float.

CAUTION

When taking the measurements, do not exceed300 to 500 Lbs. of force at point of contact ordamage may result to the bearings.

A) Shut down and de-pressurize the unit, asoutlined in section 0.01.

B) Main rotor bearing float.

1) Remove the coupling guard, then re-move the center member from the cou-pling.

2) Attach a dial indicator to the compres-sor frame as shown and zero indicator.Place a lever arm and fulcrum behindthe compressor coupling half and pushthe coupling towards the motor (notemeasurement).

TABLE 0.1MAXIMUM BEARING FLOAT

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

Lbs. Lbs.

3) Re-Zero indicator, now position the ful-crum on the motor and use the lever armto push the input shaft towards the com-pressor (note measurement).

4) Add both readings, the total indicatormovement is the bearing float and thisshould not exceed 0.003”.

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C) Gate rotor bearing float.

1) Remove the side covers and position adial indicator on the gate rotor.

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

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

D) Measure the gate rotor to blade float. Somemovement between blade and support is nec-essary to prevent damage to the compressorblade, however at no time should the bladeuncover the support.

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

2) Position a dial indicator at the tip of thesupport. The total movement of thedamper pin in the bushing is the gaterotor float. Refer to table 0.2 to find themaximum blade to support float (on newcompressor parts only).

TABLE 0.2. GATE ROTOR FLOAT

MODEL FLOAT

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

VSR 111 THRU VSS 601 0.045”VSS 751 & VSS 901 0.055”VSS 1051 & VSS 1201 0.060”VSS 1501 & VSS 1801 0.060”

E) Readings could be higher than 0.020. Ifreadings is greater than 0.030 over tabletolerance contact Vilter’s home office.

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

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

0.06 NORD-LOCK WASHERS

A) Nord-Lock® lock washer sets are used inmany areas on the Single Screw Compres-sor that requires a vibration proof lockwasher.

B) The lock washer set is assembled so thecourse serrations that resemble ramps aremated together.

C) Once the lock washer set is tightened down,it takes more force to loosen the bolt then itdid to tighten it. This is caused by the wash-ers riding up the opposing serrations.

ramp.

Fine serrations face out.

Coarse serrationsmate together.

Coarse Serrationsmate together

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1.00 GATE ROTOR ASSEMBLYCAUTION

Gate rotor removal and assembly is divided intodistinct instructions, instructions for all VSS andVSR models and different instructions for allVSM models. Please follow the appropriate setof instructions.

1.01 A REMOVAL (All VSS and VSRModels)

A) Prepare the compressor for servicing as out-lined in section 0.01.

NOTE:All parts must be kept with their appropriate sideand not mixed when the compressor is reas-sembled.

B) Remove two upper bolts from the side cover,and install guide studs in the holes. Removethe remaining bolts and side cover. Therewill be some oil drainage when the cover isremoved.

C) Turn the main rotor so a driving edge of anyone of the main rotor grooves is even withthe back of the gate rotor support.

D) Insert the gate rotor stabilizer. The side railsare not required on VSS 451/601 and VSRcompressors. For the VSS 751/901 and VSS1051/1201 compressors, use the side railsand assemble to the gate rotor stabilizer asstamped. For the VSS 1501/1801, use theside rails and assemble to the gate rotor sta-bilizer.

The gate rotor stabilizer is designed to holdthe gate rotor support in place and preventdamage to the gate rotor blade as the thrustbearings and housing is being removed.

Drive End

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E) Remove the hex head and socket head boltsfrom the thrust bearing cover. Insert two ofthe bolts into the threaded jacking holes toassist in removing the cover. Retain the shimpack and keep it with the bearing housingcover.

F) Hold the gate rotor support with a suitablewrench on the flats provided near the rollerbearing housing. Remove the inner retainerbolts and the retainer. To remove the thrustbearing housing, install the thrust bearingremoval and installation tool with the smallerpuller shoe. Turn the jacking screw clock-wise. The thrust bearings and housing as-sembly will be pulled off the shaft and out ofthe frame.

G) Remove the bolts on the roller bearing hous-ing. Thread two bolts into the jack screwholes provided in the housing to assist in re-moving it.

H) To remove the gate rotor support, carefullymove the support opposite the direction ofrotation and tilt the roller bearing end to-wards the suction end of the compressor. Thecompressor input shaft may have to be turnedto facilitate the removal of the gate rotor sup-port. On dual gate compressor units, repeatthe procedure for the remaining gate rotorsupport assembly.

901

911

910

916

913 917

914

112

152

110retainer.

Use flats providedon gaterotor support to preventrotation whenremoving bearing

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1.01 B REMOVAL (ALL VSM MODELS)

The removal of the gate rotor assembly for theVSM compressors is similar for the VSS/VSRcompressors. However, the thrust bearing outerraces are not secured in a stationary bearing hous-ing as on the VSS/VSR compressors. On VSMcompressors the thrust bearings are located inthe gate rotor support and rotate with the sup-port when the compressor is in operation. Theinner races are secured to the stationary bearingspindle.


B) Remove the upper bolt from the side coverand install a guide stud in the hole. Removethe remaining bolts and side cover. Therewill be some oil drainage when the cover isremoved.

C) The side cover that contains the suctionstrainer should have the suction line prop-erly supported before the bolts securing theline to the cover can be removed. After theline is removed, the cover can be removedper paragraph B.

D) Turn the main rotor so the driving edge ofthe groove is between the top of the shelf orslightly below the back of the gate rotor sup-port. At this point install the gate rotor sta-bilizing tool.

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

F) Remove bolts that hold the thrust bearinghousing to the compressor. Insert two of thebolts into the threaded jacking holes to as-sist in removing the bearing housing fromthe compressor. When the housing is re-moved, there will be shims between thespindle and thrust bearings. These controlthe clearance between the shelf and gate ro-tor blades. These must be kept with theirrespective parts for that side of the compres-sor.

G) Remove the bolts from the roller bearinghousing. After the bolts have been removed,the housing can be removed from the com-pressor.

H) To remove the gate rotor support, carefullymove the support opposite the direction ofrotation and tilt the roller bearing end to-wards the suction end of the compressor. Thecompressor input shaft may have to be turnedto facilitate the removal of the gate rotor sup-port. On dual gate versions, repeat the pro-cedure for the remaining gate rotor supportassembly.

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1.02 A INSTALLATION (All VSS andVSR Models)

A) Install the gate rotor support by carefully tilt-ing the roller bearing end of the gate rotorsupport towards the suction end of the com-pressor. The compressor input shaft mayhave to be rotated to facilitate the installa-tion of the gate rotor support.

Install gate rotor stabilizer. The gate rotorstabilizer (901) will hold the gate rotor sup-port in place as the thrust bearing housingis being installed. If the gate rotor supportis not restricted from moving, the gate rotorblade may be damaged.

B) Install the roller bearing housing (112) witha new O-ring (141). Tighten the bolts (152)to the recommended torque value.

C) When installing the thrust bearing housing(113), a new O-ring (142) must be used whenthe housing is installed. Lubricate the out-side of the housing and bearings with cleancompressor oil to aid in the installation. Dueto the fit of the bearings on the gate rotorshaft, the thrust bearing removal and instal-lation tool with the pusher shoe must be used.Turn the jacking screw clockwise. This willpush the thrust bearings onto the shaft andpush the housing assembly into the frame.Install the inner retainer (115) and bolts(151) using Loctite® 242 thread locker.Tighten the bolts to the recommended torquevalue.

113

142115

151143

116

152

106

160

152

112

141

901

912

910

913 916

915

914

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D) Set the clearance between the gate rotor bladeand the shelf.

1. Place a piece of 0.003”-0.004” shimstock between the gate rotor blade andthe shelf.

2. Measure the depth from the top of thecompressor case to the top of the thrustbearing housing. This determines theamount of shims needed for the correctclearance.

3. Use factory installed shim pack (106)and bearing housing cover (116) with-out the O-ring (143). Check the clear-ance between the entire gate rotor bladeand the shelf, rotate the gate rotor to findthe tightest spot. It should be between0.003”-0.004”. Make adjustments, ifnecessary. It is preferable to shim thegate rotor blade looser rather than tighteragainst the shelf.

Note: Replacement blades are precisely thesame dimensionally as blades installedoriginally at factory: Therefore, the sameamount of shims will be required for replace-ment blades.

E) After clearance has been set install a new O-ring (143) on bearing housing cover, installcover and tighten the bolts to the recom-mended torque value.

F) Install side cover with a new gasket. Tightenthe bolts to the recommended torque value.The unit can then be evacuated and leakchecked as outlined in section 0.03.

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Service

1.02B INSTALLATION (All VSM Mod-els)

A) Install the gate rotor support. Carefully tiltthe roller bearing end of the gate rotor sup-port towards the suction end of the compres-sor. The compressor input shaft may haveto be rotated to facilitate the installation ofthe gate rotor support.

B) Install the roller bearing housing with a newO-ring. Tighten the bolts to the recom-mended torque value.

C) Install the spindle with shims and o-ring,tighten the bolts to the recommended torquevalue, measure the clearance between theshelf and blade.

D) Check the clearance between the entire gaterotor blade and the shelf, rotate the gate ro-tor to find the tightest spot. It should bebetween 0.003”-0.004”. Make adjustments,if necessary. It is preferable to shim the gaterotor blade looser rather than tighter againstthe shelf.

Important: Read note on page 42.

E) Once the clearance is set remove the spindle.Install new o-ring, apply Loctite 242 threadlocker to the socket head cap screw clamp-ing the thrust bearings to the spindle. Torqueall bolts to the recommended torque values.

F) Install side covers with new gaskets. Tightenbolts to the recommended torque value. Theunit can now be evacuated and leak checkedas outlined in section 0.03.

Gaterotor for C-flange Models

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1.03 GATE ROTOR BLADE REMOVAL

A) Remove the gate rotor assembly. Refer tosection 1.01 or 1.01B on gate rotor assemblyremoval.

B) Remove the snap ring and washer from thegate rotor assembly. Lift gate rotor bladeassembly off the gate rotor support.

C) Check damper pin and bushing for exces-sive wear. Replace if necessary.

1.04 GATE ROTOR BLADEINSTALLATION

A) There are two sizes of damper pins and bush-ings that have been used in single screw com-pressors. The gate rotor supports, pins andbushings are not interchangeable. If the gaterotor support has a small diameter pin, onlythe small diameter bushing can be used withit. Additionally a large diameter pin cannotbe used in a gate rotor support machined fora small diameter pin.

Small Pin=Small Damper

Large Pin= Large Damper

All new compressors and replacement gaterotor support assemblies are provided withthe large diameter damper pins. The follow-ing table shows the sizes of pins used.

TABLE 1.1 DAMPER PIN DIAMETERS

130119

111

120

135

110

MODEL SMALL LARGEPIN DIA. PIN DIA.

VSM 71 thru VSM 401 - - - 0.4375”VSM 501 thru VSM 701 - - - 0.4375”VSR 111 thru VSR 301 0.250” 0.4375”VSS 451 & VSS 601 0.250” 0.4375”VSS 751 & VSS 901 0.3125” 0.4375”VSS 1051 & VSS 1201 0.375” 0.4375”VSS 1501 & VSS 1801 0.375” 0.500”

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B) Install damper pin bushing (120) in gate ro-tor blade (111) from the back side of theblade. Be sure the bushing is fully seated.

C) Place the blade assembly on the gate rotorsupport. Locating Damper over pin.

D) Install washer (119) and snap ring (130) ongate rotor assembly. The bevel on the snapring must face away from the gate rotorblade. After the gate rotor blade and sup-port are assembled, there should be a smallamount of rotational movement between thegate rotor and support.

E) For installation of the gate rotor assemblyand setting of gate rotor clearance, refer tosection 1.02.

1.05 GATE ROTOR THRUSTBEARING REMOVAL

A) Refer to section 1.01 for removal of the gaterotor bearing housings and gate rotor sup-ports.

B) For removal of thrust bearings on VSS andVSR units:

1) Remove bolts (150) from the clampingring (114).

2) Remove thrust bearing clamping ring.

3) Remove thrust bearings (126) fromhousing (113).

C) For removal of thrust bearings on VSM units:

1) Remove retaining ring from gate rotorsupport.

2) Remove bearings from support.

3) Remove bearing retainer from innerrace.

150

114

126

113

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1.06 GATE ROTOR THRUSTBEARING INSTALLATION

A) For installation of thrust bearings on VSSand VSR units:

1) Install bearings (126) in the housing sothe bearings are face to face.

The larger sides of the inner races areplaced together. A light application ofclean compressor lubricating oil shouldbe used to ease the installation of thebearings into the housing.

2) Center the bearing retainer ring on hous-ing, use Loctite® 242-thread locker andevenly tighten the bolts to the recom-mended torque value.

3) For installation of the bearing housingand the setting of the gate rotor bladeclearance, refer to section 1.02.

B) For installation of thrust bearings on VSMunits:

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

2) The bearing with the retainer should beplaced in the housing first, retainer to-wards the support. Install the secondbearing. The bearings should be posi-tioned face to face. This means that thelarger sides of the inner races are placedtogether. A light application of cleancompressor lubricating oil should beused to ease the installation of the bear-ings into the gate rotor support.

3) Install the bearing retaining snap ring.

4) For installation of the bearing housingand the setting of the gate rotor bladeclearance, refer to section 1.02A.

Inner Retainer

Ball BearingsRetaining Ring

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1.07 GATE ROTOR ROLLERBEARING REMOVAL

A) Refer to section 1.01 for removal of the gaterotor bearing housings and gate rotor sup-ports.

B) Remove the snap ring (131), which retainsthe roller bearing in the bearing housing.

C) Remove the roller bearing (125) from thebearing housing (112).

D) Use a bearing puller to remove the rollerbearing race (125) from the gate rotor sup-port (110).

1.02 GATE ROTOR ROLLERBEARING INSTALLATION

A) Match up the part numbers on the inner raceto the part numbers outer race. Press the bear-ing race (numbers visable) onto the gate ro-tor support.

B) Install the outer bearing into the bearinghousing so the numbers match the numberson the inner race. Install the snap ring re-tainer in the housing. The bevel on the snapring must face away from the roller bearing.

C) For installation of the bearing housing, re-fer to section 1.02.

VSM Only

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2.00 INPUT SHAFT SEALREPLACEMENT

There are two types of shaft seals that have beenused interchangeably in the Vilter VSS and VSRSingle Screw Compressors. The first type has astationary mirror face and rotating carbon. Thesecond type has a stationary carbon and a rotat-ing mirror face. Either type of seal may be usedin the compressors. On Vilter VSM compressorsthe type of seal utilized has a stationary carbonand a rotating mirror face.

2.01 INPUT SHAFT SEAL REMOVAL


B) Remove bolts (281) holding the shaft sealcover (218). Insert two of the bolts into thethreaded jacking holes to assist in removingthe cover. There will be a small amount ofoil drainage as the cover is removed.

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

D) Remove oil seal (230) from cover.

E) Remove the stationary portion of the shaftseal (219B) from the seal cover using a brassdrift and hammer to tap it out from the backside of the seal cover.

230 218 265 260 219B

219C219A281

230 218 265 260 219B

219C219A281

Roll pin # 265 only usedon VSS 751 and larger.

Seal with stationary mirror face (219B) androtating carbon face (219C).

Used till mid 1995. on VSG non c-flangecompressors.

Seal with stationary carbon face (219B) androtating mirror face (219C).

Current Shaft Seal and for all Replace-ment.

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2.02 SHAFT SEAL INSTALLATION

NOTE:When replacing the stationary members of theseal on the VSR 111 thru VSR 301, and VSS451 and VSS 601, the roll pin in the cover isused only with the seal assembly having a sta-tionary mirror face. If a seal assembly with astationary carbon face is installed, the roll pinmust be removed.

A) Install new oil seal in cover.

CAUTION

Care must be taken when handling the shaftseal and mirror face so it is not damaged. Donot touch the carbon or mirror face as body oiland sweat will cause the mirror face to corrode.

B) To install the carbon cartridge part of theseal in the seal cover; clean the seal cover,remove protective plastic from the carboncartridge, do not wipe or touch the carbonface. Lubricate the sealing O-ring with cleancompressor lubricating oil. If applicable,align the hole on the back of the carbon car-tridge with the dowel pin in the seal cover.Install cartridge using seal installation toolor similar (see tool lists).

C) Wipe clean, the compressor input shaft andthe shaft seal cavity in the compressor hous-ing. Apply clean compressor oil to the shaftseal seating area on input shaft.

260

261

Stationary seal265

Align slot in sealwith dowel pin orkey in shaft.

Make sure that seal isbottomed against shoulder on shaft.

265

Align slot in sealwith dowel pin orkey in shaft.

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D) Lubricate the inside area of the rotating sealwith clean compressor lubricating oil, do notwipe or touch the face of the rotating portionof the seal. Align the slot in the rotating sealwith the drive pin on the compressor inputshaft. Carefully push the seal on, holdingonto the outside area of the seal until theseal seats against the shoulder on the inputshaft. Make sure the seal is seated againstthe shoulder. If the seal is not fully seatedagainst the shoulder, the shaft seal carbonwill be damaged when the seal cover is in-stalled.

Maintenance Suggestion:

A spray bottle filled with clean compressor oilmay be used to lubricate the faces of the sealswithout touching the seal.

E) Install a new O-ring on the seal cover, mak-ing sure the O-ring is placed in the O-ringgroove and not the oil gallery groove. Lu-bricate both seal faces with clean compres-sor lubricating oil.

F) Carefully install the seal cover on the com-pressor shaft, evenly tightening the bolts tothe recommended torque values.

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

2.03 MAIN ROTOR ASSEMBLY

Due to the procedures and tools involved in thedisassembly and reassembly, the main rotor as-sembly must be performed by qualified individu-als. Please consult the factory if maintenance isrequired.

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3.00 INSPECTION OF SLIDE VALVEASSEMBLIES IN THECOMPRESSOR

Prepare the compressor for servicing as outlinedin section 0.01.

A) Remove the gate rotor access covers. Usinga mirror and flashlight, visually inspect theslide valve carriage through the gas bypassopening. Look for any significant signs ofwear on the slide valve carriage.

B) To check the clearance of the slide valveclamps, the gate rotor support must be re-moved. Refer to section 1.00 for removal ofthe gate rotor support.

C) Using a feeler gauge, inspect the clearancebetween capacity and volume slide valveclamps and slide valve carriage through thegas bypass opening. The clearance shouldbe less than 0.002”.

D) If the slide valves are worn in excess of thetolerances, the factory should be contacted.

3.10 REMOVAL SLIDE VALVECARRIAGE ASSEMBLIES


B) If only one of the slide valve carriages is re-moved only the corresponding gate rotor sup-port needs to be removed. If both carriagesare removed both gate rotors must be re-moved. Remove the gate rotor assembliesas outlined in section 1.01.

C) Remove the capacity and volume actuatorsas outlined in section 4.01. Remove the dis-charge manifold, capacity and volume cross

Check for wear in these areas.

Feeler gauge Measure here

Check for excessive wear in theseareas.

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shafts and the slide valve racks as outlined insection 4.10.

D) Locate and remove the socket head plugsabove the slide valve carriage attachmentbolts. Remove the bolts located under theplugs.

E) The slide valve carriage may now be re-moved. On newer carriages there is athreaded hole in the back of the slide valvecarriage to aid in its removal. Use a threadedtip slide hammer to aid in the removal of thecarriage.

Note: Slide Valves may be re-positioned to aidin removal of assembly.

3.20 INSTALLATION OF SLIDEVALVE CARRIAGE ASSEMBLIES

A) Position the slide valves to the center of thecarriage. Place the slide valve assembly inthe bore of frame and use the slide hammerto slowly tap the carriage into position. Re-positioning slide valves once inside bore mayaid installation. Adjust the carriage so thatthe 3-holes line up.

B) Install the 3 socket head cap screws with newNord-Lock washers beneath the heads, butdo not tighten them.

C) Work a piece of 0.005”shim stock betweenthe slide valves and the main rotor to helpposition the carriage.

D) Tighten, to the correct torque the hold downbolts to secure the carriage in the frame. Theedges of the slide valves themselves shouldbe at or slightly below the main rotor bore.

E) Re- Install the capacity and volume slidevalve cross shafts, slide valve racks and dis-charge manifold as outlined in section 4.01.

F) Re-install the gate rotor assemblies as out-lined in section 1.02

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4.00 CAPACITY AND VARIABLEVOLUME RATIO CONTROLASSEMBLY

A) The following instructions are applicable formost units equipped with optical gear mo-tors built after 11-1-01. For units equippedwith potentiometer feed back gear motorbuilt after 5-1-95, see section 4.10. For unitsbuilt before 5-1-95, see Section 4.11.

B) On VSS units and dual gate VSM units, eachpair of volume or capacity slide valves aremechanically connected and actuated tomove as a balanced pair. On VSR unitsand single gate VSM units, there is onlyone set of volume or capacity slide valves.However, all information on removing thevolume or capacity control assemblies isapplicable to all units.

4.01 OPTICAL SLIDE VALVEACTUATOR REMOVAL

A) Follow appropriate lock out tag out proce-dures to shut off the electricity to the micro-processor. Disconnect cables from actuator.

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

C) Loosen shaft collar locking screw. Slide thecollar onto the actuator shaft. Lightly tightenlocking screw to hold it in place.

D) Remove the (4) #10 socket head cap screwsholding the bracket to the base plate.

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

Collar

Locking Screw

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4.02 OPTICAL SLIDE VALVEACTUATOR INSTALLATION

A) Install the key in the command shaft keyway.

B) Slide the actuator assembly on to the com-mand shaft. While aligning one of the twokey slots in the actuator shaft with the key onthe command shaft. Make sure that the collarremained on the actuator shaft. Due to theposition of the slide valve in the compressor,use of the other key slot may be required toalign the bracket holes with the threadedmounting plate holes.

C) Slide the collar until it is flush with the endof the actuator shaft. Check to make surethe key is fully inserted in the actuator shaft.The key should be flush with the end of theactuator shaft.

D) Tighten the shaft collar ¼” socket head capscrew to 16 ft/lbs. (192 in/lbs.). Failure tocorrectly torque the locking screw may re-sult in a failure of the actuator.

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

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GEAR MOTOR TO OPTICAL SLIDEVALVE ACTUATOR CONVERSION,REMOVAL OF GEARMOTOR

A) Follow appropriate lock out tag out proce-dures to shut off the electricity to the mi-croprocessor.

B) Remove the six hex head cap screws thatsecure the slide valve actuator cover. Removecover and gasket.

C) Disconnect the motor and potentiometerleads.

D) Remove the four 5/16” hex head cap screwsholding the motor support to the mountingplate. Remove the gear motor assembly.

E) Remove the ¼” retaining nut, washer andplastic gear from the end of the commandshaft. Loosen the set screw securing thelarge drive gear to the command shaft. Re-tain drive key for possible re-use with newactuator assembly.

GEAR MOTOR TO OPTICAL SLIDEVALVE ACTUATOR CONVERSION,INSTALLATION OF ACTUATOR

A) Remove the four self tapping screws thatsecure the side covers to the actuator bracket.This will allow access to the actuator shaft.

B) On certain units with economizer, the ac-tuator bracket may have to be rotated fromits original position with the motor. To ac-complish this remove the four hex head capscrews holding the bracket to the motor.Rotate the motor from the original posi-tion. Make sure the electrical connectionson the actuator are not to the top position.This will allow enough clearance betweenthe motor and economizer line.

C) The four #10 holes in the existing mountingplate that will be utilized to attach the actua-tor must be in good condition. A 10-24 N.C.tap can be utilized to clean out the threadedholes.

D) Install the key in the command shaft keyway.

E) Slide the actuator assembly on to the com-mand shaft. Align one of the two key slotsin the actuator shaft with the key on the com-mand shaft. Make sure that the collar re-mained on the actuator shaft. Due to theposition of the slide valve in the compres-sor, use of the other key slot may be requiredto align the bracket holes with the threadedmounting plate holes.

F) Slide the collar until it is flush with the endof the actuator shaft. Check to make surethe key is fully inserted in the actuator shaft.The key should be flush with the end of theactuator shaft.

G) Tighten the shaft collar ¼” socket head capscrew to 16 ft/lbs. (192 in/lbs.). Failure tocorrectly torque the locking screw may re-sult in a failure of the actuator.

H) Install the side covers to the bracket withhex washer head self tapping screws.

I) Refer to the slide valve actuator calibrationinstructions in the Vission/Vantage manualor the instructions packed with actuators oncalibration procedures

4.05 COMMAND SHAFT ASSEMBLYREMOVAL

The following steps can be used to remove orinstall either the capacity or volume commandshaft assemblies.


B) Follow the appropriate instructions to re-move control actuator as outlined in sections4.01 or 4.10.

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457 477 415

C) Remove four socket head cap screws (457)and Nord-Lock washers (477) securingmounting plate (415) to manifold.

D) The command shaft and mounting plate maynow be removed from the compressor.

4.06 COMMAND SHAFT ASSEMBLYINSTALLATION

A) Install the command shaft assembly with anew o-ring (446) on the manifold. Make surethat the command shaft tongue is engagedin the cross shaft slot. Rotate the bearinghousing so the vent holes point down, thiswill prevent water and dust from enteringthe vents.

Command shaftassembly.

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

446

Rotate bearing housingso vent hole points down.

B) Install the actuator mounting plate with thefour socket head cap screws and Nord-Lockwashers securing it with proper torque.

C) The unit can now be leak checked as out-lined in section 0.03.]

4.07 COMMAND SHAFT BEARINGAND O-RING SEALREPLACEMENT

A) Remove command shaft assembly as outlinedin section 4.05.

B) Remove snap ring retainer (451) from com-mand shaft housing (412). Push the com-mand shaft assembly out of the housing.

C) The command shaft bearing (435) is a pressfit on the command shaft (413). Remove thecommand shaft bearing with a suitable press.

436

445

Vent hole.

D) Remove the O-ring seal (445) from the com-mand shaft housing. The command shaftbushing (433 and 436) might have to be re-moved to gain access to o-rings. Replacebushing if the bore is deeply scored or exces-sively worn.

Old Style Motor Plate

Div.2O n l y

Reference “PartsSection” for current

Housing

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4.08 COMMAND SHAFT BEARINGAND O-RING SEALREASSEMBLY

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 shaftbearing housing to allow any refrigerant andoil that may leak past the O-ring seal to ventto atmosphere and not into the slide valvemotor housing. Install snap ring retainer andwasher on the command shaft.

B) Remove any burrs from the command shaftto prevent damage to the O-ring when as-sembling. Press the command shaft bearingonto the command shaft. Insert the com-mand shaft into the housing appling pres-sure on outer race of bearing. Make sure thebearing is fully seated in the command shafthousing. Install the snap ring retainer inthe command shaft housing.

C) Install command shaft assembly as outlinedin section 4.02.

4.09 DISCHARGE MANIFOLDREMOVAL

A) Remove both control actuators and commandshaft assemblies as outlined in sections 4.01and 4.05.

B) On VSS and VSR compressors, remove thedischarge spool between the manifold andseparator. Remove one bolt from each sideof the discharge manifold and install (2)guide rods approximately 6” long, to sup-port the manifold. Remove the remainingbolts (note length and location of bolts) andtake off the discharge manifold.

Note: Mainfold has dowel pins to locate iton the compressor housing. Therefore, re-move manifold straight back approximately1” as not to break dowel pins.

547

548

549

550

551

540

536

512511

519

Guide rodsDischargespool

NOTE:When removing the discharge manifold on VSMcompressor the compressor must be properly sup-ported to keep the compressor from moving whenthe manifold is removed.

C) On VSM compressors unbolt the dischargeflange from the discharge manifold.

D) Remove one bolt from each side of the dis-charge manifold and install (2) guide rodsapproximately 6” long, to support the mani-fold. Remove the remaining bolts (notelength and location of bolts) and take off thedischarge manifold.

4.10 DISCHARGE MANIFOLDINSTALLATION

A) Install (2) guide rods to position the dis-charge manifold. Install a new manifoldgasket and the discharge manifold. Installthe dowel pins and bolts, tighten manifoldbolts to the recommended torque value.

B) On VSS and VSR compressors install thedischarge spool or elbow between the dis-charge manifold and oil separator with newgaskets. When installing the discharge el-bow tighten the bolts to the correct torqueon the manifold flange first before tighten-ing the separator flange bolts. Install thedrain plug in the bottom of the dischargemanifold.

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C) On VSM compressors install the bolts in thedischarge flange. Install the drain plug inthe bottom of the discharge manifold.

D) Install both command shaft assemblies andcontrol actuators as outlined in sections 4.05and 4.01.

4.11 SLIDE VALVE GEAR AND RACKINSPECTION

A) Remove the discharge manifold as outlinedin section 4.09

B) Check rack to rack clamp and rack clampspacer clearance on all four slide valves.

TABLE 4.1RACK CLEARANCE VALUES

MEASUREMENT CLEARANCE

Rack to clamp. 0.005 to 0.010”

Rack to clamp spacer. 0.003 to 0.005”

C) Check torque of socket heat cap screws.

D) Check for excessive movement between theslide valve rack shafts and the rack. Thejam nuts on the end of the slide valve rackshaft should be tight.

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

Loose nuts Roll pinsRack toclamp

Rack to

spacerclamp

Check

on captorque

screws

F) Look for any excessive wear on all movingparts and replace the worn parts.

G) Reassemble the manifold and discharge el-bow as outlined in section 4.10.

4.12 REMOVAL OF CAPACITY ORVOLUME CROSS SHAFTS

A) Remove the discharge manifold as outlinedin section 4.09.

B) To remove the capacity or volume ratio slidevalve racks, remove the two jam nuts and lockwashers (361) securing the rack (316) to theslide valve shafts. The racks can now bepulled off the slide valve shafts. Repeat theprocedure for the remaining pair of slide valveracks.

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

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VSS compressors cross shafts.

228 269 268

222

222

221228

268

269

VSR compressors cross shafts.Volume control cross shaft.

221

234222

269

268268

269

Capacity control cross shaft.

222

268

269228 221

228

269

268

D) Drive the roll pins from pinion gear from oneside. Remove pinion gear. Slide the crossshaft with the remaining pinion gear or spac-ers out of the opposite side. Repeat the pro-cedure for the remaining cross shaft.

4.13 INSTALLATION OF CAPACITYOR VOLUME CROSS SHAFTS

A) To reassemble either set of capacity or vol-ume ratio slide valve racks, install the crossshaft with the pinion gear onto the back plate,place the remaining pinion gear on the shaftand drive in the roll pins. Install clamps,spacers and bolts on both sides. Tighten thebolts to the recommended torque values.

B) The slide valve sets must be synchronizedon VSS and dual gate VSM units. Both slidevalve racks for either the volume ratio orcapacity slide valves must engage the crossshaft gears at the same time. Push the racksall the way towards the suction end of thecompressor until they stop. Install washersand jam nuts on the slide valve shafts. Re-peat the procedure for the remaining set ofslide valve racks.

must engage the axleshaft gears at the same time.

When installing the slidevalve racks, both racks

C) Install (2) guide rods to position the dischargemanifold. Install a new manifold gasket andthe discharge manifold. Install the dowel pinsand bolts, tighten manifold bolts to the rec-ommended torque value.

D) On VSS, VSM and VSR compressors installthe discharge as outlined in section 4.11.

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4.20 REMOVAL AND INSTALLATIONOF CAPACITY OR VOLUME RATIO ACTUATORS (PRIOR TO 11- 1-01 AND AFTER 5-1-95

The capacity and volume ratio control assemblieswith their potentiometers are not interchangeableand must not be switched when they are re-in-stalled on the compressor. The following stepsare used to remove the control assemblies thatutilize a potentiometer that were manufacturedor retrofitted between 5-1-95 and 11-1-01.

NOTE:The capacity and volume control motors areequipped with a brake. If it is necessary to oper-ate the control motors manually, the brake must bedisengaged. The brake can be disengaged bypushing on the motor shaft on the cone end. Theshaft should be centered in its travel. Do not useexcessive force manually operating the motor ordamage may result.

4.21 REMOVAL


B) Remove the six screws from the cover. Re-move the cover for the slide valve actuator.Mark and disconnect the wires to the slidevalve control actuator and potentiometer.

C) Remove the four hex bolts and Nord-Lock®

washers holding the slide valve control mo-tor assembly in place. The motor can nowbe removed.

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D) Remove nut and Nord-Lock® washers, secur-ing the potentiometer drive gear to the com-mand shaft assembly. Loosen the set screw.The command shaft drive gear and drive keymay now be removed from the commandshaft assembly. Remove the four socket headbolts and Nord-Lock washers, securing themotor plate and command shaft assembly.The motor plate and command shaft assem-bly can now be removed from the dischargemanifold.

4.22 INSTALLATION

A) Install the command shaft assembly with anew O-ring on the manifold. Make surethe command shaft tongue is engaged in thecross shaft slot. Rotate the bearing housingso the vent holes points down, to preventwater and dust from entering the vents.

B) Install the motor plate and the four sockethead bolts, and Nord-Lock® washers secur-ing it. Tighten the bolts to the recom-mended torque value.

C) Install the drive key in the command shaftkeyway. Align the keyway on the commandshaft drive gear with the key on the com-mand shaft, and slide the gear onto the com-mand shaft. Tighten the set screw on the

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gear. Install the spacer, potentiometer drivegear, Nord-Lock washers and nut on thecommand shaft and tighten the nut to therecommended torque value.

477

465

D) Install the slide valve control motor assem-bly with the four hex head bolts and Nord-Lock washers that hold the slide valve con-trol motor assembly to the motor plate.Connect the wires to the slide valve controlmotor and potentiometer.

E) Refer to the appropriate Microprocessor In-struction Manual for the procedure torecalibrate the potentiometers. The unit cannow be evacuated and leak checked as out-lined in section 0.03.

4.23 POTENTIOMETER REMOVAL(GEAR MOTOR ONLY)

A) Remove the cover for the slide valve controlassembly. Mark and disconnect the wires tothe potentiometer (419).

B) The capacity gearmotor potentiometer usesa larger potentiometer gear and a small drivegear on the command shaft. The volumeratio gearmotor uses a small potentiometergear and a large drive gear on the commandshaft. The potentiometer bracket (428) is in-terchangeable and can be used for either thecapacity or volume control.

C) Loosen and remove the socket head capscrews (456) and Nord-Lock® (476) wash-ers to remove the potentiometer assemblyfrom the slide valve motor bracket.

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D) Loosen the potentiometer gear clamp (432)and remove the gear (424 capacity and 425volume ratio) from the potentiometer shaft.

E) To remove the potentiometer (419) from thebracket (428), loosen and remove nut (419A)and lock washer (419B) from the potentiom-eter.

4.24 POTENTIOMETERINSTALLATION

A) Install potentiometer in the bracket. Installthe lock washer and nut on the potentiom-eter. Do not over tighten nut on the potenti-ometer.

B) Install the potentiometer gear and clamp onthe potentiometer shaft.

C) Loosely install only one of the two mountingscrews and its set of Nord-Lock® washers.Connect the wires to the potentiometer. Redpotentiometer lead goes to the white wire,purple potentiometer lead goes to the red wireand brown potentiometer lead goes to theblack wire. Recalibrate the potentiometer ac-cording to the appropriate Microprocessoroperating manual. The remaining screw cannow be installed and both screws torqued.

Do not apply excessive force when meshing thepotentiometer gear, slide load on potientometershaft can cause rapid failure

4.30 RETROFIT CAPACITY AND VOL-UME RATIO CONTROL ASSEMBLIES ONALL VSS AND VSR COMPRESSORSMANUFACTURED BEFORE MAY 1, 1995.

This section will cover the retrofit parts requiredto update units manufactured before 5-1-95, tocurrent capacity and volume ratio control actua-tor assemblies.

4.31 REMOVAL

To change to the new style optical motors, thecommand shaft and mounting plate must be re-placed. This will require the unit to be evacuatedfor servicing.


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B) Remove the hex head cap screws (452) fromthe cover (418) for the slide valve controlmotor, and remove cover. Mark and discon-nect the wires to the slide valve control motorand potentiometer (425). Remove the two hexbolts (453) under the mounting plate (415) thathold the motor bracket (405) in place. Themotor can now be removed.

C) Removes the four socket head cap screws(455) securing the motor plate and commandshaft assembly. The motor plate and com-mand shaft assembly can now be removedfrom the discharge manifold.

D) Repeat the above steps to remove the oppo-site slide valve control motor and commandshaft assembly.

4.32 INSTALLATION OF RETROFITCONTROL ASSEMBLY

A) Install the new command shaft assembly witha new O-ring on the manifold. Make sure thecommand shaft coupling is engaged in thecross shaft gear. Rotate the bearing housingso the vent holes points down, to preventwater and dust from entering the vent.

B) Install the new motor plate (415) and the foursocket head cap screws (457), and Nord-

Lock® washers (477) securing it. Tighten thebolts to the recommended torque value.

C) Install the drive key (427) in the commandshaft keyway.

D) Install the new style optical gear motor asoutlined in section 4.02 Optical Slide ValveActuator Installation.

E) Refer to the appropriate Microprocessor op-erating manual for the procedure to recalibratethe actuator. The unit can now be evacuatedand leak checked as outlined in section 0.03.

4.33 COMMAND SHAFT BEARINGAND O-RING SEAL REPLACEMENTFOR RETROFIT CONTROL AS-SEMBLIES

A) Remove command shaft assembly as outlinedin section 4.05.

B) With a suitable pin punch, drive out roll pins(490) and (491). Remove coupling (414) fromthe command shaft and dress out any burrsaround the roll pin hole on the command shaft.

C) Remove snap ring retainer (451) from com-mand shaft housing (412). Push the com-mand shaft assembly out of the housing.

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D) The command shaft bearing (435) is a pressfit on the command shaft (413). Remove thecommand shaft bearing with a suitable press.

E) Remove the O-ring seal (445) from the com-mand shaft housing. The command shaftbushing (436) should only be removed if thebore is deeply scored or excessively worn.

4.34 COMMAND SHAFT BEARINGAND O-RING SEAL REASSEMBLY

A) If the command shaft bushing (436) was re-moved, install a new bushing in housing. In-stall new O-ring seal (445) in the commandshaft housing. Lubricate the O-ring with cleancompressor oil. Install snap ring retainer (450)and washer (480) on the command shaft (413).

B) Remove any burrs from the command shaft toprevent damage to the O-ring when assem-bling. Press the command shaft bearing (435)onto the command shaft.

IMPORTANT

Do not press on outer bearing race when install-ing the bearing on to the command shaft.

C) Insert the command shaft into the housing.Make sure the bearing is fully seated in thecommand shaft housing. Install the snap ringretainer in the command shaft housing.

D) Place the coupling on the command shaft and

align roll pin holes. Drive in roll pins.

E) Install the command shaft assembly with anew o-ring (446) on the manifold. Make surethat the command shaft tongue is engaged inthe cross shaft slot. Rotate the bearing hous-ing so the vent holes point down, this willprevent water and dust from entering thevents.

F) Install the actuator mounting plate with thefour socket head cap screws and Nord-Lockwashers securing it.

G) The unit can now be leak checked as out-lined in section 0.03.

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5.00 LIQUID INJECTION PLUGREPLACMENT

A) Electrically lock out and tag out the screwcompressor package.

B) Isolate the screw compressor packagefrom the package.

C) Remove the refrigerant from the screwcompressor package in an approved man-ner.

5.01 REMOVAL OF PLUG

A) Remove the socket head pipe plug, fromthe top of VSS compressors or the bot-tom of VSR compressors. Some of thepipe plugs were sealed with red refriger-ant grade thread sealing compound. Thismay require a moderate amount of heatto be applied to the plug, not to exceed300°F.

B) Two types of inner plugs are used.

1) The first style of plug assembliesconsists of a steel plug with acrushed Teflon® pellet on top of thesteel plug, which holds the steelplug in position. To remove thesteel plug, the crushed Teflon pel-let must be dug out from the top ofthe steel plug. Care must be takenthat all of the Teflon is removedfrom the threads.

2) After the threads are clean, the steelplug can be removed with a ¼” x20 threaded rod or bolt. After theplug is removed, clean and inspectthe port in the compressor framefor debris.

3) The second type consists of a steelplug and O-ring assembly. Thesteel plug utilized a ¼” x 20 tappedhole to assist in removing the plug.This plug can be removed by in-serting a ¼” x 20 threaded rod orbolt to pull the plug out.

5.02 INSTALLATION OF PLUG

A) Apply refrigerant grade thread sealant to thethreads of the replacement plug. Install pluginto compressor frame.

B) Rotate the compressor input shaft by handto make sure the compressor turns overfreely.

C) Pressurize the screw compressor packageand check for leaks.

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TABLE 5.1 VSS AND VSR LIQUID INJECTIONPLUG APPLICABILITY

COMPRESSOR MODEL VPN

VSR 111/211 NONEVSR 151/301 25905BCVSS 451 25905BBVSS 451E NONEVSS 601 25905BAVSS 601E 25905BAVSS 751 25905CBVSS 751E 25905CBVSS 901 25905CAVSS 901E 25905CAVSS 1051 25905DBVSS 1051E 25905DCVSS 1201 25905DAVSS 1201E 25905DAVSS 1501 NONEVSS 1501E NONEVSS 1801 NONE** EXCEPT S/N 819, 820 & 821 25905EAVSS 1801E NONE

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HEAD OUTSIDE DIAMETER OF BOLT SHANK

TYPE BOLT MARKINGS 1/4" 5/16" 3/8" 7/16" 1/2" 9/16" 5/8" 3/4"

SAE GRADE 2 6 12 20 32 47 69 96 155

SAE GRADE 5 10 19 33 54 78 114 154 257

SAE GRADE 8 14 29 47 78 119 169 230 380

SOCKET HEAD 16 33 54 84 125 180 250 400CAP SCREW

A. The Nord-Lock® lock washer sets are usedin many areas in both the VSR and VSS screwcompressors that require a vibration proof lockwasher.

B. The lock washer set is assembled so thecourse serrations that resemble ramps aremated together.

C. Once the lock washer set is tighteneddown, it takes more force to loosen the boltthat it did to tighten it. This is caused by thewashers riding up the opposing ramps.

Fine serrations face out.

Coarse serrationsmate together.

Torque Specifications

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6.00 OIL FILTER ELEMENTS

The following is a description of the oil filterelements supplied on standard VSS, VSR andVSM single screw compressor units

6.01 1833C FILTER ELEMENTS

Vilter Part Number 1833C

Usage VSS451 toVSS 1801Dates All unitsprior to 3-1-00Length 18”

Diameter 6-1/8”

A) Characteristics;

1) The outside of the filter element iscovered with a perforated metal sur-face.

2) At each end of the filter, there is alarge thick elastomeric seal.

3) The housing is a fabricated steel hous-ing with bolted end cover. The hous-ing can contain one or two elements.

4) Simplex filter housing is standardwith duplex filter housings with abypass valve arrangement is optional,so that the filter can be changed whileunit is in operation.

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6.02 KT 721 FILTER ELEMENTS

Vilter Part Number KT 721

Tank O-Ring 2176BU

Usage VSR Compres-sorsDates 1992 to 8-1-96

Length 8”

A) Characteristics;

1) Pleated type element with a screen cov-ering the surface of the element.

