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VMC 400 Series Compressor - Emerson Climate Technologies

1. DISCHARGE lt 6410 5 S HIGH STAGE C2 STER SUCTION FROM SUCTION RECEIVER BOOSTER d DISCHARGE A d HIGH STAGE DISCHARGE T Front 7 Drive End and Pump 2 r3 2 0 OLL PUMP X TO CRANKCASE 2 2 5 Se MEM ITEM NUMBER DESCRIPTION DESCRIPTION Oil Pressure Failure Switch PSO Dual Pressure Switch PSD High Pressure Switch PSH Low Pressure Gauge Crankcase Pressure Gauge Oil Pressure Gauge 2 High Pressure Gaug FIGURE 18 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH HALOCARBON DESUPERHEATER Safety Valve set 300 psig 2 Thermostatic Expansion Valve Solenaid Valve SVL and Strainer Assembly Capacity Control Switch 17 Liquid Line Valve 2 intermediate Pressure Gauge VMC 2101 OPERATION 26 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MuitiCylinder Compressor VILTER L3 Water Regulating Valve FIGURE 19 450XL WATER JACKET CONNECTIONS VMC 2 01 OPERATION 27 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Water Modulating Valve To Water Jackets 1 2 Water In 452 Water Solenoid Valve OPTIONAL NOTES 1 Set Moduiating V
2. 34 5 kPa 12 CYL 8 7 5 psi 5 3 8 psi 0 50 sec 51 7 kPa 0 32 sec 26 2 kPa 16 CYL 8 10 psi 5 5 0 psi 0 50 sec 63 9 kPa 0 32 sec 3 8 kPa Pressure Drop A provision should be made to shut off the wa ter when the machine is stopped The most positive way is to connect a solenoid water valve between the regulating valve and the jacket inlet with electrical connections made so the solenoid is open when the compressor is running and closed when the compressor stops Regulate the water quantity to maintain a tem perature of 100 F 37 8 C off cylinder covers CAUTION To avoid condensation of refrigerant in the compressor turn off water flow through the heads during compressor shutdown 20 NOTE In order to further minimize the possibility of condensation water flow through the cylinder cover is routed through the loaded cylinder banks first This inlet to the loaded heads will always be on the side opposite the crankcase handhole cover F Water Regulating Valve A wide variety of water regulating valves are available for use with water cooled condensers They maintain a constant condensing pressure and prevent waste of water 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor F Water Regulating Valve cont d Water regulating valves are installed at the wa ter inlet of the condenser There is a small cap
3. 400 Series VMC 2 01 SERVICE 34 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 5 FACTORY RUNNING DIMENSIONS TOLERANCES CLEARANCES amp ALLOWABLE WEAR LIMITS FOR 440 450 amp 450XL VMC COMPRESSORS cont d MAXIMUM ITEM PART NAME COMPRESSOR DIMENSION TOLERANCE CLEARANCE ALLOWABLE SIZE WEAR 10 Discharge Valve Thickness 440 ALL 030 001 None None 450 ALL None Height of Disch Valve Seat ALL n Measured From Head To Rail 005 Minimum Height 11 Oil Pump Axial Clearance 002 2 Pump 400 Series VMC 2 01 SERVICE 35 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor FIGURE 17 TYPICAL 400 SERIES COMPRESSOR VERTICAL CROSS SECTION AND LUBRICATION SYSTEM 400 Series VMC 2 01 SERVICE 96 Replaces all Previous Issues February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 1 May 1985 450XL VMC COMPRESSORS REPLACEMENT PARTS LIST Note Except where noted in the description column part listed apply to all 450XL High Stage Booster and Two Stage Compressors TABLE OF CONTENTS PAGE 1 REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS 2 Illustration 2 Cylinder Figure 1 3 Illustration 4 6 amp 8 Cylinder Figure 2 4 Illustration 12 amp 16 Cylinder Figure 3 5 Parts List DISCHARGE SUCTION GAUGE 9 Illustration Figure 4 10 Parts List CRAN
4. 1 1 a 235 Pin 4 x 1 Dowel 2 2 13162 236 Bolt 1 2 x 13 Machine 4 4 2796EL 237 Bearing Upper Right Half or Lower Left Half lt 2 2 33508A 238 Bearing Upper Left Half or Lower Right Half x 2 2 33508 240 Pin Threaded Taper zx 1 1 33497A 241 Case Bearing Support 1 1 242 Washer 1 2 Spring Lock n s zz 4 4 13165F 243 Nut 7 Hex 4 4 1726E 244 Nut 16 Hex 1 1 13253F 246 Key Crankshaft 1 1 1 1 1 1 33505B 247 Screw Flywheel Hub 1 1 1 1 1 1 31956A 248 Washer Flywheel Hub Screw 1 1 1 1 1 1 33495A 249 Gauge Oil Pressure 300 PSI 1 1 1 1 1 1 1204E 250 Stedy Mount 1 1 1 1 1 1 A17311SS 251 Valve 1 2 Screw End Globe 1 1 1 1 1 1 A11392A 252 Nipple 1 2 x 7 Sch 80 Pipe 1 1 1 1 1 1 13181 253 Connector 1 4 MPT x 1 4 O D Compression 1 1 1 1 1 1 13229D 254 Tee 4 1 1 1 1 1 1 1098B 255 Nipple 1 2 x 2 Sch 80 Pipe 1 1 1 1 1 1 13181C NOTES Patents Pending Matched set with pins sold as assembly A32163A Shown in fiveparts to illustrate disassembly VILTER MANUFACTURING CORPORATION February 2001 Replaces SECTION 100 R May 1985 PAGE 12 450XL VMC COMPRESSORS REAR BEARING COVER REPLACEMENT PARTS FIGURE 6 Typical arrangement when optional Center Tube Spool Assembly Item 31 without bypass reliefis used 327A 327A see insert 2115 L I
5. 9 HIGH PRESSURE LIQUID O LOW STAGE SUCTION GAS Op 0 INTERMEDIATE PRESSURE GAS qo HIGH STAGE DISCHARGE GAS 8 HIGH STAGE THERMOSTATIC EXPANSION SOLENOID VALVF VALVE SVL d C ef a im 9 d k ee o uu SUCTION LOW STAGE DISCHARGE X 1 1 oF HIGH STAGE S CYLINDER lt LOW STAGE vA CYLINDER NOTE 6 CYLINDER MODEL USING ANY REFRIG ERANT SHOWN 12 CYLINDER MODEL OPERATION IS SIMILAR If user installs stop valves in this line pump down coil be fore closing valve or install relief valve This will prevent pos sible rupturing of tubes when unit is shut down and warms up FIGURE 13 TYPICAL REFRIGERANT FLOW DIAGRAM FOR SIX AND TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSORS WITH INTERCOOLER OPERATION 2 01 21 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor LIQUID FROM RECEIVER pecias AER SURCOOLED A LIQUID TO SYSTEM TO ATMOSFPHERE OR BOOSTER SUCTION see local codes Yea To Frant Bearing Cover Drive End BOOSTER DISCHARGE and Pump Y 0 4 HIGH STAGE i DISCHARGE BOOSTER IW SUCTION We 43 OIL PUMP REMOTE Q lt 2 0 MOUNTED a CONTROL 4 when capacity 7 TO CRANKCASE Oy reduction is used 5 NUMBER DESCRIPTION Safety Valve Set 300 psig Thermo
6. 1 0 1659 A32612D 224 Complete Crankshaft Assy 1000 RPM Thru For Cast Iron Pistons 1 0 3067 2612 233 For Cast Iron Pistons 1 0 3067 A32612D 225 Lockwasher Crankshaft Bearing 1 1 1 1 aie 1 0 9999 33365 225 Lockwasher Crankshaft Bearing E 1 1 1 0 9999 35502 226 Lock Bearing 1 1 1 1 25 1 0 1659 31902 229 T Crankshaft 1200 RPM w oilways plug For Cast Iron Pistons 1 0 1659 A30291A For Cast Iron Pistons 1 0 1659 A30304A 229 T Crankshaft 1000 RPM w oilways plug For Cast Iron Pistons 1 0 3067 A30291A For Cast Iron Pistons 1 0 3067 A30304A NOTES Some compressors using cast iron pistons were equipped with an obsolete pump drive If the compressor is not equipped with Item 233 and an interchangeable replacement crankshaft is ordered it is necessary to order Item 233 at extra cost When ordering a crankshaft bearing locknut Item 224 for a compressor with Serial No 9999 and below also order crankshaft bearing lockwasher Item 225 1 When ordering bare crankshaft for compressor with Serial 9999 and below also order Item 224 crankshaft bearing locknut and retaining compound kit T Crankshafts for Cast Iron Piston for these machines are no longer available Use current crankshaft and convert the compressor
7. Used without Water Jacket 20 40 60 80 120 160 40 80 0 Present 13152G 103 Cover Water Jacket Amm amp R22 1 2 3 4 6 8 1 2 0 Present 30299A 104 Gasket Water Jacket Amm amp R22 1 2 3 4 6 8 1 2 0 Present 33329A 105 Cover Cylinder Without Capacity Reduction 1 2 4 0 Present A30332A With Capacity Reduction Oil Type it 21 4t 0 Present 30332B With Capacity Reduction Gas Type 1 2 4 0 Present 30332G Without Capacity Reduction 1 1 2 3 6 0 Present A30364A With Capacity Reduction Oil Type 11 21 AT 21 61 0 Present 30364B With Capacity Reduction Gas Type 11 2 4 0 Present 30364G With Capacity Reduction Two Stage 1t 0 Present 30364F 106 Gasket Cylinder Cover 1 2 3 4 6 8 3 6 0 Present 33330A 107 Stud 7 x 3 shown only on 2 cyl 8 4 4 4 8 8 4 8 0 Present 13156D 107 Stud 3 2 x 31 not shown 4 4 4 4 0 Present 13157D 108 Tee Suction 2 x 212 all 1 2s x gt 0 Present 30319A 3 x 212 Ammonia 1 0 Present 32417C 37 x 3 Halocarbon 1 0 Present 32417B 3 x 4 Amm amp Boosters 1 1 Tir 36254A 4 x 4 Halocarbon 1 Ke 36254B 4 x 4 Amm amp Boosters zi aS sis 1 a 22 XA ES de id 36254B 5 x 4 Halocarbon 1 535 rap 36254 Elbow Suction 4 x 3 Amm amp Boost
8. Valve Retaining 2 4 6 8 12 16 6 12 3638 Present 1776B 514 Washer Diaphragm Valve 2 4 6 8 12 16 6 12 3638 Present 31990B 515 Valve Diaphragm Discharge 6 12 18 24 36 48 18 36 3638 Present 31939B 516 Spacer Diaphragm Valve 2 4 6 8 12 16 6 12 3638 Present 31990A 517 T Safety Head Ammonia for Helical Springs 2 4 6 8 12 16 6 12 3638 Present 33531B 517 Safety Head R12 and R22 for Helical Springs 2 4 6 8 12 16 6 12 3638 Present 33532B 518 Screw Valve Retaining 60 2 4 6 8 12 16 6 12 3638 13 490 31964 518 Screw Valve Retaining 82 2 4 6 8 12 16 6 12 13491 Present 1527 519 Springs Valve Helical 8 16 24 32 48 64 24 48 3638 Present 33803A 520 Yoke Safety Head 2 4 6 8 12 16 6 12 3638 Present 31941B 521 Spring Safety Head 2 4 6 8 12 16 6 12 3638 Present 31882A NOTES 1 For replacement parts for compressors having serial numbers below 3638 see page 29 These oil rings do not require expanders Do not use expanders They may cause excessive wear Replacement bushing must be reamed after installation to properly accommodate piston pin Replaces bearing half with groove If compressor has standard size bearings with groove order 31957B Std Size bearing half If crankshaft is groove undersize order KT513 or KT513A bearing half set with locknuts with no groove When ordering safety head Item 517 for machines with serial number below 13491 Item 518 1527B must also be ordered Screw ho
9. Vi gt 5 2 8 Socket weld shown weld neck ODS available HCK4 3 4 5 2 BOLT de PAN HCK4 7 8 9 0 1 4 B D Ecc available OLT y Socket weld shown Weld neck ODS available HCK4 check valves are normally closed valves As inlet pressure increases it overcomes the closing spring force As the seat disc is pushed back and away from the seat cartridge flow through the valve occurs The valve will remain open until the inlet pressure drops below the closing spring force or there is a flow reversal at which time the seat disc will close against the seat cartridge preventing reverse flow SIZING Check valves are normally selected on the basis of line size However for gas flow applications at low load conditions a minimum of 1 psid across the valve is essential This will maintain valve at full open position Valve Cv Kv is listed in the installation dimension table on page 2 Factory valve sizing assistance is available SERVICE AND MAINTENANCE These valves are a reliable part of a refrigeration system However if valve does not appear to be Operating satisfactorily isolate it from the refrigeration system Remove all refrigerant from associated piping and valves Follow the guidelines in the caution section Loosen each flange nut on the check valve Break eac
10. Compresser Drive End FIGURE 7 HIGH STAGE 16 CYLINDER COMPRESSOR FOR 400 SERIES CAPACITY REDUCTION ARRANGEMENT TYPICAL SCHEMATIC VMC 2 01 OPERATION 15 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor STANDARD UNLOADING MAXIMUM UNLOADING 3 CYLINDER 3 CYLINDER UNLOADING UNLOADING 33 1 3 Single 33 66 5 CYLINDER UNLOADING 20 40 60 CYLINDER UNLOADING 20 40 2 5 Single 7 CYLINDER UNLOADING 14 29 7 CYLINDER UNLOADING 14 29 43 57 FIGURE 8 UNLOADING ARRANGEMENT SCHEMATIC 3 5 AND 7 CYLINDER 300 SERIES COMPRESSORS VMC 2401 OPERATION 16 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor STANDARD UNLOADING MAXIMUM UNLOADING 4 CYLINDER 4 CYLINDER UNLOADING UNLOADING 50 25 50 75 6 CYLINDER UNLOADING 17 33 50 66 6 CYLINDER UNLOADING 33 66 8 CYLINDER 8 CYLINDER UNLOADING Yo UNLOADING 25 12 50 25 75 37 50 62 75 9 UNLOADER ARRANGEMENT SCHEMATIC 4 6 AND 8 CYLINDER 300 SERIES COMPRESSORS VMC 2 01 OPERATION 17 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MuitiCylinder Compressor STANDARD UNLOADING MAXIMUM UNLOADING Koro UNLOADING 33 66 QNO UNLOADING 2596 5096 FIGURE 10 UNLOADING ARRANGEMENT SCHEMATIC
11. Driva 2 01 REPLACES ALL PREVIOUS ISSUES MANUFACTURING CORPORATION VILTER MultiCytinder Compressor 8 CYLINDER COMPRESSOR STANDARD PERCENT REDUCTION 25 50 To Golenck Valve To Solenoid Yave 8 CYLINDER COMPRESSOR 8 CYLINDER COMPRESSOR OPTION 1 OPTION 2 PERCENT REDUCTION 25 50 75 PERCENT REDUCTION 25 50 75 100 ToS Valve To Solenoid Vaive To Solenoid Vatve 12 CYLINDER COMPRESSOR STANDARD PERCENT REDUCTION 33 66 To Splenold Valve Sol af 6206 PERCENT REDUCTION 33 66 100 Bolenoid Valve Compressor Drive End FIGURE 6 HIGH STAGE 8 AND 12 CYLINDER COMPRESSOR FOR 400 SERIES CAPACITY REDUCTION ARRANGEMENT TYPICAL SCHEMATIC VMC OPERATION 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 16 CYLINDER COMPRESSOR 16 CYLINDER COMPRESSOR STANDARD OPTION 1 PERCENT REDUCTION 25 50 PERCENT REDUCTION 25 50 75 To Solenmid To Soleucid Valve Solenuid Valve Ah RN 5 3 3 O G Snlenaid Valve Saleanid Vater Solanoid Vakre Salenaid Valve OL OL O_O GLI9 G9 5 ee Oe G Compressor Drive End Cempressor Drive End 16 CYLINDER COMRPESSOR exc OPTION 2 PERCENT REDUCTION 25 50 75 100 To Solenaid Valve To Salenaid Valve 9r 9
12. Features and Benefits Built in Time Delay Relay Minimizes timing fluctuations due to temperature with Ambient Compensation variations Trip free Manual Reset Provides manual reset that cannot be overridden by pressing and holding the reset button Replaceable Time Delay Allows easy field replacement of the time delay Relay Assembly relay and terminal board Available with Runlight and Allows the control to be wired for normal oil Alarm Terminals pressure runlight signals and shutdown alarm circuits for remote monitoring of oil pressure status 1998 Johnson Controls Inc 1 Part No 24 7664 605 Rev A Code No LIT 125420 Introduction A WARNING Personal injury hazard All P28 and P128 controls are designed as lubrication protection controls Failure of the P28 or P128 could allow the refrigeration compressor to be damaged in a way that may not be apparent upon visual inspection Follow proper procedures and the compressor manufacturer s instructions as well as any warning signs on or around the equipment when discharging and disassembling the compressor Environmental damage hazard If leakage of sensed media such as refrigerant or oil can be harmful to the environment or hazardous in any way user must provide for proper containment The P28 and P128 controls measure the net oil pressure available to circulate oil throughout a pressure lubricated refrigeration system The net oil pressure is the dif
13. General Service Instructions 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A Disassembly After the cylinder covers valves and handhole cover have been removed the first step in re moving the piston and rod assembly is to remove the Palnut locknuts on the rod bearing bolts Then remove the plain nuts and slide the bear ing cap off of the nuts The Palnut locknut is not used with this type of locknut Handle the bearing cap carefully to avoid dam age to the bearing half insert Push the rod and piston out through the top of the cylinder Avoid possible mixing with components Keep all parts together in relation to their position in the com pressor Connecting rods and rod caps are match marked to aid in reassembly On reas sembly all parts must be installed in the same position in the compressor As soon as the parts are removed from the com pressor they should be thoroughly cleaned with a Suitable refrigeration parts cleaner Once the oil film is removed the bare metal is subject to rust This reaction can start immediately There fore lubricate the surfaces of the parts lightly with clean compressor oil immediately after cleaning The tabs on the bearing half insert fit into the re cess in the rod and rod cap and the inserts can be slipped out without difficulty To replace the rod bearings it is necessary to change the in serts only an
14. Hex Head Used with Water Jacket 20 40 60 80 120 160 13152L 102 Screw 5 5 x 22 Hex Head Cap Used when Water Jacket not used 20 40 60 80 120 160 13152G 103 Cover Water Jacket Ammonia and R22 1 2 3 4 6 8 30299A 104 Gasket Water Jacket Ammonia and R22 1 2 3 4 6 8 33329A 105 Cover Cylinder Banks w o Capacity Reduction 1 2 4 A30332A Banks w Capacity Reduction Oil Act 1 2 4 30332B Banks w Capacity Reduction Gas Act 1 2 4 303320 Banks w o Capacity Reduction 1 1 A30364A Banks w Capacity Reduction Oil Act 17 2 4 EE 30364B Banks w Capacity Reduction Gas Act 15 2 4 30364G Banks w o Capacity Reduction Two Stage 3 6 A30364A 106 Gasket Cylinder Cover 1 2 3 4 6 8 33330A 107 Stud 2 6 x 3 shown only on 2 cylinder 8 4 4 4 8 8 13156D 107 Stud 3 4 x 3 7 not shown 4 4 4 13157D 107A Nut 5 8 11NC 2B 1726G 107A Nut 10 2 4 4 4 1726H 108 Tee Suction 212 x 222 1 A30319A 31 x 3 1 A32417B Elbow Discharge 2 x 2 Ammonia 1 12270E 2 x 2 2 Ammonia 1 12270F 3 x 3 Ammonia 1 2 2 12271E 4 x 3 Ammonia 1 2498 109 Suction Screen 1 2428 109 Suction Screen 1 A32428D 109 Suction Screen 2 2 2565 109 Bag Suction Screen not shown
15. tube running from the valve to the dis charge line of the compressor the hot gas line or the top of the condenser When the pressure builds up on the high side of the system it is transmitted through this capillary to the valve This acts against a spring holding the valve closed Spring tension can be varied by means of an adjusting screw on the valve When the valve is adjusted properly it automatically opens and closes in response to the pressure on the high side of the system maintaining a constant con densing pressure When cooling towers are used and no other positive means of regulating head pressure is provided a water pressure regulating valve serves to regulate head pressure Adequate head pressure is often important to provide proper refrigerant flow through expansion valves or float valves in order to maintain the suction pressure above the setting of the low pressure cut out to prevent short cycling XII SAFETY DEVICES Plant safety requirements vary according to lo cal ordinances Research local codes before construction begins In addition to devices for refrigerant control safety devices are required for belt full guards and electrical equipment When required a totally enclosed belt guard is available for VMC Compressors NOTE Make all arrangements for installation of electric power and inspection services by local authori ties prior to construction so all work is per formed before th
16. x 3 shown only 2 Cylinder 8 4 4 4 8 8 13156D 107 Stud 34 x 314 not shown 4 4 4 13157D 107 Stud 34 x 394 5 lt se zm 8 8 13157F 107 A Nut Hexagon see Figure 1 8 4 4 4 1726G 107 A Nut 34 Hexagon see Figure 1 4 4 4 1726 108 Tee Suction 212 x 27 see Figure 1 1 A30319A 108 Tee Suction 31 2 x3 not shown 1 2417 108 t Tee Suction 5 x4 not shown 1 36254C 108 t Tee Suction 4 x4 not shown High Stage 1 6254 1081 Tee Suction 4 not shown Booster 1 A36254A 1081 Tee Suction 5 4 not shown 1 6254 108 T Elbow Suction 4 not shown 1 12273C 108 A Gasket 4 Flange Suction Discharge Conn 2 2 113231 108 A Gasket 27 Flange Suction Discharge Conn 1 2 11323 108 Gasket 312 Flange Suction Discharge Conn 1 11323K 108 A Gasket 3 Flange Suction Discharge Conn 3 11323J 108 A Gasket 5 Flange Suction Discharge Conn 1 1 11323 108 Ring Male Joint 4 Suction s 215 1 13151L 109 Suction Screen 1 2 2 A32428D 109 Suction Screen 1 A32428A 109 Suction Screen Center 1 2428 1091 Suction Screen RH Side 75 Cap Red 1 A32428D 109 Suction Screen
17. 1 1 5215 109 Suction Screen 2 2 A32565A 109 A Bag Suction Screen not shown 1 A33474A 109 A t Bag Suction Screen not shown 1 2 3 A33474B 109 A Bag Suction Screen not shown 2 2 A33474G 109 A t Bag Suction Screen not shown 1 1 5234 110 Gasket Suction Screen Cover 1 2 2 31892A 110 Gasket Suction Screen Cover 2 2 33493A 110 f Gasket Suction Tee Cover 1 1 11323 1101 Gasket Suction Tee Cover 1 1 35217A 111 Cover Suction Screen 1 2 2 31893A 111 Cover Suction Screen 2 2 33492 1113 Cover Suction Tee VPN 32417 36254 1 1 2 13706A 111 Cover Suction Tee VPN 36254 a 1 1 35216 112 Screw 9 5 x 1 Hex Head Cap 5 5 13152C 112 Screw 5 x 194 Hex Head Cap 6 6 13152D 112 Screw 12 x 1 Hex Head 6 12 12 16 16 2796E 113 Valve 1 2 Oil Charge and Drain 1 1 1 1 1 1 A15375A 113 Nipple 12 4 Sch 80 Pipe 1 1 1 1 1 1 13189G 114 Gasket Crankcase Oil Screen 1 1 1 1 1 1 31889A 115 Crankcase Oil Screen Assembly 1 1 1 1 1 1 A31886A 116 Plug 34 Hex Head Pipe not shown on 12 1 1 1 1 1 1 13264E 116 Plug 1 2 Hex Head Pipe not shown on 2 thru 8 1 1 1 1 1 1 13264D NOTES E May not be shown or only shown typically on one illustration Part Number on application T 6 Oylinder Compressors with serial numbers below 45
18. NOTE Before proceeding refer to Paragraph I General Service Instructions A Disassembly To remove the compressor cylinder covers re move the capacity control lines and water lines or liquid cooling lines if any from the covers that will be removed Next remove two screws that are opposite each other diagonally across the cover i e two screws by water connections Install two assembly studs into these holes and tighten them to thread bottom Screw on nuts to within one thread of touching the cover Remove the other screws Slowly back the two nuts off and make sure the cover follows If the cover doesn t follow STOP DO back off nuts more than one turn Break the gas ket seal and then continue cover removal The studs are long enough to relieve all the spring tension before the nuts are removed Remember the studs must not be turned out with the nuts After all of the spring tension is re moved the nuts can be removed covers lifted off and head springs removed It is best to keep all parts in the correct cylinder assignment Invert the cover and place on work surface placing each spring in its corresponding location in the cover 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A Disassembly a o FIGURE 1 BEARING AND CYLINDER COVERS ASSEMBLY amp DISASSEMBLY STUD B Assembly Before replacing the cover on the c
19. R12 R22 for cylinders with unloading include all the parts listed in paragraph 1 and 3 except the Connecting Rod Assembly and Connecting Rod Bearing Halves SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 25 Replaces 440 VMC COMPRESSORS March 1975 OLD STYLE CYLINDER LINER amp CAPACITY CONTROL REPLACEMENT PARTS FOR 1200 RPM HIGH STAGE COMPRESSORS WITH SERIAL NUMBERS BELOW 3638 FIGURE 11 409 Two Rings Per Groove 407 Sees 410 401 February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 26 August 1974 440 VMC COMPRESSORS CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 1200 RPM HIGH STAGE COMPRESSORS Serial Numbers 3637 and below ITEM DESCRIPTION NO REQUIRED PER COMPRESSOR SERIAL NO PART NO OF CYL 2 4 6 8 12 16 FROM THRU NO 401 thru Cylinder Liner Kit 405 For Cylinders w Unloading 1 2 4 4 8 8 0 3637 KT033 401 Cylinder Liner Kit And For Cylinders w o Unloading 2 2 2 4 4 8 0 3637 KT032 402 For Cylinders w o Unloading 12 0 3637 KT032 401 Liner Cylinder 2 4 6 8 12 16 0 3637 A32609A 402 Seal O Ring 2 4 6 8 12 16 0 3637 2176BH 403 Unloader Ring Assembly 1 2 4 4 8 8 0 3637 A33434A 404 Washer Unloader Spring 2 4 8 8 16 16 0 3637 33436A 405 Spring Unloader Ring 2 4 8 8 16 16 0 3637 33428A 407 Plate Suction Valve 2 4 6 8 12 16 0 3637 33422A 408 Spring Valve Volute 8 16
20. Remove the support bolts if used supporting the center ring in one of the other ways Using paragraph VI B 3 above install the second disc pack to the hub The remaining boits for this end can now be installed These bots go in from the hub side first through the washer the disc pack and then the bolt hole in the center nng adding the locknut The locknuts can be snugged up at this time The disc pack as installed should look flat and parallel with the mating hub and center ring fingers 5 Make the final coupling alignment check at this time 8 Torque up the locknuts See Table 1 for torque values It is recommended that all locknuts be retightened after several hours of initial operation T For further help with the installation or alignment consult Rexnord NOTE it may be necessary to use an open end wrench to torque the locknuts at the hub end due to the lack of room Table 2 FLYWHEEL ADAPTER 811050 120959 121375 920941 930642 837205 Thess locknuts are cad plated PER COUPLING MADE TO CUSTOMERS SPECIFICATIONS 002235 008571 Rexnord WIE NN Park par Cplg Disc Two om Center Ri Slain aloy tess VII 7 For further help with the installation or alignment consult Rexnord Disc Pack Replacement If it becomes necessary to replace the disc pack it can be done as follows A At the hub end of the coupling remove all locknuts and washers Back out a
21. Turn 7 8 NC adjustment bolt counter clockwise to raise foundation V Slot for nailing isolator housing to concrete form work Neoprene accustical friction cup 77 Z Yl pu 7 PERATING 2122 CLEARANCE CROSS SECTION VIEW TYPE KIP C VIBRATION ISOLATORS 2 01 mer dem REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor FORMS AND TEMPLATES Prints showing foundation layouts are included with each unit When locating the foundation remember to allow adequate space for servic ing the compressor and removing the crank shaft Consult Table 2 for overall dimensions Crankshaft minimum allowances for the various machines are given in Table 3 These are minimum clearances in inches millimeters to remove crankshafts measured from compres sor frames TABLE 3 CRANKSHAFT REMOVAL CLEARANCES COMPRESSOR MODEL 300 SERIES MODEL 400 SERIES SIZE DRIVE PUMP DRIVE PUMP cyl qty END END END END 3 thru 8 30 30 762 mm 762 mm 2 thru 8 30 22 762 mm 558 8 mm 12 amp 16 60 52 j 1524 mm 1320 8 mm Use a form similar to that in Figure 4 to con struct the concrete pad Construct this form to withstand the weight of wet concrete In addi tion nail a 1 25 4 mm beveled strip around the top edge of the form to eliminate a sharp corner at the top of the pad Make the templat
22. move the cylinder covers refer to paragraph I A In cylinders without unloaders the valve assemblies may be removed as soon as the cov ers are removed On compressor cylinders equipped with unload ers the unloader needs to be forced down before the valves are serviced If the unloader remains up the suction valve is forced off its seat and will not seat and locate properly during reassembly To hold the unloader mechanism down remove the plug from the hole B in the frame Force the unloader piston down and insert a short 1 7 93 mm diameter metal rod through the hole to restrain the piston Use a wooden block to force the piston down to avoid scratching or damaging the top of the unloader piston Once the piston is held down the valve assemblies can be ser viced 1 440 Compressor Mushroom Style See Figure 7 Lift out the safety head yoke which holds the safety head assembly in place When the yoke is out lift out the safety head as sembly and suction valve plate To disassemble the safety head assembly remove the locknut on the valve retaining screw 1 440 Compressor Mushroom Style 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Lift off the washer two diaphragm valves spacer and last diaphragm valve Turn the safety head assembly over and remove the valve retaining screw Remove the helical suction valve springs fro
23. under Pressure with the Vilter Motor Driven Oil Charger It s Ideal For Reciprocating And Screw Compressors The addition of oil to a compressor crankcase under pressure is usually accomplished in either one of two different ways One means is to pipe oil can containing a fine mesh screen to the oil drain valve The suction valve is then closed creat ing a partial vacuum and the oil drain valve is cracked to draw oil into the crankcase The biggest disadvantage of this method is the disruption of the system which results when the suction valve is closed Great care must also be taken to prevent the contamination of the oil or the entrance of air into the compressor during the operation In addi iion continued use of this procedure results in untidy engine room floors The other alternative is to use a hand pump to charge the oil into the crankcase This is a consid erable improvement since il does not disrupt the system keeps air from entering the crankcase prohibits any contamination of the and elimi nates the untidiness of the operation However it can be a strenuous and time consuming proce dure particularly when a large charge has to be added to a crankcase or an oil separator But there is a third method of charging oil into a compressor under pressure an extremely effec tive melhod requiring an absolute minimum of effort and time 178 through the use of the Vilter Motor Driven Oil Charger
24. 1 474 109 Bag Suction Screen not shown 1 2 3 3474 109 Bag Suction Screen shown 2 2 A33474G 110 Gasket Suction Screen Cover 1 2 2 31892 110 Gasket Suction Screen Cover 2 2 33493A 110 Gasket Suction Cover 1 1 11323 111 Cover Suction Screen 1 2 2 31893A 111 Cover Suction Screen 2 2 33492A 111 Cover Suction Screen 1 1 13706 112 Screw x 2 Hex Head 5 5 13152 112 Screw 12 x V Hex Head 6 12 12 16 16 2796E 113 Valve V Oil Charge and Drain Ammonia 1 1 1 1 1 1 1956B 113 Valve 1 2 Oil Charge and Drain Halocarbon 1 1 1 1 1 1 1956A 113 A Nipple 1 2 x 4 Sch 80 Pipe 1 1 1 1 1 1 13189G 114 Gasket Crankcase Oil Screen 1 1 1 1 1 1 31889A 115 Crankcase Oil Screen Assembly 1 1 1 1 1 1 A31886A 116 Plug 34 Hex Head Pipe not shown on 12 amp 16 1 1 1 1 1 1 13264E 116 Plug 1 2 Hex Head Pipe not shown on 2 thru 8 1 1 1 1 1 1 13264D NOTES A Unless otherwise indicated quantities shown are for compressors with standard capacity reduction and may vary if compressor is equipped with other versions See Page 13 for application notes Patents Pending Items shown are for compressors with optional oil unloading or optional single cylinder unloading See Page 15 for application notes Part Number on application May not be shown or only shown ty
25. 1 246 Key Crankshaft 1 1 ss S 31994 246 Key Crankshaft E 1 1 1 1 33505B 247 Screw Flywheel Hub 1 1 1 1 1 1 31956A 248 Washer Flywheel Hub Screw 1 1 1 1 33495A 249 Gauge Oil Pressure 300 PSI 1 1 1 1 1 1 1204E 250 Stedy Mount 1 1 1 1 1 1 A17311SS 251 Valve 1 2 Screw End Globe 1 1 1 1 1 1 A11392A 252 Nipple 1 2 x 7 Sch 80 Pipe 1 1 1 1 1 1 13181M 253 Connector 14 MPT x O D Compression 1 1 1 1 1 1 13229D 254 Tee 1 1 1 1 1 1 1098B 255 Nipple 1 2 x 2 Sch 80 Pipe 1 1 1 1 1 1 13181C NOTES Matched set with pins sold as assembly A32163A Shown in three parts to illustrate disassembly See Page 8 for symbol regarding this information Compressors below serial number 45330 were furnished with the no longer available front bearing cover assemblies A30294A 2 and 4 cylinders or 2162 6 8 12 cylinders and front bearing retainer 31885A 2 and 4 cylinders or 33500A 6 8 and 12 cylinders without oil hole Former front bearing retainers 31885A 33500A without oil holes cannot be used with current front bearing cover assemblies A36240A 2 and 4 cylinders and A36241A 6 8 and 12 cylinders as there is no way for oil to get to the bearing If front bearing cover is being replaced a current front bearing retainer 31885A or 33500A with oil hole must be ordered also unless one of these current styles is already being used If a current front bearing retainer 31885A or 33500A
26. 2 4 6 4 1193X 416 Pin Short Pivot 1 1 2 3 2 4 6 4 33250B 417 Spring Unloader Yoke Standard 4 4 8 12 8 16 24 16 33686A 417 Spring Unloader Yoke High Suction 6 6 12 18 12 24 36 24 33686 418 Yoke Guide Assy Std Single Cylinder 1 3 6 A33576A 418 Yoke Guide Assy Hi Suct Single Cyl 1 3 6 A35249A 418 Yoke Guide Assy Hi Suct Double Cyl 1 2 2 4 4 A35248A 419 Screw s x 1 Cap Lock 2 6 12 1352D 420 Spacer Sleeve 2 6 12 33618 NOTES pages 16 17 18 25 and 26 for notes and lower serial number applications February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 20 February 1985 440 VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS FIGURE 10 SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 21 Replaces 440 VMC COMPRESSORS February 1985 PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1200 RPM High Stage and Two Stage Compressors Serial Number 3638 to Present NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 501 thru 505 Piston Flat AL Rings and Pin Kit 4 6 8 12 16 6 12 3638 Present 213 501 thru Pis
27. 3 4 AND 5 CYLINDER 300 SERIES COMPRESSORS Class 1 Group D Division Explosion Proof Units VMC 2 01 OPERATION 18 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor MAXIMUM UNLOADING STANDARD UNLOADING 6 CYLINDER 7 CYLINDER OOO 1 15 8 CYLINDER 8 CYLINDER G 5 h UNLOADING 1296 2596 37 5094 6204 75 FIGURE 11 UNLOADING ARRANGEMENT SCHEMATIC 6 7 AND 8 CYLINDER 300 SERIES COMPRESSORS Class 1 Group D Division It Explosion Proof Units 2 01 OPERATION 19 REPLACES ALL PREVIOUS ISSUES MANUFACTURING CORPORATION VILTER MultiCylinder Compressor THERMOSTATIC SOLENOID 2 EXPANSION VALVE VALVE HIGH STAGE DISCHARGE od LOW STAGE DISCHARGE LOW STAGE SUCTION Pan INTERMEDIATE PRESSURE LIQUID NOTE 6 CYLINDER MODEL USING ANY RE FRIGERANT SHOWN 12 CYLINDER MODEL S D cO INTERMEDIATE PRESSURE GAS QUO 10 HIGH STAGE DISCHARGE GAS FIGURE 12 TYPICAL REFRIGERANT FLOW DIAGRAM FOR SIX AND TWELVE CYLINDER TWO STAGE COMPRESSORS WITH DESUPERHEATER VMC 2 01 OPERATION 20 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor LIQUID FROM RECEIVER 245 LIQUID TO ACCUMULATOR 2 DISCHARGE LOW STAGE SUCTION X e INTERMEDIATE PRESSURE LIQUID es
28. 501 thru Piston Rings and Connecting Rod Assy Kit 2 4 6 8 KT573 508 501 Piston Ring Compression 6 12 18 24 31989M 502 Piston Ring Oil 2 4 6 8 31989N 503 Piston and Connecting Rod Assy 2 4 6 8 504 507 Bearing Half and Lock Nut Kit 2 4 6 8 KT575 amp 508 504 Lock Nut 7 Connecting Rod 4 8 12 16 2028A 505 Nut Plain Hex UNF 4 8 12 16 2027A 506 Bolt Connecting Rod 4 8 12 16 31955A 507 Bearing Half Connecting Rod upper 2 4 8 Order KT575 508 Bearing Half Connecting Rod lower 2 4 6 8 Order KT575 509 Spring Safety Head 2 4 6 8 35252A 510 Safety Head Yoke Kit includes 4 of item 513 2 4 6 8 KT543 511 Spring Valve 16 32 48 64 33803A 512 Plate Discharge Valve 2 4 6 8 3508055 513 Safety amp Pins Assy Standard Ammonia Compr 2 4 6 8 A35082A 514 Safety Hd amp Pins Assy 2 4 6 8 A35272A 513 Pin Roll 0 187 dia x 11 16 Ig 8 16 24 32 1712F 514 Safety Head 2 4 6 8 515 Spring Valve 8 16 24 32 33803A NOTES Piston wrist pin and connecting rod sold only as a kit ee Shown for disassembly purposes only order assembly This Safety Head and Pins Assembly is used on standard Halocarbon and High Suction Pressure Ammonia Compressors High Suction Pressure Compressors are identified with an X in the serial number 35391 Rev 1a 5 14 Emerson and Vilter are trademarks of Emerson Electric Co or one of its affiliated companies 2014 Emerson Climate Technologies Inc All rights reserved Printed in
29. Hi Suct 1 2 2 4 4 150 22799 A33335A 415 Pin 3 2 x Vie Ig Roll 1 1 2 2 4 4 3 6 150 22799 1193X 416 Pin Short Pivot 1 1 2 2 4 4 3 6 30000 32499 33250B 417 Spring Unloader Yoke Std 4 4 8 8 16 16 12 24 30000 32499 33686A 417 Spring Unloader Yoke Hi Suct 6 6 12 12 24 24 30000 32499 33686A 418 Yoke Guide Assembly std single 1 3 6 30000 32499 A33576A 418 Yoke Guide Assembly std double 1 2 2 4 4 30000 32499 A33347A 418 Yoke Guide Assembly Hi Suct 1 2 4 4 30000 32499 A35248A 419 Screw s x 1 Cap Lock 2 6 12 30000 32499 1352D 420 Spacer Sleeve 2 de zE 2e as 6 12 30000 32499 33618A NOTES These items are used on Two Stage and 2 cylinder compressors only when equipped with unloading For single cylinder unloading the yoke assembly Item 414 and the two pins on the yoke guide assembly Item 418 have drilled and tapped holes to accommodate screws Item 419 and spacers Item 420 Replacement parts for 1200 RPM compressors with serial numbers below 3638 are on pages 25 and 26 Spring part number was 33353A and quantity was 6 Replace all springs in the assembly Actuation type can be determined by checking unloading solenoid valve oil uses three way valves gas uses two way valves For serial numbers above these see page 19 Four roll pin holes are drilled thru the safety head and safety head yoke into
30. INSTALLATION 23 To properly evacuate the system and to re move all non condensibles air and water vapor us a high vacuum capable of attaining a blanked 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 some where below 1000 microns Evacuation should not be done unless the room temperature is 60 F 15 6 C or higher Attach vacuum gauge s reading in the 20 to 20 000 micron gauge range to the refrigerant system These gauge s should be used in conjunction with the high vacuum pump The reading from these gauge s indicates when the system has reached the lowest absolute pres sure required for 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 high side and low side of the system to insure sys tem evacuation Attach the vacuum gauge to the system in accordance with the manufac turer s instructions A single evacuation of the system does not sat isfactorily remove all of the non condensibles air and water vapor To do a complete job a triple evacuation is recommended When the pump is first turned on bring system pressure to as low a vacuum level as possible and con tinue operation for 5 to 6 hours Stop the pump and isolate the system Allow the unit to stand at this vacuum for another 5 to 6 hours After this tim
31. L I 1 te DO NOT DISASSEMBLE CENTER TUBE FACTORY PRESET RELIEF VALVE PATENTS PENDING February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 13 May 1985 450XL VMC COMPRESSORS REAR BEARING COVER REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 301 thru Rear Bearing Cover Assembly Kit 1 1 1 1 1 1 KT092 304 amp 333 301 Cover Rear Bearing 1 1 1 1 1 1 Order Kit 302 Plug 34 Hex Socket Head Pipe 1 1 1 1 1 1 13163 303 Pin x 1 Dowel 1 1 1 1 1 1 2868H 304 Orifice Oil Metering not shown 1 1 1 1 1 1 33361A 305 Gasket Oil Pump Body 1 1 1 1 1 1 31899A 306 Oil Pump Assembly 1 1 1 1 1 1 A33480A 307 Gasket Oil Pump Cover 1 1 1 1 1 1 31900A 308 Gasket Oil Pump and Rear Bearing Cover Seal 1 1 1 1 1 1 33320A 309 Cover Oil Pump and Filter Head R12 amp R502 1 1 1 1 1 1 34565A 309 Cover Oil Pump and Filter Head R717 amp R22 1 1 1 1 1 1 34760AB 310 Filter Assy Complete without Bypass Relief 1 1 1 1 1 1 A35241A 310 Filter Assy Complete with Bypass Relief 1 1 1 1 1 1 A35240A 311 Spool Assembly without Bypass Relief 1 1 1 1 1 1 2046A 311A 312 Spool Strainer Tube Assembly 1 1 1 1 1 1 1448U 313 amp 314 311A 312 Thru 314 amp Filter Assembly without Shell 1 1 1 1 1 1 1448T 315A thru 319 amp 321 311A Spool Assembly with Bypass Relief 1 1 1 1 1 1 1448J 312
32. Low Side Equipment cont d d e f 9 Correct fan and pump rotation Evaporator pressure regulators and so lenoid valves open Water pumps and motor aligned V belt drives accurately aligned and tensioned Proper power voltages to motors correctly Compressors a b c d e f g Correct oil level Voltage agrees with motor characteris tics Properly sized motor fuses and heater V belt drives aligned and couplings tight Direct drives aligned and couplings tight All suction and discharge valves open All gauges reading correctly Condenser a b c d e Water available at water cooled con densers and supply line valve open Water in sump of evaporative con denser and make up water available Correct rotation of pump and fan mo tors V belt drives aligned and tensioned cor rectly Pump fans and motor lubricated Controls a Controls at proper setting Refrigerant Charging There are two methods of charging refrigerant into the system through the high side or through the low side High side charging is usually used for initial charging because this method fills the system much faster Low side charging is usually reserved for adding only VMC INSTALLATION 26 small amounts of refrigerant after the system is in operation 1 High Side Charging Initial Charging a Connect a full drum of refrigerant to the liqu
33. Plain Hex UNF 4 8 12 16 24 32 2027A 510 Bolt Connecting Rod 4 8 12 16 24 32 31955A 511 Connecting Rod and Cap 2 4 6 8 12 16 55 512 Bearing Half Connecting Rod All Compressors Except 16 Cylinder High Stage Standard Size 2 4 6 8 12 16 KT512 0 015 Undersize 2 4 6 8 12 16 KT513A 0 030 Undersize 2 4 6 8 12 16 KT513 512 Bearing Half Connecting Rod Heavy Duty High Stage 8 32 352735 513 Spring Safety Head 2 4 6 8 12 16 35252A 514 Safety Head and Pins Assembly Standard Comp 2 4 6 8 12 16 A35082A 518 Safety Head and Pins Assembly Hi Suction Comp 2 4 6 8 12 16 A35272A 514 Pin Roll 0 187 dia x Ag Ig t 8 16 24 32 48 64 1712F 515 Safety Head Yoke Kit includes 4 of item 514 2 4 6 8 12 16 KT543 516 Spring Valve 16 32 48 64 96 128 33803A 517 Plate Discharge Valve 2 4 6 8 12 16 35080SS 518 Safety Head 2 4 6 8 12 16 519 Spring Valve 8 16 24 32 48 64 33803A NOTES A Early 450 compressors were equipped with pistons having 2 compression rings and 2 oil control rings Replacement wrist pin bushing must be reamed after installation to properly accommodate wrist pin See Service Instructions for additional details Shown for disassembly purposes only Order appropriate Kit or Assembly Piston Assembly with three compression rings and one oil ring is standard beginning with serial number 45664 oil unloading and 60433 gas unloading It is a direct replacement for former piston assembly two compression
34. both with oil hole is used with former style cover A30294A A32162A having an oil hole remove orifice in cover A30294A A32162A and replace with solid 1 8 pipe plug Dams Item 239 and screws Item 245 are not needed when using VILTER s patented joined crankshafts In this design version introduced in 1980 two 6 cylinder or two 8 cylinder crankshafts are joined by a sleeve to form an inseparable 12 cylinder or 16 cylinder crankshaft This specially machined sleeve eliminates the dams This design is completely interchangeable with the former design SECTION 102 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 12 Replaces 450 VMC COMPRESSORS April 1984 High Stage Two Stage Booster and Heavy Duty REAR BEARING COVER REPLACEMENT PARTS FIGURE 6 Used when Center Tube Spool Assembly Item 311 without Bypass Relief is used i asso Q115C February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 13 March 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty REAR BEARING COVER REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 301 thru 304 Rear Bearing Cover Assembly Kit 1 1 1 1 1 1 KT092 301 Cover Rear Bearing 1 1 1 1 1 1 Order Kit 302 Plug 3 2 Hex Socket Head Pipe 1 1 1 1 1 1 13163E 303 Pin 7 x 1 Dowel not show
35. case 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor B Lift Rings For Unloading There are two styles of unloading lift ring assem blies 1 440 Lift Ring Assembly Rotate the lift to align the notches with the pins The springs will follow The lift ring will then drop to the bottom of the liner Note the position of each lift pin They will have to be returned to that position for reas sembly Push the lift pins up and out of the top of the liner to remove them The assembly of the lift ring is the reverse order of disassembly Place the lift ring on a flat surface with the notches facing up Put the liner in the center of the ring and place a spring on each roll pin in the ring Install a lift pin in each of the 4 slots along the outside of the liner The flat on the bot tom of the lift pin should be flush to the di ameter of the liner Lift the ring up the liner and engage all four lift pin slots in the notches on the ring Rotate the ring so the four springs engage in the holes of the lift ring stop 2 450 450XL Lift Ring Assembly Invert the liner and place on a flat surface Locate the notched end of the snap ring that retains the lift ring while pushing down on the lift ring in this area Pry the snap ring out of its groove and continue all the way around the liner Remove the snap ring and slide the ring up and off the liner Now th
36. dia Steel 1 1 1 1 13155K 209 thru Front Bearing Cover Assembly for 2 2 Shaft 1 1 1 1 6240 211 Requires Oil Orifice in 214 209 thru Front Bearing Cover Assembly for 3 Shaft 1 1 1 1 A36241A 211 Requires Oil Orifice in Item 214 209 Plug 4 Hex Head Pipe 1 1 1 1 13264B 210 Plug 7 Hex Head Pipe 1 1 1 1 13264C 211 Cover Front Bearing 1 1 1 1 Order Assy 211B Shield Splash 1 1 1 1 35274A 211C Screw Hexagon Hd No 10 32 long 3 3 3 3 2583A 212 Gasket Bearing Cover 1 1 1 1 31890A 213 Screw e x 4 Hex Socket Head Cap 2 2 2 2 13159E 214 Retainer Front Bearing with Oil Hole 1 1 1 1 31885A 215 Screw x 2 Hex Head Cap 6 6 6 6 13152 216 Screw 1 2 x 4 Hex Head 3 3 3 3 13153Q 217 amp 218 Seal and Gasket Kit 1 1 1 1 KT509 217 Seal Rotary Shaft Assembly 1 1 1 1 A33483A 218 Gasket Shaft Seal Cover 1 1 1 1 31897A 219 Screw 1 2 x 134 Hex Head Cap 8 8 8 8 13153F 220 amp 220A Cover and Tube Assembly Shaft Seal 1 1 1 1 A32564A 220A Drain Tube 1 1 1 1 35078A 224 Crankshaft and Bearings Assembly 1 A34555HX Thru Crankshaft and Bearings Assembly E 1 A34555KX 233 Crankshaft and Bearings Assembly 1 A34555LX Crankshaft and Bearings Assembly 1 A34555BX 224 Locknut and Retaining Compound Kit 1 1 1 1 KT366 227 Front Bearing and Retaining Compound Kit 1 1 1 1 KT368 228 Ring Front Bearing Retainer 1 1 1 1 33144A 229 Crankshaft and Retaining Com
37. headache or you Are you tired of the oil mess on the floor and worrying about oil contamination and air getting into ihe compressor If so how would you like one simple hand pump that will a Introduce oil into the crankcase quickly cleanly and efficiently b Charge oil separators c Charge oil lines and the seal chamber before starting the compressor d Flush the oilways in the crankshaft Vilter has offered such a pump called the Oil Charger since 1957 With this simple easy to operate pump it takes only about 16 strokes lo add a quart of oil In addition with the Vilter Oil Charger there is 1 No interference with compressor operation because the oil can be added any time as long as the crankcasc pressure is below 100 psi 2 No danger of air being drawn into thc compres sor because the oil lines from the supply can to the crankcase always remain completely filled after priming 3 No oil drips on the floor when connecting or dis connecting the lincs because the quick coupler instantly shuts off both the charging hose and crankcase adapter connection 4 No inconvenience in pouring oil from container lo container because the oil is pumped directly from the refinery sealed can to thc compressor 5 No oil contamination during storage because the seal cap protects the hose coupler end and the oil can remains closed aficr the pump is attached The Vilter Oil Charger is perfect for use with Viltcr VMC reciproc
38. responsibility of the installer to add devices safety limit controls or systems alarm supervisory systems that protect against or warn of control failure Features Long life contact structure with high contact force right up to break no bounce on make Make reset models are trip free Ranges available to cover most applications Auxiliary contact can be used to actuate an alarm circuit when the main contact opens Two pole construction provides a number of application advantages see General Description Heavy gauge low profile stainless steel element cup to protect against mechanical damage Specifications Series A70 Single Pole See Table for Type Number Selection A72 Two Pole See Table for Type Number Selection Adjusting Screwdriver Slot Adjusting Knob On Differential or Range Screw When Required 6 1 8 m Long Standard Longer Capillary Tube Up Capillary to 10 3 m in 2 0 6 Increments Over 10 in 5 Fig 1 Single function temperature control Style 1 General Description The A70 controls provide dependability and quality at attractive prices The A72 DPST controls provide a number of application advantages such as Control of polyphase motors without use of magnetic starters where protection against overloading and single phasing is otherwise provided e Provides two separate control circuits necessary for the control of multipl
39. the fesult oft ERE a shaft and Iflywheel or ousting bore having move ment relative to one another This is usually due to the incorrect tightening of drive com ponents use of oil or other anti seize com pounds worn components burrs or other imperfections not allowing the flywheel and crankshaft to mate properly 400 Series VMC SERVICE 8 Signs of fretting corrosion are reddish brown powdery oxidation and wearing away of the surface of the shafts or drive component shaft bores Minor fretting corrosion may be eliminated through light sanding after which the adequate contact area between the crankshaft and flywheel must be assured to prevent further fretting Heavy fretting corro sion will require repair or replacement of the motor shaft or replacement of the compres sor crankshaft and drive components The flywheel or crankshaft should not be re matched to eliminate the results of the fret ting corrosion as adequate clearances can not be assured after remachining The drive keys should fit tightly in their re spective grooves and be free of damage The keyways should also be free of chips and burrs that would not allow full contact of the key to the keyway The flywheel and sheave should be in spected for abnormal wear and damage A groove wear gauge should be used to check condition of the sidewalls and width of the groove Excessive wear is not permitted as this will lead to problems in achieving correct bel
40. to aluminum pistons February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 32 March 1984 440 VMC COMPRESSORS HEAVY DUTY V BELT DRIVEN REPLACEMENT PARTS Heavy Duty 8 cylinder 440 VMC Compressors are also available for use with V Belt drives up to a maximum of 125 BHP as compared to the maximum of 100 BHP for the standard 8 cylinder 440 VMC Compressors This compressor will supplement not replace the standard 8 cylinder 440 VMC Compressor This higher BHP is possible due to modifications of design Construction of the Heavy Duty compressor will be the same as the standard 8 cylinder 440 VMC Compressor except that a 12 or 16 cylinder front bearing cover assembly and rotary shaft seal replace the standard 8 cylinder parts The crankshaft T is of special stepped design with a 3 diameter on the drive end and a 2 diameter on the pump end The standard 8 cylinder 440 Compressor has a straight shaft of 212 diameter REPAIR PARTS FOR 8 CYLINDER 1000 AND 1200 RPM HEAVY DUTY 440 VMC COMPRESSORS CAN BE SELECTED FROM THE PRECEDING REPAIR PARTS PAGES FOR THE LATEST DESIGN OF STANDARD 8 CYLINDER COMPRESSOR WITH THE EXCEPTION OF THE FOLLOWING ITEM NUMBER PART NUMBER DESCRIPTION REQUIRED NUMBER 201 thru 211A Front Bearing Cover and Relief Assembly 1 A32566A 209 thru 211A Front Bearing Cover Assembly 1 A36241A 211 Cover Front Bearing 1 214 Retainer Front Bearing 1 33500A 217 Rota
41. 0000 Mounted 2 4 6 8 0073 0071 0073 0002 0002 8 HD 12 16 0074 0074_ 450XL ALL 0008 0068 0008 1 Crankshaft Crankpin ALL 2 874 Dia Std Size Except 450XL 015 U S ALL 2 859 Except 450XL 030 U S ALL 2 844 Except 450XL Std Size 450XL 3 124 All Models 015 U S 450XL ALL 3 109 030 U S 450XL ALL 3 094 400 Series VMC MAXIMUM ALLOWABLE WEAR NONE NONE 009 MAX END PLAY 002 2 01 SERVICE 32 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 5 FACTORY RUNNING DIMENSIONS TOLERANCES CLEARANCES amp ALLOWABLE WEAR LIMITS FOR 440 450 amp 450XL VMC COMPRESSORS cont d MAXIMUM ITEM PART NAME COMPRESSOR DIMENSION TOLERANCE CLEARANCE ALLOWABLE SIZE WEAR 3 Connecting Rod I D w Large End ALL Brgs Installed Except 450XL Std 450XL ALL 3 1255 W 015 U S ALL Brgs Installed Except 450XL 2 8605 450XL ALL 3 1105 001 W 030 U S ALL Brgs Installed Except 450XL 2 8455 450XL 3 0955 4 Shell Bearing Thickness Std ALL 0750 0000 None 015 U S ALL 0825 0003 Brg to Rod 0005 030 U S ALL 0900 3 Connecting Rod 001 001 Scuffing Width ALL 993 Side 006 001 001 Clearance ALL Each rod 1 Crankshaft Center Brg 3 999 000 001 3 002 O D 12 16 4 Shell Bearings 0026 5 0005 I D 4 0010 0000 Theoretical Thickness 1255 0000 Verti
42. 071116 1 4 x 1 8 6 SH11116 5 S 5 16 5 32 15 07118 1 4 x 1 8 6 SD13838KS 3 8 x 3 1 5 QT1316 1 4 x 1 8 6 SD1716 3 8 x 3 1 4 QT114 1 4 x 1 8 6 SD112 3 8 x 31 4 071516 516 116 6 E 17 SD1916 3 8 x 3 1 3 QT138 516x116 6 116 17 SDS9 16 18 116 17 580158 3 8 x 3 2 0 1716 3 8 x 1 16 6 SDS58 3 16 x 3 32 1 6 5 3 8 x 3 1 2 QT112 3 8 x 1 16 6 SDS11 16 3 16 x 3 32 1 6 5 3 8 x 1 8 4 1 2 x 1 8 1 SDS34 316x3 32 16 JA BUSHINGS xine 10 JAMPB No KS 8 SDS78 3 16 x 3 32 15 5 1 15 16 1 2 x 1 9 JA12 1 8 x 1 16 8 SDS15 16 1 4 x 1 8 15 5 2 No KS 8 JA9 16 1 8x116 8 SDS1 14x18 15 58 3 16 3 32 8 5051116 1 4 x 1 8 14 11 16 3 16 3 32 8 505118 1 4 x 1 8 14 No KS JA34 316x3 32 8 SDS1316 14x18 14 1 8 x 1 16 JA13 16 3 16 3 32 8 505114 14x18 13 1 8 x 1 16 JA78 3 16 3 32 8 SDS1516 5 16 5 32 13 3 16 x 3 32 JA15 16 1 4 x 1 8 8 SDS138 5 16 x 5 32 12 3 16 x 3 32 JAI 1 4 1 6 8 SDS13838KS 38x3 6 1 2 3 16 x 3 32 JA1116 14 1 6 8 SDS1716 3 8 x 3 1 1 2 3 16 x 3 32 JA118 14x116 8 SDS112 3 8 x 3 1 14 3 16 x 3 32 JA1316 14x116 8 SDS1916 3 8 x 3 1 14 1 4 x 1 8 JA114 1 4 x 1 32 8 SDS158 3 8 x 3 1 10 1 4 x 1 8 SDS11116 3 8 x 3 1 1 0 1 4 x 1 8 SH BUSHINGS 05134 3 8x1 B 1 0 14 18 No KS 11 SDS11316 1 2 x 1 8 9 1 4 x 1 8 SH12 1 8 x 116 14 505178 1 2 x 1 16 9 1 4 x 1 8 SH9 16 1 8 1 16 11 50511516 8 9 16 x 9 32 SH58 3 16 x 3 32 11 SDS2 7 3 8 x 3 16 SH11 16 3 16 x 3 32 1 0 5 1
43. 1 KT378 229 Crankshaft amp Retaining Compound Kit 1 KT379 229 Crankshaft amp Retaining Compound Kit 1 KT380 229 Crankshaft amp Retaining Compound Kit HD 1 559 229 Crankshaft amp Retaining Compound Kit 1 KT381 229 Crankshaft amp Retaining Compound Kit H S HD 1 560 229 Crankshaft amp Retaining Compound Kit Booster 1 561 229 Plug Pipe s Hex Socket Head not shown 5 5 5 5 8 8 13163A 231 Retainer Rear Bearing 1 1 1 1 1 1 31904A 231A amp 231B Rear Bearing and Lock Pin Kit 1 1 1 1 1 1 KT353 231 A Pin Bearing Lock 1 1 1 1 1 1 33678A 231 B Bearing Rear 1 1 1 1 1 1 A33509A 232 Screw 9 6 x 1 Hex Head 4 4 4 4 4 4 1736G 233 Crank Oil Pump Drive 1 1 1 1 1 1 33403A 234 Cap Bearing Support 1 1 235 Pin 4 x 1 Dowel 2 2 13162 236 Bolt v x 13 Machine 4 4 2796EL 237 Bearing Upper Right Half or Lower Left Half x gt lt 2 2 33508 238 Bearing Upper Left Half Lower Right Half pE 2 2 33508B 239 T Dam Center Bearing Oil E 2 2 33498A T 240 Pin Threaded Taper m 1 1 33497A 241 Case Bearing Support 1 1 242 Washer V Spring Lock Ae is Ex me 4 4 13165F 243 Nut 7 Hex 4 4 1726 244 Nut 16 Hex 1 1 13253F 2451 Screw 14 x V Hex Head Cap 8 8 2796
44. 1 1 1 1 A33480A 307 Gasket Oil Pump Cover 1 1 1 1 31900A 308 Gasket Oil Pump and Rear Bearing Cover Seal 1 1 1 1 33320A 309 Cover Oil Pump and Filter Head used when Oil Cooler 1 1 1 1 36190A not used 309 Cover Oil Pump and Filter Head used when Oil Cooler 1 1 1 1 34760AB is used 310 Filter Assy Complete with Bypass Relief 1 1 1 1 A35240A 311 Spool Assembly with Bypass Relief 1 1 1 1 1448J 311A 312 Spool Strainer Tube Assembly 1 1 1 1 1448U 313 amp 314 311A 312 Thru 314 amp Filter Assembly without Shell 1 1 1 1 1448T 315A thru 319 amp 321 312 Seal Spool End 1 1 1 1 1448H 313 Strainer Tube 1 1 1 1 1448 314 Ring Retaining 1 1 1 1 1448L 315 Recharge with Bypass 1 1 1 1 1448C 316 Pressure Plate Assembly 1 1 1 1 1448M 317 Pressure Plate 1 1 1 1 1448N 318 O Ring Seal Pressure Plate not shown 1 1 1 1 1448P 319 Spring Pressure Plate 1 1 1 1 1448Q 320 Plug Steel Hexagon Head T Pipe 1 1 1 1 13264A 321 Gasket Oil Filter Head 1 1 1 1 1448B 322 Filter Shell with Flange and Plug 1 1 1 1 A34623A 322A Flange Cil Filter Tank 1 1 1 1 35125A 322B Tank Oil Filter 1 1 1 1 34623A 323 Screw Hexagon Head Cap 7 16 x 2 4 4 4 4 1689G 324 Instruction Nameplate for use with A35241A 1 1 1 1 40680AJ not shown 324 Instruction Nameplate for use with A35240A 1 1 40680AT not shown 325 Gauge 2 0 300 PSI Oil Filter 1 1 1 1 31890A 326 Elbow 14 90 Female Compression 1 1 1 1 1892B 327 Tubing 1
45. 1 1 1 40680AJ 324 Instruction Nameplate for use with A35240A 1 1 1 1 1 1 40680AT 325 Gauge 2 0 300 PSI Oil filter 1 1 1 1 1 1 2047A 326 Elbow 14 90 Female Compression 1 1 1 1 1 1 1892B 327 Tubing 14 O D Steel AR As Required AR AR AR AR AR AR S1589A 328 Tee 4 Compression 2 2 2 2 2 2 13239C 329 Connector 1 4 MPT x 1 4 O D Compression 2 2 2 2 2 2 13229D 330 Valve 3 Way Oil Filter 1 1 1 1 1 1 2030A 331 Bracket Valve 1 1 1 1 1 1 35106A 332 Elbow 14 90 Male Compression 1 1 1 1 1 1 13375D 332A Control Pressure Differential 1 1 1 1 1 1 1643V 333 Gasket Bearing Cover 1 1 1 1 1 1 31890A 334 Screw 5 x 2 Hex Head Cap 10 10 10 10 10 10 13152E 335 Screw 1 2 x 134 Hex Head Cap 8 8 8 8 8 8 2796EL NOTES Filter with bypass relief is standard beginning with S N 45497 oil unloaded 60080 gas unloaded Used when center tube Spool Assembly Item 311 without bypass relief is used 1 Replacement recharge also includes gasket 1448B Item 321 February 2001 SECTION 102 R VILTER MANUFACTURING CORPORATION PAGE 14 Replaces 450 VMC COMPRESSORS March 1984 High Stage Two Stage Booster and Heavy Duty CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS FIGURE 7 410A 409 5 K Use with Gas Actuated Unloading ma 401 e 410 x TWO RINGS PER GROOVE xi 407 i Use with Oil Actuated Unloading Used for Single Cylinder
46. 17 B TYPICAL CRANKCASE HANDHOLE COVER 400 VMC COMPRESSOR MODEL SERIES 18 9 SHELL amp TUBE OIL COOLER PAGE TABLE 2 1 VILTER VMC COMPRESSOR DISPLACEMENT AND CONNECTIONS 3 2 VILTER VMC COMPRESSOR DIMENSIONS AND WEIGHTS 8 3 CRANKSHAFT REMOVAL CLEARANCES 11 4 DRIVE COUPLING PART NUMBER CROSS REFERENCE 19 5 STANDARD OIL COOLER APPLICATION 20 6 COMPRESSOR COOLING WATER FLOW RATES 25 7 COMPRESSOR CRANKCASE OIL CHARGE 29 8 OIL PRESSURE ADJUSTING VALVE LOCATIONS VMC 2 01 INSTALLATION B REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor l INTRODUCTION Proper installation of the refrigeration compres sor and its accessories is one of the most im portant aspects of system design By perform ing the procedures in the following sections you assure the optimum performance and effi ciency of your Vilter VMC MultiCylinder Com pressor ll DELIVERY All VMC Compressors are thoroughly inspected and run in by our factory to ensure all units are mechanically sound upon shipment Since damage can occur during shipment however units should be thoroughly inspected upon arri val at the installation side Immediately report any damage found to the transportation com pany and to your local Vilter representative or the Vilter Home Office IIl LOCATING THE UNIT Before anchoring the unit and connecting the refrigerant piping and electrical lines there are several factors to cons
47. 205 Packing 7 8 x 39 4 ILD x 2 8 1 1 1 1 1 1 31048E 206 Stem Valve 1 1 1 1 1 1 31048C 207 Spring 1 1 1 1 1 1 31048F 208 Ball dia Steel 1 1 1 1 1 1 13155K 209 thru Front Bearing Cover Assembly 1 1 A36240A 211A Front Bearing Cover Assembly Re 1 1 1 1 A36241A 209 Plug 4 Hex Head Pipe 1 1 1 1 1 1 13264B 210 Plug 7 Hex Head Pipe 1 1 1 1 1 1 13264C 211 Cover Front Bearing 1 1 1 1 1 1 Order Assy 211A Orifice Oil Metering 1 1 1 1 1 1 33361A 211B Shield Splash 1 1 1 1 1 1 35274A 211C Screw Round Head No 10 32 x 2 long 3 3 3 3 3 3 1332C 212 Gasket Bearing Cover 1 1 1 1 1 1 31890A 213 Screw 5 5 x 4 Hex Socket Head Cap 2 2 2 2 2 2 13159E 2144 Retainer Front Bearing with Oil Hole 1 1 31885A 214 Retainer Front Bearing with Oil Hole 1 1 1 1 33500A 215 Screw x 2 Hex Head Cap 6 6 6 6 6 13152E 216 Screw 1 x 4 Hex Head Cap 3 3 3 3 3 3 2796EV 217 Seal Rotary Shaft Assembly 1 1 48 217 Seal Rotary Shaft Assembly 1 1 1 1 A33489A 218 Gasket Shaft Seal Cover 1 1 31897A 218 Gasket Shaft Seal Cover 1 1 1 1 33496 219 Screw 1 2 x 194 Hex Head 8 8 8 8 8 8 2796EL 220 amp 220A Cover Shaft Seal Small 1 1 31044A 220 amp 220A Cover Shaft Seal Large 1 1 1 1 2564 220 1 1 1 1 1 1 35078 224 Crankshaft and Bearings Assembly 1 4
48. 24 32 0 2049 31915 408 Spring Valve Helical 8 16 24 32 48 64 2050 3289 33803A 408 Spring Valve Damped Helical 8 16 24 32 48 64 3290 3637 13556ATT 409 Outer Seat Ammonia or R12 amp R22 Discharge Valve for Volute Springs 2 4 6 8 0 2049 Obsolete 409 Outer Seat Ammonia or R12 amp R22 Discharge Valve for Helical Springs 2 4 6 8 12 16 2050 3289 Obsolete 409 Outer Seat Ammonia Discharge Valve for Damped Helical Springs 2 4 6 8 12 16 3290 3637 33587ATT 409 Outer Seat R12 amp R22 Discharge Valve 2 4 6 8 12 16 3290 3637 33586ATT for Damped Helical Springs 410 thru Piston Kit Capacity Reduction T5 1 2 2 4 4 150 3637 KT034 412 410 Piston Ring Unloader 4 4 8 8 16 16 150 3637 35278 411 Piston 1 1 2 2 4 4 150 3637 31989L 412 Pin Long Pivot 1 1 2 2 4 4 150 3637 33250C 413 Complete Capacity Control Mechanism Assy 1 150 3637 577 Thru Complete Capacity Control Mechanism Assy 1 2 2 4 4 150 3637 A33354AT 420 413 Arm Yoke Lifting 1 1 2 2 4 4 150 3637 33338A 414 Yoke Assembly 1 ee 150 3637 A33575A 414 Yoke Assembly 1 2 2 4 4 150 3637 A33335A 415 Pin 5 5 x g long Roll 1 1 2 2 4 4 150 3637 1193X 416 Pin Short Pivot 1 1 2 2 4 4 150 3637 33250B 417 Spring Unloader Yoke 6 6 12 12 24 24 150 3637 33686A 418 Yoke Guide Assembly 1 150 3637 A33576A 418 Yoke Guide Assembly 1 2 2 4 4 150 3637 A33347A 419 Screw 3 8 x 1 Nylok Cap 2 150
49. 3 Set the cut out pointer 6 to 8 psi 41 to 55 kPa below the established running net oil pressure with the Adjusting Disk using a standard screwdriver To increase the cut out pressure turn the Adjusting Disk counterclockwise To decrease turn clockwise To raise the pressure differential turn the Adjusting Disk see Figure 2 to the left when viewing the front of the control Turn the adjusting disk to the right to lower the pressure differential Test for Shutdown Immediately after installing and at regular intervals thereafter the time delay relay should be tested to verify that all circuits are operating correctly A WARNING Shock hazard Disconnect power from the control before testing for shutdown to avoid electrical shock or damage to the equipment To test for shutdown 1 Remove power from the control and remove the control cover 2 Connect a jumper between Terminals 1 and 2 See Figure 3 for terminal locations Note If the control is mounted on a condensing unit where air from auxiliary equipment blowers or fans may strike the control the control cover should be replaced before proceeding to Step 3 3 Apply power to start the compressor The time delay relay should trip after the time interval and stop the compressor 4 Remove power from the control and remove the jumper between Terminals 1 and 2 5 Replace the cover on the control and apply power 6 Manually reset the time delay r
50. 35078A 224 Crankshaft and Bearings Assembly 1 4555 Thru Crankshaft and Bearings Assembly 1 A34555KX 233 Crankshaft and Bearings Assembly 1 A34555LX Crankshaft and Bearings Assembly s 1 A34555BX 224 thru Crankshaft and Bearings Assembly Kit 1 588 244 less Crankshaft and Bearings Assembly Kit 1 589 224 Locknut and Retaining Compound Kit 1 1 1 1 1 1 KT367 227 Front Bearing and Retaining Compound Kit 1 1 1 1 1 1 KT369 228 Ring Front Bearing Retainer 1 1 1 1 1 1 33145A 229 Crankshaft and Retaining Compound Kit Assembly Above NOTES Less items 234 235 and 241 Patents Pending February 2001 Replaces May 1985 VILTER MANUFACTURING CORPORATION 450XL VMC COMPRESSORS CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS continued SECTION 100 R PAGE 11 May 1985 QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 229A Plug Pipe Hex Socket Head not shown 3 3 3 3 5 5 13163A 229B Plug 3 Pipe Hex Socket Head not shown 2 2 2 2 4 4 2606A 231 Retainer Rear Bearing 1 1 1 1 1 1 31904A 231A amp 231B Rear Bearing and Lock Pin Kit 1 1 1 1 1 1 KT353 232 Screw 5 16 x 11 Hex Head 4 4 4 4 4 4 1736G 233 Crank Oil Pump Drive 1 1 1 1 1 1 33403A 234 Cap Bearing Support
51. 3637 1352D 420 Spacer Sleeve 2 150 3637 33618 These items used 2 cylinder compressors only when equipped with unloading For single cylinder unloading the yoke assembly Item 414 and two pins on the yoke guide assembly Item 418 have drilled and tapped holes to accommodate screws Item 419 and spacers Item 420 All 1200 RPM VMC Compressors equipped with old style 1200 RPM parts from Serial No 2050 thru 3289 had helical valve springs Below 2050 had volute springs except 829 831 1489 1706 1707 1723 1733 and 1735 which also had helical springs Above 3289 and thru 3637 had damped helical springs Individual springs of each type are available for replacement however discharge valve outer seats to accommodate only the damped helical springs are available obsoleting all other seats Therefore when ordering seats for replacement on models previous to 3290 four damped helical valve springs must also be ordered with each seat Damped springs must then be specified for any subsequent spring replacement It is not essential that this change be made on all cylinders if made on one As a means of identification the regular helical springs are 7 16 long and are constructed with two dead coils at the end of the spring that is inserted into the hole The damped springs are gt long and are constructed with a special coil at one end with a closer winding pitch not completely closed If desired see page 24
52. 5 11 4 151 5 Mating hub length 1 MAX INCH BORE WITH KEYSEAT 2 MAX MM BORE WITH STANDARD KEYSEAT See pages A1 4 to 1 8 for Bore and Keyseat information and weights SURE GRIP BUSHINGS BORE AND KEYSEAT DIMENSIONS Wood s Inches Sure Grip Bushings are available from stock with all the bores and keyseats listed below In some cases as the bore increases in diameter a shallow keyseat is provided due to insufficient metal thickness When this happens Wood s furnishes the correct rectangular key to suit at no charge This does not affect the bushing s ability to transmit the load The rectangular key or flat key as some call it fits into the standard keyway in the shaft Product Wt Product Wt Product No Key Seat No QT BUSHINGS SH B QTMPB No KS 6 SH1116 1 4 x 1 8 9 3 16 x 3 32 2 0 0 12 1 8x116 6 SH118 1 4 x 1 8 9 S 3 16 x 3 32 2 0 QT9 16 1 8x116 6 SH1316 1 4 x 1 8 8 S 3 16 x 3 32 19 QT58 3 16 3 32 6 SH114 1 4 x 1 8 8 S 1 4 x 1 8 9 QT11 16 3 16x3 32 6 SH1516 5 16 5 32 7 S 1 4 x 1 8 8 QT34 3 16 3 32 6 SH138 5 16 x 5 32 7 1 4 x 1 8 8 QT13 16 316x3 32 6 SH1716 3 8x116 7 S 1 4 x 1 8 7 0 78 3 16 3 32 6 SH112 3 8x1 16 6 S 1 4 x 1 8 7 0 15 16 1 4 x 1 8 6 SH1916 3 8x1 16 6 1 4 x 1 8 6 0 1 14 18 6 SH158 3 8x116 5 S 5 16 x 5 32 16
53. 56 mm 79 mm 79 mm 79 mm 78 mm 78 mm 102 mm 105 mm 127 mm 3 26 4 4 4 6 06 6 06 7 06 7 06 9 89 83 mm 102 mm 102 mm 102 mm 154 mm 154 mm 179 mm 179 mm 251 mm 0 33 0 49 0 59 0 62 0 71 0 87 0 96 1 08 1 40 8 mm 12 mm 15 mm 16 mm 18 mm 22 mm 24 mm 27 mm 36 mm Valve Cv 5 8 5 8 2 7 11 7 10 14 0 12 39 33 50 43 74 63 93 80 210 180 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 J N HCK4 2 2 BOLT DESCRIPTION Valve Assembly Kit Above Kit Consists of PARTS LIST 1 Seat Disc 1 72 0069 2 Closing Spring 1 72 0070 3 Seat Cartridge 1 72 0068 4 Seat Cartridge O ring 1 72 0071 5 Flange Gasket 2 70 0065 6 Body HCK4 2 1 72 0067 7 7 16 14 x 3 25 2 70 0225 8 Nut 7 16 14 2 70 0055 9 SW WN ODS 2 FACTORY HCK4 3 4 5 2 BOLT ITEM DESCRIPTION Valve Assembly Kit Above Kit Consists of 1 Seat Disc 1 72 0006 2 Closing Spring 1 70 0204 Seat Cartridge 1 72 0002 4 Seat Cartridge O ring 1 72 0003 5 Flange Gasket 2 70 0132 6a Body HCK4 3 1 72 0004 6b Body HCK4 4 1 72 0008 6c Body HCK4 5 1 7
54. 6 6 6 0 Present 13152E 216 Screw 1 2 x 4 Hex Head 3 3 3 3 3 3 3 3 0 Present 2796EV 217 Seal Rotary Shaft Assembly 1 1 1 1 1 0 Present A33483A 217 Seal Rotary Shaft Assembly 1 1 1 0 Present A33489A 218 Gasket Shaft Seal Cover 1 1 1 1 1 0 31897 218 Gasket Shaft Seal Cover 1 1 1 0 Present 33496A 219 Screw 1 2 x 1 Hex Head Cap 8 8 8 8 8 8 8 8 0 Present 13153F 220 Cover Shaft Seal 1 1 1 1 1 0 Present 31044A 220 Cover Shaft Seal 1 1 0 Present 32564A 220A Tube Oil Drain 1 1 1 1 1 1 1 0 Present 35078A 224 Complete Crankshaft Assy 1200 RPM Thru For Aluminum Pistons 1 1660 Present A32574A 233 For Aluminum Pistons 1 1660 Present A32574B For Aluminum Pistons 1 1 1660 Present A32574C For Aluminum Pistons 1 e 1660 Present A32574D NOTE See page 31 for serial numbers below 1660 Sold only in Front Bearing Cover Assembly Crankshafts for Cast Iron Piston for these machines are no longer available Use current crankshaft and convert the compressor to aluminum pistons ttt See note with same symbol on Page 11 kkk February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 10 April 1984 440 VMC COMPRESSORS CRANKSHAFT AND FRONT BEARING COVER REP
55. 81 28 kW 118 31 rad s 137 95 kW 1000 165 104 7 rad s 123 04 kW 458HD 900 145 94 23 rad s 108 13 kW 810 130 84 81 rad s 84 81 rad s 96 94 kW 730 730 120 76 43 rad s 76 43 rad s 89 48 kW 4200 1200 300 125 64 rad s 107 38 kW 125 64 rad s 223 71 kW 1130 138 1130 285 118 31 rad s 102 91 kW 1000 250 104 7 rad s 94 7 kW 104 7 rad s 186 43 kW 900 120 4516HD 900 225 94 23 rad s 89 48 kW 94 23 rad s 167 78 kW 810 100 810 200 84 81 rad s 74 57 kW 84 81 rad s 149 14 kW NOTE Recommended operating oil temperature is 100 F to 130 F 37 8 C to 54 4 C Operating at or near maximum temperature could result in excessive wear A HD Large Diameter 3 1 8 7 94 cm crankpin 2 01 OPERATION 31 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 6 450XL VMC COMPRESSOR MAXIMUM LIMITS Suction Superheat 717 25 F Discharge Pressure 350 PSIG 3 9 C 2413 18 kPa 8 1 R717 Suction Pressure 150 PSIG 40 1 R290 1034 22 kPa 12 1 R22 250 PSIG 1723 7 kPa Compression Ratio Pressure Differential Oil Temperature 150 F 65 6 C 375 BHP 279 64 kW Discharge Temperature Direct Drive Motor Horsepower V BELT DRIVE HORSEPOWER LIMITS MAX BHP kW 125 43 rad s 4130 118 31 rad s 1000 104 7 rad s 900 94 23 rad s 810 84 81 rad s 145 41 kW 185 137
56. ARRANGEMENT 440 COMPRESSOR OLD STYLE MUSHROOM TYPE 400 Series VMC 2 01 SERVICE 13 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Actuator Mechanism Removal The first step of removing capacity control actuator from the machine is to push the unloader piston down with a block of wood This holds the assembly depressed and makes handling much easier Push the assembly away from the unloader piston until the notch in the yoke lifting arm slides free of the flats on the long pivot pin Then remove the mechanism through the liner hole in the top of the frame Remove the long pivot pin from the shaft of the pis ton Now slide the piston out of the cylinder and slip the ring or rings off the piston taking care not to break any NOTE Gas actuated unloader pistons have two grooves and use four metal piston pins Oil actuated unloader pistons have one groove and use a rubber piston ring o ring Actuator Mechanism Replacement Gas actuated unloader piston Clean the piston thoroughly and place four steel rings in each groove Work the rings in carefully Avoid breaking them Place the piston in the cylinder and compress the rings to work them into the cylinder Oil actuated unloader piston Clean the piston thoroughly and place the o ring on it Work the o ring on carefully to avoid breaking or excessively stretching it Liberally coat piston and o rin
57. Amp 8 0 60 33 Locked Rotor Amp 960 552 48 0 36 0 198 180 AC Non Inductive Amp 160 92 80 72 60 60 60 60 Pilot Duty Both Poles 125 VA 120 to 600 VAC 57 5 VA 120 to 300 VDC STYLE 5 la SAE MALE FLARE CONNECTOR amp 20 NFZ THREAD STYLE 5 4 IB FNPT THREAD BRASS FOR NON CORROSIVE REFRIGERANTS STEEL FOR AMMONIA STYLE 13 la SAE BRASS FLARE NUT COPPER TUBING STYLE 34 P COPPER s Fig 2 Pressure element styles available on the P74 Style 13 is standard Other styles shown above can be supplied on quantity orders Optional Constructions Pressure Elements Regularly supplied for non corrosive refrigerants fluorinated hydrocarbons Available for ammonia service with 1 4 in 18 FNPT connector See Style Chart Fig 2 Pressure Connectors Standard controls supplied with 36 in capillary tubing with 1 4 in flare nut Style 13 Controls with 1 4 in SAE male flare connector no capillary tubing Style 5 36 in capillary tubing with 1 4 in sweat section Style 34 or 1 4 in FNPT connector Style 15 may be supplied on quantity orders see Pressure Element Styles Repairs and Replacement Field repairs must not be made For a replacement control contact the nearest Johnson Controls distributor Ordering Information To order specify 1 Quantity required COMPRESSOR COMPRESSOR WATER CHILLER Fig 3 Typical p
58. Clearances necessary for removing crankshafts are listed in Para graph V IV FOUNDATION Vilter Manufacturing Corporation maintains the highest standards in the design and manufac ture of its VMC Compressors All rotating parts are balanced and the weights of reciprocating parts calculated to keep vibration to a minimum while the compressor is operating Some vibration will exist however Take pre cautions to prevent its transmission to the build ing structure or noise problems may develop Vibration is transmitted in two ways through the base and foundation of the machine and through the piping The following detailed methods of installation insure a minimum of vi bration transmission 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 1 VILTER COMPRESSOR DISPLACEMENT AND CONNECTIONS COMPRESSOR DISPLACEMENT ee OGAREDR LINE SIZE INCHES CYLINDER ATMAXRPM R717 HAOCARBON MODEL QUANTITY CFM SUCTION DISCHARGE SUCTION DISCHARGE 92 08 mm 35 6 92 08 79 38 mm 4 Var fa 104 78 mm 79 38 mm 226 66 68 350 ES SERIES 2 50 8 mm 2 101 6 mm 101 6 mm 76 2 mm 4 4 3 101 6 mm I 101 6 mm 76 2 mm 5 2 3 127 127 mm 76 2 mm 6 2 3 152 4 152 4 2 2 2 63 5 mm 63 5 mm 60 8 mm 3 y 3 76 2 mm 76 2 mm 450 XL
59. Compressors except booster models and those controlled through microproc essors are equipped with dual pressure switches These switches protect the compres sor from high excessive discharge pressures and excessively low suction pressures The switches will open a set of contacts which stop the compressor whenever one of the previously mentioned conditions occur If the low pressure side contacts open they close automatically when the pressure reaches a level sufficient for the cut in setting However if the high side pressure contacts open they must be reset manually This is an indication of a major malfunction occurring in the system The contacts cannot be reset until the pressure drops below the cut in setting The cut in and cut out set points should be set on the low pressure side On the high pressure side set the cut out point only The differential between cut in and cut out is factory set at 5 psig 34 47 kPa Refer to manufacturer s in struction sheets for further information B Oil Pressure Failure Switch standard feature on each Vilter VMC Com pressor except those controlled through a mi croprocessor is an oil failure switch that meas ures useable pressure available for lubrication If or when the oil pressure drops below the pre scribed levels the pressure switch automatically shuts down the compressor Useable oil pres sure is a combination of the crankcase pressure and oil pump pressure The swi
60. FRONT COVER ASSEMBLY AND DISASSEMBLY STUD 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor FLOATING SEAT DRIVE RETAINER SEAT O RING SEAT RING 7 CRANKSHAFT ATMOSPHERE SIDE CRAHKCASE SIDE FROHT BEARIHG RETAIHER SEAL COVER FIGURE 12 CRANKSHAFT SEAL ASSEMBLY 400 Series VMC 2 01 SERVICE 22 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor B Reassembly cont d Connecting rod bolts are secured with one plain steel nut and one spring steel locknut Commonly referred to as a Palnut The plain nut tighten ing torque should be listed in Table 2 3 or 4 de pending upon compressor model The torque wrenches should be set to the high side of the tightening torque range As the rods bearing inserts and crank pins are all machine to fine tolerances no further adjust ments are necessary te LG locking feature is lost and a loose rod connection may result After each rod is installed rotate the crankshaft by hand to make sure everything is free and there is no binding of the rotating parts CAUTION Late model VMC compressors may push lin ers out XIII CYLINDER LINERS NOTE Before proceeding refer to Paragraph I General Service Instructions A Removal Once the piston and rod assemblies are re moved the liner ca
61. Handhole Cover 30651B 20 Ft Cap Valve 13264B Plug Hex Pipe Plug 20 Ft 13264C 35 Ft Lb 13159E Plug Hex Pipe Plug 4 100 Ft Lb Front Bearing Cover 13153E 92 100 Ft Lb Front Bearing Cover 13153Q x4 75 Ft Lb Front Bearing Retainer 13153F 1 2 x 1 75 Ft Lb Shaft Seal Cover 31909 2 dia X 18 Bearing Locknut 1736G 1 11 Ft Lb Rear Bearing Retainer 13160D p x1 11 Ft Lb Rear Bearing Retainer 11396D See Item 243 1726E Yo Nut 50 Ft Lb Center Bearing Support Half Bolt Used on Item 236 1 2 x 1 34 Bolt VPN 11396D 13253F Nut 65 Ft Lb Center Bearing Tapered Pin 31956A 1 1 250 Ft Lb Flywheel Hub 13163E 34 Hex Socket Pipe Plug 75 Ft Lb 1689G 30 Ft Lb Oil Filter Shell 13153E 2 100 Ft Lb Rear Bearing Cover 13153F Ve x 1 75 Ft Lb Oil Pump Cover 13153E Same as 326 13153F Same as 327 1352D x 20 Ft Lb Yoke Assembly 2027A 24 Nut Conn Rod Cap 2028A Palnut Conn Rod w Nut Lock 1776B g Locknut 25 Ft Lb Discharge Valve Retaining 1472A g Locknut 15 18 Ft Lb Discharge Valve Retaining 31964A X 17 15 18 Ft Lb Use with 510A a x 1 20 25 Ft Lb Use with 513 NOTE ig Refer to Connecting Rod Nuts Tightening Instructions VMC Compressors
62. MANUFACTURING CORPORATION VILTER MultiCylinder Compressor OIL SEPARATOR RETURN LINE B LIQUID INJECTION DISGHARCGE LINE REMOTE MOUNTED CONTROL when capacity reduction is used HIGH STAGE DISCHARGE CX e pm wp HIGH STAGE QO 4 SUCTION LIQUID FROM SUCTION RECEIVER 6 To Front X Hearing Cover D xw Drive End RAE E yd He STAGE and Oil Pump DISCHARGE T AZ OIL PUMP di TO CRANKCASE KEY ITEM ITEM NUMBER NUMBER DESCRIPTION Oil Pressure Failure Switch PSO Dual Pressure Switch PSD High Pressure Switch Low Pressure Gauge Crankcase Pressure Gauge Oil Pressure Gauge High Pressure Gauge 2 DESCRIPTION Safety Valve set 300 psig 2 Thermostatic Expansion Valve Solenoid Valve SVL and Strainer Assembly Capacity Control Switch PC 1 Liquid Line Valve 2 Intermediate Pressure Gauge FIGURE 17 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH AMMONIA DESUPERHEATER 2401 OPERATION 25 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor LIQUID INJECTION BOOSTER DISCHARGE OIL SEPARATOR lt RETURN LINE v 9 REMOTE MOUNTED CONTROL when capacity f reduction is used he HIGH STAGE
63. Numbers Below 3638 ITEM DESCRIPTION NO REQUIRED PER COMPRESSOR SERIAL NO PART NO OF CYL 2 4 6 8 12 16 FROM THRU NO 501thru Piston Cup Cl and Conn Rod Assy Kit 2 4 6 8 0 1659 116 512 Piston Cup AL and Conn Rod Assy Kit 2 4 6 8 12 16 1660 3637 KT117 501 Piston Ring Compression 4 8 12 16 24 32 0 3637 31989M 502 Piston Ring Oil 2 4 6 8 12 16 0 3637 31989N 503 Snap Ring Piston Pin 4 8 12 16 24 32 0 3637 33244A 504 and Piston Cup Cl and Piston Pin Assy 2 4 6 8 0 1659 A32457A 505 Piston Cup AL and Piston Pin Assy 2 4 6 8 12 16 1660 3637 A32567A 506 507 Connecting Rod Assembly with 2 4 6 8 12 16 0 3637 KT212 510 511 amp Bearing Kit 512 506 Bushing Piston Pin 2 4 6 8 12 16 0 3637 31896B 507 Connecting Rod and Cap 2 4 6 8 12 16 0 3637 Order Kit 509 Nut Plain Hex 24UNF 4 8 12 16 24 32 0 3637 2027A 510 Nut Lock e 24NF 4 8 12 16 24 32 0 3637 2028A 511 Bearing Half Connecting Rod 4 8 12 16 24 32 0 3637 KT512 511 Bearing Half Connecting Rod 030 Undersize 8 12 16 24 32 0 3637 KT513 512 Bolt Connecting Rod 12 16 24 32 0 3637 31955A 519 Safety Yoke and Discharge Valve Inner Thru Seat Assembly 525 for Volute Springs 2 4 6 8 0 2049 Obsolete Except for Helical Springs 2 4 6 8 12 16 2050 3289 Obsolete 521 for Damped Helical Springs Amm amp R22 2 4 6 8 12 16 3290 3637 A33588A for Damped Helical Springs R12 2 4 6 8 12 16 3290 3637 A33588B 519 thru Complete Safety Yoke Assy Ki
64. Page 17 SECTION 102 R VILTER MANUFACTURING CORPORATION PAGE 16 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS FIGURE 8 February 2001 Replaces March 1985 February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 17 March 1985 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 501 Thru Piston Rings and Pin Assembly Kit 2 4 6 8 12 16 KT213 506 501 Piston Rings and Connecting Rod Assy Kit Thru All Compressors except 16 Cyl High Stage 2 4 6 8 12 16 KT478 512 Piston Rings and Connecting Rod Assy Kit Heavy Duty High Stage 8 16 478 501 Piston Ring Compression 6 12 18 24 36 48 31989M 502 Piston Ring Oil 2 4 6 8 12 16 31989N 504 Retaining Ring Wrist Pin 4 8 12 16 24 32 33244A 505 and Piston and Wrist Pin Assembly matched 2 4 6 8 12 16 ds 506 507 Connecting Rod Assembly with Bearings Kit Thru All Compressors except 16 Cyl High Stage 2 4 6 8 12 16 KT463 512 Connecting Rod Assembly with Bearings Kit Heavy Duty High Stage 9 16 KT463A 507 Bushing Wrist Pin 2 4 6 8 12 16 31896B 508 Lock Nut s Connecting Rod 4 8 12 16 24 32 2028A 509 Nut
65. Part Number Part Number Part Number Part Number Kits With Connecting Rod Assemblies 1200 RPM High Stage with KT119 KT127 KT123 KT131 Aluminum Plug Type Pistons 1200 RPM High Stage with Cast Iron Plug Type Pistons Kits Without Connecting Rod Assembly 1200 RPM High Stage with KT073A 75 74 KT076A Aluminum Plug Type Pistons 1200 RPM High Stage with Cast Iron Plug Type Pistons Kits with Cast Iron Pistons are no longer available Please contact the home office 1 Kits KT119 KT120 Ammonia and Kits KT127 KT128 R12 R22 for cylinders without unloading include the necessary piston rings Piston and Pin Assembly Piston Pin Snap Rings Connecting Rod Assembly Connecting Rod Bearing Halves Cylinder Liner O Ring Seal Safety Head Assembly Safety Yoke Suction Valve Plate and Helical Valve Springs required to convert one cylinder from a plug type to a flat top piston 2 Kits KTO73A KTO73C Ammonia and Kits 75 075 R12 R22 for cylinders without unloading include all the parts listed in paragraph 1 except the Connecting Rod Assembly and Connecting Rod Bearing Halves 3 Kits KT123 KT124 Ammonia and Kits KT131 KT132 R12 R22 for cylinders with unloading include all the parts listed in paragraph 1 as well as the Lift Ring and Spring Post Assembly Lift Springs and Lift Pins 4 Kits KTO74A KTO74C Ammonia and Kits KTO76A KTO76C
66. SECTION 1 WOOD S SURE GRIP QD BUSHINGS e Provide a True Clamp Fit e Are Easy to Install and Remove e Permit Four Way Mounting TIL SURE GRIP BUSHING FEATURES WN Wood s Sure Grip Quick Detachable bushings are easy to install and remove They are split through flange and taper to provide a true clamp on the shaft that is the equivalent of a shrink fit All sizes except JA and QT have a setscrew over the key to help Precise taper 3 4 in per ft on diameter 6 hole drilling most sizes provides proper wedging action makes installation and removal quick and easy Saw cut through flange and taper and sometimes cut down into keyway also to provide a true clamp fit Cap screws used to secure bushings to sheave and to remove bushing from sheave Keyseat 180 from split 4 9 9 9 maintain the bushing s position on the shaft until the cap screws are securely tightened Sure Grip bushings have a very gradual taper 3 4 inch taper per ft on the diameter which is about half the inclined angle of many other bushings The result is the Sure Grip securely clamps the shaft with twice the force of those competitive bushings to provide extreme holding power Versatile Sure Grip bushings permit the mounting of the same mating part on shafts of different diameters and the mounting of different sheaves on the same shaft using the same bush
67. Seal Spool End 1 1 1 1 1 1 1448H 313 Strainer Tube 1 1 1 1 1 1 1448K 314 Ring Retaining 1 1 1 1 1 1 1448L 31977 Recharge for A35241A amp 2046 w o Bypass t 1 1 1 1 1 1 2115C 1 315A Recharge for 5240 amp 1448J with Bypass T 1 1 1 1 1 1 1448C 1 316 Pressure Plate Assembly 1 1 1 1 1 1 1448M 317 Pressure Plate 1 1 1 1 1 1 1448N 318 O Ring Seal Pressure Plate 1 1 1 1 1 1 1448P 319 Spring Pressure Plate 1 1 1 1 1 1 1448Q 320 Plug Steel Hexagon Head UA Pipe 1 1 1 1 1 1 13264 321 Gasket Filter Head 1 1 1 1 1 1 1448B 322 Filter Shell with Flange and Plug 1 1 1 1 1 1 A34623A 322A Flange Oil Filter Tank 1 1 1 1 1 1 35125A 322B Tank Oil Filter 1 1 1 1 1 1 34623A 323 Screw Hexagon Head Cap 7 16 x 2 4 4 4 4 4 4 1689G 324 Instruction Nameplate for use with A35241A 1 1 1 1 1 1 40680AJ not shown 324 Instruction Nameplate for use with A35240A 1 1 1 1 1 1 40680AT not shown 325 Gauge 2 0 300 PSI Oil Filter 1 2047A 326 Elbow 14 90 Female Compression 1 1892B 327 Tubing 14 O D Steel 3ft 3ft 3ft 3ft 3ft 3ft S1589AA 327A Tubing Steel AR As Required AR AR AR AR AR AR S1589AA 328 Tee 1 2 Compression 2 2 2 2 2 2 13239C 329 Connector 1 4 MPT x 1 4 O D Compression 2 2 2 2 2 2 13229D 329A Connector 1 2 MPT x 1 4 O D Compression 2 2 2 2 2 2 13229D 330 Valve 3 Way Oil Filter 1 1 1 1 1 1 2030A 331 Bracket Valve 1 1 1 1 1 1 35106A 332 C
68. Separator 1 General Description The oil separators for VMC Compressors are either the demister pad standard oil separator or the flanged coalescing ele ment Super Separator Both styles of oil separators are mounted in the compressor discharge line The stan dard style oil separator can only be mounted in the horizontal position The Super Separator style oil separator can be mounted in vertical or horizontal positions NOTE The separator should be installed with the flow in the direction of the arrow on the separator The separator and piping should be sup ported so no piping loads are transmitted through the compressor frame No initial oil charge is necessary for these separator types Oil separators prevent oil from reaching the evaporator where it would impair efficiency They are espe cially recommended for flooded systems low temperature applications and any other installation where oil return from the low side may not be positive 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor HORIZONTAL SEPARATOR SUCTION or SUPER SEPARATOR 1 1 5 FB 300 YMC MODEL SERIES END VIEW TYPICAL COMPRESSOR OIL RETURN CONNECTION Must be supported externally High stage and booster models only Two stage model has connection on second stage suction DESCRIPTION INSTALLATION KIT PART NO External Hi
69. Steps of capacity reduction T Items shown are for compressors with optional oil unloading or optional single cylinder unloading e 6 cylinder compressors with serial numbers below 21937 oil unloading and 30039 gas unloading are equipped with a suction elbow and two suction screens VPN A32428D located behind the suction screen covers on the frame 6 cylinder compressors with serial numbers 21937 oil unloading and 30039 gas unloading and above are equipped with a suction tee VPN 36254 Series and a single suction screen VPN 352154 located in the suction tee 8 cylinder compressors with serial numbers below 21937 oil unloading and 30039 gas unloading are equipped with a suction tee VPN 32010 and three suction screens one in the tee and two behind the suction screen covers on the frame 8 cylinder compressors with serial numbers 21937 oil unloading and 30039 gas unloading and above are equipped with suction tee VPN 36254 series and a single suction screen VPN A352154 located in the suction tee February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 6 February 1985 440 VMC COMPRESSORS BASIC FRAME REPLACEMENT PARTS FOR ALL VMC COMPRESSORS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 112 Screw x 17 Hex Head Cap 5 5 0
70. This eliminates the possibility of oil build up in one compressor and insufficient oil in others VMC INSTALLATION 25 TABLE 7 COMPRESSOR CRANKCASE OIL CHARGE COMPRESSOR OIL CHARGE GALLONS SIZE 300 400 CYLINDER SERIES SERIES QUANTITY COMPRESSOR COMPRESSOR 2 mm 5 3 3 m 4 3 7 5 3 6 3 7 7 3 9 3 7 12 14 16 14 Oil for VMC Compressors Due to the need for adequate lubrication Vilter recommends only the use of Vilter lubricants designed specifically for Vilter VMC Compres sors With the extensive research Vilter has performed we are able to offer refrigerant spe cific lubricating oils Use of oil not specified or supplied by Vilter will void the compressor war ranty Please contact your local Vilter representative or Home Office for further information XVI SYSTEM REFRIGERANT CHARGING After the system is leak free and evacuation is complete it is ready for charging Prior to final charging the entire operation of the refrigera tion system should be inspected as outlined be low A Equipment Inspection 1 Low Side Equipment a Fans on air handling equipment run ning b Pumps on water cooling equipment running c Proper location and attachment of thermostatic expansion valve bulb to suction line 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor
71. VILTER MANUFACTURING CORPORATION VILTER MultiCytinder Compressor OPERATION SECTION TABLE OF CONTENTS PAGE COMBINATION UNLOADER AND CAPACITY CONTROL Introduction Gas Operating Unloader Single Stage Compressor Oil Operated Unloader 400 Series Single Stage Booster Integral Two Stage And 300 Series Compressors wh AUTOMATIC CONTROLS Dual Pressure Switch Pressure Failure Switch High Pressure Switch Capacity Reduction Oil Filter Differential Switch O 00 N WARM START PROTECTION SYSTEM General Description Tri Micro Full Flow Filter And Differential Pressure Switch SETTING THE CAPACITY REDUCTION CONTROL Single Compressor System Dual Compressor System Two Stage Compressor System 400 Series Only COMPRESSOR OIL SYSTEM Description Oil Regulating Valve Adjustable Oil Relief 1 Stage Oil Drain Arrangement Two Stage Compressors Only IID Onc INTERCOOLER AND DESUPERHEATER TWO STAGE COMPRESSORS ONLY Intercooler VMC 2 01 OPERATION A REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor OPERATION SECTION ILLUSTRATIONS AND TABLES PAGE FIGURE 2 1 TYPICAL OIL UNLOADING SOLENOID VALVE 10 2 TYPICAL ELECTRICAL SCHEMATIC 11 3 AUTOMATIC CONTROL CONNECTIONS TYPICAL SCHEMATIC 12 4 SCHEMATIC CAPACITY REDUCTION CONNECTIONS AND UNLOADER MECHANISM ARRANGEMENT TWO STAGE COMPRESSOR ONLY 13 5 HIGH STA
72. ail pressures needs changing Check refrigerant levels in vessels Check filters in air handling units Check low temperature coils for defrosting Check all gauge and temperature readings Monthly Items 1 thru 7 and 8 thru 11 Lubricate each piece of equipment in ac cordance with the manufacturers instruc tions As a general guide bearings requir ing oil should be given attention at least once a month and those requiring grease at least once every six months Check drives for tightness and alignment Direct drives should have coupling bolts tightened V belt drives should have cor rect tension Check cooling towers and evaporative condensers for scaling or algae Check sprays and screens for clogging Consult manufacturers of water treatment supplies for corrective measures of scaling and al gae problems VMC INSTALLATION 30 11 12 13 14 15 16 17 18 Check compressor oil coolers when used for any evidence of corrosion scaling or other fouling See paragraph XI C for maintenance and servicing Yearly Items 1 thru 11 and 12 thru 21 Check entire system thoroughly for leaks Drain water from condensers cooling tow ers and check tubes Check carefully for damage by corrosion or scale Remove all rust from equipment clean and paint Check motors and fans for shaft wear and end play Check operation and general condition of electrical controls Check all water st
73. amp 8 Cylinder Figure 2 Illustration 12 amp 16 Cylinder Figure 3 Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Illustration 2 thru 8 Cylinder Figure 4 Illustration 12 and 16 Cylinder Figure 5 Parts List REAR BEARING COVER REPLACEMENT PARTS Illustration with Standard Tri Micro Filter Option Figure 6 Parts List Illustration with Tri Micro Filter Option Figure 7 Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS Illustration Figure 8 Parts List CAPACITY CONTROL MECHANISM ASSEMBLY REPLACEMENT PARTS Illustration Figure 9 Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS Illustration Figure 10 Parts List MODERNIZING 1200 RPM COMPRESSORS CYLINDER LINER amp CAPACITY CONTROL REPLACEMENT PARTS SERIAL NUMBERS BELOW 3638 Illustration Figure 11 Parts List PISTON AND CONNECTING ROD REPLACEMENT PARTS SERIAL NUMBERS BELOW 3638 Illustration Figure 12 Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS SERIAL NUMBERS BELOW 9999 Parts List HEAVY DUTY V BELT DRIVEN REPLACEMENT PARTS Parts List RECOMMENDED SPARE PARTS LIST VILTER MANUFACTURING CORPORATION PRINTED IN U S A SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 1A Replaces 440 VMC COMPRESSORS March 1975 REPLACEMENT PARTS ORDERING INSTRUCTIONS 1 Give the size and speed of the compressor as well as serial number and refrigerant used When recording serial n
74. assumed the compressor has been shut down a sufficient length of time for the pres sure to equalize After a short period the pressure differential should be sufficient to op erate the capacity reduction mechanism and the two banks of cylinders are loaded As suction pressure decreases to 20 psig 137 9 kPa with a drop off of the load control A energizes a solenoid valve and unloads the cylinder bank As suction pressure decreases to 19 psig 131 00 kPa control B energizes a solenoid and unloads the cylinder bank If the load decreases and the suction pressure drops to 18 psig 124 11 kPa the low pres sure switch will enable and shut down the compressor When suction pressure decreases to 23 psig 158 58 kPa the compressor starts and one cylinder bank operates fully loaded bank with out capacity reduction The two remaining cylinder banks are unloaded If the load increases suction pressure to 24 psig 165 48 kPa control B will operate and load a cylinder bank An increase in suction pressure to 25 psig 172 37 kPa loads the re maining cylinder bank At this point the com pressor is operating at full capacity The preceding example describes a rapidly fluctuating load In the case of loads that re main constant for long durations the compres sor could operate with one bank of cylinders cycling between loaded and unloaded position B Dual Compressor System NOTE Pressures shown below are
75. be secured to the floor and grouted The compressor should be checked for a soft foot and shimmed accordingly Elimina tion of a soft foot in a belt drive compressor is essential to reduce vibration and mis alignment problems The sheave and pulley should be checked for paint and foreign matter in the grooves Any foreign material will cause a decrease in the horsepower transmitting ability of the belts and lead to accelerated wear of the belts pulley and sheave If this is an existing installation the motor and compressor shafts should be checked to see if they are level and in the same plane before starting the alignment process If the compressor has been moved or if there is a complaint of excessive vibration the com pressor should be checked for a soft foot Absolutely no lubricants or anti seize com pounds should be used in the installation of the motor sheave and bushing or the crank shaft and flywheel The bushing as supplied by the manufacturer should not have any lu bricant applied to it or the sheave bore The applied lubricant will be trapped between mating surfaces of the sheave and bushing or bushing and shaft When the components are tightened the resulting hydraulic pres sure of the lubricant trapped between the mating surfaces will result in a cracked sheave or bushing Lubricant or anti seize is usually applied to the shaft for ease of dis 400 Series VMC SERVICE 10 assembly As the anti seize
76. between the center ring fingers Start a bolt through a bolt hole in the hub Hold the disc pack in one hand slip it down between the hub and the center ring until one hole in the disc pack lines up with the bolt Slide the bolt through this hole into the disc pack Add a washer The beveled side of the washer should always be against the disc pack install the locknut 5 036 174 28 156 036 5 16 24 25 2 036 5 18 24 25 043 3 8 24 30 072 11 16 16 062 Torque In Lbs 1 5 8 12 1 3 4 12 1 7 8 12 2 1 8 8 1 These torque values are approximate for stee bolts with lubricated threads 2 Bolts should be held from rotating while the tocknuts are torqued to the values shown 3 These locknuts are cad plated NOTE All bolt threads should be lubricated A clean motor is recommended Do not torque any locknuts at this time Remove the disc pack alignment boit if used Now pivot the pack around until it lines up with the rest of the bolt holes in the hub Install the rest of the hub bolts through the hub bolt holes disc pack washers and locknuts The remaining bolts for this end can be put through the center ring bolt holes disc pack washers and locknuts The locknuts can be snugged up at this time disc pack installed should look flat and parallel with the mating hub and center ring fingers 4 Now proceed to the other end of the coupling
77. bi 13152C 112 Screw x 134 Hex Head 6 6 6 131520 112 Screw 1 2 x 17 Hex Head 6 12 12 225 12 2t 0 Present 2796E 112 Screw 1 2 x 114 Hex Head Cap es 16 16 16 0 Present 2796EJ 113 Valve 1 2 Oil Charge amp Drain Ammonia 1 1 1 1 1 1 1 1 0 Present A15375A 113 Valve 1 2 Oil Charge amp Drain Halo 1 1 1 1 1 1 1 1 0 Present 1956A 114 Gasket Crankcase Oil Screen 1 1 1 1 1 1 1 1 0 Present 31889A 115 Crankcase Oil Screen Assembly 1 1 1 1 1 1 1 1 0 Present A31886A 116 Plug 3 2 Hex Head Pipe not shown on 12 1 1 1 1 1 1 1 1 0 Present 13264E amp 16 116 Plug 1 2 Hex Head Pipe not shown on 2 1 1 1 1 1 1 1 1 0 Present 13264D thru 8 117 Pin Retaining Assy Crankcase Oil Screen 1 1 1 1 1 1 1 1 0 Present A31936A 118 Safety Valve Internal Relief 1 1 1 1 2 2 0 Present 1721B 118A Valve Crankcase Check not shown 2 su p ENS 2 2 sit 568 119 Gasket 2 Flange 1 1 1 1 2 2 0 Present 11323G 120 Cover Safety Valve 1 1 1 1 2 2 0 Present 31954A 121 Screw 5 6 x 2 Hex Head Cap 2 2 2 2 4 4 ses 0 Present 13152E 122 Gasket Handhole Cover 1 1 1 1 2 2 1 2 0 Present 31894A 123 amp Handhole Cover and 2 Sight Glass Assy 124A With openings for 560W NEMA 1 amp 7 Htr amp Therm 1 1 1 1 1 1 1 1 0 Present A33034G 300W NEMA 1 amp 7 Htr F V amp Therm 1 1 1 1 1 1 1 1 0 Pres
78. determined from superheat and pressure drop Thermostats should be set for desired tempera ture The condenser water regulating valve should be adjusted to maintain the design head pres sure Open for increased flow in cases of high compressor head pressure and close for de creased flow in case of low head pressure B Final Precautions The compressor suction valve compressor dis charge valve condenser water shut off valve and other shut off valves should be open Running parts of the compressor should have freedom of movement Check this by turning the compressor input shaft over by hand Solenoid valves should be mechanically con nected and under electrical control All gauges should be open and functional Oil level in the sight glass shows at least one half full Before initial compressor start up verify that the oil charging procedure as outlined in paragraph XVI is followed If the procedure is followed compressor start up should commence as fol lows It is essential the compressor pick up the entire load gradually It should be run for a few min utes and then stopped for a cooling off period Lengthen each running period until the operator is sure no moving parts are heating up exces sively When the compressor operates with normal running temperatures allow it to run for whatever length of time the load requires C Final Precautions cont d 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTU
79. for example pur poses only PRESSURE RANGES AND OP ERATING PRESSURES MUST BE BASED ON ACTUAL SYSTEM PARAMETER 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION MulttiCylinder Compressor B Dual Compressor System cont d When two Vilter VMC Compressors operate on one load Vilter recommends both machines op erate together As an example two 6 cylinder VMC Compres sors are running automatically on widely varying loads Set the switches and controls as follows TABLE 2 DUAL COMPRESSOR RANGE amp OPERATIONS COMPRESSOR 1 Low Pressure Control Control A Switch Bank 2 Bank 1 21 psig 23 psig 25 psig 144 79 kPa 158 58 kPa 172 37 kPa Cutin Loaded Loaded 16 psig 18 psig 20 psig 110 32 kPa 124 11 kPa 137 9 kPa Cut out Unloaded Untoeded COMPRESSOR 2 Low Pressure Switch 20 psig psig 151 69 kPa 137 9 kPa 165 48 kPa Cut4n Loaded Loaded 15 psig 17 psig 19 psig 103 42 kPa 117 21 kPa 131 00 kPa Cut out Unloaded Unloaded Assume the compressors have shut down be cause the suction pressure has dropped to its cut out set point When suction pressure in creases to 20 psig 137 9 kPa the low pressure switch starts compressor 2 One bank is loaded The two remaining cylinder banks are unloaded When pressure sises to 21 psig 144 79 kPa compressor 1 starts with two cylinder