2) One end of the element is solid whilethe other has a pilot hole with a cap-tive “o”-ring.


Vilter Part Number KT 722

Tank O-Ring 2176AJ

Usage VSR Compres-sorsDates 1996 to 2002

Length 16.8”

A) Characteristics;

1) Pleated type element with a screen cov-ering the surface of the element.

2) One end of the element is solid whilethe other has a pilot hole with a cap-tive “o”-ring.

96

Service

6.04 KT 773A & B FILTER ELEMENTS

Vilter Part KT 773A KT 773BNumberTank O-Ring 2176BY 2176BZ

Usage 3109A 3111ADuplex SimplexHousing Housing

Usage 1. VSM all models 4/1/00 topresent.

2. VSS 451 to 1201 models with30” and smaller oil separators 3/1/00 to present

Length 16”

A) Characteristics;1) Pleated type element with a screen

covering the surface of the element.

2) One end of the element is solid while theother has a pilot hole with a captive “o”-ring.

3) On duplex models only the end cap isremoved from the filter bowl

B) Usage;

1) Used in simplex and duplex applications.

2) The O-rings for the simplex and duplexhousings are not interchangeable.

Simplex filter housing. Duplex filter housing.

97

Service


Vilter Part KT 774NumberTank O-Ring 2176BY

Usage 3112A 3110ASimplex DuplexHousings Housings1. VSS 1501 & 1801 3-1-00 topresent.2. All other VSS models with 30”and larger oil separators3/1/00 to present.

Length 39”

C) Characteristics;

1) Pleated type element with a screen coveringthe surface of the element.

2) One end of the element is solid while theother has a pilot hole with a captive “o”-ring.

3) Only end cap is removed from the filterbowl.

D) Usage;

1) Used in simplex and duplex applications.

Simplex filter housing.

Duplex filter housing.

98

VSS, VSM and VSR SINGLE SCREW COMPRESSORSSERVICE INTERVAL REQUIREMENTSFOR VILTER EXTENDED WARRANTY

The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrigerationoil in VSS, VSM and VSR Single Screw Compressor units.

SERVICE INTERVAL (HOURS)

OIL CIRCUITOil Change (1) R R R R R R ROil Analysis (2) S S S S S S S S S S S S SOil Filters (3) R R R R R R R R R R R R R ROil Strainer I I I I I I I I I I I I I I

PACKAGECoalescing Elements R R R RSuction Screen I I I I I I I I I I I I I ILiquid Line Strainers I I I I I I I I I I I I I ICoupling Alignment andIntegrity I I I I I I I I I I I I I I

CONTROLCALIBRATION 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 ICOMPRESSOR

Inspect Compressor I I I I I I IBearings 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. Thefrequency 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 onsystem 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.

200

5,00

0

10,0

00

20,0

00

30,0

00

40,0

00

50,0

00

60,0

00

70,0

00

80,0

00

90,0

00

100,

000

110,

000

120,

000

Inspection Or

Group Maintenance Item

99

RecommendedSpare Parts List

100

VSS

- V

SR -

VSM

Spa

re P

arts

Lis

t

SPA

RE

PART

S FO

R:

PART

WH

ERE

USE

D:

CO

MPO

NE

NT

VSS

VSM

VSR

V.P.

#D

ESC

RIP

TIO

NQ

TY

DE

SCR

IPT

ION

MU

LTO

il Se

para

tor

X29

23A

Def

ogge

r/Coe

lece

nt E

lem

ent

116

" O

il Se

para

tor

140A

X28

79C

Def

ogge

r/Coe

lece

nt E

lem

ent

120

" O

il Se

para

tor

111R

Gas

kets

X69

203C

Cov

er G

aske

t1

16"

Oil

Sepa

rato

r14

0AX

9355

9AC

over

Gas

ket

120

" O

il Se

para

tor

112R

Oil

Sepa

rato

rX

X1

20"

Oil

Sepa

rato

rX

X2

24"

Oil

Sapa

rato

rX

X28

79A

Def

ogge

r/Coe

lece

nt E

lem

ent

330

" O

il Se

para

tor

140A

X4

36"

Oil

Sepa

rato

rX

542

" O

il Se

para

tor

Gas

kets:

XX

9355

9AC

over

Gas

ket,

13"

x 12

"1

20"

Oil

Sepa

rato

r11

2Rch

oose

sepa

rato

rX

124

" O

il Se

para

tor

size

X1

30"

Oil

Sepa

rato

rX

9356

0AC

over

Gas

ket,

16"

x 15

"1

36"

Oil

Sepa

rato

r11

2RX

142

" O

il Se

para

tor

XK

T721

Oil

Filte

r El

emen

t1

Use

d on

VSR

com

pres

sors

111R

VSR

Uni

tsm

anuf

actu

red

Bef

ore

8-8-

96O

il Fi

lter

XK

T722

Oil

Filte

r El

emen

t1

Use

d on

VSR

com

pres

sors

111R

+++

man

ufac

ture

d

Afte

r 8-

8-96

X18

33C

Oil

Filte

r El

emen

t1

Sing

le E

lem

ent F

ilter

Tan

k11

2RV

SS U

nits

Bef

ore

Apr

il - 2

000

2D

ual E

lem

ent F

ilter

Tan

k11

2RO

il Fi

lter

X35

197A

Filte

r Tan

k C

over

Gas

ket

1Si

ngle

or D

ual E

lem

ent F

ilter

Tan

k11

2R +

++(I

nclu

ded

with

183

3C)

XX

3109

AD

uple

x H

ousi

ng -

16"

Bow

l<

or =

30"

Oil

Sepa

rato

r11

1RX

3110

AD

uple

x H

ousi

ng -

39"

Bow

l >

30"

Oil

Sepa

rato

r11

1RV

SS/V

SMX

X31

11A

Sing

le H

ousi

ng -

16"

Bow

l<

or =

30"

Oil

Sepa

rato

r11

1RO

il Fi

lter

X31

12A

Sing

le H

ousi

ng -

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XK

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l Rel

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XX

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98A

250

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R-7

17 R

elie

f Val

ve2

250

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ual R

elie

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VF

XX

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300

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Hal

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bon

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ocar

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l Rel

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Dua

l Rel

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NO

TE

: R

ECO

MM

END

ED S

PAR

E PA

RTS

MA

RK

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e su

re to

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ck p

art #

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cor

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el S

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pres

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arke

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ith “

X”

101

VSS

- V

SR -

VSM

Spa

re P

arts

Lis

t

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RE

PART

S FO

R:

PART

CO

MPO

NE

NT

VSS

VSM

VSR

V.P.

#D

ESC

RIP

TIO

NQ

TY

DE

SCR

IPT

ION

MU

LTX

XX

2650

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,1

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ies

Sole

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ve, 1

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VF

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w a

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Lead

sX

XX

2650

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leno

id C

oil,

230V

/50

Hz.

,1

2650

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ies

Sole

noid

Val

ve, 2

30V

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Rep

lace

men

tYe

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XX

2650

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,1

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Ser

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Sole

niod

Val

ve, 1

20V

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VF

Valv

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oils

Blue

lead

sX

XX

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leno

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oil,

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/60

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,1

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ve, 2

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Red

Lead

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11 G

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9611

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Rep

lace

men

t Sha

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al fo

r1

11 G

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ore

1996

111R

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mp

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mp

122

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B

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9611

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rep

l’mt

X29

54H

Bar

e 31

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Oil

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p1

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PM O

il Pu

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Bef

ore

1996

111R

shaf

t sea

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lace

men

t Sha

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1 G

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XX

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10 G

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il Pu

mp

w/B

rack

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ub O

K11

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lace

men

t Sha

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ps

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111R

1548

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ange

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ket

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aigh

tX

XX

3022

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20 G

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il Pu

mp

w/B

rack

et1

Was

302

2D (B

efor

e 19

95) r

eq’s

291

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ub11

1RO

il Pu

mp

XX

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epla

cem

ent S

haft

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124

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il Pu

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AFl

ange

Gas

ket

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ote

req’

d hu

b)X

XX

3022

GU

30 G

PM O

il Pu

mp

w/B

rack

et1

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302

2G (B

efor

e 19

95) r

eq’s

291

3E h

ub11

1RX

XX

3022

CU

Rep

lace

men

t Sha

ft Se

al1

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ps

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111R

1548

AA

Flan

ge G

aske

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& r

epl’m

tX

3022

JU40

GPM

Oil

Pum

p w

/Bra

cket

1W

as 3

022J

(Bef

ore

1995

) req

’s 2

913S

hub

111R

shaf

t sea

lsX

3022

CU

Rep

lace

men

t Sha

ft Se

al1

40U

Oil

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ps

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ER

4-1

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111R

1548

AA

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ge G

aske

t2

X30

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U54

GPM

Oil

Pum

p w

/Bra

cket

1W

as 3

022M

(Bef

ore

1995

) req

’s 2

913S

hub

111R

X30

22C

VR

epla

cem

ent S

haft

Seal

154

U O

il Pu

mps

A

FTE

R 4

-19-

0211

1R15

48BA

Flan

ge G

aske

t2

X30

22Q

U80

GPM

Oil

Pum

p w

/Bra

cket

1W

as 3

022Q

(Bef

ore

1995

) req

’s 2

913R

hub

111R

X30

22C

VR

epla

cem

ent S

haft

Seal

180

U O

il Pu

mps

A

FTE

R 4

-19-

0211

1R15

48BA

Flan

ge G

aske

t2

XX

2545

A1.

5KW

/240

V—

375W

/120

V1

befo

re 1

999

on 2

0" &

24"

Sep

arat

or11

2RH

eate

rX

2545

B2K

W/2

40V

—50

0W/1

20V

1be

fore

199

9 on

30"

Sep

arat

or11

2R(p

re 1

999)

X25

45C

2.5K

W/2

40V

—62

5W/1

20V

1be

fore

199

9 on

36"

Sep

arat

or11

2RX

2545

D3K

W/2

40V

—75

0W/1

20V

1be

fore

199

9 on

42"

Sep

arat

or11

2R

Hea

ter(

afte

r ’9

9)X

X31

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750W

/120

V C

artri

dge

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ter

>>af

ter 1

999

on a

ll se

para

tors

—qt

y 1

or 2

111R

102

Spar

e Pa

rts

Con

t.....

VSS

- V

SR -

VSM

Spa

re P

arts

List

VIL

TER

OIL

XX

X29

39A

717—

5 G

ALL

ON

CA

NFO

R A

LL S

CR

EW &

REC

IP C

OM

P2H

VF

+++

XX

X29

39B

717—

55

GA

LLO

N D

RU

MFO

R A

LL S

CR

EW &

REC

IP C

OM

P2H

VF

XX

X31

00A

HA

LOC

AR

BO

N —

5 G

AL

CA

NFO

R A

LL S

CR

EW &

REC

IP C

OM

P2H

VF

XX

X31

00B

HA

LOC

AR

BO

N —

55G

AL.

DR

UM

FOR

ALL

SC

REW

& R

ECIP

CO

MP

2HV

FSh

aft S

eal

XX

KT7

09A

Shaf

t Sea

l Kit

1V

SR11

1-V

SS60

1 &

VSM

501

-701

111R

Am

mon

iaX

KT7

09B

Shaf

t Sea

l Kit

1V

SS75

1 - 1

201

111R

+++

XK

T709

CSh

aft S

eal K

it1

VSS

1501

- 18

0111

1RX

KT7

09D

Shaf

t Sea

l Kit

1V

SM 7

1-40

111

1RSh

aft S

eal

XX

KT7

81A

Shaf

t Sea

l Kit

1V

SR11

1-V

SS60

1 &

VSM

501

-701

111R

Oth

er R

efri

g.X

KT7

81B

Shaf

t Sea

l Kit

1V

SS75

1 - 1

201

111R

+++

XK

T781

CSh

aft S

eal K

it1

VSS

1501

- 18

0111

1RX

KT7

81D

Shaf

t Sea

l Kit

1V

SM 7

1-40

111

1RSl

ide

Valv

eX

XX

KT7

20A

Gea

rmot

or/ C

apac

ity S

lide

Valv

e1

All

Sing

le S

crew

Com

pres

sors

111R

Mot

ors

XX

XK

T720

CG

earm

otor

/ Vol

ume

Slid

e Va

lve

1A

ll Si

ngle

Scr

ew C

ompr

esso

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1R +

++X

XX

2597

2AN

EW C

apac

ity &

Vol

ume

1C

ompl

ete

Ret

rofit

for

all V

iss/

Vant

Opt

ical

Act

uato

r A

ssem

bly

pane

ls &

Com

pres

sors

aft

er 1

/01/

0211

1RSh

aft S

eal

XX

A25

931A

VSR

’S &

451

& 6

011

2-C

heck

s, B

affle

, Tef

lon

Seal

111R

Baffl

eX

A25

942A

AV

SM1

& R

etai

ner R

ing

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Ass

embl

yX

A25

932A

751-

1201

1

“

“

111R

XA

2593

3A15

01-1

801

1

“

“

111R

XA

2603

4BV

SM 5

01-7

011

Hub

bel

XX

X28

03

103

VSS and VSR ReplacementParts Section

VSS and VSR Replacement Parts Section................................................................ 103Gate Rotor ...................................................................................................................................................................................... 104Shaft Seal ....................................................................................................................................................................................... 108Main Rotor ..................................................................................................................................................................................... 110Slide Valve Cross Shafts and End Plate ....................................................................................................................................... 114

Slide Valve Cross Shafts Prior to 5-1-95 .................................................................................................................................... 115Slide Valve Carriage Assembly ..................................................................................................................................................... 120

Capacity Control Actuating Motor and Command Shaft ........................................................................................................... 122Slide Valve Actuating Motor and Command shaft Before 5-1-95 ............................................................................................... 126Volume Ratio Control Actuating Motor and Command Shaft ..................................................................................................... 128Miscellaneous Frame Components ............................................................................................................................................... 132Tubing and Fittings ........................................................................................................................................................................ 132Miscellaneous Frame Components ............................................................................................................................................... 134C-Flange Adapter Components ..................................................................................................................................................... 138Replacement Parts Tools ............................................................................................................................................................... 140

VSS

&

VSR

PartsList

104

Gate Rotor

105

Gate Rotor

MODEL NUMBERITEM DESCRIPTION VSR 111 & VSR 221 VSR 151 & VSR 301VSS 451 VSS 601

QTY VPN QTY VPN QTY VPN QTY VPNGATE ROTOR BLADE AND BEARINGREPLACEMENT KIT, 111, 118, 120A,120B, 121, 122, 123, 124, 125, 126, 130,131, 141, 142 & 143. 1 KT712A 1 KT712B 2 KT712A 2 KT712BGATE 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 A25159BA102 GATE ROTOR SUPPORT ASSEMBLY

100, 111, 120B, 119 & 130. 1 A25161BB 1 A25161BA 2 A25161BB 2 A25161BA105 GATE ROTOR GASKET SET 118, 141,

142 & 143. 1 A25164B 1 A25164B 2 A25164B 2 A25164B106 SHIM PACK SET (2) 121, (2) 122,

(1) 123, (1) 124. 1 A25165B 1 A25165B 2 A25165B 2 A25165B110 SUPPORT. 1 25606A 1 25520A 2 25606A 2 25520A111 GATE ROTOR. 1 25557A 1 25534A 2 25557A 2 25534A112 SMALL BEARING HOUSING. 1 25518A 1 25518A 2 25518A 2 25518A113 LARGE BEARING HOUSING. 1 25517A 1 25517A 2 25517A 2 25517A114 RETAINER. 1 25008A 1 25008A 2 25008A 2 25008A115 RETAINER. 1 25009A 1 25009A 2 25009A 2 25009A116 BALL BEARING COVER. 1 25258A 1 25258A 2 25258A 2 25258A117 GATE ROTOR COVER. 1 25519A 1 25519A 2 25519A 2 25519A118 GATE ROTOR COVER GASKET. 1 25259A 1 25259A 2 25259A 2 25259A119 WASHER. 1 25007A 1 25007A 2 25007A 2 25007A120A BUSHING, SMALL DOWEL PIN. 1 25006A 1 25006A 2 25006A 2 25006A120B BUSHING, LARGE DOWEL PIN. 1 25760A 1 25760A 2 25760A 2 25760A121* SHIM 0.002". ar 25010AA ar 25010AA ar 25010AA ar 25010AA122* SHIM 0.003". ar 25010AB ar 25010AB ar 25010AB ar 25010AB123* SHIM 0.005". ar 25010AC ar 25010AC ar 25010AC ar 25010AC124* SHIM 0.010". ar 25010AD ar 25010AD ar 25010AD ar 25010AD125 ROLLER BEARING. 1 2864B 1 2864B 2 2864B 2 2864B126 BALL BEARING. 2 2865B 2 2865B 4 2865B 4 2865B130 RETAINING RING. 1 2866A 1 2866A 2 2866A 2 2866A131 RETAINING RING. 1 2867A 1 2867A 2 2867A 2 2867A135A DOWEL PIN, SMALL, 0.250" O.D.. 1 2868B 1 2868B 2 2868B 2 2868B135B DOWEL PIN, LARGE, 0.4375" O.D.. 1 25910A 1 25910A 2 25910A 2 25910A141 O-RING ROLLER BRG HSG. 1 2176M 1 2176M 2 2176M 2 2176M142 O-RING BALL BRG HSG. 1 2176R 1 2176R 2 2176R 2 2176R143 O-RING BRG HSG COVER. 1 2176N 1 2176N 2 2176N 2 2176N150 HEX HEAD CAP SCREW. 6 2796AJ 6 2796AJ 12 2796AJ 12 2796AJ151 HEX HEAD CAP SCREW. 3 2796B 3 2796B 6 2796B 6 2796B152 HEX HEAD CAP SCREW. 20 2796CJ 20 2796CJ 40 2796CJ 40 2796CJ153 HEX HEAD CAP SCREW. 16 2796E 16 2796E 32 2796E 32 2796E160 SOCKET HEAD CAP SCREW. 6 2795E 6 2795E 12 2795E 12 2795E

NOTE: * Not picturedar = As required

VSS

&

VSR

PartsList

106

Gate Rotor

ITEM DESCRIPTION VSG 751 VSG 901 VSG 1051 VSG 1201QTY 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 KT712FGATE 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 A25159DA102 GATE ROTOR SUPPORT ASSEMBLY

100, 111, 120B, 119 &130 2 A25161CB 2 A25161CA 2 A25161DB 2 A25161DA105 GATE ROTOR GASKET SET 118, 141,

142 & 143. 2 A25164C 2 A25164C 2 A25164D 2 A25164D106 SHIM PACK SET (2) 121, (2) 122,

(1) 123, (1) 124. 2 A25165C 2 A25165C 2 A25165C 2 A25165C110 SUPPORT. 2 25612A 2 25553A 2 25614A 2 25587A111 GATE ROTOR. 2 25608A 2 25554A 2 25610A 2 25588A112 SMALL BEARING HOUSING. 2 25281A 2 25281A 2 25313A 2 25313A113 LARGE BEARING HOUSING. 2 25282A 2 25282A 2 25333A 2 25333A114 RETAINER. 2 25084A 2 25084A 2 25084A 2 25084A115 RETAINER. 2 25085A 2 25085A 2 25085A 2 25085A116 BALL BEARING COVER. 2 25284A 2 25284A 2 25335A 2 25335A117 GATE ROTOR COVER. 2 25285A 2 25285A 2 25311A 2 25311A118 GATE ROTOR COVER GASKET. 2 25088A 2 25088A 2 25132A 2 25132A119 WASHER. 2 25086A 2 25086A 2 25086A 2 25086A120A BUSHING, SMALL DOWEL PIN. 2 25087A 2 25087A 2 25104A 2 25104A120B BUSHING, LARGE DOWEL PIN. 2 25760B 2 25760B 2 25760B 2 25760B121* SHIM 0.002". ar 25089AA ar 25089AA ar 25089AA ar 25089AA122* SHIM 0.003". ar 25089AB ar 25089AB ar 25089AB ar 25089AB123* SHIM 0.005". ar 25089AC ar 25089AC ar 25089AC ar 25089AC124* SHIM 0.010". ar 25089AD ar 25089AD ar 25089AD ar 25089AD125 ROLLER BEARING. 2 2864C 2 2864C 2 2864G 2 2864G126 BALL BEARING. 4 2865A 4 2865A 4 2865A 4 2865A130 RETAINING RING. 2 2866B 2 2866B 2 2866B 2 2866B131 RETAINING RING. 2 2867E 2 2867E 2 2867L 2 2867L135A DOWEL PIN, SMALL, 0.3125" O.D.. 2 2868F 2 2868F 2 2868H 2 2868H135B DOWEL PIN, LARGE, 0.4375" O.D.. 2 25910B 2 25910B 2 25910B 2 25910B141 O-RING ROLLER BRG HSG. 2 2176N 2 2176N 2 2176AJ 2 2176AJ142 O-RING BALL BRG HSG. 2 2176V 2 2176V 2 2176AM 2 2176AM143 O-RING BRG HSG COVER. 2 2176U 2 2176U 2 2176U 2 2176U150 HEX HEAD CAP SCREW. 12 2796B 12 2796B 12 2796B 12 2796B151 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796N 8 2796N152 HEX HEAD CAP SCREW. 26 2796Q 26 2796Q 26 2796Q 26 2796Q153 HEX HEAD CAP SCREW. 32 2796R 32 2796R 36 2796R 36 2796R160 SOCKET HEAD CAP SCREW. 12 2795H 12 2795H 12 2795H 12 2795H

ar = As required

107

Gate Rotor

ITEM DESCRIPTION VSG 1501 VSG1801QTY VPN QTY VPN

GATE ROTOR BLADE AND BEARINGREPLACEMENT KIT, 111, 118, 120A, 120B,121, 122, 123, 124, 125, 126, 130, 131, 141,142 & 143. 2 KT712G 2 KT712HGATE ROTOR BLADE REPLACEMENTKIT, 111, 118, 120A, 120B, 121, 122, 123, 124,130, 141, 142 & 143. 2 KT713G 2 KT713H

100 SUPPORT ASSEMBLY 110 & 135B. 2 A25159EB 2 A25159EA101 GATE ROTOR ASSEMBLY 111 & 120. 2 A25160EB 2 A25160EA102 GATE ROTOR SUPPORT ASSEMBLY

100, 111, 120B, 119 &130. 2 A25161EB 2 A25161EA105 GATE ROTOR GASKET SET 118, 141,

142 & 143. 2 A25164E 2 A25164E106 SHIM PACK SET (2) 121, (2) 122,

(1) 123, (1) 124. 2 A25165E 2 A25165E110 SUPPORT. 2 25687A 2 25665A111 GATE ROTOR. 2 25647A 2 25645A112 SMALL BEARING HOUSING. 2 25667A 2 25667A113 LARGE BEARING HOUSING. 2 25669A 2 25669A114 RETAINER. 2 25141A 2 25141A115 RETAINER. 2 25789A 2 25789A116 BALL BEARING COVER . 2 25351A 2 25351A117 GATE ROTOR COVER. 2 25354A 2 25354A118 GATE ROTOR COVER GASKET. 2 25790A 2 25790A119 WASHER. 2 25788A 2 25788A120A BUSHING, SMALL DOWEL PIN. 2 25104A 2 25104A120B BUSHING, LARGE DOWEL PIN. 2 25760C 2 25760C121* SHIM 0.002". ar 25791AA ar 25791AA122* SHIM 0.003". ar 25791AB ar 25791AB123* SHIM 0.005". ar 25791AC ar 25791AC124* SHIM 0.010". ar 25791AD ar 25791AD125 ROLLER BEARING. 2 2864K 2 2864K126 BALL BEARING. 4 2865K 4 2865K130 RETAINING RING. 2 2866G 2 2866G131 RETAINING RING. 2 2867R 2 2867R135A DOWEL PIN, SMALL, 0.375" O.D.. 2 2868H 2 2868H135B DOWEL PIN, LARGE, 0.500" O.D.. 2 25910C 2 25910C141 O-RING ROLLER BRG HSG. 2 2176U 2 2176U142 O-RING BALL BRG HSG. 2 2176BD 2 2176BD143 O-RING BRG HSG COVER. 2 2176P 2 2176P150 HEX HEAD CAP SCREW. 12 2796CJ 12 2796CJ151 HEX HEAD CAP SCREW. 8 2796N 8 2796N152 HEX HEAD CAP SCREW. 32 2796CJ 32 2796CJ153 HEX HEAD CAP SCREW. 44 2796R 44 2796R160 SOCKET HEAD CAP SCREW. 16 2795G 16 2795G

ar = As required

VSS

&

VSR

PartsList

108

Shaft Seal

Shaft Seal With Stationary Carbon Face

Important:Item # 244- TapperedID Faces Outward.

Shaft Seal Baffle Assemmbly

109

Shaft Seal

MODEL NUMBERITEM DESCRIPTION VSR 111 & VSR 151& VSS 751-1201 VSS 1501-1801

VSR 221 VSR 301VSS 451 VSS 601

QTY VPN QTY VPN QTY VPN QTY VPNSHAFT SEAL AMMO KIT; 219, 230 & 260. 1 KT709A 1 KT709A 1 KT709B 1 KT709CSHAFT SEAL HALO KIT 219,230 & 230 1 KT781A 1 KT781A 1 KT781B 1 KT781C

203 BAFFLE SHAFT SEAL 1 25931A 1 25931A 1 25932A 1 25933A

218 SEAL HOUSING. 1 25269A 1 25269A 1 25269B 1 25670A219.# SHAFT SEAL. (Ammonia) 1 25043A 1 25043A 1 25043B 1 25378A219.# SHAFT SEAL (Halo) 1 25432B 1 25432B 1 25432C 1 25432E230 OIL SEAL. 1 25040A 1 25040A 1 25064A 1 2930B244.> TEFLON SEAL 1 25939B 1 25939B 1 25939C 1 25939D252> RETAINER RING 1 2928N 1 2928N 1 2928N 1 2928P260 O-RING. 1 2176F 1 2176F 1 2176AC 1 2176BH264 ROLL PIN. 1 1193RR 1 1193RR 1 1193RR 1 1193RR265 DOWEL PIN . n/a n/a 1 2868A 1 2868A281 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796B 13 2796B

NOTE: * Not pictured.# Sold only as a kit.> See recommended spare parts lists for complete assembly.

VSS

&

VSR

PartsList

110

Main RotorVSS

111

Mai

n R

otor

VSS

VSS

&

VSR

PartsList

MO

DEL

NU

MB

ER

ITE

MD

ESC

RIP

TIO

N

V

SS 4

51

VSS

601

V

SS75

1

VSS

901

VSS

1051

V

SS12

01 V

SS15

01 V

SS18

01

QTY

PA

RT#

Q

TY P

ART

#

Q

TY P

ART

#Q

TY

PART

#Q

TY

PART

#Q

TY

PART

#Q

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ART

#Q

TY

PART

#

201

RO

TOR

ASS

Y1

A25

168B

B1

A25

168B

A1

A25

168C

B1

A25

168C

A1

A25

168D

B1

A25

168D

A1

A25

168E

B1

A25

168A

E

206

SHIM

PA

CK

1 A

2517

3B1

A25

173B

1 A

2517

3C1

A25

173C

1 A

2517

3D1

A25

173D

1 A

2517

3E1

A25

173E

207

SHIM

PA

CK

1 A

2517

7B1

A25

177B

1 A

2517

7C1

A25

177C

1 A

2517

7D1

A25

177D

1 A

2517

7E1

A25

177E

213

RO

TOR

SEA

L1

255

09A

1 2

5509

A1

252

73A

1 2

5273

A1

253

22A

1 2

5322

A1

253

59A

1 2

5359

A21

4H

OU

SIN

G B

ALL

BR

G1

255

31A

1 2

5531

A1

252

72A

1 2

5272

A1

253

21A

1 2

5321

A1

253

58A

1 2

5358

A21

5R

ET, O

UTE

R R

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BR

G1

250

01A

1 2

5001

A1

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61A

1

2506

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41A

1 2

5141

A1

257

95A

1 2

5795

A21

6R

ET, I

NN

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EAR

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1 2

5000

A1

250

00A

1 2

5062

A1

250

62A

1 2

5142

A1

251

42A

1 2

5796

A1

257

96A

220

END

PLA

TE1

255

30A

1 2

5530

A1

255

43A

1 2

5543

A1

255

93A

1 2

5593

A1

256

61A

1 2

5661

A24

5B

ALL

BEA

RIN

G2

286

5A2

286

5A2

286

5E2

28

65E

2 2

865G

2 2

865G

2 2

865J

2 2

865J

246

RO

LLER

BEA

RIN

G1

286

4A1

286

4A1

286

4D1

28

64D

1 2

864D

1 2

864D

1 2

864J

1 2

864J

250

RET

AIN

ING

RIN

G

n/a

n/a

1 2

867M

1 2

867M

1 2

867M

1 2

867M

1

2867

P1

286

7P25

1R

ETA

ININ

G R

ING

2 2

867B

2 2

867B

1 2

867N

1

2867

N1

286

7N1

286

7N1

28

67Q

1 2

867Q

264

RO

LLPI

N1

119

3RR

1 1

193R

R1

119

3RR

1 1

193R

R1

119

3RR

1 1

193R

R1

11

93R

R1

119

3RR

275

HEX

HD

CA

P SC

REW

6 2

796A

E6

279

6AE

10

279

6B

1

0 2

796B

6 2

796Q

6 2

796Q

6

2796

Q6

279

6Q27

6H

EX H

D C

AP

SCR

EW3

279

6B3

279

6B

n/a

n/a

5 2

796B

5 2

796B

5

2796

B5

279

6B27

7H

EX H

D C

AP

SCR

EW4

279

6CL

4 2

796C

L

1

0 2

796E

L

10

279

6EL

10 2

796E

L

10

279

6EL

n

/a

n/

a27

8H

EX H

D C

AP

SCR

EW2

279

6CT

2 2

796C

T2

279

6EU

2

2796

EU2

279

6EU

2 2

796E

U2

27

96EU

2 2

796E

U27

9H

EX H

D C

AP

SCR

EW2

279

6CZ

2 2

796C

Z2

279

6EX

2

2796

EX2

279

6EX

2 2

796E

X2

27

96EX

2 2

796E

X28

0H

EX H

D C

AP

SCR

EW6

279

6EL

6 2

796E

L

n/

a

n

/a

n

/a

n/

a

1

4 2

796R

14

279

6R28

1H

EX H

D C

AP

SCR

EW8

279

6B8

279

6B8

279

6B8

279

6B8

279

6B8

279

6B

1

3 2

796B

13

279

6B28

2SO

C H

D C

AP

SCR

EW2

279

5D2

279

5D2

279

5D2

279

5D2

279

5AL

2 2

795A

L2

279

5AK

2 2

795A

K28

5SO

C H

D C

AP

SCR

EW

12

279

5R

12

279

5R

12

27

95F

12

2795

F

12

27

95K

12

279

5K

16 2

795A

E

16

279

5AE

112

Main RotorVSR

113

Main RotorVSR

VSS

&

VSR

PartsList

MODEL NUMBER

ITEM DESCRIPTION VSR 111-221 VSR 151-301

QTY PART # QTY PART #201 MAIN ROTOR ASSY 1 A25168BD 1 A25168BC206 SHIM PACK 1 A25173C 1 A25173C207 SHIM PACK 1 A25177B 1 A25177B203 BAFFLE, SHAFT SEAL 1 A25931A 1 A25931A213 SEAL 1 25630A 1 25630A214 SUPPORT BEARING 1 25649B 1 25630A215 OUTER BEARING RET 1 25001C 2 25001C216 INNER BEARING RET 1 25062B 1 25062B220 ENDPLATE ASSY 1 A25851BC 1 A25851BC245 BEARING BALL 2 2865E 2 2865E246 BEARING ROLLER CYL. 1 2864A 1 2864A251 RETAINING RING 2 2867B 2 2867B275 SOC HD CAP SCREW 6 2795E 6 2795E276 HEX HD CAP SCREW 3 2796B 3 2796B277 HEX HD CAP SCREW 4 2796CL 4 2796CL278 HEX HD CAP SCREW 2 2796CT 2 2796CT279 HEX HD CAP SCREW 2 2796CZ 2 2796CZ280 HEX HD CAP SCREW 6 2796EL 6 2796EL282 SOC HD CAP SCREW 2 2795D 2 2795D285 SOC HD CAP SCREW 12 2795R 12 2795R

114

Slide Valve Cross Shafts and End Plate

115


ITEM DESCRIPTION MODEL NUMBERVSR111-221 VSR 151-301 VSS 451 VSS 601

QTY VPN QTY VPN QTY VPN QTY VPN220 END PLATE 1 25530A 1 25530A 1 25530A 1 25530A221 SHAFT. 2 25843A 2 25843A 2 25843A 2 25843A222 GEAR. 2 25027A 2 25027A 4 25027A 4 25027A226 RACK CLAMP. 1 25913A 1 25913A 2 25913A 2 25913A227 RACK CLAMP. 1 25913B 1 25913B 2 25913B 2 25913B228 SPACER. 1 25847A 1 25847A 2 25847A 2 25847A229 SPACER. 1 25234A 1 25234A 0 n/a 0 n/a234 SPACER 1 25873A 1 25873A 0 n/a 0 n/a267 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 2 2606E 2 2606E 2 2606E 2 2606E286 SOCKET HEAD CAP SCREW. 4 2795F 4 2795F 8 2795F 8 2795F297 SET SCREW 2 2060J 2 2060J 2 2060J 2 2060J298 SET SCREW 2 2060H 2 2060H 2 2060H 2 2060H

Slide Valve Cross Shafts Prior to 5-1-95

MODEL NUMBERVSR111-221 VSR 151-301 VSS 451 VSS 601

ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN

221 SHAFT. 2 25031A 2 25031A 2 25031A 2 25031A222 GEAR. 2 25027A 2 25027A 2 25027A 2 25027A223 GEAR. 2 25028A 2 25028A 2 25028A 2 25028A228 SPACER. 2 25033C 2 25033C 2 25033C 2 25033C229 SPACER. 0 n/a 0 n/a 0 n/a 0 n/a268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA

VSS

&

VSR

PartsList

116


MODEL NUMBERITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201

QTY VPN QTY VPN QTY VPN QTY VPN220 END PLATE 1 25543A 1 25543A 1 25593A 1 25593A221 SHAFT. 2 25844A 2 25844A 2 25845A 2 25845A222 GEAR. 4 25027A 4 25027A 4 25027A 4 25027A226 RACK CLAMP. 4 25913C 4 25913C 4 25913C 4 25913C228 SPACER. 4 25033C 4 25033C 4 25033C 4 25033C267 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 2 2606E 2 2606E 2 2606E 2 2606E286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F 8 2795F297 SET SCREW 2 2060J 2 2060J 2 2060J 2 2060J298 SET SCREW 2 2060H 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.

Slide Valve Cross Shafts Prior to 5-1-95


QTY VPN QTY VPN QTY VPN QTY VPN220 END PLATE 1 25543A 1 25543A 1 25543A 1 25543A221 SHAFT. 2 25068A 2 25068A 2 25139A 2 25139A222 GEAR. 2 25027A 2 25027A 2 25027A 2 25027A223 GEAR. 2 25028A 2 25028A 2 25028A 2 25028A228 SPACER. 2 25033B 2 25033B 2 25033B 2 25033B229 SPACER. 2 25033C 2 25033C 2 25033C 2 25033C268 EXPANSION PIN. 2 1193D 2 1193D 2 1193D 2 1193D269 EXPANSION PIN. 2 2981AA 2 2981AA 2 2981AA 2 2981AA

NOTE: Three piece rack spacers and clamp are obsolete, use VPN 25913C instead.

117


MODEL NUMBERITEM DESCRIPTION VSS 1501 VSS1801

QTY VPN QTY VPN220 END PLATE 1 25661A 1 25661A221 SHAFT. 2 25793A 2 25793A222 GEAR. 4 25027A 4 25027A226 RACK CLAMP. 4 25913C 4 25913C228 SPACER. 4 25033C 4 25033C267 DOWEL PIN. 2 2868B 2 2868B268 EXPANSION PIN. 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA270 PIPE PLUG. 2 2606A 2 2606A286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F297 SET SCREW 2 2060J 2 2060J298 SET SCREW 2 2060H 2 2060H

NOTE: * Not pictured

VSS

&

VSR

PartsList

118

Cap

acity

Slid

e

Volu

me

Slid

e

Car

riag

e Ass

embl

y

Slide Valve Carriage Assembly

119


MODEL NUMBER

ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS601

QTY VPN QTY VPN QTY VPN QTY VPN300 CARRIAGE ASSEMBLY. 1 A25179B 1 A25179B 2 A25179B 2 A25179B304 CAPACITY PISTON 340, 341, 350 & 355. 1 A25183B 1 A25183B 2 A25183B 2 A25183B305 VOLUME PISTON 340, 342, 350 & 355. 1 A25184B 1 A25184B 2 A25184B 2 A25184B307 GASKET SET 345B. 0 n/a 0 n/a 2 A25200B 2 A25200B316 RACK. 1 25024A 1 25024A 2 25024A 2 25024A323 RACK. 1 25023A 1 25023A 2 25023A 2 25023A340 PISTON. 2 25017A 2 25017A 4 25017A 4 25017A341 CAPACITY PISTON SHAFT. 1 25019A 1 25019A 2 25019A 2 25019A342 VOLUME PISTON SHAFT. 1 25018A 1 25018A 2 25018A 2 25018A343A COVER, SEPARATE VOL. & CAP. 0 n/a 0 n/a 4 25022A 4 25022A343B COVER, ONE PIECE CAST. 0 n/a 0 2 25399A 2 25399A345A GASKET, SEPARATE VOL. & n/a

CAP COVERS. 0 n/a 0 n/a 4 25021A 4 25021A345B GASKET, ONE PIECE CAST COVER. 0 n/a 0 n/a 2 25900A 2 25900A350 PISTON RING SET. 2 2953AA 2 2953AA 4 2953AA 4 2953AA355 EXPANSION PIN. 2 1193PP 2 1193PP 4 1193PP 4 1193PP359 PIPE PLUG. 3 2606D 3 2606D 6 2606D 6 2606D360 LOCK WASHER (PAIR). 2 3004C 2 3004C 4 3004C 4 3004C361 WASHER. 2 13265B 2 13265B 4 13265B 4 13265B363 NUT. 4 2797A 4 2797A 8 2797A 8 2797A366A HEX HEAD CAP SCREW, SEPARATE

VOL. & CAP COVERS. 0 n/a 0 n/a 24 2796N 24 2796N366B HEX HEAD CAP SCREW, ONE PIECE

CAST COVER. 0 n/a 0 n/a 24 2796B 24 2796B372 SOCKET HEAD CAP SCREW. 0 n/a 0 n/a 2 2795M 2 2795M373 SOCKET HEAD CAP SCREW. 3 2795V 3 2795V 4 2795N 4 2795N374 LOCK WASHER (PAIR). 3 3004C 3 3004C 3 3004C 3 3004C

VSS

&

VSR

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120


QTY VPN QTY VPN QTY VPN QTY VPN300 CARRIAGE ASSEMBLY. 2 A25179C 2 A25179C 2 A25179D 2 A25179D304 CAPACITY PISTON 340, 341, 350 & 355. 2 A25183C 2 A25183C 2 A25183D 2 A25183D305 VOLUME PISTON 340, 342, 350 & 355. 2 A25184C 2 A25184C 2 A25184D 2 A25184D307 GASKET SET 345B & 378**. 2 A25200C 2 A25200C 2 A25200D 2 A25200D316 RACK. 2 25080A 2 25080A 2 25080C 2 25080C323 RACK. 2 25080B 2 25080B 2 25080D 2 25080D340 PISTON. 4 25076A 4 25076A 4 25138A 4 25138A341 CAPACITY PISTON SHAFT. 2 25078A 2 25078A 2 25078E 2 25078E342 VOLUME PISTON SHAFT. 2 25078B 2 25078B 2 25078F 2 25078F343A COVER, SEPARATE VOL. & CAP. 2 25123B 2 25123B 4 25123C 4 25123C343B COVER, ONE PIECE CAST. 2 25279A 2 25279A 2 25401A 2 25401A344 COVER, SEPARATE VOL. & CAP. 2 25123A 2 25123A n/a n/a n/a n/a345A GASKET, SEPARATE VOL. &

CAP COVERS. 2 25124B 2 25124B 4 25124C 4 25124C345B GASKET ONE PIECE CAST COVER. 2 25902A 2 25902A 2 25901A 2 25901A346 GASKET, SEPARATE VOL. & CAP

COVERS. 2 25124A 2 25124A n/a n/a n/a n/a347 PISTON SLEEVE. 2 25079A 2 25079A n/a n/a n/a n/a350 PISTON RING SET. 4 2953AB 4 2953AB 4 2953AC 4 2953AC355 EXPANSION PIN. 4 1193PP 4 1193PP 4 1193PP 4 1193PP359 PIPE PLUG. 6 2606D 6 2606D 6 2606E 6 2606E360 LOCK WASHER (PAIR). 4 3004C 4 3004C 4 3004C 4 3004C361 WASHER. 4 13265B 4 13265B 4 13265B 4 13265B363 NUT. 8 2797A 8 2797A 8 2797A 8 2797A366A HEX HEAD CAP SCREW. 12 2796B 12 2796B 24 2796B 24 2796B366B HEX HEAD CAP SCREW. 12 2796P 12 2796P 24 2796P 24 2796P367 HEX HEAD CAP SCREW. 12 2796BN 12 2796BN n/a n/a n/a n/a373 SOCKET HEAD CAP SCREW. 6 2795N 6 2795N 6 2795P 6 2795P374 LOCK WASHER (PAIR). 6 3004C 6 3004C 6 3004D 6 3004D378 0-RING. 2 2176Y 2 2176Y n/a n/a n/a n/a380 RETAINER RING. 2 2866C 2 2866C n/a n/a n/a n/a


121


MODEL NUMBERITEM DESCRIPTION VSS 1501 VSS 1801

QTY VPN QTY VPN300 CARRIAGE ASSEMBLY. 2 A25179E 2 A25179E304 CAPACITY PISTON 340, 341, 350 & 355. 2 A25183E 2 A25183E305 VOLUME PISTON 340, 342, 350 & 355. 2 A25184E 2 A25184E307 GASKET SET 345 & 378. 2 A25200E 2 A25200E316 RACK. 2 25779A 2 25779A323 RACK. 2 25780A 2 25780A325 SHAFT. 2 25778A 2 25778A340 PISTON. 4 25782A 4 25782A341 CAPACITY PISTON SHAFT. 2 25784A 2 25784A342 VOLUME PISTON SHAFT. 2 25783A 2 25783A343B COVER. 2 25690A 2 25690A345B GASKET. 2 25384A 2 25384A347 PISTON SLEEVE. 4 25786A 4 25786A350 PISTON RING SET. 4 2953AD 4 2953AD355 EXPANSION PIN. 4 1193PP 4 1193PP359 PIPE PLUG. 6 2606E 6 2606E360 LOCK WASHER (PAIR). 4 3004C 4 3004C361 WASHER. 4 13265B 4 13265B363 NUT. 8 2797A 8 2797A366B HEX HEAD CAP SCREW. 28 2796BL 28 2796BL373 SOCKET HEAD CAP SCREW. 6 2795AG 6 2795AG374 LOCK WASHER (PAIR). 6 3004D 6 3004D378 0-RING. 4 2176AG 4 2176AG380 RETAINER RING. 4 2755AG 4 2755AG

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Capacity Control Actuating Motor andCommand Shaft

Note: Steel Bushing until 10/25/04then modified housing

See noteabove

New housing designstarting 10/25/04 for all

command shaft assemblies.