80. has only the hole in the rod half to allow oil to travel up the rod The second type has annular grooves to allow a continuous supply of oil CAUTION 400 Series VMC SERVICE 21 The bearing inserts should never be spread open by hand or any other means to provide for a tighter fit in the rod If an inspection indicates the rod bearing sur faces are worn replace the bearing insert As semble bearing inserts by pressing them into place making sure the notch in the rod is clear If the bearing insert does not properly fit in the rod and it falls out during assembly either the bearing insert or the rod is worn or incorrectly made When installing the bearing insert into the con necting rod make sure there is no oil on the con necting rod or the back side of the bearing insert If the original bearings have failed check the crankshaft bearing surface If there are slight imperfections due to bearing failure remove by polishing with fine crocus cloth Then clean the bearing surface with suitable refrigeration cleaner and lubricate with clean compressor oil Lubricate the inside of the cylinder and the entire piston The recommended method of installing the piston in the liner is with the use of a Piston Ring Compressor See Figure 10 Attach the oil line to the bottom of the front hous ing Do not over tighten the nut Rotate the shaft a few times to help the seal settle into position CA P FIGURE 11
81. is trapped when the parts are tightened it will create a sliding layer between the parts The parts are not free to move independent of each other while the unit is in operation creating fretting corrosion This results in excessive wear of the drive components and the possibility of the parts welding themselves together The belts can now be installed The motor should be moved towards the compressor to facilitate the installation of the belts The belt closest to the compressor should be installed first The belts should not be rolled or pried when installing them as this will damage the cords in the belts and cause a failure in a short time Drive Alignment There are 3 different types of misalignment that are possible more than one of which may be present at any one time These are Horizontal angular Vertical angular Parallel Although V belt drives are somewhat tolerant to misalignment the maximum amount of misalignment permitted is 1 of an inch per 12 of shaft center to center distance If this is exceeded excessive drive belt and bear ing wear will result Horizontal angular misalignment results when the motor and compressor shafts are in the same horizontal plane but not in the same vertical plane A straight edge is held against the compressor pulley face The dis tance from the straight edge to the motor sheave sides is compared They should be the same If they not the same adjust the
82. lift pins lift ring and lift springs all assembled to the cylinder liner To remove these parts from the cylinder liner place the liner on a flat surface in an upright position Rotate the lift ring slightly until the four semi circular notches line up with the lift pins and slide the ring down off the liner Lift the pins out of the top of the liner In order to put the unloading mechanism onto the cylinder liner set the lift ring on a flat surface with the guides for the lift springs facing up Next place the cylinder liner in side the lift ring Drop the four lift pins into their holes in the liner with the notched ends of the pins facing down and the flat side fac ing out Lift the rings so the semicircular notches slide over the pins Then rotate the lift ring so the springs fit into their holes in the cylinder liner 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Suction Valve Plate Install as marked TOP Cylinder Cover Hole A 1 16 Dia Gas Actuated Unload Only Compressor Frame Use this illustration for Gl Unloading Yoke assembly is bolted down on one end as 222 shown the two cylinder and two stage com Both Stages of 2 Stage pressor capacity control mechanism All other Gas Actuated Unloading compressors do not use these bolts e High Stage e High Stage of 2 Stage FIGURE 7 TYPICAL CAPACITY CONTROL MECHANISM
83. liquid mixture by the subsequent boiling off of the liquid contained in this mixture from the inner vessel and by contact with the relatively outside surface of VMC OPERATION the inner shell The desuperheated gas from this outer shell is fed into the second stage cylinders where it is compressed and dis charged into the condenser The thermostatic expansion valve bulb is lo cated at the outlet of the intercooler second stage suction line where it senses the tem perature of the leaving gas adjusts the flow of refrigerant into the flooded inner vessel and controls superheat to the second stage A subcooler or intercooler should not be in stalled in the high pressure liquid line before the two stage compressor intercooler This is to avoid excessive thermostatic expansion valve feed due to work not being done in the compressor intercooler CAUTION Periodic interruption of the liquid feed to the intercooler should be avoided especially if a float switch control is used on the evapo rator This can result in excessive hunting E of the intercooler thermostatic expansion 4 valve resulting in possible liquid carry over Higher capacities are obtained with an inter cooler than with a desuperheater if the effect of the subcooled liquid is used to the best ad vantage Certain operational pitfalls must be avoided so the advantage gained by subcool ing the liquid is not lost The liq
84. location Spring assemblies can be identified by designation stamped on nameplate and or color code i Center spring assembly under the washer in the top of the housing and turn up adjustment bolt by hand until it seats within washer j With wrench take four complete turns counterclockwise on adjusting bolt of each mount Repeat this procedure three additional times making a total of sixteen turns on each bolt Take addi tional turns as required to raise founda tion 19 05 mm of sub base Level foundation by taking additional turns on bolts of mounts at low side of corner If equipment requires extensive piping connections it may be desirable to sta bilize the foundation by inserting shims underneath while the piping work is done m Piping should be independently sup ported and brought to the equipment so pipe load is not placed on founda tion n After piping and electrical connections are made shims may be knocked out and the equipment operated 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 4 3 32 lt 69067 F TOP VIEW 5516 6 5 16 Fa FRONT VIEW FIGURE 3 VMC INSTALLATION ISOLATOR IMBEDDED IN CONCRETE AND IN THE RAISED POSITION 1 2 Reinforcing Concrete 2 Grooves for bars by others Pad
85. of pipe needed to go over the wrench The mechanic s weight hanging on this horizontal length of pipe will put the desired inch pounds of torque on the locknut Example 925 requires 1800 of torque Mechanic s weight is 200 Ibs 1800 200 9 The distance from the center of the jocknut to the mechanic should be 9 feet This is a dead weight hanging force It is recommended that all locknuts be retorqued after several hours of initia operation B When two hubs are used AMR 1 If the coupling arrived assembled the disc packs are still attached to the center ring Before taking the disc packs off first install one hub through each disc pack and secure with a locknut This will help when the pack is reinstalled later Remove disc pack H the coupling was shipped disassembled the bolt through the pack is not required as the discs in the pack are factory taped together 2 With the hubs mounted and the span length C set proceed to put the center ring into place between the two hubs Care should be takea when handling the center ring Support the center ring on wood blocks with nylon straps from a hoist or some other convenient way It may help to support the end not being worked on with holts through the center ring bolt holes and into the hub flange bolt holes This will hold the parts in line at that end 3 Now install the disc pack Rotate the hub or center ring so that the hub bolt holes line up
86. of the piston the yoke springs force the yoke lift ring and lift pins up ward This lifts the suction valve plate which unloads a bank of cylinders When the compressor is started the suction pressure is high This results in minimal or no pressure difference on the unloader piston The unloading cylinders remain unloaded for the ini tial revolutions After the initial revolutions the suction pressure decreases and the discharge pressure increases resulting in an increase in pressure difference across the unloader piston When the pressure reaches 35 psi 241 32 kPa the unloader piston will depress reseating the suction valve plate and loading the bank of cyl inders The compressor remains loaded during normal operation When suction pressure drops below normal set point the pressure control is af VMC OPERATION fected Pressure controls used for unloading are not standard low pressure switches They have a low pressure range but the contact closes a circuit when pressure drops below a prescribed level As pressure drops the pres sure control closes a contact and energizes the solenoid valve connected to a bank of cylin ders When the solenoid valve is energized it opens a pipe connection direct to the suction of the compressor This allows pressurized gas above the unloader piston to escape to suc tion An equalized pressure condition is pro duced above and below the unloader piston lifting the suction plates via
87. on page 31 400 Series VMC SERVICE 28 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 3 TORQUE SPECIFICATION VMC MODEL 450 REQUIRED VPN BOLT SIZE TORQUE APPLICATION 13152L X 3 2 95 Ft Lb Cylinder Head 13152C 5 6 x 1 95 Ft Lb Suction Screen Cover 13152D 5 6 1 95 Ft Lb Suction Screen Cover 13153E 1 2 x 11 75 Ft Lb Suction Screen Cover 13164E 3 Hex Pipe Plug 75 Ft Lb Plug 13264D V Hex Pipe Plug 50 Ft Lb Plug 13152E 2 95 Ft Lb Safety Valve Cover 13153E Ve x 1 75 Ft Lb Handhole Cover 30641B 20 Ft Lb Valve Cap 13264B Hex Pipe Plug 20 Ft Lb Front Bearing Cover 13264C 3 Hex Pipe Plug 35 Ft Lb Front Bearing Cover 13159E 4 100 Ft Lb Front Bearing Cover 13152 2 100 Ft Lb Front Bearing Cover 13153Q Vex 4 75 Ft Lb Front Bearing Retainer 13153F Ve x 1 75 Ft Lb Shaft Seal Cover Bearing Locknut 1736G we x 1 11 Ft Lb Rear Bearing Retainer 11396D Ve x 1 See Item 243 Bearing Support 1726E V2 Nut Item 236 50 Ft Lb Bearing Support Half 13253F 9 16 Nut 65 Ft Lb 1603A 1 4 x 1 2 6 Ft Lb 31956A 1x 17 250 Ft Lb Flywheel Hub 1689G gx 2 30 Ft Lb Oil Filter Shell 13152 2 95 Ft Lb Rear Bearing Cover 13153F Ve x 1 75 Ft Lb Oil Pump 1352D 3 2 X 1 20 Ft Lb Yoke Assembly 2
88. plant management This is especially im portant for owners of small plants where quali VMC INSTALLATION 32 fied personnel are not available to perform the preventive maintenance which is recom mended 2 01 REPLACES ALL PREVIOUS ISSUES DBZ DBZ A DBZ B Coupiings Thomas Installation Instruction Warning All rotating power transmission products are potentially dangerous and must be properly Quarded in compliance with OSHA standards for the speed and applications for which they are in tended it Is the responsibility of the user to provide proper guarding STANDARD CENTER HE ASSEMBLY AND HDUR OT EXTENDED CENTER EXTENDED HUB ASSEMBLY AND H R EXTENDED HUB Purpose These instructions intended to help you to install afign and maintain your THOMAS coupling H Scope Covered here will be general information hub mounting alignment assembly iocknut torquing disc pack replacement and part numbers WASHERS ON SIZES 101 163 AND 201 General Information The coupling as raceived may or may not be assembled if assembled the locknuts are not torqued Examine the parts to assure there is no visible damage If coupling is assembled remove the bolts that attach the hubs to the disc packs Remove both hubs Leave the disc packs attached to the center member Hub Mounting General Clean hub bores and shafta Remove any nicks or burrs If bore is
89. quick connector mounted on it The female half is easily and quickly snapped onto the male half of the con nector which is attached to the oil charging valve on the compressor crankcase If more than one compressor is used it is rec ommended extra male halves of the quick con nectors be purchased and installed on each machine This makes it easy to connect either of the two pumps to the oil charging valve and charge the required amounts of oil into the compressor crankcase To charge oil into the compressor with either of the oil chargers first attach the female half of the connector to the male half Open the oil charging valve to the compressor crankcase and in the case of the hand operated oil charger the pump is hand operated until such time as sufficient oil is pumped into the crank case Using the hand operated charger ap proximately 8 full strokes are needed to force 1 pint of oil into the crankcase Using the Vilter motor driven chargers after the two halves of the quick connector are con nected and the oil charging valve is opened turn on the charger motor with the switch and allow it to operate until sufficient oil has been pumped into the compressor 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor XV COMPRESSOR OIL CHARGING cont d After charging oil with either of the two charg ers the charging valve on the compressor should be closed to relieve
90. recess up Oil the o ring sealing area Take the mirror face do not touch the mirrored surface oil outer o ring and lay it in the cover or retainer with the mirror face upward Using a very clean cloth or similar item cover mirror face and using palm of hand set it in the recess Repeat this assembly process for the other mirror face Vilter recommends that if any part of a seal needs replacement the entire shaft seal should be replaced with a new one Make sure the oil passage in the shaft is unob structed Install the inner retainer with mirror face flush in front housing with the word TOP at the top Tighten down evenly with the 3 screws The shaft seal assembly is symmetrical It can be installed in either direction Spray oil on inner mirror face Liberally coat oil on one of the bel lows and carbon assemblies Avoid coming in contact with carbon Carefully slip the assembly on the shaft until the carbon touches the mirror face Put the spring over the shaft and seal on the bellows assembly and slide it onto the shaft to join up with the spring With the new cover gasket in place install the cover over the end of the shaft Push the cover all the way on lining up the bolt holes so the drain is to the bottom Tighten down the 8 screws evenly to the torque requirements in Table 2 3 or 4 depending upon compressor model XII CONNECTING RODS AND PISTONS NOTE Before proceeding refer to Paragraph I
91. rings and two oil rings with expander Piston ring part numbers are the same for either assembly Current assembly is interchangeable with and can be mixed with former piston assemblies within a compressor Do not use expanders in either assembly they are no longer needed Install with pin s outside longitudinal seam facing outside diameter of safety head High Suction Pressure Compressors are identified by an X in the serial number Heavy Duty Compressors are identified by HD in the serial number Do not use undersize bearing halves on 6 8 and 12 Cylinder Belt Driven High Stage compressors Bearing half sets with quantities enough for one connecting rod are also available For sets without Lock Nuts order 35086ST 41726ST 35214ST or 35273ST For sets with Lock Nuts order KT512 KT513 or KT513A SECTION 102 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 18 Replaces 450 VMC COMPRESSORS April 1984 CAPACITY CONTROL MECHANISM REPLACEMENT PARTS Version used beginning with Serial Number 61 200 for Gas Unloading 46 000 for Oil Unloading FIGURE 9 aao Dad tev erage Sun Cu ness Coes ever tn tere cede 5 419 413 1 410 411 i 1 Used with single cylinder unloading 418 QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8
92. that the indicator reading is within 002 inch per inch of the axial length between flex elements See Chart A AMR Figure Z AMR Figure 3 SUGGESTED MAXIMUM ALIGNMENT VALUES NOTE If the driver or driven equipment alignment specificatiuon is tighter than these recommendations then those manufacturer s specifications should be used Also be sure to compensate for any thermal growth which may occur during normal equipment operation The coupling is capable of approximately three times the shaft misalignment tolerances shown in the chart below However the more exact the alignment is at installation will definately result in a much longer coupling life and smoother operation TOTAL INDICATOR READING T 1 A ANGULAR forCMR PARALLEL 008 lt lt lt m o o e CHART FINAL ASSEMBLY With tha coupling in good alignment the bolts will fit through the holes in the flanges and the disc packs more easily See Figure 1 When fly wheel adapter is used CMR 1 if the coupling am ved assembied the disc packs center ring and fiywheel adapter are still attached Before taking the disc pack off the hub end first instalt one hub bolt through the disc pack and secure with a locknut This will help when the pack is reinstalled later Remove disc pack if the coupling was shipped disassembled the bolt through the pack is not required as t
93. the USA EMERSON CONSIDER IT SOLVED
94. the VMC Compressor 1 equipped with this system when the lube is too cold A General Description Some Vilter VMC Compressors incorporate an optional warm start oil protection system This option features a differential oil pressure control across the inlet and outlet of a special Tri Micro micronic type oil filter Any effort to start a VMC Compressor equipped with this feature when the lubrication oil is cold and viscous can result in extreme oil pressure build up and severe pump damage Before initial starting of the compressor and or after a scheduled maintenance check tum on the crankcase heater for an extended time pe riod The heater should remain on until the oil temperature has reached 100 F 37 8 C set ting of thermostat equipped 400 Series crank case heater The 300 Series Compressor heater is not equipped with a thermostat The VMC OPERATION time frame for reaching the temperature will vary depending on the compressor location indoors or outdoors Special insulation may be necessary in unheated environments Con sult the factory B Tri Micro Fuil Flow Oil Filter And Differ ential Oil Pressure Switch The Tri Micro pressurized oil filter in the VMC Compressor is connected to a manual reset differential oil pressure switch see paragraph The manual reset feature is provided to warn the operator when the oil filter element is dirty and to repiace the recharge Read
95. the cylinder liner Drilled replacement parts are interchangeable with undrilled parts Discard roll pins from kits if new liner is used with former style safety head safety head yoke and frame with built in guide lugs High suction compressors are identified by an X in the serial number February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 18 March 1985 440 VMC COMPRESSORS CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 1000 RPM HIGH STAGE AND TWO STAGE COMPRESSORS AND 1200 RPM BOOSTER COMPRESSORS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 401 Cylinder Liner Kit w unloading 1 2 4 4 S 275 Sa 0 Present KT072 Thru Cylinder Liner Kit w unloading 8 8 0 Present KT033 406 Cylinder Liner Kit w unloading 8 8 2656 Present KT072 Cylinder Liner Kit w unloading 3 6 0 14203 072 Cylinder Liner Kit w unloading TE um Es 3 6 14204 Present A33179B 401 Cylinder Liner Kit w o unloading 2 2 2 4 x s 0 Present KT071 Thru Cylinder Liner Kit w o unloading 4 8 2656 Present KT071 402A Cylinder Liner Kit w o unloading 1 0 Present KT071 Cylinder Liner Kit w o unloading 3 6 0 14203 KTO71 Oylinder Liner Kit
96. the oil pressure differential across the Tri Micro filter by alternately flipping the valve handle of the manual 3 way valve in opposite directions Vilter strongly recommends the contro setting on the filter oil pressure differential be checked by the operator prior to initial start up of the compressor Set the switch to provide a maxi mum of 40 psig 275 79 kPa oil pressure dif ferential across the filter On a new compressor the filter element should be changed after 300 hours of break in opera tion or whenever a gauge reading taken on both sides of the filtering system indicates a maximum pressure difference of 25 psig 172 37 kPa Replace the filter element whenever the oil pressure drop across the fil tering system reaches 25 psig 172 37 kPa the compressor is opened for servicing the filter is subjected to moisture or whenever pe riodic oil checks reveal a gradual darkening of the oil IV SETTING THE CAPACITY REDUCTION CONTROL When setting the pressure controls for capacity reduction and unloading consider the operat ing conditions Under varying loads the ca pacity reduction controls maintain predeter mined suction pressure and reduce machine 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MulitiCylinder Compressor SETTING THE CAPACITY REDUCTION CONTROL cont d capacity to suit the conditions Under constant load conditions the capacity reduction control is not
97. this time remove the oil circuit piping tee in the middle of the oil cooler 400 Series VMC SERVICE 25 side the frame Slip out the spring behind the tee with a piece of wire Secure a 1 2 13NCx10 long rod Screw this into the threads in the end of the oil feed connector tube Remove the tube from the frame with a slight pull on the rod After the tube is taken out separate the nut from the taper pin in the center bearing and tap the pin out of its hole This releases the center bearing and allows the crankshaft to be removed Once the front housing is removed the crank shaft should be blocked from inside the frame due to its weight Adjust the blocking as the work proceeds so the crankshaft does not bump the front bore nor make any contact with the journals To aid in removal a simple step can be added Before removing the shaft from the rear housing remove the rear bearing retainer and tap the cen ter hole to 1 31 75 mm Reinstall the retainer on the end of the crankshaft 1 31 75 mm pipe can be threaded into it and used as an extension bar for handling the crankshaft during removal C Removal From The Pump End To pull the crankshaft from the pump end of the compressor remove the pump cover filter adapter the complete oil pump assembly and the rear bearing housing The crankshaft does need to be blocked to prevent damage and on 12 and 16 cylinder compressors the center bearing needs t
98. to Paragraph I General Service Instructions A Removal To remove the oil filter drain the tank by remov ing the pipe plug on the bottom or side Next re move one of the front screws It can then be threaded back in at least 2 turns or a 4 6 35 mm longer screw can be used and also threaded in 2 turns This will be the pivot point or hinge to swing the filter and tank out for ease of removal By unscrewing the remaining 3 screws alternately the tank will start to lower until the first screw installed comes in contact with the fil ter adapter Force the center tube top plate down and out of its connection hole while pivot ing the filter tank Now that the filter and center tube can be removed disassemble the center tube by removing the bottom spring plate Slide the old filter off and discard properly The tube should be washed off and clean B Replacement Make sure to remove the used gasket of the filter adapter and install a new one After cleaning the tank reinstall the pipe plug in the drain Install it on its pivot screw Add fresh oil to fill half the tank Reassemble the new filter on the center tube Slowly place the filter in the tank and allow the filter to absorb the new oil Pivot the tank un der the adapter and align the center tube in its hole Start the remaining 3 screws than tighten the tank flange to the adapter The proper placement of the mechanism once in the frame is having the curved si
99. 01 thru Piston Rings and Connecting Rod Assembly Kit 1 1 2 2 2 2 KT573 508 501 Piston Ring Compression 6 12 18 24 36 48 31989M 502 Piston Ring Oil 2 4 6 8 12 16 31989N 504 507 Bearing Half and Lock Nut Kit 2 4 6 8 12 16 KT575 amp 508 511 515 amp Spring Valve 24 48 72 96 144 192 33803A 512 Plate Discharge Valve 2 4 6 8 12 16 3508055 Safety Hd amp Pins Assy Std Ammonia 2 4 6 8 12 16 A35082A 513 Safety Pins Assy 2 Stage High Side Comp 2 4 514 Safety Hd amp Pins Assy Halo 2 4 6 8 12 16 A35272A Safety Hd amp Pins Assy 2 Stage High Side Comp 2 4 Booster Safety Head Ammonia 2 4 6 8 12 16 A32695C 513 thru Booster Safety Head Halo 2 4 6 8 12 16 A32695D 518 2 Stage Low Side Safety Head Ammonia 4 8 A32695C 2 Stage Low Side Safety Head Halo 4 8 A32695D Gasket Kit Complete 041 Gasket Kit Complete 1 KT043 Gasket Kit Complete 1 045 Gasket Kit Complete 1 KT049 Gasket Kit Complete 1 KT051 Gasket Kit Complete 1 055 The above listing includes the minimum selection and quantity of recommended spare parts All items listed do not necessarily apply to every compressor because of type size or optional features apply Patents Pending When capacity reduction is supplied This Safety Head and Pins Assembly is used on standard Halocarbon
100. 027A s X 24 Nut Connection Rod Cap 2028A Palnut Connection Rod Cap NOTE Refer to Connecting Rod Nuts Tightening Instructions VMC Compressors on page 31 400 Series VMC 2 01 SERVICE 29 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 4 TORQUE SPECIFICATION VMC MODEL 450XL REQUIRED VPN BOLT SIZE TORQUE APPLICATION 13152L 7 3 95 Ft Lb Cylinder Head 13152E 95 Ft Lb Suction Screen Cover 13153E Vex 11 75 Ft Lb Suction Screen Cover 13264E 3 Hex Pipe Plug 75 Ft Lb Plug 13264D v Hex Pipe Plug 50 Ft Lb Plug 13152E pee 95 Ft Lb Safety Valve Cover 13153E 1 2 x 11 75 Ft Lb Handhole Cover 30651B 20 Ft Lb Valve Cap 13264B Hex Pipe Plug 20 Ft Lb Front Bearing Cover 13264C 373 Hex Pipe Plug 35 Ft Lb Front Bearing Cover 13159 100 Ft Lb Front Bearing Cover 13153E 100 Ft Lb Front Bearing Cover 13153Q 75 Ft Lb Front Bearing Retainer 13153F Ve x 1 75 Ft Lb Shaft Seal Cover KT 367 Bearing Locknut 1736G Um x 1 11 Ft Lb Rear Bearing Retainer 13153F Ve x 1 Machine Bolt 1726E Ve Nut 50 Ft Lb Bearing Support Half 13253F 9 16 Nut 65 Ft Lb 31956A 1x17 250 Ft Lb Flywheel Hub 1689G exe 30 Ft Lb Oil Filter Shell 13153E 2 95 Ft Lb Rear Bearing Cover 13153F Ve x 1 75 Ft Lb Oil Pump 1352D 3 2 1 20 Ft Lb Yoke
101. 1 1 1 2 2 31894A 123 Handhole Cover and Sight Glass Assy Std Conn 1 1 1 1 2 2 A33034L 124 Glass Oil Sight 2 1 1 1 1 2 2 1484A 125 Screw 1 2 x 17 Hex Head Cap 16 16 16 16 32 32 2796E 126 Tube Oil Feed Connector 1 1 33494A 127 Spring 1 1 31789 February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Original Issue PAGE 7 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty DISCHARGE SUCTION GAUGE REPLACEMENT PARTS FIGURE 4 USED ON 2 THRU 4 CYLINDER COMPRESSORS 129 USED ON 12 AND 16 CYLINDER COMPRESSORS 133 131 132 SECTION 102 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 8 Original Issue 450XL VMC COMPRESSORS DISCHARGE SUCTION GAUGE REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 128 Heater Electric Crankcase Oil 115V not shown 1 1 1 1 2 2 2069J 128 Heater Electric Crankcase Oil 230V not shown 1 1 1 1 2 2 2069K 129 Gauge Discharge 300 PSI 1 1 1 1 2 2 1204E 129 Gauge Suction 150 PSI 1 1 1 1 1 1 1204C 130 Stedy Mount 2 2 2 2 3 3 A17311SS 131 Connector 14 MPT x O D Compression 2 2 2 2 3 3 13229D 133 Nipple 2 x 4 Sch 80 Pipe 2 2 2 2 3 3 13181G 134 Thermometer Crankcase Oil not shown 1 1 1 1 1 1 1467F February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 9 A
102. 10 10 10 10 10 10 0 Present 13152E 342 Screw 12 x 194 Hex Head Cap 8 8 8 8 8 8 8 8 0 Present 2796EL NOTES AR As required Cut to suit when assembling Not shown here cover replaces item 123 Thermometer and heater mount on crankcase handhole cover so oil temperature can be monitored and raised to 100 F thermostat setting before starting compressor If an attempt is made to start with cold oil the filter pressure differential switch will stop compressor rear bearing cover is sold only Kit 092 When Kit KT361A amp B is ordered the overall length of the existing oil pump Item 306 on the compressor should be checked If the length from the end of the pump shaft to the end of the pump boss measures 57 32 a new oil pump must be ordered with Kit KT361A amp B February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 16 February 1984 440 VMC COMPRESSORS CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS FIGURE 8 407 410A Use with pr Gas Actuated X Unloading 406 6 D 410 TWO RINGS PER GROOVE Suction ports are elongated on 3 high speed units This groove and seal Item 402 B used on Two Stage Units only Meen 403 418 Used with single cylinder unloading SECTION 105 R PAGE 17 CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 440 VMC COMPRESSORS VILTER MANUFACTURING CORPORATION Fe
103. 12 16 NUMBER 410 amp 411 Piston amp Rings Assy Cap Red Gas or Oilt 1 1 2 3 2 4 6 4 A35315CX 410 Ring Set PTFE amp rubber 1 1 2 3 2 4 6 4 2557A 411 Piston Unloader Gas or Oil 1 1 2 3 2 4 6 4 Order Assy 413 Complete Capacity Control Mechanism Assembly Thru 2 Cylinder and Two Stage only 1 3 6 41787 420 Complete Capacity Control Mechanism Assembly 1 2 2 4 A41788BX 413 Arm Yoke Lifting 1 1 2 3 2 4 6 4 41725A 414 Yoke Assembly 2 Cylinder and Two Stage only 1 ag 3 gt 6 A33575A 414 Yoke Assembly 55 1 2 2 4 4 A33335A 415 Pin x Vie Ig Roll 1 1 2 3 2 4 6 4 1193X 416 Pin Short Pivot 1 1 2 3 2 4 6 4 33250B 417 Spring Unloader Yoke 4 4 8 12 8 16 24 16 33686A 418 Yoke Guide Assy 2 Cylinder and Two Stage only 1 3 6 A33576A 418 Yoke Guide Assembly 1 2 2 4 4 A33347A 419 Screw s x 1 Cap Lock 2 6 12 1352D 420 Spacer Sleeve 2 6 12 33618A NOTES T See Pages 12 and 13 for notes and lower serial number applications February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 19 March 1985 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty RECOMMENDED SPARE PARTS LIST QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBE
104. 128 Where Separate Supply is Provided for Control Circuit Jumper between 2 and M or L must be field installed 1 1 jum e cm mm tTa Crankcase KI Runlight Heater When Used X Alarm if Used Operating Control Additional controls in this line only P28 or P128 When crankcase heater is used disconnect jumper 2 to M and reconnect 2 to L Also make sure that control circuit transformer has sufficient output for additional load Figure 7 P28 or P128 Wired for 440V Supply and 240V Magnetic Start Coil Also for 550V Using Proper Transformer Jumper between 2 and M or L must be field installed P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin 5 Compressor Operating 240 y r Control SEN E T T T oe K Runlight 3 if Used When Used 1 oT 2 oT Junction Box Note This system would provide shutdown on low Additional controls lube oil pressure in either of two compressors in this line only operated by the common motor Pas or pieg Figure 10 P28 or P128 and P74AA Wired for an When crankcase heater is used disconnect jumper from 2 to M Oil Pressure Control System Where One Motor and reconnect 2 to L Operates Two Compressors Figure 8 P28 or P128 Where Manual Start Stop Adjustments Pushbutton Station is Used Jum
105. 1707 1723 1733 and 1735 which also had helical springs Above 3289 and thru 3637 had damped helical springs Individual springs of each type are available for replacement however safety yoke and pin assemblies and safety yoke and discharge valve inner seat assemblies to accommodate only the damped helical springs are available obsoleting all previous comparable assemblies Therefore when ordering these assemblies for replacement on models previous to 3290 eight damped helical valve springs must also be ordered with each assembly Damped springs must then be specified for any subsequent spring replacement It is not essential that this change be made on all cylinders if made on one As a means of identification the regular helical springs are Thie long and constructed with two dead coils at the end of the spring that is inserted into the hole The damped springs are 3 long and are constructed with a special coil at one end with a closer winding pitch not completely closed If desired see page 24 for converting to new style 1200 RPM parts See note with same symbol on page 21 February 2001 Replaces February 1985 440 VMC COMPRESSORS VILTER MANUFACTURING CORPORATION SECTION 105 R PAGE 30 PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1000 RPM HIGH STAGE AND 1200 RPM BOOSTER COMPRESSORS Serial Numbers 3067 and below ITEM DESCRIPTION NO REQUIRED PER C
106. 1984 High Stage Two Stage Booster and Heavy Duty 2 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 1 February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 3 April 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty 4 6 AND 8 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 2 NOTE HANDHOLE COVER ACTUALLY LOCATED ON OPPOSITE SIDE OF FRAME ON 4 6 amp 8 CYLINDER COMPRESSORS Q 123 February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R PAGE 4 Replaces April 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty 12 AND 16 CYLINDER BASIC FRAME REPLACEMENT PARTS LcI 9cI FIGURE 3 GNI ALISOddO TVEIAS February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 5 April 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty BASIC FRAME REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 101 Frame 1 1 1 1 1 1 102 Screw e x 3 Hex Head Used with Water Jacket 20 40 60 80 120 160 13152L 102 Screw 5 5 x 22 Hex Head Used when Water Jacket not used 20 40 60 80 120 160 13152G 103 Cover Water Jacket Ammonia and R22 1 2 3 4 6 8 30299A 104 Gasket Water Jacket Ammonia and R22 1 2 3 4 6 8 33329A 107 Stud
107. 1A 405A Ring Lift 1 2 4 4 35380A 405B Pin Roll 4 4 4 4 1193SS 406 Spring Lift 4 8 16 16 33352A 407 Pin Lift 4 8 16 16 33350A 408 Retainer Lift Ring 1 2 4 4 1971A 409 Plate Suction Valve 2 4 6 8 31909A 410 amp 411 Piston amp Rings Assy Cap Red Gas or Oil T 1 1 2 2 A35315BX 410 amp 411 Piston amp Rings Assy Cap Red Gas or Oilt 1 1 2 2 A35315CX 410 Ring Set PTFE amp rubber 1 1 2 2 2557A 410A Seal Unload Piston Oil only 1 1 1 1 2639A 410B Ring Retaining Unload Piston Oil only 1 1 1 1 2638A 411 Piston Unloader 1 1 2 2 35315A 413 thru Complete Capacity Control Mechanism Assembly 1 2 2 A41788BX 420 Low Suction R717 and all Booster 413 Arm Yoke Lifting 1 2 2 41725A 414 Yoke Assembly ae 1 2 2 A33335A 415 Pin 4g Ig Roll 1 2 2 1193X 416 Pin Short Pivot 1 2 2 33250B 417 Spring Unloader Yoke 4 8 8 33686A 418 Yoke Guide Assembly 1 2 2 A33347A February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 X Original Issue PAGE 12 460 VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS FIGURE 6 504 SECTION 105 VILTER MANUFACTURING CORPORATION February 2001 PAGE 13 Original Issue 460 VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 NUMBER
108. 2 0001 7 Bolt 5 11 x 4 2 72 0005 8 Nut 5 s 11 2 70 0136 9 SW WN ODS 2 FACTORY HCK4 7 8 9 0 1 4 BOLT DESCRIPTION 1a Disc 112 2 1 72 0016 1b Seat Disc 212 3 1 72 0034 1 Seat Disc 4 1 72 0053 2 Closing Spring 1 2 1 72 0021 2b Closing Spring 212 3 1 72 0032 2 Closing Spring 4 1 72 0048 Seat Cartridge 17 2 1 72 0020 3b Seat Cartridge 212 1 72 0029 Seat Cartridge 3 1 72 0028 3d Seat Cartridge 4 1 72 0047 4 Seat Cartridge O ring 112 2 1 72 0017 4b Seat Cartridge O ring 272 3 1 72 0027 Seat Cartridge O ring 4 1 72 0049 Flange Gasket 172 2 2 75 0138 5b Gasket 212 2 75 0125 5c Flange Gasket 3 2 75 0137 5 Gasket 4 2 75 0253 HCK4 7 1 72 0042 6b Body HCK4 8 1 72 0019 Body HCK4 9 1 72 0025 Body HCK4 0 1 72 0026 6e Body HCK4 1 1 72 0046 Bolt HCK4 7 8 s 11 x 6 4 70 0268 7b Bolt HCK4 9 0 34 10 x 7 4 72 0033 Bolt HCK4 1 7 s 9 x 7 5 4 72 0051 HCK4 7 8 5 11 4 70 0136 8b HCK4 9 0 34 10 4 75 0210 8c Nut HCK4 1 7 s 9 4 75 0280 9 SW WN ODS 2 FACTORY HCK4 2 2 BOLT a G oj g 7 8 19 4 6 19 18
109. 211 201 Cap Valve 1 1 1 1 1 1 1 1 0 Present 17355A 202 Gasket 1 1 1 1 1 1 1 1 0 Present 30651C 203 Nut Packing 1 1 1 1 1 1 1 1 0 Present 31048A 204 Washers 2 2 2 2 2 2 2 2 0 Present 31048D 205 Packing O D x 2 64 1 0 x 3 6 1 1 1 1 1 1 1 1 0 Present 31048B 206 Stem Valve 1 1 1 1 1 1 1 1 0 Present 31048C 207 Spring 1 1 1 1 1 1 1 1 0 Present 31048F 208 Ball 7 Dia Steel 1 1 1 1 1 1 1 1 0 Present 13155K 209 Front Bearing Cover Assembly ttt 1 1 1 1 1 See notettt Present A36240A Thru Front Bearing Cover Assembly ttt 1 1 1 See notettt Present A36241A 211A 209 Plug 24 Hex Head Pipe 1 1 1 1 1 1 1 0 Present 13264B 210 Plug 3 3 Hex not used after 12 81 1 1 1 1 1 1 1 0 Present 13264C 211 Cover Front Bearing 1 1 1 1 0 Present dis 211 Cover Front Bearing 1 1 1 0 Present 211A Orifice Oil Metering 1 1 1 1 1 1 1 1 0 21354 33361A 211B Shield Splash Oil Relief Outlet Hole 1 1 1 1 1 1 1 1 0 Present 35274A 211C Screw Rd Hd No 10 32 4 Lg 3 3 3 3 3 3 3 3 0 Present 1332C 212 Gasket Bearing Cover 1 1 1 1 1 1 1 1 0 Present 31890A 213 Screw x 4 Hex Socket Head Cap 2 2 2 2 2 2 2 2 0 Present 13159E 214 Retainer Front Bearing w oil hole ttt 1 1 1 1 1 See notettt Present 31885A 214 Retainer Front Bearing w oil hole ttt Es 1 1 1 See notettt Present 33500A 215 Screw x 2 Hex Head Cap 6 6 6 6 6
110. 3 Arm Yoke Lifting 1 1 2 3 2 4 6 4 41725A 414 Yoke Assembly 2 Cylinder and Two Stage only 1 3 6 A33575A 414 Yoke Assembly 1 2 2 4 4 A33335A 415 Pin 4g Ig Roll 1 1 2 3 2 4 6 4 1193X 416 Pin Short Pivot 1 1 2 3 2 4 6 4 33250B 417 Spring Unloader Yoke 4 4 8 12 8 16 24 16 33686A 418 Yoke Guide Assembly 1 2 2 4 4 3347 NOTES Patents Pending Two cylinder high stage and 6 amp 12 cylinder Two Stage Compressor only Unloading is NOT standard When supplied as an option single cylinder unloading is provided on 50 of the cylinders These items and quantities in are then used Also for single cylinder unloading the yoke assembly Part Number A33575A and two pins on the Yoke Guide Assembly Part Number A33576A have drill and tapped holes to accommodate screw Item 419 and spacers Item 420 Parts quantities are listed for standard unloading only except 2 cylinder and two stage see note Standard unloading on compressors with 2 cylinders is none 4 cylinders is 50 6 cylinders is 33 amp 66 8 cylinders is 25 amp 50 12 cylinders is 33 amp 66 16 cylinders is 25 amp 50 and two stage is none See Operation Section for other unloading options Actuation type presently on your compressor can be determined by checking unloading solenoid valve oil uses three way valves gas uses two way valves Gas unloading was considered standard
111. 31B Ammonia 5171 Safety Head for Helical Springs 12 16 2656 Present 33531B Ammonia 5171 Safety Head for Helical Springs R12 amp 2 4 6 8 6 12 2199 Present 33532B R22 5171 Safety Head for Helical Springs R12 amp 12 16 2656 Present 33532B R22 518 Screw Valve Retaining 60 2 4 6 8 6 12 2656 13490 31964A 5181 Screw Valve Retaining 82 2 4 6 8 6 12 1349 Present 1527B 518 Screw Valve Retaining 60 12 16 2656 13490 31964A 5181 Screw Valve Retaining 82 da gu ze 12 16 m d 13491 Present 1527B NOTES The latest design for cast iron flat top pistons utilizes a set of three compression rings Part No 31989M and can be used in a compressor having cast iron pistons with two compression rings T See note with same symbol on page 21 A See note with same symbol on page 23 Abbreviation Cast Iron Pistons Al Aluminum Pistons SECTION 105 R PAGE 23 February 1985 440 VMC COMPRESSORS VILTER MANUFACTURING CORPORATION February 2001 Replaces February 1985 PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1000 RPM HIGH STAGE AND TWO STAGE COMPRESSORS AND 1200 RPM BOOSTER COMPRESSORS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBE
112. 32428C 109 Suction Screen R H Side 8 cyl 75 Cap Red 1 A32428D 109 A Bag Suction Screen not shown 1 A33474A 109 A Bag Suction Screen not shown 1 2 3 A33474B 109 A Bag Suction Screen not shown 1 1 A35234A 110 Gasket Suction Screen Cover 1 2 2 31892 110 Gasket Suction Screen Cover 1 11323 110 Gasket Suction Cover 1 1 35217 111 Cover Suction Screen 1 2 2 31893A 111 Cover Suction Screen 1 1 13706 111 Cover Suction Screen 1 1 35216A 112 Screw 17 Hex Head Cap 5 5 13152 112 Screw e x 194 Hex Head Cap 6 EA 12 12 13153E 113 Valve 12 Oil Charge and Drain Ammonia 1 1 1 1 A15375A 113 Valve 1 2 Oil Charge and Drain Halocarbon 1 1 1 1 1956A 113A Nipple 1 2 x 4 Sch 80 Pipe 1 1 1 1 13189G 114 Gasket Crankcase Oil Screen 1 1 1 1 31889A 115 Crankcase Oil Screen Assembly 1 1 1 1 A31886A 116 Plug v2 Hex Head Pipe 1 1 1 1 13264D 116 Plug 34 Hex Head Pipe 1 1 1 1 13264E 117 Pin Retaining Assembly for Compressor Oil Screen 1 1 1 1 A31936A 118 Safety Valve Internal Relief 1 1 1 1 1721B 119 Gasket 2 Flange 1 1 1 1 11323G 120 Cover Safety Valve 1 1 1 1 31954A 121 Screw 5 5 x 2 Hex Head Cap 2 2 2 2 13152bE 122 Gasket Handhole Cover 1 1 1 1 31894A NOTES Part Number on application VILTER MANUFACTURING CORPORATION SECTION 105 X February 2001 Original Issue Page 5 460 VMC COMPRESSORS B
113. 4 Steel 3ft 3ft 3ft 3ft S1589AA 327A Tubing 1 2 O D Steel AR As Required AR AR AR AR S1589AA 328 Tee Compression 2 2 2 2 13239C 329 Connector 1 4 MPT x 1 4 O D Compression 2 2 2 2 13229D 329A Connector 1 4 MPT x 1 4 O D Compression 2 2 2 2 13229D 330 Valve 3 Way Oil Filter 1 1 1 1 2030A 331 Bracket Valve 1 1 1 1 35106A 332 Control Pressure Differential 1 1 1 1 1643V 333 Gasket Bearing Cover 1 1 1 1 31890A 334 Screw 2 8 x 2 Hexagon Head Cap 10 10 10 10 13152E 335 Screw 1 2 x 194 Hexagon Head Cap 8 8 8 8 2796EL February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 Original Issue PAGE 10 460 VMC COMPRESSORS CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS FIGURE 5 402 405 FOR CYLINDERS WITH UNLOADING SECTION 105 VILTER MANUFACTURING CORPORATION February 2001 PAGE 11 Original Issue 460 VMC COMPRESSORS CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 NUMBER 401 402 Cylinder Liner Assembly amp 403 for cylinder without unloading 2 2 2 4 KT475 401 402 Cylinder Liner Assembly Thru 408 for cylinder with unloading 1 2 4 4 KT476 401 Liner Cylinder 2 4 6 8 34510A 402 Seal O Ring upper 2 4 6 8 2176BH 403 Pin Roll 0 125 dia X 1 Ig 8 16 24 32 1193Q 405 Ring Lift 1 2 4 4 A3335
114. 4 K 4 SERIES 101 6 mm 101 6 mm 76 2 mm 4 gt 4 3 101 6 mm 101 6 mm 76 2 mm VMC 2 01 INSTALLATION 2 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 2 VILTER VMC COMPRESSOR DIMENSIONS AND WEIGHTS OVERALL DIMENSIONS COMP UNIT WEIGHT BARE COMP jj es QTY L Ww H L W H DRIVE DRIVE 3 6 47 37 300 76 337 33 1010 1495 1385 SERIES 6 67 45 36 3 re Tto 15751485 8 68 45 36 2 69 48 50 1200 2000 1900 72 49 52 1600 2500 2400 L 156 L 43 4r 190 300 290 40 8 39 oe 45 39 2200 3400 3300 SERIES L3 rere 3600 i e 16 84 67 129 57 64 4000 i B Ro Ro 2 Stage 2 Stage NOTES i Unit length in inches unit length dependent on size and make of motor Unit weight in pounds motor and starter not included in unit weights Dimensions approximate and not to be used for construction Certified prints will be furnished for this purpose VMC 2 01 INSTALLATION 3 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A Ground Floor Installation Vilter VMC Compressors are available with structural steel bases or the customer may mount units on
115. 400 series compressor Operation and service manual gt 5 MANUFACTURING CORPORATION Multicylinder Compressor OPERATING INSTRUCTION MANUAL 400 SERIES COMPRESSORS READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR The entire manual should be reviewed before attempting to install service or repair the compressor A refrigeration compressor is a positive displacement machine It is designed to pump superheated vapor The compressor must not be subjected to liquid carry over Care must be exercised in properly designing and maintaining the system to prevent conditions that could lead to liquid carry over Vilter Manufacturing Corporation is not responsible for the system or the controls needed to prevent liquid carry over and as such Vilter Manufacturing Corporation cannot warrant equipment damaged by im properly protected or operating systems Vilter screw compressor components are thoroughly inspected at the factory assuring the shipment of a mechanically perfect piece of equipment Damage can occur in shipment however For this reason the units should be thoroughly inspected upon arrival Any damage noted should be reported immediately to the Transportation Company This way an authorized agent can examine the unit determine the extent of damage and take necessary steps to rectify the claim with no serious or costly delays At the same time the local Vilter representative o
116. 461 oil unloading and 60019 gas unloading are equipped with a suction elbow and two suction screens VPN A32428B located behind the suction screen covers on the frame 6 Cylinder compressors with serial numbers 45461 oil unloading and 60019 gas unloading and above are equipped with a suction tee VPN 36254 and a single suction screen VPN A35215A located in the suction tee 8 Cylinder compressors with serial numbers below 45461 oil unloading and 60019 gas unloading are equipped with a suction tee VPN 36254C and three suction screens one in the tee and two behind the suction screen covers on the frame 8 Cylinder compressors with serial numbers 45461 oil unloading and 60019 gas unloading and above are equipped with suction tee VPN 36254 and a single suction screen VPN A352154 located in the suction tee tt Part Number on application SECTION 102 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 6 Replaces 450 VMC COMPRESSORS April 1984 High Stage Two Stage Booster and Heavy Duty BASIC FRAME REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 117 Pin Assembly Crankcase Oil Screen Retaining 1 1 1 1 1 1 A31936A 118 Safety Valve Internal Relief 1 1 1 1 2 2 1721B 119 Gasket 2 Flange 3 1 1 1 2 2 11323G 120 Cover Safety Valve 1 1 1 1 2 2 31954A 121 Screw x 2 Hex Head 2 2 2 2 4 4 13152 122 Gasket Handhole Cover 1
117. 5 16 SK2916 2 9 16 NoKS 13 E158 1 5 8 3 8x 3 16 F2916 2 9 16 5 8 x 5 16 SK258 2 58 NoKS 11 11146 1 11 16 3 8x 3 16 F258 2 5 8 5 8 x 5 16 E134 3 8 x 3 16 F21116 2 11 16 5 8 x 5 16 SF BUSHINGS 11316 12 x 1 4 F234 2 3 4 5 8 x 5 16 SFMPB 1 2 No KS 51 E178 1 2 1 4 F21316 2 13 16 3 4 x 3 8 SF12 1 2 1 8 1 16 54 11516 1 2 1 4 F278 2 7 8 3 4 x 3 8 SF58 5 8 3 16 x 3 32 5 0 E2 1 2 x 1 4 F21516 2 15 16 3 4 x 3 8 SF34 3 4 3 16 x 3 32 5 0 E2116 1 2 1 4 3 4 x 3 8 SF78 7 8 3 16 3 82 4 9 218 1 2 1 4 3 4 x 3 8 SFi5 16 15 16 14x18 48 E216 1 2 x 1 4 3 4 x 3 8 SFI 1 1 4 x 1 8 4 8 E214 1 2 x 1 4 3 4 x 3 8 SF1116 1 1 16 1 4 x 1 8 47 E21458KS 5 8 x 5 16 7 8 x 3 16 SF118 1 18 14x18 47 E2516 5 8 x 5 16 F338 3 3 8 7 8x3 16 SFi316 1 3 16 14 18 46 E238 5 8 x 5 16 F3716 3 7 16 7 8 x 3 16 SF114 1 14 14x18 45 2716 5 8 x 5 16 F312 3 1 2 7 8x 3 16 SF1516 1 5H6 5 16 5 32 45 E212 5 8 x 5 16 F358 3 5 8 7 8 x 3 16 SF138 1 3 8 5 16 5 39 44 2916 5 8 x 5 16 F31116 3 11 16 7 8 x 3 16 SFI3838KS 1 3 8 3 8x3 16 44 258 2 518 S 8 x 5 16 7 8 x 3 16 SH716 12716 3 8x3 6 43 E116 241 16 5 8 x 5 16 1x 1 8 SF112 112 38x36 42 2 3 4 5 8 x 5 16 1x 1 8 SF1916 1 916 3 8x 3 16 42 E21316 2 13 16 3 4 x 3 8 No KS SF158 1 5 8 38x36 41 E278 2 18 3 4 x 3 8 J BUSHINGS SF11116 1 1116 3 8 x 3 16 4 0 E21516 2 15 16 3 4 x 1 8 SFI34 134 3 8x3 16 39 E3 3 3 4 x 1 8 JMPB 1
118. 554 Thru Crankshaft and Bearings Assembly 1 z A34554B 233 Crankshaft and Bearings Assembly 1 4555 Crankshaft and Bearings Assembly is E 1 Re zu A34555B Crankshaft and Bearings Assembly HD Pu n xis 1 Ee A34555BX Crankshaft and Bearings Assembly Kit 1 556 Crankshaft and Bearings Assy Kit High Stage HD 1 557 Crankshaft and Bearings Assy Kit Booster 1 558 224 Locknut and Retaining Compound Kit 1 1 KT366 224 Locknut and Retaining Compound Kit 1 1 1 1 KT367 227 Front Bearing and Retaining Compound Kit 1 1 KT368 227 Front Bearing and Retaining Compound Kit LES 1 1 1 1 KT369 228 Ring Front Bearing Retainer 1 1 2 xz E n 33144A 228 Ring Front Bearing Retainer p 1 1 3e 33145A 228 Ring Front Bearing Retainer gt 25 1 zi 1 34564A NOTES Less items 234 235 236 239 and 241 See note with same symbol on Page 9 February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 11 April 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS continued QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 229 Crankshaft amp Retaining Compound Kit 1 KT377 229 Crankshaft amp Retaining Compound Kit
119. 6 401A 402 Cylinder Liner Assembly Two Stage only 403 amp 408A for cylinder without unloading 6 3 12 6 A35108D 401A 402 Cylinder Liner Assembly Two Stage only Thru 408A for cylinder with unloading 3 6 5108 401 Liner Cylinder 2 4 6 8 12 16 34510A 401A Liner Cylinder Two Stage only ae 57 6 12 25 34710 402 Seal Ring upper 2 4 6 8 12 16 2176BH 403 Pin Roll 0 125 dia x 1 Ig 8 16 24 32 48 64 1193Q 405 Ring Lift 1 2 4 3 4 8 6 8 35071A 405A 4 Ring Lift 1 2 4 4 8 8 35380A 405B Pin Roll 4 4 4 4 4 4 119355 406 Spring Lift 8 16 32 24 32 64 48 64 35069A 407 Pin Lift 8 16 32 24 32 64 48 64 35070A 408 Retainer Lift Ring 1 2 4 3 4 8 6 8 1971A 408A Seal O Ring lower Two Stage only 6 12 2176BL 409 Plate Suction Valve 2 4 6 8 12 16 31909A 410A B amp Piston amp Rings Assy Cap Red Oil 1 1 2 3 2 4 6 4 A35315BX 411 410 amp 411 Piston amp Rings Assy Cap Red Gas 1 1 2 3 2 4 6 4 A35315CX 410 Ring Set PTFE amp rubber 1 1 2 3 2 4 6 4 2557A 410A Seal Unload Piston only 1 1 1 1 1 1 2639A 410B Ring Retaining Unload Piston Oil only 1 1 1 1 1 1 2638A 411 Piston Unloader Gas or Oil 1 1 2 3 2 4 6 4 Order Assy 413 thru Complete Capacity Control Mechanism Assembly 1 2 2 4 4 41788 420 Low Suction R717 and all Booster 41