Optical Actuator

123

MODEL NUMBERITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS601

QTY VPN QTY VPN QTY VPN QTY VPN

GEAR MOTOR REPLACEMENT (410, 440, 455, 475). 1 KT720A 1 KT720A 1 KT720A 1 KT720AGEAR MOTOR REPLACEMENT (DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B 1 KT720B 1 KT720BRETROFIT GEAR MOTOR ASSEMBLYFOR UNITS BUILT BEFORE 5-1-95. * 1 A25819B 1 A25819B 1 A25819B 1 A25819BRETROFIT GEAR MOTOR ASSEMBLY FOR UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25860B 1 A25860B 1 A25860B 1 A25860B

410 GEAR MOTOR. 1 25380A 1 25380A 1 25380A 1 25380A410A GEAR MOTOR (DIV. 2). 1 25868A 1 25868A 1 25868A 1 25868A411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A412 BEARING HOUSING. 1 25364A 1 25364A 1 25364A 1 25364A413 COMMAND SHAFT. 1 25382A 1 25382A 1 25375A 1 25375A413A COMMAND SHAFT, RETROFIT. 1 25803A 1 25803A 1 25803A 1 25803A414 COUPLING, RETROFIT 1 25032A 1 25032A 1 25032A 1 25032A415 MOUNTING PLATE. 1 25805A 1 25805A 1 25805A 1 25805A416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A416A COVER STEEL (DIV. 2). 1 25535A 1 25535A 1 25535A 1 25535A419 POTENTIOMETER. 1 2935D 1 2935D 1 2935D 1 2935D420 MOTOR SHAFT GEAR. 1 25029A 1 25029A 1 25029A 1 25029A421 COMMAND SHAFT GEAR. 1 25806A 1 25806A 1 25806A 1 25806A422 GEAR. 1 25832A 1 25832A 1 25832A 1 25832A424 GEAR. 1 2107B 1 2107B 1 2107B 1 2107B426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A432 CLAMP FOR ITEM 424. 1 2013A 1 2013A 1 2013A 1 2013A433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A 1 2908A 1 2908A436** SLEEVE BEARING. 1 25853B 1 25853B 1 25853B 1 25853B 1440 PUSH-ON RETAINER. 1 2866F 1 2866F 1 2866F 1 2866F445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C 1 2867C 1 2867C455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN 4 2795AN 4 2795AN456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M 4 2795M 4 2795M465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE466 HEX HEAD CAP SCREW. 6 2583C 6 2583C 6 2583C 6 2583C470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT475 LOCK WASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A476 LOCK WASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B477 LOCK WASHER (PAIR). 8 3004C 8 3004C 8 3004C 8 3004C480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D491 ROLL PIN. 1 2981AA 1 2981AA 1 2981AA 1 2981AA492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E

Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer tonew style gear drive potentiometer. Less items 416, 429 & 466.

** Item 412 was modified to remove sleeve bearing.


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MODEL NUMBERITEM DESCRIPTION VSS 751 VSS 901 VSS 1051 VSS 1201

QTY VPN QTY VPN QTY VPN QTY VPNGEAR MOTOR REPLACEMENT(410, 440, 455, 475). 1 KT720A 1 KT720A 1 KT720A 1 KT720AGEAR MOTOR REPLACEMENT(DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B 1 KT720B 1 KT720BRETROFIT GEAR MOTOR ASSEMBLYFOR UNITS BUILT BEFORE 5-1-95. * 1 A25819C 1 A25819C 1 A25819D 1 A25819DRETROFIT GEAR MOTOR ASSEMBLYFOR UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25860C 1 A25860C 1 A25860D 1 A25860D

410 GEAR MOTOR. 1 25380A 1 25380A 1 25380A 1 25380A410A GEAR MOTOR (DIV. 2). 1 25868A 1 25868A 1 25868A 1 25868A411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A412 BEARING HOUSING. 1 25364A 1 25364A 1 25364A 1 25364A413 COMMAND SHAFT. 1 25376A 1 25376A 1 25377A 1 25377A413A COMMAND SHAFT, RETROFIT. 1 25810A 1 25810A 1 25811A 1 25811A414 COUPLING, RETROFIT 1 25032A 1 25032A 1 25032A 1 25032A415 MOUNTING PLATE. 1 25805A 1 25805A 1 25805A 1 25805A416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A416A COVER STEEL (DIV. 2). 1 25535A 1 25535A 1 25535A 1 25535A419 POTENTIOMETER. 1 2935D 1 2935D 1 2935D 1 2935D420 MOTOR SHAFT GEAR. 1 25029A 1 25029A 1 25029A 1 25029A421 COMMAND SHAFT GEAR. 1 25806A 1 25806A 1 25806A 1 25806A422 GEAR. 1 25832A 1 25832A 1 25832A 1 25832A424 GEAR. 1 2107B 1 2107B 1 2107B 1 2107B426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A432 CLAMP FOR ITEM 424. 1 2013A 1 2013A 1 2013A 1 2013A433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A 1 2908A 1 2908A436** SLEEVE BEARING. 1 25853B 1 25853B 1 25853B 1 25853B440 PUSH-ON RETAINER. 1 2866F 1 2866F 1 2866F 1 2866F445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C 1 2867C 1 2867C455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN 4 2795AN 4 2795AN456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M 4 2795M 4 2795M465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE466 HEX HEAD CAP SCREW. 6 2583C 6 2583C 6 2583C 6 2583C470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT475 LOCK WASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A476 LOCK WASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B477 LOCK WASHER (PAIR). 8 3004C 8 3004C 8 3004C 8 3004C480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D491 ROLL PIN. 1 2981AA 1 2981AA 1 2981AA 1 2981AA492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E

Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer tonew style gear drive potentiometer. Less items 416, 429 & 466.

** Item 412 was modified to remove the sleeve bearing.

125



QTY VPN QTY VPNGEAR MOTOR REPLACEMENT (410, 440, 455, 475). 1 KT720A 1 KT720AGEAR MOTOR REPLACEMENT (DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B

410 GEAR MOTOR. 1 25380A 1 25380A410A GEAR MOTOR (DIV. 2). 1 25868A 1 25868A411 MOTOR MOUNT. 1 25374A 1 25374A412 BEARING HOUSING. 1 25364A 1 25364A413 COMMAND SHAFT. 1 25369A 1 25369A415 MOUNTING PLATE. 1 25805A 1 25805A416 COVER PLASTIC. 1 25697A 1 25697A416A COVER STEEL (DIV. 2). 1 25535A 1 25535A419 POTENTIOMETER. 1 2935D 1 2935D420 MOTOR SHAFT GEAR. 1 25029A 1 25029A421 COMMAND SHAFT GEAR. 1 25806A 1 25806A422 GEAR. 1 25832A 1 25832A424 GEAR. 1 2107B 1 2107B426 KEY. 1 25039BC 1 25039BC427 KEY. 1 25039BC 1 25039BC428 BRACKET. 1 25804A 1 25804A429 GASKET. 1 25757A 1 25757A430 BUSHING. 1 25809A 1 25809A431 SPACER. 1 25830A 1 25830A432 CLAMP FOR ITEM 424. 1 2013A 1 2013A433 BUSHING (DIV. 2). 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A436** SLEEVE BEARING. 1 25853A 1 25853B440 PUSH-ON RETAINER. 1 2866F 1 2866F445 O-RING. 1 2176W 1 2176W445A O-RING (DIV. 2). 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE466 HEX HEAD CAP SCREW. 6 2583C 6 2583C470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT475 LOCK WASHER (PAIR). 4 3004A 4 3004A476 LOCK WASHER (PAIR). 3 3004B 3 3004B477 LOCK WASHER (PAIR). 8 3004C 8 3004C480 WASHER. 1 2906AA 1 2906AA485 JAM NUT. 1 13283A 1 13283A492 DOWEL PIN. 1 2868J 1 2868J497 PIPE PLUG. 1 2606E 1 2606E

** Note: Item 412 was modified to remove the sleeve bearing.

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Slide Valve Actuating Motorand Command shaft

Before 5-1-95

429

450

425

418

452

412

430

439

431

440

410

447446

419

417

458

443

459

458

416420 421OR

408

408

463451

407

403

405

404

454419

443

455

463

415

453 435

438

411

2 O-RINGS ONLYIF SPECIFIED.

127

Slide Valve Actuating Motorand Command shaft

Before 5-1-95

MODEL NUMBERITEM DESCRIPTION

VSR 111-301 VSS 451-601 VSS 751-901 VSS 1201QTY 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/a404 MOUNTING BLOCK. n/a n/a n/a n/a n/a n/a n/a n/a405 MOTOR BRACKET. n/a n/a n/a n/a n/a n/a n/a n/a406 CLIP. n/a n/a n/a n/a n/a n/a n/a n/a407 COLLAR. n/a n/a n/a n/a n/a n/a n/a n/a408 LOCKING TAB. n/a n/a n/a n/a n/a n/a n/a n/a410 BEARING HOUSING. n/a n/a n/a n/a n/a n/a n/a n/a411 SHAFT. n/a n/a n/a n/a n/a n/a n/a n/a412 COUPLING. 2 25032A 2 25032A 2 25032A 2 25032A415 PLATE. n/a n/a n/a n/a n/a n/a n/a n/a416 GEAR. 2 25029A 2 25029A 2 25029A 2 25029A417 GEAR. n/a n/a n/a n/a n/a n/a n/a n/a418 COVER. 2 25697A 2 25697A 2 25697A 2 25697A419 KEY. 4 25039BC 4 25039BC 4 25039BC 4 25039BC420 POSITION INDICATOR, CAPACITY. n/a n/a n/a n/a n/a n/a n/a n/a421 POSITION INDICATOR, VOLUME. n/a n/a n/a n/a n/a n/a n/a n/a425 POTENTIOMETER. n/a n/a n/a n/a n/a n/a n/a n/a429 GASKET. 2 25757A 2 25757A 2 25757A 2 25757A430 O-RING. 2 2176W 2 2176W 2 2176W 2 2176W431 O-RING. 2 2176X 2 2176X 2 2176X 2 2176X435 BALL BEARING. 2 2908A 2 2908A 2 2908A 2 2908A438 RETAINER RING. 2 2866D 2 2866D 2 2866D 2 2866D439 RETAINER RING. 2 2867C 2 2867C 2 2867C 2 2867C440 WASHER. 2 2906AA 2 2906AA 2 2906AA 2 2906AA443 PUSH ON RETAINER. 4 2866F 4 2866F 4 2866F 4 2866F446 EXPANSION PIN. 2 1193D 2 1193D 2 1193D 2 1193D447 EXPANSION PIN. 2 2981AA 2 2981AA 2 2981AA 2 2981AA450 NUT. 4 1393E 4 1393E 4 1393E 4 1393E451 SOCKET HEAD CAP SCREW. 8 2795Z 8 2795Z 8 2795Z 8 2795Z452 HEX HEAD CAP SCREW. 12 2583C 12 2583C 12 2583C 12 2583C453 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE454 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB 4 2795AB 4 2795AB455 SOCKET HEAD CAP SCREW. 8 2795L 8 2795L 8 2795L 8 2795L458 SOCKET HEAD SET SCREW. 4 2060F 4 2060F 4 2060F 4 2060F459 SOCKET HEAD SET SCREW. 2 2060E 2 2060E 2 2060E 2 2060E463 WASHER. 8 2880E 8 2880E 8 2880E 8 2880E

NOTE: * Not pictured.n/a No longer available, contact Home Office.

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Volume Ratio Control Actuating Motorand Command Shaft

Optical Actuator

Note: Steel Bushing until 10/25/04then modified housing

New housing designstarting 10/25/04 for all

command shaft assemblies.

See Noteabove

See page 122 for assembly

129


MODEL NUMBERITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS 601

QTY VPN QTY VPN QTY VPN QTY VPNGEAR MOTOR REPLACEMENT(410, 440, 455, 475). 1 KT720C 1 KT720C 1 KT720C 1 KT720CGEAR MOTOR REPLACEMENT (DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D 1 KT720D 1 KT720DRETROFIT GEAR MOTOR ASSEMBLYFOR UNITS BUILT BEFORE 5-1-95. * 1 A25820B 1 A25820B 1 A25820B 1 A25820BRETROFIT GEAR MOTOR ASSEMBLY FOR UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25861B 1 A25861B 1 A25861B 1 A25861B

410 GEAR MOTOR. 1 25379A 1 25379A 1 25379A 1 25379A410A GEAR MOTOR (DIV. 2). 1 25867A 1 25867A 1 25867A 1 25867A411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A412 BEARING HOUSING. 1 25364A 1 25364A 1 25364A 1 25364A413 COMMAND SHAFT. 1 25375A 1 25375A 1 25375A 1 25375A413A COMMAND SHAFT, RETROFIT. 1 25803A 1 25803A 1 25803A 1 25803A414 COUPLING, RETROFIT 1 25032A 1 25032A 1 25032A 1 25032A415 MOUNTING PLATE. 1 25805A 1 25805A 1 25805A 1 25805A416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A416A COVER STEEL (DIV. 2). 1 25535A 1 25535A 1 25535A 1 25535A419 POTENTIOMETER. 1 2935D 1 2935D 1 2935D 1 2935D420 MOTOR SHAFT GEAR. 1 25029A 1 25029A 1 25029A 1 25029A421 COMMAND SHAFT GEAR. 1 25806A 1 25806A 1 25806A 1 25806A423 GEAR. 1 25831A 1 25831A 1 25831A 1 25831A425 GEAR. 1 2107A 1 2107A 1 2107A 1 2107A426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A432 CLAMP FOR ITEM 424. 1 2013A 1 2013A 1 2013A 1 2013A433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A 1 2908A 1 2908A436** SLEEVE BEARING. 1 25853B 1 25853B 1 25853B 1 25853B440 PUSH-ON RETAINER. 1 2866F 1 2866F 1 2866F 1 2866F445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C 1 2867C 1 2867C455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN 4 2975AN 4 2975AN456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M 4 2795M 4 2795M465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE466 HEX HEAD CAP SCREW. 6 2583C 6 2583C 6 2583C 6 2583C470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT475 LOCKWASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A476 LOCKWASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B477 LOCKWASHER (PAIR). 8 3004C 8 3004C 8 3004C 8 3004C480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D491 ROLL PIN. 1 2981AA 1 2981AA 1 2981AA 1 2981AA492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E

Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to newstyle gear drive potentiometer. Less items 416, 429 & 466.


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MODEL NUMBERITEM DESCRIPTION VSS 751 VSS 901 VSS 1051 VSS 1201

QTY VPN QTY VPN QTY VPN QTY VPNGEAR MOTOR REPLACEMENT(410, 440, 455, 475). 1 KT720C 1 KT720C 1 KT720C 1 KT720CGEAR MOTOR REPLACEMENT (DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D 1 KT720D 1 KT720DRETROFIT GEAR MOTOR ASSEMBLY FORUNITS BUILT BEFORE 5-1-95. * 1 A25820C 1 A25820C 1 A25820D 1 A25820DRETROFIT GEAR MOTOR ASSEMBLY FOR UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25861C 1 A25861C 1 A25861D 1 A25861D

410 GEAR MOTOR. 1 25379A 1 25379A 1 25379A 1 25379A410A GEAR MOTOR (DIV. 2). 1 25867A 1 25867A 1 25867A 1 25867A411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A412 BEARING HOUSING. 1 25364A 1 25364A 1 25364A 1 25364A413 COMMAND SHAFT. 1 25376A 1 25376A 1 25377A 1 25377A413A COMMAND SHAFT, RETROFIT. 1 25810A 1 25810A 1 25811A 1 25811A414 COUPLING, RETROFIT 1 25032A 1 25032A 1 25032A 1 25032A415 MOUNTING PLATE. 1 25805A 1 25805A 1 25805A 1 25805A416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A416A COVER STEEL (DIV. 2). 1 25535A 1 25535A 1 25535A 1 25535A419 POTENTIOMETER. 1 2935D 1 2935D 1 2935D 1 2935D420 MOTOR SHAFT GEAR. 1 25029A 1 25029A 1 25029A 1 25029A421 COMMAND SHAFT GEAR. 1 25806A 1 25806A 1 25806A 1 25806A423 GEAR. 1 25831A 1 25831A 1 25831A 1 25831A425 GEAR. 1 2107A 1 2107A 1 2107A 1 2107A426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A432 CLAMP FOR ITEM 424. 1 2013A 1 2013A 1 2013A 1 2013A433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A 1 2908A 1 2908A436** SLEEVE BEARING. 1 25853B 1 25853B 1 25853B 1 25853B440 PUSH-ON RETAINER. 1 2866F 1 2866F 1 2866F 1 2866F445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C 1 2867C 1 2867C455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN 4 2975AN 4 2975AN456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M 4 2795M 4 2795M465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE466 HEX HEAD CAP SCREW. 6 2583C 6 2583C 6 2583C 6 2583C470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT475 LOCKWASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A476 LOCKWASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B477 LOCKWASHER (PAIR). 8 3004C 8 3004C 8 3004C 8 3004C480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D491 ROLL PIN. 1 2981AA 1 2981AA 1 2981AA 1 2981AA492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E

Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometerto new style gear drive potentiometer. Less items 416, 429 & 466.


131



QTY VPN QTY VPNGEAR MOTOR REPLACEMENT(410, 440, 455, 475). 1 KT720C 1 KT720CGEAR MOTOR REPLACEMENT(DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D

410 GEAR MOTOR. 1 25379A 1 25379A410A GEAR MOTOR (DIV. 2). 1 25867A 1 25867A411 MOTOR MOUNT. 1 25374A 1 25374A412 BEARING HOUSING. 1 25364A 1 25364A413 COMMAND SHAFT. 1 25369A 1 25369A415 MOUNTING PLATE. 1 25805A 1 25805A416 COVER. 1 25697A 1 25697A416A COVER STEEL (DIV. 2). 1 25535A 1 25535A419 POTENTIOMETER. 1 2935D 1 2935D420 MOTOR SHAFT GEAR. 1 25029A 1 25029A421 COMMAND SHAFT GEAR. 1 25806A 1 25806A423 GEAR. 1 25831A 1 25831A425 GEAR. 1 2107A 1 2107A426 KEY. 1 25039BC 1 25039BC427 KEY. 1 25039BC 1 25039BC428 BRACKET. 1 25804A 1 25804A429 GASKET. 1 25757A 1 25757A430 BUSHING. 1 25809A 1 25809A431 SPACER. 1 25830A 1 25830A432 CLAMP FOR ITEM 424. 1 2013A 1 2013A433 BUSHING (DIV. 2). 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A436** SLEEVE BEARING. 1 25853B 1 25853B440 PUSH-ON RETAINER. 1 2866F 1 2866F445 O-RING. 1 2176W 1 2176W445A O-RING (DIV. 2). 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE466 HEX HEAD CAP SCREW. 6 2583C 6 2583C470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT475 LOCKWASHER (PAIR). 4 3004A 4 3004A476 LOCKWASHER (PAIR). 3 3004B 3 3004B477 LOCKWASHER (PAIR). 8 3004C 8 3004C480 WASHER. 1 2906AA 1 2906AA485 JAM NUT. 1 13283A 1 13283A492 DOWEL PIN. 1 2868J 1 2868J497 PIPE PLUG. 1 2606E 1 2606E


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Miscellaneous Frame Components Tubing and Fittings

559 560

567

559 560 561

558

568567

556

555

555OR

555

558

555

555

555

563

564555555

565

566

555

Slide Valve Piston Equalizing LinesVSS 451&VSS 601 VSS 1051&VSS1201VSS 751&VSS 901

Seal Chamber Oil LineVSS 451&VSS1201 VSS 1501&VSS 1801

Gate Rotor Bearing Supply LinesVSR 111&VSR 301 VSS 451-VSS 1801

133

Miscellaneous Frame Components Tubing and Fittings

MODEL NUMBERITEM DESCRIPTION VSR 111-VSR 221 VSR 151-VSR 301 VSS 451 VSS 601

QTY VPN QTY VPN QTY VPN QTY VPN555 ELBOW . 2 13375D 2 13375D 5 13375D 5 13375D556 STRAIGHT. n/a n/a n/a n/a 1 13229D 1 13229D557 TEE, RUNNING. n/a n/a n/a n/a 1 1509A 1 1509A558 HEX BUSHING. 1 13231AA 1 13231AA 1 13231AA 1 13231AA560 ELBOW. n/a n/a n/a n/a 1 13375Z 1 13375Z561 ELBOW. n/a n/a n/a n/a 1 13375F 1 13375F562 PLUG. n/a n/a n/a n/a 1 2606E 1 2606E


QTY VPN QTY VPN QTY VPN QTY VPN555 ELBOW. 5 13375D 5 13375D 3 13375D 3 13375D556 STRAIGHT. 1 13229D 1 13229D 2 13229D 2 13229D557 TEE, RUNNING. 1 1509A 1 1509A 1 1509A 1 1509A558 HEX BUSHING. 1 13231AA 1 13231AA 1 1101H 1 1101H559 HEX BUSHING. 0 n/a 0 n/a 1 1101K 1 1101K560 ELBOW. 1 13375Z 1 13375Z 1 13375Z 1 13375Z561 ELBOW. 1 13375F 1 13375F 1 13375F 1 13375F562 PLUG. 1 2606E 1 2606E 1 2606A 1 2606A563 TEE. n/a n/a n/a n/a 2 13376D 2 13376D564 TEE. n/a n/a n/a n/a 1 13239C 1 13239C565 TEE. 2 1884A 2 1884A n/a n/a n/a n/a566 NIPPLE. 2 13181D 2 13181D n/a n/a n/a n/a


QTY VPN QTY VPN555 ELBOW. 2 13375D 2 13375D557 TEE, RUNNING. 1 13376D 1 13376D558 HEX BUSHING. 1 13231AA 1 13231AA559 HEX BUSHING. 1 1101H 1 1101H560 ELBOW. 1 13375Z 1 13375Z567 CONNECTOR. 1 13299C 1 13299C568 REDUCING BUSHING. 1 1101M 1 1101M

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Miscellaneous Frame Components

VSS Screw Compressor

VSR Mini Screw Compressor

135


MODEL NUMBER

ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS601QTY VPN QTY VPN QTY VPN QTY VPN

GASKET AND O-RING KIT; n/a n/a n/a n/a 1 KT710A 1 KT710A504 FLANGE SET 513, 514 & 547A. 1 A25190A 1 A25190A 1 A25190A 1 A25190A

ECON-O-MIZER PORT. n/a n/a n/a n/a 2 A25190B 2 A25190B506 ECON-O-MIZER PLUG. 1 A25243BD 1 A25243BC

511 DISCHARGE MANIFOLD. 1 25634A 1 25634A 1 25502A 1 25502A512 MANIFOLD GASKET. 1 25648A 1 25648A 1 25503A 1 25503A513 FLANGE OIL. 1 25058A 1 25058A 1 25058A 1 25058A513A FLANGE ECON-O-MIZER. n/a n/a n/a n/a 2 25058A 2 25058A514 FLANGE GASKET OIL. 1 11323D 1 11323D 1 11323D 1 11323D514A FLANGE GASKET ECON-O-MIZER. n/a n/a n/a n/a 2 11323D 2 11323D515 KEY. 1 25039AA 1 25039AA 1 13396R 1 13396R518 SUCTION FLANGE GASKET. 1 11323L 1 11323L 1 25199C 1 25199C519 DISCHARGE FLANGE GASKET. 1 11323J 1 11323J 1 25199B 1 25199B522 LOCKING WASHER. n/a n/a n/a n/a 1 25004A 1 25004A523 LOCKING TAB. n/a n/a n/a n/a 1 25005A 1 25005A524 COVER. 1 25346A 1 25346A n/a n/a n/a n/a525 GASKET. 1 11323L 1 11323L n/a n/a n/a n/a527 INLET SCREEN. 1 2881E 1 2881E n/a n/a n/a n/a528 ECON-O-MIZER PLUG. 1 25240B 1 25240A n/a n/a n/a n/a530 O-RING 2 2176AB 2 2176AB 2 2176AB 2 2176AB532 O-RING. 2 2176BA 2 2176BA n/a n/a n/a n/a535 PIPE PLUG 1/4" MPT. 1 2606C 1 2606C n/a n/a n/a n/a535 PIPE PLUG 3/8" MPT. 1 2606D 1 2606D 2 2606D 2 2606D536 PIPE PLUG 1/2" MPT. 6 2606E 6 2606E 11 2606E 11 2606E537 PIPE PLUG 1-1/4" MPT. n/a n/a n/a n/a 2 13163G 2 13163G539 PIPE PLUG. 1 13264F 1 13264F n/a n/a n/a n/a540 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B541 SET SCREW. n/a n/a n/a n/a 1 13298G 1 13298G545 HEX HEAD CAP SCREW FOR OIL n/a n/a n/a n/a n/a n/a n/a n/a

SUPPLY FLANGE. 2 2796C 2 2796C 2 2796C 2 2796C545 HEX HEAD CAP SCREW FOR n/a n/a n/a n/a n/a n/a n/a n/a

ECON-O-MIZER FLANGE. n/a n/a n/a n/a 4 2796C 4 2796C547 HEX HEAD CAP SCREW. 15 2796F 15 2796F 8 2796C 8 2796C548 HEX HEAD CAP SCREW. n/a n/a n/a n/a 4 2796GQ 4 2796GQ549 HEX HEAD CAP SCREW. 2 2796GZ 2 2796GZ 2 2796GZ 2 2796GZ550 HEX HEAD CAP SCREW. 2 2796GAF 2 2796GAF 2 2796GAF 2 2796GAF551 HEX HEAD CAP SCREW. 2 2796GP 2 2796GP 2 2796GP 2 2796GP552 HEX HEAD CAP SCREW. 8 2796C 8 2796C n/a n/a n/a n/a552 HEX HEAD CAP SCREW. 2 2796HJ 2 2796HJ n/a n/a n/a n/a553 HEX HEAD CAP SCREW. 4 2796HM 4 2796HM n/a n/a n/a n/a554 HEX HEAD CAP SCREW. n/a n/a n/a n/a 1 2796U 1 2796U569 PIPE PLUG 1/4" MPT. n/a n/a n/a n/a 2 2606C 2 2606C650 O-RING. 2 2176AZ 2 2176AZ n/a n/a n/a n/a651 O-RING. 1 2176AB 1 2176AB n/a n/a n/a n/a

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QTY VPN QTY VPN QTY VPN QTY VPNGASKET 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 A25190B504 FLANGE SET 513A, 514A & 547

ECON-O-MIZER PORT. 2 A25190B 2 A25190B 2 A25190B 2 A25190B511 DISCHARGE MANIFOLD. 1 25540A 1 25540A 1 25597A 1 25597A512 MANIFOLD GASKET. 1 25541A 1 25541A 1 25324A 1 25324A513 FLANGE OIL. 1 25058A 1 25058A 1 25058B 1 25058B513A FLANGE ECON-O-MIZER. 2 25058A 2 25058A 2 25058B 2 25058B514 FLANGE GASKET OIL. 1 11323D 1 11323D 1 11323E 1 11323E514A FLANGE GASKET ECON-O-MIZER. 2 11323D 2 11323D 2 11323E 2 11323E515 KEY. 1 13396S 1 13396S 1 13396S 1 13396S518 SUCTION FLANGE GASKET. 1 25199C 1 25199C 1 25199D 1 25199D519 DISCHARGE FLANGE GASKET. 1 25199B 1 25199B 1 25199C 1 25199C522 LOCKING WASHER. 1 25004A 1 25004A 1 25004A 1 25004A523 LOCKING TAB. 1 25005A 1 25005A 1 25005A 1 25005A526 ORIFICE PLATE. 1 25223CB 1 25223CA 1 25223DB 1 25223DB529 WAVE SPRING. 1 2912E 1 2912E 1 2912E 1 2912E530 O-RING 2 2176J 2 2176J 2 2176J 2 2176J535 PIPE PLUG 3/8" MPT. 2 2606D 2 2606D 2 2606D 2 2606D536 PIPE PLUG 1/2" MPT. 8 2606E 8 2606E 4 2606E 4 2606E537 PIPE PLUG 1-1/4" MPT. 2 13163G 2 13163G 2 13163G 2 13163G538 PIPE PLUG 3/4" MPT. 6 2606A 6 2606A540 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B541 SET SCREW. 1 13298G 1 13298G 1 13298G 1 13298G545 HEX HEAD CAP SCREW FOR OIL

SUPPLY FLANGE. 2 2796C 2 2796C 2 2796C 2 2796C545 HEX HEAD CAP SCREW FOR

ECON-O-MIZER FLANGE. 4 2796C 4 2796C 4 2796C 4 2796C547 HEX HEAD CAP SCREW. 21 2796GP 21 2796GP 24 2796GP 24 2796GP548 HEX HEAD CAP SCREW. 2 2796GAB 2 2796GAB 2 2796GAB 2 2796GAB549 HEX HEAD CAP SCREW. 2 2796GAE 2 2796GAE 2 2796GAE 2 2796GAE554 HEX HEAD CAP SCREW. 1 2796U 1 2796U 1 2796U 1 2796U569 PIPE PLUG 1/4" MPT. 2 2606C 2 2606C 2 2606C 2 2606C

NOTE: ** For VSS 1051 Econ-o-Mizer model.

137



QTY VPN QTY VPNGASKET AND O-RING KIT; 1 KT710D 1 KT710D

504 FLANGE SET 513, 514 & 547. 1 A25190C 1 A25190C504 FLANGE SET 513A, 514A & 547

ECON-O-MIZER PORT. 2 A25190D 2 A25190D511 DISCHARGE MANIFOLD. 1 25663A 1 25663A512 MANIFOLD GASKET. 1 25676A 1 25676A513 FLANGE OIL. 1 12477C 1 12477C513A FLANGE ECON-O-MIZER.514 FLANGE GASKET OIL. 1 11323F 1 11323F514A FLANGE GASKET ECON-O-MIZER.515 KEY. 1 25039AC 1 25039AC518 SUCTION FLANGE GASKET. 1 25199D 1 25199D519 DISCHARGE FLANGE GASKET. 1 25199C 1 25199C522 LOCKING WASHER. 1 25004C 1 25004C523 LOCKING TAB. 1 25005C 1 25005C530 O-RING 2 2176J 2 2176J536 PIPE PLUG 1/2" MPT. 3 2606E 3 2606E537 PIPE PLUG 1-1/4" MPT. 2 13163G 2 13163G538 PIPE PLUG 3/4" MPT. 3 2606A 3 2606A540 DOWEL PIN. 2 2868K 2 2868K541 SET SCREW. 1 13298G 1 13298G542 PIPE PLUG 3/4" MPT. 1 13163F 1 13163F545 HEX HEAD CAP SCREW FOR

OIL SUPPLY FLANGE. 4 11397E 4 11397E545 HEX HEAD CAP SCREW FOR

ECON-O-MIZER FLANGE.548 HEX HEAD CAP SCREW. 26 2796HR 26 2796HR549 HEX HEAD CAP SCREW. 2 2796HAB 2 2796HAB550 HEX HEAD CAP SCREW. 2 2796HAF 2 2796HAF554 HEX HEAD CAP SCREW. 1 2796U 1 2796U569 PIPE PLUG 1/4" MPT. 2 2606C 2 2606C

NOTE: * Not pictured** For VSS 1801 Serial Numbers 819, 820 & 821 only.

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C-Flange Adapter Components

630

620

610

640

601

641

630601 620610

640

641

642

650

651

139

C-Flange Adapter Components

MODEL NUMBERITEM DESCRIPTION VSR 111 & VSR 221 VSR 151 & VSR 301

QTY VPN QTY VPN601 C-FLANGE ADAPTER.610 KEY. 1 25039AA 1 25039AA620 HEX HEAD CAP SCREW. 8 2796C 8 2796C630 LOCKWASHER (PAIR). 8 3004H 8 3004H640 CONNECTOR. 1 13229C 1 13229C641 TUBE 1/4" O.D. x 6" LONG. 0.5 Ft. S1589AA 0.5 Ft. S1589AA642 PIPE PLUG. 1 2606C 1 2606C650 O-RING. 2 2176AZ 2 2176AZ651 O-RING. 1 2176AB 1 2176AB

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Replacement PartsTools

141


MODEL NUMBER

ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS 601QTY 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 A25698B901B HEX HEAD CAP SCREW. 4 2796A 4 2796A 4 2796A 4 2796A901C RAIL, SIDE. 2 25698A 2 25698A 2 25698A 2 25698A910 PULLER BAR. 1 25204A 1 25204A 1 25204A 1 25204A911 PULLER SHOE. 1 25157A 1 25157A 1 25157A 1 25157A912 PUSHER SHOE. 1 25157B 1 25157B 1 25157B 1 25157B913 JACKING SCREW. 1 A25156B 1 A25156B 1 A25156B 1 A25156B914 GUIDE STUD. 1 25908A 1 25908A 1 25908A 1 25908A915 GUIDE STUD. 2 25908B 2 25908B 2 25908B 2 25908B916 STUD. 3 25908C 3 25908C 3 25908C 3 25908C917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W 2 2795W 2 2795W918 HEX NUT 3 13228F 3 13228F 3 13228F 3 13228F


QTY VPN QTY VPN QTY VPN QTY VPN900 GATEROTOR TOOLS (901, 910, 911,

912, 913, 914, 915, 916 & 917). 1 A25205C 1 A25205C 1 A25205C 1 A25205C901 GATEROTOR STABILIZER SET

(901A, 901B & 901C). 1 A25698A 1 A25698A 1 A25698A 1 A25698A901A GATEROTOR STABILIZER. 1 A25698B 1 A25698B 1 A25698B 1 A25698B901B HEX HEAD CAP SCREW. 4 2796A 4 2796A 4 2796A 4 2796A901C RAIL, SIDE. 2 25698A 2 25698A 2 25698A 2 25698A910 PULLER BAR. 1 25204B 1 25204B 1 25204B 1 25204B911 PULLER SHOE. 1 25157C 1 25157C 1 25157C 1 25157C912 PUSHER SHOE. 1 25157D 1 25157D 1 25157D 1 25157D913 JACKING SCREW. 1 A25156B 1 A25156B 1 A25156B 1 A25156B914 GUIDE STUD. 1 25908A 1 25908A 1 25908A 1 25908A915 GUIDE STUD. 2 25908B 2 25908B 2 25908B 2 25908B916 STUD. 2 25908C 2 25908C 2 25908C 2 25908C917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W 2 2795W 2 2795W918 HEX NUT 2 13228F 2 13228F 2 13228F 2 13228F

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QTY VPN QTY VPN900 GATEROTOR TOOLS (901, 910,

911, 912, 913, 914, 915, 916 & 917). 1 A25205E 1 A25205E901 GATEROTOR STABILIZER SET (

901A, 901B, 901C & 901D). 1 A25699A 1 A25699A901A GATEROTOR STABILIZER. 1 A25699B 1 A25699B901B HEX HEAD CAP SCREW. 4 2796A 4 2796A901C RAIL, SIDE. 2 25698C 2 25698C901D LOCK WASHER. 4 13165B 4 13165B910 PULLER BAR. 1 25204C 1 25204C911 PULLER SHOE. 1 25157E 1 25157E912 PUSHER SHOE. 1 25157F 1 25157F913 JACKING SCREW. 1 A25156B 1 A25156B914 GUIDE STUD. 1 25908A 1 25908A915 GUIDE STUD. 2 25908B 2 25908B916 STUD. 2 25908C 2 25908C917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W918 HEX NUT 2 13228F 2 13228F


143

VSM ReplacementParts Section

VSM Replacement Parts Section .............................................................................. 143Gaterotor Assembly ....................................................................................................................................................................... 144Shaft Seal ....................................................................................................................................................................................... 147Main Rotor, Slide Valve Cross Shafts and End Plate (Models 71-401) ..................................................................................... 148Main Rotor, Slide Valve Cross Shafts and End Plate (Models 501-701 .................................................................................... 152Slide Valve Carriage Assembly ..................................................................................................................................................... 154Actuating Motor with Optical Sensor and Command Shaft ........................................................................................................ 156Miscellaneous Frame Components ............................................................................................................................................... 158Replacement Parts Accessories ..................................................................................................................................................... 160Replacement Tools ......................................................................................................................................................................... 162

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Gaterotor Assembly

145

Gaterotor Assembly

Part totals indicated are for one gate rotor assembly, machines with two gate rotors will require double thecomponents listed below.

MODEL NUMBERITEM DESCRIPTION VSM-71, 151, 301 VSM-91, 181, 361 VSM-101, 201, 401

QTY VPN QTY VPN QTY VPN100 SUPPORT ASSEMBLY 110 & 135B. 1 A25222AB 1 A25222AA 1 A25222AC101 GATE ROTOR & DAMPER ASSEMBLY

111,120. 1 A25160AB 1 A25160AA A25160AC102 GATE ROTOR SUPPORT ASSEMBLY

100, 101, 119 & 130. 1 A25161AB 1 A25161AA A25161AC105 GATE ROTOR GASKET SET

141 & 143. 1 A25164A 1 A25164A A25164A106 SHIM PACK SET (2) 121, (2) 122,

(1) 123, (1) 124. 1 A25165A 1 A25165A A25165A110 SUPPORT. 1 25723D 1 25723C 1 25723B111 GATE ROTOR. 1 25718B 1 25718C 1 25718D112 SMALL BEARING HOUSING. 1 25407B 1 25407B 1 25407B114 SNAP RING. 1 2867L 1 2867L 1 2867L115 RETAINER BALL BEARING 1 25935A 1 25935A 1 25935A116 BALL BEARING SUPPORT. 1 25408B 1 25408B 1 25408B117 GATE ROTOR COVER. 1 25416B 1 25416B 1 25416B118 GATE ROTOR COVER GASKET. 1 25259B 1 25259B 1 25259B119 WASHER WAVE SPRING. 1 3203A 1 3203A 1 3203A120 DAMPER. 1 25760A 1 25760A 1 25760A121* SHIM 0.002". ar 25921AA ar 25921AA ar 25921AA122* SHIM 0.003". ar 25921AB ar 25921AB ar 25921AB123* SHIM 0.005". ar 25921AC ar 25921AC ar 25921AC124* SHIM 0.010". ar 25921AD ar 25921AD ar 25921AD125 ROLLER BEARING. 1 2864F 1 2864F 1 2864F126 BALL BEARING. 2 2865L 2 2865L 2 2865L130 RETAINING RING. 1 2866H 1 2866H 1 2866H131 RETAINING RING. 1 2867S 1 2867S 1 2867S132 RETAINING RING. 1 2866J 1 2866J 1 2866J135 DOWEL PIN 1 25910A 1 25910A 1 25910A141 O-RING ROLLER BRG HSG. 1 2176L 1 2176L 1 2176L143 O-RING BALL BRG SUPPORT. 1 2176F 1 2176F 1 2176F151 SOC HEAD CAP SCREW. 1 2795AP 1 2795AP 1 2795AP152 HEX HEAD CAP SCREW. 11 2796CG 11 2796CG 11 2796CG155 SHIM ar 25977D ar 25977D ar 25977D156 SHIM ar 25977C ar 25977C ar 25977C170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C176 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 NUMBERITEM DESCRIPTION VSM-501 VSM-601 VSM-701

QTY VPN QTY VPN QTY VPN100 SUPPORT ASSEMBLY 110 & 135B. 1 A26011BB 1 A26011BA 1 A26011BA101 GATE ROTOR & DAMPER ASSEMBLY

111,120. 1 A26002BB 1 A26002BA 1 A26002BC102 GATE ROTOR SUPPORT ASSEMBLY

100, 101, 119 & 130. 1 A26003BB 1 A26003BA 1 A26003BC105 GATE ROTOR GASKET SET 118,

141 & 143. 1 A26005B 1 A26005B 1 A26005B106 SHIM PACK SET (2) 121, (2) 122,

(1) 123, (1) 124. 1 A26035B 1 A26035B 1 A26035B110 SUPPORT. 1 26030BB 1 26030BA 1 26030BA111 GATE ROTOR. 1 26032A 1 26031A 1 26033A112 SMALL BEARING HOUSING. 1 25518B 1 25518B 1 25518B114 SNAP RING. 1 2867U 1 2867U 1 2867U115 RETAINER BALL BEARING 1 25935B 1 25935B 1 25935B116 BALL BEARING SUPPORT. 1 26019B 1 26019B 1 26019B117 GATE ROTOR COVER. 1 26021B 1 26021B 1 26021B118 GATE ROTOR COVER GASKET. 1 25259C 1 25259C 1 25259C119 WASHER. 1 25007A 1 25007A 1 25007A120 DAMPER. 1 25760A 1 25760A 1 25760A121* SHIM 0.002". ar 26027AA ar 26027AA ar 26027AA122* SHIM 0.003". ar 26027AB ar 26027AB ar 26027AB123* SHIM 0.005". ar 26027AC ar 26027AC ar 26027AC124* SHIM 0.010". ar 26027AD ar 26027AD ar 26027AD125 ROLLER BEARING. 1 2864B 1 2864B 1 2864B126 BALL BEARING. 1 2865B 1 2865B 1 2865B130 RETAINING RING. 1 2866A 1 2866A 1 2866A131 RETAINING RING. 1 2867A 1 2867A 1 2867A132 RETAINING RING. 1 2866K 1 2866K 1 2866K135 DOWEL PIN 1 25910A 1 25910A 1 25910A141 O-RING ROLLER BRG HSG. 1 2176M 1 2176M 1 2176M143 O-RING BALL BRG SUPPORT. 1 2176R 1 2176R 1 2176R151 SOC HEAD CAP SCREW. 1 2795AAA 1 2795AAA 1 2795AAA152 HEX HEAD CAP SCREW. 12 2796CG 12 2796CG 12 2796CG155 SHIM ar 25977G ar 25977G ar 25977G156 SHIM ar 25977H ar 25977H ar 25977H170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C176 PIPE PLUG. 1 2606D 1 2606D 1 2606D

NOTE: * Not picturedar = As required

147

MODEL NUMBERITEM 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 KT781A218 SEAL HOUSING. 1 25410B 1 25269A219 SHAFT SEAL. 1 A 1 A230 OIL SEAL. 1 2930C 1 25040A244- TEFLON SEAL 1 25939A 1 25939A252- RETAINER RING 1 2928M 1 2928M260 O-RING 1 2176U 1 2176F261 O-RING. (205 Only) 1 2176AE n/a264 ROLL PIN. 1 1193RR 1 1193RR281 HEX HEAD CAP

SCREW. 6 2796N 8 2796B

NOTE * Not pictured.A Sold only as kit.- See recommended spare parts lists for complete assembly.