120. 6 12 0 Present Order Kit 509 Nut Plain Hex 24UNF 4 8 12 16 24 32 12 24 0 Present 2027A 510 Nut Lock Connecting Rod 4 8 12 16 24 32 12 24 0 Present 2028A 511 Bearing Half Conn Rod w o Groove Standard Size 4 8 12 16 24 32 12 24 0 Present KT512 0 015 Undersize 4 8 12 16 24 32 12 24 0 Present KT513A 0 030 Undersize 4 8 12 16 24 32 12 24 0 Present KT513 512 Bolt Connecting Rod 4 8 12 16 24 32 12 24 0 Present 31955A 513 Safety Head Assembly Ammonia Thru for Helical Springs 2 4 6 8 6 12 2199 Present A32695C 518 for Helical Springs 12 16 2656 Present A32695C 513 Safety Head Assembly R12 and R22 Thru for Helical Springs 2 4 6 8 6 12 2199 Present A32695D 518 for Helical Springs 12 16 2656 Present A32695D 513 Lock Nut 75 Valve Retaining 2 4 6 8 6 12 0 Present 1776B 513 Lock Nut 7 5 Valve Retaining 12 16 2656 Present 1776 514 Washer Diaphragm Valve 2 4 6 8 mE 6 12 0 Present 31990B 514 Washer Diaphragm Valve 12 16 2656 Present 31990B 515 Valve Diaphragm Discharge 6 12 18 24 v 18 36 0 Present 31939B 515 Valve Diaphragm Discharge Sa PE 36 48 zm m 2656 Present 31939B 516 Spacer Diaphragm Valve 2 4 6 8 6 12 0 Present 31990A 516 Spacer Diaphragm Valve 12 16 2656 Present 31990A 517 Safety Head for Helical Springs 2 4 6 8 6 12 2199 Present 335
121. 6 x 5 32 SH34 3 16 x 3 32 1 0 3 8 x 3 1 SH13 16 3 16 x 3 32 1 0 SDMPB 116 NoKS 21 3 8 x 3 1 SH78 316x332 10 50 12 18x16 21 303 SH15 16 1 4 x 1 8 1 0 SD9 16 9 16 1 8 x 116 21 3 8 x 3 1 SHI 14 18 9 5058 5 8 3 16 x 3 32 21 3 8 x 3 1 5011 16 1116 3 16 3 32 2 0 3 8 x 3 3 8 x 3 1 12 x 1 4 Approximate weight in Ibs MPB Bushings are unsplit Continued next page SURE GRIP BUSHINGS BORE AND KEYSEAT DIMENSIONS TB ll Wood s Inches Product Wt Product No Bore Key Seat No SK BUSHINGS continued E BUSHINGS K11316 1 13 16 1 2 x 1 4 24 EMPB No KS 3 8 x 3 16 SK178 1 7 8 1 2 x 1 4 24 E78 3 16 x 3 32 1 2 1 4 SK11516 1 15 16 1 2x 14 2 3 E15 16 1 4 x 1 8 1 2x 1 4 SK 2 1 2 x 1 4 22 El 1 4 x 1 8 1 2x 1 4 SK 116 2 116 1 2 x 1 4 2 1 E118 1 4 x 1 8 1 2 x 1 4 SK218 2 1 8 1 2 x 1 4 2 0 E1316 1 3 16 1 4x 1 8 2 1 8 1 2 x 1 4 5 2316 2 3 16 1 2 x 1 8 2 0 E114 1 1 4 1 4 x 1 8 2 346 1 2 x 1 4 SK214 2 1 4 1 2 x 1 8 1 9 E1516 1 5 16 5 16 x 5 32 2 1 4 1 2 x 1 4 SK21458KS 2 1 4 5 8 x 1 8 19 E138 1 3 8 5 16 x 5 32 F21458KS 2 1 4 5 8 x 5 16 SK2516 2 516 5 8 x 1 16 1 8 E13838KS 1 3 8 3 8 x 3 16 F2516 2 516 5 8 x 5 16 58098 23 8 58x116 17 6 1 716 3 8x 3 16 F238 2 3 8 5 8 x 5 16 52716 27 6 58 116 16 1 1 2 3 8x3 16 F2716 2 716 5 8 5 16 0212 242 5 8 116 15 1916 1 9 16 3 8x 3 16 F212 242 5 8 x
122. 64 0 2655 33803A 410B 411A Piston Kit Cap Red Oil Actuated 1 1 2 2 4 4 3 6 19247 22799 KT364 412 410 411 Piston Kit Cap Red Gas Actuated 1 1 2 2 4 4 3 6 1501 19246 KT034 412 30000 32499 410 Piston Ring Steel for gas actuated 4 4 8 8 16 16 12 24 30000 32499 31989L 410A O Ring Rubber for 0 187 Groove 1 1 2 2 4 4 3 6 19247 22673 2176AX 410B Ring Set PTFE for 0 120 Groove 1 1 2 2 4 4 3 6 22674 22799 2557A 411 411A Piston Unloader gas or oil 1 1 2 2 4 4 3 6 Ses Order Kit 412 Pin Long Pivot 1 1 2 2 4 4 3 6 1501 22799 33250 413 thru Capacity Control Mechanism Assembly 4 3 6 1501 22799 577 420 Capacity Control Mechanism Assembly 1 4 4 1501 22799 A33354A 413 Arm Yoke Lifting 1 1 4 4 3 6 1501 22799 33338A 414 Yoke Assembly 1 3 6 1501 22799 575 414 Yoke Assembly 1 2 2 4 4 1501 22799 A33335A 415 Pin 4 Ig Roll 1 1 2 2 4 4 3 6 1501 22799 1193 416 Pin Short Pivot 1 1 2 2 4 4 3 6 30000 32499 33250B 417 Spring Unloader Yoke 4 4 8 8 16 16 12 24 30000 32499 33686A 418 Yoke Guide Assembly 1 3 6 30000 32499 A33576A 418 Yoke Guide Assembly 1 2 2 4 4 30000 32499 A33347A 419 Screw x 1 Cap Lock 2 6 12 30000 32499 13520 420 Spacer Sleeve 2 ae s 2 6 12 30000 32499 33618A NOTES or See note with s
123. 76 No KS SF11316 1 13 16 1 2 1 4 3 8 E318 3 1 8 3 4x 1 8 J1716 12 H6 3 8 3 16 SF178 1 7 8 12x14 37 8316 3 3 16 3 4 x 1 8 J112 1 1 2 3 8 x 3 16 SH1516 1 15 16 12x14 36 E314 31 4 3 4 x 1 8 J1916 1 9 16 3 8 x 3 16 SF2 2 12x14 35 E3516 3 516 7 8 x 1 16 Jt1116 1 1 16 3 8x 3 16 SF2116 24 16 12x14 34 E338 3 38 7 8 116 3 8 x 3 16 SF218 2 8 12 14 33 E3716 3 7 16 7 8 x 1 16 1 2 x 41 4 5 2316 2316 12x14 32 3 2 78 16 12 x 1 4 SF214 2 1 4 1 2 x 1 4 3 1 1 2 x 1 4 SF21458KS 2 1 4 5 8 x 5 16 3 1 F BUSHINGS 1 2 x 1 4 SF2516 2 5 16 5 8 x 3 16 3 1 FMPB No KS 1 2 x 1 4 SF238 23 8 5 8x316 30 H 1 4 x 118 12 x 4 4 SF2716 2 716 5 8x3 16 2 9 F118 1 4 x 1 8 5 8 x 5 16 SF212 2 1 2 5 8 x 3 16 2 8 F1316 1 4 x 1 8 5 8 x 5 16 SF2816 2 916 5 0x1 16 2 6 F114 1 4 x 1 8 5 8 x 5 16 SF258 2 0 8 5 8 116 2 5 F138 5 16 x 5 32 5 8 x 5 16 SF21116 2 11 16 5 8 1 16 24 F1716 3 8 x 3 16 5 8 x 5 16 SF234 234 Sxil6 22 F12 3 8 x 3 16 5 8 x 5 16 S78 278 4 1 6 18 916 3 8 x 3 16 5 8 x 5 16 21516 2 15 16 34x1 82 17 58 3 8 x 3 16 3 4 x 3 8 Approximate weight in Ibs MPB Bushings are unsplit Continued next page VMC SERVICE PAGE 1 5 5 3 VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor SERVICE SECTION TABLE OF CONTENTS GENERAL SERVICE INSTRUCTIONS General Comments Preparation Of Compressor For Serv
124. 90A 321 Gasket Oil Filter Head 1 1 1 1 1 1 1 1 0 Present 1448B 322 Filter Shell with Bolt Ring 1 1 1 1 1 1 1 1 0 Present A34623A 323 Screw Hex Head Cap 7 16 x 2 4 4 4 4 4 4 4 4 0 Present 1689G 324 Instruction Nameplate 1 1 1 1 1 1 1 1 0 Present 40680 325 Gauge 2 0 300 PSI Oil Filter 1 1 1 1 1 1 1 1 0 Present 2047A 326 Elbow 1 4 90 Female Compression 1 1 1 1 1 1 1 1 0 Present 1892B 327 Tubing O D x 5 ft Steel AR AR AR AR AR AR AR AR 0 Present 51589 328 Tee 1 2 Compression 2 2 2 2 2 2 2 2 0 Present 13239C 329 Connector X 1 O D Compression 3 3 3 3 3 3 3 3 0 Present 13229D 330 Valve 3 Way Oil Filter 1 1 1 1 1 1 1 1 0 Present 2030A 331 Bracket Valve 1 1 1 1 1 1 1 1 0 Present 35106A 332 Elbow 1 4 90 Male Compression 1 1 1 1 1 1 1 1 0 Present 13375D 333 Control Pressure Differential 1 1 1 1 1 1 1 1 0 Present 1643V 334 Screw 10 32 x 3 8 Long Round Head 2 2 2 2 2 2 2 2 0 Present 1332C 335 Washer Lock 3 4 2 2 2 2 2 2 2 2 0 Present 13165A 336 Washer Flat 3 16 4 4 4 4 4 4 4 4 0 Present 13265A 337 Cover Crankcase Handhole 1 1 1 1 1 1 1 1 0 Present A33034L 338 Thermometer Crankcase Oil 1 1 1 1 1 1 1 1 0 Present 1467F 339 Heater 535W 115V Electric Crankcase 1 1 1 1 1 1 1 1 0 Present 2069J 339 Heater 535W 230V Electric Crankcase 1 1 1 1 1 1 1 1 0 Present 2069K 340 Gasket Bearing Cover 1 1 1 1 1 1 1 1 0 Present 31890A 341 Screw 5 x 2 Hex Head 10 10
125. 95 kW 165 123 04 kW 145 108 13 kW 130 96 94 kW 4516XL 125 64 rad s 1130 118 31 rad s 1000 104 7 rad s 900 94 23 rad s 810 84 81 rad s 223 71 kW 285 212 52 kW 250 186 43 kW 225 167 78 kW 200 149 14 kW NOTE Recommended operating oil temperature is 100 F to 130 F 37 8 C to 54 4 C Operating at or near maximum oil temperature could resuit in excessive wear VMC 2 01 OPERATION 32 REPLACES ALL PREVIOUS ISSUES Master Catalog 125 CONTR LS Pressure Controls Section Product Technical Bulletin P28 Issue Date 0498 P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay The P28 and P128 Series Lube Oil Controls provide dependable and economical oil pressure cut out for pressure lubricated refrigeration compressors The field adjustable pressure differential of these controls E provides compressor operation according to the co manufacturer s specifications The P28 and P128 E controls operate by measuring the net lube oil pressure f EM and de energizing the compressor if the pressure falls below the differential setpoint Manual or automatic reset models are available with factory set and sealed time delays of 30 45 60 90 or 120 seconds all time delays may not be available on all models The P128 is the same control as the P28 but with 1 4 inch male flare pressure connections Figure 1 P128AA
126. A 33500A without oil holes cannot be used with current bearing cover assemblies A36240A and A36241A There is no provision for oil to get to the bearings If front bearing cover is being replaced a current front bearing retainer must be ordered also un less one of these current styles is already being used lf a current front bearing retainer is used with former style cover having an oil hole re move orifice in cover and replace with solid 3 2 mm flush pipe plug SEE SKETCH BELOW FOR LOCATION AND DESCRIPTION OF OIL HOLE IN CURRENT BEARING RETAINER FIGURE 16 400 Series VMC SERVICE 27 STAMPED THIS SURFACE OIL HOLE 346 DIA V DEEP 0 041 DIA THRU ON VERTICAL CENTERLINE RETAINER PARTIAL VERTICAL CROSS SECTION 2 01 Replaces all Previous Issues VPN VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 2 BOLT SIZE TORQUE SPECIFICATION VMC MODEL 440 REQUIRED TORQUE APPLICATION 13152L X 3 95 Ft Head Bolt with H2O Jacket 13152G 5 6 X 2 95 Ft Head Bolt without H2O Jacket 13152 5 6 x 1 95 Ft Suction Screen Cover 13152D 2 6 X 1 95 Ft Suction Screen Cover 13153E Ve x 11 75 Ft Suction Screen Cover 13153D Ve x 114 75 Ft Suction Screen Cover 13152bE 5 2 95 Ft Safety Valve Cover 13153E Ve x 1i 75 Ft
127. A Style 13 or Style 5 Manual Non corrosive 24 VAC VDC No All range P28PA Style 5 Manual Non corrosive 24 VAC VDC All range Style 5 connections are 1 4 in 6 4 mm SAE male flare connectors no capillary tubing Style 13 connections are 36 in 914 mm capillary tubing and 1 4 in 6 4 mm flare nut Style 15 connections are 1 4 in 6 4 mm female National Pipe Thread connectors Specifications Product P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Power Requirements See Tables 1 and 2 Pressure Specifications Adjustable Cut out Pressure Difference 8 to 70 psi 55 to 483 kPa Maximum Differential 70 psi 483 kPa Maximum Working Pressure 250 psig 1724 kPa on the high side Maximum Overpressure 325 psi 2240 kPa oil and low side pressure The time delay relay is de energized 3 to 5 psi 21 to 34 kPa above the cut out scale setting Pressure Switch Units Enclosed Dust protected Pennswitch Ambient Operating Conditions 32 to 104 F 0 to 40 C Material Case 0 062 in 1 6 mm Galvanized Steel Cover 0 028 0 7 mm Cold Rolled Steel plated and painted Mounting Flat Surface or with a Universal Mounting Bracket Part No 271 51 Wiring Terminal Large 8 32 x 1 4 in Binder Head Screws Agency Listings UL Guide No SDFY File SA516 CSA Class No 1222 01 File LR948 Most models Contact Johnson Controls for a complete listing Dimensions HxWxD 5 66 x 5 32 x 2 09 in 144 x 135 x 53 mm Shipping We
128. A70GA Open Low 1 No A70HA Open Low 1 Yes A70JA Open High 1 No A70KA Open High 1 Yes Two Pole A72AA Open Low 2 No A72AC Open Low 2 No A72AE Open Low 2 No A72AP Open Low 2 No A72CA Open High 2 No A72CE Open High 2 No be supplied with mounting brackets at additional cost Part No 271 350 is standard e M 271 350 Fig 2 Standard mounting Temperature Elements bracket Standard temperature element styles are shown on Page 5 For styles other than shown please check with the nearest Johnson Controls district office or Customer Service Type Number Selection Knob Conduit Misc Opening No 1 2 in Yes 1 2 in Manual Start No 1 2 in No 1 2 in No 1 2 in Reverse Acting Aux Contact No 1 2 in Reverse Acting Aux Contact No 1 2 in Reverse Acting Aux Contact No 1 2 in Reverse Acting Aux Contact No 3 4 in No 3 4 in No Cover No 3 4 in Outdoor Case No 3 4 in Manual Start No 3 4 in No 3 4 in Outdoor Case JeHNSON CONTRELS P74 Series Master Catalog 125 Pressure Controls Section Product Bulletin 74 Issue Date 0204 Differential Pressure Controls The controls are available for applications sensing air oil or liquid Typical applications are proof of flow across a chiller or water cooled condenser proof of flow in a heating or cooling coil and lube oil pressure sensing on refrigeration compressors On a proof of flow application the control measures pre
129. ASIC FRAME REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 NUMBER 123 Handhole Cover and 2 Sight Glass Assy 124 With openings for 560W NEMA 1 8 7 Htr F V amp Therm 1 1 1 1 A33034G 300W NEMA 1 amp 7 Heater and Therm 1 1 1 1 A33034GA 560W NEMA 1 8 7 Htr amp Therm 1 1 1 1 A33034L 300W NEMA 1 8 7 Htr amp Therm 1 1 1 1 A33034LA 123A Cover Handhole without openings not shown ne 33034B 124 Glass Oil Sight 2 1 1 1 1 1484A 125 Screw 1 2 x 1 Hex Head Cap 16 16 16 16 2796E SECTION 105 VILTER MANUFACTURING CORPORATION February 2001 PAGE 6 Original Issue 460 VMC COMPRESSORS CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS FIGURE 3 248 SECTION 105 VILTER MANUFACTURING CORPORATION February 2001 PAGE 7 Original Issue 460 VMC COMPRESSORS CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 NUMBER 201 thru Front Bearing Cover and Relief Valve Assy 1 1 1 1 A32566A 211 201 Cap Valve 1 1 1 1 17355A 202 thru Oil Relief Valve Kit 1 1 1 1 KT486 208 202 Gasket Valve Cap 1 1 1 1 30651C 203 Nut Packing 1 1 1 1 31048A 204 Washer 2 2 2 2 31048D 205 Packing x 39 4 ILD x 9 1 1 1 1 31048E 206 Stem Valve 1 1 1 1 31048C 207 Spring 1 1 1 1 31048F 208 Ball
130. Assembly 2027A 3 x 24 Nut Connection Rod Cap 2028A 4 Palnut Connection Rod NOTE Refer to Connecting Rod Nuts Tightening Instructions VMC Compressors page 31 400 Series VMC 2 01 SERVICE 30 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor CONNECTING ROD NUTS TIGHTENING INSTRUCTIONS VMC COMPRESSORS All VMC Compressor connecting rod bolts use a plain nut with a spring steel locknut Palnut combination PLAIN NUTS Plain nuts may be re used Torque the plain nuts as follows Connecting Rod Assembly Torque Value A33171A Aluminum 18 to 21 ft Ib 24 to 28 Nm A31045D Steel 30 to 35 ft Ib 41 to 48 Nm A34762A Steel 30 to 35 ft Ib 41 to 48 Nm LOCK NUTS New unused locknuts Palnuts must be used each time the connecting rods are serviced After the plain nut is torqued to the specified value assemble the palnut to the rod bolt with the open end of the hexagon pointing away from the hex plain nut CAUTION OPEN END MUST POINT AWAY FROM PLAIN NUT If palnut is installed the other way it will not lock and will eventually work loose during operation Turn the palnut until the mating parts are pulled together and tightening begins Final tightening and locking of the palnut is achieved by an additional 1 3 to 1 2 maximum turn Order spare palnuts by Vilter part number 2028A SOCKET A special shallow hexagon socket is av
131. Compressors with Standard Tri Micro Filter FIGURE 6 325 310 DO NOT DISASSEMBLE CENTER TUBE FACTORY PRESET RELIEF VALVE SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 13 Replaces 440 VMC COMPRESSORS July 1986 REAR BEARING COVER REPLACEMENT PARTS Compressors With Standard Tri Micro Filter NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 301 Thru Rear Bearing Cover Assembly Kit 1 1 1 1 1 1 1 1 0 Present KT092 304 301 Cover Rear Bearing 1 1 1 1 1 1 1 1 0 Present d 302 Plug 34 Hex Socket Head Pipe 1 1 1 1 1 1 1 1 0 Present 13163E 303 Pin 5 4 x 1 Dowel not shown 1 1 1 1 1 1 1 1 0 Present 2868H 304 Orifice Oil Metering not shown 1 1 1 1 1 1 1 1 0 Present 33361A 305 Gasket Oil Pump body 1 1 1 1 1 1 1 1 0 Present 31899A 306 Oil Pump Assembly 1 1 1 1 1 1 1 1 0 Present A33480A 307 Thru Conversion Kit Std Tri Micro 1 1 1 1 1 1 1 1 0 13374 KT361A amp B 324 307 Gasket Oil Pump Cover 1 1 1 1 1 1 1 1 0 Present 31900A 308 Gasket Oil Pump and Rear Bearing 1 1 1 1 1 1 1 1 13375 Present 33320A Cover Seal 309 Cover Oil Pump and Filter Head Used when Oil Cooler not used 1 1 1 1 1 1 1 1 13375 Present 36190A 309 Cover Oil Pump and Filter Head Used when Oil Cooler is used 1 1 1 1 1 1 1 1 13375 Present 34759A 310
132. Contacts close simultaneously when TD contacts open alarm circuit DR Voltage dropping resistor used in dual voltage models H Heater for time delay relay Connect Terminals L and M as a single pole switch Connect Terminals 2 and 240 or 120 to energize circuit only when motor starter is closed Figure 3 P28 or P128 Internal Wiring Circuit Showing Alarm Circuit and Runlight Terminals 4 P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin 240V 3 phase Crankcase Operating Heater Control When Used P28 or P128 Crankcase heater cannot be cycled with this hookup See Figure 5 Figure 4 P28 or P128 Used on a 240V System with 240V Magnetic Starter Coil Additional controls in this line only 240V 3 phase un 2d L QL bL 1 1 NE C i 211545 ri Operating eater Control x Runlight When Used if Used P28 or P128 When crankcase heater is used disconnect jumper from 2 to M and reconnect from 2 to L Figure 5 P28 or P128 Wired for 3 wire Control Jumper between 2 and M or L must be field installed Ground Any Voltage 120 or 240V Supply i OL dls Hot eee eee gs Heater r When Used Operating _ Control Additional controls in this line only P28 or P128 When crankcase heater is used disconnect jumper from 2 to M and reconnect from 2 to L Figure 6 P28 or P
133. E SIDE OF FRAME ON 4 6 amp 8 CYLINDER 121 COMPRESSORS SECTION 105 VILTER MANUFACTURING CORPORATION February 2001 PAGE 4 Original Issue 460 VMC COMPRESSORS BASIC FRAME REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 NUMBER 101 Frame 1 1 1 1 102 Screw 2 8 2 1 Hex Head Cap Used w o Water Jacket 20 40 60 80 13152G 102 Screw e x 3 1 Hex Head Cap Used with Water Jacket 20 40 60 80 13152L 103 Cover Water Jacket 1 2 3 4 30299A 104 Gasket Water Jacket 1 2 3 4 33329A 105 Cover Cylinder w o Capacity Reduction 1 2 A30332A w Capacity Reduction 1 2 30332B w Capacity Reduction 1 1 64 Banks w o Capacity Reduction 1 1 A30364A w Capacity Reduction 1 1 30364 106 Gasket Cylinder Cover 1 2 3 4 33330A 107 Stud x 3 shown only on 2 cylinder 8 4 4 4 13156D 107 Stud 3 2 x 344 not shown 4 4 4 13157D 107A Nut 5 11 NC 2B 1726G 107A Nut 34 10NC 2B 4 4 4 1726 108 Tee Suction 212 x 212 1 19 3 x 3 s 1 A32417B Elbow Discharge 2 x 2 Ammonia 1 12270 2 x 22 Ammonia 1 12270F 3 x 3 Ammonia 1 12271 4 x 3 Ammonia 1 A32498A 109 Suction Screen 1 2 2 A32428B 109 Suction Screen 1 A32428A 109 Suction Screen Center 1 A
134. E DIMENSIONS 1 375 34 9 mm 1 625 41 3 mm 1 875 47 6 mm Pilot hole PART NUMBER 226 2 1 883 47 8 mm 1 875 47 6 mm 2 125 5 4 mm 2 375 60 3 mm Pilot hole 262 AMR 1 992 50 6 mm 1 875 47 6 mm 2 125 5 4 mm 2 375 60 3 mm Pilot hole 312 AMR 1 992 50 6 mm 2 484 63 09 mm 2 984 75 79 mm 2 125 54 mm 2 375 60 3 mm 2 875 73 mm Pilot hole 350 AMR 1 992 50 6 mm 2 492 63 3 mm 2 992 76 mm 2 125 54 mm 2 375 60 3 mm 2 875 73 mm Pilot hole 375 AMR VMC INSTALLATION 2 492 63 3 mm 2 992 76 mm 2 375 60 3 mm 2 875 73mm 2 375 60 3 mm Pilot hole 41 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor FIGURE 5 A V Belt Installation The motor of the V belt driven compressor is mounted on a slide rail that enables movement of the motor toward or away from the compres sor by loosening four adjusting screw lock nuts eight guide clamp bolts and nuts and turning the two adjustment screws The proper method of installing V belts is as follows 1 Move the sheaves toward each other to each V belt installation SHEAVES AND BELTS NOTE Mount the motor sheave as close as possible to the motor housing Keeping the V belt pull as close to the motor and compressor as possible gives the
135. EPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 201 thru Front Bearing Cover and Relief Valve Assy 1 1 1 1 1 1 A32566A 211 201 Cap Valve 1 1 1 1 1 1 17355A 202 thru Oil Relief Valve Kit 1 1 1 1 1 1 KT486 208 202 Gasket Valve Cap 1 1 1 1 1 1 30651C 203 Nut Packing 1 1 1 1 1 1 31048A 204 Washer 2 2 2 2 2 2 31048D 205 Packing x 9 4 LD x 4 1 1 1 1 1 1 31048E 206 Stem Valve 1 1 1 1 1 1 31048C 207 Spring 1 1 1 1 1 1 31048F 208 Ball gt dia Steel 1 1 1 1 1 1 13155K 209 thru Front Bearing Cover Assembly 1 1 1 1 1 1 A36241A 211 209 Plug 4 Hex Head Pipe 1 1 1 1 1 1 13264B 210 Plug Hex Head Pipe 1 1 1 1 1 1 13264 211 Cover Front Bearing 1 1 1 1 1 1 Order Assy 211B Shield Splash 1 1 1 1 1 1 35274A 211C Screw Hexagon Hd No 10 32 x s long 3 3 3 3 3 3 2583A 212 Gasket Bearing Cover 1 1 1 1 1 1 31890A 213 Screw e x 4 Hex Socket Head Cap 2 2 2 2 2 2 13159E 214 Retainer Front Bearing with Oil Hole 1 1 1 1 1 1 33500A 215 Screw 5 5 x 2 Hex Head 6 6 6 6 6 6 13152 216 Screw 12 x 4 Hex Head 3 3 3 3 3 3 2796EV 217 amp 218 Seal and Gasket Kit 1 1 1 1 1 1 KT509 217 Seal Rotary Shaft Assembly 1 1 1 1 1 1 A33489A 218 Gasket Shaft Seal Cover 1 1 1 1 1 1 33496A 219 Screw 1 2 x 194 Hex Head Cap 8 8 8 8 8 8 2796EL 220 amp 220A Cover and Tube Assembly Shaft Seal 1 1 1 1 1 1 A32564A 220A Drain Tube 1 1 1 1 1 1
136. ESS STEEL SEAT DISC LAPPED METAL SEATING was 77777 LIZ CLOSING SPRING DUAL BODY CARTRIDGE SEALS ADDITIONAL FEATURES Mounts in any position Less than 1 PSID wide opening pressure Can be close coupled Low bubble leakage tolerance For Ammonia R22 R134a and other approved refrigerants Dimensionally replaces R S CK4A 2 3 4 8 amp 1 U L Listed MATERIAL SPECIFICATIONS INSTALLATION Body Valve may be located in any position Arrow on 5 thru 174 Steel ASTM A108 zinc chromate valve body should match direction of flow Secure plated valve with gaskets between flanges and tighten 1 thru 4 Ductile iron ASTM A536 zinc bolts evenly Do not use this valve or any component chromate plated to align pipes or tighten gap between flanges Seat Disc Stainless steel Seat Cartridge Do not install on inlet side of solenoid valves or 5 thru 174 Stainless steel ASTM A582 control valves with electric shut off or shut off valves 1 thru 4 Steel ASTM A108 zinc chromate unless a relief valve is used from therein between plated piping Do not install on inlet side of outlet pressure Spring Stainless steel regulators where liquid may become trapped Safe Working Pressure 400 PSIG 27 bar Instead check valves should be located on outlet Operating Temperature 60F to 240F 50 to 115 C side of these valves Check valves can be close coupled to other matching solenoid valves press
137. Filter Assy Complete Tri Micro 1 1 1 1 1 1 1 1 13375 Present A35240A Items 311 thru 322B 311 312 313 amp Spool Strainer Tube Assembly 1 1 1 1 1 1 1 1 13375 Present 1448U 314 311 312 thru 314 amp 315 Filter Assembly without shell 1 1 1 1 1 1 1 1 13375 Present 1448T thru 319 amp 321 311 Spool Assembly with bypass relief 1 1 1 1 1 1 1 1 13375 Present 1448J 312 Seal Spool End 1 1 1 1 1 1 1 1 13375 Present 1448H 313 Strainer Tube 1 1 1 1 1 1 1 1 13375 Present 1448K 314 Ring Retaining 1 1 1 1 1 1 1 1 13375 Present 1448L 315 Recharge Gasket 1448B included 1 1 1 1 1 1 1 1 13375 Present 1448 316 Pressure Plate Assembly 1 1 1 1 1 1 1 1 13375 Present 1448M Items 317 318 and 319 317 Pressure Plate 1 1 1 1 1 1 1 1 13375 Present 1448N 318 O Ring Seal Pressure Plate 1 1 1 1 1 1 1 1 13375 Present 1448P 319 Spring Pressure Plate 1 1 1 1 1 1 1 1 13375 Present 1448Q 320 Plug Steel Square Head Pipe 1 8 1 1 1 1 1 1 1 1 13375 Present 13264A 321 Gasket Oil Filter Head 1 1 1 1 1 1 1 1 13375 Present 1448B 322 Filter Shell with Flange and Plug 1 1 1 1 1 1 1 1 13375 Present A34623A Items 320 322A and 322B 322A Flange Oil Filter Tank 1 1 1 1 1 1 1 1 13375 Present 35125A 322B Tank Oil Filter 1 1 1 1 1 1 1 1 13375 Present 34623A 323 Screw Hex Head Cap 7 15 x 2 4 4 4 4 4 4 4 4 13375 Present 1689G 324 Instruction Name Plate not shown 1 1 1 1 1 1 1 1 13375 Present 40680 325
138. Float Valve 17 Crankcase Heater 18 Oil Cooler 18 Introduction 19 Installation 19 Operating Pressure 19 Inspection 19 Service 20 Water Cooled Cylinder Covers 20 Water Regulating Valve 21 SAFETY DEVICES 21 ELECTRICAL EQUIPMENT AND SPECIFICATIONS 22 TESTING REFRIGERATION SYSTEM LEAKS 22 Ammonia Systems 23 Other Refrigerant Systems 23 Evacuating The System 24 COMPRESSOR OIL CHARGING 25 Oil For VMC Compressor VMC 2 01 INSTALLATION A REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor INSTALLATION SECTION TABLE OF CONTENTS cont d PAGE 25 SYSTEM REFRIGERANT CHARGING 25 Equipment Inspection 25 Low Side Equipment 26 Compressors 26 Condenser 26 Controls 26 Refrigerant Charging 26 High Side Charging Initial Charging 27 Low Side Charging Adding Refrigerant To Operating System 28 THE INITIAL START 28 Controls 28 Final Precautions 30 MAINTENANCE SUGGESTIONS 29 Daily 30 Weekly 30 Monthly 30 Yearly 31 System Leaks 31 Year Round Operation 31 Flushing The Oil Circuit 32 Crankshaft Seal Oil Leakage 32 Seasonal Operation 32 Service Contracts ILLUSTRATIONS AND TABLES PAGE FIGURE 4 1 TYPICAL GROUND FLOOR INSTALLATION VMC COMPRESSORS WITH STRUCTURAL STEEL BASE 5 2 UPPER FLOOR INSTALLATION 7 3 TYPE KIP C VIBRATION ISOLATORS 9 4 CONCRETE PAD FORM 12 5 SHEAVES AND BELTS 14 6 BELT ALIGNMENT 16 7 PIPING SCHEMATIC TYPICAL OIL SEPARATOR INSTALLATION
139. GE 2 THRU 6 CYLINDER FOR 400 SERIES COMPRESSOR CAPACITY REDUCTION ARRANGEMENT TYPICAL SCHEMATIC 14 6 HIGH STAGE 8 AND 12 CYLINDER COMPRESSOR FOR 400 SERIES CAPACITY REDUCTION ARRANGEMENT TYPICAL SCHEMATIC 15 7 HIGH STAGE 16 CYLINDER COMPRESSOR FOR 400 SERIES CAPACITY REDUCTION ARRANGEMENT TYPICAL SCHEMATIC 16 8 UNLOADING ARRANGEMENT SCHEMATIC 3 5 AND 7 CYLINDER 300 SERIES COMPRESSOR 17 9 UNLOADER ARRANGEMENT SCHEMATIC 4 6 AND 8 CYLINDER 300 SERIES COMPRESSOR 18 10 UNLOADING ARRANGEMENT SCHEMATIC 3 4 AND 5 CYLINDER 300 SERIES COMPRESSOR 19 11 UNLOADING ARRANGEMENT SCHEMATIC 6 7 AND 8 CYLINDER 300 SERIES COMPRESSOR 20 12 TYPICAL REFRIGERANT FLOW DIAGRAM FOR SIX AND TWELVE CYLINDER TWO STAGE COMPRESSORS WITH DESUPERHEATER 21 13 TYPICAL REFRIGERANT FLOW DIAGRAM FOR SIX AND TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSORS WITH INTERCOOLER 22 14 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM SIX CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH INTERCOOLER 23 15 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM SIX CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH DESUPERHEATER 24 16 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH INTERCOOLER 25 17 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH AMMONIA DESUPERHEATER 26 18 REFRIGERANT AND PRESSUSRE CONNECTIONS SCHEMATIC DIAGRAM TWELVE CYLINDER INTEGRAL TWO STAGE C
140. GE TWO STAGE 2 4 6 8 12 16 6 12 es Gasket Kit Complete KT041 1 Gasket Kit Complete KT043 1 Gasket Kit Complete KT045 1 Gasket Kit Complete KT049 1 Gasket Kit Complete KT051 1 Gasket Kit Complete KT055 1 ES Gasket Kit Complete KT056 1 Gasket Kit Complete 089 1 118 Safety Valve Internal Relief 1721B 1 1 1 1 2 2 217 Rotary Shaft Seal Assembly A33483A 1 1 1 1 1 217 Rotary Shaft Seal Assembly A33489A 1 1 1 306 Oil Pump Assembly for all 440 VMC Compressor A33480A 1 1 1 1 1 1 1 1 315 Recharge Includes Gasket 1448B Standard Tri Micro Filter 1448C 1 1 1 1 1 1 1 1 315 Recharge Includes Gasket 1448B Special Improved Tri Micro Filter Option 2115C 1 1 1 1 1 1 1 321 Gasket Oil Filter Head 1448B 1 1 1 1 1 1 1 401 Cylinder Liner Kit for Cylinder w o Unloading Thru a 1000 RPM Compressors KT071 1 1 2 2 2 2 2 2 402A b 1200 RPM Compressors Serial No 3638 71 1 1 2 2 2 2 2 2 to present 401 Cylinder Liner Kit for Cylinder w Unloading Thru a 1000 RPM Compressors KT072 1 1 2 2 2 2 2 2 406 b 1200 RPM Compressors Serial No 0 to KT033 1 1 2 2 2 2 3637 1200 RPM Compressors Serial 3638 KT072 1 1 2 2 2 2 2 2 to Present 405 Spring Lift 1000 RPM 1200 RPM 3638 to 33352A 4 4 8 8 8 8 8 8 Present and All Boos
141. Gasket Bearing Cover 1 1 1 1 1 1 1 1 0 Present 31890A 326 Screw x 2 Hex Head 10 10 10 10 10 10 10 10 0 Present 13152E 327 Screw 12 x 194 Hex Head 8 8 8 8 8 8 8 8 0 Present 2796EL NOTES A Tri Micro is a registered trademark of Vilter Manufacturing Corporation The rear bearing cover is sold only in Kit KT092 When Kit KT256 is ordered the overall length of the existing oil pump Item 306 on the compressor should be checked If the length from the end of the pump shaft to the end of the pump boss measures 57 32 a new oil pump must be ordered with Kit KT256 February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R PAGE 14 Replaces July 1986 440 VMC COMPRESSORS REAR BEARING COVER REPLACEMENT PARTS Compressors With Special Improved Tri Micro Filter Option FIGURE 7 Typical Arrangement DO NOT DISASSEMBLE CENTER TUBE FACTORY PRESET RELIEF VALVE SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 15 Replaces 440 VMC COMPRESSORS February 1984 REAR BEARING COVER REPLACEMENT PARTS Compressors With Special Improved Tri Micro Filter Option NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 301 thru Rear Bearing Cover Assembly Kit 1 1 1 1 1 1 1 1 0 Present KT092 304 301 Cover Rear Bear
142. Gauge intermediate Pressure Gauge FIGURE 15 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM SIX CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH DESUPERHEATER VMC 2 01 OPERATION 23 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor OIL SEPARATOR RETURN LINE BOOSTER DISCHARGE LIQUID INJECTION REMOTE LINE 9 MOUNTED CONTROL when capacity reduction E is used HIGH STAGE T PER A XPISCHARGE 9 5 NA Z I LIQUID FROM Z RECEIVER 2 HIGH STAGE BOOSTER SUCTION SUCTION 10 a 2 SUBCOOLED TO SYSTEM To Front Bearing Cover Drive End 5 P d and Oil ES OIL PUMP TO CRANKCASE KEY ITEM NUMBER ITEM NUMBER DESCRIPTION Oil Pressure Failure Switch PSO Dual Pressure Switch PSD High Pressure Switch PSH Low Pressure Gauge Crankcase Pressure Gauge Oil Pressure Gauge High Pressure Gauge 2 FIGURE 16 DESCRIPTION Safety Valve Set 300 psig 2 Thermostatic Expansion Valve Solenoid Valve SVL and Strainer Assembly Capacity Control Switch 17 Liquid Line Valve 2 Intermediate Pressure Gauge o m Qo to REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM TWELVE CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH INTERCOOLER VMC OPERATION 24 2 01 REPLACES ALL PREVIOUS ISSUES VILTER
143. KSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 9 Illustration Figure 5 10 Parts List REAR BEARING COVER REPLACEMENT PARTS 12 Illustration Figure 6 13 Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 14 Illustration Figure 7 15 Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 16 Illustration Figure 8 17 Parts List 18 RECOMMENDED SPARE PARTS LIST REPLACEMENT PARTS ORDERING INSTRUCTIONS Give the size voltage original order number and serial number of the compressor All of this information is stamped on the nameplate attached to the compressor frame The serial number is also stamped on the compressor frame The compressor frame serial number location is directly above the suction flange on the frame of the compressor or directly above the rear bearing cover The rear bearing is located on the oil pump filter end of the compressor Always give the name of the part as well as the corresponding part number and or item number Also include the quantity of parts required Should there be a doubt regarding the part number or name send a sketch of the part required or return the old part as a sample transportation charges prepaid Orders on which part numbers and description do not agree will be filled according to our best interpretation All prices are F O B factory Minimum domestic parts order is 75 00 net price Please indicate on the order preferred method of shipment We will fol
144. LACEMENT PARTS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 224 Complete Crankshaft Assy 1000 RPM Thru For Aluminum Pistons 3068 Present A32574A 233 For Aluminum Pistons 3068 Present A32574B For Aluminum Pistons 1 1 3068 Present A32574C For Aluminum Pistons 1 5 3068 Present A32574D 224 Complete Crankshaft Assembly Kit Thru 1000 or 1200 RPM for Aluminum Pistons si 1 1 0 Present 068 245 1000 or 1200 RPM for Aluminum Pistons 5 EX 1 0 Present KT069 less items 225 226 230 234 235 241 2247 Locknut and Retaining Compound Kit 1 1 1 0 Present KT366 224 Locknut and Retaining Compound Kit m 1 1 ats 1 0 Present KT367 227 Front Bearing and Retaining Compound Kit 1 1 1 0 Present KT368 227 Front Bearing and Retaining Compound Kit 1 1 1 0 Present KT369 228 Ring Front Bearing Retainer 1 1 Soh aoe 1 E 0 Present 33144A 228 Ring Front Bearing Retainer zs 1 1 1 0 Present 33145A 229 Crankshaft 1200RPM with oilway plugs For Aluminum Pistons TT 1660 Present KT370 For Aluminum Pistons TT 1660 Present KT371 For Aluminum Pistons tt 1 1 1660 Present KT372 For Aluminum Pistons tt 1 1660 Present KT373 For Aluminum Pisto
145. OMPRESSOR SERIAL NO PART NO OF CYL 4 6 8 12 16 FROM THRU NO 501 Thru Piston Flat Cl Rings amp Pin Kit 4 6 8 0 3067 214 505 501 Piston Flat Cl amp Conn Rod Assy Kit 4 6 8 0 3067 114 Thru Piston Cup AL amp Conn Rod Assy Kit 12 16 0 2655 KT117 512 504 amp Piston Cup AL amp Pin Assy 12 16 0 2655 A32567A 505 519 Safety Yoke amp Discharge Valve Inner Thru Seat Assy amp R22 12 16 0 2655 A33588A 525 Safety Yoke amp Discharge Valve Inner Except Seat Assy R12 12 16 0 2655 A33588B 521 520 Assembly Safety Yoke amp Pin 12 16 0 2655 A33585A 523 Nut 1 Flexloc 12 16 0 2655 1330B 524 Plate Discharge Valve Amm amp R22 ae m 25 24 32 0 2655 33423A 524 Plate Discharge Valve R12 12 16 0 2655 33423A 525 Inner Seat Discharge Valve E 12 16 0 2655 33421A SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 31 Replaces 440 VMC COMPRESSORS April 1984 CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS Serial Numbers 9999 and below NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 220 Shim Rear Bearing Retainer 1 1 1 0 1659 A31905A 224 Complete Crankshaft Assy 1200 RPM Thru For Cast Iron Pistons 1 0 1659 2612 233 For Cast Iron Pistons
146. OMPRESSOR WITH HALOCARBON DESUPERHEATER 27 19 450XL WATER JACKET CONNECTIONS 28 20 450XL WATER MODULATING VALVE CONNECTIONS PAGE TABLE 5 1 SINGLE COMPRESSOR RANGE amp OPERATION DUAL COMRPESSOR RANGE amp OPERATION 320 340 350ES VMC COMPRESSOR MAXIMUM LIMITS 440 VMC COMPRESSOR MAXIMUM LIMITS 450 VMC COMPRESSOR MAXIMUM LIMITS 450XL VMC COMPRESSOR MAXIMUM LIMITS 6 29 30 31 32 NAUN VMC 2 01 OPERATION B REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor L COMBINATION UNLOADER AND CAPACITY CONTROL introduction Vilter MultiCylinder Compressors VMC 400 Series cylinder unloaders are supplied as either gas or oil actuated The 300 Series cylinder unloaders are oil actuated only Gas actuation is standard on ail high stage compressors except those equipped with 10096 intemal capacity re duction Oil actuation is standard on all high stage compressors with 10095 internal capacity reduction all booster compressors and all two stage compressors The method of unloading is determined by the solenoid valve connections two tube connections indicate a two way sole noid and gas unloading three tube connectors indicate a three way solenoid and oil unloading B Gas Operating Unloader Single Stage Compressor The mechanism is spring loaded and actuated by an unloader piston When the compressor is not operating and suction and discharge are equalized on both sides
147. OMPRESSORS DISCHARGE SUCTION GAUGE REPLACEMENT PARTS FIGURE 4 USED ON 2 THRU 4 CYLINDER COMPRESSORS USED ON 12 AND 16 CYLINDER COMPRESSORS 129 S 130 133 131 132 PATENTS PENDING SECTION 100 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 8 Original Issue 450XL VMC COMPRESSORS DISCHARGE SUCTION GAUGE REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 128 Heater Electric Crankcase Oil 115V not shown 1 1 1 1 2 2 2069J 128 Heater Electric Crankcase Oil 230V not shown 1 1 1 1 2 2 2069K 129 Gauge Discharge 300 PSI 1 1 1 1 2 2 1204E 129 Gauge Suction 150 PSI 1 1 1 1 1 1 1204C 130 Stedy Mount 2 2 2 2 3 3 A17311SS 131 Connector 14 MPT x 1 4 O D Compression 2 2 2 2 3 3 13229D 133 Nipple 4 x 4 Sch 80 Pipe 2 2 2 2 3 3 13181G 134 Thermometer Crankcase Oil not shown 1 1 1 1 1 1 1467F Patents Pending February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 9 May 1985 450XL VMC COMPRESSORS CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS FIGURE 5 211C 211B e fe 7 201 29 2 thru 8 cylinder PATENTS PENDING SECTION 100 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 10 Replaces 450XL VMC COMPRESSORS May 1985 CRANKSHAFT AND FRONT BEARING COVER R
148. ON SECTION 105 R Replaces PAGE 8 April 1984 440 VMC COMPRESSORS CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 12 AND 16 CYLINDER COMPRESSORS FIGURE 5 232 231 SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 9 Replaces 440 VMC COMPRESSORS April 1984 CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART cones 2 4 6 8 12 16 6 12 FROM THRU NUMBER The following complete crankshaft sub assemblies are available for all 440 VMC Compressors with aluminum pistons for 1000 RPM compressors from serial number 3068 thru present and for 1200 RPM compressors from serial number 1660 thru present 201 Complete Crankshaft Sub Assembly Kit 1 See 077 Thru Complete Crankshaft Sub Assembly Kit 1 078 233 Complete Crankshaft Sub Assembly Kit 1 1 Above KT079 Complete Crankshaft Sub Assembly Kit 1 See 080 201 Complete Crankshaft Sub Assembly Kit 1 1 KT081 Thru Complete Crankshaft Sub Assembly Kit 1 Above KT082 245 201 Front Brg Cover amp Relief Valve Assy 1 1 1 1 Be 1 0 Present A31121A Thru Front Brg Cover amp Relief Valve Assy 1 1 1 0 Present 2566
149. Place the suction valve springs into the holes with the end that has two coils wound towards the bottom of the hole and twist The springs lock in place When the springs are properly installed the safety head can Before removing valve plates look for the word be inverted without the springs falling out TOP etched on each plate and ring plate dis Place the suction valve plate in the cavity of charge valve This denotes the unlapped upper the cylinder liner with the side marked TOP face If the etching is not clearly visible dot the facing up upper face of the valve plate with dye or tape Do this sparingly Any marking applied must be removed prior to reassembly Ensure the valve plate rotates freely without binding Replace the safety head assembly in the frame Be sure no debris or foreign material is on any parts Replace safety yoke on top of the safety head assembly The safety head contains four helical suction valve springs which are identical to the eight discharge valve springs These need to be kept separated The suction valve can be lifted out B Reassembly 1 440 Compressor Mushroom Style 400 Series VMC 2 01 SERVICE 4 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Compressor Frame 1 2 5 47 K KEY ITEM NO ITEM NAME ITEM NO ITEM NAME 1 Cylinder Liner Valve Retaining Screw 2 Suction Valve Plate Hex
150. R Gasket Kit Complete 1 KT041 Gasket Kit Complete 1 KT043 Gasket Kit Complete 1 045 Gasket Kit Complete 1 049 Gasket Kit Complete 1 KT051 Gasket Kit Complete 1 055 118 Safety Valve Internal Relief 1 1 1 1 1 1 1721B 217 Rotary Shaft Seal Assembly 1 1 48 217 Rotary Shaft Seal Assembly 1 1 1 1 A33489A 306 Oil Pump Assembly 1 1 1 1 1 1 A33480A 315 Recharge Oil Filter Gasket 1448B included For use with 2046A and A35241A 1 1 1 1 1 1 2115C 315 Recharge Oil Filter Gasket 14483 included For use with A35240A and 1448J 1 1 1 1 1 1 1448C 401 Oylinder Liner Assembly Kit Thru for cylinder without unloading High Stage 1 1 2 2 2 2 KT475 404 for cylinder without unloading Two Stage zi 1 52 1 A35108D 401 Cylinder Liner Assembly Kit Thru for cylinder with unloading High Stage 1 1 2 2 2 2 KT476 408 for cylinder with unloading Two Stage 1 1 A35108C 409 Plate Suction Valve 2 4 6 8 12 16 31909A 413 Capacity Control Assembly Thru Two Cylinder and Two Stage Compressor 1 1 1 A33577A 420 4 thru 16 Cylinder Compressors 1 1 1 1 1 A33354A Piston Rings and Connecting Rod Assembly Kit 501 All Compressors except 16 Cyl High Stage 1 1 2 2 2 2 KT478 Thru Piston Rings and Connecting Rod Assembly Kit 512 Heavy Duty High Stage 2 2 478 501 Pi
151. R 519 Springs Valve Volute 8 16 24 32 0 2198 31915 519 Springs Valve Helical 8 16 24 32 48 64 24 48 2199 Present 33803A 520 Yoke Safety Head 2 4 6 8 s 6 12 0 Present 31941B 520 Yoke Safety Head 25 m SE 12 16 2656 Present 31941 521 Spring Safety Head 2 4 6 8 12 16 6 12 0 Present 31882A NOTES 1000 RPM high stage and VMC booster compressors with Serial No s 2198 and below have volute springs with the exception of Serial Nos 2160 2163 2168 2169 2182 2183 2184 2185 and 2186 which have helical springs All 1000 RPM high stage and VMC booster compressors with Serial Nos 2199 and above have helical springs The old type volute springs are If a replacement safety head for volute springs is needed it will be necessary to purchase the helical spring as well as the safety head for helical springs When this conversion is made it is not necessary to make the conversion on all cylinders of the compressors It may be well to do so to eliminate available However the safety head for volute springs is not available confusion in the future February 2001 Replaces March 1975 VILTER MANUFACTURING CORPORATION 440 VMC COMPRESSORS MODERNIZING 1200 RPM COMPRESSORS Pages 24 through 31 pertain to replacement parts for high speed compressors having serial numbers below 9999 These redesigned replacement parts are incorporated on all high speed compressors having serial numbers 3638 and above The re
152. RATION VILTER MultiCylinder Compressor 1 High Side Charging Initial Charging cont d CAUTION Take care refrigerant does not flood into the compressor Liquid slugging can cause considerable damage d Continue charging refrigerant into the system until the design operating re quirements are satisfied Close the liq uid charging connection Open the liq uid line valve allowing the system to operate normally When enough refrig erant has been added the liquid sight glass shows no bubbles and the re ceiver will be sealed If these two con ditions are not satisfied add additional refrigerant e When sufficient refrigerant is charged into the system close the charging and drum valves Then remove the drum from the system f During the charging period watch the gauge to ensure no operating difficul ties Check head pressure to make sure condensers are functioning prop erly Since it is usually necessary to use more than one drum when charging a system follow procedures in paragraph a and b under the title High Side Charging Initial Charging when at taching a new drum After charging keep the refrigerant drums nearby for several days as it is sometimes neces sary to add more refrigerant once the system settles down VMC INSTALLATION 27 2 Low Side Charging Adding Refrigerant To Operating System Use low side charging on small systems only when adding a small
153. RING CORPORATION VILTER MultiCylinder Compressor After the compressor is running to provide quick response from the compressor unloader mechanism set the oil relief valve to maintain 45 psi 310 27 kPa net oil pressure in the 400 Series Compressors and 65 psi 448 15 kPa net in the 300 Series Compressors Hold net oil pressure between 45 psi 310 27 kPa and 50 psi 344 74 kPa in the 400 Series Compres sors and between 60 psi 143 69 kPa and 70 psi 482 64 kPa in the 300 Series Compres sors NOTE Net oil pressure is calculated by subtracting the compressor suction pressure from the oil pres sure gauge reading while the compressor is running The pressure is regulated by turning the adjusting valve stem See Table 8 for loca tion To raise the oil pressure turn the valve stem to the right or in Turning the valve stem to the left or out decreases the oil pressure TABLE 8 OIL PRESSURE ADJUSTING VALVE LOCATIONS COMPRESSOR VALVE LOCATION Model Rear Bearing Housing 300 Oil Pump Filter End Series Model Front Bearing Housing 400 Drive Seal End Series VMC INSTALLATION 29 CAUTION When the Compressor has completed 24 hours of operation remove and inspect the suction strainer bag This bag is placed in the suction strainer to catch any foreign ma terial present in the system at start up If when the bag is removed and inspected there is an unusual amoun
154. SHAFT ALIGNMENT Move equipment into place Soft Foot The equipment must sit flat on its base Any soft foot muat be corrected now SUGGESTED MAXIMUM ALIGNMENT VALUE TOTAL INDICATOR i dR COUPLING i tala P 50 62 equipment The coupling is capable of approximately four times the above shaft misalignment tolerances However close alignment at Installation will provide longer ANGULAR PARALLEL service with smoother operation 003 VI FINAL ASSEMBLY With the coupling in good alignment the bolts will fit through 75 the holes the flanges and the diac packs 101 more easily 128 A If the coupling arrived assembled the disc packs are still attached to the center ring Before taking the disc packs off first instal one hub bolt through each diac pack and secure with a iocknut This will help when the pack is reinstalled later if the coupling was shipped disassembied the bolt through the pack Is not required as the discs in the pack are factory taped together B Remove the long bolts Mount the disc packs on the hubs with the one bolt D Parallel Offset Rigidly mount dial indicator on one hub or shaft reading the other hub flange outside diameter as shown in Figure 3 Indicator set up sag must be compensated for Rotate both shafts together Adjust the through the disc pack allyned with a clearance hole in the hub install the short bolts through the hub disc pack bevel washer or link and secu
155. Safety Head and Pins Assembly is used on standard Halocarbon and High Suction Pressure Ammonia Compressors High Suction Pressure Compressors are identified with an in the serial number Also used 2 Stage High Side Halo Compressors SECTION 100 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 18 Replaces 450XL VMC COMPRESSORS May 1985 RECOMMENDED SPARE PARTS LIST QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 118 Valve Internal Relief 1 1 1 1 1 1 1721C 217 amp 218 Rotary Shaft Seal Assembly 1 1 1 1 1 1 KT 509 306 Oil Pump Assembly 1 1 1 1 1 1 A33480A 315 Recharge Oil Filter Gasket 1448B included for use with 2046A amp A35241A w o bypass 1 1 1 1 1 1 2115C 315 Recharge Oil Filter Gasket 1448B included for use with A35240A amp 1448J with bypass 1 1 1 1 1 1 1448C 401 Oylinder Liner Assembly Kit Thru for cylinder without unloading 1 1 2 2 2 2 KT475 404 for cylinder without unloading Two Stage d zs 1 1 A35108D 401 Cylinder Liner Assembly Kit Thru for cylinder with unloading 1 1 2 2 2 2 KT476 408 for cylinder with unloading Two Stage 1 1 5108 409 Plate Suction Plate 2 4 6 8 12 16 31909A 413 Capacity Control Assembly Thru Two Cylinder and Two Stage Compressor 1 1 1 41787 420 4 thru 16 Cylinder Compressors 1 1 1 1 1 A41788BX 5
156. Stedy Mount for applications under pressure limitations governed by Codes other than ANSI ASHRAE 15 Safety Code For Mechanical Refrigeration Vilter will be glad to test the Stedy Mount for your specific pressure requirement Installation And Servicing Before installing the Stedy Mount should be checked to make sure the coil spring has not been compressed THE FULL BENEFITS OF STEDY MOUNT IN STALLATION WILL NOT BE ACHIEVED IF THE FITTINGS STRIKE EACH OTHER DURING ERATION It is of extreme importance that the upper and lower coil fittings be separated by a space of Sja when the Stedy Mount stands free before the gauge is screwed into place Since this 5 space is enclosed within the Neo prene damper and is not visible it cannot be meas ured directly However it can be checked by meas uring the overall free length of the unit If the Stedy Mount measures exactly 3 overall the air gap or space between fittings is exactly 5 4 as required there is less than J air gap or free movement the fittings can be pulled apart by hand to slightly overstretch the coil and then compressed again to obtain the required air gap or 3 overall free unit length When heavier gauges are used it may be necessary to slightly increase the air gap by over stretching the coil to allow more than a 7 15 air gap Because periodic recalibration is necessary for all types of pressure gauges it is suggested
157. UR With the hub expanded slide it up the shaft to the desired axial position A pre set axial stop device can be helpful Angular Alignment Rigidiy mount dial Indicator on one hub or shaft reading the face of the other hub fiange as shown In Figure 2 Rotate both shafts together making sure the shaft axial epacing remains constant Adjust the equipment by shimming and or moving that the Indicator reading Is within 002 inch per inch of coupling flange diameter See Chart NOTE DBZ hubs have pressed in bushings Make aure the bushings are facing the disc pack Taper Bore Put the hub on the shaft without key s place Light y tap hub up the shaft with a soft hammer This will assure a metal to metal fit between shaft and hub This is the starting point for the axial draw Record this poaltion between shaft end and hub face with a depth micrometer Mount dial indicator to read hub movement Set the indicator to 0 Remove hub and instal key s Remount hub drawing It up the shaft to the 0 set point Continue to advance hub up the taper to the desired axial position Use the indicator as a guide only A pre set axial stop device can be helpful Check the final results with depth micrometer The hub may have to be heated in order to reach the desired position on the shaft DO NOT SPOT HEAT THE HUB OR DISTORTION MAY OCCUR Install shaft locknut to hold hub In place V
158. Unloading only February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 15 March 1985 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS For All Serial Numbers Unless Otherwise Noted QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 401 402 Cylinder Liner Assembly High Stage amp 403 for cylinder without unloading 2 1 2 2 4 4 8 KT475 401 402 Cylinder Liner Assembly High Stage Thru 408 for cylinder with unloading 1 2 4 4 8 8 476 401A 402 Cylinder Liner Assembly Two Stage 403 amp 408A for cylinder without unloading 2 3 4 6 A35108D 401A 402 Cylinder Liner Assembly Two Stage Thru 408A for cylinder with unloading 4 3 8 6 5108 401 Liner Cylinder High Stage 2 4 6 8 12 16 34510A 401A Liner Cylinder Two Stage us 2 6 ae 12 gt 34710A 402 Seal O Ring upper High Stage amp Two Stage 2 4 6 8 12 16 2176BH 403 Pin Roll 0 125 dia X 177 Ig 8 16 24 32 48 64 1193Q 405 Ring Lift 1 2 4 3 4 8 6 8 35071A 406 Spring Lift 8 16 32 24 32 64 48 64 35069 407 Pin Lift 8 16 32 24 32 64 48 64 35070A 408 Retainer Lift Ring 1 2 4 3 4 8 6 8 1971A 408A Seal O Ring lower Two Stage only 6 12 2176BL 409 Plate Suctio
159. With the flick of a switch oil is delivered from a refinery sealed can into the crankcase at the rate of 1 gallons per minute against a maxi mum discharge pressure of 100 psi At this rate a Vilter reciprocating compressor crankcase can be filled in less than 5 minutes A motor driven pump is mounted on a bracket assembly which enables it to be easily attached to a 5 gallon can of compressor lubricant simply by tightening a thumb screw The bracket is also formed to provide a convenient carrying handle for movement throughout the compressor room Connection to the compressor is just as rapid since a quick coupling two way shul off attachment is VILTER MANUFACTURING CORPORATION 5555 SOUTH PACKARD AVENUE BOX 8904 CUDAHY WISCONSIN 531 10 8904 TELEPHONE 414 744 0111 FAX 414 744 3483 used This means opportunity for oil drips the floor When the coupling is snapped apart both ihe charging hose and the adapter connection in the crankcase are instantly shut off The Viler Motor Driven Oi Charger has been designed to give many years of trouble free service A 1 2 H P 115 volt motor is used to drive the pump on off switch is located in the motor ter minal block and an 8 ft long cord and plug set is furnished The motor can also be supplied for 220 volt operation if desired Suction and discharge hoses are of reinforced Neoprene wilh a working pressure of 125 psi The quick coupler is all steel d