Shaft Seal

264

VSM

PartsList

148

Main Rotor, Slide Valve Cross Shaftsand End Plate

(Models 71-401 Only Counter-clockwise)

149

VSM

PartsList


(Models 71-201 Only CounterClockwise)

MODEL NUMBERITEM DESCRIPTION VSM 71 AND 151 VSM 91 AND 181 VSM 101 AND 201

QTY VPN QTY VPN QTY VPN201 MAIN ROTOR ASSEMBLY. 1 A25266AB 1 A25266AA 1 A25266AC203 OIL BAFFLE ASSEMBLY (1) 217,

(1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA207 SHIM ASSORTMENT (2) 240,

(2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A217 OIL BAFFLE PLATE. 1 25719D 1 25719D 1 25719D220 END PLATE. 1 25719B 1 25719B 1 25719B221 SHAFT. 2 25941A 2 25941A 2 25941A222 GEAR. 4 25027A 4 25027A 4 25027A227 CLAMP. 4 25913A 4 25913A 4 25913A228 SPACER. 4 25847A 4 25847A 4 25847A240 SHIM 0.002” A 25409AA A 25409AA A 25409AA241 SHIM 0.003” A 25409AB A 25409AB A 25409AB242 SHIM 0.005” A 25409AC A 25409AC A 25409AC243 SHIM 0.010” A 25409AD A 25409AD A 25409AD244 TEFLON RING. 1 25939A 1 25939A 1 25939A248 CHECK VALVE. 1 3120A 1 3120A 1 3120A249 CHECK VALVE. 1 3120B 1 3120B 1 3120B250 RETAINING RING. 2 2867T 2 2867T 2 2867T252 RETAINING RING 1 2829M 1 2829M 1 2829M254 WAVE SPRING. 1 2912G 1 2912G 1 2912G267 DRILL BUSHING. (See item 271) 2 3121A 2 3121A 2 3121A268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 3 2606B 3 2606B 3 2606B271** PLUG SOLID 1 25422A 1 25422A 1 25422A277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N286 SOCKET HEAD CAP SCREW. 4 2795F 4 2795F 4 2795F297 SET SCREW. 2 2060J 2 2060J 2 2060J298 SET SCREW. 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.** Required at top locate single gaterotor only.

150


(Models 301-401 Only Counter-clockwise)

MODEL NUMBERITEM DESCRIPTION VSM 301 VSM 361 VSM 401

QTY VPN QTY VPN QTY VPN201 MAIN ROTOR ASSEMBLY. 1 A25226AB 1 A25226AA 1 A25226AC203 OIL BAFFLE ASSEMBLY (1)

217, (1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA207 SHIM ASSORTMENT (2) 240,

(2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A217 OIL BAFFLE PLATE . 1 25938A 1 25938A 1 25938A220 END PLATE. 1 25719D 1 25719D 1 25719D221 SHAFT. 2 25941A 2 25941A 2 25941A222 GEAR. 4 25027A 4 25027A 4 25027A227 CLAMP. 4 25913A 4 25913A 4 25913A228 SPACER. 4 25847A 4 25847A 4 25847A240 SHIM 0.002” A 25409AA A 25409AA A 25409AA241 SHIM 0.003” A 25409AB A 25409AB A 25409AB242 SHIM 0.005” A 25409AC A 25409AC A 25409AC243 SHIM 0.010” A 25409AD A 25409AD A 25409AD244 TEFLON RING. 1 25939A 1 25939A 1 25939A248 CHECK VALVE. 1 3120A 1 3120A 1 3120A249 CHECK VALVE. 1 3120B 1 3120B 1 3120B250 RETAINING RING. 2 2867T 2 2867T 2 2867T252 RETAINING RING 1 2829M 1 2829M 1 2829M254 WAVE SPRING. 1 2912G 1 2912G 1 2912G267 DRILL BUSHING. (See item 271) 2 3121A 2 3121A 2 3121A268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 3 2606B 3 2606B 3 2606B271** PLUG SOLID 1 25422A 1 25422A 1 25422A277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F297 SET SCREW. 2 2060J 2 2060J 2 2060J298 SET SCREW. 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.** Required at top locate single gaterotor only.A As required.

151

See Next Page for Models 501-701Main Rotor, Slide Valve Cross Shafts

and End Plate

VSM

PartsList

152


(Model 501-701 Only Clockwise)

153


(Model 501-701 Only Clockwise)

MODEL NUMBERITEM DESCRIPTION VSM 501 VSM 601 VSM 701

QTY VPN QTY VPN QTY VPN201 MAIN ROTOR ASSEMBLY. 1 A26010BB 1 A26010BA 1 A26010BC203 OIL BAFFLE ASSEMBLY (1) 217,

(1) 244, (1) 248, (1) 249, (1) 252. 1 A26034B 1 A26034B 1 A26034B207 SHIM ASSORTMENT (2) 240,

(2) 241, (1) 242, (1) 243 1 A25177B 1 A25177B 1 A25177B217 OIL BAFFLE PLATE. 1 A26034B 1 A26034B 1 A26034B220 END PLATE. 1 26025B 1 26025B 1 26025B221 SHAFT. 2 25843A 2 25843A 2 25843A222 GEAR. 4 25027A 4 25027A 4 25027A228 SPACER. 4 25847A 4 25847A 4 25847A240 SHIM 0.002” A 25255AA A 25255AA A 25255AA241 SHIM 0.003” A 25255AB A 25255AB A 25255AB242 SHIM 0.005” A 25255AC A 25255AC A 25255AC243 SHIM 0.010” A 25255AD A 25255AD A 25255AD244 TEFLON RING. 1 25929B 1 25929B 1 25929B248 CHECK VALVE. 1 3120A 1 3120A 1 3120A249 CHECK VALVE. 1 3120B 1 3120B 1 3120B250 RETAINING RING. 2 2867B 2 2867B 2 2867B252 RETAINING RING 1 2928N 1 2928N 1 2928N255 WASHER 2 25977E 2 25977E 2 25977E256 WASHER 2 25977F 2 25977F 2 25977F267 DRILL BUSHING. 2 3121A 2 3121A 2 3121A268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA270 PIPE PLUG. 3 2606B 3 2606B 3 2606B277 HEX HEAD CAP SCREW. 2 2796CL 2 2796CL 2 2796CL278 HEX HEAD CAP SCREW. 2 2796CT 2 2796CT 2 2796CT279 HEX HEAD CAP SCREW. 2 2796CZ 2 2796CZ 2 2796CZ280 HEX HEAD CAP SCREW. 6 2796EL 6 2796EL 6 2796EL281 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796B282 SOCKET HEAD CAP SCREW 2 2795D 2 2795D 2 2795D297 SET SCREW. 2 2060J 2 2060J 2 2060J298 SET SCREW. 2 2060H 2 2060H 2 2060H

NOTE: * Not pictured.A As required.

VSM

PartsList

154

Volu

me R

atio

Cap

acity

Slid

e

Car

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155


MODEL NUMBERITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501 - 701

QTY VPN QTY VPN300 CARRIAGE ASSEMBLY. 1 A25179A 1 A26012B304 CAPACITY PISTON 340, 341, 350 & 355. 1 A25183A 1 A25183B305 VOLUME PISTON 340, 342, 350 & 355. 1 A25184A 1 A25184B316 CAPACITY RACK. 1 25023D 1 25024A318 CAPACITY RACK SHAFT. 1 25772C 1 25772A323 VOLUME RATIO RACK. 1 25023C 1 25023A325 VOLUME RATIO RACK SHAFT. 1 25772D 1 25772B340 PISTON. 2 25017B 2 25017A341 CAPACITY PISTON SHAFT. 1 25018B 1 25019A342 VOLUME PISTON SHAFT. 1 25018C 1 25018A350 PISTON RING SET. 2 2953AE 2 2953AA355 EXPANSION PIN. 2 1193PP 2 1193PP359 PIPE PLUG. 3 2606D 3 2606D360 LOCK WASHER (PAIR). 2 3004C 2 3004C361 WASHER. 2 13265B 2 13265B363 NUT. 4 2797A 4 2797A372* SOCKET HEAD CAP SCREW. N/A 1 2795M373 SOCKET HEAD CAP SCREW. 3 2795A 3 2795N374 LOCK WASHER (PAIR). 3 3004C 3 3004C

Notes: There are two slide valve carriages per compressor. Each one each has its own VolumeRatio and Capacity slide valves. The above totals are per side of the compressor, doublethe quantities if both slide valve carriages are being worked on.

*. Not Pictured.

VSM

PartsList

156

Actuating Motor with Optical Sensorand Command Shaft

Kit assemblies are as follows:A25975A VSM71-401

A25975B VSM 501-701

157

Actuating Motor with Optical Sensorand Command Shaft

MODEL NUMBERITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501- 701

QTY VPN QTY VPN

412 BEARING HOUSING. 1 25364A 1 25364A413 COMMAND SHAFT. 1 25417A 1 25375A415 MOUNTING PLATE. 1 25805B 1 25805B416 COVER. 1 15653E 1 15653E427 KEY. 1 25039BC 1 25039BC433 BUSHING. 1 25853A 1 25853A435 BALL BEARING. 1 2908A 1 2908A436* SLEEVE BEARING. 1 25853B 1 25853B445 O-RING. 1 2176W 1 2176W445A O-RING. 1 2176W 1 2176W446 O-RING. 1 2176X 1 2176X450 RETAINING RING. 1 2866D 1 2866D451 RETAINING RING. 1 2867C 1 2867C457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M466 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB475 LOCKWASHER (PAIR). 4 3004A 4 3004A477 LOCKWASHER (PAIR). 4 3004C 4 3004C480 WASHER. 1 2906AA 1 2906AA

Notes: There are two slide valve actuators per compressor. One each for the control of theVolume Ratio and Capacity slide valves. If both actuators or parts are to be replaceddouble the quantities above.

* Bearing changed to steel until 10/25/04, then removed due to housing being modified.

VSM

PartsList

158


Model VSM 501-701

Model VSM 71-401

159


MODEL NUMBERITEM DESCRIPTION ALL VSM 71-401 ALL VSM 501 - 701

QTY VPN QTY VPN511 DISCHARGE MANIFOLD. 1 25734B n/a511 240 mm DISCHARGE MANIFOLD

WITH DOWN DISCHARGE. n/a 1 25024BC511 240 mm DISCHARGE MANIFOLD

WITH HORIZONTAL DISCHARGE. n/a 1 25024BB511 240 mm DISCHARGE MANIFOLD

WITH UP DISCHARGE. n/a 1 25024BA512 MANIFOLD GASKET. 1 25737A 1 26037A514 ECON-O-MIZER GASKET. 2 11323GG 2 11323D515 KEY. 1 13396R 1 13396R522 COUPLING LOCK PLATE n/a 1 25004D523 LOCK WASHER n/a 1 3004H528 ECON-O-MIZER PLUG. 2 25419A 2 25397K530 O-RING n/a 2 2176BF535 PIPE PLUG. 7 2606E 2 2606D536 PIPE PLUG. 1 13163F 6 2606E537 PIPE PLUG. 1 13163G 1 13163G538 PIPE PLUG. 9 2606B 2 2606B540 DOWEL PIN 2 2868B 2 2868B542 PIPE PLUG 3 2606C 10 2606B545 HEX HEAD CAP SCREW 4 2796EL 4 2796C546 SOCKET HEAD CAP SCREW 7 2795AK 6 2795GD547 HEX HEAD CAP SCREW 3 2796EN 4 2796F548 SOCKET HEAD CAP SCREW n/a 3 2795GH549 CAP SCREW 3 2796EY 1 2795GP550 CAP SCREW 2 2796AB 2 2795GS551 HEX HEAD CAP SCREW n/a 2 2796C570 BEARING OIL PLUG 1 25978A n/a571 PLUG 1 25979A n/a572 SPRING 1 3148A n/a

Notes *. Not Pictured.

VSM

PartsList

160

Replacement Parts AccessoriesH

ousi

ng A

cces

sori

es

C-F

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161

Replacement Parts Accessories

MODEL NUMBERITEM DESCRIPTION VSM 71 - 701

QTY VPN117 GATE ROTOR COVER. 1 25416B118 COVER GASKET. 2 25259B127 SUCTION TEE. 1 25735B128 BLIND FLANGE WITH TAP. 1 25967A129 GASKET. 1 11323T153 HEX HEAD CAP SCREW. 32 2796DC154 HEX HEAD CAP SCREW. 8 1139BE171 LOCKWASHER (PAIR). 8 3004J180 INLET SCREEN. 1 25920A190 PIPE PLUG. 2 2606C191 PIPE PLUG. 1 2606E343 PISTON COVER. * 1 25724B

MODEL NUMBERITEM DESCRIPTION VSM 71 - 401 VSM 501 - 701

QTY VPN QTY VPN1 C-FLANGE. 1 A 1 A2 ADAPTER. 1 A 1 A3 HEX HEAD CAP SCREW. 8 2796F 8 2796F4 HEX HEAD CAP SCREW. 4 2796EL 4 A5 LOCKWASHER (PAIR). 8 3004H 8 3004H6 LOCKWASHER (PAIR). 4 3004F 4 A7 PORT COVER. 2 25685A 2 25685B8 HEX HEAD CAP SCREW. 2 2796AC 2 2796AC9 CONNECTOR 1 13229C 1 13229C10 TUBE (CUT TO LENGTH) 1 S1589A 1 S1589A345 O-RING. 4 2176BX 4 2176CA346 O-RING. 2 2176BG 2 2176BG

NOTE: A. Contact Home Office for part number and quantity.

Housing Accessories

C-Flange Assembly

VSM

PartsList

162

Replacement Tools

MODEL NUMBERITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501 - 701

QTY VPN QTY VPN901 GATEROTOR STABILIZER. 1 25742A 1 25742B902 SEAL INSTALLATION TOOL 1 25455A 1 25455B

163

Vendor AssessoriesSection

Vendor Assessories Section ........................................................................................ 163

HAIGHT PUMPS 10-80 Pumps ................................................................................................................................................................PARKER Inlet Pressure Regulators ..........................................................................................................................................................CARTRIDGE HEATERS .............................................................................................................................................................................SPORLAN Strainers ...................................................................................................................................................................................VIKING PUMP Pumps and Pressure Relief Valves ..................................................................................................................................FLUID POWER ENERGY Thermostatic Valves .....................................................................................................................................SPORLAN Solenoid Valve and Thermostatic Expansion Valve ..............................................................................................................HANSEN HA4AOAS INLET/OUTLET REGULATOR ............................................................................................................................

Note: See spare parts lists for Vilter’s Part numbers.

164

Haight Pumps

10-80 GPM OIL PUMPSVILTER PART NUMBER

3022UB, EU and HUHAIGHT MODEL 10-80U Series

PREPARATION OF OIL PUMPFOR MAINTENANCE

1 Prepare compressor unit for servicingas outlined in the service section of the manual.

2. Remove the refrigerant from the unit inan appropriate manner and equalize to atmosphericpressure.

3. Isolate the oil pump in the oil circuit.

4. Make sure that the electricity is turnedoff to the oil pump motor and remove the 4 boltsand washers from the oil pump mounting face (25and 26), remove bolts securing the motor to theunit and slide the oil pump motor from the oil pump.

5. Remove the set screw from the couplinghalf and slide the coupling off of the oil pump shaft.Remove the key (1) from shaft.

6. Using fine emery paper remove any burrsfrom the key way area and the end of theshaft.

SHAFT SEAL INSPECTION.REMOVAL AND INSTALLATION.

1. Prepare the pump for servicing as statedin the previous paragraph.

2. Remove the seal housing by unscrewingthe cap (2) using care as the seal in compressedwith a spring, therefore the cap may release towardsthe key way as the cap is unscrewed. With the capunscrewed, slide it off of the shaft. The seal (21)will now be visible, but possibly under compres-sion as the bellows of theseal may be sticking to the shaft.

Carefully, rotate the shaft and inspect the bellowsof the seal for damage. If it is damaged the sealmust be replaced at this time. If the bellows is ingood shape, then the carbon face and the matting

face of the seal will need to be inspected for crack-ing or excessive wear. If they are damaged the sealmust be replaced at this time.

3. Replace cap "o"-ring (3) at this time.

4. If the shaft seal is to be replaced, removethe stationary portion of the seat from theinside of the cap. The stationary portion of the sealis pressed in finger tight and is held in place by an"o"-ring.

IMPORTANT

Care must be taken when installing the seal asnot to touch or scratch the polished side or thecarbon portion of the seal.

5. Install the new stationary portion of theseal in the cap with the polished surface faces therotating portion of the seal when assembled. Lu-bricate the "o''-ring of the stationary portion of theseal with clean compressor oil to facilitate the in-stallation.

6. Remove the rotating portion of the sealfrom the oil pump shaft Oil the shaft to aid in theremoval of the seal. The bellows may stick to theshaft, this is a normal, this wilt require a little pres-sure to start it moving. After the rotating portionof the seal is removed, inspect the shaft (22) fordamage and replacd if necessary.

7. Lubricate the shaft with dean com-pressor oil and push the replacement seal on to theshaft taking care not to touch the carbon face of theseal.

8. Screw the cap back on to the pump hous-ing and torque 40 to 60 ft.lbs.

9. Re-install the key and coupling, tightenthe set screw after it is determined that the cou-plings mate up correctly. Pressurize and leak checkthe unit concentrating on areas that repairs weremade.

10. It is normal for the seal to weep a smallamount of oil on start-up until the bellows takes aset on the shaft.

165

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 berequired to upgrade to an “U” and a new Hub will also need to be purchased.

Vilter Part # 3022BU ,EU,and HUVilter Shaft Seal Part # 3022C

166

Haight Pumps

12

10U through 40U Haight Pump w/o Relief Valve10U through 40U Haight Pump with Relief Valve

Item Qty.Number Description Required1 Screw on O-ring gland 12 O-Ring 1

-Buna -Viton® -Neoprene -Kalrez® -Teflon

3 Thurst Washer Kit 1 Nut Washer Washer Washer Bearing Washer

4 Screw 85 Cover 16 & 6A Bearing 2

-Bronze -Iron -Graphite -DU

7 Wiper Seal 2 -Buna -Neoprene -Viton®

8 O-Ring 1 -Buna -Viton® -Neoprene -Kalrez® -Teflon

9 Shaft & Pinion Assy-std. 19 Shaft & Pinion Assy-OBB 110 Pinion 1

11 Shaft 112 Key 1

13 Rotor*-C.I. Standard 114 Case 1

-1" ports -1-1/4" ports -1-1/2" ports

15 Lip Seal 1 -Buna -Viton® -Neoprene

15A Mechanical Seal 1 -Buna -Viton® -Neoprene

15B Packing Seal 1 -Graphoil -Teflon

16 Set Screw 117 Gland 118 Set Screw 119 Roll Pin 120 O-Ring 1

-Buna -Viton® -Neoprene

21 O-Ring 2 -Buna -Viton® -Neoprene -Teflon

22 Screw 423 Cover Plate 124 Valve Body 1

Item Qty.Number Description Required

1Refrigerating Specialties Division

CHECK VALVEType CK4APort Size 13 - 100mm (1/2” - 4”)FOR AMMONIA, R12, R22, R502AND OTHER COMMON REFRIGERANTS

FEATURES• UL Listed (Thru 3" Size)

• Installs in any position

• Compact

• Lightweight

• In-Line

• Design Pressure (MRP): 34.5 bar (500 psi)

BULLETIN 50-16C

September 1990Installation, Service and Parts Information

050280I S O 9 0 0 1 C E R T I F I E D

DescriptionThese compact valves are spring closing with a lapped,stainless steel or chrome plated seat for positive closingaction and low leakage. A minimum pressure difference of0.05 bar (0.75 psi) is required to hold the valve in the openposition. Removable seat plate with combination O-ring andmetal-to-metal knife edge seal allows the valve to bedisassembled for maintenance. They may be ordered withmale adapter rings for close-coupling to other RefrigeratingSpecialties valves and may be installed in any position.

PurposeThe Type CK4A Check Valves prevent backward flow of fluidin refrigerant suction, hot gas or liquid lines. The most frequentuse for these valves is in recirculating (overfeed) systems.They are especially suited for high speed compressordischarge, pump discharge, suction - down to -50°C (-60°F)and hot gas lines (pan to evaporator).

Certain refrigerant flows pulsate sufficiently or with afrequency in harmony with the valve’s natural frequency,which can cause “slapping” or even wholesale failure. Thesevalves are not recommended for slow speed compressordischarge lines (See CK-1, Bulletin 50-10B) or for anycompressor discharge where a low speed machinedischarges into the same downstream header, or for use onside-port suction lines on a screw compressor installation.

OperationThese are light spring-closing check valves. An increase inthe pressure drop across the valve overcomes the force ofthe closing spring and the disc is forced away from its seatpermitting flow. As the flow decreases, the disc is forcedback against its seat by the expansion of the closing spring.Flow is then stopped.

InstallationKeep dirt from entering the valve. Do not remove protectivepackaging until ready to install.

Install the valve where it can be serviced easily. DO NOTINSTALL AT THE INLET OF A SOLENOID VALVE, OR AREGULATOR WITH AN ELECTRIC SHUT-OFF FEATURE; DONOT INSTALL AT THE INLET OF AN OUTLET PRESSUREREGULATOR IN A SYSTEM WHERE LIQUID MAY BETRAPPED BETWEEN TWO VALVES. Check Valves when usedwith such valves should always be installed at the outlet ofthe valves.

NOTE: THE ODS COPPER FLANGES AVAILABLE ARE ONLYFOR INSTALLATIONS WHERE R-12, R-22, AND R-502 OROTHER HALOCARBON REFRIGERANTS ARE USED. DONOT USE THESE FLANGES FOR AMMONIA. FORINSTALLATIONS USING AMMONIA THE FPT, SOCKET WELDOR WELD NECK FLANGES SHOULD BE USED.

The Type CK4A Valves may be installed in any position. Thevalve must be installed with the arrow pointing in the directionof flow. After installing the valve, tighten the flange bolts evenly.

The CK4A Check Valves may be closed-coupled toRefrigerating Specialties Refrigerant Valves and most handvalves by using a Refrigerating Specialties Male Adapter Ring.

Fig. 1

Refrigerating Specialties Division 2

ITEMITEMITEMITEMITEM PORPORPORPORPORT SIZET SIZET SIZET SIZET SIZE

NO.NO.NO.NO.NO. DESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTIONDESCRIPTION QTYQTYQTYQTYQTY 50mm (2")50mm (2")50mm (2")50mm (2")50mm (2") 65mm (2-1/2")65mm (2-1/2")65mm (2-1/2")65mm (2-1/2")65mm (2-1/2") 75mm (3")75mm (3")75mm (3")75mm (3")75mm (3") 100mm (4")100mm (4")100mm (4")100mm (4")100mm (4")

6 Valve Seat 1

7 O-Ring 1

8 Disc Assembly 1 Available Only With Kit

9 Comp. Spring 1

4 Flange Gasket 2

4,6,7,8,9 Repair Kit — 202089 202090 202091 202092

4 Flange Gasket Pkg. 12 202081 202082 202083 202084

Repair Kits for Type CK4A Check Valves

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”)

Amm 75 113 95 114 148 148 179

inch 29.3 4.43 3.75 4.50 5.81 5.81 7.06

Bmm 38 62 95 114 148 148 179

inch 1.50 2.43 3.75 4.50 5.81 5.81 7.06

Cmm 27 32 50 60 70 81 89

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”

Emm 82 97 117 117 126 136 171 177 215 245 298

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

Fmm 76 82 98 99 193 99.5 111 119 130 159 193 177 205 203 250 228 248 285

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

Nmm 9 13 29 20 24 25 28 25 28 34 28 34 37 37 42 42 48 55

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

Pmm 13 13 15 15 25 29 32

inch .50 .50 .60 .60 1.0 1.1 1.3

Dimensional Data

Note: 13-32mm (½” - 1¼”) do not have Repair Kits available.

4Parker Hannifin Corporation • Refrigerating Specialties Division2445 South 25th Avenue • Broadview, IL 60155-3891Telephone: (708) 681-6300 • Fax (708) 681-6306

ServiceDirt or other foreign material in the system is the greatestsingle cause of valve malfunction.

Before disassembling a check valve for servicing, read andbecome familiar with the Safe Operation Instructions in thisbulletin as well as in the current issue of Safety Bulletin RSB.

Check the following chart for possible symptoms andcorrections.

Symptom Probable Reason Correction

Valve does not Dirt or chips Disassemble valveclose or there under valve seat. and cleanis leakage thoroughly.through valve. Replace any

damaged parts.

Valve chatters. Valve is Replace withoversized. smaller port size or

use Type CK-1.

DisassemblyCautionCautionCautionCautionCaution - If the valve to be disassembled or removed isclose-coupled to a solenoid operated valve make sure thatthe power supply to the valve is de-energized and allrefrigerant is pumped out of the line. Refer to Page 3 asnecessary. After removing the valve from between the flangesremove the parts in the numerical order shown in theapplicable exploded view. In all CK4A Valves the seat plateswith the O-rings are removed by gently tapping out the seatfrom the opposite end of the valve body. Use a wooden dowelfor this purpose.

AssemblyBefore assembling all parts must be clean, dry and lightlycoated with refrigerant oil. If an existing valve or strainer isclose-coupled to the check valve, either one should beopened, inspected and cleaned before putting it and thecheck valve back in service.

Refer to Page 3 as applicable. Assemble the valve in thereverse numerical order shown in the exploded view. Makesure the O-ring is firmly seated and permanently retained bythe seat plate when reassembled.

WarrantyAll Refrigerating Specialties products are warranted againstdefects in workmanship and materials for a period of oneyear from date of shipment from originating factory. Thiswarranty is in force only when products are properly installed,field assembled, maintained, and operated in use and serviceas specifically stated in Refrigerating Specialties Catalogsor Bulletins for normal refrigeration applications, unlessotherwise approved in writing by Refrigerating SpecialtiesDivision. Defective products, or parts thereof returned to thefactory with transportation charges prepaid and found to bedefective by factory inspection will be replaced or repairedat Refrigerating Specialties option, free of charge, F.O.B.

factory. Warranty does not cover products which have beenaltered, or repaired in the field; damaged in transit, or havesuffered accidents, misuse, or abuse. Products disabled bydirt or other foreign substances will not be considereddefective.

THE EXPRESS WARRANTY SET FORTH ABOVECONSTITUTES THE ONLY WARRANTY APPLICABLE TOREFRIGERATING SPECIALTIES PRODUCTS, AND IS IN LIEUOF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,WRITTEN OR ORAL, INCLUDING ANY WARRANTY OFMERCHANTABILITY, OR FITNESS FOR A PARTICULARPURPOSE. No employee, agent, dealer or other person isauthorized to give any warranties on behalf of RefrigeratingSpecialties, nor to assume, for Refrigerating Specialties, anyother liability in connection with any of its products.

Safe Operation (See also Bulletin RSB)People doing any work on a refrigeration system must bequalified and completely familiar with the system and theRefrigerating Specialties Division valves involved, or all otherprecautions will be meaningless. This includes reading andunderstanding pertinent Refrigerating Specialties Divisionproduct Bulletins, and Safety Bulletin RSB prior to installationor servicing work.

Where cold refrigerant liquid lines are used, it is necessarythat certain precautions be taken to avoid damage whichcould result from liquid expansion. Temperature increase ina piping section full of solid liquid will cause high pressuredue to the expanding liquid which can possibly rupture agasket, pipe or valve. All hand valves isolating such sectionsshould be marked, warning against accidental closing, andmust not be closed until the liquid is removed. Check valvesmust never be installed upstream of solenoid valves, orregulators with electric shut-off, nor should hand valvesupstream of solenoid valves or downstream of check valvesbe closed until the liquid has been removed. It is advisableto properly install relief devices in any section where liquidexpansion could take place.

Avoid all piping or control arrangements which might producethermal or pressure shock.

For the protection of people and products, all refrigerant mustbe removed from the section to be worked on before a valve,strainer, or other device is opened or removed.

Flanges with ODS connections are not suitable for ammoniaservice.


BULLETIN 23-05B

Type A4A, A4AK, A4AE, A4AR

January 2003

Installation, Service and Parts Information

INLET PRESSURE

REGULATORSType A4A, A4AK, A4AE, A4ARPort Size 20 - 100 mm (3/4" - 4")

FOR AMMONIA, R-12, R-22, R-502

OTHER REFRIGERANTS AND OIL

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 andcopper tube (copper not for ammonia)

• Interchangeable parts

• Easy to service

• Close coupled strainers, optional

• Many control variations are possible with theuse of a few Modules and kits. (SeeAdaptomode Pressure Regulator Bul. 23-06)

• Stainless Steel Diaphragm

• Chrome Plated Pilot Seat

• Manual Opening Stem

DescriptionThese compact, heavy duty, pilot operated, iron alloy

(ASTM A126 Class B) Inlet Pressure Regulators are

suitable for Ammonia, R-12, R-22, R-502 and other

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

00-10 for strainer information.)

PurposeModulates flow of refrigerant gas or liquid to maintain

constant upstream (or inlet) pressure as set-for, despite

load fluctuations. The A4AR is a main valve only and will

control pressures as determined by the remote pilot(s)

piped to it.

The fluid temperature range for the A4 Series of

Regulators is -45°C to 105°C (-50°F to 220°F).

A4A, A4AE

A4AK A4AR

A4A INLET PRESSURE REGULATOR

Fig. 1

050274

SEAL CAP

ADJUSTINGSTEM

RANGE SPRING

PILOT SEAT

GAUGE PORT

DIAPHRAGM

POWER PISTON

MODULATINGPLUG

CLOSINGSPRING

DIRT WIPER

MANUALOPENINGSTEM

I S O 9 0 0 0 - 2 0 0 0 C E R T I F I E D


Principles of Operation (See Fig. 1)The inlet pressure enters the space under the diaphragm

through passage N. When the force created by the

pressure exceeds the force of the range spring, the

diaphragm is lifted off the pilot seat allowing pressure to

enter on top of the power piston. This causes the power

piston to move downward forcing the modulating plug to

open and modulate to maintain constant inlet pressure.

An increase in inlet pressure lifts the diaphragm further,

allowing more pressure on top of the power piston and

opening the valve wider. A decrease in inlet pressure

causes the diaphragm to move closer to the pilot seat

reducing the pressure on the top of the power piston and

causing the closing spring to reduce the valve opening.

The pressure on top of the power piston is controlled by

the flow through the pilot seat and the bleed off through

the bleed hole in the power piston and through the

clearance between the piston and cylinder. A minimum of

0.14 bar (2 psig) pressure drop across the valve is required

to open it fully.

The A4A Inlet Pressure Regulator therefore opens on a

rise in the inlet pressure above its set point and closes on

a drop in inlet pressure below its set point. The inlet

pressure set point is not appreciably affected by variations

in the outlet pressure.

Manual Opening StemAll Type A4A Regulators are provided with a manual

opening stem. To open the regulator manually, back the

stem out (turn counter-clockwise) until it stops. To put the

regulator into automatic operation, turn the stem in

(clockwise) until only the flats on the stem protrude from

the packing nut. Always retighten packing nut after

changing position of the manual opening stem.

InstallationAll regulators are packed for maximum protection. Unpack

carefully. Check the carton to make sure all flanges and

other items are unpacked. Save the enclosed instructions

for the installer and eventual user.

Do not remove the protective coverings from the inlet and

outlet of the regulator until the regulator is ready to be

installed. Protect the inside of the regulator from moisture,

dirt and chips before and during installation. When welded

or brazed flange connections are used, all slag, scale and

loose particles should be removed from the flange interior

before the regulator is installed between the flanges. It is

advisable to install a close-coupled companion strainer

(RSF) at the inlet of the regulator to help protect it from

any foreign material in the system.

The A4A Series of Regulators will give optimum

performance if mounted in a horizontal line in a vertical

position with the manual opening stem on bottom. Where

other positions are desired, the factory should be

consulted; please give application and piping details. The

regulator must be installed with the arrow on the valve

body pointing in the direction of the fluid flow for the

regulator to function properly. Backward flow through the

regulator is uncontrolled and will vary with the valve model

and the reverse pressure drop encountered. The regulator

is not a check valve.

Tighten the flange bolts and nuts evenly to provide proper

seating of the flange gasket and to avoid damage to

gaskets or flanges. (See Flange Bolt Torque Table, p. 12)

Avoid using the regulator flange bolts to stretch or align

pipe. Even the heavy-duty iron alloy body of an A4A can

be distorted, causing the precision parts to bind.

The regulator should be installed in a location where it is

easily accessible for adjustment and maintenance. The

location should be such that the regulator can not be easily

damaged by material handling equipment. When it is

necessary to insulate the regulator (and companion

strainer), the insulation should be installed to provide

access to the regulator (and companion strainer) for

adjustment and maintenance. Proper indicating gauges

should be installed to be easily visible to the operating

engineer for system checking and adjusting purposes.

Disassembly and AssemblyRefer to the exploded view (Fig. 2) for parts discussed in

this section.

Before disassembling any A4A type regulator, read the

information in this bulletin and Bulletin RSB, Safety

Procedures for Refrigerating Specialties Division

Refrigeration Control Valves.

Before a regulator is removed from the line or

disassembled in the line, make sure that all refrigerant

has been removed from the regulator, including the

bonnet, where applicable, and the close coupled strainer.

The regulator must be isolated from the rest of the system

in a safe manner. When pumping down to remove the

refrigerant, the manual opening stem 33A must be turned

out (counter clockwise) to make sure the valve is open.

All A4A RegulatorsGeneral Procedure

The construction of the regulator and the method of

disassembly are relatively simple, but some procedures

must be followed to avoid damage. The following describes

the procedure for the basic A4A; special instructions for

other styles will be included in other appropriate sections.


Disassembly - Take care when removing Seal Caps 1

and 44 in case some refrigerant may be trapped inside.

Back the Adjusting Stem 6 all the way out to remove any

pressure from Range Spring 13 otherwise damage to

Diaphragm 17 or Pilot Seat 18 may occur. Remove Bonnet

8 by carefully removing Cap Screws 11. Take care not to

damage Diaphragm Follower 15. Remove Adapter 28 by

removing Cap Screws 31. Turn the Manual Opening Stem

33A all the way in until the flats on the stem barely protrude

from the stuffing box nut. Push Piston 30 down against

the spring force. The piston should move freely down and

be returned by the spring force. If the piston is jammed or

sticky, remove Bottom Cap Assembly, which includes

Items 33 through 42, by removing Cap Screws 39 or

unscrewing Bottom Cap, 20mm through 32mm (3/4"

through 1-1/4"). Using a hard wood dowel rod inserted

through the bottom of the valve, tap the piston upward

and out. Thoroughly clean all parts. If jamming has taken

place and the piston and bore are scored, remove all burrs

by polishing the piston, bore and modulating plug with

fine crocus cloth. Inspect the seating area of the

Modulating Plug 33 for damage or erosion. If damaged it

should be replaced. It would be advisable to replace the

entire bottom cap assembly. Inspect all gaskets and “O”

rings for damage and replace where necessary.

Assembly - When reassembling the valve, all internal

parts should be clean, dry and lightly oiled with refrigerant

oil, except “O” rings. Apply silicone grease to the “O” rings.

Care must be taken especially when the parts are cold

since moisture can condense on parts and cause rapid

rusting. When replacing gaskets, they should be oiled very

lightly with refrigerant oil before assembly. Install bottom

cap assembly first and tighten in place. Carefully replace

the piston; never try to force it in place. Align the Adapter

Gasket 29 carefully with the proper holes in the adapter

and valve body and fasten adapter in place. Before

assembling the bonnet be sure the Adjusting Stem 6 is

turned all the way out. Place Gasket 19, Diaphragm 17

and Gasket 16 in Adapter 28. The raised center of the

diaphragm must be towards the bonnet. Stack Diaphragm

Follower 15, Lower Spring Rest 14, Spring 13 and Upper

Spring Rest 12 on top of diaphragm and carefully lower

bonnet in place and tighten Screws 11 in place. For range

“D” use two diaphragms. Tighten Cap Screws 11 evenly.

The ideal tightening torque is 1.5 Kg-m (11 ft. lbs.). Valve

is now ready to be adjusted for normal operation.

If close coupled strainer is used, it may be cleaned before

putting the valve back in operation. The regulator must be

tested for leaks with refrigerant gas or other appropriate

gas before the system is put into operation.

A4AAfter the General Procedure for disassembly, inspect the

Pilot Seat 18 top seating surface for dirt, wear or damage.

Remove seat from valve body and clean, lap on a flat

plate or replace as necessary. Examine the diaphragm

region which contacts the seat surface, look for dirt, heavy

scratches or corrosion. If the diaphragm cannot be easily

wiped clean, it should be replaced. Reassemble the

regulator following the General Procedure.

A4AKFor disassembly and assembly follow the General

Procedure and the procedure for A4A. This regulator has

a sealed wire connection to keep the seal cap from being

removed. This wire must be removed before the regulator

can be disassembled. Please Note: Removal of the seal

voids any Refrigerating Specialties Division factory

responsibility for the regulator pressure set-point.

Adjustment

Install an accurate pressure gauge in the gauge port. Back

the adjusting stem all the way out to stop. This will reduce

the set point to its lowest level and cause the valve to

open wide. Start the system, and when suction pressure

is about the desired pressure, turn the adjusting stem in

until the pressure gauge shows a slight rise in the inlet

pressure. At this point the adjusting stem may be turned

in (clockwise) to raise the pressure further, or backed out

(counterclockwise) to lower it; but the final adjustment

should be made after the system has been operating for

a period of time.

INLET PRESSURE SETTING RANGES

Approx. Pressure Change Factory Set Point

Set Point Ranges per Turn of (unless otherwise)

Adjusting Screw specified)

A: 0 to 10.3 bar 1 .7 bar (25 psi) 2.8 bar (40 psig)

(0 to 150 psig)

V: 500mm hg to 8.3 bar 1 .7 bar (25 psi) 1 . 0 bar (15 psig)

(20in hg to 120 psig)

D: 5.2 to 19.3 bar 3.7 bar (53 psi) 9.7 bar (140 psig)

(75 to 280 psig)

A4AE Inlet Pressure Regulator,

Remote Sensing ConnectionThis regulator allows control of upstream pressure at a

point remote from the regulator inlet. Gasket 19 has no

hole, thus blocking flow of upstream pressure to under

the diaphragm. The sensing pressure from the desired

control point, upstream of the regulator, is connected to

the gauge port leading to under the diaphragm. Thus the

regulator will control the pressure at this point. The

regulator operation and adjustment is the same as for

A4A.

(continued on page 8)


20mm (3/4") 25mm (1 “)Item No. Description Kit No. Qty Kit No. Qty

1 Seal Cap Only Avail. with Kit 1 Only Avail with Kit 12 Seal Cap Gasket Only Avail with Kit 1 Only Avail. with Kit 1

1-2 Cap Kit, Seal 202110 1 202110 13 Nut, Packing Only Avail. with Kit 1 Only Avail. with Kit 14 Packing, Stem Only Avail. with Kit 1 Only Avail. with Kit 15 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 1

3-5 Packing Kit, Stem 202100 1 202100 16 Stem, Adjusting Only Avail. with Kit 1 Only Avail. with Kit 1

4-6 Stem Kit, Adjusting 202120 1 202120 112 Plate, Spring, Upper Only Avail with Kit 1 Only Avail. with Kit 113 Spring, Comp. Only Avail. with Kit 1 Only Avail. with Kit 114 Plate, Spring, Lower Only Avail. with Kit 1 Only Avail. with Kit 115 Follower, Diaphragm Only Avail. with Kit 1 Only Avail. with Kit 1

3-5, 6, Spring/ Range A/V 202006 1 202006 112-15 Stem Kit Range D 202007 1 202007 1

8 Bonnet Only Avail. with Kit 1 Only Avail. with Kit 111 Screw, Hx. Hd. Only Avail. with Kit 8 Only Avail. with Kit 816 Bonnet Gasket Only Avail. with Kit 1 Only Avail. with Kit 1

1-6, 8, Spring Kit Range A/V 202008 1 202008 111-16 with Bonnet Range D 202009 1 202009 112-14, Spring Kit, Range A/V 202481 1 202481 1

16 Less Bonnet Range D 202482 1 202482 117 Diaphragm Only Avail. with Kit 1 Only Avail. with Kit 119 Gasket Only Avail. with Kit I Only Avail. with Kit 1

16,17, 19 Diaphragm Kit Range A/V 200770 1 200770 117 Diaphragms Range D Only Avail. with Kit 2 Only Avail, with Kit 2

16,17, 19 Diaphragm Kit Range D 200771 1 200771 116-19 VC Vacuum Cartridge 202004 1 202004 1

Pilot Seat/ Range A 202000 1 202000 116-19 Diaphragm Kit Range V 202004 1 202004 1

(Not A4AO) Range D 202002 1 202002 127 Plug Pkg, 1/4" NPT 202552 5 202552 528 Adapter Only Avail. with Kit 1 Only Avail. with Kit 129 Gasket Only Avail. with Kit 1 Only Avail. with Kit 1

19,28, 29 Adapter Kit 200703 1 200703 130 Piston/Stem Assembly Only Avail. with Kit 1 Only Avail. with Kit 1

29,30 Piston Kit 200760 1 200760 132 Valve Body Not Available Not Available34 Spring, Comp. Only Avail. with Kit 1 Only Avail. with Kit 135 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 136 Wiper, Dirt Only Avail. with Kit 1 Only Avail. with Kit 137 “O” Ring Only Avail. with Kit 1 Only Avail. with Kit 1

34-37 Spring Kit, (A4A) 202300 1 202300 1 Closing (A4AK) 202298 1 202298 1

33 Plug/Stem Assembly Only Avail. with Kit 1 Only Avail. with Kit 140 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 141 Packing, Stem Only Avail. with Kit 1 Only Avail. with Kit 142 Nut, Packing Only Avail. with Kit 1 Only Avail. with Kit 1

33, 34-37, Full Cap. Plug (A4A) 202021 1 202022 140-42 Kit, Modul. (A4AK) 202037 1 202038 1

33, 34-37, 50% Cap. Plug (A4A) 202029 1 (*)40-42 Kit, Modul. (A4AK) 202036 1 (*)

33, 34-37, 35% Cap. Plug (A4A) Not Available Not Available40-42 Kit, Modul. (A4AK) Not Available Not Available

33, 34-37, 17% Cap. Plug (A4A) 202030 1 (*)40-42 Kit, Modul. (A4AK) 202030 1 (*)

Repair Kits for A4A, A4AE, A4AK and A4AR

(*) All Plug Kits and Bottom Assembly Kits for 3/4" Port Size Valves can be used in the 1" Port Size

Valves for reducing capacity.

A4A, A4AK A4AE, A4AR

Fig. 2

12345

6

11 8 9

10

12

13

1516

14

112

A4ARCover

31

45

1718192827

2930

SeeNote

46

47

Modulating Plugfor Port Sizes3/4" to 1-1/4" only 33

33B

33A

3435

363738

37

38

Bottom Capfor Port Sizes

20mm thru 32mm(3/4" thru 1-1/4")

only.

39

4041424344

Note: Piston for port sizes 3/4” thru 1-1/4” only.


32mm (1-1/4") 40mm (1-5/8") 50mm (2") 65mm (2-1/2") 75mm (3") 100mm (4")Item No. Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty

1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 12 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

1-2 202110 1 202110 1 202110 1 202110 1 202110 1 202110 13 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 14 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 15 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

3-5 202100 1 202100 1 202100 1 202100 1 202100 1 202100 16 Only Avail. with Kit 1 Only Avail with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

4-6 202120 1 202120 1 202120 1 202120 1 202120 1 202120 112 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 113 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 114 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit I Only Avail. with Kit 115 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

3-5, 6, 202006 1 202006 1 202006 1 202006 1 202006 1 202006 112-15 202007 1 202007 1 202007 1 202007 1 202007 1 202007 1

8 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 111 Only Avail. with Kit 8 Only Avail. with Kit 8 Only Avail. with Kit 8 Only Avail. with Kit 8 Only Avail. with Kit 8 Only Avail. with Kit 816 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

1-6, 8, 202008 1 202008 1 202008 1 202008 1 202008 1 202008 111-16 202009 1 202009 1 202009 1 202009 1 202009 1 202009 112-14, 202481 1 202481 1 202481 1 202481. 1 202481 1 202481 1

16 202482 1 202482 1 202482 1 202482 1 202482 1 202482 117 Only Avail with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 119 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

16,17, 19 200770 1 200770 1 200770 1 200770 1 200770 1 200770 117 Only Avail with Kit 2 Only Avail with Kit 2 Only Avail. with Kit 2 Only Avail. with Kit 2 Only Avail. with Kit 2 Only Avail. with Kit 2

16,17, 19 200771 1 200771 1 200771 1 200771 1 200771 1 200771 116-19 202004 1 202004 1 202004 1 202004 1 202004 1 202004 1

202000 1 202000 1 202000 1 202001 1 202001 1 202001 116-19 202004 1 202004 1 202004 1 202004 1 2020 4 1 202004 1

202002 1 202002 1 202002 1 202003 1 202003 1 202003 127 202552 5 202552 5 202552 5 202552 5 202552 5 202552 528 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 129 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

19.28,29 200700 1 200725 1 200725 1 200685 1 200713 1 200716 130 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

29,30 200767 1 200389 1 200389 1 200391 1 200393 1 200227 132 Not Available Not Available Not Available Not Available Not Available Not7vailable34 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 135 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Onlv Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 136 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 137 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

34-37 202301 1 202302 1 202302 1 202303 1 202304 1 202305 1202299 1 202302 1 202302 1 202303 1 202304 1 202305 1

33 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 140 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 141 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 142 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

33,34-37, 202023 1 202024 1 202025 1 202026 1 202027 1 202028 140-42 202039 1 202024 1 202025 1 202026 1 202027 1 202028 1

33, 34-37, Not Available Not Available Not Available Not Available Not Available Not Available40-42 Not Available Not Available Not Available Not Available Not Available Not Available

33, 34-37, 202031 1 202032 1 (**) 202033 1 202034 1 202035 140-42 202031 1 202032 1 (**) 202033 1 202014 1 202035 1

33, 34-37, Not Available Not Available Not Available Not Available Not Available Not Available40-42 Not Available Not Available Not Available Not Available Not Available Not Available


(**) 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.


20mm (3/4") 25mm (1")Item No. Description Kit No. Qty Kit No. Qty

37 O-Ring/Gasket Only Avail. with Kit 1 Only Avail. with Kit 138 Cover, Bottom Only Avail. with Kit 1 Only Avail with Kit 140 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 141 Packing, Stem Only Avail. with Kit 1 Only Avail. with Kit 1

37,38,40,41 Cover Kit 200761 1 200761 142 Nut, Packing Only Avail. with Kit 1 Only Avail. with Kit 1

40-42 Packing Kit, Stem 202100 1 202100 143 Gasket Only Avail. with Kit 1 Only Avail. with Kit 144 Seal Cap Only Avail. with Kit 1 Only Avail. with Kit 1

43, 44 Seal Cap Kit 202110 1 202110 133-38, Full Cap. Bottom A4A 202010 1 202011 140-44 Assembly Kit A4AK 202018 1 202019 133-38, 50% Cap. Bottom A4A 202347 1 (*) 140-44 Assembly Kit A4AK Not Available Not Available33-38, 17% Cap. Bottom A4A 202346 1 (*) 140-44 Assembly Kit A4AK Not Available Not Available

3-6, 12-19, Full Cap. Repair Rge. A 202041 1 202044 129, 30, 33-37, Kit, Reg, (All Rge. V 202040 1 202043 1

40-42 except A4AK) Rge. D 202042 1 202045 13-6, 12-19, 50% Cap. Repair Rge. A 202352 1 (*) 1

29-30, 33-37, Kit, Reg. (All Rge. V 202354 1 (*) 140-42 except A4AK) Rge. D 202353 1 (*) 1

3-6, 12-19, 17% Cap, Repair Rge. A 202349 1 (*) 129-30, 33-37, Kit, Reg. (All Rge. V 202351 1 (*) 1

40-42 Except A4AK) Rge. D 202350 1 (*) 1112 Cover, Top Only Avail. with Kit 1 OnIy Avail. with Kit 1

29,112 A4AR Cover Kit 200680 1 200680 12, 16(2), 19(2), Gasket Kits (includes complete set of gaskets plus “O” Rings if applicable)25,26,29,37,

43, 45(3) Gasket Kit A4/S4 202112 1 202112 1 lndv’l Gaskets, “0” Rings & Valve Pk’g sold & pkgd in qtys only as indicated.

29 Gasket Pkg, Adapter 202406 5 202406 537 ‘’0'’ Ring/Gasket Pkg, Bottom Cap 202384 3 202384 343 Gasket Pkg, Seal Cap (Bottom) 202408 12 202408 122 Gasket Pkg, Seal Cap (Top) 202408 12 202408 1245 Gasket Pkg, Flange 202079 12 202079 124 Packing Pkg, Stem (Top) 202478 25 202478 2541 Packing Pkg, Stem (Bottom) 202478 25 202478 25

Bolt Package Kits11 Bolt Package, A4A Bonnet 202246 8 202246 831 Bolt Package, Adapter 202248 8 202249 839 Bolt Package, Bottom Cap Not Required Not Required

Flange Bolt Package includes bolts and nuts; no gaskets46 Nut 5/8"-11 2 5/8” –11 247 Bolt 5/8"-11x 3” 2 5/8" -11x3” 2

46, 47 Bolt Kit, Flange 201585 1 201585 1

Flange Kit FK-25 FK-25 Specify Flange, Style, FPT, SW, ODS FPT, SW, ODS Connection, Size WN WN Kit includes 2 Flanges only Std Also Std Also Std Also Std AlsoConnections Available Avail. Avail. Avail. Avail. Sizes in Inches 3/4 1, 7/8 1-1/8, 1 3/4 1-1/8 1-3/8

1-1/4 1-3/8 1-1/4 1-5/8

A4A, A4AK A4AE, A4AR

Fig. 2

(*) All Plug Kits and Bottom Assembly Kits for 3/4" Port Size Valves can be used in the 1" Port Size

Valves for reducing capacity.


12345

6

11 8 9

10

12

13

1516

14

112

A4ARCover

31

45

1718192827

2930

SeeNote

46

47

Modulating Plugfor Port Sizes3/4" to 1-1/4" only 33

33B

33A

3435

363738

37

38

Bottom Capfor Port Sizes

20mm thru 32mm(3/4" thru 1-1/4")

only.

39

4041424344

Note: Piston for port sizes 3/4” thru 1-1/4” only.


FK-32 FK-40 FK-50 FK-65 FK-75 FK-100FPT, SW ODS FPT, SW ODS FPT, SW ODS FPT, SW ODS FPT, SW ODS FPT, SW ODS

WN WN WN WN WN WNStd. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also

Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail.1-1/4 1-1/2 1-3/8 1-5/8, 1-1/2 2 1-5/8 2-1/8, 2 1-1/2 2-1/8 2-5/8 2-1/2 2-5/8 3-1/8 3 3-1/8 3-5/8 4 4-1/8

2-1/8 2-5/8

32mm (1-1/4") 40mm (1-5/8") 50mm (2") 65mm (2-1/2") 75mm (31) 100mm (4")Item No. Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty

37 Only Avail. with Kit 138 Only Avail. with Kit 140 Only Avail. with Kit 141 Only Avail. with Kit 1

37,38,40,41 200761 1 Not Available Not Available Not Available Not Available Not Available42 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

40-42 202100 1 202100 1 202100 1 202100 1 202101 1 202101 143 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 144 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit I Only Avail. with Kit 1 Only Avail with Kit 1 Only Avail with Kit 1

43, 44 202110 1 202110 1 202110 1 202110 1 202111 1 20211133-38 202012 1 202013 1 202014 1 202015 1 202016 1 202017 140-44 202020 1 1 202014 1 202015 1 202016 1 202017 133-38,40-44 Not Available Not Available Not Available Not Available Not Available Not Available33-38,40-44 Not Available Not Available Not Available Not Available Not Available Not Available

3-6, 12-19, 202047 1 202050 1 202053 1 202056 1 202059 1 202062 129, 30, 33-37 202046 1 202049 1 202052 1 202055 1 202058 1 202061 1

40-42 202048 1 202051 1 202754 1 202057 1 202060 1 202063 13-6, 12-19, NOTE: 50% Capacity Repair Kit is not available for port sizes 1-1 /4" to 4". Capacity reduction can be obtained through use of

29-30, 33-37, field installing ‘’Reduced Capacity Plug Kits’’. See description and contents of these kits elsewhere this section.40-42

3-6, 12-19, NOTE: 17% Capacity Repair Kit is not available for port sizes 1-1 /4" to 4". Capacity reduction can be obtained through use of29-30, 33-37, field installing ‘’Reduced Capacity Plug Kits’’. See description and contents of these kits elsewhere this section,

40-42112 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1

29,112 200669 1 200673 1 200673 1 200690 1 200676 1 200677 12, 16(2), 19(2), Gasket Kits (includes complete set of gaskets plus “O” Rings if applicable)25, 26, 29, 37

43, 45(3) 202113 202114 202114 202115 202116 202117Individual Gaskets, “O” Rings and Valve Packing sold and packaged in quantities only as indicated.

29 202407 5 202397 3 202397 3 202396 3 202399 3 202400 337 202384 3 202374 6 202374 6 202374 6 202382 3 202383 343 202408 12 202408 12 202408 12 202408 12 202404 5 202404 52 202408 12 202408 12 202408 12 202408 12 202408 12 202408 1245 202080 12 202081 12 202081 12 202082 12 202083 12 202084 124 202478 25 202478 25 202478 25 202478 25 202478 25 202478 2541 202478 25 202478 25 202478 25 202478 25 202479 5 202479 5

Bolt Package Kits11 202246 8 202246 8 202246 8 202246 8 202246 8 202246 831 202248 8 202249 8 202249 8 202249 8 202250 6 202250 639 Not Required 202251 6 202251 6 202251 6 202252 6 202252 6

Flange Bolt Package includes bolts and nuts; no gaskets46 5/8"-11 4 5/8"-11 4 5/8"-11 4 3/4"-10 4 3/4"-10 4 7/8"-9 447 5/8"-11x2-3/4” 4 5/8"-11x3-1/4 “ 4 5/8”-11x3-1/4" 4 ¾”-10x3-3/4" 4 ¾” – 10x3-3/4” 4 7/8” –9x4-1/2” 4

46,47 201595 1 201604 1 201604 1 201611 1 201611 1 201620 1



A4AK Reseating Relief RegulatorThis regulator is adjusted at the factory for a given inlet

pressure. The seal cap is wired to a bonnet cap screw

and the wires are sealed with a lead seal. The relief

pressure setting is stamped on the seal. Breaking or

removal of the seal voids the factory responsibility for the

relief setting of the regulator. Normal set-point is 4.8 bar

(70 psig)

The operation and other construction features are similar

to A4A, except that sizes 20mm (3/4") through 32mm

(1-1/4") use a PTFE seat in the modulating plug.

Because of slight leakage tolerance, this regulator is not

intended for use as a safety relief valve to the atmosphere,

but rather to a lower pressure section of that system.

Because of large diaphragm to seat area ratio, setting is

affected only slightly by outlet pressure.

The A4AK Regulator is often used as a defrost pressure

relief regulator.

For atmospheric relief, use Type H high capacity safety

relief valve. (See Bul. 70-01 for information and selection).

A4AR Main Regulator for Remote PilotThe A4AR is the main regulator only, without the pressure

pilot being an integral part thereof. Instead, the main valve

has a valve cover tapped 3/8" NPT. With this arrangement,

external pressure pilot and solenoid, if positive electric

shut-off is required, may be connected to control the main

valve. These items can be remotely located from the main

valve where they may be more convenient to adjust,

service or perhaps be in a non-corrosive or non-explosive

area.

Remote pilot piping should not exceed 6m (20 ft.) in total

length and should be 3/8" pipe or equivalent tube size.

The remote piping must originate in the upstream pipe,

not at the A4AR valve itself.

See current issue of Bul. 21-02 for details of A2B Inlet

Pressure Pilot. Use A2B2 with 20-50mm (3/4" - 2") A4AR.

Use A2B Inlet Pressure Pilot with 65-100mm (2-1/2"- 4")

A4AR.

If main valve is to perform as an Outlet Pressure

Regulator, use Outlet Pressure Pilots A2BO2E for

20-50mm (3/4" - 2") A4AR, or A2BO4E for 65-100mm

(2-1/2" - 4") A4AR.

For positive electric shut-off, for all sizes A4AR Main Valve,

use direct operated pilot solenoid Type S6N. See Bul.

30-90C for details.

Maintenance and ServiceGENERAL PROCEDURE:Dirt in the system is the greatest single cause of regulator

malfunction. All screens or filters must be cleaned or

replaced when they become dirty. At start up it is especially

important that these items are cleaned or changed

frequently. When the RSF close-coupled companion

strainers are used, maintain according to instructions in

Bulletin 00-10. Moisture in halocarbon systems in

particular can cause corrosion or form ice, causing the

piston to freeze in position. Filter-driers should be used

and maintained for halocarbon systems.

Before deciding to disassemble a regulator for servicing,

the following investigations should be made:

• Check the manual opening stem; it should beturned in for automatic operation.

• Check the regulator setting to make sure it isproperly adjusted. Turn adjusting screw slowly tosee if regulator responds. Check regulator pressurerange; if wrong, range spring must be replaced.

• Check other system components for properoperation.

• Check hand valves in the system to make sure theyare open or closed as required and the system isreceiving liquid or gas as the case may be.

Before disassembly of regulator, make certain that

all refrigerant has been removed (pumped out) from

the regulator and its companion strainer where one

is used. Read Safety Bulletin RSB.

Safe Operation (See also Bulletin RSBCV)People doing any work on a refrigeration system must be

qualified and completely familiar with the system and the

Refrigerating Specialties Division valves involved, or all

other precautions will be meaningless. This includes

reading and understanding pertinent Refrigerating

Specialties Division product Bulletins, and Safety Bulletin

RSB prior to installation or servicing work.

Where cold refrigerant liquid lines are used, it is necessary

that certain precautions be taken to avoid damage which

could result from liquid expansion. Temperature increase

in a piping section full of solid liquid will cause high

pressure due to the expanding liquid which 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 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 valves upstream of solenoid

valves or downstream of check valves be closed until the

liquid has been removed. It is advisable to properly install

relief devices in any section where liquid expansion could

take place.

Avoid all piping or control arrangements which might

produce thermal or pressure shock.

For the protection of people and products, all refrigerant

must be removed from the section to be worked on before

a valve, strainer, or other device is opened or removed.

Flanges with ODS connections are not suitable for

ammonia service.


SERVICE POINTERS (Check General Procedure)

SYMPTOM PROBABLE REASON CORRECTION

Regulator does not Diaphragm or seat dirty, damaged or frozen. Clean or replace. Clean strainer.

shut off flow.

Diaphragm follower stuck or damaged. Clean or replace. Install follower carefully.

Piston jammed with excess dirt. Remove and polish piston and bore with

crocus cloth. Clean valve and strainer.

Throttling plug leaking due to excess Clean or replace. If used on liquid, check for

dirt or damage. erosion due to excessive flash gas. Reduce

flash gas by sub-cooling or by reducing

pressure drop across valve by providing

restriction at valve outlet.

Diaphragm and seat eroded due to flash gas. Replace. Reduce flash gas by sub-cooling or by

reducing pressure drop across regulator by

providing restriction at valve outlet.

Regulator does not A4A (inlet) Pressure Regulator Diaphragm Replace. If Range D make sure has 2

open. ruptured or badly deformed. diaphragms.

Diaphragm follower stuck, damaged Clean or replace. Install follower carefully.

or frozen.

Piston worn, too much clearance. Replace piston. Check for reason. If used on

liquid, check for flash gas.

Regulator Operation Diaphragm or seat dirty or damaged. Clean or replace. Clean strainer.

erratic.

Diaphragm follower has dirt on the outside Clean or replace.

diameter or outside diameter is damaged.

Other system components, line controllers, Adjust, repair or replace.

thermostats, etc. , erratic.

Regulator too far oversized. Check load. Replace with smaller regulator or

investigate use of Reduced Capacity Plug Kit.

Pressure drop across Inlet or outlet restricted. Check for restriction. Clean strainer.

regulator too high.

Regulator too small. Replace with proper size regulator.

Large amount of flash gas in liquid line. Reduce flash gas by sub-cooling. Reduce line

restriction by increasing line size, particularly

at the regulator outlet. Replace with larger

regulator.

High pressure drop causes high rate of Increase pipe size at the outlet of the

expansion of gas at regulator outlet. regulator.

Regulator does not open all the way. Check piston for wear. Replace, if needed.


PIPING AND LAYOUT FOR STANDARD A4A BACK PRESSURE REGULATOR

PORTA B C PIPE F.P.T. (D)

SOCKET (E) WELD (F)

WELD NECK

SIZE mm INCHES mm INCHES mm INCHES SIZE mm INCHES mm INCHES mm INCHES

¾” ¾” 216 8.5” 216 8.5" 254 10.0”

& 164 6 2" 244 9.6” 392 15.4” 1” 216 8.5" 216 8.5” 261 10.3”

1” 1-1 / 4” 216 8.5” 216 8.5” 261 10.3”

1-1 / 4” 256 10.1” 256 10.1” 300 11.8”

1-1/4” 203 8 0" 248 9.8” 410 16.1” 1-1/2" 256 10.1” 256 10.1” 304 12.0"

1-5/8" 1-1/2" 307 12.1” 307 12.1” 364 14 .3"

& 251 9.9” 287 11.3" 464 18.2” 2” 307 12.1” 307 12.1” 371 14.6"

2”

2-1/2” 331 13.0” 331 13.0” 401 15.8”

2-1/2” 252 9.9” 302 11.9” 483 19.0”

3” 389 15.3” 389 15.3” 478 18.8”

3” 311 12.2" 324 12.8” 597 23.5”

4” 359 14.1” 361 14.2” 653 25.7” 4” 450 17.7” 450 17.7” 571 22.5”

A4A, A4AE

Fig. 3

Allow 25mm (1”) below valve

to operate manual opening stem.


PORT SOLDER O.D. SOLDER (G)

TUBE O.D.S.H J K L M

SIZE mm INCHES mm INCHES mm INCHES mm INCHES mm INCHES mm INCHES mm INCHES

¾" 28.57 1-1/8" 286 11.3"

& 34.92 1-3/8" 285 11.2" 117 4.6" 98 5.9" 241 9.5" 71 2.8" 97 3.8"

1" 41.27 1-5/8" 299 11.8"

34.92 1-3/8" 324 12.8"

1-1/4" 41.27 1-5/8" 339 13.3" 117 4.6" 178 7.0" 254 10.0" 76 3.0" 102 4.0"

53.97 2-1/8" 370 14.6"

1-5/8" 41.27 1-5/8" 414 16.3"

& 53.97 2-1/8" 404 15.9" 140 5.5" 251 9.9" 307 12.1" 114 4.5" 140 5.5"

2” 66.67 2-5/8" 429 16.9"

66.67 2-5/8" 432 17.0"159 6.2" 314 12.4" 325 12.8" 130 5.1" 155 6.1"

2-1/2" 79.37 3-1/8" 468 18.4"

3"79.37 3-1/8" 496 19.5"

176 7.0" 314 12.4" 432 17.0" 152 6.0" 178 7.0"92.07 3-5/8" 542 21.3"

4" 104.78 4-1/8" 613 24.1" 222 8.9" 363 14.3" 478 18.8" 157 6.2" 183 7.2"

PIPING AND LAYOUT FOR STANDARD A4A BACK PRESSURE REGULATOR

A4AR

Fig. 4

Allow 25mm (1”) below valve

to operate manual opening stem.

12Parker Hannifin Corporation • Refrigerating Specialties Division2445 South 25th Avenue • Broadview, IL 60155-3891Telephone: (708) 681-6300 • Fax (708) 681-6306

VALVE À FPT FLANGES WELDING FLANGES Ã FLANGES

SIZE Nominal Sock Weld Weld Neck Flange Package Tubing Fitting

Nom. Flange Pipe Size Sock t I.D. Neck O.D. Number(2/Pkg) O.D. I.D. Flge Pkg.

Pipe Size Pkg. No. Á Socket Weld Â No. (2/Pkg)

mm Inches Inches (2/Pkg) Inches NW No. Inches mm Inches mm Weld Neck Inches mm Inches mm

20 3/4 3/4 200016 3/4 20 1.070 27.81 1.050 26.67 200020 200023 1-1/8 28.57 1.130 28.70 200027

and and 1 200017 1 25 1.365 34.67 1.315 33.40 200021 200024 1-3/8 34.92 1.380 33.05 200028

25 1 1-1/4 200018 1-1/4 32 1.705 43.31 1.660 42.16 200022 200025 1-5/8 41.27 1.631 41.43 200029

1-1/4 200030 1-1/4 32 1.705 43.31 1.660 42.16 200032 200034 1-3/8 34.92 1.380 35.05 200036

32 1-1/4 1-1/2 200031 1-1/2 40 1.930 49.02 1.900 48.26 200033 200035 1-5/8 41.27 1.631 41.43 200037

2-1/8 53.97 2.131 54.13 200038

40 1-5/8 1-1/2 200039 1-1/2 40 1.930 49.02 1.900 48.26 200041 200043 1-5/8 41.27 1.631 41.43 200045

and and 2 200040 2 50 2.445 62.10 2.375 60.33 200042 200044 2-1/8 53.97 2.131 54.13 200046

50 2 2-5/8 66.67 2.631 66.83 200047

65 2-1/2 2-1/2 200048 2-1/2 65 2.945 — 2.875 73.03 200049 200050 2-5/8 66.67 2.631 66.83 200051

3-1/8 79.37 3.131 79.53 200052

75 3 3 200053 3 80 3.575 90.81 3.500 88.90 200054 200055 3-1/8 79.37 3.131 79.53 200056

3-5/8 92.07 3.631 92.23 200057

100 4 4 200062 4 100 4.575 116.20 4.500 114.30 200063 200064 4-1/8 104.77 4.132 104.95 200065

À FPT: Internal NPT (USA Standard Taper Pipe Thread).

Á NW: Metric equivalent nominal size for steel tubing.

Â Metric copper tubing used for refrigeration.

Ã ODS connections to fit copper tubing of given outside

diameter. (Not for use with ammonia)

Definitions:

ODS - Outside Diameter Sweat

I.D. - Inside Diameter

O.D. - Outside Diameter

N.A. - Not Available

Flange Bolt Torque Requirements

Bolt Diameter Valve Port Size Torque

11 mm (7/16") 13mm (1/2 ") 3.9 mkg (28 ft lb)

16m m (5/8") 20-50mm (3/4 "- 2") 11.8 mkg (85 ft lb)

19m m (3/4") 65-75mm (2-1/2 "- 3") 14.5 mkg (105 ft lb)

22mm (7/8") 100mm (4") 22.1 mkg (150 ft lb)

WarrantyAll Refrigerating Specialties Products are warranted

against defect in workmanship and materials for a period

of one year from date of shipment from factory. This

warranty is in force only when products are properly

installed, field assembled, maintained and operated in use

and service as specifically stated in Refrigerating

Specialties Catalogs or Bulletins for normal refrigeration

applications, unless otherwise approved in writing by

Refrigerating Specialties Division. Defective products, or

parts thereof, returned to the factory with transportation

charges prepaid and found to be defective by factory

inspection will be replaced or repaired at Refrigerating

Specialties’ option, free of charge, F.O.B. factory. Warranty

does not cover products which have been altered or

repaired in the field; damaged in transit, or have suffered

accidents, misuse, or abuse. Products disabled by dirt,

or other foreign substances will not be considered

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,

Factory Repair and RebuildingFor the convenience of our customers, we have a standard

factory repair and rebuilding service. Repairable returned

Regulators are disassembled, cleaned, sandblasted, worn

parts replaced, reassembled and re-painted. For quickest

service, it is advisable that this be done during the off

peak season.

including any warranty of merchantability or warranty

of fitness for a particular purpose and in no event is

Refrigerating Specialties responsible for any

consequential damages of any nature whatsoever. No

employee, agent, dealer or other person is authorized to

give any warranties on behalf of Refrigerating Specialties,

nor to assume, for Refrigerating Specialties, any other

liability in connection with any of its products.

FLANGES

C A R T R I D G E H E A T E R S

Hi-Temp Cartridge heaters are designed for

optimum performance above and beyond

the norm.

®

21FAST HEAT, INC.

CARTRIDGEHEATERS

HI-TEMP OPEN AIR TEST

This test was conducted using a 5/8” dia. x 6”

(15.8 mm x 152 mm) long, 750 watt 240 volt

Hi-Temp Cartridge heater. The test was con-

ducted in ambient air 70º F (21º C). A type ‘J’

thermocouple was attached to the heater at

the center of the sheath. The voltage was

varied through a variac to obtain proper

power input for corresponding watt density.

WATT DENSITY CALCULATIONS:

Watt density of a Hi-Temp Cartridge is

simply the total heater wattage divided by

the heated area of the cartridge in square

inches.

Heated Length = OAL – Unheated Sections

(OAL - Overall Length)

The subtraction of 3/4” from the overall

length in the above equations is a general

allowance for the watt density calculations

on Standard Cartridge heaters only.

Hi-Temp Cartridge heaters, heated length

varies depending upon heater diameter

and length.

For specific unheated sections contact

Fast Heat.

Watt

Density

Total Heater Wattage

(Heated Length) x Cartridge Dia. x 3.14

=

1600º F (871º C)

1500º F (815º C)

1400º F (760º C)

1300º F (704º C)

1200º F (649º C)

1100º F (593º C)

1000º F (538º C)

900º F (482º C)

800º F (427º C)

10 w/in2

(1.6 w/cm2)

20 w/in2

(3.1 w/cm2)

30 w/in2

(4.7 w/cm2)

45 w/in2

(7 w/cm2)

40 w/in2

(6.2 w/cm2)

WATTS PER SQUARE INCH / WATTS PER SQUARE CM SHEATH; HI-TEMP CARTRIDGEHEATER (THIS GRAPH FOR REFERENCE ONLY)

AP

PR

OX

IMA

TE T

EMP

ERA

TUR

E IN

DEG

REE

S A

T TH

EC

ENTE

R O

F TH

E H

EATE

R

8 FAST HEAT, INC.

STANDARDCARTRIDGE HEATERS

STANDARD CARTRIDGES

Our Standard Cartridge heaters are

designed as an economical, quality heater

for lower temperature use (typically 40

watts per square inch, depending on the

application). Standard Cartridges can meet

U.L./C.S.A. approval, use the chart on page

151 for reference and consult factory.

The Standard Cartridge Heater is made to

withstand internal temperatures of up to

1000º F (538º C) and features a stainless

steel sheath for resistance to oxidation.

High-purity magnesium oxide (MgO) fills

any space around the resistor wire in order

to optimize heat transfer and increase the

life of the heater.

For faster shipment, Standard Cartridges are

available through our Fast Track delivery

program. Refer to page 2 for a complete

description of these rapid delivery programs.

APPLICATIONS

Standard Cartridge heaters can be used in

virtually any application involving lower

temperatures and relatively little vibration or

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-

tive features and options to customize the

heater to your specific needs.

FEATURES AND BENEFITS

• Wide range of diameters.

• Many termination styles.

• Voltage variations.

• U.L. approved and C.S.A. recognized.

• Top quality ceramic element support.

• Unique winding design allows faster

heating and longer life.

• High purity MgO packing for even

heat distribution.

• Fiberglass insulated lead wire is standard.

Other lead wire insulation available

upon request.

MATERIAL AND CONSTRUCTION

• Computer designed specifications.

• 304 stainless steel sheath for oxidation

resistance.

• Ceramic insulator spaces helically wound

resistor inside the sheath.

• Helically wound nickel chromium resistor

is of a conservative design for each

application and evenly stretched through

the ceramic insulators.

• Fine grain high purity magnesium oxide

(MgO) fills any voids around the resistor

wire to optimize heat transfer, dielectric

strength and life of the heater.

• Resistor wire is joined to the leads by

placing each end into nickel chromium

which, upon crimping, affords a positive

and consistent junction.

• U.L. approved and C.S.A. certified flexible

nickel conductor with fiberglass insulated

lead wire 482º F, (250º C) is standard.

Mica tape/fiberglass insulated 842º F,

(450º C) available when requested

as dictated by the application.

• Disc end of the heater rests on a mica

insulator and is held in position when

the sheath is rolled over onto it. This is a

standard assembly procedure unless the

application requires moisture or water-

proof sealing, at which time the end cap

can be sealed by brazing or welding.

• Ceramic cap standard; cement, epoxy or

RTV seal also available.

Ceramic cap

Lead wire

Spacer

Crimped tubing

Core

MgO

THE STANDARD CARTRIDGE HEATER

9FAST HEAT, INC.

STANDARDCARTRIDGE HEATERS

SPECIFICATIONS

Wattage Tolerances: +5% – 10% based on

Nema standards.

Resistance Tolerances: +10% – 5% to give

above power tolerances. Note that above

tolerances are based on internal operating

temperature since the room temperature

resistance of an element wire is normally

8.5% lower than when operating.

Standard voltages are 120V or 240V. 120V

max. for short length units 3/16”, 1/4”, and5/16” dia. (4.7, 6.3, 7.9 mm).

SPECIAL NOTE ON WARRANTY

Heaters with an operating voltage higherthan 250 Volts must be larger than orequal to 5/8” diameter to be eligible for a warranty.

DIAMETER TOLERANCE

ENGLISH SIZES METRIC EQUIVALENT

3/16” (0.1875) = .183 ± .001 4.6 mm ± .02

1/4” (0.250) = .245 ± .002 6.3 mm ± .05

5/16” (0.312) = .308 ± .002 7.8 mm ± .05

3/8” (0.375) = .370 ± .002 9.4 mm ± .05

7/16” (0.437) = .432 ± .002 11.0 mm ± .05

1/2” (0.500) = .494 ± .003 12.6 mm ± .07

9/16” (0.562) = .562 ± .003 14.3 mm ± .07

5/8” (0.625) = .620 ± .003 14.3 mm ± .07

11/16” (0.687) = .681 ± .003 15.8 mm ± .07

3/4” (0.750) = .744 ± .003 17.3 mm ± .07

13/16” (0.812) = .812 ± .003 20.6 mm ± .07

7/8” (0.875) = .869 ± .003 22.2 mm ± .07

15/16” (0.937) = .932 ± .002 23.7 mm ± .07

1” (1.000) = .992 ± .005 25.2 mm ± .12

1 1/4” (1.250) = 1.244 ± .003 31.6 mm ± .12

METRIC SIZES

10 mm = 9.8 ± .05

Length Tolerances: ± .062” (1.6 mm).

For closer tolerances contact Fast Heat.

The Fast Heat Standard Cartridge heater is

computer designed and specified to include

components that are equal to the wide

variety of applications to which this style of

heater will be subjected.

As with the Hi-Temp Cartridge heater, a

variety of termination styles can be adapted

to this style of heater. When there are

termination requirements other than the

ones illustrated, please contact Fast Heat.

There may be applications where, due to

the wattage requirement, it would be

appropriate to specify a Standard Cartridge

heater but the application dictates that a

Hi-Temp be considered. Such applications

are where distributed wattage is required or

the heater would be subjected to extreme

vibration or impact in operation.

Contact Fast Heat for higher voltage and

amperage ratings, and special diameters

or tolerances.

AVOIDING COMMON HEATER FAILURE MODES

Use recommended maximum watt

density range to avoid excessive watt

densities which result in the internal

overheating of the heater.

A clean and properly bored hole in rela-

tion to heater diameter is required for

good heat transfer.

Be aware that moisture/contamination

will reduce the life expectancy of a heater.

Consider specifying that either the disc or

lead end or both be sealed, depending

upon the specific conditions to which the

heater is being subjected.

Review lead exit variations and select the

style that best suits your particular

application. Consider such conditions as

contamination, abrasion, flexing and

sharp bending of the leads as they exit

the heater.

It is recommended that watt density be

reduced by 20% for those heaters

subjected to frequent cycling.

To avoid burn-out by operating in open

air, heated length must always be fully

inserted. In addition, an exposed heated

section of the heater may cause a

hazardous condition.

Sheath

End disc

Resistorcoil

ENGLISH EQUIVALENT

.394” = .389” ± .003

10 FAST HEAT, INC.

HI-TEMP/STANDARDCARTRIDGE HEATERS

Internally connected leads.

For applications requiring maximum

flexibility at lead exit.

10” (25.4 cm) leads standard, other lengths

are available.

Repairable silk and paint leads for Standard

Cartridges.

Hi-Temp Cartridges are provided with

approx. 1” (25.4 mm) sleeving as standard.

Silk and paint leads are optional on

Hi-Temps.


are available.

Hi-Temp Cartridges are provided with

approx. 1” (25.4 mm) sleeving over lead

junction as standard.


are available.

Clip support helps to minimize lead

breakage where leads exit heater.


are available.

FLEXIBLE LEADS

EXTERNALLY CONNECTED LEADS

STRAIGHT LEADS W/SILK AND PAINT

STRAIGHT LEADS W/CLIP SUPPORT

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Overall length

Overall length

Overall length

Overall length

11FAST HEAT, INC.


Straight strain relief spring minimizes

bending strain on lead wires.

Spring extends approximately 3” (76.2 mm)

beyond end of sheath.

Stainless steel braid over lead wires.

For applications requiring small radius

bending and lead wire abrasion protection.

10” (25.4 cm) braid standard, other lengths

are available.

Straight stainless steel armor cable protects

leads from abrasion.

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.

STRAIGHT STRAIN RELIEF SPRING

BRAID OVER PAIR OF LEADS

SQUARE-LOCK ARMOR STRAIN RELIEF

CONVOLUTED ARMOR STRAIN RELIEF

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Overall length

Overall length

Overall length

Overall length

CONVOLUTED ARMOR

• Used in situations that require moisture resistant armor.• Available in most instances in which armor is utilized.• Some size restrictions apply.

POTTING SYSTEMS AVAILABLE

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.

• Teflon® Cap requires an extended

lead time.

?

12 FAST HEAT, INC.


Must specify insert length.

Bushing material is copper.

10” (25.4 cm) leads standard, other lengths are available.

For immersion applications, specify sealedend. Up to 3⁄4” (19 mm) dia.

Hex head N.P.T. bushing attached.

Must specify insert length and bushingmaterial.

Sheath material types: stainless steel, coldrolled or galvanized.

Bushing material types: brass, stainless steelor steel.


For immersion applications, specify sealedend. Up to 3⁄4” (19 mm) dia. Octagonal box available.

N.P.T. BUSHING

HEX CENTER BUSHING

ADAPTERS

ADAPTERS WITH HEX HEAD


Sheath material types: stainless steel, coldrolled or galvanized.



For immersion applications, specify sealedend. 5⁄8” to 1” (15.8 mm to 25.4 mm) dia.

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Insert length

Insert length

Insert length

Insert length

Hex head N.P.T. bushing attached.


Sheath material types: stainless steel, steelor brass.



For immersion applications, specify sealed end.

Octagonal or explosion-proof boxes can beadapted to both Standard and Hi-Temp Cartridge heaters.

Consult Fast Heat for details.

Contact Fast Heat for available NPT Bushing sizes.

Contact Fast Heat for available Adapter sizes.

Contact Fast Heat for available Adapter sizes.

13FAST HEAT, INC.


Hex head N.P.T. bushing and armor cable

with power plug attached.

Sheath material types: stainless steel, coldrolled or steel.

Must specify insert length, bushing material,

armor length and Hubbell® power plug

number.

Moisture-resistant armor available.

Armor cable with power plug attached.

Must specify armor length and Hubbell®

power plug number.


Other Plugs are available, contact Fast Heat

or see page 26 of our QuickShip catalog.

Fast Heat bolt heaters are designed to

heat drilled metal surfaces quickly while

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

assembly and/or servicing of heavy duty

equipment such as compressors, steam

turbines, pressure vessels, etc.

ARMOR WITH PLUG

BUSHING, ARMOR AND PLUG

BOLT HEATER

Hi-Temp

Standard

Hi-Temp

Standard

Standard

Insert length

Insert length

Insert length

Armor length

Armor length

14 FAST HEAT, INC.


Right angle copper elbow with armor cable

for applications requiring right angle lead

exit and lead wire abrasion protection.

Moisture-resistant armor and seal are

optional.

10” (25.4 cm) armor standard, other lengths

are available.

Both Hi-Temp and Standard Cartridges

are available with either Convoluted or

Square-Lock Armor over the leads.

NOTE: Convoluted armor is available in

3/8” and 5/8” diameters.

Right angle copper elbow with spring for

applications requiring right angle lead exit

and reduced bending strain on lead wire.

Spring approximately 3” (76.2 mm) long.


are available.

Right angle copper elbow for applications

requiring right angle lead exit.

Moisture-resistant seal is optional.


are available.

Both Hi-Temp and Standard Cartridges are

also available with stainless steel braid over

the leads (See Standard at left).

RIGHT ANGLE ELBOW

RIGHT ANGLE ELBOW W/ARMOR

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

B

A

C

B

A

C

B

A

C

Insert length

Insert length

Insert length

RIGHT ANGLE ELBOW W/SPRING

Braid over leads

Standard leads

Convoluted Armor

Square-Lock Armor

A B CIN MM IN MM IN MM

3/8 9.5 1 25.4 1 25.41/2 12.8 1 1⁄4 31.8 1 1⁄4 31.85/8 15.9 1 1⁄4 31.8 1 1⁄2 38.13/4 19.1 1 5⁄8 41.3 1 1⁄2 38.1

ELBOW DIMENSIONS

15FAST HEAT, INC.


90º LEADS

90º S. ST. ARMOR

90º LEADS W/CLIP Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Braided leads exit at 90ºangle for applica-

tions requiring small radius bends, lead wire

protection and where space is limited.


are available.

Order by overall length.

Armor cable exit at 90º angle for applications

where space is limited and lead wire

abrasion protection is required.


are available.


Leads exit at 90º angle for applications

requiring small radius bends, lead wire



are available.


Insert length

A

DOverall length

A

D Overall length

A

DOverall length




are available.

A D (min.)IN MM IN MM

3/8 9.5 3/8 9.51/2 12.7 1/2 12.85/8 15.9 5/8 15.93/4 19.0 3/4 19.0

90º LEADS W/S. ST. BRAID

16 FAST HEAT, INC.


SCREW TERMINALS Screw terminals for applications with high

amps and requiring universal connection

capability.

Standard Cartridge 10-32 screw terminal 1⁄2”

to 11⁄4” (12.7 mm - 31.7 mm) dia.

Hi-Temp 10-32 screw terminal 1⁄2” to 3⁄4“

(12.7 mm - 19 mm) dia.

NOTE: The Terminal dimensions shown are

approximate size.

Screw terminals for applications with high

amps and requiring universal connection

capability. Screw terminals are attached to

external pins.

Standard Cartridge 10-32 screw terminal on3⁄8” to 15⁄16” (9.5 mm - 23.8 mm) dia.

Hi-Temp 1⁄2” to 3⁄4“ (12.7 mm - 19 mm) dia.


approximate size.

Screw terminals are flush with cap.

Standard Cartridge 10-24 screw terminal 1”

to 11⁄4” (25.4 mm - 31.8 mm) dia.


approximate size.

1“

3⁄4“

3⁄4“

3⁄4“

1/2” -5/8”

Standard

Hi-Temp

Standard

Hi-Temp

Standard

Overall length

Overall length

Overall length

SCREW TERMINALS

SCREW TERMINALS

17FAST HEAT, INC.

THERMOCOUPLE LOCATIONCARTRIDGE HEATERS

BOTTOM GROUNDED

For fast response, heater is positioned in a

blind hole or where material flows past or

encompasses the heater.

The end disk is always welded in place.

Machined flat up to 1⁄2“ (12.7 mm) dia.

BOTTOM UNGROUNDED

Where circumstances are such that an

ungrounded thermocouple is required.

CENTER UNGROUNDED

The thermocouple is positioned internally

and ungrounded to monitor the heater

temperature.

Generally used in research and

development applications.

REMOVEABLE THERMOCOUPLE

The thermocouple is inserted down a

hypotube for easy removal.

T/C AT BOTTOM

T/C AT CENTER

HTR GROUNDED UNGROUNDED

DIA. BOTTOM CENTER BOTTOM CENTER

1/4” (6.4 mm) Y N Y Y5/16” (7.9 mm) Y N Y Y3/8” (9.5 mm) Y Y Y Y1/2” (12.7 mm) Y Y Y Y

5/8” (15.9 mm) Y Y Y Y

T/C AVAILABILITYAll heaters shown are Hi-Temp 10” leads, type “J” T/C standard, type “K” T/C is available.

T/C available in all Standard Cartridge heaters. Located at bottom ungrounded and center ungrounded.

HI-TEMP T/C LOCATION AVAILABILITY

Hi-Temp

Hi-Temp

Hi-Temp

Hi-Temp

Hi-Temp

?

CENTER GROUNDED

Selected when a fast response is required.

The thermocouple can be located in any

position along the length of the heater.

Standard location is midway along the

length with approximately 1⁄4” (6.4 mm)

cold section on either side of the junction.

Not available on 1/4” diameter heaters.

REMOVEABLE THERMOCOUPLE

18 FAST HEAT, INC.

SQUARECARTRIDGE HEATERS

Straight stainless steel armor cable protects

leads from abrasion.



are available.



Straight strain relief spring minimizes bend-

ing strain on lead wires.

Spring extends approx. 3“ (76.2 mm) beyond

end of sheath.


are available.

NOTE: All of the Square Cartridge heaters

are available in either Hi-Temp (85 to 90

watts per square inch, depending on the

application) or Standard (35 to 40 watts per

square inch, depending on the application).

Stainless steel braid over lead wires.

For applications requiring small radius

bending and lead wire abrasion protection.


are available.

Internally connected leads.