160. a gel desiccant put inside the bag around the motor When the moisture indicator shows the desiccant has lost its effectiveness as by a change in color the bag should be opened and the desiccants replaced with fresh ones Whenever the motor cannot be sealed space heaters must be installed to keep it at least 10 above the ambient temperature NOTE Rodents and other animals like to house inside motors in search of warm surroundings or food Some of them attack the insulating materials Their access to the motor should be restricted 5 Rotate the shaft several revolutions once every month VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor INSTALLATION SECTION TABLE OF CONTENTS PAGE INTRODUCTION DELIVERY INSPECTION LOCATING THE UNIT Drains Ventilation Servicing Space FOUNDATION Ground Floor Installation Upper Floor Installation Type FLS Vibration Isolators KIP C Vibration Isolators FORMS AND TEMPLATES CONSTRUCTION OF REINFORCED CONCRETE PAD CONCRETE 10 SETTING AND LEVELING UNIT ON CONCRETE PAD 10 DIRECT CONNECTION DRIVEN COMPRESSOR UNIT 10 V BELT COMPRESSOR UNIT e 12 V Belt Installation 13 V Belt Adjustment General Comments 13 Single 5V V Belt Adjustment 15 Banded Joined 5V V Belt Adjustment 15 V Belt Removal For Servicing 15 ACCESSORIES AND ASSOCIATED EQUIPMENT 15 Oil Separator 15 General Description 17 Oil Separator
161. agon Lock Nut 3 Suction Valve Spring 4 Valve Washer 4 Safety Head Yoke Valve Spacer 5 Safety Head Spring 4 Diaphragm Discharge Valves 3 5 Roll Pin 4 Safety Head FIGURE 2 UPPER CYLINDER CROSS SECTION 400 Series VMC 2 01 SERVICE 5 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor VALVE WASHER STRAIGHT EDGE GAP ee SPACER 713 DIAPHRAGMS SAFETY HEAD RETAINING SCREW mm FIGURE 3 DISCHARGE DIAPHRAGM VALVE PLACEMENT 400 Series VMC 2 01 SERVICE 6 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 1 440 Compressor Mushroom Style cont d All replacement parts are drilled They are interchangeable with original parts All re placement cylinder line kits have roll pins Discard roll pins if new liner is being used with old safety head and safety head yoke The old style frames have built in guide lugs which serve the same purpose as the roll pins Replace safety springs and cylinder covers on the compressor NOTE Compressors with serial numbers 7000 and higher have 4 holes drilled through the safety head and safety head yoke into the cylinder liner to accommodate roll pins After replacing the cylinder cover return the unloader mechanism to its operating position by removing the metal rod from the hole in the frame This allows the pi
162. ailable for easier assembly This socket is in diameter 274 long and has 3 2 square socket drive The socket is specially made for this type of nut allowing more convenient gripping and tightening of the palnut Order Vilter part number 2040A TORQUE LIMIT ADAPTOR Also available is a torque limit adaptor This lightweight compact rugged and square male drive tool is factory set to a predetermined torque value Use with any socket driving device The adaptor allows the accurate torquing of the plain nut to the specified value in the confined crankcase space One adaptor is needed for each different con necting rod Order by part number listed below Adaptor Part No Drive Overall Dimension Torque Limit Setting Use w Rod 2287A Sla 19 ft Ib 26 Nm A33171A 2287B Vo D 33 ft Ib 45 Nm A31045D 2287B Vo t 33 ft Ib 45 Nm A34762A 400 Series VMC 2 01 SERVICE 91 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 5 FACTORY RUNNING DIMENSIONS TOLERANCES CLEARANCES amp ALLOWABLE WEAR LIMITS FOR 440 450 amp 450XL VMC COMPRESSORS ITEM PART NAME COMPRESSOR DIMENSION TOLERANCE CLEARANCE SIZE 1 Crankshaft Main Brg Journal 2 4 6 8 2 8145 Dia Drive End 8 HD 12 16 3 1895 Dia 450XL ALL Pump End 2 8140 Dia 4 000 0015 001 0000 2 Bearings bis End 2 4 6 8 2 8125 4 0005 8 HD 12 16 3 1875 0000 450XL ALL Pump End ALL 2 8125 4 0005
163. all flywheel grooves will be filled Drive belts should be inspected for abrasion tearing separation or checking that would indicate possible damage to drive compo nents or alignment problems They should 400 Series VMC SERVICE 9 also be inspected for sharp bends and kinks while they are slack as this indicates internal damage due to incorrect installation tech niques The belts can be cleaned at this time Only soap and water should be used to clean the belts and other components Belt dressing should never be used on drive components as it will attack the elastomer used in construction of the belts Belts should always be changed in sets to minimize length variations between used and new belts Note the match numbers on the belts The same number must be on all belts in the set Drive Installation If installation is new and the belts are being installed for the first time the following items must be taken care of before the belts can be installed 2 01 Replaces all Previous Issues 5 VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Drive Installation cont d The compressor motor and base should be level This will help speed the alignment process of the unit if the shafts are level and in the same plane before starting the align ment process All piping must be finished and properly sup ported Any piping stress must not be per mitted to act on the compressor frame The base must
164. alve to maintain a 110 to 125 F crankcase oil temperature 2 Maximum crankcase oil temperature is 150 F 3 Maximum water inlet temperature is 80 F 4 Maximum water flow is 4 GPM FIGURE 20 450XL WATER MODULATING VALVE CONNECTIONS VMC 2 01 OPERATION 28 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MuttiCylinder Compressor TABLE 3 320 340 350ES VMC COMPRESSOR MAXIMUM LIMITS Suction Superheat 25 Discharge Pressure 350 PSIG 3 9 C 2413 18 kPa Compression Ratio 12 1 R22 Suction Pressure 85 PSIG 586 06 kPa Pressure Differential 300 PSIG Oil Temperature 150 F 2068 44 kPa 65 5 Discharge Temperature Direct Dive Motor Horsepower 111 85 kW V BELT DRIVE HORSEPOWER LIMITS RAD S RAD S kW 40 1750 1055 323 328 183 23 rad s 110 46 rad s 28 83 kW 1435 60 844 30 150 24 rad s 88 37 rad s 22 37 kW 50 30 NOTES Recommended operating oil temperature is 100 F to 130 F 37 8 F to 54 4 F Operating at or near maximum oil temperature could result in excessive wear Increase 15 when shot peened crankshaft is ordered VMC 2 01 OPERATION 29 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 4 440 VMC COMPRESSOR MAXIMUM LIMITS Suction Superheat 25 F 3 9 C 12 1 R22 Discharge Pressure 350 PSIG 2413 18 kPa 150 PSIG 1034 22 kPa 150 F Compression Ratio Suction Pres
165. ame symbol on Page 17 See Pages 25 and 26 for illustration 1 Refer to Home Office for compressor with serial numbers below 150 SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 19 Replaces 440 VMC COMPRESSORS March 1975 CAPACITY CONTROL MECHANISM ASSEMBLY t REPLACEMENT PARTS Version used beginning with Serial Number 32 500 for Gas Unloading 22 800 for Oil Unloading FIGURE 9 T Patents Pending QUANTITY REQUIRED PER COMPRESSOR PART ITEM DESCRIPTION NUMBER OF CYLINDERS NUMBER 2 4 6 8 12 16 410 amp Piston amp Rings Assy Cap Red 1 1 2 3 2 4 6 4 A35315BX 411 Gas or Oil A35315CX 410 Ring Set PTFE and rubber 1 1 2 3 2 4 6 4 2557A 411 Piston Unloader Gas or Oil 1 1 2 3 2 4 6 4 Order Assy 413 Complete Cap Control Mech Assy Thru Standard Single Cylinder 1 3 6 A41787AX 420 Standard Double Cylinder 1 2 2 4 4 A41788BX High Suction Single Cylinder 1 3 E 6 ne A35305AX High Suction Double Cylinder st 1 2 2 4 4 A35304AX 413 Arm Yoke Lifting 1 1 2 3 2 4 6 4 41725A 414 Yoke Assy Standard Single Cylinder 1 3 6 575 414 Yoke Assy Standard Double Cylinder 1 2 2 4 4 A33335A 414 Yoke Assy High Suct Single Cylinder 1 3 6 5247 414 Yoke Assy High Suct Double Cylinder ae 1 2 2 4 4 A33335A 415 Pin g Ig Roll 1 1 2 3
166. amount of refrig erant Unlike high side charging where re frigerant is added as a liquid in low side charging refrigerant enters as a gas This method is relatively slow To charge refrig erant into the low side use the following procedure a Keep the refrigerant drum in an upright position Close the valve to the suction gauge and remove the line to the suc tion valve Attach a tee to the valve and reconnect the gauge to the tee Connect the charging line following all applicable safety and venting law pro cedures b To charge gas into the compressor throttle the valve to create a lower pressure in the compressor Open the drum valve marked Vapor if drum is equipped with two valves Then open the gauge valve and refrig erant will draw out of the drum and into the compressor FOR HALOCARBON UNITS ONLY During the charging process the drum may get too cold This prevents gas from boiling off fast enough Heat can be applied to the drum Place the drum in a pail of warm water not exceeding 125 F 51 7 C or wrap the drum in bur lap and pour hot water on it 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 2 Low Side Charging Adding Refrigerant To Operating System cont d CAUTION Direct flame or steam must NEVER be ap plied directly to the drum as this can pro duce dangerous pressures in the drum c Check the sight glass du
167. and High Suction Pressure Ammonia Compressors High Suction Pressure Compressors are identified with an X in the serial number Also used in 2 Stage High Side Halo Compressors Items should be selected for each individual compressor as they February 2001 VILTER MANUFACTURING CORPORATION SECTION 102 R Replaces PAGE 1 April 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty REPLACEMENT PARTS LIST NOTE Parts applying only to certain models are indicated throughout the parts list TABLE OF CONTENTS PAGE 1 REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS 2 Illustration 2 Cylinder Figure 1 3 Illustration 4 6 amp 8 Cylinder Figure 2 4 Illustration 12 amp 16 Cylinder Figure 3 5 Parts List DISCHARGE SUCTION GAUGE 7 Illustration Figure 4 8 Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 9 Illustration Figure 5 10 Parts List REAR BEARING COVER REPLACEMENT PARTS 12 Illustration Figure 6 13 Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 14 Illustration Figure 7 15 Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 16 Illustration Figure 8 17 Parts List CAPACITY CONTROL MECHANISM REPLACEMENT PARTS 18 Illustration Figure 9 18 Parts List 19 RECOMMENDED SPARE PARTS REPLACEMENT PARTS ORDERING INSTRUCTIONS 1 Give the size and speed of the compressor as well as serial number and refrigerant used The serial
168. and lines before connecting the pressure control 2 Connect the oil pressure line pump discharge to the pressure connector labeled OIL 3 Connect the crankcase pressure line to the pressure connector labeled LOW 4 Coil and secure excess capillary or tubing to avoid vibration Wiring A WARNING Shock hazard Disconnect all power supplies before making wiring connections to avoid electrical shock or damage to the equipment e Make all wiring connections using copper conductors only e Wire in accordance with National Electric Code and local regulations For maximum electrical rating of the control see the label inside the control cover e Use the terminal screws furnished 8 32 x 1 4 in binder head Substitution of other screws may cause faulty connections P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin See Figures 3 through 10 for typical wiring diagrams or refer to the compressor manufacturer s specifications When the P28 or P128 control is supplied with a Terminal 3 it may be wired to operate a runlight for indicating when there is sufficient net oil pressure When the control is supplied with a Terminal A it can be wired to operate a shutdown alarm or signal for indicating when the compressor has tripped For applications using a 208V control circuit it is suggested that one leg of the 208V circuit anda neutral or ground wire be us
169. atch flats in pump drive key The locating dowel pin in the rear housing should align with hole in the pump hous ing to the top left center Install the pump and seat it against the inner gasket The outer surface of the pump should now be recessed approximately 3 175 mm to the rear bearing housing Install gasket Vilter Part No 31900A correctly aligning the holes The slot in this gasket should be at the 9 o clock position Place the rubber seal gasket on the filter adapter and reattach the filter assembly onto the rear housing Install screws and tighten down evenly 400 Series VMC SERVICE 18 Before proceeding refer to Paragraph I General Service Instructions A Handhole Cover Removal To work internally on the compressor the hand hole cover and crankcase oil will have to be re moved to gain access The heater will have to be electrically disconnected at this time Re member to shut the power off and lock it out After disconnecting the wiring loosen all but two screws on the upper corners of the cover This helps support the cover during removal and pre vents damaging the heater If the cover sticks to the frame a slight tap with a lead or soft face hammer will free it Holding the cover in place remove the two re maining screws and pull the cover straight back away from the frame Remove any gasket mate rial from the cover and frame face Also inspect and remove any bu
170. ating compressors as well as Vilter Single Screw and Twin Screw compressors in fact for any refrigeration compressor with a closed crankcasc Ii can also be uscd for other applications such as adding oil to the seal chamber on liquid pumps Multiple compressor installations arc no problem since extra adapters are available For Easy Adding Crankcase Oil Use The Vilter Oil Charger It s Ideal For Reciprocating And Screw Compressors It takes only a few seconds to make the coupler connections and begin pumping The oil charger is suitable for reciprocating and rotary screw compressors The Vilter Oil Charger offers many outstanding con struction features The cylinder is made of steel hydraulic fluid line tubing for easier pumping and no oil leakage The two plunger cups are of die formed Neoprene and fit the cylinder exactly for high pres sure pumping The hose is of reinforced Neoprene with a working pressure of 125 psi The quick cou pler is all steel not brass and designed for refrigera tion service The check valvcs are also of all steel construclion In short each eomponent is designed for easy operation and a long working life The Vilter Oii Charger can make your job a lot easier so call your nearby Vilter District Office or Distributor today See Back Side For Information On Vilter s Motor Driven Oil Charger VILTER Since 1867 har Se 1 gallons 9 ankcase Oil a min te
171. banks un loaded With an increase in suction pressure to 22 psig 151 69 kPa control D of compressor 2 loads a cylinder bank A nse to 23 psig 158 58 kPa loads bank 2 of compressor 1 As pressure rises to 24 psig 165 48 kPa bank 1 of compressor 1 loads At this point both com pressors are operating at full capacity A load decrease reduces the capacity of each compressor inversely Bank 1 compressor 1 unioads at 20 psig 137 9 kPa bank 1 compressor 2 unloads at 19 psig 131 00 kPa bank 2 compressor 1 at 18 psig VMC OPERATION 124 11 kPa and bank 2 compressor 2 at 27 psig 186 16 kPa If suction pressure drops below 16 psig 110 32 kPa compressor 1 shuts down if suction pressure drops below 15 psig 103 42 kPa compressor 2 shuts down C Two Stage Compressor System 400 Se ries Only Two stage compressors are supplied as stan dard without capacity reduction but 5096 ca pacity reduction is available as an option This is available for both the six cylinder and twelve cylinder models On the six cylinder compressor two low stage booster cylinders and one high stage cylinder are unloaded and on the twelve cylinder com pressor four low stage booster cylinders and two high stage cylinders are unloaded Both three way solenoid valves used for high stage unloading and for low stage booster unloading are wired in parallel so both the low stage booster and high stage are loaded and unloaded si
172. bruary 2001 Replaces March 1975 1200 RPM HIGH STAGE AND TWO STAGE COMPRESSORS Serial Number 3638 to as indicated NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 401 Cylinder Liner Kit w Unload Std 1 2 4 4 8 8 3638 Present KT072 Thru Cylinder Liner Assy w Unload Hi Suct 2 4 4 8 8 3638 Present A31194B 406 Cylinder Liner Kit w Unloading 3 6 3638 14203 KT072 Cylinder Liner Assy w Unloading ef me 3 6 14204 Present A33179B 401 Cylinder Liner Kit w o Unloading 2 2 2 4 4 8 3638 Present 071 Thru Cylinder Liner Kit w o Unloading 6 12 3638 14203 KT071 402A Cylinder Liner Kit w o Unloading 3 6 3638 14203 KTO71 Oylinder Liner Kit w o Unloading 1 3638 Present KT071 401 Cylinder Liner Assy w o Unloading 6 12 14204 Present A33179A Thru Cylinder Liner Assy w o Unloading 3 6 14204 Present A33179A 402B 401 Liner Cylinder 2 4 6 8 12 16 e 3638 Present 32687A 401 Liner Cylinder s 6 12 3638 14203 32687A 401 Liner Cylinder zm zz 6 12 14204 Present 33179A 402 Seal O Ring Upper 2 4 6 8 12 16 6 12 3638 Present 2176BH 402A P
173. cal 0003 5 Piston 4 4955 000 001 l 001 6 Cylinder Bore ALL 4 500 001 005 005 5 9965 5 9955 None 6 000 001 000 400 Series VMC 2 01 SERVICE 33 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 5 FACTORY RUNNING DIMENSIONS TOLERANCES CLEARANCES amp ALLOWABLE WEAR LIMITS FOR 440 450 amp 450XL VMC COMPRESSORS cont d MAXIMUM ITEM PART NAME COMPRESSOR DIMENSION TOLERANCE CLEARANCE ALLOWABLE SIZE WEAR 5 Piston Pin Bore ALL 1 14250 Finger Drops Except 450XL 1 1248 0002 Tight thru Dry 450XL 1124 Tight ALL 1 1238 0003 0007 None 0012 Pin Dia ALL 1 1250 4 0000 See Above 0005 0002 Pin Bore Connecting Rod 1427 0004 Pin Bushing I D ALL L H8 1254 0003 to 001 0009 Rings Piston 013 025 025 Compression 4 500 Bore Oil Solid 025 Oil Flex Oil Rails ALL 002 004 002 In Oil Solid Piston 002 Oil Flex Groove With Rails Suction Valve Thickness 061 003 None None 6 Cylinder T None Valve Seat 010 None Lapped Height phe Flat to Seat To Top of Liner 134 002 None None To Lapped 132 Flat to Seat Piston Top to Bottom 035 023 012 Must be Of Safety Head ALL L gt 2 Measured Minimum 010 Dimension does not apply to assembled 450XL piston on connecting rod piston shrink fit to wrist pin
174. capacity It is best to have reduced the pressure to 2 psig 13 79 kPa to minimize the amount of foaming After the compressor has been serviced do not reuse this oil Even reconditioned oil contains contaminates that could cause compressor damage C Preparation Of Compressor For Initial Start After Servicing Vilter recommends charging 1 to 2 gallons of fresh oil into the compressor via the oil pressure gauge port in the front housing This eliminates dry start up by forcing oil into the passageways in the crankshaft to the connecting rods and having a good supply of oil for the shaft seal Add oil to crankcase via drain valve to within 1 2 of the sight glass in the handhole cover Connect power to the crankcase heater close all open valves and check for leaks When oil has reached approximately 100 F 37 8 C start the compressor and allow it to pull the load down gradually Run the compressor for a few minutes then stop for a cooling off period Restart and run for a longer time Stop and allow for a cooling off period again 400 Series VMC SERVICE 2 Lengthen each running period until it is deter mined no moving parts are heating up exces sively When the compressor operates with normal run ning temperatures allow it to run for whatever length of time the load requires With new or re placement compressors the suction bag should be removed after running for 24 hours ll CYLINDER COVERS
175. d connecting rods Examine each of the oil pas sages to the connecting rods Inspect the con necting rod bearings The preceding instructions enable a me chanic technician to flush the shaft and pas sages on the 2 through 8 cylinder machines and the drive end of the 12 and 16 cylinder ma chines In order to flush the pump end of the shaft on the 12 and 16 cylinder machines re move the connection to the center bearing and connect the pump there Perform the flushing procedures in the same manner for this end of the shaft as for the other end After the passages are flushed open the con nection on the bottom of the seal chamber and drain the flushing fluid out Drain solvent from the crankcase and the interior surfaces of the machine Replace the pipe fitting in the bottom of the seal chamber and fill the chamber with clean oil Be sure to pump in enough oil to fill the passages in the crankshaft Follow the pro cedure found in Paragraph XVI Remove the pump and replace the fitting in the top of the seal chamber Replace the crankcase cover and charge the machine with clean oil H Crankshaft Seal Oil Leakage 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor In refrigeration compressors a slight amount of oil leakage past the crankshaft seal is normal and acceptable It lubricates the bellows and o rings and cools mating rotating parts to provide less wear and longer
176. d not the entire rod 1 440 amp 450 VMC Compressors Only To remove the rod from the piston take out the piston pins Remove the spring locks from the pin hole on each side of the piston and slide out the pins If this cannot be ac complished by hand it may be necessary to force the pin out with a brass rod and ham mer Be careful not to damage spring lock grooves To remove the piston rings use the ring expander Caution should be exer cised to prevent the rings from scoring the piston 400 Series VMC SERVICE 20 2 450XL Compressor Only If the piston rings to be removed wrap piece of thin shim stock around the piston Work the rings carefully out of their grooves and onto the shim stock They can then be worked down over the piston Caution must be exercised to prevent breaking the rings The piston and connecting rod assembly should not be disassembled further It is furnished only as a complete assembly and should not be worked on in the field B Reassembly All new compressors use three compression rings and one oil control ring When replacing rings use the ring expander Check the grooves to make sure they are clean FIGURE 10 PISTON RING COMPRESSING TOOL 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Reassembly cont d The easiest way to replace the rings on the pis ton is to wrap a thin piece of shim stock ar
177. d to pump air Serious overheating and damage could result Test pressures for various refrigerants are listed in ASHRAE Standard 15 Code brochure enti tled Safety Code For Mechanical Refrigera tion These pressures usually suffice Re search local codes and ordinances before test ing begins Determine the system tolerances for safety de vices and relief valves If the test pressure ex ceeds system tolerances then remove valves and the appropriate devices Plug all connections All valves should be open except those leading to the atmosphere Manually open all solenoids and pressure regulators Open all bypass devices and proceed with testing VMC INSTALLATION 22 Because of differences in characteristics of various refrigerants two different testing meth ods are necessary A Ammonia Systems Dry nitrogen may be used to raise the pressure in an ammonia system to the proper level for the test The gas may be put into the system through the charging valve or any other suitable opening Carbon Dioxide should NOT be used as a test ing gas in a system in which ammonia is al ready dissolved in any moisture remaining This will cause ammonium carbonate to precipi tate when the CO is added If heavy enough this precipitate may cause the machine to freeze and clog the strainers mixture of four parts water to one part liquid soap with a few drops of glycerin added makes a good testing
178. des of the bottom plate on the mechanism aligned between the lower liner bores 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor IX OIL PUMP ASSEMBLY NOTE Before proceeding refer to Paragraph General Service Instructions X PREPARATION FOR INTERNAL SERVICING A Removal To remove the oil pump assembly first remove the filter tank and adapter from the rear housing Be prepared for a small amount of oil to drain from adapter The pump will be exposed in the center and the outer pump housing will be cov ered by a gasket Remove gasket At the top right and bottom left you will find tapped holes to aid in removing the pump if necessary The pump housing is approximately 1 38 1 mm thick so it requires jack screws 2 50 8 mm or longer to release the inner gasket Once loose pull the oil pump straight back The oil pump is a factory built and tested compo nent It is furnished as a complete assembly only and cannot be serviced in the field B Replacement To replace the oil pump assembly first rotate the crankshaft so the drive key is hanging from one of four screws through the rear bearing retainer Make sure the small orifice plug in the rear hous ing at the 12 o clock position is clear Clean all gasket surfaces Install gasket Vilter Part No 31899A correctly aligning oil passage holes Align pump shaft flats to m
179. ding point on com pressor FIGURE 3 AUTOMATIC CONTROL CONNECTIONS TYPICAL SCHEMATIC VMC 2 01 OPERATION 11 REPLACES ALL PREVIOUS ISSUES NOTES Number within a circle indicates arrangement sequence of connecting rods on crankshaft counting from com pressor pump end Also used to designate cylinder location When solenoid valves are energized the compressor is unloaded When solenoid valves are de energized the compressor is loaded oil flow direction A B C VMC OPERATION From Oil Crankcase Pump Gauge To Oil Pressure Failure To Oil Failure VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 6 CYLINDER COMPRESSOR WITH 50 CAPACITY REDUCTION OPTION 3 Way Solenoid SVU 1 3 Way Solenoid Valve SVU 2 Pressure Pump Gauge Crankcase Pressure ange To Oil Pump Switch Failure Switch 12 CYLINDER COMPRESSOR WITH 50 CAPACITY REDUCTION OPTION 3 Way Solenoid Valve svu 2 Stage Suction 3 Way Solenoid Valve svu 1 FIGURE 4 SCHEMATIC CAPACITY REDUCTION CONNECTIONS AND UNLOADER MECHANISM ARRANGEMENT TWO STAGE COMPRESSOR ONLY 2101 12 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor KEY TO SCHEMATIC Number indicates arrangement Donates double cylinder of connecting rads unioading mechaniam for a on crankshaft countng from particular cyl
180. e All Vilter shell and tube oil coolers are de signed for 300 psig 2068 44 kPa on both the oil and water sides Inspection Because water contains a variety of chemi cals in solution and the water side of the cooler is continually exposed to those chemicals inspect the condition of the VMC INSTALLATION tubes frequently Inspect the tube side for any evidence of corrosion scaling or other fouling If there is evidence of these prob lems take steps to correct them immedi ately 19 NOTE Because Vilter has no control over field condi tions of cooling water Vilter cannot assume li ability for damage to the compressor or the sys tem due to problems arising from corrosion scaling or fouling Service Temperature Control The function of the oil cooler is to maintain specified oil temperatures When the tem perature of the oil rises above normal it is an indication some part of the temperature control system is not functioning properly or a system or mechanical problem in the compressor Inspect all manual and auto matic control valves in the system for cor rect operation Check all pressure gauges and thermostats Inspect the water level to make sure proper flow through the cooler has been provided Clean all strainers Disassembly and Cleaning If the temperature does not return to nor mal after adjustments are made and the specified amount of cooling water is circu latin
181. e reset will not permit restart until reset button is pushed and released The operation point of the control is readily adjusted by rotating the adjusting disk The control set points are easily read ona calibrated scale 2 P74 Product Bulletin Electrical Ratings P74AA P74AB P74BA 1 Phase Motor Ratings 120 V 208 V 240 V 277 V AC Full Load Amp 20 0 18 7 17 0 AC Locked Rotor Amp 120 0 112 2 102 0 AC Non Inductive Amp 22 0 22 0 22 0 Filot Duty 125 VA 120 to 600 VAC 57 5 VA 120 ta 300 VDC P74CA P74CB P74DA P74DB 1 Phase Polyphase 120 V 208 V 240V 277V 208 V 240 V Motor Ratings Horsepower 2 a 3 5 5 AC Full Load Amp 24 0 187 17 0 165 15 6 AC Locked Rotor Amp 144 0 1122 102 0 99 0 90 0 AC Non Inductive Amp 24 0 24 0 24 0 22 0 Pilot Duty 125 VA 120 to 660 VAC 57 5 V 120 to 300 VDC P74EA Motor Ratings 120 V 208 V 240 V 277 V AC Full Load Amp 16 0 9 2 8 0 AC Locked Rotor Amp 96 0 55 2 48 0 AC Non Inductive Amp 16 0 16 0 16 0 16 0 Pilot Duty 125 VA 120 to 600 VAC P7AFA Motor Ratings 120 V 208 V 240 V 277 V AC Full Load Amp 6 0 3 4 3 0 AC Locked Hotor Amp 36 0 20 4 18 0 AC Non Inductive Amp 10 0 10 0 16 0 10 0 Pitot Duty 125 VA 120 to 277 VAC P74HA Pole Number Motor Rating LINE M2 Main LINE M1 Auxiliary 120 V 208 V 240 V 277V 120 V 208 V 240 V 277 V 180 92 AC Full Load
182. e break the vacuum and bring the system pressure up to 0 psig 0 kPa with dry nitrogen To begin the second evacuation allow the pump to operate and reduce the pressure again to within 50 to 1000 microns After this reading is reached allow the pump to operate 2 or 3 hours stop the pump and let the system stand with this vacuum and again with dry nitrogen raise the system pressure to zero D Evacuating The System cont d 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor For the third evacuation follow the previous procedure with the pump operating until system pressure is reduced below the 1000 micron level Run the pump an additional 6 hours and hold the system for approximately 12 hours at low pressure After this again break the vac uum with dry nitrogen and allow the pressure in the system to rise slightly above zero pounds psig Install new drier cartridges and moisture indicators Evacuate the system once more below the 1000 micron level and charge with refrigerant designed for the system When properly evacuating the system as out lined above the system is dry oxygen free and free of non condensibles The piping should not be insulated before the evacuation process is started If moisture is in the system before evacuation it will condense in low places and freeze If this happens it can be removed by gently heating the trap farthest away from the vacuum pu
183. e 8 pins and springs can be removed from the liner Reverse the procedure to install a lift ring assembly on any 450 450XL liner 400 Series VMC SERVICE 24 B Installation Of Liners Before the liner is installed make sure the outer surface of the liner is clean and the seat area in the frame is free of foreign matter If a new o ring is required lubricate the o ring and frame seating area with refrigeration oil Slide the liner into the frame and align with the bore Roll pin on the top of the liner can be orientated so if an imaginary line is drawn to opposite pins it forms the letter X Seat the liner in the frame recess firmly by use of Vilter Cylinder Liner Tool Vilter Part No 33464A similar tool can be con structed Be sure to protect the liner lapped seats to prevent damage Hardwood Gasket FIGURE 14 CYLINDER LINER ASSEMBLY TOOL 4 716 Dia Plate a FIGURE 15 CYLINDER LINER REMOVAL TOOL XIV CRANKSHAFT 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A General Removing the crankshaft from the compressor is basically the same for all units regardless of size Because of a center bearing on all 12 and 16 cylinder compressors and the radius the 8 cyl inder throws on the crankshaft an extra step must be taken A crankshaft may be removed from either end of the compressor It is how ever easier to take the crankshaft out
184. e Location 20 10 Piston Ring Compressing Tool 21 11 Front Cover Assembly And Disassembly Tool 22 12 Crankshaft Seal Assembly 23 13 Piston Ring Dimensions 24 14 Cylinder Liner Assembly Tool 25 15 Cylinder Liner Removal Tool 27 16 Retainer Partial Vertical Cross Section 36 17 Typical 400 Series Compressor Vertical Cross section And Lubrication System PAGE TABLE 23 1 Piston Ring Dimensions And Tolerances 28 2 Torque Specifications VMC Model 440 29 3 Torque Specifications VMC Model 450 30 4 Torque Specifications VMC Model 450XL 32 5 Factory Running Dimensions Tolerances Clearances amp Allowable Wear Limits For 440 450 amp 450XL VMC Compressors VMC 2 01 SERVICE REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor l GENERAL SERVICE INSTRUCTIONS A General Comments When working on the compressor care must be taken to ensure contaminants such as water from melting ice or snow dirt and dust DO NOT enter the compressor while it is being serviced It is essential that all dust oil or ice that has accu mulated on the outside of the compressor be re moved before servicing All gaskets o rings roll pins and lock washers must be replaced when servicing and reassem bling the compressor As an aid in servicing compressors a tool kit is available and can be ordered as Vilter Part No KT067 This kit includes necessary wrenches as well as all the servicing t
185. e compressor trial run VMC INSTALLATION 21 XIII ELECTRICAL SPECIFICATIONS EQUIPMENT AND Electric solenoid valves for liquid and solenoid lines used in automatic refrigeration systems should always be mounted outside of the refrig erated room if possible in all installations If it is impossible to mount the electric valves out side the low temperature room mount the valves so no moisture drips into them during defrosting periods or any other time In fresh produce or banana storage rooms consider able moisture is always present in the air Un der no circumstances should electrical equip ment be mounted in the room or difficulties will be experienced within a short time in electrical wiring as well as control devices Mount thermostats outside of the refrigerated room Only the remote bulb of the temperature controller is in the refrigerated space For proper electrical connections color code all control circuits All wires common to the same control wire starting from the motor starter should be the same color Where a tempera ture difference exists between various rooms in which the electric wiring is run make provision for sealing off the conduits between such rooms This is necessary to prevent condensa tion forming in the lower temperature room Connect control devices such as electric valves pressure switches and thermostats with flexible conduit or BX armored cable accord ing to local el
186. e manner and the water will absorb the rest of the ammonia Do not leave hoses in the water if work has to stop and the frame is still warm Cooling of the frame could siphon water back into the frame through the hose Halocarbon Refrigerant Compressor The procedure for removing halocarbon re frigerant from a compressor is NOT the same as described for an ammonia com pressor To evacuate a compressor using halocarbon refrigerant employ certified technicians to pump down the unit according to applicable laws and ordinances When the unit is pumped down the tempera ture of the machine drops Before opening the machine allow it to warm up to room temperature Opening the machine before it is warmed up produces condensation on the metal surfaces Moisture is detrimental to compressor operation It leads to system operating difficulties and rusting of parts 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 3 Compressor Oil Removal If service will be performed on unloader so lenoids oil filter change suction or dis charge valves or crankshaft seal the oil will not require removal If it becomes necessary to open the crankcase disconnect power to the heater and remove oil through the drain valve If a slight positive pressure is allowed to re main in the crankcase before compressor is opened it will force the oil from the drain valve into a container of sufficient
187. e net oil pres sure in excess of 45 pounds net to provide quick response of the unloader arrangement C 1 Stage Oil Drain Arrangement Two Stage Compressors Only During compressor operation any oil return with the suction gas usually accumulates in the 1 low stage suction manifold Oil is drained automatically and returned to the compressor crankcase as follows As the oil settles in the suction manifolds of the two outside banks of the compressor it drains by gravity through a check valve into the oil reservoir The equalizing line between the oii reservoir and 1 low stage suction is open through the three way solenoid valve When the oil level rises in the oil reservoir to the ac tuating level of the oil float switch the solenoid valve is made to change ports This action causes the oil reservoir s 1 low stage suction equalizing line to close and the line between the high stage discharge and oil reservoir to open Simultaneously the timer is energized The discharge gas pushes the oil out of the reservoir through a check valve and into the compressor crankcase At the end of the time cycle the solenoid valve reverts to the original position to aliow for draining from the low stage suction 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor D 1 Stage Oil Drain Arrangement Two Stage Compressors Only cont d The cycle is continuously repeated as
188. e systems One set of contacts breaks the hot line when wired as a two pole switch in single phase 1 5 m Increments Open On Rise Close On Rise SPDT As Required Snap Acting High Contact Force Right Up to Contact Break Point No Bounce Beryllium Copper Conductor Leaves with Silver Cadmium Oxide Contacts circuits Contact Action Permits control of two Contact Unit separate load circuits Finish Sea Automatic control of heavy ase 6 mm Cold Rolled Stee i electrical loads Material Cover 0 028 0 7 mm Cold Rolled Steel Holes in Back of Case or with Part No 271 350 e All A70 A72 controls have a Mounting Mounting Bracket Controls Supplied Less Bracket Unless Specified single calibrated scale which shows directly both cut in and Shipping Weights With Knob 2516 1 1 kg cutout settings Adjustments Approx Overpack 4916 22 2 kg can be made readily without of 20 removing the cover Weights will vary somewhat depending on construction features supplied type of element etc Less Knob 2 416 1 1 kg 1996 Johnson Controls Inc 1 Code No LIT 125155 Optional Constructions Adjusting Knobs May be supplied on differential or range adjusting screw for limited adjustment within specified limits Adjustment Cutout Stops Cutout stops factory set as specified Bulb and Capillary Standard bulb and capillary are copper Stainles
189. e valve stem fully back seated the valve disc is lifted slightly allowing flow in either direction Installation The new design will apply only to the 2 thru 4 stop valves Retrofitting a field installation will require replacing the bonnet assembly The bonnet must be installed with the spring towards the bottom see illustrations above The drill fixture is designed so that the hole for the spring will always be drilled on the opposite side from the cast in Vilter name on the bonnet From the outside of the valve the casting numbers must always be towards the top of the valve VILTER MANUFACTURING CORPORATION VILTER STEDY MOUNT New improved all stainless steel Pulse Control model _ NEOPRENFE DAMPER p sug US PAIENI NO 8 915 UUN Temperature And Pressure Application Range Stedy Mounts are factory tested for service within an ambient temperature range of 50 F to 150 F and are suitable for system temperatures up to 300 F and system pressures up to 300 psig For applications from 300 to 7000 psig consult the Vilter Home Office If you want to use the
190. eck Valve INTRODUCTION The HCK4 series of dependable compact rugged in line check valves disc type non return valves is ideally suited for refrigerant flow control applications Valves open wide for flow in the arrow direction on the valve body Valves close quickly and reliably when flow reversals occur Plated bodies and stainless steel seat discs and springs enable them to withstand expected industrial refrigeration conditions Furthermore these check valves can be mounted in any position close coupled to other valves and use same flanges as Parker R S Frick and Henry ADVANTAGES These compact check valves offer reliable operation regardless of position Corrosion resistant stainless steel seat disc Metal to metal seats facilitate durable tight closing of valves APPLICATIONS These in line check valves are designed to provide refrigerant flow control to hot gas lines liquid lines compressor discharge lines suction lines and hot gas heated drain pans These valves are not recommended for use with pulsating loads such as low speed compressor discharge and screw compressor side port applications For applications such as these use Hansen HCK1 piston type check valves Bulletin C401d March 2002 Specifications Applications Service Instructions amp Parts HCK4 IN LINE CHECK VALVES 5 thru 4 PORT 16 thru 100 mm Flanged 3 s thru 4 FPT SW WN ODS for refrigerants KEY FEATURES STAINL
191. ectrical code These flexible con nections permit the device removal with no diffi culty Locate these devices with sufficient head room to permit removal from the piping lines The wiring diagram shown in this manual is only a typical schematic It is necessary for the elec trical contractor to make additions as required for construction purposes when meeting local code requirements 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor XIV TESTING REFRIGERATION SYSTEM FOR LEAKS Before proceeding with testing the system for leaks or evacuation of the system please re view all local laws and ordinances for informa tion on the specific refrigerant used Vilter equipment is factory tested for leaks Af ter the equipment is leak free the unit is charged slightly above atmospheric pressure with a holding charge of nitrogen This pre vents impurities from entering the equipment during shipment Upon receipt of the equip ment thoroughly check to see if a leak has de veloped If a leak has developed it should be repaired tested evacuated and charged as described on the following pages One of the most important steps in installing a refrigeration system is testing for leaks Testing ensures a tight system which will operate with out loss of refrigerant To test for leaks pres surize the system Do not use the compressor to build pressure as the compressor is not de signe
192. ed as a 120V source to power the time delay relay Table 2 Electrical Ratings Pilot Duty When a P28 or P128 is installed on a 440 or 550 VAC system use an external step down transformer to provide either 120 or 240V to the pilot and time delay relay circuits The transformer must be of sufficient volt ampere capacity to operate the motor starter and the time delay relay Table 1 presents the power requirements for the P28 or P128 time delay relay Table 2 presents the electrical ratings Table 1 Electrical Power Required for Time Delay Relay Voltage Timing inSeconds 12 24 or 120V 240V Time Delay Relay Pilot Circuit Alarm Circuit Crankcase Heater Runlight Circuit Terminal 1 Terminal 3 120 240 VAC 750 VA 120 240 VAC 10W Tungsten 120 240 VAC 10 Ampere 120 VAC 10W Tungsten 5 Ampere 240 VAC 24 VAC VDC 125 VA 24 VAC 125 VA 24 VAC 10W Tungsten 12 VAC VDC 57 5 VA 24 VDC 57 5 VA 24 VDC Must be the same voltage as the pilot circuit Must be the same voltage as the time delay relay circuit PC Pressure actuated contacts Open on increase in pressure difference between oil and low pressure conntectors Makes and breaks time delay heater circuit PC Contacts close simultaneously when PC contacts open runlight circuit TD Time delay relay Contacts open after time delay interval if pressure dfference between oil and low pressure connectors is not established or maintained TD
193. ed previously and replace the handhole cover Electrode Location 1 2 FIGURE 9 SHELL amp TUBE OIL COOLER Refill the crankcase with oil and return the compressor to service The 300 Series Com pressor crankcase with factory installed heater is installed in a well on the drive side of the VMC INSTALLATION 2 01 18 REPLACES ALL PREVIOUS ISSUES 1 TABLE 5 VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Introduction cont d STANDARD OIL COOLER APPLICATION CYLINDERS QUANTITY OIL COOLER NOMINAL OF OVERALL DIMENSIONS 300 SERIES 3 thru 8 3 20 76 2 mm 508 mm 400 SERIES 4721 20 508 mm 2 and 16 Installation Strainers and Filter Vilter recommends the use of strainers when foreign matter is present in the water Certain types of service require suitable fil ters to maintain standard efficiency Piping Layouts All water piping leading into the oil cooler should be of sufficient size to assure an adequate supply of water Zinc Electrodes All coolers designed for marine service are provided with one or more zinc electrodes Make sure all required electrodes are in stalled in the oil cooler prior to placing in service Prevention of Gasket Leaks Check all bolts for tightness before install ing any oil cooler Use caution when tight ening bolts to prevent gasket surface dam age Operating Pressur
194. elay if required Checkout Procedure Before leaving the installation observe at least three complete operating cycles to be sure that all components are functioning correctly Fungus Proofing Fungus proofing can be supplied at extra cost when specified Conforms to government specifications MIL V 173A R epairs and Replacement Field repairs must not be made except for replacement of the time delay relay assembly For a replacement control or time delay relay assembly contact the nearest Johnson Controls representative or Refrigeration Application Engineering at 414 274 5535 Table 3 Replacement Time Delay Relay Assemblies Part Number Voltage Reset Type Timing in Seconds Alarm Circuit mavas vanzaovac 9 O o e menn oova o wo avasin P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin 7 Ordering Information Table 4 Ordering Information Series Part Pressure Reset Type Refrigerant Time Delay Alarm Runlight Number Connections Relay Voltage Terminal Terminal P28AA Style 13 Style 5 Manual Non corrosive 120 240 VAC No or Style 15 All range P128AA Style 5 Manual Non corrosive 120 240 VAC All range P28AN Style 15 120 240 VAC 1 0 P28DA Style 13 Manual Non corrosive 120 240 VAC All range P28DN Style 15 120 240 VAC ves _ 28 Style 13 Automatic Non corrosive 120 240 VAC All range P28N
195. elts to be removed from the drive without having to pry or roll the belts off If belts are to be reused mark the belts to orientation on the drive The belts can now be removed 2 Flywheel Removal Remove flywheel screw holding the flywheel on the shaft Install flywheel puller on the flywheel An al ternate tool can be fabricated from a 4 107 95 mm diameter steel plate 1 2 12 7 mm thick with three equally spaced g 17 46 mm holes on a 37 82 55 mm or 3 g 98 43 mm bolt circuit See Figure 4 Also needed are several 134 44 45 mm plate washers and three 15 88 mm x 134 44 45 mm long screws Place several washers against the end of the shaft so they extend past the flywheel hub 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Flywheel Removal Screw the plate to the flywheel and tighten the screws so the plate pulls tight against the washers Tighten the screws evenly so they pull the flywheel Apply pressure until the flywheel breaks free FIGURE 4 FLYWHEEL REMOVAL TOOL Sheave Removal Specific instructions for motor sheave main tenance are located after the Operation Sec tion of this manual These should be con sulted for specific maintenance instructions Drive Inspection Inspect the motor and compressor shafts sheave bushing and flywheel for fretting cor rosion or other wear Fretting corrosion is
196. en steps of ca pacity is limited by the minimum differential of the controlling device i e pressure switch mi croprocessor thermostat or other device Stan VMC OPERATION dard compressors and condensing units are controlled by pressure switches Port P to B open when valve is de energized Port P to open whan valve is anargized A Drain to crunkcaee P to unioader piston _ B Oll supply from pump FIGURE1 TYPICAL OIL UNLOADING SOLENOID VALVE Capacity reduction solenoid valves are con trolled electricaily and the device used to ac tuate the unloader solenoid valves are either temperature or pressure responsive depending upon the application type When standard unloading is used capacity control solenoid valves are energized or de energized in series Controls are single pole single throw and closes on a pressure or tem perature drop Single step unloading alternates the single and double cylinder unloading mechanics The ca pacity controls are wired to allow the double cylinder solenoid valve to de energize while the single cylinder is energized and vice versa I AUTOMATIC CONTROLS Refer to Vilter Reciprocating Compressor Mi croprocessor Operating Manual for compres sors equipped with a microprocessor control unit 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A Dual Pressure Switch All Vilter