For applications requiring maximum

flexibility at lead exit.


are available.

FLEXIBLE LEADS

BRAID

ARMOR

SPRING

Overall length

Overall length

Overall length

Overall length

Square-Lock Armor

Convoluted Armor

19FAST HEAT, INC.

SQUARECARTRIDGE HEATERS

STRAIGHT CLIP SUPPORT

90º CLIP SUPPORT

90º ARMORArmor cable exit at 90º angle for applica-

tions where space is limited and lead wire

abrasion protection is required.


are available.







are available.




are available.

Braided leads exit at 90º angle for applica-

tions requiring small radius bends, lead wire



are available.


WIDTHSIZE TOLERANCE DIM. A MAX.

3/8” x 3/8” .370” ± .002” 7/16”(9.5 mm x 9.5 mm) (9.4 mm ± .05 mm) (11.1 mm)

1/2” x 1/2” .495” ± .002” 9/16”(12.7 mm x 12.7 mm) (12.6 mm ± .05 mm) (14.3 mm)

5/8” x 5/8” .620” ± .002” 11/16”(15.9 mm x 15.9 mm) (15.7 mm ± .05 mm) (17.5 mm)

A

A

Overall length

Overall length

Overall length

Convoluted Armor

Square-LockArmor

Overall length

90º BRAID

20 FAST HEAT, INC.

CARTRIDGEHEATERS

APPLICATION FOR SELECTION OFCARTRIDGE HEATERS IN PLATENS

Whether round or square cartridges are

used, close contact of the heater to the

component being heated is important.

When the application is such that the hole

into which a round heater is to be inserted is

too long for practical drilling and reaming, a

Square Cartridge can be selected.

By considering a split plate design, platen

recesses for the Square heater can be milled

for greater lengths or to keep the machine

in-house.

For even heating along the length of the

heaters, consider distributed wattage.

If terminations are protected by a wire

enclosure box and the platen is operating in

excess of 450º F (232º C), consider specifying

high temperature mica tape leads.

To leads that are flexing, add clip supports;

where there is abrasion, cover the leads with

stainless steel braid. For possible contamina-

tion, request armor.

PRECISION STANDARD SQUARE CARTRIDGE HEATERS

Our Square Cartridge heaters, 3/8” (9.5 mm),1/2” (12.7 mm), and 5/8” (15.9 mm) square,

provide more surface area contact than

cylindrical types. Square Cartridge heaters

are normally inserted in a milled slot, there-

fore permitting greater lengths than would

be practically feasible with a drilled or

reamed hole.

As with our Standard Cartridge, Fast Heat’s

Square Cartridge heater features a stainless

steel sheath for resistance to oxidation and

can withstand internal temperatures of up

to 1000º F (538º C). In order to optimize heat

transfer and lengthen the life of the heater,

high-purity magnesium oxide (MgO) insula-

tion fills any space around the resistor wire.

APPLICATIONS

Square Cartridge heaters can be used in

virtually any application involving average

temperatures and vibration. Some examples

include sealing bars, heating platens,

heating fluids and forming.

Square Cartridges can also be modified to

meet the demands of virtually any special

application. Our engineers can utilize a vari-

ety of alternative features and options to

customize the heater to your specific needs.

39FAST HEAT, INC.

HI-TEMP/STANDARD CARTRIDGEIMMERSION HEATERS

CARTRIDGE IMMERSION HEATER

Attention must be given to selecting the proper watts per square inch for thematerial to be heated. Refer to the watt density chart on page 150.

There are applications, because of the surrounding exterior of the container, inwhich a terminal box will not be required.

Most standard immersion heater designs can be adapted to fit special applications.

FEATURES AND BENEFITS

• Durable sheath material designed for

water or oil immersion.

• Magnesium oxide provides an excellent

heat transfer medium.

• Resistance wire is precision wound to

provide long heater life.

• N.P.T. fitting provides easy installation.

• BX Box isolates lead wires.

SPECIFICATIONS

TOLERANCES:

Wattage: + 5% -10% based on NEMA standards

MAX. VOLTAGES:

1/2” (12.7 mm) diameter & below: . . 240 V AC5/8” (15.9 mm) diameter: . . . . . . . . . . . 480 V AC3/4” (19.1 mm) diameter: . . . . . . . . . . . 480 V AC

1” (25.4 mm) diameter: . . . . . . . . . . . . . 480 V AC

BUSHING MATERIALS:

Stainless steel, Brass, and CRS

LEADS:

Conductor and insulation selected with

respect to the design and environment

exterior to the heater.

SHEATH MATERIALS:

Stainless steel

Incoloy®

CARTRIDGE IMMERSION HEATER

Immersion cartridge heaters may be selected when a tubular style heater may be too large for the application.

Heaters are constructed using the Fast HeatHi-Temp design allowing for higher watt densities, thus making it possible to concen-trate more heat into a smaller package.

Standard designs are listed in this section;however, heaters of other diameters,lengths and fitting sizes for similar applications can be designed.

Disc end of heater opposite the lead end iswelded. Lead end is sealed against moisture.

APPLICATIONS

This type of immersion heater can be foundin applications where hot water forfood/beverage vending, hot water for processing applications, etc. is required.

Optimum utilization of heat is experiencedwhen an immersion heater can be adaptedto a fluid heating application.

Durable sheath material designed for water or oil immersion.

Magnesium oxide provides an excellent heat transfer medium.

Resistance wire is precision wound to provide long heater life.

BX Box isolates lead wires.

N.P.T. fitting provides easyinstallation.

40 FAST HEAT, INC.

HI-TEMP/STANDARD CARTRIDGEIMMERSION HEATERS

SCREW TERMINALS

SCREW TERMINALS

FIBERGLASS LEADS

FIBERGLASS LEADS

3/4” (19.1 MM) DIA. OIL/WATER

3⁄4" (19.1 mm) dia.

Screw terminals inside octagonal terminal box.

3⁄4" (19.1 mm) N. P. T. brass bushing.


5⁄8" (15.9 mm) dia.

Screw terminals inside octagonal terminal box.



3⁄4" (19.1 mm) dia.

10" (25.4 cm) fiberglass leads inside octagonal terminal box.

3⁄4" (19.1 mm) N. P. T. steel bushing.


5⁄8" (15.9 mm) dia.

10" (25.4 cm) fiberglass leads inside octagonal terminal box.


Insert Length

Insert Length

Insert Length

Insert Length

FITTING CHART

Brass, steel or stainless steel fittings are avail-able for liquid immersion applications. Otherheater N.P.T. combinations available.

MALE PIPE N.P.T. FITTINGS FOR CARTRIDGE HEATERS

N.P.T. SIZE 1/8" (3.2 mm) 1/4 (6.4) 3/8 (9.5) 1/2 (12.7) 3/4 (19.1)

CART. DIA. 1/4" (6.4 mm) 3/8 (9.5) 1/2 (12.7) 5/8 (15.9) 3/4 (19.1)


STOP / STRAINER VALVEPort Size 13-100mm (1/2”- 4”)

FOR AMMONIA, R12, R22, R502

AND OTHER COMMON REFRIGERANTS

FEATURES

BULLETIN 86-00

March 2003

Installation, Service and Parts Information

I S O 9 0 0 1 C E R T I F I E D

• 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

• Fluid Temperature Range -65°F to +350°F

Fig. 1

SCREEN

ASSEMBLY

DRAIN CONNECTION

STAINLESS

STEEL STEM

HANDWHEEL SEAL CAP

ANGULAR SEAT

PTFE SEAT

DISC

Description

The Refrigerating Specialties combination stop/strainer

shut-off valves are designed to provide all the benefits of a

typical valve and strainer assembly within a single valve

body. This unique combination valve decreases the

effects of pressure drop in a system by eliminating the

need for a separate strainer, while reducing system and

installation costs.

WarrantyAll Refrigerating Specialties products are warranted against defects inworkmanship and materials for a period of one year from date of shipmentfrom originating factory. This warranty is in force only when products areproperly installed, field assembled, maintained, and operated in useand service as specifically stated in Refrigerating Specialties Catalogsor Bulletins for normal refrigeration applications, unless otherwiseapproved in writing by Refrigerating Specialties Division. Defectiveproducts, or parts thereof returned to the factory with transportationcharges prepaid and found to be defective by factory inspection will bereplaced or repaired at Refrigerating Specialties option, free of chargeF.O.B. factory. Warranty does not cover products that have been aftered,or repaired in the field; damaged in transit, accidents, misuse, or abuse.Products disabled by dirt or other foreign substances will not beconsidered defective.

The express warranty above constitutes the only warranty of RefrigeratingSpecialties products, and is in lieu of all other warranties, expressed orimplied, written or oral, including any warranty of merchantability orwarranty of fitness for a particular purpose and in no event is RefrigeratingSpecialties responsible for any consequential damages of any naturewhatsoever. No employee, agent, dealer or other person is authorizedto give any warranties on behalf of Refrigerating Specialties nor toassume for Refrigerating Specialties any other liability in connectionwith any of it products.

Safe Operation (See also Bulletin RSB)People doing any work on a refrigeration system must be qualified

and completely familiar with the system and the Refrigerating

Specialties Division valves involved, or all other precautions will

be meaningless. This includes reading and understanding

pertinent Refrigerating Specialties Division product Bulletins and

Safety Bulletin RSB prior to installation or servicing work.

Where cold refrigerant liquid lines are used, it is necessary that certain

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

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.

Avoid all piping or control arrangements that might produce thermal or

pressure shock. For the protection of people and products, all

refrigerant must be removed from the section to be worked on before a

valve, strainer, or other device is opened or removed. Flanges with

ODS connections are not suitable for ammonia service.

310604


ITEM DESCRIPTION

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

PORT SIZE

ITEM DESCRIPTION

1 Body

2 Gasket, Bonnet

3 Bonnet

4 Stem, Valve

5 Disc Carrier

6 Seat Disc

7 Washer, Retaining

8 Ring, Retaining

9 Roll Pin

10 Packing Cartridge

11 O-ring, Bonnet

12 O-ring, Stem

13 Packing Nut

14 Bolt, Bonnet

15 Screen

16 Bottom Cap

17 Gasket

18 Spring

19 Bolt, Cover

20 Plug

* 2 Bolt body construction

SPARE PARTS

MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM INCH MM 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

OVERALL VALVE DIMENSIONS

3" 4"

(100 MM)(75 MM)

1/2" & 3/4"* 1/2" & 3/4" 1"* 1" 1-1/4" 1-1/2" 2-1/2"2"

(50 MM)(13 & 20

MM)

(13 & 20

MM)PORT SIZE (25 MM) (25 MM) (32 MM) (40 MM) (65 MM)

* 2 Bolt body construction

** Dimension AW is for the stem in wide open (back seated position)

20

3

4

5

678

9

1011

12

13

15

16 17

19

18

14

1

20

2122

23

24

June 2000 / BULLETIN 50-10

Bulletin 50-10, June 2000 supersedes Bulletin 50-10 dated July 1996 and all prior publications.© Copyright 2000 By Sporlan Valve Company, Washington, Missouri.

“Y”TYPE FORGED BRASS STRAINER

TYPE 6000 STRAINER suitable for brine and water applications, and otherliquids where a strainer made of nonferrous material is desirable.

These strainers have a forged brass body, and stainless steel wire clothscreen. Types 6022 through 6088 have a knife edge seal plug. The maxi-mum safe working pressure is 500 psig.

All cleanable strainers have an access for easy re-moval of the screen assembly. This facilitates clean-ing and inspection, without breaking the line con-nections.

MESH SIZESDepending upon the type of application, screen as-sembly mesh sizes of 80 and 100 are recommendedin strainers for refrigerant liquid line applicationsup to and including 1-1/8 line sizes. A 60 meshscreen is recommended for strainers on lines largerthan 1-1/8 OD.

Screen assemblies of 40 mesh size are recommendedfor refrigerant suction line applications, and for themajority of applications involving water, brine, andother liquids. Excessive pressure drop develops inscreen assemblies of 80 and 100 mesh are used forsuch applications.

The mesh size of the screen assembly in a straineris stamped on the flange cap and/or seal plug ofeach strainer.

Sporlan Strainers are designed for either liquid orsuction line applications. They provide free flowwith negligible pressure drop and can be used for avariety of liquids.

All Sporlan Strainers contain the maximum effec-tive screen area. Screen assemblies are seamwelded, and the ends reinforced or capped with sealrings. This construction reduces the possibility ofbursting the screen assembly. The end of the screenassembly seats against the flange plate to form atight seal, thereby preventing dirt from bypassingthe strainer screen.

STRAINERSfor REFRIGERANTS / BRINE / WATER / OIL

TYPE 6000 SERIES

TYPE 8000 SERIES

TYPE 9000SERIES

TYPE XD

EPYT.ON

-CENNOCSNOITsehcnI

NEERCSHSEM

EZIS

.sbL-THGIEW sehcnI-SNOISNEMID

AERA.nI.qS

TRAP.ON TEN -PIHS

GNIP A B C

2206 4 TPF2 2-5834

08 1 -1 252.2 00.1 60.2

3206 a TPF

4306 2 TPF 3 2-5934 05.2 00.1 05.2

6506 w TPF 5 1-504404

-1 2 -2 2 52.3 44.1 31.3

8806 TPF1 8 1-5144 4 5 31.4 57.1 88.3

EPYT.ON

SNOITCENNOCsehcnI NEERCS

HSEMEZIS

.sbL-THGIEW sehcnI-SNOISNEMID

TELNI TELTUO* AERA.nI.qS

TRAP.ON TEN -PIHS

GNIP A B C E F G H K L

470DX 2 TPF egnalF 6.6 3-536 001 -1 w 3 91.4 05.1 52.2 88.2 00.2 87.0 90.1 05.0 31.0

SPECIAL PURPOSE STRAINER

“Y”TYPE CAST SEMI-STEEL STRAINERS

Page 2 / Bulletin 50-10

TYPE XD STRAINER is for use with Ammonia andother liquids where a steel construction is suitable. Maybe used with companion flange or can be bolted di-rectly to Type D Thermostatic Expansion Valves andType MA5A3 Solenoid Valves.

Semi-cast steel body with FPT inlet and flanged outlet connections. Strainer screenis stainless steel with a seal plug for screen removal. Complete unit is zinc platedand painted. The maximum safe working pressure is 500 psig.

* Strainers are supplied with female companion flange. Available without flange when so ordered.

TYPE 8000 STRAINER is

used primarily for Ammonia

(Refrigerant 717), but can

also be used for halocarbon

refrigerants (R-22, R-134a

and R-404A) and other liquids where a steel construc-

tion is applicable. FPT inlet, standard two bolt Yorkflange outlet connection. Types 8004 and 8006 strain-ers can be bolted direct to the inlet of Type A Thermo-static Expansion Valves or Type MA17A3 SolenoidValves on Ammonia applications. The unit is zinc

plated. The maximum safe working pressure is 500 psig.

TYPE 9000 STRAINERS forlarge Ammonia (R-717) instal-lations are also adaptable tolarge halocarbon refrigerant(R-22, R-134a and R-404A)applications, and other liquids where a steel construc-tion is suitable. The strainer is zinc plated. The maxi-mum safe working pressure is 400 psig.

FPT inlet, standard four bolt York flange outlet con-nections. The Type 9008 and 9010 strainers bolt di-rectly to inlet of Types MA32P3 and DMA32P3 Sole-noid Valves.

* 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.

15-600 Printed in U.S. of A.www.sporlan.com

EPYT.ON

NOITCENNOCsehcnI

NEERCSHSEM

EZIS

THGIEW.sbL sehcnI-SNOISNEMID

AERA.nI.qS

TRAP.ON TEN -PIHS

GNIP A B C D E F G H K L

4008 2 *TPF51 3-7904 08 5 7 96.5 57.2 60.5 60.2 18.3 96.2 82.1 57.1 65.0

31.06008 w *TPF

8009 **TPF132 3-0114 06

1131 65.7 31.3 05.7 44.2 57.3 18.1 13.2 57.0

0109 -1 4 **TPF -01 2

Specifications, Applications,Service Instructions & Parts

HANSEN TECHNOLOGIESCORPORATION

Bulletin C401dMarch, 2002

Flanged3/8" thru 4"

FPT, SW, WN, ODSfor refrigerants

HCK4-4 Check Valve

INTRODUCTIONThe HCK4 series of dependable, compact, ruggedin-line check valves (disc type non-return valves) isideally suited for refrigerant flow control applications.Valves open wide for flow in the arrow direction onthe valve body. Valves close quickly andreliably when flow reversals occur.

Plated bodies and stainless steel seat discs andsprings enable them to withstand expectedindustrial refrigeration conditions. Furthermore, thesecheck valves can be mounted in any position, close-coupled to other valves, and use same flanges asParker R/S, Frick, and Henry.

ADVANTAGESThese compact check valves offer reliable operationregardless of position. Corrosion resistant stainlesssteel seat disc. Metal-to-metal seats facilitate durable,tight closing of valves.

APPLICATIONSThese in-line check valves are designed to providerefrigerant flow control to hot gas lines, liquid lines,compressor discharge lines, suction lines, and hotgas heated drain pans.

These valves are not recommended for use withpulsating loads such as low speed compressordischarge and screw compressor side portapplications. For applications such as these, useHansen HCK1 piston type check valves.

ADDITIONAL FEATURESMounts in any positionLess than 1 PSID wide opening pressureCan be close-coupledLow bubble leakage toleranceFor Ammonia, R22, R134a, and other approved

refrigerantsDimensionally replaces R/S CK4A-2, -3, -4, -8, & -1U.L. Listed

KEY FEATURES

HCK4 IN-LINECHECK VALVES

5/8" thru 4" PORT(16 thru 100 mm)

2

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.*

=

MATERIAL SPECIFICATIONSBody:

5/8" thru 1¼": Steel, ASTM A108, zinc chromateplated1½" thru 4": Ductile iron, ASTM A536, zincchromate plated

Seat Disc: Stainless steelSeat Cartridge:

5/8" thru 1¼": Stainless steel, ASTM A5821½" thru 4": Steel, ASTM A108, zinc chromateplated

Spring: Stainless steelSafe Working Pressure: 400 PSIG (27 bar)Operating Temperature: -60F to 240F (-50 to 115°C)

INSTALLATIONValve may be located in any position. Arrow onvalve body should match direction of flow. Securevalve with gaskets between flanges and tightenbolts evenly. Do not use this valve or any componentto align pipes or tighten gap between flanges.

Do not install on inlet side of solenoid valves orcontrol valves with electric shut-off or shut-off valvesunless a relief valve is used from therein betweenpiping. Do not install on inlet side of outlet pressureregulators where liquid may become trapped.Instead, check valves should be located on outletside of these valves. Check valves can be close-coupled to other matching solenoid valves, pressureregulators, or strainers by using a Male AdapterRing and longer bolts supplied when so specifiedon order.

INSTALLATION DIMENSIONS

D = Socket Weld DepthJ = Weld NeckK = ODS Solder

=

5/8"

A2.50"

(64 mm)3.25"

(83 mm)3.25"

(83 mm)3.25"

(83 mm)5.06"

(129 mm)5.06"

(129 mm)6.06"

(154 mm)6.06"

(154 mm)6.39"

(162 mm)

B3.19"

(81 mm)4.50"

(114 mm)4.50"

(114 mm)4.50"

(114 mm)4.56"

(116 mm)4.56"

(116 mm)6.00"

(152 mm)6.00"

(152 mm)7.13"

(181 mm)

C3.50"

(89 mm)4.50"

(114 mm)4.50"

(114 mm)4.50"

(114 mm)6.38"

(162 mm)6.38"

(162 mm)7.50"

(191 mm)7.50"

(191 mm)8.00"

(203 mm)

D0.38"

(10 mm)0.50"

(13 mm)0.50"

(13 mm)0.50"

(13 mm)0.75"

(19 mm)0.75"

(19 mm)1.00"

(25 mm)1.00"

(25 mm)1.00"

(25 mm)

E1.03"

(26 mm)1.22"

(31 mm)1.22"

(31 mm)1.22"

(31 mm)2.56"

(65 mm)2.56"

(65 mm)2.92"

(74 mm)2.92"

(74 mm)3.50"

(89 mm)

F1.50"

(38 mm)2.37"

(60 mm)2.37"

(60 mm)2.37"

(60 mm)3.62"

(92 mm)3.62"

(92 mm)4.84"

(123 mm)4.84"

(123 mm)6.06"

(154 mm)

G1.56"

(40 mm)2.50"

(64 mm)2.50"

(64 mm)2.50"

(64 mm)4.56"

(116 mm)4.56"

(116 mm)6.00"

(152 mm)6.00"

(152 mm)7.13"

(181 mm)

H2.19"

(56 mm)3.12"

(79 mm)3.12"

(79 mm)3.12"

(79 mm)3.06"

(78 mm)3.06"

(78 mm)4.00"

(102 mm)4.12"

(105 mm)5.00"

(127 mm)

J3.26"

(83 mm)4"

(102 mm)4"

(102 mm)4"

(102 mm)6.06"

(154 mm)6.06"

(154 mm)7.06"

(179 mm)7.06"

(179 mm)9.89"

(251 mm)

K0.33"

(8 mm)0.49"

(12 mm)0.59"

(15 mm)0.62"

(16 mm)0.71"

(18 mm)0.87"

(22 mm)0.96"

(24 mm)1.08"

(27 mm)1.40"

(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"

3

1a Seat Disc 1½", 2" 1 72-00161b Seat Disc 2½", 3" 1 72-00341c Seat Disc 4" 1 72-00532a Closing Spring 1½", 2" 1 72-00212b Closing Spring 2½", 3" 1 72-00322c Closing Spring 4" 1 72-00483a Seat Cartridge 1½", 2" 1 72-00203b Seat Cartridge 2½" 1 72-00293c Seat Cartridge 3" 1 72-00283d Seat Cartridge 4" 1 72-00474a Seat Cartridge O-ring 1½", 2" 1 72-00174b Seat Cartridge O-ring 2½", 3" 1 72-00274c Seat Cartridge O-ring 4" 1 72-00495a Flange Gasket 1½", 2" 2 75-01385b Flange Gasket 2½" 2 75-01255c Flange Gasket 3" 2 75-01375d Flange Gasket 4" 2 75-02536a Body, HCK4-7 1 72-00426b Body, HCK4-8 1 72-00196c Body, HCK4-9 1 72-00256d Body, HCK4-0 1 72-00266e Body, HCK4-1 1 72-00467a Bolt, HCK4-7, -8 4 70-02687b Bolt, HCK4-9, -0 (¾" - 10 x 7") 4 72-00337c Bolt, HCK4-1 4 72-00518a Nut, HCK4-7, -8 4 70-01368b Nut, HCK4-9, -0 (¾" - 10) 4 75-02108c Nut, HCK4-1 4 75-02809 Flange (FPT, SW, WN, ODS) 2 FACTORY

Above Kit Consists of:

1 Seat Disc 1 72-00692 Closing Spring 1 72-00703 Seat Cartridge 1 72-00684 Seat Cartridge O-ring 1 72-00715 Flange Gasket 2 70-00656 Body, HCK4-2 1 72-0067

7 Bolt 2 70-02258 Nut 2 70-00559 Flange (FPT, SW, WN, ODS) 2 FACTORY

PARTS LIST

HCK4-2 (2-BOLT) HCK4-2 (2-BOLT)

HCK4-7, -8, -9, -0, -1 (4-BOLT)

Above Kit Consists of:

1 Seat Disc 1 72-00062 Closing Spring 1 70-02043 Seat Cartridge 1 72-00024 Seat Cartridge O-ring 1 72-00035 Flange Gasket 2 70-01326a Body, HCK4-3 1 72-00046b Body, HCK4-4 1 72-00086c Body, HCK4-5 1 72-0001

7 Bolt 2 72-00058 Nut 2 70-01369 Flange (FPT, SW, WN, ODS) 2 FACTORY

(5/8" -11 x 4")(5/8" -11)

HCK4-3, -4, -5 (2-BOLT)Socket weld shown. FPT, weld neck, ODS: available.

HCK4-3, -4, -5 (2-BOLT)

Socket weld shown. FPT, weld neck, ODS: available.

HCK4-7, -8, -9, -0, -1 (4-BOLT)

(5/8" - 11 x 6")

(7/8" - 9 x 7.5")(5/8" - 11)

(7/8" - 9)

Socket weld shown. Weld neck, ODS: available.

(7/16" - 14)(7/16" - 14 x 3.25")

Replaces R/S CK4A-2, CK4A-3, CK4A-4, CK4A-8, & CK4A-1.HCK4-2 close-couples to HS6 & HS8 Solenoid Valves.HCK4-3, -4, & -5 close-couples to HS7 Solenoid Valve.FPT available only 3/8" to 1¼".

TO ORDER: Specify valve type, connection style andsize, and close-coupling information if needed.

TYPICAL SPECIFICATIONS"Refrigeration in-line check valves shall have steelor ductile iron bodies, stainless steel seat discs,stainless steel closing springs, and be suitable fora safe working pressure of 400 PSIG, as manufacturedby Hansen Technologies Corporation type HCK4 orapproved equal."

HCK4-2* (16) ½"

HCK4-3* ¾" (20) ¾" 1", 1¼"

HCK4-4* 1" (25) 1" ¾", 1¼"

HCK4-5 1¼" (32) 1¼" ¾", 1"

HCK4-7 1½" (40) 1½" 2"

HCK4-8* 2" (50) 2" 1½"

HCK4-9 2½" (65) 2½" 3"

HCK4-0 3" (80) 3" --

HCK4-1* 4" (100) 4" --

Printed in U.S.A.

HANSEN TECHNOLOGIESCORPORATION6827 High Grove BoulevardBurr Ridge, Illinois 60527 U.S.A.Telephone: (708) 325-1565 FAX: (708) 325-1572Toll-free: 1-800-426-7368

OPERATIONHCK4 check valves are normally closed valves. Asinlet pressure increases, it overcomes the closingspring force. As the seat disc is pushed back andaway from the seat cartridge, flow through the valveoccurs. The valve will remain open until the inletpressure drops below the closing spring force orthere is a flow reversal, at which time the seat discwill close against the seat cartridge, preventingreverse flow.

SIZINGCheck valves are normally selected on the basis ofline size. However, for gas flow applications at lowload conditions, a minimum of 1 psid across thevalve is essential. This will maintain valve at fullopen position. Valve Cv (Kv) is listed in theinstallation dimension table on page 2. Factory valvesizing assistance is available.

SERVICE AND MAINTENANCEThese valves are a reliable part of a refrigerationsystem. However, if valve does not appear to beoperating satisfactorily, isolate it from the refrigerationsystem. Remove all refrigerant from associated pipingand valves. Follow the guidelines in the cautionsection. Loosen each flange nut on the check valve.Break each flange gasket seal. Carefully loosenflange bolts one at a time, being cautious to avoidany refrigerant which still may be present. Removecheck valve from flanges and inspect. Lapped seatingsurfaces should be smooth and free of pits orscratches.

To confirm valve operation, move seat disc witheraser end of pencil. Movement should be free fromfriction. If not, disassemble and visually inspect fordirt in valve or burrs on seat disc. Clean or replaceparts as necessary. Valve discs and seats can berestored by lapping on a flat plate.

Reassemble valve and insert between flanges.Replace and tighten bolts and nuts evenly. Carefullycheck for leaks before returning to service.

CAUTIONHansen check valves are only for refrigerationsystems. These instructions and related safetyprecautions must be completely read and understoodbefore selecting, using, or servicing these valves.Only knowledgeable, trained refrigeration mechanicsshould install, operate, or service these valves. Statedtemperature and pressure limits should not beexceeded. Valves should not be removed unlesssystem has been evacuated to zero pressure. Seealso Safety Precautions in current List Price Bulletinand Safety Precautions Sheet supplied with product.Escaping refrigerant might cause personal injury,particularly to the eyes and lungs.

WARRANTYHansen valves are guaranteed against defectivematerials or workmanship for one year F.O.B. ourplant. No consequential damages or field labor isincluded.

ORDERING INFORMATION,HCK4 CHECK VALVES

*

Typical close-coupling to solenoid valve.

7/8"

11/8"

13/8"

15/8"

21/8"

31/8"

41/8"

3/8", ¾" 5/8"5/8"

25/8"

© 1995 Hansen Technologies Corporation

Hansen Technologies Corp.Burr Ridge, IL Cert. # 000472Orlando, FL Cert. # 001523

ISO 9002

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

Pressure Relief Valve Instructions 7

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.

Model Number Chart

VIKING PUMP INC. • A Unit of IDEX Corporation •

UNMOUNTED PUMP UNITS

Foot Mounted

GG 4195

HJ 4195

HL 4195

AS 4195

Units Are Designed By The Un-Mounted Pump Model Numbers Followed By A Letter(s) Indicating Drive Style.

AK 4195

AL 4195 D = Direct Drive

Flange Mounted

GG 495 M = Horizontal Direct Drive

HJ 495

HL 495 IM = Vertical In Line Direct Drive

AS 495

AK 495

AL 495

FIGURE 2 AS, AK and AL 4195 SERIES

Foot Type Unmounted Pump with Tapped Ports

FIGURE 1 GG. HJ and HL 4195 SERIES

Foot Type Unmounted Pump with Tapped

TECHNICAL SERVICE MANUAL

HEAVY DUTY PUMPS

SERIES 4195 and 495

SERIES GG - AL

SECTION TSM 144

PAGE 1 OF 9

ISSUE B

FIGURE 4 AS, AK and AL SIZE 495 SERIES

Unmounted Pump with Tapped Ports

FIGURE 3 GG. HJ and HL SIZE 495 SERIES

Unmounted Pump with Tapped Ports

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.

SPECIAL INFORMATION

ROTATION: Viking pumps operate equally well in a

clockwise or counterclockwise rotation. Shaft rotation

determines which port is suction and which is discharge.

Suction Port is where pumping elements (gear teeth) come

out of mesh.

PRESSURE RELIEF VALVES:

1. Viking pumps are positive displacement pumps and

must be provided with some sort of pressure protection.

This may be a relief valve mounted directly on the

pump, an inline pressure relief valve, a torque limiting

device or a rupture disk.

2. There are relief valve options available on those pump

models designed to accept a relief valve. Options may

include a return to tank relief valve and a jacketed relief

valve. Pumps equipped with a jacketed head plate are

generally not available with a relief valve.

3. If pump rotation is reversed during operation, pressure

protection must be provided on both sides of pump.

4. Relief valve adjusting screw cap must always point

towards suction side of pump. If pump rotation is

reversed, remove pressure relief valve and turn end for

end. Refer to Figure 5.

5. Pressure relief valves should not be used to control

pump flow or regulate discharge pressure.

For additional information on pressure relief valves, refer to

Technical Service Manual TSM 000 and Engineering

Service Bulletin ESB-31.

MAINTENANCE

Series 4195 and 495 pumps are designed for long, trouble-

free service life under a wide variety of application

conditions with a minimum of maintenance. The points

listed below will help provide long service life.

CLEANING PUMP: Keep pump as clean as possible. This

will facilitate inspection, adjustment and repair work and

help prevent overlooking a dirt covered grease fitting.

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

internal pump parts. Lubricate fittings and apply grease to

pump shaft extension. Viking suggests rotating pump shaft

by hand one complete revolution every 30 days to circulate

the oil.

SUGGESTED REPAIR TOOLS: The following tools must

be available to properly repair Series 4195 and 495 pumps.

These tools are in addition to standard mechanics’ tools

such as open end wrenches, pliers, screw drivers, etc.

Most of the items can be obtained from an industrial supply

house.

1. Soft Headed hammer

2. AlIen wrenches (set screws & special mechanical seals)

3. Snap Ring Pliers

INTERNAL – Viking Part No. 2-810-047-999

GG-HJ-HL 4195-495

EXTERNAL – Viking Part No. 2-810-029-375

GG-HJ-HL 4195-495

4. Mechanical Seal Installation Sleeve

2-751-001-900 for 0.75 inch seal; GG 4195-495

2-751-004-900 for 1.25 inch seal; AS-AL 4195-495

5. Bearing Locknut Spanner Wrench

(Source: #471 J.H. Williams & Co. or equal)

6. Spanner Wrench, adjustable pin type for use on bearing

housing end cap.

(Source: #482 J.H. Williams & Co. or equal)

7. Brass bar

8. Arbor press

SPECIAL INFORMATION

RELIEF VALVE ADJUSTING SCREW CAP

DISCHARGE SUCTION

SPECIAL MECHANICAL SEALS

This bulletin illustrates the mechanical seal which isstandard in the catalog pump. A Seal InstallationDrawing will be furnished with a pump fitted with a non-standard mechanical seal. Consult this Seal InstallationDrawing before disassembling pump.

Modifications are required to install Teflon seals inthese pumps. Contact factory for specific information.

DANGER

BEFORE OPENING ANY VIKING PUMP LIQUIDCHAMBER (PUMPING CHAMBER,RESERVOIR, RELIEF VALVE ADJUSTING CAPFITTING ETC.) BE SURE:

1. THAT ANY PRESSURE IN CHAMBERHAS BEEN COMPLETELY VENTEDTHROUGH SUCTION OR DISCHARGELINES OR OTHER APPROPRIATEOPENINGS OR CONNECTIONS.

2. THAT THE DRIVING MEANS (MOTOR,TURBINE, ENGINE, ETC.) HAS BEEN“LOCKED OUT” OR MADE NON-OPERATIONAL SO THAT IT CANNOT BESTARTED WHILE WORK IS BEING DONEON PUMP.

3. THAT YOU KNOW WHAT LIQUID THEPUMP HAS BEEN HANDLING AND THEPRECAUTIONS NECESSARY TO SAFELYHANDLE THE LIQUID. OBTAIN AMATERIAL SAFETY DATA SHEET(MSDS) FOR THE LIQUID TO BE SURETHESE PRECAUTIONS AREUNDERSTOOD.

FAILURE TO FOLLOW ABOVE LISTEDPRECAUTIONARY MEASURES MAY RESULTIN SERIOUS INJURY OR DEATH.

FIGURE 5

PAGE 2 OF 9ISSUE BSECTION TSM 144

DISASSEMBLY 1. Refer to figures 7 & 8 page 4 for model to be

disassembled and name of parts. Models 4195 & 495 are

disassembled and assembled the same. The difference

between these models is the casings.

2. Mark head and casing before disassembly to insure

proper reassembly. The idler pin, which is offset in the

pump head, must be positioned up an equal distance

between port connections to allow for proper flow of liquid

through the pump.

3. Remove the head capscrews.

NOTE: The four valve capscrews, valve and gasket must

be removed from the GG 4195-495 model before the six

head capscrews are removed.

4. Tilt top of head back when removing to prevent idler from

falling off idler pin.

5. Remove idler and bushing assembly. If idler bushing

needs replacing, see “Installation of Carbon Graphite

Bushings”, page 7.

6. Insert a brass bar or piece of hardwood in the port

opening and between the rotor teeth to keep the shaft

from turning. Turn the locknut counterclockwise and

remove locknut. See Figure 9 or 10.

7. Loosen two setscrews in face of bearing housing and turn

thrust bearing assembly counterwise and remove from

casing. See Figure 9 or 10.

8. GG, HJ, HL: Remove snap ring from shaft. See Figure 9.

AS, AK, AL: Remove bearing spacer from shaft. See

Figure 10.

9. Remove brass bar or piece of hardwood from port

opening.

FIGURE 6 - CUTAWAY OF MODELS GG, HJ, or HL 4195

MECHANICAL SEAL

BALL BEARINGS

SHAFT

SNAP RINGS

ROTORIDLERHEAD

PRESSURE RELIEF VALVE

IDLER PINCASING

HEAD GASKET

DANGER






SECTION TSM 144 ISSUE B PAGE 3 OF 9

FIGURE 8 – EXPLODED VIEW MODELS AS, AK and AL 4195 and 495

ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART

1 Locknut 7 Bearing Spacer 12 Relief Valve 18 Idler and Bushing

2 Bearing Spacer Collar 8 Ball Bearing, Inner 13 Pipe Plug 19 Head Gasket

3 End Cap for Bearing Housing 9 Bearing Retainer Washer 14 Capscrew for Valve 20 Idler Pin

4 Lip Seal for Bearing Housing 10 Casing (4195) 15 Rotor and Shaft 21 Check Valve

5 Ball Bearing, Outer 10A Casing (495) 16 Mechanical Seal 22 Head and Idler Pin

6 Bearing Housing 11 Gasket for Relief Valve 17 Idler Bushing 23 Capscrew for Head

FIGURE 7 – EXPLODED VIEW MODELS GG, HJ and HL 4195 and 495

* NOT USED ON “GG” SIZE PUMPS

Teflon® - Registered Trademark of DuPont Dow Elastomers L.L.C.

Modifications to pump casing and rotor are required for installation of optional Teflon® Mechanical Seal. Consult the factory.

Modifications to pump casing and rotor are required for installationof optional Teflon® Mechanical Seal. Consult the factory.

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


10. The rotor and shaft can now be removed by tapping on

end of shaft with a lead hammer or, if using a regularhammer, use a piece of hardwood between shaft andhammer. The rotary member of the seal will come outwith rotor and shaft.

11. AS,AK,AL: Remove bearing retainer washer. The

washer may have stayed with Rotor andShaft when removed or is against ballbearing. See Figure 10.

12. Remove the mechanical seal rotary member and spring

from rotor and shaft assembly.

13. GG, HJ, HL: Remove inner snap ring and single row

ball bearing from casing. AS, AK, AL: Remove single row ball bearing from

casting.

14. Remove seal seat or stationary part of seal from casing.

15. Disassemble thrust bearing assembly.

GG, HJ, HL: Remove outer snap ring from bearing

housing and remove ball bearing. SeeFigure 9.

AS, AK, AL: Loosen two set screws in flange outside

diameter. Rotate end cap and lip sealcounterclockwise and remove. Removeball bearing. See Figure 10.

BEARING SPACER

LOCKNUT

INNER BALL BEARING

BEARING HOUSING

BEARING RETAINER WASHER

SETSCREW

LIP SEAL

END CAP

NYLON INSERT

BALL BEARING

SETSCREW

SHAFT

BALL BEARING

BEARING HOUSING

BALL BEARING

LOCKNUT

OUTER SNAP RING

INNER SNAP RING

INNER BALL BEARING

SHAFT SNAP RING SHAFT

FIGURE 9 – THRUST BEARING ASSEMBLY GG, HJ and HL SIZES

FIGURE 10 – THRUST BEARING ASSEMBLY AS, AK and AL SIZES


ASSEMBLY

4. Place tapered installation sleeve on shaft, refer to Figure

11. Sleeve is furnished with GG, AS, AK and ALreplacement mechanical seals. Coat rotor shaft, taperedinstallation sleeve and inner diameter of mechanical sealrotary member with a generous amount of non-detergentSAE 30 weight oil. Petrolatum may be used but grease isnot recommended.

5. Place seal spring on shaft against rotor hub. Refer to

Figure 12.

6. Slide rotary member, lapped contact surface facing away

from spring, over installation sleeve on shaft until justcontacting the spring. Do not compress spring. Removeinstallation sleeve.

7. Coat rotor shaft with non-detergent SAE 30 weight oil.

Install shaft slowly pushing until the ends of rotor teethare just below the face of the casing.

8. Leave the rotor in this position. Withdrawal of rotor and

shaft may displace the carbon seal rotating face andresult in damage to the seal.

9. Place O-ring gasket on head and install head and idler

assembly on pump. Pump head and casing were markedbefore disassembly to insure proper reassembly. If not,be sure idler pin, which is offset in pump head, ispositioned up and equal distance between portconnections to allow for proper flow of liquid throughpump.

10. Tighten head capscrews evenly.

11. If pump was equipped with a relief valve and was

removed during disassembly, install on head with newgaskets. Relief valve adjusting screw cap must alwayspoint towards suction port. Refer to Figure 5 page 2. Forrelief valve repair or adjustments, see PRESSURERELIEF VALVE INSTRUCTIONS, Page 7.

SHAFT

MECHANICAL SEAL

(ROTARY MEMBER)

SPRING ROTOR HUB

FIGURE 12

FIGURE 11

COAT WITH LIGHT OIL BEFORE ASSEMBLY

TAPERED SLEEVE

MECHANICAL SEAL (ROTARY MEMBER)SPRING

Assembly Notes On Standard Mechanical Seal(Synthetic Rubber Bellows Type)

READ CAREFULLY BEFORE REASSEMBLING PUMP

The seal used in this pump is simple to install and goodperformance will result if care is taken during installation.

The principle of mechanical seal is contact between therotary and stationary members. These parts are lapped toa high finish and their sealing effectiveness depends oncomplete contact.

Prior to installing rotary portion of mechanical seal, prepareand organize rotor shaft, head and idler assemblies andappropriate gaskets for quick assembly.

Once rotary portion of mechanical seal is installed on rotorshaft, it is necessary to assemble parts as quickly aspossible to insure the seal does not stick to shaft in wrongaxial position. The seat will stick to the shaft after severalminutes setting time.

Never touch sealing faces with anything except cleanhands or clean cloth. Minute particles can scratch the sealfaces and cause leakage.

1. Coat idler pin with non-detergent SAE 30 weight

oil and place idler and bushing on idler pin inhead. If replacing a carbon graphite bushing, referto Installation of Carbon Graphite Bushings, page7.

2. Clean rotor hub and casing seal housing bore.

Make sure both are free from dirt and grit. Coatouter diameter of seal seat and inner diameter ofseal housing bore with non-detergent SAE 30weight oil.

3. Start seal seat in seal housing bore. If force is

necessary protect seal face with a cleancardboard disc and gently tap i1 in place with apiece of wood. Be sure seal seat is completelyseated in the bore.

The casing should be examined for wear, particularly in thearea between ports. All parts should be checked for wearbefore pump is put together.

When making major repairs, such as replacing a rotor andshaft; it is advisable to also install a new mechanical seal,head and idler pin, idler and bushing. See "Installation ofCarbon Graphite Bushings" page 7.

Clean all parts thoroughly and examine for wear ordamage. Check lip seals, ball bearings, bushing and idlerpin and replace if necessary. Check all other parts fornicks, burrs, excessive wear and replace if necessary.

Wash bearings in clean solvent. Blow out bearings withcompressed air. Do not allow bearings to spin; turn themslowly by hand. Spinning bearings will damage race andballs. Make sure bearings are clean, then lubricate withnon-detergent SAE 30 weight oil and check for roughness.Roughness can be determined by turning outer race byhand. Replace bearings if bearings have roughness.

Be sure shaft is free from nicks, burrs and foreign particlesthat might damage mechanical seal. Scratches on shaft inseal area will provide leakage paths under mechanicalseal. Use fine emery cloth to remove scratches or sharpedges.


INSTALLATION OF CARBON

GRAPHITE BUSHINGS

When installing carbon graphite bushings, extreme care

must be taken to prevent breaking. Carbon graphite is a

brittle material and easily cracked. If cracked, the bushing

will quickly disintegrate. Using a lubricant and adding a

chamfer on the bushing and the mating part will help in

installation. The additional precautions listed below must

be followed for proper installation:

1. A press must be used for installation.

2. Be certain bushing is started straight.

3. Do not stop pressing operation until bushing is in

proper position, starting and stopping will result in a

cracked bushing.