197. ent A33034GA 560W NEMA 187 Heater amp Therm 1 1 1 1 1 1 1 1 0 Present A33034L 300W NEMA 187 Heater amp therm 1 1 1 1 1 1 1 1 0 Present A33034LA 560W NEMA 187 Heater amp Float Valve 1 1 1 1 1 1 1 1 0 Present A33034G 560W NEMA 1 amp 7 Heater 1 1 1 1 1 1 1 1 0 Present A33034L 123 Cover Handhole with openings 1 1 1 1 1 1 1 1 0 Present Order Assy 123A Cover Handhole without openings S5 z 1 1 1 0 Present 33034B 124A Glass Oil Sight 2 1 1 1 1 1 1 1 1 13050 Present 1484 124 Glass Oil Sight 3 1 1 1 1 1 1 1 1 0 13049 31212A 125 Washer Oil Sight Glass 3 1 1 1 1 1 1 1 1 0 13049 31636A 126 Lock Oil Sight Glass 3 1 1 1 1 1 1 1 1 0 13049 31211A 127 Gasket Oil Sight Glass 3 2 2 2 2 2 2 2 2 0 13049 31226A 128 Screw 1 2 x 11 Hex Head Cap 16 16 16 16 32 32 16 32 0 Present 2796E 130 Tube Oil Feed Connector 1 1 1 0 Present 33494A 131 Spring 1 1 1 0 Present 31789A NOTES See Note Page 5 For use on compressors without external oil drain arrangement The crankcase cover for the 3 sight glass is not available but these sight glass parts can still be supplied SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 7 Replaces 440 VMC COMPRESSORS APRIL 1984 CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 2 THRU 8 CYLINDER COMPRESSORS FIGURE 4 February 2001 VILTER MANUFACTURING CORPORATI
198. ers 1 1 0 Bold 32418A 4 x 4 Halocarbon 1 0 es 12273C 109 Screen Suction Right amp Left Side 1 2 2 2 0 pat A32428D Screen Suction 1 0 Present A32428A Screen Suction Center 1 0 A32428C Screen Suction 2 2 1 0 Present A32565A Screen Suction 1 2 3 2 0 di A32428D Side 8 cyl 75 Cap Red Screen Suction 1 1 1 Tu pio A35215A 109 A Bag Suction Screen not shown ZA 1 s zs zs gt 0 Present A33474A Bag Suction Screen not shown 1 2 3 2 0 755 A33474B Bag Suction Screen not shown 2 2 1 0 Present A33474G Bag Suction Screen not shown 1 1 1 T A35234A 110 Gasket Suction Screen Cover 1 2 2 2 0 uds 31892A Gasket Suction Screen Cover 2 2 1 0 Present 33493A Gasket Suction Tee Cover 1 1 1 0 NER 11323J Gasket Suction Tee Cover 1 1 1 ane 35217 111 Cover Suction Screen 1 2 2 2 0 Present 31893A Cover Suction Screen 2 2 1 0 Present 33492A Cover Suction Tee for VPN 32010 1 1 0 13706 Cover Suction Tee for VPN 36254 1 1 1 pu TES 35216A NOTES Part Number on application li Quantities shown are for compressors with standard capacity reduction and will vary if compressor is equipped with additional
199. ery important For example on a four V belt set drive tension readings of 14 13 13 and 12 although the average is 13 pounds indicate misalignment probable trouble Drive horsepower capa bility can be reduced by as much as 50 if uniform V belt tension is not attained V belts could slip pop out of grooves or roll over Run the compressor at full load in the rec ommended direction This direction tends to tighten rather than loosen the front bear ing lock nut This is extremely important if the locking compound is accidentally omit ted Be certain V belts are not slipping The belts will not slip when the correct ten sion has been applied After operating 2 to 4 hours retension the drive to the high side of the normal required tension 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor HORIZONTAL ANGLE MISALIGNMENT WRONG 0 RIGHT FULL EQUAL DISTANCE FROM CONTACT STRAIGHTEDGE VERTICAL ANGLE MISALIGNMENT CHECK FIGURE 6 BELT ALIGNMENT VMC 2 01 INSTALLATION 14 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Single 5V V Belt Adjustment cont d 6 It is recommended that belt tension be checked 24 to 48 hours after initial installa tion 7 Recheck the motor and compressor shafts and sheaves for alignment If shafts or sheaves are not in alignme
200. es Compressors cont d de energized Oil traveis through the cylinder covers into the untoader cylinders producing a pressure build up Pressure is directed into the cylinder of the unloader mechanism which forces the unloader piston downward The yoke arms of the unloader assembly lowers the lift pins and seats the suction valve plate The operation is complete and the cylinders are fully loaded To unload the cylinder the solenoid valve ener gizes and bleeds off the pressure in the un loader cylinder Oil flows through the solenoid valve and into the compressor crankcase The capacity control system typically operates two cylinders When single cylinder unloading is required the lift pins are omitted from one liner in a cylinder bank and the unioader mechanism unloads one cylinder By controlling the sole noid valve in the line connected to the single cylinder unloader the capacity reduction of alt sizes of Vilter VMC Compressors is obtained in one cylinder increments The minimum gas flow through a VMC Com pressor of any size should never be less than 25 of the maximum unless special precautions are taken to ensure proper cooling NOTE Machines with 10096 built in capacity reduction require an oil cooler crankcase thermometer and a timer to avoid running longer than 30 min utes unloaded and a crankcase oil temperature thermostat if temperature exceeds 150 F 66 5 C The pressure differential betwe
201. es for locating the structural steel base anchor bolts from 1 25 4 mm to 6 152 4 mm boards Accurately locate holes in the templates and nail templates in place In sert the anchor bolts with sleeves on them in the holes Screw down the nuts until the sleeve is drawn up against the template Make this sleeve from a light weight metal shaped oylinder to a diameter three times that of the anchor bolt Place a washer of the same material at the bottom of the sleeve VI CONSTRUCTION OF CONCRETE PAD REINFORCED To construct a reinforced pad place reinforcing steel rods in the concrete pad while it is being poured Place layers of steel rods 6 152 4 VMC INSTALLATION mm apart with individual rods placed at a minimum of 6 152 4 mm from center to cen ter Position the layers in the pad to give a crosshatch effect i e one layer placed length wise the next crosswise and so on Keep the rod length about one inch less than the inside dimension of the form so it is laid in place quickly and easily To facilitate even spacing and quick placement wire the rods together at 6 152 4 mm intervals using 6x6 wire mesh There are variations for any given installation but in all cases the weight of the concrete pad should equal or exceed the weight of the com pressor and drive See Table 2 for approximate unit weights Extend the pad at least 6 152 4 mm beyond the outside of the structural steel base and at leas
202. esigned for refrigeration service The Vilter Motor Driven Oil Charger is ideal for use with VMC reciprocaiing compressors as well as Vilter Single Screw and Twin Screw com pressors In faci it can be used on any refrigera tion compressor having a closed crankcase It is especially appropriate for multiple compressor installations Extra adapter kits which include a bushing nipple and the plug portion of the cou pling are available to enable the operating engi neer to install a set in the oil charging valve of each compressor As a result a tedious 1nessy job that used io require hours to perform is quickly and effectively finished in minutes Coniact your nearby Vilter District Office or Distributor Hc is prepared to give you immediate service and will be happy to provide any additional information you may require VILTER Since 1867 Bulletin No 9641 Vilter Manufacturing Corporation 1996 Printed in U S A Vilter Stop Check Valve General Information AUTO In the Auto Position the stop valve is operating as a check valve allowing flow in the directions of the arrows To set the valve to the automatic position fully close the valve and turn the stem out as indicated by the chart below CLOSED In the manually Closed Postion the stop check is operating as a convientional stop valve not allowing flow in either direction OPEN In the manually Open Position with th
203. ference between the oil pressure at the pump discharge and the refrigerant pressure in the compressor crankcase Example If the oil pressure pump discharge reading is 90 psi 621 kPa and the crankcase pressure is 70 psi 483 kPa the net oil pressure is 20 psi 138 kPa The P28 and P128 have a built in time delay relay This relay allows the oil pressure to build up for the time delay period before the compressor trips This also prevents nuisance lockouts due to intermittent loss of oil pressure The time delay relay is a trip free device The manual reset cannot be overridden by pressing and holding the reset button Manual reset models are available with time delays of 30 45 60 90 or 120 seconds Automatic reset models are available with a 90 second time delay The time delay relay is compensated to minimize the effect of ambient temperature variations However the time delay relay will be affected by voltage variations Dimensions 4 98 126 Figure 2 P28 or P128 Dimensions in mm Operation When the compressor starts the timer is energized because the net oil pressure of the system is zero During normal operation the net oil pressure should build up to the pressure switch s cut out setting scale setting plus the switch differential 3 to 5 psi 21 to 34 within the required time delay causing the time de
204. for converting to new style 1200 RPM parts Refer to Home Office for Compressors with Serial Numbers below 150 Also available Kit KTO35 036 or KTO37 See page 29 SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 27 Replaces 440 VMC COMPRESSORS March 1975 CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 1000 RPM HIGH STAGE AND 1200 RPM BOOSTER COMPRESSORS Serial Numbers 2655 and below ITEM DESCRIPTION NO REQUIRED PER COMPRESSOR SERIAL NO PART NO OF CYL 2 4 6 8 12 16 FROM THRU NO 401 Thru Cylinder Liner Kit w o unloading 4 8 0 2655 KT032 402A 403 Unloader Ring Assembly 8 8 0 2655 A33434A 404 Washers Unloader Spring 16 16 0 2655 33436 409 Outer Seat Ammonia Discharge Valve 12 16 0 2655 33587A 409 Outer Seat R12 amp R22 Discharge Valve 12 16 0 2655 33586A NOTE These parts are given for information purposes only parts are no longer available February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 28 August 1974 440 VMC COMPRESSORS OLD STYLE PISTON AND CONNECTING ROD REPLACEMENT PARTS 1200 RPM COMPRESSORS SERIAL NUMBERS BELOW 3638 FIGURE 12 501 507 SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 29 Replaces 440 VMC COMPRESSORS March 1984 PISTON AND CONNECTING ROD REPLACEMENT PARTS FOR 1200 RPM HIGH STAGE Serial
205. g All rotating power transmission products are potentially dangerous and must be properly guarded in compliance with OSHA standards for the speed and applications for which they are intended It is the responsibility of the user to provide proper guarding D DISC PACK ENSE L CENTEA RING CENTER RING ME FLYWHEEL _ BEVEL ADAPTER WASHER CMR AMR f Qure 7 Purpose These instructions are intended to help you necessary use a very large rose bud tip to give to install align and maintain your THOMAS coupling even heat distribution thermal heat stick wili help determine hub temperature DO NOT SPOT HEAT THE HUB OR DISTORTION MAY OCCUR With the hub expanded slide it quickly up the shaft to the desired axial position A pre set axial stop device can be helpful Scope Covered here will be general information hub mounting alignmerrt assembly locknut torquing disc pack replacement and part numbers General Information The coupling as received may or may not be assembled if assembled the locknuts are not torqued Examine the parts to assure there s n no visible damage If coupling is assembled remove Bis ae the bolts focknuts and washers that attach the hub s a dr E Tike LF pele E metal to metal to the disc pack Remove the Leave the disc fit between shatt and hub This is the starting point packs aftached to the center ring a
206. g as well as cylinder bore with compressor oil Place the piston in the cylinder and compress the o ring to work it into the cylinder Next insert the long pivot pin into its hole in the piston shaft and position it so the flats will receive the slot of the yoke lifting arm The end of the pin is machined flat so the in staller can see the position of the inner flat Compress the yoke assembly and place a piece of 23 81 mm o d steel rod under 400 Series VMC SERVICE 14 the rear of the lifting rod This keeps the yoke depressed for easier handling Place the yoke into the frame through the cylinder opening and position it so the slot on the yoke lifting arm registers with the flats on the long pivot pin Depress the piston with a block of wood and remove the rod or piece of wood used to hold the yoke assembly de pressed Then center the assembly be tween the two cylinder liner holes New Style Bullet Type Lift Pins Ring and Springs Removal In order to put the unloading mechanism back in the cylinder liner place the lift pins with the springs around them in their holes Place the lift ring on the pins with the smaller inside diameter facing top of the liner so it will slip over and cover the retainer when it is in place Placing the liner on its side and holding the lift ring back against the pins and springs slide the ring retainer over the liner into its groove Unloader Piston Removal It is no
207. g through the tubes inspect the cooler for foreign deposits When materials accumulate in the cooler cooling efficiency is impaired Those ma terials should be removed Remove all foreign substances from inside heads Clean all gasket surfaces and install new gaskets wherever necessary The type and condition of the water used and the operating conditions determine the clean ing periods Using strainers in water lines extends the period between cleanings 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor b Disassembly and Cleaning cont d NOTE The concentration of chemicals and tempera ture varies in sea water and consequently the disintegration of zinc electrodes will be more rapid under some conditions This is especially true where water is warm It is important zinc electrodes are inspected once every thirty days The condition of the zinc electrodes at the time of inspection should govern the policy for future servicing If zinc electrodes are corroded and coated with foreign material electrode effec tiveness is either retarded or greatly reduced Clean electrodes by wire brushing and scrap ing If after cleaning zinc electrodes are more than 5096 disintegrated they must be replaced Make certain zinc electrodes are tightened to ensure good metal contact E Water Cooled Cylinder Covers Water cooled cylinder covers are furnished for some
208. gh Pressure Float Valve Float Chamber KT1019 Ammonia Inner Flange Gasket Or x 14 Cap Screws Qty Six KT1018 Halocarbon x lg Sch 160 Pipe Nipple Standard Screw End Valve KEY x 272 19 Sch 80 Pipe Nipple Angle Screw End Valve Ye O D x Compression Connector KT1017 Ammonia Ye O D x MPT Compressor Connector Or 74 O D x 10 ft Steel Tubing Qty Two KT1016 Halocarbon 1 O D Tubing Clips Qty Six 4 O D x 2 O D Compression Union FIGURE 7 PIPING SCHEMATIC TYPICAL OIL SEPARATOR INSTALLATION VMC 2 01 INSTALLATION 16 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Oil Separator 1 General Description cont d Vilter Horizontal Oil Separators are con structed for use with either steel pipe or copper tubing The steel inlet and outlet connections are counterbored to form a socket so they will accept copper tubing Cut off the counterbored portion when us ing this oil separator with steel pipe The wall thickness of the counterbored portion is too thin for the discharge pressure in volved 2 Oil Separator Float Valve An external high pressure float valve is used in conjunction with the oil separator A 6 35 mm line coming from the float valve returns oil to the compressor On the 300 Series Compressors oil is returned to the crankcase chamber on the drive end of the compressor On the 400 Series Com
209. h flange gasket seal Carefully loosen flange bolts one at a time being cautious to avoid any refrigerant which still may be present Remove check valve from flanges and inspect Lapped seating surfaces should be smooth and free of pits or scratches To confirm valve operation move seat disc with eraser end of pencil Movement should be free from friction If not disassemble and visually inspect for dirt in valve or burrs on seat disc Clean or replace parts as necessary Valve discs and seats can be restored by lapping on a flat plate Reassemble valve and insert between flanges Replace and tighten bolts and nuts evenly Carefully check for leaks before returning to service CAUTION Hansen check valves are only for refrigeration systems These instructions and related safety precautions must be completely read and understood before selecting using or servicing these valves Only knowledgeable trained refrigeration mechanics should install operate or service these valves Stated temperature and pressure limits should not be exceeded Valves should not be removed unless system has been evacuated to zero pressure See also Safety Precautions in current List Price Bulletin and Safety Precautions Sheet supplied with product Escaping refrigerant might cause personal injury particularly to the eyes and lungs WARRANTY Hansen valves are guaranteed against defective materials or workmanship for one year F O B our plant No conseq
210. hafts In this design version introduced in 1980 two 6 cylinder or two 8 cylinder crankshafts are joined by a sleeve to form an inseparable 12 cylinder or 16 cylinder crankshaft This specially machined sleeve eliminates the dams This design is completely interchangeable with the former design ttt See page 9 for symbol regarding this information Compressors below serial number 21355 were furnished with the no longer available front bearing cover assemblies 294 2 4 6 8 cylinders or A32162A 12 and 16 cylinders and front bearing retainer 31885A 2 4 6 and 8 cylinders or 33500A 12 and 16 cylinders without the oil hole Former front bearing retainers 31885A or 33500A without oil holes cannot be used with current front bearing cover assemblies A36240A 2 4 6 and 8 cylinders and A36241A 12 and 16 cylinders as there is no way for oil to get to the bearing If front bearing cover is being replaced a current front bearing retainer 31885A or 33500A with oil hole must be ordered also unless of these current styles is already being used lf a current front bearing retainer 31885A or 33500A both with oil hole is used with former style cover A30294A or A32162A having an oil hole remove orifice in cover A30294A or A32162A and replace with solid 8 pipe plug February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 12 August 1982 440 VMC COMPRESSORS REAR BEARING COVER REPLACEMENT PARTS
211. he discs in the pack are factory taped together 2 H coupling is not preassembled start with the center ring on a work bench Put the bolts through the bolt holes at one end Slide the disc over the bolts Add the washers The beveled side of the washer shouid always be against the disc pack Secure with the locknuts Torque locknuts to the value shown in Table 1 Now mount the flywheel adapter to this disc pack by putting the bolts through the holes in the adapter from the back side seating the head of the bolt in the stot provided and then through the remaining disc pack holes Add the washers and secure with the jocknuts The locknuts can now torqued to the values shown in Table 1 NOTE Ail bolt threads should be iubricated A clean motor cil is recommended If the coupling was preassembled flywheel adapter disc pack and center ring the locknut in this sub be torqued to the values shown in able 1 The disc pack when installed should look fiat and Parallel with mating adapter and center ring fingers 3 With the hub mounted and the span length C set proceed to put the sub assembly flywheel adapter disc pack and center ring into place between the flywheel and hub Bolt the adapter to the flywheel in the manner prescribed by the angine manufacturer 4 Now install the remaining disc pack Rotate the hub or center ring so that the hub boit holes line up between the center ring fingers Start a boi
212. he sleeves after the unit is in place When the compressor unit is placed on the concrete pad check both lengthwise and crosswise to assure it is level Use shims and wedges under the steel base to adjust the level of the unit if it is not satisfactory Once the unit is perfectly level it should be grouted in with a suitable tool for working the grouting into hard to get at places Allow the grouting to harden completely then tighten the anchor bolts Recheck the unit alignment to insure its position has not changed XIV DIRECT CONNECTED DRIVEN COMPRESSOR UNIT CAUTION IMPORTANT PRE START OPERATION NOTICE The drive coupling installed on your com pressor is NOT completely aligned DO NOT attempt to run unit until proper motor coupling compressor alignment is attained Misalignment beyond specified limits causes excessive vibrations and premature failure of bearings coupling and seal The same care in installing and aligning the flexible coupling used on direct connected VMC Compressors should be exercised when install ing a rigid flange coupling To correctly install and align the coupling see the insert of manu facturer procedures The Thomas Coupling VMC INSTALLATION 10 Division type number must be known in order to use these aligning instructions Some cou plings are only identified with a Vilter part num ber In those cases use cross reference Table 3 to find the corresponding Th
213. ial No 9999 and below also order Item 224 crankshaft bearing locknut and retaining compound kit tt Supplied as a kit includes retaining compound for bearing locknut Retaining compound also available separately order Part No KT365 N S Not Shown SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 11 Replaces 440 VMC COMPRESSORS August 1982 CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 231 Retainer Rear Bearing 1 1 1 1 1 1 1 1 1 0 Present 31904A 231A Rear Bearing and Lock Pin Kit 1 1 1 1 1 1 1 1 0 Present KT353 231B 231A Pin Bearing Lock 1 1 1 1 1 1 1 1 4233 Present 33678A 231B Bearing Rear Crankshaft 1 1 1 1 1 1 1 1 0 Present 3509 232 Screw 716 x 1 Hex Socket Head 4 4 4 4 4 4 4 4 See 13160D 232 Screw 5 16 x 177 Hex Head Cap 4 4 4 4 4 4 4 4 Note T 1736G 233 Crank Oil Pump Drive 1 1 1 1 1 1 1 1 0 Present 33403A 234 Cap Bearing Support 1 1 1 0 Present 235 Pin 1 2 x 1 Dowel 2 2 2 0 Present 13162 236 Bolt 7 x 134 Machine 4 4 4 0 Present 11396D 237 Bearing Half Upper Right or Lower Left Sg 2 2 2 0 Present 33508A 238 Bearing Half Upper Left or Lower Right is 2 2 ki 2 0 Prese
214. icing Refrigerant 717 Ammonia Compressor Halocarbon Refrigerant Compressor Compressor Oil Removal Preparation Of Compressor For Initial Start After Servicing CYLINDER COVERS Disassembly Assembly SUCTION AND DISCHARGE VALVE PLATES Disassembly 440 Compressor Mushroom Style 450 450XL Compressor Bullet Style Reassembly 440 Compressor Mushroom Style 450 450XL Compressor Mushroom Style COMPRESSOR DRIVE TYPES V Belt Drive Compressors Belt Removal Flywheel Removal Sheave Removal Drive Inspection Drive Installation Drive Alignment Belt Tension Single 5V V Belts Banded 5V V Belts Direct Drive Compressors Coupling Removal Coupling Replacement CAPACITY CONTROL Old Style Mushroom Type Lift Pins Ring and Springs Removal Actuator Mechanism Removal Actuator Mechanism Replacement New Style Bullet Type Lift Pins Ring and Springs Removal Unloader Piston Removal Unloader Piston Replacement Actuator Mechanism Removal Actuator Mechanism Replacement 2 01 A REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor SERVICE SECTION TABLE OF CONTENTS cont d PAGE 16 SAFETY VALVE INTERNAL RELIEF 16 Removal 16 Replacement 17 OIL PRESSURE ADJUSTMENT ASSEMBLY 17 Disassembly 17 Reassembly 17 Adjustment 17 TRI MICRO OIL FILTER 17 Removal 17 Replacement 18 OIL PUMP ASSEMBLY 18 Removal 18 Replacement 18 PREPARATION FOR INTERNAL SERVICING 18 Handhole Cover Removal 18 Handhole Cove
215. id charging valve following all ap plicable safety and venting law proce dures Invert the refrigerant drum if drum is not equipped with Liquid and Vapor valves and place in such a position the refrigerant can only enter the system The vacuum in the system will draw in the refrigerant It is important that dur ing this operation the air handling units are running and water is circulating through the chillers The low pressures in the system can cause the refrigerant to boil at a low temperature and possi bly freeze the water if it is not kept cir culating Water freezing in a chiller can rupture the tubes and cause exten sive damage to the system It is desir able to charge the initial amount of re frigerant without water in the shell and tube equipment to eliminate the possi bility of freeze up After some refrigerant has entered the system carefully start the compressor It is essential the compressor be al lowed to pick up the load gradually and let it run for a few minutes at a time During its intermittent operating period the operator should check for proper oil pressures and excessive heating at the bearings In between running periods allow the compressor to cool The run ning periods may be gradually length ened until the operator is sure no mov ing parts are heating excessively The compressor may then be operated automatically 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPO
216. ider A Drains Locate the unit near a floor drain Since a con siderable amount of water must be transported away when draining units with water cooled condensers for repairs or seasonal shut downs a floor drain is important B Ventilation Proper ventilation is required for efficient opera tion Heat generated by the compressor and its motor must be vented to avoid motor overheat ing and burn out If your Vilter VMC Compres sor is installed in a large room that does not have abundant natural ventilation mechanical ventilation is recommended VMC INSTALLATION Use a small unit cooler in conjunction with inlet condenser water where the fan operates when the compressor is running Another possibility for units using an evaporative condenser is to draw air for the evaporative condenser through the condenser room Also exhaust air from conditioned spaces is effectively utilized when passing it over the compressor and motor The importance of adequate cooling cannot be over emphasized Motors that occasionally operate at more than nameplate rating have a shorter life if not sufficiently cooled For motors which operate within nameplate rat ings room temperatures can be a maximum of ten degrees greater than normal room tempera ture Consult local codes for ventilation re quirements C Servicing Space Provide adequate space around the unit for servicing and maintenance work See Table 2 for overall dimensions
217. igh stage cylinders through the outlet connection of the desuper heater The gas is compressed to discharge conditions and directed to the compressor OPERATION 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor SHORT CIRCUIT PROTECTION BY CUSTOMER lU _ 118ViE0HZ ce LZ OMIT IF 115 CONTROL OIL FAIL PSO S a COMPRESSOR MOTOR STARTER UNLOADING SOLENOID UNLOADING SOLENOID CRANKCASE HEATER MS OL s MAGNETIC STARTER FUSE SWITCH HAND OFF AUTO PRESSURE SWITCH DUAL PRESSURE SWITCH OIL PRESSURE CONTROL UNLOADER SOLENOID VALVE UNLOADER TIMER UNLOADED START CRANKCASE HEATER FILTER DIFFERENTIAL PRESSURE SWITCH NOTES 1 WIRING PER NEMA 12 2 CONTROL WIRING 14 AWG JIC COLOR CODE UNLESS REPRESENTS FIELD WIRING 3 DOTTED WIRING REPRESENTS FIELD WIRING 4 DOTTED COMPONENTS NOT BY VILTER 5 DENOTES TERMINALS FOR CUSTOMER CONTROL OR INTERLOCK 6 9 DENOTES TERMINAL IN VILTER CONTROL PANEL FIGURE 2 TYPICAL ELECTRICAL SCHEMATIC VMC 2 01 OPERATION 10 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor NOTES Control arrangements vary with compressor model and are pictured accordingly Symbol with letter inside indicates control connecting points It ties particular point to its correspon
218. ight 3 0 Ib 1 36 kg The performance specifications are nominal and conform to acceptable industry standards For application at conditions beyond these specifications consult the local Johnson Controls Refrigeration Application Engineering at 414 274 5535 Johnson Controls Inc shall not be liable for damages resulting from misapplication or misuse of its products CONTRSLS Controls Group FAN 125 507 E Michigan Street Master Catalog P O Box 423 Printed in U S A Milwaukee WI 53201 8 P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin CONTROLS Master Catalog 125 Temperature Controls Section A Product Bulletin 70 A72 Issue Date 0996 A70 A72 Series Temperature Controls for Refrigeration and Heating Application The 70 single pole and 72 two pole controls are supplied in a wide selection of ranges to meet most application needs See Temperature Ranges Models may be supplied to open a circuit on temperature increase or close a circuit on temperature increase as required An A70 single pole control may optionally include a separate reverse acting auxiliary contact Models are available with a SPDT enclosed Pennswitch All Series A70 A72 controls are designed for use only as operating controls Where an operating control failure would result in personal injury and or loss of property it is the
219. in Roll 8 16 24 32 48 64 24 48 7000 Present 1193Q 4028 Seal Ring Lower 6 12 14204 Present 2176BL 402 Lift Ring amp Post Assy Std 1 2 4 4 8 8 3 6 3638 Present A33351A 403 Lift Ring amp Post Assy Hi Suct 2 8 8 ui Sc 3638 Present A33351A 405 Spring Lift 4 8 16 16 32 32 12 24 3638 Present 33352A 406 Pin Lift 4 8 16 16 32 32 12 24 3638 Present 33350A 407 Plate Suction Valve 2 4 12 16 6 12 3638 Present 31909A 410B 411A amp Piston Kit Cap Red Oil Actuated 1 1 2 2 4 4 3 6 19247 22799 KT364 412 410 411 Piston Kit Cap Red Gas Actuated 1 1 2 2 4 4 3 6 3638 19246 KT034 412 30000 32499 410 Piston Ring Steel For Gas Actuated 4 4 8 8 16 16 12 24 30000 32499 31989L 410A O Ring Rubber For 0 187 Groove 1 1 2 2 4 4 3 6 19247 22673 2176AX 410 Ring Set PTFE For 0 120 Groove 1 1 2 2 4 4 3 6 22674 22799 2557A 411 411 Piston Unloader Gas or Oil 1 1 2 2 4 4 97 6 Order Kit A 412 Pin Long Pivot 1 1 2 2 4 4 3 6 3638 22799 33250C 413 Cap Cont Mech Assy Std Single 1 3 6 150 22799 577 Thru Cap Cont Mech Assy Std Double 1 2 2 4 4 150 22799 A33354A 420 Cap Cont Mech Assy Hi Suct 1 2 2 4 4 150 22799 A35253A 413 Arm Yoke Lifting 1 1 2 2 4 4 3 6 150 22799 33338A 414 Yoke Assembly Std Single 1 3 6 150 22799 A33575A 414 Yoke Assembly Std Double amp
220. inder bank compressor pump end Also used to designate cylindar n ORO Z Compressor cylinder bank Compressor drive end 2 4 Denotes end of compressor where crankshaft comes through frame and motor is Denotes unloading attached mechanism piston hole Denctes single cylinder in compressor frame and ism for a connection leading lo pesticutes solenoid velvs 2 CYLINDER COMPRESSOR 2 CYLINDER COMPRESSOR 2 CYLINDER COMPRESSOR STANDARD 1 2 PERCENT REDUCTION 0 PERCENT REDUCTION 50 PERCENT REDUCTION 100 To To Solanok Valve 9 sor aser Compressor 4 CYLINDER COMPRESSOR 4 CYLINDER COMPRESSOR 4 CYLINDER COMPRESSOR STANDARD N 1 OPTION 2 PERCENT REDUCTION 50 PERCENT REDUCTION 25 50 75 PERCENT REDUCTION 50 100 To Solenoid Valve To Solenoid Valve To Salanald Vaiva D G D O O G DLO e 5 NTAN 9 OLG i a Compressor p Camprassar ppm or Solenoid Valve End To Saleneid Valve Drive Ena Due End Drive 6 CYLINDER COMPRESSOR 6 CYLINDER COMPRESSOR STANDARD o PERCENT 33 88 PERCENT 33 66 100 Selaneid Valve LIN FEN I ONO Salenaid Valve Solenoid Valve a x OLO OLO EN G Compressor End 9 Os N Cempreseor Er Drive FIGURE 5 13 VMC OPERATION HIGH STAGE 2 THRU 6 CYLINDER FOR 400 SERIES COMPRESSOR CAPACITY REDUCTION ARRANGEMENT TYPICAL SCHEMATIC
221. ing Their interchangeability extends through sheaves pulleys timing pulleys sprockets flexible and rigid couplings made to order items by Wood s and to product lines of several other mechanical power transmission manufacturers Sure Grip bushings are manufactured with the drilled and tapped holes located at a precise distance from the keyseat thus a wide mating part having a bushing in each end can be mounted on a common shaft with the two keyways in line This feature not only facilitates installation but also permits both bushings to carry an equal share of the load REVERSE MOUNTING Gm fm 1 Cap screws from outside 2 Cap screws from inside 3 Cap screws from inside 4 Cap screws from outside through drilled holes in the mating part and into threaded holes in the bushing flange located on the inside of the assembly Or the complete assembly reversed on the shaft and 1 2 through drilled holes in the mating part and into threaded holes in the bushing flange located on the outside of the assembly through drilled holes in the bushing flange located on the inside of the assembly and into threaded holes in the mating part through drilled holes in the bushing flange located on the outside of the assembly and into threaded holes in the mating part SURE GRIP BUSHING DIMENSIONS Wood s Sure Grip bushings are designed to transmit the rated to
222. ing 1 1 1 1 1 1 1 1 0 Present yi 302 Plug 34 Hex Socket Head Pipe 1 1 1 1 1 1 1 1 0 Present 13163E 303 Pin 3 x 1 Dowel not shown 1 1 1 1 1 1 1 1 0 Present 2868H 304 Orifice Oil Metering not shown 1 1 1 1 1 1 1 1 0 Present 33361A 305 Gasket Oil Pump Body 1 1 1 1 1 1 1 1 0 Present 31899A 306 Oil Pump Assembly 1 1 1 1 1 1 1 1 0 Present A33480A 307 Conversion Kit Special improved 1 1 1 1 1 1 1 1 0 Present KT361A Thru Tri Micro Oil Filter 120 volts 339 Conversion Kit Special improved 1 1 1 1 1 1 1 1 0 Present KT361B Tri Micro Oil filter 240 volts 307 Gasket Oil Pump Cover 1 1 1 1 1 1 1 1 0 Present 31900A 308 Gasket Pump and Rear Bearing 1 1 1 1 1 1 1 1 0 Present 33320A Cover Seal 309 Cover Oil Pump and Filter Head 1 1 1 1 1 1 1 1 0 Present 34565A 310 Filter Assembly Complete Tri Micro 1 1 1 1 1 1 1 1 0 Present A35241A 311 Spool Assembly without bypass relief 1 1 1 1 1 1 1 1 0 Present 2046A 312 Seal Spool End 1 1 1 1 1 1 1 1 0 Present 1448H 313 Strainer Tube 1 1 1 1 1 1 1 1 0 Present 1448K 314 Ring Retaining 1 1 1 1 1 1 1 1 0 Present 1448L 315 Recharge Gasket 1448B included 1 1 1 1 1 1 1 1 0 Present 2115C 316 Pressure Plate Assembly 1 1 1 1 1 1 1 1 0 Present 1448M 317 Pressure Plate 1 1 1 1 1 1 1 1 0 Present 1448N 318 O Ring Seal Pressure Plate 1 1 1 1 1 1 1 1 0 Present 1448P 319 Spring Pressure Plate 1 1 1 1 1 1 1 1 0 Present 1448Q 320 Plug Steel Square Head Pipe 1 1 1 1 1 1 1 1 0 Present 11
223. isance oil failures are possi ble The crankcase heater prevents this in most cases Heater Heater Sight Cover Glass Hole Eo O p Thermostat or Thermometer Hole Screws Leave in place when installing heater FIGURE 8 TYPICAL CRANKCASE HAND HOLE COVER 400 VMC COMPRESSOR MODEL SERIES The third type is a cartridge type heater It is mounted in the drive end of the frame on 300 Series VMC Compressors 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor C Crankcase Heater cont d NOTE It is extremely important the heater be ener gized when the compressor is not operating for compressors having TRI MICRO filter with out internal bypass The heater is equipped with a non adjustable internal thermostat set at 100 F 37 8 C When installing the heater make electrical con nections by removing the heater cover and in serting wires through the knock out holes Be sure the heater is on separate circuit NEVER COMBINE WITH OTHER CONTROL CIRCUITS To install or replace a crankcase heater on a 400 Series Compressor already in service pump down the compressor as described in the Service Section If heater is to be replaced use appropriate lockout and tag out procedures and electrically disconnect the heater before removing oil The oil drain valve at the lower end of the compres sor should be opened and the oi
224. itches etc All pneumatic controllers and valves if applicable are to be covered with plastic bags with desiccant inside On bare shaft compressors a holding charge of oil pumped dry nitrogen should be placed in the compressor If the compressor will be inactive for ANY length of time the compressor should be rotated five 5 complete revolutions once every month If a screw compressor is part of the system the oil pump for the unit should be run for approximately two 2 minutes each week Motors NOTE the following are general recommendations Consuit the manufacturer of your motor for specific recommendations 1 Disassemble and thoroughly clean the unit For periods over six months storage repaint ail previously painted surfaces internal as well as external Do not contaminate the lubricant 2 Reassemble the unit Insert one half pound bags of silica gel or other desiccant material into the air inlets and outlets of drip proof type motors NOTE The bags must remain visible so they will be noticed and removed when the unit is prepared for service 3 Cover the unit completely to exclude dirt dust moisture and other foreign materials At a bare minimum slip a heavy waterproof bag over the motor 4 if the motor can be moved it is suggested the entire motor be encased in a strong transparent plastic bag Before sealing this bag a moisture indicator should be attached to the side of the motor and several bags of silic
225. l allowed to drain out completely Next only on 400 Series VMC Compressors remove the handhole cover and substitute with a cover having a drilled and tapped hole for the heater compressor It is not necessary to pump the compressor down and remove the oil to change the cartridge heater D Oil Cooler 1 Introduction Multipass shell and tube oil coolers are fur nished on many VMC Compressors and are mounted at the pump end Oil coolers prevent excess thinning of oil during opera tion and decrease oil consumption Cooler oil oxidizes less reducing sludge deposits in the compressor Oil from the compressor pump enters the cooler then the TRI MICRO filter Water enters on the tube side It flows through the cooler and is expelled to a drain or condenser sump NOTE Water circuit through oil cooler and water cooled heads is in parallel section See Operation Gasket 1 2 Oil Connections 1 2 20 G Water Out Place the cover in a vise making sure the two E screws below the heater are left in place If this is not done the two screws can not be rein serted into the holes due to interference of the installed heater Insert the heater element through a tapped hole and tighten the fitting Water in 1 2 Position the heater so the electrical connections are in the correct orientation Connect wires as explain
226. lace the mechanism into the frame through the cylinder liner opening and position it Install unloader piston as detailed above Depress the unloader piston with a block of wood and remove the rod or piece of wood used to hold the yoke assembly depressed Then 400 Series VMC SERVICE 16 center the mechanism between the two cyl inder liner holes VI SAFETY VALVE INTERNAL RELIEF A Removal If for any reason the safety valve has relieved install a new valve Make no attempt to adjust the relief valve To replace the safety valve re move the cover on the top of the compressor frame marked safety valve by taking out the two screws which hold it in place Then remove the safety valve by using a standard 134 44 45 mm socket SAFETY VALVE COVER SCREWS AND GASKET COMPRESSOR FRAME CHAMBER Note Safety Valve is set at a differential pressure of 300 PSIG 2069 kPa Maximum discharge temperature is 300 F 150 C FIGURE 9 SAFETY VALVE LOCATION B Replacement Lightly oil the threads of the valve and screw the valve into place Lightly oil a new gasket and place it on the frame Position the cover and tighten it down 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Vil OIL PRESSURE ADJUSTMENT ASSEMBLY A Disassembly The oil pressure adjustment assembly is located in the front bearing housing It consists of a spring loaded ball p
227. lay relay to de energize If the net oil pressure does not rise to the cut out pressure setting plus the switch differential within the required time delay the time delay relay trips and stops the compressor If the net oil pressure drops below the cut out pressure setting during the compressor s run cycle the time delay relay energizes If the net oil pressure returns within the time delay the time delay relay de energizes and the compressor continues to operate normally If the net oil pressure does not return within the time delay the control shuts down and locks out the compressor 2 P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin Example Net oil pressure oil pump pressure minus crankcase pressure required to the bearings is 9 psi 62 kPa The control scale setting should be 9 psi 62 kPa The switch differential is 5 psi 84 kPa Upon initial start of the compressor the time delay relay energizes If the net oil pressure does not build up to 14 psi 97 kPa or the scale setting 9 psi plus the switch differential 5 psi during the time delay the control breaks the circuit to the compressor If the pressure of 14 psi 97 kPa is reached during the time delay the time delay relay de energizes and the compressor continues to operate normally Installation Mounting CAUTION Equipment damage hazard A P28AN P28DN control used for ammonia service
228. le was changed from a 60 hole to an 82 hole AL Aluminum Pistons February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 R Replaces PAGE 22 February 1985 440 VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 1000 RPM HIGH STAGE AND TWO STAGE COMPRESSORS AND 1200 RPM BOOSTER COMPRESSORS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 501 Piston Flat AL Rings amp Pin Kit 2 4 6 8 6 12 3068 Present KT213 Thru Piston Flat AL Rings amp Pin Kit 3S 25 ze 12 16 S ae 2656 Present KT213 505 501 Piston Flat AL amp Conn Rod Assy Kit 2 4 6 8 6 12 3068 Present KT478 Thru Piston Flat AL amp Conn Rod Assy Kit 12 16 se 2656 Present KT478 512 501 Piston Ring Compression 4 8 12 16 24 32 12 24 0 Present 31989M 502 Piston Ring Oil 2 4 6 8 12 16 6 12 0 Present 31989N 503 Snap Ring Piston Pin 4 8 12 16 24 32 12 24 0 Present 33244A 506 Connecting Rod Assy with Bearings Kit 2 4 6 8 12 16 6 12 0 Present KT463 Thru 512 510 amp Bearing Half amp Lock Nut Kit Std Size 2 4 6 8 12 16 6 12 0 Present KT512 511 Bearing Half amp Lock Nut Kit Undersize 2 4 6 8 12 16 6 12 0 Present KT513 506 Bushing Piston Pin 2 4 6 8 12 16 6 12 0 Present 31896B 507 Connecting Rod and Cap 2 4 6 8 12 16
229. life Make provisions for collecting this oil J Seasonal Operation In instances where there is a seasonal opera tion of air conditioning systems special consid erations must be given to the equipment Whenever equipment is shut down for any length of time as over the winter pumpdown the refrigerant and store it in the receiver Only experienced refrigerant personnel should per form this operation Never fill the receiver to more than 809 of its capacity and after filling it should be thoroughly checked for leaks When starting up a system after a seasonal shutdown allow only enough refrigerant to en ter the system to pressurize for leak testing Any leaks that may have developed during the shut down period may be found with a minimum of refrigerant loss It is extremely important to check for leaks before a system is put back into operation Be sure the system is sealed before the full supply of refrigerant is allowed to enter it After the system has operated for several hours another leak check should be made K Service Contracts Vilter Distributors offer a variety of mainte nance inspection and repair services Plans are available for almost any need It is recom mended that owners avail themselves of these services If a Vilter Distributor is not available your area contact the Vilter Manufacturing Corporation Home Office Provisions for a ser vice contract should be carefully considered by the
230. locating the bolt holes for the isolators bolting the isolators down making sure they are level and mounting the unit on the isolators 2 Type KIP C Vibration Isolators For more critical upper floor installations it may be necessary to increase the static mass to further reduce the vibration ampli tude Figure 2 illustrates a practical method of accomplishing this Instructions for installing and adjusting the type KIP C vibration isolators are as fol lows a Place two layers of waterproof paper on sub base where concrete foundation is to be poured b Construct foundation formwork See Figure 4 c Place KIP C mount housings without spring elements within formwork in ac cordance with foundation plan d Drive nails through V slots provided in KIP C housings into formwork to keep housings in place VMC INSTALLATION Lay the necessary reinforcing steel in place within the formwork and locate anchor bolts for the equipment as re quired f Pour concrete foundation compacting thoroughly Concrete is 137 lbs per cu ft Concrete should be at least equal weight of the unit In a 9 228 6 mm high base pour concrete in until the height is at least 4 114 3 mm g After foundation has set and cured and formwork removed set equipment in place on foundation h Insert spring assemblies in place in KIP C housings checking carefully that assembly of proper capacity is set in each
231. long as the compressor is running VI INTERCOOLER AND DESUPERHEATER TWO STAGE COMPRESSORS ONLY Intercooler The function of an intercooler in a two stage compressor system is to remove the heat of compression from the first stage discharge gas before the gas enters the second stage cylin ders and to subcoo the liquid from the con denser or receiver The intercooler is a horizontally mounted vessel consisting of an inner flooded vessel containing a tube bundle through which liquid from the re ceiver is circulated and a concentric outer ves sel that receives the first stage discharge gas and gas liquid mixture from the inner vessel thermostatic expansion valve controls the amount of superheat in the first stage discharge gas passing through the intercooler Liquid refrigerant from the receiver enters the tube bundle of the inner shell A small amount of this liquid is bled off and metered through the thermostatic expansion valve to maintain a level at intermediate pressure in the inner flooded vessel As the warm liquid passes through the tubes it is subcooled by the lower temperature liquid in the inner shell The heat absorbed by the liquid in the inner shell causes it to boil The resultant gas liquid mixture is then piped into the first stage discharge lines leading to the outer shell and is mixed with the first stage discharge gas The first stage discharge gas is desuperheated by mixing with the cooler gas
232. low your instructions unless it is to your best interest to change routing If you purchased the compressor from a party other than Vilter Manufacturing Corporation please state when you purchased the compressor and from whom Patents Pending VILTER MANUFACTURING CORPORATION PRINTED IN U S A VILTER MANUFACTURING CORPORATION February 2001 SECTION 100 R PAGE 2 Replaces May 1985 450XL VMC COMPRESSORS 2 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 1 PATENTS PENDING February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 3 May 1985 450XL VMC COMPRESSORS 4 6 AND 8 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 2 NOTE HANDHOLE COVER ACTUALLY LOCATED ON OPPOSITE SIDE OF FRAME ON 4 6 amp 8 CYLINDER 121 COMPRESSORS PATENTS PENDING SECTION 100 R VILTER MANUFACTURING CORPORATION PAGE 4 450XL VMC COMPRESSORS 12 AND 16 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 3 121 120 SERIAL NUMBER p ux OPPOSITE END ES 126 E 116 PATENTS PENDING 112 111 February 2001 Replaces May 1985 February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 5 May 1985 450XL VMC COMPRESSORS BASIC FRAME REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 101 Frame 1 1 1 1 1 1 102 Screw 5 3 x 3
233. m their sockets with a twisting pulling motion 450 450XL Compressor Bullet Style See Figure 8 Lift out the safety head yoke which holds the safety head assembly in place Invert the yoke to make sure all eight coil springs are intact within it If any springs are broken locate and remove pieces Springs can be removed and replaced without tools Since they are only finger tight in the bottom of the hole they can be removed with a twisting pulling motion After the safety yoke has been removed lift out the ring plate discharge valve refer to note below Slip the safety head up and off the roll pin that guides it NOTE Before reassembling the safety head as sembly the top of the discharge diaphragm valve must be determined Place a straight edge on the diaphragms to reveal the dome Diaphragms are installed with the dome on top All pieces of the safety head assembly should be clean and lightly lubricated with compressor oil before reassembly To reassemble the safety head assembly insert the valve retaining screw in the safety head Place one of the domed discharge diaphragm valves on the screw making sure the dome is up Next place the thin spacer on the screw Follow it with the two remain ing diaphragms both having the dome on top Place the thicker washer and nut on the valve retaining screw Tighten the nut to the torque value listed in Table 2 3 or 4 de pending upon compressor model
234. maining repair parts pages apply to all existing high speed 440 VMC compressors If it is desired to convert an existing high speed 440 VMC compressor having a serial number below 3638 to the latest design arrangement kits listed below are offered depending upon the particular compressor involved It is recommended though not mandatory that the old parts be replaced by these kits containing the latest design parts when making a major parts replacement general overhaul of the compressor It is also recommended that all cylinders be converted at one time to avoid unnecessary complications when stocking and ordering future replacement It will not impair the performance of the machine if a combination of converted and unconverted cylinders exist in one machine however care must be exercised thereafter in ordering the proper replacement parts for each cylinder Purchasing these conversion parts in kit form will result in some savings as opposed to the purchasing of former style high speed replacement parts individually Refer to the Home Office for prices on these conversion kits Include all information especially serial number regarding the compressor to be converted Also include correct part number for kit as listed below KITS ARE AVAILABLE AS FOLLOWS SECTION 105 R PAGE 24 CYLINDERS WITHOUT UNLOADING CYLINDERS WITH UNLOADING COMPRESSOR AMMONIA R12 R22 AMMONIA R12 R22 DESCRIPTION