4. Check bushing for cracks after installation.

THRUST BEARING ADJUSTMENT

See Figures 9 and 10.

Loosen two screws in face of thrust bearing assembly.

If shaft cannot be rotated freely, turn thrust bearing

assembly counterclockwise until shaft can be turned

easily.

To set end clearance:

1. While turning rotor shaft, rotate thrust bearing

assembly clockwise until noticeable drag occurs.

This is zero end clearance.

2. Mark position of bearing housing with respect to the

casing.

3. Rotate thrust bearing assembly counterclockwise the

distance listed below as measured on outside ofbearing housing.

4. Tighten two setscrews in face of bearing housing

after adjustment is made to secure thrust bearingassembly position.

For viscosities above 2500 SSU, add additional endclearance (0.004” for GG, HJ and HL size pumpsand 0.005” for AS, AK and AL size pumps).

DANGER

BEFORE STARTING PUMP, BE SURE ALLDRIVE EQUIPMENT GUARDS ARE IN PLACE.

FAILURE TO PROPERLY MOUNT GUARDSMAY RESULT IN SERIOUS INJURY OR DEATH.

12. Pack inner ball bearing with multi-purpose grease,

NLGI #2.

GG, HJ, HL: Install bearing in casing with sealed side

towards head end of pump. Drive thebearing into the bore. Tap the inner racewith a brass bar and lead hammer toposition bearing.Install inner snap ring.

AS, AK, AL: Install bearing retainer washer over the

shaft before installing ball bearing. Installball bearing in casing with sealed sidetowards head end of pump. Drive thebearing into the bore. Tap the inner racewith a brass bar and lead hammer toposition bearing.

13. GG, HJ, HL: Install shaft snap ring in groove in the

shaft. See Figure 9.

AS, AK, AL: Install bearing spacer over shaft and

against single row ball bearing. SeeFigure 10.

14. Pack lubrication chamber between inner ball bearing

and double row ball bearing in the thrust bearingassembly approximately one-half full of multi-purposegrease, NLGI #2. The thrust bearing assembly will takethe remaining space. See Figure 9 and 10.

15. Pack double row ball bearing with multi-purpose

grease, NLGI #2.

GG, HJ, HL: Install ball bearing into bearing housing

with shield side toward coupling end of shaft. SeeFigure 9. Install snap ring into bearing housing toretain ball bearing. This snap ring has a tapered edgeto fit tapered groove in bearing housing. The taperededge is located away from ball bearing.

AS, AK, AL: Install ball bearing into bearing housing.

Install lip seal in bearing housing end cap. The lipshould face towards end of shaft. Put bearing spacercollar in lip seal and install in bearing housing andtighten set screws securely. See Figure 10.

16. Insert brass bar or hardwood through port opening

between rotor teeth to keep shaft from turning.

17. Start thrust bearing assembly into casing. Turn by

hand until tight. This forces rotor against head.Replace and tighten locknut or shaft.

18. Remove brass bar or hardwood from port opening.

19. Adjust pump end clearance, refer to page 7.

Pump Size Distance In Inches On

O.D. Of Bearing HousingEnd

Clearance

GG 0.44” .003

HJ, HL 0.56” .003

AS, AK, AL 0.5” .003


PRESSURE RELIEF VALVE INSTRUCTIONS

VALVE - LIST OF PARTS

1. Valve Cap 6. Valve Body

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet 10. Bonnet

DISASSEMBLY

Mark valve and head before disassembly to insure proper

reassembly.

1. Remove valve cap.

2. Measure and record length of extension of adjusting

screw. Refer to “A” on Figures 13 and 14.

3. Loosen locknut and back out adjusting screw until

spring pressure is released.

4. Remove bonnet, spring guide, spring and poppet from

valve body. Clean and inspect all parts for wear or

damage and replace as necessary.

ASSEMBLY

Reverse procedures outlined under Disassembly. If valve

is removed for repairs, be sure to replace in same

position. Relief valve adjusting screw cap must always

point towards suction side of pump. If pump rotation is

reversed, remove relief valve and turn end for end. Refer

to Figures 5, page 2.

FIGURE 14

VALVE – AS, AK and AL SIZES

VALVE - LIST OF PARTS

1. Valve Cap 6. Valve Body

2. Adjusting Screw 7. Valve Spring

3. Lock Nut 8. Poppet

4. Spring Guide 9. Cap Gasket

5. Bonnet

FIGURE 13

VALVE - GG, HJ, and HL SIZES

DANGER







PRESSURE ADJUSTMENT

If a new spring is installed or if pressure setting of pressure

relief valve is to be changed from that which the factory has

set, the following instructions must be carefully followed.

1. Carefully remove valve cap which covers adjusting

screw.

Loosen locknut which locks adjusting screw so

pressure setting will not change during operation of

pump.

2. Install a pressure gauge in discharge line for actual

adjustment operation.

3. Turn adjusting screw in to increase pressure and out to

decrease pressure.

4. With discharge line closed at a point beyond pressure

gauge, gauge will show maximum pressure valve will

allow while pump is in operation.

IMPORTANT

In ordering parts for pressure relief valve, always give

model number and serial number of pump as it appears on

nameplate and name of part wanted. When ordering

springs, be sure to give pressure setting desired.

WARRANTY

Viking warrants all products manufactured by it to befree from defects in workmanship or material for aperiod of one (1) year from date of startup, providedthat in no event shall this warranty extend more thaneighteen (18) months from the date of shipment fromViking. If, during said warranty period, any productssold by Viking prove to be defective in workmanship ormaterial under normal use and service, and if suchproducts are returned to Viking’s factory at Cedar Falls,Iowa, transportation charges prepaid, and if theproducts are found by Viking to be defective inworkmanship or material, they will be replaced orrepaired free of charge, FOB. Cedar Falls, Iowa.

Viking assumes no liability for consequentialdamages of any kind and the purchaser by acceptanceof delivery assumes all liability for the consequences ofthe use or misuse of Viking products by the purchaser,his employees or others. Viking will assume no fieldexpense for service or parts unless authorized by it inadvance.

Equipment and accessories purchased by Vikingfrom outside sources which are incorporated into anyViking product are warranted only to the extent of andby the original manufacturer’s warranty or guarantee, ifany.

THIS IS VIKING’S SOLE WARRANTY AND IS INLIEU OF ALL OTHER WARRANTIES,EXPRESSED OR IMPLIED, WHICH AREHEREBY EXCLUDED, INCLUDING INPARTICULAR ALL WARRANTIES OFMERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE. No officer or employee

of IDEX Corporation or Viking Pump, Inc. is

authorized to alter this warranty.

TECHNICAL SERVICE MANUAL

HEAVY DUTY PUMPS

SERIES 4195 and 495

SERIES GG - AL

SECTION TSM144

PAGE 9 OF 9

ISSUE B

VIKING PUMP INC. • A Unit of IDEX Corporation •

VIKING PUMP INC. • Copyright© 2000 •

DANGER

BEFORE STARTING PUMP, BE SURE ALLDRIVE EQUIPMENT GUARDS ARE IN PLACE.

FAILURE TO PROPERLY MOUNT GUARDSMAY RESULT IN SERIOUS INJURY OR DEATH.

Features

Wide Range of Temperatures

Heavy Duty

Self-Contained

Replaceable Element

Non-Adjustable

Rugged Construction

Tamper-Proof

Operate in Any Position

Compact

Available for Refrigeration Service

FLUID POWER ENERGY, INC.W229 N591 Foster Court • Waukesha, WI 53186

262 •548 •6220 Fax 262 •548 • 6239www.fpevalves.com

Three-WayThermostatic Valve

MADE IN

U. S. AISO 9001-2000

Model 2010

2010 2” NPT2010-1 1 1/2” NPT2010J24 1 1/2” SAE O-RingA2010J32 2” SAE O-RingF2010 2” 125# FF FlangeSF2010 2” 150# RF FlangeSF2010X 2” 300# RF Flange

Fluid Power Energy (FPE) Thermostatic Valves utilize the principle ofexpanding wax, which in the semi-liquid state undergoes large expansionrates within a relatively narrow temperature range. The self-contained ele-ment activates a stainless steel sleeve, which directs flow. All FPEThermostatic Valves are factory set at predetermined temperatures: no fur-ther adjustments are necessary. A wide range of temperatures are avail-able for water and oil temperature control applications.

When used in a diverting application, on start-up the total fluid flow is rout-ed back to the main system. As fluid temperature rises to the controlrange, some fluid is diverted to the cooling system. As fluid temperaturecontinues to increase, more flow is diverted. When the thermostat is in afully stroked condition, all fluid flow is directed to the cooling system. FPEThermostatic Valves may also be used in a mixing application.

In a mixing application, hot fluid enters the “B” port and colder fluid entersthe “C” port. The flows mix and the thermostat adjusts to reach the desiredtemperature, exiting the “A” port.

Standard FPE thermostatic valve housings are made from aluminum andgrey iron castings, however, ductile iron, bronze, steel and stainless steelhousings are available.

Available Connections: NPT, SAE O-Ring, 125# FF Flange, 150# and300# RF Flange.

Optional features: High over temperature element, plated element. Otheroptions available upon request.

PRESSURE RATINGSMATERIAL PSI

A, B 150D 250

S, SS 500SF, SSF 275

SFX, SSFX 720

FLUID POWER ENERGY, INC.W229 N591 Foster Court • Waukesha, WI 53186

262 •548 •6220 Fax 262 •548 • 6239www.fpevalves.com

Model 2010

*2010-1, *2010, *2010J

* (Replace * with body material type; A=Cast Iron, B=Bronze, D=Ductile, S=Steel, SS=Stainless Steel)

To OrderSpecify Model Number, nominal

temperature desired, and housing material. For Model coding information,

visit our website or consult yourfactory representative.

FPE-2010-050803

*F2010, *F2010X

Flow vs. Pressure Drop

FLOW IN U.S. GPMSAE 10 @ 100° F

1 1/2”

2”

PART # DESCRIPTION*2010 VALVE BODY (*See table for material)*2020 VALVE COVER (*See table for material)1570** O-RING (Standard material is Buna-N)2071 LIP SEAL2050-Temp THERMOSTAT (Temp to follow dash)1600 HEX BOLT1601 LOCK WASHER

FPE Model 2000** Replacement Kit (Includes the following:)

1570** BUNA O-RING (Standard material is Buna-N)2071 LIP SEAL2050-Temp THERMOSTAT (Temp to follow dash)(For Viton® (V) or Neoprene (E) O-Ring material, replace ** with V or E)

Viton® is a registered trademark of Dupont Dow ElastomersRecommended Pressure Drop is 2 to 7 PSI

SOLENOID VALVES

N O T F O R U S E O N H A Z A R D O U S O R C O R R O S I V E F L U I D S

August 2003 / BULLETIN 30-11

To insure peak performance, solenoid valves must be selected andapplied correctly; however, proper installation procedures are equallyimportant. The following instructions list the essential points forcorrect installation.

An exploded view of a typical solenoid valve is illustrated in Figures5, 5A and 6, page 4.

Position — All standard solenoid valves may be mountedhorizontal, on its side or in a vertical line with the exception of thefollowing: A3 dated 6-86 or before, MA32, B33, OB33, MA42,MA50, MA5A, MA17A, XWG, XUP, XRN, XRM and XPO series.These valves MUST be installed in horizontal lines with the coilhousing no more than 45° from vertical, see table on page 2. Thedirection of flow is indicated by an arrow or the word IN on the inletof the valve body. For heat pump applications, valve types C(M)Eand C(M)B are typically installed with the directional arrow pointingtoward the outdoor coil. Or, the IN connection toward the indoor coil.

NOTE: Solenoid valves having a type number starting with the letter"X" are Special Solenoid Valves (non-standard). Contact SporlanValve Company, Washington, MO if valve mounting is in question.

SOLDER CONNECTIONSBecause of possible damage to valve components due to the hightemperatures of soldering and brazing, "B" Series Solenoid Valveswith brass connections are shipped handtight to facilitatedisassembly, with the exception of the (M)B33S2 & OB33S2. It isnecessary to completely disassemble these valves before any heat isapplied to the valve body. The following steps outline recommendedprocedures when installing these valves.

Soldering Precautions — Solder connections on Sporlan SolenoidValves are either copper or brass. Any of the commonly used types ofsolder are satisfactory with these materials. Regardless of the type ofsolder used, it is important to avoid overheating the valve.

The tip of the soldering torch should be large enough to avoidprolonged heating of the connection during the soldering operation.Overheating can also be minimized by directing the flame away fromthe valve body.

Type A3S1, S4S1, S6S1, S7S11. Remove the coil assembly.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

solder.4. Replace the coil assembly and tighten coil hex screw.

Types B6, B9, B10, B14, B19, B25 Series (Brass Connections)1. Remove the coil assembly, enclosing tube and nut, all internal

parts, and manual lift stem assembly.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

solder.

4. Re-assemble as follows, see Figures 1, 5, and 5A:a. Place the seat disc into the valve body with the smaller

diameter end facing up.b. Place the enclosing tube gasket onto the valve body above the

threads.c. Hold the plunger with one hand so that the pointed end is

resting in the pilot port of the disk. Make sure the small spring is in place on the top of the plunger. (NOTE: Does notapply to normally open and rapid cycle series.)

d. With the other hand, place the enclosing tube over the plunger,making sure the enclosing tube gasket is in position.

e. Replace the enclosing tube locknut and tighten. (Seerecommended torque in the table on page 2.) Do not overtighten.

f. Replace manual lift stem. Tighten lift stem assembly and seal cap.g. Replace the coil assembly. (NOTE: For normally open and

rapid cycle valves replace spacer and spacer cupwith coil assembly.)

NOTE: Excessive tightening of the enclosing tube locknut candamage the valve body bore. Please observe the torques listed onpage 2.

Types: All E Series (Extended Copper Connections)Brazed into the line without disassembly because the valve containsextended connections. Use caution by placing a wet cloth or chillblock on the extensions at the body to prevent excessive overheating.Follow Type A3S1 installation instructions.

Enclosing Tube

Kickoff Spring

Valve Body

EnclosingTube Locknut

EnclosingTube Gasket

Stem and Plunger

Seat Disc

Manual Lift Stem(if required)

■ Figure 1

I n s t a l l a t i o n a n d S e r v i c i n g I n s t r u c t i o n s

© COPYRIGHT 2003 BY SPORLAN VALVE COMPANY, WASHINGTON, MISSOURI

BULLETIN 30-11, AUGUST 2003 SUPERSEDES BULLETIN 30-11, NOVEMBER 2000 AND ALL PRIOR PUBLICATIONS.

■ The molded MKC-1 coil fits the A3, E3,W3, S4, E5, B6, E6, S6,W6, S7, R183, R184 and R246 series normally closed solenoidvalves.

■ The OMKC-1 coil fits the XWG, XUP and XXF series rapidcycle solenoid valves.

■ The MKC-2 coil fits the B9, E9, B10, E10, B14, E14, W14, B19,E19, W19, B25, E25, W25, B33, E33, E34, E42 series normallyclosed solenoid valves and the 180 solenoid pilot control...and all solenoid valves in the field that are equipped withthe old style KC-2 coil.

■ When changing from the old KC model coils to the currentMKC molded model coils, discard the coil housing, coilhousing bottom plate, two coil sleeves (not used with KC-1coil) AND THE SPACER.

■ The OMKC-2 coil fits the OB9, OE9, OB10, OE10, OB14, OE14,OB19, OE19, OB25, OE25, OB33, OE33, OE34, OE42 seriesnormally open solenoid valves and the XRN, XRM, XPOseries rapid cycle solenoid valves.

■ Other Sporlan Valve products using a molded coil are asfollows:MKC-1 — OM-1, SORIT, 8D, 12D, 10G, SORIT-PI, 5D, SHGB(E)-8.MKC-2 — 16D, DDR-20, SHGB(E)-15, OLDR-15 and OLDR-20.OMKC-2 — LDR-15, LDR-20, XTM and XTO.

PIPE CONNECTIONSTypes A3, W3, B6, W6, B9, B10, B14, W14, B19, W19, B25,

W25, (K)(B)R183, (K)(B)R184, (K)(B)R246 SeriesThese valves can be installed without disassembly. Avoid excessiveamounts of pipe sealing compounds. It will interfere with the valveoperation if it comes in contact with the valve's internal parts.

NOTE: When pipe type solenoid valves are installed with pipe toODF adaptors, the valve must be disassembled prior to brazing theODF adaptors.

FLANGED CONNECTIONS—PIPE or SOLDERSolenoid valves with flanged connections may be installed withoutdisassembly. In most cases the flanges are packed disassembled fromthe valve body. Therefore, they may be installed in the line before thevalve is installed. Be certain that the correct flange is installed on theinlet line in order to properly match the flow direction of the valve. Ifthe valve is installed backwards, it will not function properly.

Types MA5A3, MA17A3, MA32P3, MA42P3, MA50P3 Avoid the use of excessive amounts of pipe sealing compounds. Itwill interfere with the valve operation if it comes in contact with thevalve's internal parts.

Types B33S2, MB33S2, OB33S2, MA42S3, MA50S3These valves are supplied with a two piece flange assembly, a semi-steel flange ring and a brass solder bushing. The flange should beplaced on the pipe before the bushing is soldered or brazed. Thesoldering discussion given under "Solder Connections" applies forthese valves except where the discussion deals with non-flangedvalves only.

With Types MA42S3 and MA50S3, use the correct flange andbushing that corresponds with its mating flange on the valve to insurecorrect flow direction.

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.

INSTALLATION—ALL VALVESMounting — A Type 1216-1 universal mounting bracket, Figure 2,is available, when ordered. It fits all standard Sporlan SolenoidValves except the Types W3, MA32, B33, E33, E34, E42, MA42,MA50, (K)(B)R183, (K)(B)R184, (K)(B)R246 series and the Type180 Solenoid Pilot Control. The slots in the bracket match the tappedholes in the standard solenoid valves so that they may be secured bytwo screws supplied with the bracket. A locknut is also furnished foruse with Types MA5A3 and MA17A3. Both types of installations areshown in Figure 2. The manual lift stem seal cap is replaced after thelocknut is tightened against the bracket.

Page 2 / BULLETIN 30-11

SEIRESEVLAV 11111GNISOLCNE

EBUTTUNKCOL 55555

GNISOLCNEEBUT

SWERCS

EVLAVTOLIPYLBMESSA

TUNKCOL

REWOLYDOB

TUNKCOLLIOCWERCS

LIOCTUNKCOL

EGNALFETALP/STLOBSWERCS

EGNALFNOITCENNOC

STLOB

TFILLAUNAMMETS

YLBMESSAPACLAES

NOITISOPGNITNUOMEVLAV

LACITREVENIL 33333

LATNOZIROHENIL

NOEDIS 33333

7S,6S,4S,3A --- --- --- --- 3.2 --- --- --- --- ---SEY

68-7detadretalro

SEY

5E,3E---

------ --- 3.2 --- --- --- --- ---

SEY SEY3W 76.1–5.1GWX --- ON SEY 22222

6W,6E,6B51–01 --- --- --- 3.2 0.4 --- --- 21–11 6–4

SEY SEYPUX ON SEY 22222

9EO,9BO,9E,9B03–52 --- --- --- 3.2 0.4 --- --- 21–11 6–4

SEY SEYNRX ON SEY 22222

01EO,01BO,01E,01B

04–02 --- --- --- 3.2 0.4 --- --- 21–11 6–4SEY SEY,41W,41E,41B

41EO,41BOMRX ON SEY 22222

,91W,91E,91B91EO,91BO 54–53 --- --- --- 3.2 0.4 --- --- 21–11 6–4

SEY SEY

OPX ON SEY 22222

52W,52E,52B56–06 --- --- --- 3.2 0.4 --- --- 21–11 6–4 SEY SEY

52EO,52BO33B

03–52 --- --- --- 3.2 0.4 21–8

73

21–11 6–4

ON SEY 22222

43E --- SEY SEY33BO 73 ON SEY 22222

43EO --- SEY SEY24EO,24E 03–52 --- --- --- 3.2 0.4 02–31 --- 21–11 51–01 SEY SEY

3A5AM05–52 --- --- --- --- 0.4 ---

4221–11 51–01 ON SEY ON

3A71AM 7323AM

--- --- --- --- --- 0.421–8

47 21–11 51–01 ON SEY ON24AM 02–2105AM 53–52

642R,481R,381R --- 6 --- --- 3.2 --- --- --- --- --- SEY SEYD8

51–01 --- 56–0656–06

3.2 ---

---

--- --- --- SEY SEYD21 --- 81–51D61 53–03 --- 44444 --- 42–02G01 51–01 --- 56–06 56–06 ---

RECOMMENDED TORQUE (ft.–lbs.)

Hole throughwhich solenoid

is screwed tobracket

■ Figure 2

Installationusing locknut onmanual stem for

MA5 & MA17

Installation for Types A3, E3*, E5*, B6, E6*, W6, B9, E9*,B10, E10, B14, E14, W14, B19, E19, W19, B25, E25, W25,Series & Types MA5A, MA17A Solenoid Valves.*Are not supplied standard with mounting holes.

FRONT VIEW BOTTOM VIEW

1.50 1.50

1.75

1.06

2.16

1.16

1.31

1Valves with mounting holes use a #8-32 screw torqued not more than 15 in.-lb. Note: Standard torque charts do not apply. 2Coil housing to be no more than 45° from the vertical. 3Coilhousing must not be below horizontal. 4The 16D pilot assembly is connected to the body with a pipe connection. Apply a light coat of #242 (Blue) Loctite to the male pipe thread and torqueto 30-60 ft.-lb. 5Do not over tighten the enclosing tube locknut. Damage to the enclosing tube assembly could result from over tightening.

BULLETIN 30-11 / Page 3

Wiring — Check the electrical specifications of the coil to be surethey correspond to the available electrical service.

The 1/2" BX conduit connection or junction box on the coil may berotated to any position by loosening the coil hexscrew. Solenoidvalves with four-wire dual voltage coils have a wiring diagram decal,Figure 3, on the coil housing or bracket. This illustrates which wiresto connect for either 120, 208 or 240 volt operation. Wiring andfusing (when used) must comply with prevailing local and nationalwiring codes and ordinances.

Direct Current Valves — A surge protector is supplied with eachsolenoid valve with a 115 volt DC coil. The surge protector isnecessary to absorb the high counter-voltage generated when thecircuit is broken, thereby protecting the electrical contacts of thethermostat. It should be wired as shown in Figure 4.

SERVICING INSTRUCTIONSCAUTION — Dangerous hydraulic pressures may develop if a handvalve is installed in the liquid line ahead of the solenoid valve and thehand valve is closed while the solenoid valve is closed. This maycause extrusion of the teflon seat in the disc. Extrusion may cause thevalve to fail to open, fail to close and/or have excessive seat leakage.Also the line between these two valves should be pumped downcompletely before disassembling the solenoid valve for service.

NOTE: The optional manual lift stem is designed to prevent damage tothe disc. If the stem is turned in too far, the threads become disengaged.These threads can be re-engaged by applying slight outward forcewhile turning counterclockwise. A thread stop is provided to preventthe stem from backing all the way out of the assembly. Back the stemto the stop and replace the seal cap when service is complete.

TYPICAL MALFUNCTIONSThere are only three possible malfunctions: 1. Coil burnout.2. Failure to open. 3. Failure to close. Each is discussed.

1. COIL BURNOUTCoil burnouts are extremely rare unless caused by one of thefollowing:1. Improper electrical characteristics.2. Continuous over-voltage, more than 10%.3. Under-voltage of more than 15%. This applies only if the

operating conditions are such that the reduced MOPD causesstalling of the plunger, which results in excessive current draw.

4. Incomplete magnetic circuit due to the omission of parts suchas: coil housing, coil sleeves, coil spring, coil housing bottomplate or plunger on the KC model coil and coil yoke, coilbackplate or plunger on the MKC molded model coils.

5. Mechanical interference with plunger movement which may becaused by a deformed enclosing tube.

6. Voltage spike.7. Valve ambient exceeds 120°F.8. Fluid or gas temperatures greater than 240°F, while the valve

ambient is 120°F.

2. FAILURE TO OPEN (Normally Closed Types)1. Coil burned out or an open circuit to coil connections.2. Improper electrical characteristics. 3. In pilot operated valves, dirt, scale or sludge may prevent the

piston, disc or diaphragm from lifting. This could also becaused by a deformed body.

4. High differential pressure that exceeds the MOPD rating of thevalve.

5. Diameter reduction of synthetic seating material in pilot portbecause of high temperatures and/or pressures, or severepulsations. Contact Sporlan Valve Co., Washington, MO.

The problem of dirt can be avoided by installing a SporlanCatch-AIl® Filter-Drier upstream from the solenoid valve. TheCatch-AII® Filter-Drier will retain much smaller particles than aconventional strainer.

Use a Sporlan strainer for water applications upstream of everyindustrial solenoid valve.

3. FAILURE TO CLOSE1. Valve is oversized. Pilot operated valves may fail to close due

to low pressure drop.2. In pilot operated valves, dirt, scale or sludge may prevent the

piston, disc or diaphragm from closing. This could also becaused by a deformed body.

3. Held open by the manual lift stem.4. In pilot operated valves only, a damaged pilot port may prevent

closing.5. A floating disc due to severe discharge pulses, contact Sporlan

Valve Co., Washington, MO.6. Have voltage feedback to the coil after the coil de-energizes.

MISCELLANEOUS1. Liquid Hammer — Industrial solenoid valves, or other liquid

line valves, may cause liquid hammer when installed on liquidlines with high liquid velocities. If this occurs, it can be minimizedby the use of larger pipes, (i.e. lower velocities), or a standpipeinstalled in the piping near the solenoid valve inlet. Commerciallyavailable shock absorbers may also be used to reduce this noise.Recommended maximum velocity is approximately 300 fpm.

2. AC Hum — This problem may be caused by a loose coil housingon a KC model coil. On rare occasions this may be caused byloose coil sleeves, in which case deforming them slightly willeliminate the hum. A loose coil hex screw or coil locknut maycause this problem on the MKC molded model coils.

Foreign material between the magnetic top plug and the plungerin the Types A3, E3, W3, E5, B6, E6, W6, B9, E9, B10, E10, B14,E14, W14, B19, E19, W19, B25, E25, W25, B33, E33, E34 andE42 Series Solenoid valves may cause AC hum also.

On water applications, deposits may accumulate in the valvewhich could cause AC hum. This may be eliminated by cleaningor flushing the valve.

3. Leak Testing — Special care should be taken when leak testingvalves with synthetic gaskets. Gasket materials are slightlypermeable. Leak rates of 0.5 oz. per year should be acceptable.Note the sensitivity of electronic leak detectors. Most have thecapability of finding a leak smaller than 0.05 oz. per year. Double check small seal leaks with soap bubbles or a halide torch ifpossible. Do not over tighten the enclosing tube locknut. If aleak occurs, change the gasket and verify the metal surfaces have a clean smooth finish.

LIOCTIK

c06-05/v42 c06-05/v021 c06-05/v042 remrofsnarTgnitaR

serepmA-tloVtnerruCserepmA

tnerruCserepmA

tnerruCserepmA fo%001roF

DPOMdetarevlaVfo

-nIhsur

-dloHgni

-nIhsur

-dloHgni

-nIhsur

-dloHgni

1-CKM 9.1 36. 93. 41. 91. 90. 06

1-CKMO 9.1 49. 24. 12. 02. 01. 062-CKM2-CKMO 1.3 4.1 06. 62. 13. 31. 001

3-CK 9.7 9.1 7.1 14. 38. 12. 052

TRANSFORMER SELECTION

■ Figure 3

■ Figure 4

Surge Protector

Thermostat

D. C. Line

/ BULLETIN 30-11

■ Figure 5aScrew

(normallyclosed)

■ Figure 6

■ Figure 7

■ Figure 5Lock Nut (normallyopen & rapid cycle)

or

Spacer Cup(normally open &rapid cycle only)

Nameplate

Coil

Spacer(normally open & rapid cycle only)

EnclosingTube

Lock Nut

Enclosing Tube(normally closed)

Enclosing Tube(normally open &

rapid cycle)

or

*EnclosingTube Gasket

Stem & Plunger

Assembly(normallyclosed)

Disc

Body(A & BSeries)

Body(E Series)

Manual Lift Stem Assembly(if required)

Body(E34 & E42

Series)

Piston

Spring

EnclosingTube

Gasket

Pilot Assembly

Typical View ofE34 & E42 SeriesSolenoid Valves

Typical View of B6, E6,W6, B9,E9, OB9, OE9, B10, E10, OB10,OE10, B14, E14, W14, OB14,OE14, B19, E19, W19, OB19,OE19, B25, E25, W25, OB25,OE25, XUP, XRN, XRM, & XPOSeries Solenoid Valves.

Enclosing TubeAssembly

Plunger Assembly

DiaphragmAssembly

EnclosingTube O-Ring

Body

Typical View ofDiaphragm IndustrialSolenoid Valves(K)(B)R183, (K)(B)R184& (K)(B)R246.

Nameplate

Coil

EnclosingTube

EnclosingTube O-Ring

Plunger Assembly

Body

Coil

Coil Spring

Coil Housing

Coil Sleeve

CoilHousing

Bottom Plate

Coil Sleeve

Lock Nut

Voltage Tag

Valve Nameplate

Typical View of W3, XOF& XJH Solenoid Valve

Typical View of KC-3 Coil usedon valve types: MA5A, MA17A,MA32, MA42 & MA50.

Figure 7 contains a full sizeplunger gauge, and a manuallift stem gauge for easy identi-fication of parts. Be sure togauge from the end of themanual lift stem. Do not gaugefrom the packing glandassembly.

B14, E14, W14,B25, E25, W25,

B9, E9, E34, E42

B6, E6, CB9, CE9

B19, E19, W19

B10, E10

CB10, CE10

B25, E25

E10, B19,E19, B33,E33, E34

E14

B9

B10, B14

B6, E6, E9

(see stem diameter)

Align at thispoint to gauge

Align at thispoint to gauge

Stem Diameter

Manual LiftStem Gauge(full size)place stem ondrawing

Plunger Gauge(full size)

place plunger on drawing

.165

E10, B10, E14, B14,B19, E19, B25, E25,B33, E33, E34

.125

E6, B6, E9, B9

For installation and service instructions onThree-Way Heat Reclaim Valves Type 8D,12D & 16D, request Form SD-114.

Printed in U.S. of A. 35-803

or

Stem & Plunger

Assembly(rapid cycle)

*B and E Series Solenoid Valves have been redesigned. The new design can be easily identified as a thin, syntheticcoated metal gasket, known as a Wolverine gasket. The old gasket is a thicker type of O-ring with a square crosssection, known as a tetraseal. See the partial cross sections of the valve body at right. The gaskets and theenclosing tubes of the two designs are not interchangeable. The new enclosing tube assembly is included in thereplacement parts kits.

*Tetraseal Gasket

*Wolverine Gasket

or

CB14, CE14

CB19, CE19

Screw

October 2003 / BULLETIN 10-11

Table of ContentsInstallationValve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Solder Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Bulb Location and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2External Equalizer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Driers, Strainers, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 4Test Pressures and Dehydration Temperatures . . . . . . . . . . . . . . . 4Expansion Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4How to Determine Superheat Correctly . . . . . . . . . . . . . . . . . . . . 5How to Change the Superheat Setting . . . . . . . . . . . . . . . . . . . . . 5

Field ServicingComplaint:A - Valve does not feed enough refrigerant . . . . . . . . . . . . . . . . . 6B - Valve feeds too much refrigerant . . . . . . . . . . . . . . . . . . . . . . 8C - Valve feeds too much refrigerant at start-up only . . . . . . . . . 8D - Valve doesn't feed properly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E - System hunts or cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9F - System won't perform properly . . . . . . . . . . . . . . . . . . . . . . 10

Field Assembly Instructions . . . . . . . 10

InstallationFor peak performance, it is important to select a SporlanThermostatic Expansion Valve (TEV) with correct capacity, selectivecharge, external or internal equalizer, etc. See Bulletins 10-9 and 10-10for complete application information. Equally important is the properinstallation, which can determine the success or failure of the entiresystem.

Valve LocationTEVs may be mounted in any position, but they should be installedas close to the evaporator as possible. If a refrigerant distributor isused with the expansion valve, best performance is obtained if thedistributor is mounted directly to the valve outlet. If the distributorcannot be mounted directly to the valve outlet, the distance betweenthe valve outlet and distributor should not exceed 24 inches or refrig-erant distribution problems may occur. Also, the tube connecting thevalve outlet and distributor can be sized smaller to maintain refrig-erant velocity and better distribution. Elbows located between theexpansion valve and distributor will hinder proper distribution andtherefore, are not recommended.

Best distribution is usually obtained if the expansion valve feedsvertically up or down into the distributor. System manufacturers,however, have successfully applied distributors in other orientations.

See Bulletin 20-10 for application and selection information onrefrigerant distributors.

While not always convenient or possible, valve Types BI, F, FB, andO are easier to service if mounted in a vertical and upright position.If mounted in a horizontal position, the internal parts must becarefully reassembled to prevent damage to them. Also, some consid-eration should be taken in mounting larger sized expansion valves.They must be adequately supported since system vibration and theweight of the valve may cause valve connections to fracture.

If a hand valve is located on the outlet side of the TEV it should havea full sized port. No restrictions should appear between the TEV andthe evaporator, except a refrigerant distributor if one is used.

Sporlan TEVs having Selective Charges C, Z, L, or X may beinstalled and operated in most locations. The amount of thermostaticcharge and the bulb size are such that the bulb retains control despitea colder valve body or diaphragm case. The exception is when theelement is subjected to sub-zero temperatures for extended periods oftime during an off-cycle. In this case, start-up may be prolonged untilthe bulb and element are warmed sufficiently to open the valve.

To minimize the possibility of charge migration, the Sporlan MOPtype charges (CP series, ZP series, and VGA) should be installed sothe diaphragm case is warmer than the bulb. Special non-condensablecharges without MOP and double diaphragm hydraulic elements withMOP are available for system manufacturers to overcome thispotential problem.

Occasionally, TEVs are located in corrosive atmospheric conditionsthat can damage the valve and/or the element assembly. Due to thispossibility, the valve must be protected with appropriate materials toprevent premature failure. Consult specialists in protective coatings.

Precautions:When the evaporator and TEV are located above the

receiver, there is a static pressure loss in the liquid line. This is dueto the weight of the column of liquid refrigerant, and this weight maybe interpreted in terms of pressure loss in pounds per square inch asshown in Table 3, Bulletin 10-9. If the vertical lift is great enough,vapor or flash gas will form in the liquid line causing a seriousreduction in the capacity of the TEV.

When an appreciable vertical lift is unavoidable, precautions shouldbe taken to prevent the accompanying pressure loss from producingliquid line vapor. This can be accomplished by providing enoughsubcooling to the liquid refrigerant, either in the condenser or afterthe liquid leaves the receiver. Subcooling is determined bysubtracting the actual liquid temperature from the condensingtemperature (corresponding to the condensing pressure). Asubcooling calculation example is provided in the "subcooling"section of Bulletin 10-9.

© Copyright 2003 by Sporlan Valve Company, Washington, MissouriBulletin 10-11, October 2003 Supersedes Bulletin 10-11, September 1996 and all prior publications.

ThermostaticExpansion ValvesInstallation, Field Service, and Assembly

/ BULLETIN 10-11

Liquid subcooling is provided by the followingmethods:

1. In the condenser

2. Suction – liquid heat exchanger

3. Special devices

Method 1 – will provide sufficient subcooling for the simple short-coupled system that has only moderate liquid line pressure drop.

Method 2 – will usually not provide more than 20°F subcooling onair conditioning systems operating at normal head pressures. Theamount of subcooling will depend on the design and size of the heatexchanger and on the operating suction and discharge pressures.

Method 3 – may be used to provide considerable subcoolingrequired for systems with excessive vertical lift. The followingspecial devices are the most commonly used methods:

■ Water coils in heat exchange relationship with the liquid line.■ Separate refrigeration system.■ Special heat exchanger which uses a portion of the refrigerant to

cool the main body of liquid. See Figure 1.

Ordinarily the conventional suction-liquid heat exchanger is installednear the evaporator, where the suction vapor is the coldest, to re-condense any vapor in the liquid line. When the primary purpose ofthe heat exchanger is to prevent the formation of flash gas – particu-larly on systems that have a long liquid line or excessive vertical lift– install the heat exchanger near the receiver before the vertical

lift occurs. (This also applies to the special devices described inMethod 3). Because vapor in the liquid line considerably increasesfriction losses, the total pressure drop available across the expansiondevice on these types of systems is reduced. Also, the suction line andliquid line should be carefully insulated to minimize heat gain ifsubcooled below ambient temperature.

ImportantPreventing the formation of vapor in liquid lines having high pressurelosses does not eliminate the requirement that an adequate pressuredrop must be available across the TEV. The capacity tables showvalve capacities at pressure drops lower than normal. For TEVapplication data and capacities at pressure drops below those listed,consult Sporlan Valve Company.

Solder TechniquesIt is not necessary to disassemble solder type valves when solderingto the connecting lines. Any of the commonly used types of solders,e.g., 95-5, Sil-Fos, Easy-Flo, Phos-Copper, Stay Brite 8 or equiva-lents may be used for copper to copper connections. When solderinga brass refrigerant distributor to the valve, appropriate solders forthese connections, such as 95-5, Easy-Flo, Stay Brite 8 or equivalentsmust be used. It is important however, regardless of the solder used,to direct the flame away from the valve body and avoid excessiveheat on the diaphragm, Figure 2. As an extra precaution, a wet clothmay be wrapped around the body and element during the solderingoperation.

This precaution will prevent overheating the valve body which coulddamage the superheat spring and result in flood back problems. Inaddition, the Type O, EBF/SBF, and EBS valve contain syntheticparts which can be damaged due to overheating, resulting in poorvalve performance.

Bulb Location and InstallationThe location and installation of the bulb is extremely important to theproper performance of the system and care should be taken with itsfinal location.

Accepted principles of good suction line piping should be followedto provide a bulb location that will give the best possible valvecontrol. When system manufacturers have piping recommendationsthat differ from the general industry recommendations and Sporlan’ssuggestions shown in this section, those recommendations should beused. When specific recommendations are not available, the sugges-tions below should be used.

The bulb should be attached to a horizontal suction line at theevaporator outlet (See Figures 3, 4, and 5) If the bulb cannot belocated in that manner, it may be located on a descending verticalline only (as shown in Figure 5 for “pumpdown control”). The bulbshould never be located in a trap or downstream of a trap in thesuction line. Liquid refrigerant or mixture of liquid refrigerant and oilboiling out of the trap will falsely influence the temperature of thebulb and result in poor valve control.

On suction lines 7/8” OD and larger, the surface temperature mayvary slightly around the circumference of the line. On these lines, itis generally recommended that the bulb be installed at 4 or 8 o’clockon the side of the horizontal line, and parallel with respect to thedirection of flow. On smaller lines the bulb may be mounted at anypoint around the circumference, however locating the bulb on thebottom of the line is not recommended as an oil-refrigerant mixtureis generally present at that point. Certain conditions peculiar to aparticular system may require a different bulb location than normally

Figure 2

To Compressor

Mai

n Li

quid

Lin

e

Insulation

Main Suction Line

Rece

iver

Figure 1


recommended. In these cases the proper bulb location may bedetermined by trial.

For satisfactory expansion valve control, good thermal contact

between the bulb and suction line is essential. The bulb should besecurely fastened with two bulb straps, supplied with each expansionvalve, to a clean straight section of the suction line.

Recommended suction line piping usually includes a horizontal lineleaving the evaporator to which the TEV bulb is attached. This line ispitched slightly downward, and when a vertical riser follows, a shorttrap is placed immediately ahead of the vertical line, see Figure 3.The trap will collect any liquid refrigerant or oil passing through thesuction line and prevent it from influencing the bulb temperature.

On multiple evaporator installations the piping should bearranged so that the flow from any valve cannot affect the bulb ofanother. Approved piping practices including the proper use of traps

insures individual control for each valve without the influence ofrefrigerant and oil flow from other evaporators.

For recommended suction line piping when the compressor is locatedbelow the evaporator see Figure 5. The vertical riser extending to theheight of the evaporator prevents refrigerant from draining by gravityinto the compressor during the off-cycle. When a pumpdown controlis used the suction line may turn immediately down without a trap.

On commercial and low temperature applications requiringSporlan Selective Charges C, Z, or X the bulb should be clamped onthe suction line at a point where the bulb temperature will be the sameas the evaporator temperature during the off-cycle. This will insuretight closing of the valve when the compressor stops. If bulb insula-tion is used on lines operating below 32°F, use non-water absorbinginsulation to prevent water from freezing around the bulb.

On brine tanks and water coolers, the bulb should be below the liquidsurface where it will be at the same temperature as the evaporatorduring the off-cycle. When locating the bulb in a brine tank, paint itand the capillary tubing with pitch or other corrosion resistant paint.

If, for practical reasons, the bulb must be located where its tempera-ture will be higher than the evaporator during the off-cycle, asolenoid valve must be used ahead of the TEV.

On air conditioning applications having TEVs equipped withVCP100 or VGA elements, the bulb may be located inside or outsidethe cooled space or duct. The valve body should not be located in theair stream leaving the evaporator. Avoid locating the bulb in thereturn air stream unless it is well insulated.

External Equalizer ConnectionFor a complete explanation of when an externally equalized valveshould be used, refer to "equalization method," Bulletin 10-9. Valvessupplied with an external equalizer will not operate unless thisconnection is made.

The equalizer connection should be made at a point that will mostaccurately reflect the pressure existing in the suction line at the bulblocation. See Figure 6. Generally, the connection is immediatelydownstream of the bulb. However, equipment manufacturerssometimes locate them in return bends or suction headers that are

CompressorABOVEEvaporator

Short as possible to minimize amount of oil.

Liquid and oil drainsaway from bulb...

Figure 3

Multiple EvaporatorsAbove and Below Main Suction Line

Flow from upper valve cannotaffect bulb. . . . line free draining.

Inverted trap toavoid oil draininginto idle evaporator.

Free draining.

Figure 4

Compressor BELOWEvaporator

PumpdownControl

WithoutPumpdown

Figure 5

/ BULLETIN 10-11

compatible with their specific design requirements. The differencebetween the pressure at the equalizer connection and the suctionpressure at the bulb location should not exceed reasonable pressuredrop values. The values shown in Table 1 of Bulletin 10-9 can beused as a guide in determining the value.

If any evaporator pressure or temperature control valves are locatedin the suction line at or near the evaporator outlet, the equalizer mustbe connected on the evaporator side of these valves.

Driers, Strainers, and AccessoriesMost Sporlan TEVs are equipped with built-in screens of varyingmesh sizes depending on the valve size and type. These strainers areeffective only in removing particles of scale, solder, etc. which couldobstruct the closure of the pin and seat.

Moisture and smaller particles of foreign materials are equallyharmful to the system and must be removed for peak system perfor-mance. Field experience has proven that, without a doubt, mostexpansion valve failures are due to the presence of dirt, sludge, andmoisture in the system. Furthermore, the performance and life ofother system components are also seriously affected by these foreignmaterials. The Sporlan Catch-All Filter-Drier® removes dirt,moisture, acids, and sludge, and insures the circulation of clean, dryrefrigerant through the system at all times.

For all refrigeration and air conditioning applications we recommendthat a Sporlan Catch-All Filter-Drier be installed in the liquid lineahead of the TEV. See Bulletin 40-10 for complete Catch-All Filter-Drier specifications.

Further system protection is easily and inexpensively provided withthe installation of a Sporlan See-All®. The See-All is a combinationliquid and moisture indicator that visually indicates if there is ashortage of refrigerant in the liquid line, or if the moisture content ofthe refrigerant is at a dangerous level. See Bulletin 70-10 forcomplete See-All specifications.

Test Pressures and DehydrationTemperaturesInert dry gases such as nitrogen, helium or CO2 are often

used for leak detection.

CAUTION: Inert gases must be added to the system

carefully through a pressure regulator. Unregulated gas

pressure can seriously damage the system and endanger

human life. Never use oxygen or explosive gases.

Excessive test pressures can shorten the life of the TEV diaphragm.Table 1 lists the maximum pressure that can safely be applied withthe expansion valve connected to the evaporator. These maximumpressures are well above the minimum field leak test pressures forlow sides, listed by the ANSI/ASHRAE Standard 15-2001 or latestrevision.

The external equalizer line should be disconnected if there is anypossibility of exceeding the recommended maximum pressureslisted below.

If elevated temperatures are used to assist in dehydrating the system,the TEV should not be exposed to temperatures exceeding thoseshown in Table 2.

Table 2 refers to the maximum dehydration temperatures when thebulb and valve body are subjected to the same temperature. On L, C,Z, and X charges, 250°F maximum valve body temperature ispermissible if the bulb temperature does not exceed thoseshown in the table.

Expansion Valve AdjustmentEach Sporlan TEV is thoroughly tested and set at the factory beforeshipment. This factory superheat setting will be correct and nofurther adjustment is required for the majority of applications.However, there are many factors which can affect the performance ofa TEV. These factors are independently variable and all of themcannot be compensated for in the design of a valve. When theapplication or operating conditions require a different valve settingdue to one or more of the factors listed below, the valve may beadjusted to obtain the required operating superheat. Therefore, anadjusting stem is provided on all standard valves. The valve shouldbe set with the system as near as possible to design conditions.

Figure 7

1elbaTserusserPtseTediSwoLmumixaM

epyTevlaV gisp

OllamS,SBE,S,C,GE,G,IR,FBS/FB)E(,BF,F,IN,X,I)B( 054OegraL,H,P,D 524

W,V,M,A 004

2elbaTFseergeD–serutarepmeTnoitardyheDmumixaM

tnaregirfeRegrahCcitatsomrehT

L C Z X AGV seireSPZ,epyTP

a431,21 091 091 052

012

---

05222 061 061 581 052

705,205,A404 051 051 071 ---

)ainommA(717 051 091 532 --- --- ---

External EqualizerConnection

It must be connected - NEVER CAPPED!Must be free of crimps, solder, etc.

Figure 6


Factors which affect valve performance and may make it necessaryto adjust the valve are:

1. Low temperature difference (TDs) between the refrigerant andthe air

2. TEV bulb location

3. Balance between compressor and evaporator

4. Ratio of load to TEV capacity

5. Condenser capacity

6. Operation of several fixtures on multiple installation

7. Seasonal variation in head pressure caused by extreme changes inambient air temperature.

Note: Valve Types F, (E)BF/SBF, Q, A, M, V, K, and W have non-rising adjusting stems and a change in adjustment does not changethe stem position.

When setting valves on multi-evaporator refrigeration systems withpressure or temperature sensitive evaporator control valves, thefollowing procedure is recommended:

1. Evaporator Pressure Regulating Valve (ORI Type): the ORI valveis set first at the minimum load condition. Then, if necessary, theexpansion valve is adjusted to the desired superheat setting whileunder the normal operating load condition.

2. Temperature Sensitive Evaporator Regulating Valves (CDSType): The CDS valve is forced into a fully open position first.Then the expansion valve is adjusted to the desired superheatsetting at full load condition. Finally, the controller for the CDSis set to the desired temperature. Contact Sporlan ValveCompany, or the case manufacturer, for additional details onsetting the CDS controller.

When the adjustment is completed on the TEV, always tighten theadjusting stem packing nut and replace the seal cap tightly.

Many expansion valves are made non-adjustable for use onOriginal Equipment Manufacturer’s units, particularly those valvesused on residential air conditioning and heat pump systems. Thesevalves are set at a superheat predetermined by the manufacturer’slaboratory tests and cannot be adjusted in the field.

Some non-adjustable models are modifications of standardadjustable type valves. This is done by using a solid bottom capinstead of one equipped with an adjusting stem and seal cap. Thesevalves can be identified by an N preceding the standard valve designa-tion. Adjustable bottom cap assemblies are available for convertingmost non-adjustable valves to the adjustable type. However, this israrely required. If symptoms indicate that a valve adjustment isneeded, carefully check the other possible causes of incorrectsuperheat, pages 6 through 10, before attempting an adjustment.

How to Determine SuperheatCorrectly1. Measure the temperature of the suction line at the bulb location.

2. Obtain the suction pressure that exists in the suction line at thebulb location by either of the following methods:a. If the valve is externally equalized, a gauge in the external

equalizer line will indicate the desired pressure directly andaccurately.

b. Read the gauge pressure at the suction valve of thecompressor. To the pressure add the estimated pressure dropthrough the suction line between bulb location andcompressor suction valve. The sum of the gauge reading and

the estimated pressure drop will equal the approximatesuction line pressure at the bulb.

3. Convert the pressure obtained in 2a or 2b above to saturatedevaporator temperature by using a temperature-pressure chart.

4. Subtract the two temperatures obtained in 1 and 3 – the differ-ence is superheat.

Figure 8 illustrates a typical example of superheat measurement onan air conditioning system using Refrigerant 22. The temperature ofthe suction line at the bulb location is read at 52°F. The suctionpressure at the compressor is 66 psig and the estimated suction linepressure drop is 2 psi …66 psig + 2 psig = 68 psig at the bulb, whichis equivalent to a 40°F saturation temperature. (Use dew pointtemperature for refrigerant blends.) 40°F subtracted from 52°F =12°F superheat.

Note: Refrigerated case manufacturers frequently use a “tempera-ture difference” method to approximate superheat. This procedureconsists of measuring the temperature of a location on the evaporatorwhich is representative of saturated vapor temperature; and, thensubtracting that temperature from the outlet evaporator temperaturewhich is measured at the bulb location.

While this method of reading “superheat” is acceptable on thosemanufacturer’s cases where the pressure drop through the evaporatoris low, Sporlan does not recommend the “temperature difference”method for other types of systems.

How to Change the SuperheatSettingNote: There are some valve bodies (G, EG, C, S, EBSand EMC) that have a packing nut around the adjust-ment stem. It may be necessary to loosen the packingnut slightly to turn the adjusting stem. Do not forgetto retighten the nut after the superheat is set.

To reduce the superheat, turn the adjusting stem counter-

clockwise. To increase the superheat, turn the adjusting stemclockwise. When adjusting the valve, make no more than one turnof the stem at a time and observe the change in superheat closely toprevent over-shooting the desired setting. As much as 30 minutesmay be required for the new balance to take place after an adjust-ment is made.

What's YourSuperheat?

OBTAIN SUCTION PRESSURE68 PSIG (at bulb)

Temperaturehere reads

52°40°12°

SUPERHEAT

Figure 8

/ BULLETIN 10-11

If in doubt about the correct superheat setting for a particular system,consult the equipment manufacturer. As a general rule, the propersuperheat setting will depend on the amount of temperature differ-ence (TD) between refrigerant temperature and the temperature of theair or other substance being cooled. Where high TD’s exist, such ason air conditioning applications, the superheat setting can be made ashigh as 15°F without noticeable loss in evaporator capacity. Wherelow TD’s exist, such as in low temperature blower coil applications,a superheat setting of 10°F or below is usually recommended formaximum evaporator capacity. It is these applications that the TEVwill more than likely need to be adjusted.

For the correct valve setting on factory built equipment, manufac-turers’ recommendations should be followed. Some manufacturersspecify the superheat directly; others may recommend valve adjust-ment to a given suction pressure at certain operating conditions, oruntil a certain frost line is observed. Such recommendations, howeverthey are stated, represent the results of extensive laboratory testing todetermine the best possible operation.

Field Servicing

The TEV is erroneously considered by some to be a mysterious andcomplex device. As a result, many valves are needlessly replacedwhen the cause of the system malfunction is not immediatelyrecognized.

Actually the TEV performs only one very simple function – it keeps

the evaporator supplied with enough refrigerant to satisfy

all load conditions. It is not a temperature control, suctionpressure control, a control to vary the compressor’s running time, ora humidity control.

How effective the valve performs is easily determined by measuringthe superheat as outlined in Figure 8. Observing the frost on thesuction line, or considering only the suction pressure may bemisleading. Checking the superheat is the first step in a

simple and systematic analysis of TEV performance.

■ If not enough refrigerant is being fed to the evaporator—

the superheat will be high.

■ If too much refrigerant is being fed to the evaporator —

the superheat will be low.

Although these symptoms may be attributed to improper TEVcontrol, more frequently the origin of the trouble lies elsewhere.

Note: TEVs with permanent bleed ports (BP) or Rapid PressureBalancer (RPB) construction are applied on many air conditioningand refrigeration systems by original equipment manufacturers. Eachapplication is tested and approved by the manufacturer. The primaryfunction of these devices is to equalize high-to-low side pressuresduring the off cycle on systems equipped with low starting torquecompressors.

However, some BP type valves are applied to allow small amounts ofliquid refrigerant to pass for compressor motor cooling. The specificfunction of the feature on a given unit must be determined from thesystem manufacturer. Once that is determined, it is easier totroubleshoot the system.

The primary cause of difficulty with either the BP or RPB feature isdirt and other foreign materials that restrict or plug them. And if thesystem purpose intended for either feature is not being satisfied, thevalve probably needs cleaning or replacing.

As stated in Bulletin 10-9, the RPB type valve is not to be applied onsystems using high starting torque compressors or “hard-start”electrical components, on outdoor coils of heat pumps, or on anyrefrigeration system, and it should not be used to replace BP typevalves that are applied on those types of systems. On systems otherthan those described above, the RPB type valve can replace the BPtype valve when necessary. Usually it is advisable to replace a valvewith one of the same specification unless advised differently. Consultwith the system manufacturer for assistance.

Complaint "A"“Valve does not feed enough refrigerant.”

SYMPTOMS:■ Load temperature (air or water leaving

evaporator) too high.■ Superheat too high.■ Suction pressure lower than normal with

compressor unloaders locked out or hot gasbypass shut off.*

THE CAUSE MAY BE:1. Moisture — Water or a mixture of water and oil frozen in the

valve port or working parts of the valve will prevent properoperation. This is a common source of trouble on expansionvalves. Since the valve is the first cold spot in the system,moisture will freeze and block the valve open, closed, or anyposition in between. If the valve is frozen in the intermediateposition so that flow is restricted, the superheat will be high.

Remedy — Install a Sporlan Catch-All Filter-Drier in theliquid line for removal of moisture from the refrigerant and oil.See Bulletin 40-10.

To determine a safe level of moisture in the system, install aSporlan See•All Moisture and Liquid Indicator. See Bulletin70-10.

Excessive moisture has a damaging effect on all

system components regardless of the evaporating

temperature. Moisture must be removed for trouble-

free performance.

2. Dirt or foreign material — Contaminants such as copperoxide scale, metal chips, oil breakdown sludge, etc. will restrictthe flow of refrigerant when it collects in strainers or other liquidline accessories. This produces a shortage of refrigerant at theTEV port. Conventional strainers frequently allow the materialto pass through the screen and obstruct the flow at the valveport. If a See•All is installed downstream of the restriction,bubbles will be visible. This should not be confused, however,with a refrigerant shortage or excessive liquid line pressure losswhich are also indicated by bubbles in the See•All.

Remedy — Locate and remove the foreign material creatingthe restriction. Install a Sporlan Catch-All Filter-Drier toprovide effective filtration of the refrigerant. See Bulletin 40-10.

* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEVperformance, 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.


3. Wax — Certain systems are contaminated with small amountsof wax which will precipitate at low temperatures in systemswith Refrigerants 22 or 502. Since the TEV represents the firstcold point in the refrigeration cycle, wax is most likely to format the valve port.

It is sometimes difficult to observe the wax in a valve because itmay exist in solid form only at very low temperatures. By thetime the valve has been taken apart, the temperature hasincreased enough to cause the wax to melt and thus becomedifficult to detect. When wax is suspected, it can usually bedetected on the pin and seat by packing the valve in dry icewhile disassembling.

Remedy — Clean the valve with solvent before reassemblingthe valve. The Sporlan HH style Catch-All Filter-Driers have aspecial activated charcoal desiccant that is designed to removewax in the liquid line before it causes trouble. Therefore, toprevent wax problems, use these HH style driers (e.g., C-415-S-HH) on all low temperature systems using Refrigerants 22 or502.

4. Refrigerant shortage — See•All or sight glass in theliquid line will show bubbles when the system is short of refrig-erant charge. Before adding more refrigerant however, be surethe bubbles are not produced by other causes (See ParagraphsA-2 and A-5).

A lack of refrigerant charge may also be detected by a hissingsound at the TEV. Some systems not equipped with a liquid linesight glass will have test cocks or other devices for checking therefrigerant level in the receiver.

Remedy — Add enough refrigerant to obtain desired result.

5. Gas in the liquid line — As explained in Paragraphs A-2

and A-4, liquid line vapor can be produced by a partiallyplugged strainer or drier and by a shortage of refrigerant charge.In addition, gas in the liquid line can be caused by air or othernon-condensable gases in the system or by excessive pressurelosses in the liquid line as a result of:

■ Long or undersized line.■ Liquid line vertical lift.

Remedy — Verify the correct liquid line size for the equiva-lent length and system tonnage. Consult liquid line sizing datapublished in many manufacturers’ catalogs and in textbooks. Ifundersized, repipe with the correct size.

Determine amount of vertical lift, and obtain the resultingpressure loss from Table 3, Bulletin 10-9. Using the subcoolingcalculation example provided in the "subcooling" section ofBulletin 10-9, find required subcooling necessary to preventgasification with the existing pressure losses. Provide thenecessary subcooling by using one of the methods described onPage 1.

6. Misapplication of internally equalized valve orincorrect location of external equalizer — If thepressure drop through the evaporator exceeds the predeterminedvalues shown in Table 1, Bulletin 10-9, an externally equalizedvalve must be used. When an externally equalized valve is used,the equalizer connection should be made at a point in the suctionline that will reflect the pressure existing in the line at the bulblocation.

Remedy — Replace internally equalized valve with onehaving an external equalizer.

If external equalizer is installed incorrectly, change to correctlocation. See Page 3.

7. Insufficient pressure drop across valve — One of thefactors that influence expansion valve capacity is the pressuredrop that exists between the inlet and outlet. Anythingcontributing to a reduction in this pressure drop will reduce valvecapacity. Abnormally low condensing pressures, excessive liquidline pressure losses (even with adequate subcooling), undersizeddistributor nozzle or distributor tubes may also be responsible fora very low net pressure drop across the valve port.

Remedy — Remove source of pressure loss, or install valvewith adequate capacity at the reduced pressure drop. If inletpressure to valve is low due to low condensing pressure, raisepressure.

If the refrigerant distributor nozzle is undersized replace withcorrect size. See Bulletin 20-10.

8. Dead thermostatic element or wrong thermo-static charge — If the element has partially or completelylost its thermostatic charge, the valve will be unable to feedsufficient refrigerant or will remain closed. A wrong charge maycause insufficient feed also.

Remedy — Replace the element if it is dead. If charge isincorrect, replace with proper selective charge. See Bulletin 10-9.

9. Charge migration (CP series, ZP series, and VGAcharges only) — In order for valves with these charges tomaintain control at the bulb, the bulb must be kept at a lowertemperature than the element (diaphragm case). If the thermo-static charge does migrate to the element because of a lowerelement temperature, the valve will throttle.

Detection — Warm the element with a cloth saturated withhot water. If this produces more refrigerant feed and reduces thesuperheat to normal, charge migration is responsible for thestarved evaporator.

Causes —■ Insufficient pressure drop between the valve outlet and bulb

location, possibly due to an oversized distributor nozzle or nonozzle at all.

■ Excessive pushrod leakage, which allows the leaking refrig-erant to cool the diaphragm case before passing into theequalizer line. This is a rare occurrence and should becarefully checked before arriving at this conclusion.

■ Cold location of TEV, or condensate drippage on thediaphragm case.

Remedies —■ Install distributor nozzle correctly sized in accordance with

nozzle sizing procedure given in Sporlan Bulletin 20-10.■ On valves with packed pushrod construction, remove element

and tighten the pushrod packing nuts.■ Relocate the TEV away from cold outlet air, or condensate

drippage.

10. Undersized valve

Remedy — Install valve sized in accordance with proceduregiven in Bulletin 10-9, or Bulletin 10-10.

11. High Superheat adjustment

Remedy — Turn the adjusting stem counter clockwise untilthe correct superheat is indicated.

12. Feed-back from another valve — Review instructionsfor Bulb Location and Installation, Page 2.

Remedy — Check the bulb temperature and calculate thesuperheat. If superheat is normal but too little refrigerant is

/ BULLETIN 10-11

flowing through the evaporator, check the piping for possiblerefrigerant flow from another evaporator affecting the bulb. Re-pipe if necessary. See Figure 4.

13. High pressure drop through evaporator

Remedy — Check the pressure at the evaporator inlet andoutlet with gauges. If pressure difference is greater than thevalues shown in Table 1, Bulletin 10-9, use an externallyequalized valve.

14. Restricted, plugged, or capped external equalizer —If the pressure under the diaphragm builds up due to pushrodleakage and cannot escape through the external equalizer line,the valve will remain closed.

Remedy — Check the external equalizer line to be sure it isopen or not capped.

Complaint "B"“Valve feeds too much refrigerant.”

SYMPTOMS:■ Liquid returns to compressor.■ Superheat is low.■ Suction pressure is normal or higher than

normal.

THE CAUSE MAY BE:1. Moisture — Water or a mixture of water and oil frozen in the

valve port or working parts of the valve will prevent properoperation. This is the most common source of trouble on TEVs.Since the valve is the first cold spot in the system, moisture willfreeze and block the valve open, closed, or any position inbetween. If the valve is held in the open position by ice, liquidflood-back will occur.

Remedy — Install a Sporlan Catch-All Filter-Drier in theliquid line for removal of moisture from the refrigerant and oil.See Bulletin 40-10.

For additional protection, install a Sporlan See•All Moisture andLiquid Indicator for a positive indication of when a safemoisture level is reached. See Bulletin 70-10.

2. Dirt or foreign material — Contaminants such as copperoxide scale, metal chips, oil breakdown sludge, etc. may passthrough ordinary strainers and lodge at the TEV port and preventthe valve from closing.

Remedy — Disassemble the valve and remove all foreignmaterial from the internal parts. Install a Sporlan Catch-AllFilter-Drier in the liquid line. The Catch-All filters out thesmallest particles of foreign material that might interfere withthe operation of any system component.

3. Expansion valve seat leak — When the valve port doesnot seat tightly, refrigerant will pass through during the off-cycleand fill the evaporator with refrigerant. If the seat leak is severe,the valve will feed too much refrigerant during the operatingcycle as well. (Not applicable to valves with permanent bleedports or RPB feature.)

Remedy — If the valve seat is leaking, a gurgling or hissingsound can usually be heard during the off-cycle. Also, a sightglass or See•All in the liquid line may indicate continued refrig-erant flow for a long period after the compressor has stopped.Make certain however, that the bubbles are not the result ofback-flow through a vertical liquid line.

Disassemble the valve to be certain that dirt or foreign materialis not responsible (see B-2). If the pin and seat are worn ordamaged and an internal parts kit is available, replace the parts.When parts are not available, the valve must be replaced.

4. Oversized valve — Check valve ratings considering all thefactors which affect its capacity. See Page 16, Bulletin 10-9, orPage 3, Bulletin 10-10.

Remedy — Install correctly sized valve.

5. Incorrect bulb installation — The bulb should be securelyfastened to a straight, clean, section of the suction line using twobulb straps for good thermal contact. Also, the temperature of thebulb should not be influenced by ambient temperature — anexternal heat source such as a steam pipe or heating coil.

Remedy — Install bulb correctly. See Bulb Location andInstallation, Page 2.

6. Low superheat adjustment

Remedy — Turn the adjusting stem clockwise until the correctsuperheat is indicated. See Page 4.

7. Incorrect thermostatic charge

Remedy — Select and install the correct selective charge. SeeBulletin 10-9.

8. Incorrectly located external equalizer

Remedy — Relocate external equalizer or the connectionbetween evaporator and any other temperature or pressuresensitive evaporator control valve near bulb location. See Page3 for recommendations.

9. Inefficient compressor — If the compressor is inefficientor for some other reason lacks capacity, the suction pressure willoperate higher than normal. This may or may not be accompa-nied by low superheats.

Remedy — Consult with compressor manufacturer.

Complaint "C"“Valve feeds too much refrigerant at start-up only.”

SYMPTOMS:■ Liquid returns to compressor.■ No superheat.■ Suction pressure higher than normal.

THE CAUSE MAY BE:1. Refrigerant drainage — Drainage of refrigerant from the

evaporator (during the off-cycle) when installed at a higher levelthan the compressor.

Remedy — Install a trap-riser to top of evaporator or usepump-down control. See Figure 5.

2. Compressor or suction line in cold location —During the period when the system is not in operation, liquidrefrigerant will condense at the coldest point in the system. Liquidwill condense in the compressor or suction line, if they are locatedin an ambient temperature below that of the evaporator during theoff-cycle. Upon re-starting, this liquid will slug the compressor.

Remedy — Keep compressor or suction line warm during theoff-cycle. Some compressors are equipped with crankcase heaters


for this purpose. Another corrective measure is to install a suctionline solenoid valve that is de-energized during the off-cycle.

3. Restricted or plugged external equalizer — Amomentary flood can occur when the load increases suddenly,such as at start-up because the higher suction pressure cannotreach the underside of the diaphragm and help close the valve.If the pressure under the diaphragm increases due to anypressure leakage around the pushrods, the valve will eventuallythrottle.

Remedy — Remove the restriction or plugged portion of theexternal equalizer.

4. Liquid line solenoid valve seat leak or interruptedpumpdown — Liquid refrigerant can continue to feed theTEV and/or remain in evaporator upon shut-down causingflood-back to the compressor upon start-up.

Remedy — Disassemble and clean solenoid valve and/orreplace damaged internal parts if seat leakage is the problem. Ifthe pumpdown cycle isn’t completed before the compressorcycles off, or the thermostat calls for cooling and reopens theliquid line solenoid before the evaporator has been properlyevacuated, check the low pressure cut-off setting or theelectrical controls for possible causes.

Complaint "D"“Valve doesn't feed properly.”

SYMPTOMS:■ Poor system performance.■ Superheat normal or lower than normal.■ Suction pressure lower than normal with

compressor unloaders locked out or hot gasbypass shut off.*

THE CAUSE MAY BE:1. Unequal circuit loading (Multi-circuit evaporators

and parallel evaporators connected to a singlerefrigerant distributor) — When each circuit is notsubjected to the same heat load, the lightly loaded circuits willallow unevaporated refrigerant or low temperature vapor toenter the suction line and throttle the valve. This will causenormally loaded circuits to be deprived of their share ofrefrigerant. The net result is a loss of refrigerated evaporatorsurface.

Remedy — Make necessary modifications which will alloweach evaporator circuit to receive the same percentage of thetotal load. See Bulletin 20-10 for application information onmulti-circuit evaporators using a refrigerant distributor.

2. Poor refrigerant distribution (Multi-circuit evapora-tors and parallel evaporators connected to a singlerefrigerant distributor) — If the refrigerant distribution isfaulty, the circuits receiving the largest portion of refrigerantwill have the controlling influence on the TEV. The result is thesame as in paragraph 1 above.

Remedy — Correct refrigerant distribution. See Bulletin 20-10for complete information on Refrigerant Distributors.

3. Low load— Low evaporator load may be caused by insuffi-cient air over the coil as a result of an undersized blower, dirtyair filters, or an obstruction in the air stream. In addition, frostformation on the coil or low entering air temperatures willreduce the evaporator load.

Remedy — Correct the condition responsible.

4. Flow from one coil affecting TEV bulb of another(Multiple evaporator systems only) — The tempera-ture of the bulb may be falsely influenced by flow from anotherevaporator usually because of incorrect piping.

Remedy — Correct the piping. See Figure 4, Page 3.

5. Improper compressor-evaporator balance — If thecompressor is too large for the load and evaporator capacity, thelow suction pressure which results will cause poor systemperformance.

Remedy — Consult with the manufacturer or consultingengineer, or the ASHRAE Handbook on component balancing.If necessary, change or correct the improperly sized component.Hot gas bypass may be used to balance properly.

6. Evaporator oil-logged — Poor heat transfer occurs andunpredictable performance takes place. If erratic performance isobserved over a period of time, and other causes are omittedfrom consideration, review the amount of oil in the system.Turbulent compressor oil level with little or no return to thecompressor sump indicates oil problems.

Remedy — Remove excessive oil from evaporator andconnecting piping. Many times the evaporator temperature willbe too low for the oil to be removed. Therefore, the system mustbe allowed to warm sufficiently to get cold oil to drain. Analyzesystem components for possible causes of oil problem beforerestarting the system. Consult with the compressor manufacturerfor specific details on their compressor.

Complaint "E"“System hunts or cycles.”

SYMPTOMS:■ Suction pressure fluctuates*■ Superheat fluctuates.■ Valve does not feed enough, and then too much

refrigerant.

THE CAUSE MAY BE:1. System characteristics — Certain design characteristics of

the system may have an effect on the system’s tendency to huntor cycle. As an example, after the valve admits refrigerant to theevaporator inlet, there is a time delay before the bulb senses theeffect at the evaporator outlet. This time delay is dependent onevaporator length, tube size, and load. Generally, there is morelikelihood for hunting to occur when this time interval is long.Other influencing factors are circuit arrangement, load percircuit, and temperature difference.

Remedy — When hunting is moderate particularly with nofloodback, the effect on the system is insignificant and correc-

* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEVperformance, 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

tions are not necessary. If hunting is severe with floodback tothe compressor, check the possible remedies shown inparagraphs below.

2. Valve size — An over-sized valve usually aggravates hunting.Carefully check the valve rating considering all the factorsaffecting its capacity. See Bulletin 10-9, or Bulletin 10-10.

Remedy — Replace valve with one correctly sized. Onmultiple circuit evaporators using a refrigerant distributor, thecapacity of the valve can be reduced, within certain limits, byinstalling a smaller distributor nozzle. See Bulletin 20-10.

3. Bulb location — If the bulb is located in a suction line trap,its temperature will be affected by liquid oil and refrigerantalternately collecting and evaporating at this point. Thiscondition frequently results in severe hunting.

Remedy — As a temporary measure relocate the bulb awayfrom the trap, and any turbulent areas created by elbows, tees,etc. Also remove the bulb from the air stream or insulate. Re-pipe if necessary. Sometimes another position around thecircumference of the suction line will minimize hunting. Followthe Bulb Location and Installation instructions given on Page 2for the best TEV control.

4. Refrigerant and load distribution — In addition to theeffects of poor distribution explained in paragraphs D-1 and D-

2, hunting also frequently results. This is caused by liquidrefrigerant from the overfed circuits occasionally reaching thebulb of the valve.

Remedy — Correct the faulty distribution.

5. Superheat adjustment — All Sporlan TEVs are preset atthe factory to give the best performance on the average system.A valve should not be adjusted unnecessarily, but occasionallyanother setting may prove to be better.

Remedy — Turn the adjusting stem clockwise a turn at a time.If the hunting stops or is reduced, turn the adjusting stemcounter clockwise a turn at a time to obtain the lowest superheatwith stable operation.

6. Moisture — As ice forms in a TEV from excessive moisture,a very erratic hunt may result.

Remedy — Remove the moisture with the installation of aSporlan Catch-All Filter-Drier. A safe moisture level can bedetermined by installing a Sporlan See•All.

Complaint "F"“System won't perform properly.”

SYMPTOM:■ Cannot get valve to react or regulate at all.

THE CAUSE MAY BE:1. No refrigerant being fed to evaporator. See Section

A on Pages 6 & 7.

2. Too much refrigerant being fed to evaporator. SeeSection B on Page 8.

3. Too much refrigerant being fed to evaporator atstart-up only. See Section C on Page 8.

4. Refrigerant control is erratic. See Section D on Page 9.

5. System is hunting or cycling. See Section E on Page 9.

6. The TEV has been physically abused in an effortto make the valve work properly. This is usually theresult of a mistaken analysis. It is frequently assumed that if avalve does not feed properly, it is stuck (either opened orclosed). Beating the valve body with a hammer will only distortthe body and make it impossible for the valve to work once thereal cause is determined.

If a valve “sticks,” it is usually due to moisture freezing in theport, dirt and other foreign material restricting or plugging theinternal parts, wax forming on the internal parts at low temper-atures, or the valve has been physically abused so it cannot

function.

Remedy — Inspect the valve and its internal parts, includingthe inlet strainer. If plugged or restricted in any way, clean theparts thoroughly, oil the parts with a good grade of refrigerantoil, and reassemble the parts. Complete details on this subjectare found on Pages 10 through 12.

If the valve is beyond normal cleaning processes, or if it isphysically damaged in any way, replace the valve with its properreplacement model.

Field AssemblyInstructions

Sporlan valves my be opened easily for inspection.

ThermostaticElement

Pushrods

Inlet

Body

Outlet

Seat

Pin Carrier

Spring

Spring GuideBottom CapAssembly

Seal Cap

Adjusting Stem

Figure 9


Note: These Field Assembly Instructions apply in part to all SporlanTEVs. See Figure 9 for an “exploded” view of those models that canbe completely disassembled. When a TEV is to be disassembled forinspection and cleaning, or for replacement of the thermostaticelement or the internal parts, the following information should bereviewed for assistance.

Types F dated approximately C84 or earlier and Types I, BI, NI, RI,FB manufactured prior to 1994 do not have replaceable elements norinternal parts kits, but can be disassembled for inspection andcleaning. Type F dated D84 or later, Type S valves dated B69 or later,Type C valves dated C70 or later, and ALL Type G, X, (E)BF/SBFand EBS valves employ packless pushrod construction and internalparts are NOT available for use with them. However, their elementscan be replaced and they can be disassembled for inspection andcleaning. Due to the single pushrod construction of the Type(E)BF/SBF and EBS valves, only the bottom cap assembly, pinguide, and superheat spring may be removed for inspection andcleaning.

Early production of the Type F valve with the replaceable elementrequires a 15/16" thin jaw, open end type element wrench such as aBonney 1230. Subsequent production of the Type F valve and allTypes (E)BF/SBF, I, BI, NI, RI, and FB valves require a 1" thin jaw,open end type element wrench such as the one available fromSporlan wholesalers. An open end wrench is necessary because oflimited space between the body and element of these valves.Precautions must be taken in removing the KT-43 element (F) so theelement, body, or connections are not damaged by the wrenches.

While standard open end or adjustable wrenches fit the other elementsizes, the thin jaw type wrenches are also available for the otherelement sizes: Bonney 1236 (1-1/8") for KT-53 elements, Bonney1240 (1-1/4") for KT-83 elements, Bonney 1248 for KT-33 elements,and Bonney 1252 for KT-63 and 7 elements.

Replaceable elements and internal parts kits are available for currentvalves with packed pushrod construction:Types P, H, M, D, and A.

Replaceable elements for Types O, V, W, and U are also available.However, special field assembly instructions are included with theirinternal parts kits.

Assembling InstructionsThe following steps are necessary in properly disassembling,inspecting, cleaning, and reassembling a TEV whether the valve is inor out of the refrigerant piping.

1. Before disassembling the valve, be sure the refrigerant pressurein the system has been reduced to a safe level (0 psig).

2. Remove the seal cap and turn the adjustment stem counter-clockwise to relieve the spring force. Count and record thenumber of turns so adjustment can be returned to its originalposition.

3. Using appropriate wrenches or a vise to properly support thevalve body, remove the element (if a replaceable type), thebottom cap assembly, and the internal parts. (Only remove thebottom cap, pin guide, and superheat spring on Type (E)BF/SBFand EBS valves. DO NOT remove the single pushrod fromthese valves.)

Caution: Regardless of whether the valve is in the system orin a vise, care must be taken to prevent distorting the body by

exerting too much pressure in tightening the element or inclamping the body in the vise. Also, do not use a wrench on theouter welded edge of the element.

4. Inspect parts, element, and body for any foreign materials orphysical damage.

5. On valves with replaceable elements and/or internal parts,replace any items that appear damaged.

6. Clean all parts with solvent, preferably by applying and thenblowing off with clean dry compressed air.

7. To reassemble valves with replaceable seats, screw seat intobody with a fairly light pressure since it does not require a heavypressure to make this small knife-edge joint.

Caution: Be sure hexagon corners of seat do not protrude intopushrod holes (see Figure 10).

For valves that do not have replaceable elements or for Type Ovalves, place the pushrod(s) into the body now.

8. Next, slip the pin and carrier (which have been pressedtogether at the factory) into the body and tap the pin into theseat to form a true seating surface. It is generally advisable,before tapping these parts together, to check the concentricityof both the pin and seat by engaging the parts by pressing themlightly together with one finger and noting that there is notendency to stick together. This should be repeated severaltimes after rotating the pin carrier a quarter of a turn. Inassembling valves with port sizes of 1/4" and larger which usethe flat disc instead of the tapered pin, DO NOT TAP THE

DISC AGAINST THE SEAT.

9. Now place the spring guide stamping (when used), and spring,in the pin carrier, place the lower spring guide on the oppositeend of the spring and screw the bottom cap in place. (Replacethe pin guide, spring, and bottom cap assembly together on Type(E)BF/SBF and EBS valves.) After screwing bottom capassembly in place, carefully tighten, preferable with two 10"wrenches, to seal the metal-to-metal knife edge joint. Thesealing surfaces should be free of any foreign material or nicksthat might prevent a leak-tight joint.

10. On valves with replaceable elements (except Types O,(E)BF/SBF and EBS), place the pushrods into the body andopen the valve several times by pressing down on the pins witha flat metal surface. This will help seat the pin properly.

11. Check the height of the pushrod(s) above the element sealingsurface with the pushrod gauge (see Figure 11). The gauge issupplied with internal parts kits or can be obtained at no charge

RIGHT WRONG

Figure 10

/ BULLETIN 10-11

upon request. (Since the internal parts of the Type (E)BF/SBFand EBS valves cannot be replaced, it is not necessary to checkthe pushrod height of these valves.)

The appropriate gauge numbers for the various TEV’s are givenin Table 3.

Caution: If the element-to-body joint utilizes a gasket, thegasket must be removed before checking pushrod height.

If the pushrod(s) are too long, they must be carefully ground offto the proper length. Clean the pushrod(s) of all dirt andgrindings and place them into the body.

12. Element Replacement — If the element is damaged or haslost its thermostatic charge, replace it with the same type.

To properly replace the element without damaging the elementor the valve body on valves which utilize a gasketed joint, besure only one gasket is used before assembling the element. Inassembling gasketed elements held in place by two cap screws,be sure to pull up the cap screws evenly.

On valves which utilize the threaded type of element with metal-to-metal knife edge joints, always use an appropriate wrench(10") on the wrench flats. DO NOT use a wrench on the outerwelded edge of the element. The sealing surfaces should be freeof any foreign materials or nicks that might prevent a leak-tightjoint. A few drops of refrigerant oil on the element threads willfacilitate easy assembling and removal.

13. Return the superheat spring adjustment to its original position.Replace the seal cap tightly.

Printed in U.S. of A. 1003

3elbaT

epyTevlaV Q eguaGrebmuNtnerruC etelosbO

)E(AA-CML,)E(AA --- 1)E(AD-CML,)E(AD --- 2

1-EFHroEFP 1/2 21,8,5,4,3, 7,6-EFHroEFP 1/2 11,01,

3

2-EVHroEVP 1/2 5, 1/2 ,11,7,02,61

,21,01,8,5,2-EVHroEVP81,71,51

41,8,5-EDHroEDP 7,6-EDHroEDP 1/2, 31,21,91-ERHroERP 1/2 6,4, 1/2 21,9, 7,6-ERHroERP 1/2 31,11,

---

71,21-EFU03,22-EVU12,51-EDU22,61-ERU

04,23,32-EFO 32-EFU

A307,55,04-EVO 04-EVU05,04,82-EDO 82-EDU54,53,03-ERO 03-ERU

sledoMFllA W tpecxe-)E(FF 1/8 -)E(VF, 1/4,-)E(DF 1/8 -)E(RF, 1/8

--- 4

sledoMGllA tpecxe-)E(FG 1/8 -)E(VG, 1/4,-)E(RG 1/8

sledomKllamsllA5

sledoMXllA ---,5-EFM 71/2 02,51,31,11, 71,21-EFM

6

,8-EVM 43,62,12,81,21 03-EVM9,6-EDM 52,81,51,31, 02,41-EDM

,9-ERM 52,02,51---07-EVVroEVK,54-EFVroEFK

05-ERVroERK,55-EDVroEDK52-EFM 22-EFM

A6

24-EVM 04-EVM03-EDM 62-EDM03-ERM ---

55,53-EFVroEFK 05-EFV001,25-EVVroEVK 09-EVV

56,04-EDVroEDK 06,24-EDV07,83-ERVroERK ---

011,08-EFW 001,57-EFW

7081,531-EVW ---

031,59-EDW 021,09-EDW031,001-ERW ---

-)E(FSro)E(FC 1/4, 1/2 1,1, 1/2,2,2 1/2 3,

sledoMTdnaRstnemele38htiw 8

-)E(VSro)E(VC 1/2 1,1, 1/2,5,4,3,2

-)E(DSro)E(DC 1/4, 1/2 1,1, 1/2,2,2 1/2 3,3, 1/2

-)E(RSro)E(RC 1/4, 1/2 1,1, 1/2,4,3,2

6,5-EFS,5-EFC

--- A8

01,8-EVS,8-EVC7,6-EDS,6-EDC7,6-ERS,6-ERC

21,9,6-EFO02,51,01-EVO

41,11,7-EDO21,9,6-ERO

03-EVO,61-EFO12-ERO,02-EDO E --- B8

Q Type F (internally and externally equalized) valves dated D84 or later,Type S valves dated B69 or later, Type C valves dated C70 or later, andall Type G (externally equalized only) and X valves have packlesspushrod construction and internal parts kits are not available for usewith them.

W Applies only to Type F valves with a replaceable element.E Formerly used the KT-33-8 element and gauge number 33-8 (redesig-

nated 8B). The KT-33-8 element has been replaced by the KT-83.

Check Heightof Pushrod(s)

with GaugePushrod(s) should justclear here.

Valve

Pushrod(s)

Gauge

Figure 11

Drwn By: SDP Date: 11/27/02 Vilter Mfg. Corp.

Cudahy Wi. 53110 Redrwn By: Approv. By: 3186 R0

STRAINER ST HANSEN (FILTERS)

STRAINERS

HANSEN CATALOG

NO.

VALVESIZE

(INCHES) FLANGE STYLE AND SIZE DESCRIPTION

VILTERPARTNO.

½ FPT FLANGE CONNECTIONS 3186AF ST050 ½ ½ SOCKET WELD FLANGE CONNECTIONS 3186AS

¾ FPT FLANGE CONNECTIONS 3186BF ¾

¾ SOCKET WELD FLANGE CONNECTIONS 3186BS

1 FPT FLANGE CONNECTIONS 3186CF 1

1 SOCKET WELD FLANGE CONNECTIONS 3186CS

1-¼ FPT FLANGE CONNECTIONS 3186DF

ST100

1-¼1-¼ SOCKET WELD FLANGE CONNECTIONS 3186DS

1-½ FPT FLANGE CONNECTIONS 3186EF 1-½

1-½ SOCKET WELD FLANGE CONNECTIONS 3186ES

2 FPT FLANGE CONNECTIONS 3186FF ST200

22 SOCKET WELD FLANGE CONNECTIONS 3186FS

ST250 2-½ 2-½ WELD NECK FLANGE CONNECTIONS 3186GW

REPLACEMENT SCREEN KITS

SCREEN KIT FOR: VALVE SIZES HANSEN KIT PART NO.

VILTER PART NO.

ST050 ½ 78-1001 3186AK

ST100 ¾, 1, 1-¼ 78-1003 3186BK

ST200 1-½, 2 78-1005 3186CK

ST250 2-½ 78-1006 3186DK

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.

Cudahy, WI 53110 Redrawn By: Approved By: RPK

3214 R0

DANFOSS REGULATING/MIXING VALVES

NOTE: PORT A IS FOR THE OUTLET

PORT B IS FOR THE HOT INLETPORT C IS FOR THE COLD INLET

OIL FLOW (GPM)

VILTER PART NO.

BODYHOUSING

TYPE 2 PSID 7PSID

NOMINALPIPE

DIAMETER

NO OF THERMOSTATIC

ELEMENTS VALVE TYPE

DANFOSSCODE NO.

3214A 3214B 3214C 3214D

H1H2H2H3

20424480

407183150

1” SW 1-1/2” SW

2” SW 2-1/2” BW

1112

ORV 25 SOC H1 49 C/120 F

ORV 40 SOC H2 49 C/120 F

ORV 50 SOC H2 49 C/120 F

ORV 65 A H3 49 C/120 F

148H3229 148H3232 148H3235 148H3237

SPARE/REPLACEMENT

THERMOSTAT 49 C/120 F AND GASKET + GUIDE RING

SPARE PARTS FOR CODE NO. VILTER

PART NO.

ORV 25 AND ORV 40 H1 ORV 40 AND ORV 50 H2 ORV 65 AND ORV 80 H3

148H3243 148H3244 148H3245

3214X 3214Y 3214Z

NOTES:-FLAMMABLE HYDROCARBONS ARE NOT RECOMMENDED.-CAN BE MOUNTED IN ANY DIRECTION -DESIGNED FOR MAX WORKING PRESSURE 580 PSIG -STAINLESS STEEL NICKEL PLATED THERMOSTATIC 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.

Adjusting the Inlet / Economizer or Side Load Pressure

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.

Adjusting the Outlet / Maximum Port 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 HA4AOASInlet/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)

Inlet Module Range ATurn CW to increase back pressure Turn CCW to decrease back pressure

M3S Stopping Plug

Electric Shutoff

HS2 HA2B Outlet Module Range BTurn CW to decrease outlet pressure Turn CCW to increase outlet pressure

M3E25

13668843 manual vilter

Documents

vilter order number

serial number

compressor serial

model number

local vilter representative

refrigeration compressor

theextent of damage

following instructions