235. me The compressor frame serial number location is directly above the suction flange on the frame of the compressor or directly above the rear bearing cover The rear bearing is located on the oil pump filter end of the compressor Always give the name of the part as well as the corresponding part number and or item number Also include the quantity of parts required Should there be a doubt regarding the part number or name send a sketch of the part required or return the old part as a sample transportation charges prepaid Orders on which part numbers and description do not agree will be filled according to our best interpretation All prices are F O B factory Minimum domestic parts order is 75 00 net price Please indicate on the order preferred method of shipment We will follow your instructions unless it is to your best interest to change routing If you purchased the compressor from a party other than Vilter Manufacturing Corporation please state when you purchased the compressor and from whom VILTER MANUFACTURING CORPORATION PRINTED IN U S A VILTER MANUFACTURING CORPORATION February 2001 SECTION 105 X PAGE 2 Original Issue 460 VMC COMPRESSORS 2 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 1 February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 Original Issue PAGE 3 460 VMC COMPRESSORS 4 6 AND 8 CYLINDER BASIC FRAME REPLACEMENT PARTS FIGURE 2 NOTE HANDHOLE COVER ACTUALLY LOCATED ON OPPOSIT
236. models of Vilter VMC Compressors They are mounted on top of the standard cylin der covers Maintain an adequate supply of water to the water cooled covers in order to prevent minerals in the water from depositing in the covers and causing early fouling When water is 80 F 26 7 C or lower the recom mended quantity is 272 to 4 GPM 0 16 to 0 25 l sec for 2 thru 8 cylinder machines and 5 to 8 GPM 0 32 to 0 51 l sec for 12 and 16 cylinder machines depending upon discharge tempera ture The 12 and 18 cylinder machine connec tions are actually 2 6 or 8 cylinder systems in parallel Table 6 shows the pressure drops through the cylinder covers for the recom mended minimum and maximum flow rates If the necessary water pressure is not available water connections should be configured in par allel and the quantity of water increased propor tionally A 12 7 mm thermostatic water regulating valve should be provided in the inlet to control water flow and connect the outlet to an open drain or condenser sump VMC INSTALLATION TABLE 6 COMPRESSOR COOLING WATER FLOW RATES COMP MAXIMUM MINIMUM SIZE GPM GPM 2 CYL 4 2 5 psi 2 1 3 psi 0 25 l sec 17 2 kPa 0 16 l sec 9 kPa 3 amp 4 4 5 psi 2 2 5 psi CYL 0 25 l sec 34 5 0 16 17 2 kPa 5 amp 6 4 7 5 psi 2 3 8 psi CYL 0 25 sec 51 7kPa 0 16 sec 26 2 kPa 7 amp 8 4 10 psi 2 6 psi CYL 0 25 sec 68 9 0 16
237. most rigid mounting minimizing V belt flopping VMC INSTALLATION 12 Work V belts around the sheaves by hand On drives having more V belt grooves in the sheaves than needed use grooves closest to the motor and compressor Make sure the V belts are all slack on the same side of the drive preferably the bot tom Drive should pull tight across the top of the flywheel Never mix slack and tight sides as this could cause serious damage to the V belts when tightening the drive Never pry or roll V belts onto the sheaves This can cause serious tearing and damage to the V belts Move the sheaves apart until the V belts are snug 2 01 REPLACES ALL PREVIOUS ISSUES 10 VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor V Belt Installation cont d The motor rails should be perpendicular to the base Check compressor for soft foot and shim accordingly Check the motor and compressor shafts to make sure they are parallel Check the flywheel and motor sheave with a straight edge string or wire to be sure they are parallel and in the same plane See Fig ure 6 Fix any misalignment by moving the motor by means of adjusting screws Recheck drive and tension Adjust if nec essary after 2 to 4 hours and again after 24 to 48 hours of operation to compensate for initial stretch and wearing of the V belts Make periodic checks of drive tension Speed ratio and tension should be restored as
238. motor to bring the sheave and pulley into alignment 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Drive Alignment cont d Vertical angular misalignment results when the motor and compressor shafts are in the same vertical plane but not in the same horizontal plane A straight edge is held against the compressor pulley face The distance from the straight edge to the motor sheave at the top and bottom is compared They should be the same If the back of the motor is sitting low the top of the sheave will be back further than the bottom of the sheave The motor must be shimmed so the top and bottom of the sheave are in the same plane as the compressor pulley The last check is the parallel alignment This check aligns the belt grooves of the pulley and sheave The measurement is taken from a straight edge held at the outer rim to the edge of the first groove used on the compressor pulley usually not all grooves are filled due to horsepower re quirements This is then compared to a measurement taken from the straight edge to the corresponding groove on the sheave The sheave position is then adjusted to as sure the sheave is in line with the flywheel Belt Tension Proper tension is essential to long belt life An improperly tensioned belt will result in in efficient operation and excessive heat The ideal tension is the least amount of tension at which the belt will n
239. mp This causes the ice to melt and water to boil Water vapor collects in the next trap towards the vacuum pump This process should be repeated until all pockets of water have boiled off and the vacuum pump has had a chance to remove all the water vapor from the system XV COMPRESSOR OIL CHARGING Vilter Manufacturing Corporation has made available to the field two models of oil charging pumps One model pump is hand operated while the second model is motor driven See the literature insert for more information Both pumps are used in putting the original oil charge into the compressor crankcase as well as charging oil later during service operations Using either of these two pumps eliminates the need for providing a vacuum on the compressor in order to charge oil into it Both the hand operated Vilter charger and the Vilter motor driven charger attach quickly and easily to a 5 gallon container Once connected VMC INSTALLATION 24 to the container it can be left alone until it is empty The Vilter motor driven charger clamps to the top of the can with the dip tube extending down into the can After the motor driven oil charger has been mounted on the top of the can the can and charger may be moved around as a single assembly by the carrying handles on top of the motor driven oil charger This too can be left alone until the can is empty Both oil chargers are equipped with a length of hose with a female half of a
240. multaneously See Figure 4 for oil piping connections Oil pressure supplied by the compressor oper ates the unloading mechanisms located inside the compressor in order to insure positive ac tion of the unloading mechanism the oil pres sure on the machines should be at least 40 psi 275 79 kPa above second stage suction pressure V COMPRESSOR OIL SYSTEM A Description The core of the VMC Compressor oiling system is an automatic reversible gear type positive acting pump The pump is compressor shaft driven Oil is drawn into the pump through a fine mesh strainer from the crankcase reser voir 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A Description cont d The pump discharges oil through a pressurized micronic type filter into the seal end of the com pressor enters the bottom of the seal cham ber through an external connection and is flushed upward under pressure to provide the shaft seal with full flow cooling Excess oil by passed by relief leaves at the top of the cham ber Drilled oilways in the crankshaft conduct high pressure oil from the chamber to the various crankpin bearings Cylinders are lubricated by oil thrown from the crankpin and wristpin oil bearing The shaft roller bearings receive their oil through metering orifices in the bearing cov ers In a refrigeration system using Vilter VMC Com pressors an external pressure floa
241. must be mounted separately from the electrical cabinet An ammonia leak could damage the electrical circuitry Do not use Johnson Controls Penn Ecosafe hose tubing in applications with ammonia or other corrosive refrigerants Corrosion could cause tube breakage and refrigerant leakage Use only the mounting screws supplied with the control Damage to internal components may occur if other screws are used The P28 and P128 controls are not position sensitive and can be mounted in any position Use the two mounting screw holes located on the back of the control case to mount the control directly to a wall or panel board Mount the control so that the pressure connections on the bellows are above the crankcase liquid level of the equipment being controlled Note When mounting the control to a compressor is required a mounting bracket Part No 271 51 is available Pressure Connections CAUTION Equipment damage hazard e Avoid sharp bends or kinks in the capillary or tubing to avoid damage to the capillary Coil and secure excess capillary or tubing Because harmonic vibration can break the capillary or tubing some slack must be provided Do not allow the capillary or tubing to rub against metal surfaces where friction can cause damage When using a control with 1 4 in 6 4 mm tubing a pulsation damper must be used Pulsation can cause excessive wear and damage the control 1 Purge all tubing
242. n 1 1 1 1 1 1 2868H 304 Orifice Oil Metering not shown 1 1 1 1 1 1 33361A 305 Gasket Oil Pump Body 1 1 1 1 1 1 31899A 306 Oil Pump Assembly 1 1 1 1 1 1 A33480A 307 Gasket Oil Pump Cover 1 1 1 1 1 1 31900A 308 Gasket Oil Pump and Rear Bearing Cover Seal 1 1 1 1 1 1 33320A 309 Cover Oil Pump and Filter Head 1 1 1 1 1 1 34565A 310 Filter Assy Complete without Bypass Relief 1 1 1 1 1 1 A35241A 310 Filter Assy Complete with Bypass Relief 1 1 1 1 1 1 A35240A 311 Spool Assembly without Bypass Relief 1 1 1 1 1 1 2046A 311A 312 Spool Strainer Tube Assembly 1 1 1 1 1 1 1448U 313 amp 314 311A 312 Thru 314 amp Filter Assembly without Shell 1 1 1 1 1 1 1448T 315A thru 319 311A Spool Assembly with Bypass Relief used on 1448C 1 1 1 1 1 1 1448J 312 Seal Spool End 1 1 1 1 1 1 1448H 313 Strainer Tube 1 1 1 1 1 1 1448K 314 Ring Retaining 1 1 1 1 1 1 1448L 315 Recharge for use with 2046A and A35241A t 1 1 1 1 1 1 2115C 315A Recharge for use with A35240A and 1448J t 1 1 1 1 1 1 1448C 316 Pressure Plate Assembly 1 1 1 1 1 1 1448M 317 Pressure Plate 1 1 1 1 1 1 1448N 318 O Ring Seal Pressure Plate 1 1 1 1 1 1 1448P 319 Spring Pressure Plate 1 1 1 1 1 1 1448Q 320 Plug Steel Square Head Pipe 1 1 1 1 1 1 1190A 321 Gasket Oil Filter Head 1 1 1 1 1 1 1448B 322 Filter Shell with Bolt Ring 1 1 1 1 1 1 A34623A 323 Screw Hex Head Cap 7 16 x 2 4 4 4 4 4 4 1689G 324 Instruction Nameplate for use with A35241A 1 1 1
243. n Valve 2 4 6 8 12 16 31909A 410A Piston Kit Cap Red Oil Actuated 7 411A amp 412 Serial Number 45 000 thru 45 999 1 1 2 3 2 4 6 4 KT364 410 Piston Kit Cap Red Gas ActuatedT 411 amp 412 Serial Numbers 60 000 thru 61 199 1 1 2 3 2 4 6 4 KT034 410 Piston Ring Steel For Gas Actuated 4 4 8 12 8 16 24 16 319891 410 O Ring Rubber for 0 187 Groove 1 1 2 3 2 4 6 4 2176 410 Ring Set PTFE for 0 120 Groove 1 1 2 3 2 4 6 4 2557 411 411 Piston Unloader Gas or Oil 1 1 2 3 2 4 6 4 Order Kit 412 Pin Long Pivot 1 1 2 3 2 4 6 4 33250 413 Complete Capacity Control Mechanism Assembly Thru Serial No 45 000 45 999 amp 60 000 61 199 420 2 Cylinder and Two Stage 1 3 6 A33577A High Stage fe 1 2 2 4 A33354A 413 Arm Yoke Lifting 1 1 2 3 2 4 6 4 33338A 414 Yoke Assembly 2 Cylinder and Two Stage 1 us 3 SE 6 5 A33575A 414 Yoke Assembly High Stage 1 2 2 4 4 A33335A 415 Pin 4 Ig Roll 1 1 2 3 2 4 6 4 1193X 416 Pin Short Pivot 1 1 2 3 2 4 6 4 33250B 417 Spring Unloader Yoke 4 4 8 12 8 16 24 16 33686A 418 Yoke Guide Assy 2 Oylinder and Two Stage 1 3 6 A33576A 418 Yoke Guide Assy High Stage 1 2 2 4 4 A33347A 419 Screw 9 5 x 1 Cap Lock 2 6 25 12 s 1352D 420 Spacer Sleeve 2 6 12 33618 Except fo
244. n be extracted from the frame by means of a Vilter Liner Pulling Tool KT 257 This tool or similar is required for all 440 450 compressors and 2 stage compressors FIGURE 13 PISTON RING DIMENSIONS TABLE 1 PISTON RING DIMENSIONS AND TOLERANCES DIMENSION COMPRESSION OIL RING RING A 4 500 4 500 B 0 160 to 0 170 0 170 to 0 180 0 1230 to 0 1240 0 1860 to 0 1870 D 0 013 to 0 0225 0 013 to 0 023 E 0 002 to 0 004 0 0015 to 0 004 NOTE If the cylinder bank has unloading the unloader piston needs to be held down for ease in liner removal After a plain nut has been placed on a rod bolt and torqued to the specified value turn a Palnut to the rod bolt with the open end of the hexagon pointing away from the plain nut The Palnut should be turned until mating parts are pulled together and actual tightening begins Final tightening and locking is then achieved by giving the Palnut an additional 1 3 to 1 2 maxi mum turn Although the plain steel nuts may be reused new unused Palnuts must be used each time the connecting rods are reassembled to the crankshaft If used Palnuts are installed their 400 Series VMC SERVICE 23 The liners in the 450XL compressor have a looser fit into the frame They can be removed by pulling from the bottom of the liner by hand NOTE 2 Stage liners have an extra groove without ring that seals the suction chamber from the crank
245. nd remove all but bolt It may be necessary to tap the ends of the bolts with a soft hammer to start them out Pivot the disc pack out Put one of the coupling bolts through the pack securing it with a locknut This will keep the discs together and maintain the disc orientation for later reinstallation if reused Remove the last boll and slide the pack out B For the CMR coupling 1 Remove the bolts that hold the flywheei adapter to the flywheel Remove the acapter disc pack center ring assembly and put it on a bench 2 Remove all the locknuts washers and bolts that hold the center ring to the disc pack Remove the center ring Before removing the disc pack put a bolt through the pack and secure with a locknut Remove the rest of the locknuts washers and botts 3 Replace parts as necessary Recheck alignment per Section V Reassemble per Section VILA C For the AMR coupling 1 Now disassemble the other end per VIIA above being sure to support the center ring when taking out the last boits Remove the center ring 2 Replace parts as necessary Recheck alignment per Section V Reassemble per Section VI B VIII FOR REPLACEMENT PARTS ses Table 2 Pari Numbers and Quantity Required Sete Part Pan 511049 211046 211046 110717 For further assistance call Rexnord Corp Coupling Operation Warren 814 723 6600 FAX 814 726 1740 Is adding oil to the compressor crankcase
246. nd the flywheel for the axial draw Record this position between adapter when used shaft end and hub face with depth micrometer Mount a dial indicator to read axial hub Hub Mounting movement Set the indicator to 0 Remove hub A General Clean hub bore and shaft Remove any nicks or burrs if bore is tapered check for good contact pattern If the bore is straight measure the bore and shaft diameters to assure proper fit The key s shouid have a snug side to side fit with a small clearance over the tap B Straight Bore Instali key s in the shaft If the hub is an interference fit heat the hub in an oil bath or oven until bore is sufficiently larger than the shaft 350 degrees F is usually sufficient An open flame is not recommended However if flame heating is 1 and install key s Remount hub drawing it up the shaft to the 0 set point Continue to advance hub up the taper to the desired axial position Use the indicator as a guide only A pre set axial stop device can be helpful Check the final results with depth micrometer The hub may have to be heated in order to reach the desired position on the shaft DO NOT SPOT HEAT THE HUB OR DISTORTION MAY OCCUR Install shaft locknut to hold hub in place 1 98 V SHAFT ALIGNMENT Move equipment into place A Soft Foot footplane The equipment must sit flat on its base Any soft foot must be corrected now B Axial Spacing The axial spacing of the shaft sh
247. necessary The change in speed ratio from no load to full load should not exceed 1 Save used V belts for emergency replace ment but never mix new and used V belts on a drive Keep V belts as free of dirt and oil as pos sible Never paint V grooves on flywheel or sheave Never use V belt dressing on V belts V Belt Adjustment General Comments Tension usually is not critical but a few simple rules satisfy most requirements Best tension for a V belt drive is the lowest tension at which the V belts will not slip un der the highest load condition Check tension frequently during the first day of operation Too much tension shortens V belt and bearing life VMC INSTALLATION Keep V belts and sheaves free of for eign material which may cause slip V belt slips determine the cause for slippage and take corrective action Single 5V V Belt Adjustment The method of checking single V belt tension using numerical values is as follows 1 13 After proper V belt installation measure the span in inches Use a spring scale at right angles to the center of the span Apply enough force to deflect the V belt 1 64th of an inch for every inch of span length and record the scale reading The range of force should be 12 to 18 Ibs Make sure equal tension exists on all V belts in a set Correct original tensions as needed by shifting the motor slightly This point is v
248. ng 6 If you purchased the compressor from a party other than Vilter Manufacturing Corporation please state when you purchased the compressor and from whom VILTER MANUFACTURING CORPORATION SECTION 105 R FEBRUARY 2001 Replaces PAGE 2 440 VMC COMPRESSORS March 1975 BASIC FRAME REPLACEMENT PARTS FOR 2 CYLINDER VMC COMPRESSORS FIGURE 1 ad yede axe Dm SECTION 105 R VILTER MANUFACTURING CORPORATION PAGE 3 440 VMC COMPRESSORS BASIC FRAME REPLACEMENT PARTS FOR 4 6 amp 8 CYLINDER VMC COMPRESSORS FIGURE 2 128 February 2001 Replaces March 1969 124 126 old type February 2001 VILTER MANUFACTURING CORPORATION Replaces March 1969 440 VMC COMPRESSORS BASIC FRAME REPLACEMENT PARTS FOR 12 amp 16 CYLINDER VMC COMPRESSORS FIGURE 3 116 SERIAL NUMBER OPPOSITE END 131 old type 124A SECTION 105 R PAGE 4 SECTION 105 R VILTER MANUFACTURING CORPORATION November 2001 PAGE 5 Replaces 440 VMC COMPRESSORS February 2001 BASIC FRAME REPLACEMENT PARTS FOR ALL VMC COMPRESSORS NO REQ PER COMPRESSOR SERIAL NO ITEM DESCRIPTION TWO SINGLE STAGE STAGE PART NO OF CYL 2 4 6 8 12 16 6 12 FROM THRU NUMBER 101 Frame 1 1 1 1 1 1 1 1 102 Screw 7 x Head Used with Water Jacket 20 40 60 80 120 160 20 40 0 Present 13152L 102 Screw x 2 Hex Head
249. ng set Clean and inspect for wear Replace piston if wear is excessive a ring set con sisting of PTFE outer ring and a silicone rubber inner ring is used on the piston Re place ring set carefully with a new one every time a piston is removed With eyebolt re moved place the piston into its hole in the frame Compress the rings with the fingers and work them into the hole carefully so they are not nicked or cut as the piston is moved down Push the piston down until it touches the yoke lifting arm Actuator Mechanism Removal Before a capacity control actuator mecha nism can be removed from the compressor at least one of its corresponding cylinder lin ers must be removed The first step in re moving capacity control actuator from the machine is to push the unloader piston down with a block of wood Then take a piece of steel 16 in diameter or a piece of wood and insert it between the two vertical rods on the yoke assembly accommodating the short pivot pin and fulcrum pin This will hold the assembly depressed make handling much easier Then remove the unloader pis ton as detailed above The mechanism can then be removed through the cylinder liner hole in the frame Actuator Mechanism Replacement Compress the yoke assembly and place a small piece of wood or a s 7 94 mm o d steel rod between the two vertical rods men tioned in paragraph 4 This keeps the yoke depressed for easier handling Then p
250. ns tt 1 1 0 Present KT375 For Aluminum Pistons tt 1 0 Present KT376 229 Crankshaft 1000RPM w oilway plug For Aluminum Pistons TT 3068 Present KT370 For Aluminum Pistons T1 3068 Present KT371 For Aluminum Pistons TT 1 1 3068 Present KT372 For Aluminum Pistons TT 1 3068 Present KT373 For Aluminum Pistons tt 1 1 0 Present KT375 For Aluminum Pistons T1 1 0 Present KT376 229A Plug Pipe Hex Socket Head N S 5 5 8 8 5 8 0 Present 13163A NOTE 5 This bearing is interchangeable with the bearing Part A31988A originally used on the 2 4 6 and 8 cylinder compressors A spacer is incorporated as an integral part of this bearing eliminating the use of shims and a bearing lock When installing this bearing do not use the shims Item 230 and bearing lock Item No 226 All 1200 RPM VMC Compressors with Serial No 1660 and above have aluminum pistons All other 1200 RPM VMC Compressors with serial numbers 1659 and below have cast iron pistons If it is desired to change from cast iron pistons to aluminum pistons it is absolutely necessary to change the crankshaft When ordering a crankshaft bearing locknut Item 224 for a compressor with Serial No 9 999 and below also order crankshaft bearing lockwasher Item 225 See page 31 1 When ordering bare crankshaft for a compressor with Ser
251. nsmission of the small residual vibration associated with machinery containing moving components to the building and to damp out noise CAUTION Three types of isolators are used the first two types are used when mounting the Structural steel base directly on isolators and the third when using a concrete pad along with the compressor unit Follow proper adjustments for the type used COMPRESSOR UNIT STRUCTURAL STEEL BASE SLEEVE CONCRETE PAD ANCHOR UPPER BOLT FLOOR FIGURE 2 UPPER FLOOR INSTALLATION VMC 2 01 INSTALLATION 5 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Upper Floor Installations cont d Regardless of the type of isolators used the springs should never be compressed to the point of being solid Level adjustment of 19 05 mm is provided Isolators are shipped assembled with correct springs All springs are color coded Use color chart furnished with iso lator for spring identification Type W acousti cal friction pads are provided on the bottom to eliminate the need for bolting down on most in stallations 1 Type FLS Vibration Isolators For ordinary commercial upper floor instal lations the vibration can be absorbed ade quately with type FLS vibration isolators Such an installation using only isolators is accomplished by
252. nt V belts tend to turn over in the grooves and wear un necessarily fast leading to noise and loss of transmission efficiency NOTE Do not attempt to mix V belts Use only matched V belts provided by manufacturers and always specify type and size of V belts Do not use uncoated belts D Banded Joined 5V V Belt Adjustment To check banded 5V V belt tension use the following methods 1 Method Multiply the pounds of deflection force of 12 to 18 pounds by the number of V belts in the band Apply the tension tester to de flect the entire band Place a small board or metal plate on the top of the band so all v belts in the band are deflected a uniform amount Place a straightedge across the sheaves to use as a reference for measur ing deflections 2 Method B Move the sheaves closer together to facili tate installation of banded V belts Re move slack from V belts Measure the out side circumference of V belt to the nearest 1 2 6 35 mm Multiply this reading by 0 0075 to 0 01 and add this amount by your circumference length Example 80 x 1 2 8 80 80 8 VMC INSTALLATION 15 E V Belt Removal For Servicing Whenever it is necessary to remove V belts for equipment servicing follow the installation pro cedure outlined for the initial tensioning of the V belts whenever the belts are reinstalled XI ACCESSORIES AND ASSOCIATED EQUIPMENT A Oil
253. nt 33508B 239 Oil Dam Center Bearing tt 2 2 2 0 Present 33498A 240 Pin Threaded Taper e e 1 1 x 1 0 Present 33497A 241 Case Bearing Support 1 1 1 0 Present 242 Washer 1 2 Spring Lock s 4 4 4 0 Present 13165F 243 Nut 1 Hex 4 4 4 0 Present 1726E 244 Nut 16 Hex 1 1 1 0 Present 13253F 245 Screw 4 x Hex Head Cap tt 8 8 8 0 Present 2796AC 246 Key Crankshaft 1 1 1 1 ne 1 0 Present 31994B 246 Key Crankshaft ae s5 1 1 ee 0 Present 33505B 247 Screw Flywheel Hub 1 1 1 1 1 1 1 0 Present 31956A 248 Washer Fllywheel Hub Screw 1 1 0 33495 NOTES Matched set with pin sold as assembly A32163A Shown in three parts to illustrate disassembly A bearing lock pin Item 231A is used to keep outer face of bearing Item 231B from turning If compressor does not have groove in bottom of rear bearing cover Item 301 make a notch with a deep radius and 17 9 long to accommodate pin in cover 1 Mounting holes on retainer Item 231 were changed from counterbored holes to plain straight thru holes Use replacement screw part number 13160D on the former retainer with counterbored holes Use replacement screw part number 1736G on current retainer with straight thru holes tt Dams 239 and screws Item 245 are not needed when using VILTER s patented joined cranks
254. nts and pipes If a leak is present the escaping gas causes the test solution to bubble After all leaks are found and marked relieve system pressure and re pair the leaks Never attempt to repair soldered or welded joints while the system is under pres sure Defective joints should be opened and resoldered Do not add more solder to the leak ing joint After all the joints are repaired and the system is considered tight retest the system with refrigerant Attach a drum of refrigerant to the system and allow the gas to enter until a pressure of 5 psig 34 47 kPa is reached Remove the refrigerant drum and bring pressure to the recommended test level with oil pumped dry nitrogen Check the system for leaks using an appropriate leak detector Check all flanged welded screwed and soldered joints all gasket joints and all parting lines on castings If leaks are found repair and recheck them before the system is considered tight No repairs should be made to welded or soldered joints while the system is under pressure C Evacuating The System A refrigeration system operates best when only refrigerant is present Steps must be taken to remove all air water vapor and all other non condensibles from the system before charging it with refrigerant combination of moisture and refrigerant along with any oxygen in the sys tem can form acids or other corrosive com pounds which corrode internal parts of the sys tem VMC
255. number is stamped on the nameplate and the compressor frame The compressor frame serial number location is directly above the suction flange on the frame of the compressor or directly above the rear bearing cover The rear bearing is located on the oil pump filter end of the compressor 2 Always give the name of the part as well as the corresponding part number and or item number Also include the number of parts required 3 Should there be a doubt regarding the part number or name send a sketch of the part required or return the old part as a sample transportation charges prepaid Orders on which part numbers and description do not agree will be filled according to our best interpretation 4 f parts that appear on the parts list do not appear on the price list it is because they are sold only as an assembly All prices shown on the list are F O B factory Minimum domestic parts order is 75 00 net price Prices are for a single item unless otherwise specified in the price list 5 Please indicate on the order preferred method of shipment We will follow your instructions unless it is to your best interest to change routing 6 f you purchased the compressor from a party other than Vilter Manufacturing Corporation please state when you purchased the compressor and from whom VILTER MANUFACTURING CORPORATION PRINTED IN U S A SECTION 102 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 2 Replaces 450 VMC COMPRESSORS April
256. o 3637 33423A 2 2 4 4 4 4 NOTES A The above listing includes the minimum selection and quantity of recommended spare parts It may vary considerably depending upon the circumstances All items listed do not necessarily apply to every compressor because of serial number application or optional features Items that apply should be selected for each individual compressor B All of the above parts can be used with either ammonia R12 or R22 compressors unless specified otherwise February 2001 Original Issue VILTER MANUFACTURING CORPORATION SECTION 105 X PAGE 1 460 VMC COMPRESSORS REPLACEMENT PARTS LIST TABLE OF CONTENTS PAGE 1 REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS 2 Illustration 2 Cylinder Figure 1 3 Illustration 4 6 amp 8 Cylinder Figure 2 4 Parts List CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS 6 Illustration Figure 3 7 Parts List REAR BEARING COVER REPLACEMENT PARTS 8 Illustration Figure 4 9 Parts List CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS 10 Illustration Figure 5 11 Parts List PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS 12 Illustration Figure 6 13 Parts List REPLACEMENT PARTS ORDERING INSTRUCTIONS Give the size voltage original order number and serial number of the compressor All of this information is stamped on the nameplate attached to the compressor frame The serial number is also stamped on the compressor fra
257. o be freed The shaft seal cover shaft seal and inner re tainer will also have to be removed All special notes apply to this method as well D Servicing The Center Bearing 12 amp 16 Cylinders The center bearing on this compressor is a split sleeve type bearing much like connecting rod bearings To disassemble the bearing remove the four bolts holding the halves of the center 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor bearing housing together The bearing inserts are snapped into place and can readily be re moved by pushing them out by hand Clean the bearing housing thoroughly before installing new inserts Snap the inserts into place Lubricate the bottom half with refrigeration oil and position it on the crankshaft Do the same to the upper half and locate it using the dowel pins provided When aligned bolt the halves together and tighten with a torque wrench to the values listed in Table 2 3 or 4 depending upon compressor model NOTE If oil dams are present on the center housing they will need to be reinstalled if only changing the insert bearing The current center housing does not require these dams E Reinstallation Whichever method was used to remove the crankshaft extreme care is needed when placing the shaft back into the frame Avoid any damage to the journals and block the crankshaft once in position If the c
258. of the drive end of the frame If the crankshaft is taken out of the pump end the entire shaft seal must be removed B Removal From Drive End Remove any connections that will hinder the re moval of the front bearing housing When dis connecting the front oil line be prepared to catch approximately 1 gallon of oil Remove the shaft seal and inner retainer Replace the two 75 15 88 mm x 4 101 6 mm socket head screws with threaded studs to sup port the front housing during removal Remove the 6 168 28 mm x 2 50 8 mm cap screws that hold the housing to the frame Using the 4 101 6 mm socket head screws insert them into the tapped holes on both sides of the housing to aid in the removal of the front housing from the frame and off the front bearing During this proc ess the housing will have a tendency to hang up on the outer diameter of the bearing thus pulling the entire shaft with it and possibly disengaging from the rear housing Care must be taken to prevent this from happening While the front housing is being removed push on the crank shaft to be sure it is staying in the rear housing On a 458XL and 4516XL compressor the rear housing will have to be removed because the radius of the counterweight is larger than the ra dius of the front housing bore Thus the shaft will be hindered from coming straight out of the frame On a 12 or 16 cylinder compressor the center bearing must be freed At
259. omas type num ber See Figure 5 for recommended direction of compressor rotation X V BELT COMPRESSOR UNIT Compressors equipped with SV V belt drives are designed to meet necessary horse power requirements They are furnished as a matched set of individual V belts or optionally at added cost as a banded joined unibelt The V belt is one of the simplest and most de pendable methods of transmitting power from one machine to another The drive when properly installed is quiet relatively smooth operating and practically maintenance free Use of the correct tension in any V belt drive is necessary to obtain the maximum service and capacity from the drive Excessive tension will greatly decrease the service life of the V belts while insufficient tension will not allow the V belts to transmit maximum load CAUTION Because equipment alignment could be dis rupted during shipment check drive ment before start up Always follow proper V belt tensioning procedures See V belt drive tag furnished with equipment 2 01 REPLACES ALL PREVIOUS ISSUES TABLE 4 THOMAS COUPLING DIVISION TYPE 201 DBZ B VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor DRIVE COUPLING PART NUMBER CROSS REFERENCE VILTER PART NUMBER TAPER BORE HUB COMPRESSOR BORE DIMENSIONS LARGE END 1 883 47 8 mm PART NUMBER CENTER MEMBER ASSEMBLY STRAIGHT BORE HUB MOTOR BOR
260. ompressor inspect the gasket surfaces of the cover and compressor frame Remove any debris adhering to either of these surfaces Remove any burrs or rough edges from the mating surfaces to ensure a tight seal Replace studs if removed Lightly lubricate both sides of the head gasket Position the gasket over the studs and against the com pressor frame in the correct orientation Place the springs on top of the safety head yokes ro tating the spring until it stays on the yoke Place the cover down over the studs and slowly lower on top of springs When all pieces are in align ment place the nuts on the studs and start to tighten When the cover is secure within 114 31 75 mm of the gasket install the rest of the screws so they come in contact with the cover This will ensure they will not cross thread in the holes Do not tighten each screw separately however Alternate on opposing screws until the cover is seated on the gasket Remove the studs and replace with screws Finish tightening the screws in an opposing pattern to the recommended torque values shown in Table 2 3 or 4 depend ing upon your compressor model Reinstall the capacity control and head cooling lines and check for leaks 400 Series VMC SERVICE 3 lll SUCTION AND DISCHARGE VALVE PLATES NOTE Before proceeding refer to Paragraph General Service Instructions A Disassembly To service valve plates in the compressor re
261. on all high stage compressors except those with 100 capacity reduction Oil unloading is standard on high stage compressors with 100 capacity reduction all boosters and two stage compressors with capacity reduction If a single cylinder unloader mechanism serviced uses pivot bolts to hold down one half them mechanism it should be replaced by 405A and 405B SECTION 100 R VILTER MANUFACTURING CORPORATION PAGE 16 450XL VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS FIGURE 8 Booster amp 2 Stage Low Side 520 PATENTS PENDING February 2001 Replaces May 1985 February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 17 May 1985 450XL VMC COMPRESSORS PISTON AND CONNECTING ROD ASSEMBLY AND SAFETY HEAD REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 501 thru Piston Rings and Connecting Rod Assy Kit 2 4 6 8 12 16 KT573 508 501 Piston Ring Compression 6 12 18 24 36 48 31989M 502 Piston Ring Oil 2 4 6 8 12 16 31989N 503 Piston and Connecting Rod Assy 2 4 6 8 12 16 ae 504 507 Bearing Half and Lock Nut Kit 2 4 6 8 12 16 575 amp 508 504 Lock Nut 7 Connecting Rod 4 8 12 16 24 32 2028A 505 Nut Plain Hex s UNF 4 8 12 16 24 32 2027A 506 Bolt Connecting Rod 4 8 12 16 24 32 31955A 507 Bearing Half Connecting Rod
262. ontrol Pressure Differential 1 1 1 1 1 1 1643V 333 Gasket Bearing Cover 1 1 1 1 1 1 31890A 334 Screw s x 2 Hexagon Head Cap 10 10 10 10 10 10 13152E 335 Screw 1 2 x 194 Hexagon Head 8 8 8 8 8 8 2796EL Patents Pending Filter with bypass relief is standard These items are used Filter without bypass relief is optional When supplied these items are used 1 Replacement recharge also includes gasket 1448B Item 321 SECTION 100 R VILTER MANUFACTURING CORPORATION December 2001 PAGE 14 Replaces 450XL VMC COMPRESSORS February 2001 CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS FIGURE 7 10 9 49 ow lt gt A 411 j se m 407 s 405 14 uf 4 FOR CYLINDERS WITH 7 UNLOADING 2 4 uf 408 E TWO STAGE ONLY n 405B 2 FOR CYLINDERS NEXT TO A SINGLE CYLINDER UNLOADER PATENTS PENDING December 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Replaces PAGE 15 February 2001 450XL VMC COMPRESSORS CYLINDER LINER AND CAPACITY CONTROL REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 401 402 Cylinder Liner Assembly amp 403 for cylinder without unloading 2 1 2 2 4 4 8 KT475 401 402 Cylinder Liner Assembly Thru 408 for cylinder with unloading 1 2 4 4 8 8 KT47
263. ools pictured in this sec tion B Preparation Of Compressor For Servicing Remove all refrigerant from the compressor be fore servicing it To properly evacuate the com pressor employ the following procedure 1 Refrigerant 717 Ammonia Compressor Shut down the unit open the electrical dis connect switch and pull the fuses for the compressor motor to prevent the unit from starting Put a lock on the disconnect switch and tag the switch to indicate maintenance is being performed Isolate the unit by manually closing the dis charge stop check valve Close the liquid supply valves and open all solenoid valves to prevent liquid refrigerant from being trapped between the stop valves and solenoid valves Allow the unit to equalize to suction pressure before closing the suction 400 Series VMC SERVICE 1 stop check valve After the unit has equal ized to suction pressure depressurize the unit by using a pump down compressor or other acceptable means Remove drain plugs from the bearing hous ings compressor housing and discharge manifold Drain the oil into appropriate con tainers To blow off the gas caught between the dis charge valves and discharge stop valve close the gauge valve remove gauge con nect one end of a hose to gauge valve and put the other end in a bucket of water Open the valve slowly and the water will absorb any discharged ammonia Connect hose to the suction gauge connec tion in the sam
264. ore easily VIII For spare replacement parts sse Table 2 Table 2 Part Number and Quantity Required Diac Pack Parts Kit consists of Washers or Links Ske Center wo per Cpig Bolts and Locknuts for one Coupling of Ring Tom Stain Parts Washer DBZ alo less 1 Kit or Link Long Bolt Short Bolt DBZ A Part Part Part Part Part Part Part DBZ B No No No NO No No No No No 50 114401 1514402 314405 710492 9104921716320 312659 21049 2 414412 114413 014416 510601 1710601 816320 nons 112657 01052 75 114423 814424 514427 710523 1910523 816320 none 112657 01052 101 716104 216105 814438 910619 310619 915320 511192 8 1711162 411161 126 116106 816107 414445 910618 310618 1163201002161 8 1831198 510728 163 816108 616109 0160221410954 610954 416320 002161 15 1811198 51072 201 4161101016111 414471 710624 910624 001950 002170 411206 21072 226 5161121116113 614482 1610689 210689 001953 011874 011250 01063 716414 216115 514491 920357 120357 001956 211875 710788 41078 4161151516117 414500 420359 620359 001958 411876 4 12 616118 716119 314509 820361 0203651 001960 711877 12 016122 115123 gt a For further assistance call Rexnord Corp Coupling Operation Warren PA 814 723 6800 FAX 814 728 1740 Rexnord Hae Couplings Thomas Installation Instruction Warnin
265. ositioned in a machined seat in the top of the front bearing housing An adjust ing screw turned in and out changes the amount of oil bypass thus changing the oil pressure Remove the cap A packing tool is required to remove the gland nut Vilter Part No A337814 After the gland nut has been removed use a large screwdriver to turn the stem counterclock wise and remove it completely The packing with 2 washers should also come out Using a pencil magnet pull out the spring and steel ball B Reassembly Clean the steel ball and place in the hole Place the stainless steel spring on top of it Screw the adjustment stem in the hole to get threads started Place a washer over the end then pack ing then the other washer The adjustment stem may have to be turned in so the packing nut can be installed and tightened Adjustments of the oil pressure will have to be reset after start up Re place the cap and gasket afterwards C Adjustment To provide quick response of the compressor unloader mechanism it is recommended the oil pressure relief valve be set to maintain 40 psi 275 79 kPa net oil pressure Net oil pressure should be held at 35 psi 241 32 kPa and 40 psi 275 79 kPa Net oil pressure is calculated by subtracting the compressor suction pressure from the oil pressure gauge reading while the compressor is running VIII TRI MICRO OIL FILTER 400 Series VMC SERVICE 17 NOTE Before proceeding refer
266. ot slip under the load Single 5V V belts One device that provides the most accurate way of measuring the tension of the drive belts is a belt tension spring scale Vilter Part No 3072A See Figure 6 This device measures the amount of force needed to de flect the belt a given amount The range of the readings should be between 12 to 18 lbs The deflection should be per inch of span If the span of the belts from the sheave to the flywheel is 38 inches the 400 Series VMC SERVICE 11 amount of deflection should be 4 7 54 mm and the tension required to achieve it should be between 12 to 18 lbs FIGURE 6 BELT TENSION SPRING SCALE L R SMALL O RING BODY WITH SPAN SCALE PLUNGER WITH FORCE SCALE The belt tension spring scale is placed in the center of the belt span The scale is then pushed down until the proper deflec tion is reached The tension should then be read and recorded The process is then re peated for the remaining belts If the tension is too low the belts should be tightened evenly and rechecked The tension between belts should be within 1 lbs of each other Inconsistent meas urements indicate problems with alignment belt length and or wear of the drive compo nents The problem should be corrected before the unit is returned to service Banded 5V V belts Due to their design banded V belts require special tensioning techniques in order to set the tension pro
267. ould be positioned so that the disc packs flexing elements are flat when the equipment is running under noma operating conditions This means there is a minimal amount of waviness in the disc pack when viewed from the side This will resuit in a flexing element that is centered and parailel Move the connected equipment or hub s on their respective shaft s to accomplish the above NOTE The disc pack is designed to an opti mal thickness and is not to be used for axial adjustments As a guide maximum and minimum values for dimension C are given These dimensions are suggested for initial installation Additional capacity is available to compensate for thermal and Structural movement Maximum axial capacity values for these couplings are also given See Table 1 and Figure 1 C Angular Alignment Rigidly mount a dia indicator on one hub or shaft reading the face of the other hub flange or flywheet adapter as shown in Figure 2 Rotate both shafts together making sure the shaft axial spacing remains constant Adjust the equipment by shimming and or moving so that the indicator reading is within 002 inch per inch of coupling flange diameter See Chart A D Parallel Offset Rigidly mount a dial indicator on one hub or shaft reading the other hub flange or flywheal adapter outside diameter as shown in Figure 3 Compensate for indicator set up sag Rotate both shafts together Adjust the equipment by shimming and or moving so
268. ound the pistons and slide the ring over this Do not force the rings when sliding them onto the shim stock The rings are brittle and may snap A tool is also available to aid in the installation of the rings Both compression and oil rings are marked to indicate the top of the ring Install the compres sion rings with the identifying mark to the top of the pistons Rotate the end gaps on each ring so they are not aligned on the piston Remove the piston assembly Check the fit of the piston pin bushing for wear The 440 and 450 have a different pin and piston design from the 450XL compressor The 440 and 450 piston and piston pin bushing have slip fit When replacing the piston and bushing the bushing must be reamed to the correct slip fit after in stallation into the rod to accommodate the new piston pin The 450XL piston and piston pin bushing cannot be changed in the field due to tolerances They must be purchased as a unit with the connecting rod and piston assembly The piston pin should not slip easily into its hole but it must not be driven down It may be neces sary however to tap the pin lightly with a block of wood and a hammer Be sure the hole in the rod pin bushing is aligned so the pin can slip through it When the pin has been tapped in far enough install the two piston pin lock rings one at each end of the piston pin Two styles of bearing half inserts have been used in the compressor One style
269. per between 2 and or L must be field installed The P28 and P128 controls are shipped with a cut out pressure differential of 9 psi 62 kPa However the controls can be adjusted according to the compressor manufacturer s specifications Note When the controls are shipped as an Transformer 240V ar 3 phase accessory to the compressor unit time delay and cut out pressure are set to manufacturer s specifications Replacement controls should duplicate the manufacturer s specifications Alarm if Used A CAUTION Equipment damage hazard To avoid damage to the compressor obtain the compressor manufacturer s net oil bearing pressure specifications as soon as possible If necessary reset the cut out pressure difference to the Additional controls in this line only manufacturer s specifications 12 volt also available TM When the manufacturer s specifications are not known Figure 9 P28 or P128 Where 24V Control Circuit proceed as follows to set the cut out pressure Power is from a Step down Transformer Jumper differential between 2 and M must be field installed 1 With the compressor running read the oil pressure and the crankcase pressure 2 Subtract the crankcase pressure reading from the oil pressure pump discharge reading This is the net oil pressure to the bearings 6 P P28 and P128 Series Lube Oil Controls with Built in Time Delay Relay Product Technical Bulletin
270. perly There are two methods to check the tension of banded belts They are as follows The first method utilizes a tension tester to measure the deflection The number of belt bands in the belt is multiplied by the deflec tion force of 12 to 18 lbs A board or metal plate is then placed across the bands to equalize the force as the tension tester is depressed on the board or plate Banded V belts cont d 2 01 Replaces all Previous Issues 2 VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A straight edge is positioned across the sheave and flywheel to use as a reference to measure the deflection of the belts The second method measures the amount of stretch as the belts are tightened to deter mine the tension of the belts The banded belts are installed on the drive and rotated to get all the slack on the bottom side The belts are then tightened to remove the slack from the belts Measure the outside circum ference to the nearest 1 2 6 35 mm Multi ply this reading by 34 0 0075 to 1 0 01 Add this to the circumference read ing Elongate the belt to the new length EXAMPLE 80 x 1 0 8 80 80 8 Direct Drive Compressors Coupling Removal Remove the guard Remove the bolts that extend through the coupling and remove the center member Remove the bolts that hold the shim packs to coupling and make note of location of the washers Using one or two of these bolts through
271. pically on one illustration SECTION 100 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 6 Replaces 450XL VMC COMPRESSORS May 1985 BASIC FRAME REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 117 Pin Assembly Crankcase Oil Screen Retaining 1 1 1 1 1 1 A31936A 118 Safety Valve Internal Relief 1 1 1 1 2 2 1721C 119 Gasket 2 Flange 1 1 1 1 2 2 11323G 120 Cover Safety Valve 1 1 1 1 2 2 31954A 121 Screw 2 8 x 2 Hex Head 2 2 2 2 4 4 13152 122 Gasket Handhole Cover Chain 1 1 1 1 2 2 35382A 122 Gasket Handhole Cover Strip 1 1 1 1 2 2 31894A 123 Handhole Cover and 2 Sight Glass Assy 124 With openings for 560W NEMA 1 amp 7 Htr F V amp Therm 1 1 1 1 1 1 A33034G 560W NEMA 1 amp 7 Heater and Therm 1 1 1 1 1 1 A33034L 123 Cover Handhole with openings 1 1 1 1 1 1 Order Assy 123A Cover Handhole without openings not shown Ec s 1 1 33034B 124 Glass Oil Sight 2 1 1 1 1 1 1 1484A 125 Screw 1 2 x 17 Hex Head Cap 16 16 16 16 32 32 2796E 126 Tube Oil Feed Connector 1 1 33494 127 Spring 1 1 31789 135 Hex Head Plug Long Shank Unloader Hold Down 1 2 35166A 136 Hex Head Plug Short Unloader Hold Down NOTES Patents Pending February 2001 VILTER MANUFACTURING CORPORATION SECTION 100 R Original Issue PAGE 7 450XL VMC C
272. pound Kit for Aluminum Pistons 1 KT370 for Aluminum Pistons 1 KT371 for Aluminum Pistons 1 KT372 for Aluminum Pistons F 1 KT373 231 Retainer Rear Bearing 1 1 1 1 31904A 231A amp 231B Rear Bearing and Lock Pin 1 1 1 1 KT353 232 Screw 16 112 Hex Head 4 4 4 4 1736G 233 Crank Oil Pump Drive 1 1 1 1 33403A 246 Key 27 Crankshaft 1 1 1 1 31994B 247 Screw Flywheel Hub 1 1 1 1 31956A 248 Washer Flywheel Hub Screw 1 1 1 1 33495A February 2001 VILTER MANUFACTURING CORPORATION SECTION 105 X Original Issue PAGE 8 460 VMC COMPRESSORS REAR BEARING COVER REPLACEMENT PARTS FIGURE 4 Typical arrangement when optional Center Tube Spool Assembly Item 31 without bypass relief is used 327A 327A see insert 01180 DO NOT DISASSEMBLE CENTER TUBE FACTORY PRESET RELIEF VALVE SECTION 105 VILTER MANUFACTURING CORPORATION February 2001 PAGE 9 Original Issue 460 VMC COMPRESSORS REAR BEARING COVER REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 NUMBER 301 thru Rear Bearing Cover Assembly Kit 1 1 1 1 KT092 304 amp 333 301 Cover Rear Bearing 1 1 1 1 Order Kit 302 Plug 3 2 Hex Socket Head Pipe 1 1 1 1 13163 303 Pin x 1 Dowel 1 1 1 1 2868H 304 Orifice Oil Metering not shown 1 1 1 1 33361A 305 Gasket Oil Pump Body 1 1 1 1 31899A 306 Oil Pump Assembly
273. pressors oil is returned to the crankcase chamber on the pump end of the compres sor NOTE This float valve is designed to open when oil level in the float chamber rises Make a visual check before installing in chamber The word TOP is stamped on the outside of the float Remove the tie wrap on float valve flange valve This is used to transport the valve The float valve must be installed in the chamber as indicated on the flange Proper positioning at installation will ensure trouble free operation later Connect the float valve chamber and float valve to the separator with tubing Use the support plate to hold the float valve cham ber DO NOT support the float valve chamber by the tubing or pipe along the separator or weld on the separator or float VMC INSTALLATION 17 valve chamber float valve outlet should be in the horizontal plane B Crankcase Heater Three types of crankcase heaters are available for use with all Vilter VMC Compressors The first is a blanket heater cemented to the bottom of the compressor It is primarily used in out door applications The second type is an immersion type heater It is mounted in the crankcase handhole cover on 400 Series VMC Compressors only These heaters keep the crankcase and oil warm during the off cycle preventing refriger ant from condensing When refrigerant con denses in oil during the off cycle lubrication problems and nu
274. pressure on the oil charger check valve and quick connector With the Vilter motor driven oil charger take care not to operate the charger unless the oil charging valve on the crankcase is open If a motor driven charger is allowed to operate with this valve closed enough pressure might build up to rupture the charging hose or cause damage to the pump The pump motor is pro tected by means of an automatic cut out switch mounted in the motor However do not allow the motor to cycle repeatedly on this cut out device or damage to the motor will result For the correct oil charge for VMC Compressors refer to Table 7 Reserve one to two gallons of the total com pressor oil charge and charge into the com pressor via the oil gauge connection just before initial start up Follow this same procedure af ter a compressor is shut down for an extended period of time This helps eliminate dry start up by forcing oil into small oil passageways Charging oil at this point is done as follows Remove the oil pressure gauge and Stedy Mount Connect the oil charging hose electric or manual to the oil pressure gauge connec tion Open the valve and begin charging Con tinue charging until a sufficient amount of oil is charged Disconnect charging hose close valve and reassemble gauge and Stedy Mount When several compressors are connected to a common system it is recommended that oil equalizing connections between compressors be provided
275. pril 1984 450 VMC COMPRESSORS High Stage Two Stage Booster and Heavy Duty CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS FIGURE 5 211 211 o 229 2 thru 8 cylinder 232 231 233 fv Cad 12 amp 16 cylinder SECTION 102 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 10 Replaces 450 VMC COMPRESSORS April 1984 High Stage Two Stage Booster and Heavy Duty CRANKSHAFT AND FRONT BEARING COVER REPLACEMENT PARTS QUANTITY REQUIRED PER COMPRESSOR ITEM DESCRIPTION NUMBER OF CYLINDERS PART 2 4 6 8 12 16 NUMBER 201 thru Front Bearing Cover amp Relief Valve Assy 1 1 Ses A31121A 211A Front Bearing Cover amp Relief Valve Assy a 1 1 1 1 A32566A 201 thru Complete Crankshaft Sub Assembly Kit 1 KT445 233 Complete Crankshaft Sub Assembly Kit 1 446 Complete Crankshaft Sub Assembly Kit 1 KT447 Complete Crankshaft Sub Assembly Kit 1 KT448 Complete Crankshaft Sub Assembly Kit HD 1 KT553 Complete Crankshaft Sub Assembly Kit 1 449 201 thru Complete Crankshaft Sub Assy Kit Hi Stage HD 1 554 244 less Complete Crankshaft Sub Assy Kit Booster 1 555 201 Cap Valve 1 1 1 1 1 1 17355A 202 Gasket Durabla 1 1 1 1 1 1 30651C 203 Nut Packing 1 1 1 1 1 1 31048A 204 Washers 2 2 2 2 2 2 31048D
276. r 2 cylinder and Two Stage machines parts quantities are listed for standard unloading only The 2 cylinder Two Stage quantities are listed in parentheses for the 50 option Standard unloading on compressors with 2 cylinders is none 4 cylinders is 50 6 cylinders is 33 and 66 8 cylinders is 25 and 50 12 cylinders is 33 and 66 16 cylinders is 25 and 50 and Two Stage is none See Operation Section for unloading options Also for single cylinder unloading the yoke assembly Item 414 and two pins on the yoke guide assembly Item 418 have drilled and tapped holes to accommodate screws Item 419 and spacers Item 420 Actuation type can be determined by checking the unloading solenoid valve gas uses two way valves oil uses three way valves For oil unloaded compressors In serial number range 45 000 thru 45 858 the design version of unloader piston with one Rubber Ring in a 0 187 in Groove was used In serial number range 45 859 thru 45 999 a PTFE Rubber Ring Set in a 0 120 in Groove was used Pistons are interchangeable but the rings are not This lower O Ring Seal is for Two Stage Compressors only Some initial design High Stage Compressors also had a similar seal Its use on the High Stage machine was discontinued because it is not really needed It is no longer available Do not order the Two Stage Seal for use on these older High Stage machines It will not fit For serial numbers above these ranges see
277. r Replacement 19 CRANKSHAFT SEAL 19 Seal Leakage 19 Removal 19 Installing A New Shaft Seal 19 CONNECTING RODS AND PISTONS 20 Disassembly 20 440 amp 450 VMC Compressors Only 20 450XL VMC Compressor Only 20 Reassembly 23 CONNECTING RODS AND PISTONS 23 Disassembly 23 440 amp 450 VMC Compressors Only 23 450XL VMC Compressor Only 23 Reassembly 23 CYLINDER LINERS 23 Removal 24 Lift Rings For Unloading 24 440 Lift Ring Assembly 24 450 450XL Lift Ring Assembly 24 Installation Of Liners 24 CRANKSHAFT 25 General 25 Removal From Drive End 25 Removal From The Pump End 25 Servicing The Center Bearing 12 amp 16 Cylinders 26 Reinstallation 27 MODIFICATION TO FRONT BEARING RETAINER AND FRONT BEARING COVER 440 Compressor Only 31 CONNECTING ROD NUTS TIGHTENING INSTRUCTIONS VMC COMPRESSORS VMC 2 01 SERVICE B REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor SERVICE SECTION ILLUSTRATIONS AND TABLES PAGE FIGURE 3 Bearing And Cylinder Covers Assembly amp Disassembly Stud 5 2 Upper Cylinder Cross Section 6 3 Discharge Diaphragm Valve Placement 8 4 Flywheel Removal Tool 9 5 Unit Belting Requirements Due To Horsepower 11 6 Belt Tension Spring Scale 13 7 Typical Capacity Control Mechanism Arrangement 440 Compressor Old Style Mushroom Type 15 8 Typical Capacity Control Mechanism Arrangement 450 amp 450XL Compressors New Style Bullet Type 16 9 Safety Valv
278. r the home office should be notified of any claim made TABLE OF CONTENTS This manual consists of the following sections EXTENDED STORAGE PROCEDURES INSTALLATION INSTRUCTION SECTION This section should be read thoroughly before attempting to install a VMC Compressor IMPORTANT Local codes and ordinances should be checked beforehand so that violations do not occur especially concerning devices for control and safety COMPRESSOR OPERATION SECTION COMPRESSOR SERVICE SECTION COMPRESSOR REPLACEMENT PARTS SECTION Section 100R Section 102R Section 105R Section 105X B 0 6 EXTENDED STORAGE PROCEDURES If equipment is to be used for indoor duty it must be stored in a heated enclosure If the equipment is to be used for outdoor duty and will be stored outdoors adequate drainage should be provided so water does not collect inside the base perimeter compressor stop valves are to be closed so the compressor is isolated from the remainder of the system All other valves except those venting to atmosphere are to be open Cover all bare metal surfaces coupling flange faces etc with rust inhibitor Desiccant is to be installed in the control panei if applicable If the panel is equipped with a space heater it is to be energized If the panel does not have a space heater use a 50 watt light buib Use an approved electrical spray on corrosion inhibitor for panel components relays sw
279. ra with locknut equipment by shimming and or moving et eames be that the Indicator reading is within ubricated d ed 002 inch per inch of the axlat length between fiex elements See Chart NOTE If the driver or driven equipment alignment specification is tighter than thase recommendations the specification On size 226 and larger a link must be put on the bolt first Remove the disc pack alignment bolt Proceed to mount the second disc pack to the other hub In the same way should be used Also sure to compensate for thermai movement in the Table 1 Locknut Tightening Torques Coupling Dimension Thread Torque Siza Diameter Size Ft Lbs In Lbs 50 62 2 00 1 36 1 37 1 41 6 40 2 44 1 74 1 75 1 75 10 32 75 2 69 1 77 1 78 1 75 310 32 101 3 22 2 08 2 10 1 97 112 28 96 126 3 84 2 48 2 48 2 31 1 4 28 156 163 4 56 2 46 2 48 2 31 1 4 28 156 5 34 2 96 2 98 2589 5 16 24 3 83 3 85 3 31 3 8 24 4 33 3 75 7116 20 NOTE 1 These torque vaiues are approximate for steel bolts with iubricated threads Modification will be necessary for stainless steel For stainiess steel the tightening torque must be reduced to 60 of the values shown Bolt and locknut threads must also be liberally coated with molybdenum disulflde grease 2 Bolts should be held from rotating while the locknuts are torqued to the values shown Po
280. rainers Check all V belt drives Replace worn V belts and drive components CAUTION Replace V belts in matched sets only 19 20 21 Check drains to make sure water will flow away from equipment Drain and clean compressor crankcase Flush oil circuit Replace oil filter recharge Recharge with new clean water free oil Check and clean suction strainer 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor E System Leaks Because of the demanding operational con straints of the VMC Compressor temperature variations loosening of joints due to vibration etc the need to periodically test for leaks is a necessity When any service operation is per formed on the system exercise care to make sure all opened flanges are replaced with a suitable thread filling compound all packing glands on valve stems are tightened and all valve caps are replaced When operation is restored all joints opened or any valves moved during the servicing should be checked for leaks F Year Round Operation When refrigeration equipment is operated on a continuous year round basis a yearly examina tion of all internal compressor parts is recom mended While the highest material standards are maintained through the Vilter VMC Com pressor line continuous operation and any presence of grime may prove detrimental to the machine To prevent shutdowns and or possi ble b
281. rankshaft was removed from the front end and the rear housing left in place with the oil pump it is imperative the locating pin on the rear bearing align with the slot in the bottom of the rear housing bore Also the pump drive key must engage with the pump shaft If the unit is 12 or 16 cylinder the center bearing must be guided into place Align the hole in the bearing housing for the oil feed connector tube with hole in the frame Screw the oil feed con nector loosely on the end of the 1 2 12 7 mm threaded rod and insert it into the hole Push the tube into the bearing housing Unscrew the rod from the tube Place the spring in the hole and screw in the tee Use thread sealant Insert the taper pin it its hole After placement pin must be tightened This expands the bearing housing so it fits tightly in the frame for quiet operation 400 Series VMC 2 01 SERVICE 26 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor MODIFICATION TO FRONT BEARING RETAINER AND FRONT BEARING COVER AFTER COMPRESSOR SERIAL NUMBER 21354 440 COMPRESSOR ONLY Compressors below serial number 21355 were furnished with the front bearing cover assemblies A30294A no longer available for 2 4 6 and 8 cylinders A32162A for 12 and 16 cylinders front bearing retainer 38115A for 2 4 6 and 8 cylin ders or 33500A for 12 and 16 cylinders without the oil hole Former front bearing retainers 31885
282. reakdowns your machine should be opened annually The condition of the internal components should be fully inspected to deter mine if parts need replacement or repair G Flushing The Oil Circuit The oil circuit of the Vilter VMC Compressor is protected against dirt grit and other foreign material by strainers and filters Despite the filtering system microscopic particles of foreign materials are carried through the lubrication system These materials tend to settle in and clog the oil passages Vilter recommends the oil circuit in the crankshaft be flushed periodi cally It should also be done whenever the ma chine is opened for repairs Use mineral spirits or some other suitable refrigerant parts cleaner for flushing purposes Since the flushing fluid is pumped under pressure the use of the Vilter oil charger is recommended VMC INSTALLATION 31 The machine should be pumped down for ser vicing the oil taken out and the handhole cover removed Remove the 6 35 mm pipe plug from the top of the seal chamber Connect the Vilter oil charger to this opening Pump the flushing solution through the seal chamber and into the crankshaft Remove each of the pipe plugs in the crankshaft individually and operate the pump until the cleaner is flushed through the hole Remove the plug remove the next one and repeat the pumping procedure After the plugs are removed and these pas sages flushed remove the bearing caps an
283. reinforced concrete foundations The installation illustrated in Figure 1 is rec ommended for VMC s that include a steel base The raised concrete pad allows efficient clean ing while providing a level position Regardless of method used the unit must be level NOTE For even smoother operation once base is mounted on a concrete pad encase base in concrete STRUCTURAL When placing the foundation on an existing concrete slab the surface must be rough thor oughly clean dry and free of oil Foundation bolts are to be anchored into the concrete slab and must line up with the bolt holes on the structural steel base If the floor is not of suffi cient thickness or if the subsoil has not been sufficiently compacted an inertia pad will be required to support the unit and dampen any vibration zB T mh i REBAR HH HH Hf CONCRETE AD ES EXISTING FLOOR 7 ANCHOR BOLT FIGURE 1 TYPICAL GROUND FLOOR INSTALLATION VMC COMPRESSORS WITH STRUCTURAL STEEL BASE VMC 2 01 INSTALLATION 4 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor B Upper Floor Installation Install only the 2 through 8 cylinder VMC Com pressors on upper floors Upper floor installa tions generally require using special vibration isolators to prevent tra
284. ring charging When the bubbles stop close the drum valve Next close the suction valve and operate the system in the normal manner Remove the refrigerant drum from the system and replace the gauge in its normal position XVII THE INITIAL START Before starting the compressor and putting the system into use it is advisable to check certain items to assure proper operation A Controls Check the setting of the dual pressure switch so the compressor starts at the desired suction pressure and the cut out or differential is set low enough to prevent short cycling The high pressure cut out switch should be checked for proper setting The cut out set point for R22 is 275 psi 1806 07 kPa and for R717 is 225 psi 1551 33 kPa Electrical interlocks which are installed mainly for system component protection should be checked to ensure they are functioning prop erly All safety controls must always be wired into the compressor electrical circuit to ensure protection for the compressor Check the superheat setting of the thermostatic expansion valve Take a temperature reading at the remote bulb of the valve and compare it with the temperature corresponding to the suc tion pressure The bulb temperature should be VMC INSTALLATION 28 about 10 degrees greater than suction tempera ture If there is a large pressure drop in the low side of the system the above method does not apply and the evaporator pressure should be
285. roof of flow hookup 2 Complete Product Number if available 3 If complete Product Number is not available specify Type Number see Specifications table and the following 4 Type of refrigerant or fluid a Non corrosive b Ammonia 5 Style of pressure connector Optional constructions 7 Setting contacts close at and open at OPERATING 240 VOLTS CONTROL Lo JUNCTION BOX Fig 4 Typical wiring diagram showing the P74AA and a P28 on a motor operating two compressors P74 Product Bulletin 3 L3 OR CONNECTOR AS SPECIFIED 2 MOUNTING HOLES 10 32 UNF 2B THREAD CAPILLARY fe 3225 25 3 25 100 85 f 25 4i i3 9 LOT CAPILLARY e e sas lec pia 203 DIA MOUNTING HOLE AS SPECIFIED 1 89 91 52 x 203 DIA ELONGATED 48 3 98 MOUNTING HOLE 101 Ig 19 49 2 Pressure Element Dimensions Stainless Steel Brass 209 A 1 28 1 81 94 ED 128 557 33 46 NN A 80 144 20 37 is 3 88 DIA 1 73 1 69 22 245 RI ES Bia aos CONDUIT OPENING 44 43 Dimensions mm Performance specifications appearing herein are nominal and are subject to accepted manufacturing tolerances and application variables CONTROLS Controls Group 507 E Michigan Street P O Box 423 Milwaukee WI 53202 4 P74 Product Bulletin Printed in U S A HANSEN TECHNOLOGIES CORPORATION HCK4 4 Ch
286. rque capacity listed the table below when the cap screws tightened as indicated The bushings are stocked in all popular bore sizes including metric bores within the bore range for a particular bushing Bushing Bushings Bushings QT JA to J inclusive M to S inclusive E L 3 4 taper per w Setscrew w Setscrew E ft on diameter Except JA SURE GRIP BUSHING TORQUE RATINGS AND DIMENSIONS Torque Note 1 Note 2 Cap Bush Capacity Max Max PS LIMES Bolt Screws In Lbs Bore Bore A B D E L Circle Required QT 1 750 14 30 1 4 1 625 21 2 1 1 11 4 2 2 1 4 x 1 JA 1 750 14 23 5 16 1 375 2 1 6 9 6 1 1 21 32 3 10x1 SH 3 500 1 36 1 871 211 16 1 13 16 11 21 4 3 1 4 X 1 SDS 5 000 1 42 the 2 1875 33 1 1 3 4 1 5 16 211 16 3 1 4 X 13 8 SD 5 000 1 42 The 2 1875 33 16 13 s 11 4 113 16 211 6 3 1 4 X 11 SK 7 000 21 2 56 1 2 2 8125 37 s 13 s 11 4 11 35 16 3 5 6 X 2 SF 11 000 215 16 63 1 5 3 125 45 11 2 11 4 2 37 3 3 3 X 2 E 20 000 31 2 78 3 4 3 834 6 17 15 25 s 5 3 1 2 X 23 4 F 40 000 315 16 90 the 4 4375 65 2 13 16 21 2 3 5 5 5 8 3 9 6 X 35 8 55 000 41 2 105 1 5 1484 71 31 33 15 41 2 61 4 3 5 3 X 41 2 M 125 000 51 2 130 1 6 500 91 51 2 53 16 65 4 71 4 3 4 X 63 4 N 150 000 6 140 11 2 7 000 10 65 61 4 81 s 81 2 4 7 sx 8 P 250 000 7 160 144 8 250 11 3 4 T Sla 71 4 9s s 10 4 1x 91 2 W 375 000 81 2 200 2 110 437 15 9 9 11 123 4 4 11 4 x 11 5 5 625 000 10 240 3 4 12 125 173 4 12 12 15 3 4 15
287. rrs or rough edges from the mating surfaces to ensure a tight seal at time of reassembly B Handhole Cover Replacement Lightly lubricate both sides of a new gasket with refrigerant oil or general purpose grease Place the gasket on the cover and guiding in the heater place the cover against the frame open ing While holding the cover and making sure the gasket is still in place insert two screws in the lower row to help support the cover and keep the gasket from slipping out Start the rest of the screws in their holes and continue to check gas ket placement Tighten screws evenly to the torque requirements in Table 2 3 or 4 depend ing upon compressor model Connect the B Handhole Cover Replacement cont d 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor heater wiring and heater cover add oil to crank case and turn on power to the heater to preheat the oil for operation of compressor XI CRANKSHAFT SEAL NOTE Before proceeding refer to Paragraph I General Service Instructions A Oil Seal Leakage In refrigeration compressors a slight amount of oil leakage past the crankshaft seal is normal and desirable A few drops per minute is reasonable This leakage performs two important functions It helps lubricate the neoprene bellows and o rings and it helps cool mating rotating parts to provide less wear and longer life A recep
288. ry Shaft Seal Assembly 1 A33489A 218 Gasket Shaft Seal Cover 1 33496A 220 Cover Shaft Seal 1 32564A 224 thru 233 T Complete Crankshaft Assembly for Aluminum Pistons 1 A32792B 224 Locknut and Retaining Compound Kit 1 KT367 227 Front Bearing and Retaining Compound Kit 1 KT369 228 Ring Front Bearing Retaining 1 33145A 229 T Crankshaft and Retaining Compound Kit for Aluminum Pistons 1 KT374 229 t Crankshaft for Cast Iron Pistons 1 A32255A 501 thru 505 Piston Flat Cast Iron Rings and Pin Assembly Kit 8 KT214 501 thru 505 Piston Flat Aluminum Rings and Pin Assembly Kit 8 KT213 501 Piston Ring Compression 24 31989M 502 Piston Ring Oil 8 31989N 501 thru 512 Piston Cast Iron Assembly and Connecting Rod Kit 8 KT114 501 thru 512 Piston Aluminum Assembly and Connecting Rod Kit 8 KT478 NOTES A Sold only in front bearing cover assembly Includes retaining compound for bearing lock nut Retaining compound also available separately order part number KT365 T Shot peening is not standard on Heavy Duty crankshafts but is available as an option Heavy Duty compressors are identified by HD in the serial number SECTION 105 R VILTER MANUFACTURING CORPORATION February 2001 PAGE 33 Replaces 440 VMC COMPRESSORS February 1984 RECOMMENDED SPARE PARTS LIST QUANTITY PER COMPRESSOR PART RECOMMENDED FOR STOCK ITEM PART NAME NUMBER SINGLE STA
289. s and closes the contacts from red to white colored terminals This de energizes the unloader solenoid valve and loads the compressor The opposite action occurs when the pressure drops The differential of the control is fixed at ap proximately 2 5 psi 17 24 kPa and is not ad justable Set the control to close the contacts from red to white at the desired capacity con trol cut in pressure Once the single pointer is set at the correct pressure setting the differen tial is subtracted from this setting The result ing value is the point at which the contacts close from red to blue 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor E Oil Filter Pressure Differential Switch This switch is installed on compressors equipped with the optional warm start oil protection sys tem The switch is set to cut out automatically when 40 psi 275 79 kPa pressure differential is produced across the oil filter The switch contact is normally closed when high oii pressure is not present When the 40 psi 275 79 kPa oil pressure is produced across the filter the contact opens and stops the compressor If the compressor stops due to high filter differential manually re set the filter oil differential switch before restart ing the compressor The switch reset button is located on the front of the control Ill WARM START PROTECTION SYSTEM CAUTION Never attempt to start
290. s steel monel and steel bulbs are available if required Bulb and capillary with neoprene coating to military specifications MIL R 3065 Grade SB 515 ABFF may be supplied at additional cost Capillary length 6 ft 1 8 m only Bulb Wells Supplied at extra cost when specified Capillary Tubing Standard temperature elements supplied with 6 ft 1 8 m capillary Extra length tube available at additional cost Longer capillary tube supplied up to 10 feet 3 m in 2 foot 0 6 m increments over 10 feet 3 m in 5 foot 1 5 m increments Contact Action Open on rise or close on rise as specified 2 70 A72 Product Bulletin Covers Standard finish is gray enamel Stainless steel covers available at slight additional cost for exposed installations Fungus Proofing Metric Scale Plates Temperature models are available with Celsius plates Mounting Brackets Controls are supplied less bracket unless specified Controls may Supplied at extra cost when specified Conforms to government specifications MIL V 173A Manual Reset Provides lockout which requires manual reset before a restart is possible Manual reset is trip free and cannot be blocked or tied down Button must be pressed and released before operation will resume Type Main No Lockout Number Contact of with Action Poles Manual Reset Single Pole A70AA Open Low 1 No A70AQ Open Low 1 No A70BA Open Low 1 Yes A70DA Open High 1 Yes
291. sition one set of short bolts each It is recommended that all locknuts be hub on top Now slide the canter ring retightened after several hours of initial down Into place straddiing the short operation Ska ka E For further help with the installation or center ring match marks must line up alignment consult Rexnord with both hub match marks When one bushing Is In line with the hole in the Vil Disc Pack Replacement if it becomes disc pack slide one tong bolt through necessary to replace the disc pack It can washer or link disc pack center ring be done as follows disc pack washer or link and then A Remove ali the iong bolts and lower the secure with a locknyt The long bolt center ring by silding it out from requires a minimum clearance for between the two disc packs coupling flange and stationary connectlon and re install it value of R On size 226 and larger the hote in the disc pack Put the nut on instail the rest of the long bolts in the maintains the disc orientation for later same manner reinstallation Remove the rest of the short bolts and take off the disc pack D Torque the long bolt locknuts at this Repeat for the second disc pack time See Table 1 for torque values Replace the pack s if required Recheck NOTE With the coupling in good alignment V Reassembie the bolts will fit through the holes in the fianges and the disc pack m
292. solution Apply this mix ture with a one inch round brush at all flanges threaded joints and welds Repair all visible leaks If possible leave the pressure on over night A small pressure drop of 5 Ibs over this period indicates a very tight system Remem ber to note the ambient temperature as a change in temperature will cause a change in pressure After the system is thoroughly tested open all valves on the lowest part of the system and ar range to carry the gas away from the compres sor SO dirt or foreign particles cannot enter the working parts The oil should then be charged into the compressor as described in Paragraph XVI of this section Charge a small amount of ammonia into the system Pass a lit sulfur stick around all joints and connections Any leaks will be indicated by a heavy cloud of smoke If any leaks are ob served during this test they must be repaired and rechecked before the system can be con sidered tight and ready for evacuation 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor B Other Refrigerant Systems Dry nitrogen may be used to raise the pressure to the proper level for testing When the proper pressure is attained use a one inch round brush and test for leaks with a mixture of four parts water and one part liquid soap with a few drops of glycerin added Apply to all flanges threaded soldered or welded joints Observe all welded joi
293. ssure drop across two different points in either a closed water circulating System or a city water to supply Application These differential pressure controls are for use as operating controls and or indicating system functions through display lights or panels They measure the difference in pressure exerted upon its two sensing elements system Specifications P74AA SPST Contacts Open on Differential Pressure Increase SPST Contacts Open on Differential Pressure Increase P74AB Manual Reset P74BA SPST Contacts Close on Differential Pressure Increase P74CA DPST Contacts Open on Differential Pressure Increase DPST Contacts Open on Differential Pressure Increase P74CB Manuai Reset P74DA DPST Contacts Close on Differential Pressure Increase Type Number DPST Contacts Close on Differential Pressure Increasa P74DB Manual Reset P74EA SPDT Standard Switch Differential SPDT Narrow Switch Differential P74GA Main Contacts Open on Differential Increase Separate Auxiliary Contacts Close Main Contacts Close on Differential Increase Separate e Auxiliary Contacts Open Ambient Minimum 32ZF 0 C Temperature Maximum 104 F 40 C Conduit 7 n Opening 4 22 mm Diameter Hole for Ve Conduit PALM Large Copper Backed Silver Contacts and Beryllium Contact Unit P74C P74D Copper Conductor Leaves P74G P74H P74E P74F SPDT Snap Acting Contacts in Du
294. st Protected Enclosure Differential See Table m Finish Gray Baked Material Case 062 1 6 mm Cold Rolled Stee 928 0 7 mm Cold Rolled Stee See Table ressure Mounting Universal Mounting Bracket Part No 271 51 Bracket Supplied as Standard Range See Table Individual Pack 2 4 1b 1 1 kg Shipping Overpack Weight of 20 50 5 Ib 22 8 kg Bulk Pack of 28 57 Ib 25 9 kg 2004 Johnson Controls Inc Part No 997 545 Rev Code No LIT 125490 Fig 1 P74 Differential Pressure Control with Style 13 elements On a proof of flow application in a water chiller system the control activates a light or signal to indicate a loss of water The control may also be applied as a lube oil pressure sensing control on refrigeration compressors They may be used in combination with P28 and or P45 oil pressure cutout controls on two compressor single motor units to reduce the oil system cost See Fig 4 Special low pressure models are available for variable speed and screw compressor oil pressure applications All Series P74 differential pressure controls are designed for use only as operating controls Where an operating control failure would result in personal injury and or loss of property it is the responsibility of the installer to add devices safety limit controls or systems alarm supervisory systems that protect against or warn of control failure Range and Differential Specifica
295. static Expansion Valve Solenoid Valve SVL and Strainer Assembly Capacity Control Switch PC 1 Liquid Line Valve 2 Intermediate Pressure Gauge E Oil Pressure Failure Switch PSO Dual Pressure Switch PSD Crankcase Pressure Gauge 9 Oil Pressure Gauge 10 DESCRIPTION _ NUMBER 7 8 Low Pressure Gauge High Pressure Gauge Q N FIGURE 14 REFRIGERANT AND PRESSURE CONNECTIONS SCHEMATIC DIAGRAM SIX CYLINDER INTEGRAL TWO STAGE COMPRESSOR WITH INTERCOOLER VMC 2401 OPERATION 22 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor INJECTION LINE OIL SEPARATOR RETURN LINE 10 ki d l Ue 87 5 TO ATMOSPHERE P OR BOOSTER SUCTION 44 see local codes LIQUID 10 2 FROM RECEIVER Pad p i no To Front HIGH STAGE amp Rearing Cover CTION Drive End BOOSTER and Pump DISCHARGE d 7 HIGH STAGE 7 DISCHARGE Qa BOOSTER SUCTION NA lt 3 OIL PUMP x KEY ITEM NUMBER DESCRIPTION DESCRIPTION 1 Oil Pressure Failure Switch PSO Safety Valve set at 300 psig 2 Dual Pressure Switch PSD Thermostatic Expansion Valve Solenoid Valve 3 Low Pressure Gauge and Strainer Assembly 4 Crankcase Pressure Gauge Capacity Control Switch PC 1 5 Oil Pressure Gauge Liquid Line Valve 2 6 High Pressure
296. ston Ring Compression 6 12 18 24 36 48 31989M 502 Piston Ring Oil 2 4 6 8 12 16 31989N 508 Lock Nut Connecting Rod 8 16 24 32 48 64 2028A 512 Bearing Half Connecting Rod All Compressors except 16 Cyl High Stage 2 4 6 8 12 16 35086ST or KT512 512 Bearing Half Conn Rod Heavy Duty High Stage 8 16 35273ST 516 amp Spring Valve 24 48 72 96 144 192 33803A 519 517 Plate Discharge Valve 2 4 6 8 12 16 35080SS 514 Safety Head and Pins Assembly Standard Comp 1 2 2 2 2 2 A35082A 518 Safety Head and Pins Assembly Hi Suct Comp 1 2 2 2 2 2 A35272A NOTES A The above listing includes the minimum selection and quantity of recommended spare parts All items listed do not necessary apply to every compressor because of type size or optional features Items should be selected for each individual compressor as they apply When supplied capacity reduction is optional High Suction Pressure Compressors are identified by an X in the serial number Heavy Duty Compressors are identified by HD in the serial number February 2001 Replaces March 1975 PAGE ar WP N 12 13 14 15 16 17 19 19 20 21 24 25 26 28 29 31 32 32 33 VILTER MANUFACTURING CORPORATION SECTION 105 R PAGE 1 440 VMC COMPRESSORS REPLACEMENT PARTS LIST TABLE OF CONTENTS REPLACEMENT PARTS ORDERING INSTRUCTIONS BASIC FRAME REPLACEMENT PARTS Illustration 2 Cylinder Figure 1 Illustration 4 6
297. ston to rise Put the plug back into the hole hole B in the frame and reconnect the unloader lines 2 450 450XL Compressor Bullet Style Before assembling the valves safety head and yoke use a solvent to remove any dye paint or tape you may have used as a marker Put the suction valve into their holes with the end that has two coils closely wound to wards the bottom of the hole and twist with the top of the finger This will lock the spring in its hole The springs are properly installed when the safety head can be inverted with out the springs falling out Springs of all the same hand are used wound the same way This allows the valve to rotate during operation When the valve rotates the ac tion tends to heal any small nicks or scratches on the valve or seal and clean away any foreign material or dirt which may lodge between the valve and seat This will also spread out the plate wear from the springs 400 Series VMC SERVICE Js Place the suction valve into its cavity in the cylinder liner with the top facing up The valve plate should rotate freely without bind ing Replace the safety head assembly in the frame IV COMPRESSOR DRIVE TYPES NOTE Before proceeding refer to Paragraph General Service Instructions A V Belt Drive Compressors 1 Belt Removal Remove belt guard Loosen motor rail clamps Remove tension on belts to provide enough slack to allow the b
298. sure Pressure Differential 175 PSIG Oil Temperature Discharge Temperature 1200 125 64 rad s 1130 118 31 rad s 1000 104 7 rad s 900 94 23 rad s 810 84 81 rad s 1206 59 kPa 300 F 148 9 C TE 84 25 kW 109 81 28 kW 100 74 57 KW 95 70 84 kW 80 59 66 kW 65 5 C Direct Drive Motor Horsepower 125 64 rad s 1130 418 31 rad s 1000 104 7 rad s 900 94 23 rad s 810 84 81 rad s 93 21 kW 120 89 48 kW 110 82 03 kW 104 77 55 kW 88 65 62 kW 77 NOTES Recommended operating oil temperature 100 F to 130 F 37 8 C to 54 4 C Operating at or near maximum oil temperature could result in excessive wear increase 15 when shot peened crankshaft is ordered VMC 2 01 OPERATION 30 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TABLE 5 450 VMC COMPRESSOR MAXIMUM LIMITS Suction Superheat R717 25 F Discharge Pressure 350 PSIG 3 9 C 2413 18 kPa Compression Ratio 8 1 R717 Suction Pressure 150 PSIG 1034 22 kPa Pressure Differential 175 PSIG Oil Temperature 150 F 1206 59 kPa 65 5 C Discharge Temperature 300 F Direct Drive Motor Horsepower 148 9 C VMC 450 300 BHP 223 71 kW VMC 458 4516 375 BHP 279 64 kW V BELT DRIVE HORSEPOWER LIMITS RAD S RAD S kW 1200 113 1200 195 125 64 rad s 84 25 KW 125 64 rad s 145 41 kW 1130 109 1130 185 118 31 rad s
299. t Amm 2 4 6 8 12 16 0 3637 KT035 525 Complete Safety Yoke Assy Kit R12 2 4 6 8 12 16 0 3637 KT036 Except 521 Complete Safety Yoke Assy Kit R22 2 4 6 8 12 16 0 3637 KT037 Plus 408 amp 409 519 Springs Valve Volute 16 32 48 64 0 2049 31915 519 Springs Valve Helical 16 32 48 64 96 128 2050 3289 33803A 519 Springs Valve Damped Helical 16 32 48 64 96 128 3290 3637 13556A Safety Yoke and Pin Assembly 520 for Volute Springs 2 4 6 8 0 2049 Obsolete for Helical Springs 2 4 6 8 12 16 2050 3289 Obsolete for Damped Helical Springs 2 4 6 8 12 16 3290 3637 A33585A 521 Spring Safety Head 2 4 6 8 12 16 0 3637 31882A 523 Nut 1 Flexloc 2 4 6 8 12 16 0 3637 1330B 524 Plate Discharge Valve Ammonia R22 4 8 12 16 24 32 0 3637 33423A 524 Plate Discharge Valve R12 2 4 6 8 12 16 0 3637 33423A 525 Inner Seat Discharge Valve 2 4 6 8 12 16 0 3637 33421A NOTES Designation Cast Iron Pistons Al Aluminum Pistons All 1200 RPM VMC Compressors with Serial No 1660 and above have aluminum pistons except 1875 1876 1880 which have cast iron pistons All other 1200 RPM VMC s have cast iron pistons with the exception of Serial No 1489 which has the aluminum pistons See note on Page 10 for crankshaft requirements All 1200 RPM VMC Compressors equipped with old style 1200 RPM parts from Serial 2050 thru 3289 had helical valve springs Below 2050 had volute springs except 829 831 1489 1706
300. t 12 304 8 mm deep Use base dimen sions furnished with each compressor to locate all pad anchor bolts When constructing a concrete pad including vibration isolators remember the form must be constructed and the concrete pad poured on a sub base over which two layers of waterproof paper are placed This is so the pad is raised off the sub base by isolators Vil CONCRETE It is recommended the base be filled with con crete to increase vibration dampening The unit base must be grouted in place Grout ing ensures good contact between the base and foundation allowing the foundation to stiffen the base as well as dampen any vibra tory forces The grout for filling the sleeves and leveling must be expanding grout rather than shrinking to provide a tighter bond 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor TEMPLATE FOR BASE ANCHOR BOLTS TOP OF FORM MUST BE LEVEL WHEN CONCRETE IS POURED SLEEVE CONCRETE PAD FORM FIGURE 4 2 01 REPLACES ALL PREVIOUS ISSUES INSTALLATION VMC VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor SETTING AND LEVELING UNIT ON CONCRETE PAD Immediately before the compressor is set on the concrete pad fill the sleeves on the anchor bolts with grouting In this way the anchor bolts may be moved slightly permitting final alignment with the base holes while eliminating the difficulty of filling t
301. t necessary to remove or disturb the actuator mechanism or the cylinder liners to remove the unloader piston There are two holes in the top of the unloader piston One is threaded the other is not Use 20NC eyebolt in the center hole Use the other hole to keep the piston from turning in the hole in the frame while doing this Using the eyebolt as a handle pull the piston out of its hole in the frame 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Suction Valve Plate Install as marked Cylinder Cover Lift Pin Lift Ring Spring Lift Ring Short Pivot Pin Yoke Lifting Arm Yoke Guide Assembly Serer embly Yoke Spring COMPRESSOR APPLICATION NOTE Gas Actuated Unloading is standard on Yoke assembly is bolted down one end as e High Stage except 100 internal CR shown on all compressor banks equipped with Oil Actuated Unloading is standard on optional single cylinder unloading All other e High Stage with 100 internal CR compressors do not use these bolts e Booster e Both Stages of integral 2 Stage FIGURE 8 TYPICAL CAPACITY CONTROL MECHANISM ARRANGEMENT 450 amp 450XL COMPRESSORS NEW STYLE BULLET TYPE 400 Series VMC 2 01 SERVICE 15 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Unloader Piston Replacement Before reinstalling piston remove old ri
302. t of dirt install a new bag After another 24 hour period re move and inspect the bag Continue doing this until all traces of foreign material are removed from the system The bag may then be thrown away Whenever welding is performed on system piping a suction bag should be installed After discarding the bag remove decal from the outside of the suction strainer cover and discard to avoid confusion Decal is not needed if bag is not used Clean the suction strainer after the first week of operation the first month and every six months after that The best method of doing this is to remove it from the machine knock the solids out and wash it thoroughly with mineral spirits before placing it in the machine XVIII MAINTENANCE SUGGESTIONS To insure the compressor against component malfunctions and system failure a systematic preventive maintenance program is highly rec ommended Performing the following steps at the prescribed intervals will keep the VMC Compressor in optimum working condition 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor Daily Clean the suction screen bag Discontinue use when the bag remains clean Reserve for sys tem modifications or overhauls 1 10 Weekly Check system for leaks with a suitable leak detector for first week of operation Check oil levels and oil condition Determine if oil filter Check
303. t tension and loading contributing to ex cessive belt and sheave wear Clean any foreign matter that has accumu lated in the grooves The sheave and pulley should be inspected for cracks and other damage that could af fect the integrity of the drive components The sheave and pulley should be inspected for excessive run out indicating bent com ponents Bent pulleys or sheaves will wear the groove sidewalls unevenly as the belt changes its angle of engagement as the pul ley turns 2 01 Replaces all Previous Issues VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor 456XL Booster m 458XL High Stage FIGURE 5 UNIT BELTING REQUIREMENTS DUE TO HORSEPOWER Drive Inspection cont d The groove bottom should also be checked for polishing as this indicates the belt is not riding correctly in the groove What has happened is the belt or groove has worn to the point the belt is actually rubbing on the bottom of the groove This effectively changes the pitch diameter of the sheave or pulley for that groove causing the belt to operate at a different speed than the rest This will result in excessive heat and wear to the drive components When drive components are replaced it is necessary to replace them with identical components Due to operating conditions and the horsepower requirements of the compressors the number of belts on a com pressor package can vary from 2 through 10 belts and not
304. t through the bolt hole in the hub Hold the disc pack in one hand slip t down between the hub and center ring until one hole in the disc pack lines up with the boit Slide the bolt through this into the disc pack Add a washer The beveled side of the washer should always be against the disc pack Install the tocknut Do not torque the locknut at this time Remove the disc pack alignment bolt if used Now pivot the pack around until it lines up with the rest of the bolt holes in the hub Install the rest of the hub bolts through the hub bolt holes disc pack washers and locknuts The remaining bolts for this end can now be installed These bolts go in from the hub side first through the washer the disc pack and then the bolt hole in the center ring adding the locknut The locknuts can be snugged up at this time The disc pack as installed should look flat and parallel with the mating hub and center ring fingers 5 Make the final coupling alignment check at this time 6 Torque up the locknuts See Table 1 for torque values NOTE Due to tight nut body clearances it may be necessary to use an open and wrench to torque the locknuts at the head end The lock nut torque value can be easily calculated Take the foot pounds required Couping GMA D ue Diameter 4 56 1 162 200 5 75 Locknut 225 600 Tightening 262 6 88 Torques NOTE and divide it by the weight of the mechanic This gives you the length
305. t valve is used in conjunction with a Vilter standard oil separator to facilitate oil retum Oil is returned through 1 2 6 35 mm line directly into the crankcase of the compressor via NPT tapped boss on the suction end of the compressor frame B Regulating Valve Adjustable Oil Re lief The oil pressure regulating valve on the 400 Se nes VMC Compressor is located in the front bearing housing of the machine The regulating valve on the 300 Series is located in the rear bearing housing It consists of a spring loaded ball type valve positioned in the bearing housing An adjusting screw regulates the pressure on the spring and ball With less pressure on the ball more oil bypasses the oil system and line pressure is low To adjust this valve stop the compressor and remove the cap to expose the adjusting stem Start the compressor and raise the oil pressure To lower oil pressure turn the screw counter clockwise VMC OPERATION NOTE The stem is designed so it cannot be backed out provided the stuffing box packing and packing nut are not removed Adjust the oi pressure regulating valve to maintain a minimum of 45 to 50 psig 310 27 to 344 74 kPa net oil pressure for 400 Series Compressors oil pressure minus crankcase pressure equals net oil pressure 300 Series Compressors require 60 psig 413 69 kPa net oil pressure When oil pressure actuates the unloader mechanism it is important to hav
306. tacle for collec tion is recommended B Removal The flywheel or coupling will have to be removed Detach the tubing line on the bottom of the front housing Oil will drain from the seal chamber be prepared to collect it After the oil has drained remove the 8 screws holding the cover When removing the cover caution should be taken be cause the front carbon seal might come off with the cover At this time if the seal is going to be reused clean the surface of the shaft and avoid getting anything in the housing area Grab the front rubber bellows and pull forward It should release If not pry by the tabs on the metal ring alternating force from side to side to remove it Remove the large spring Next step is to remove the 3 screws in the re tainer that hold the inner mirror seat Put 2 of these screws in the tapped holes of the retainer Rotate the retainer so screws are at 3 and 9 o clock positions Pull on the screws to aid in removing the retainer and the rest of the seal as sembly Clean out the seal chamber with suit able refrigeration parts cleaner Afterwards coat the area and crankshaft to keep them from rust ing 400 Series VMC SERVICE 19 Installing A New Shaft Seal Remove the mirror seats from the inner retainer and outer cover The mirror face can be re moved by tapping on back side that is exposed in each part Make sure these parts are then cleaned Place either on a flat surface with the
307. tapered chack for good contact pattern if the bore is straight measure the bore and shaft diameters to assure proper fit B Axial Spacing The axial spacing of the shafts should be positioned so that the disc packs flexing elementa are fiat when the equipment is running under normal operating conditions This means The key s should have a snug side to side fit with a small clearance over the top there is a minimal amount of waviness in the disc pack when viewed from the side This wilt resuit in a flexing element that Is centered and parallel to its mating flange faces Move the connected equipment or hubs on their respective shafts to accomplish the above a guide maximum and minimum velues for dimension are given See Tabie 1 and Figure 1 NOTE If the DBZ hub position on the shaft does not allow enough room to install the short bolts In the hub after hub mounting Install the bolts and disc pack before mounting hub on shaft See Section Vi A amp B Straight Bore Install in the shaft If the hub an interference fit heat the hub in an olf bath or oven until bore is sufficiently larger than the shaft 350 degrees F le usually sufficient An open ls not recommended However if flame heating le necessary use a very large rose bud tip to give even heat distribution A thermal heat stick will help determine hub temperature DO NOT SPOT HEAT THE HUB OR DISTORTION MAY OCC
308. tch senses oil pressure by using a pair of bellows The first bellows identifies oii pump pressure Another bellows which is connected directly opposite the first measures crankcase oil pressure Each switch has a 90 second time delay to prevent nuisance failures If the failure switch detects any anomalies in the first 90 seconds it will shut VMC OPERATION the compressor down The switch must be manually reset after an oil failure C High Pressure Switch All booster compressors models 2 through 8 cylinders are equipped with one high pressure switch Twelve and sixteen cylinder machines have two switches because of the double dis charge arrangement The switches open on high pressure and reset automatically when discharge pressure drops Cut out set points are adjustable but the differential is factory set On the twelve and sixteen cylinder high stage machines a single high pressure switch is used for the second discharge The high pres sure side of the dual pressure switch is con nected to the other discharge The high pres sure switch has the same manual reset feature as the high pressure side of the dual pressure switch Refer to the manufacturer s instruc tions located in this manual D Capacity Control This control operates the unloaders and has a single pole double throw action rise in pres sure will signal an increase in capacity The unloader control opens the contacts from red to blue colored terminal
309. ters 405 Spring Lift 1200 RPM below Serial No 3638 33428A 2 2 4 4 4 4 407 Suction Valve Plate 1000 RPM 1200 RPM 31909A 1 1 2 2 2 2 2 2 3638 to Present and All Boosters 407 Suction Valve Plate 1200 RPM below Serial No 33422A 1 1 2 2 2 2 3638 413 Capacity Control Assembly Thru a Two Cylinder and Two Stage Compressors A33577A 1 1 2 420 b All Other Compressors A33354A 1 1 1 2 2 501 Piston and Connecting Rod Assembly Kit Thru a Cast Iron Flat Top Piston 1000 RPM KT114 1 1 2 2 2 2 512 b Aluminum Flat Top Piston All Speeds KT478 1 1 2 2 2 2 2 2 501 Piston Ring Compression 31989M 6 12 12 12 18 24 12 18 502 Piston Ring Oil 31989N 1 1 2 2 2 2 2 2 509 Nut Plain Hex 24UNF 2027A 4 8 12 16 24 32 12 24 510 Nut Lock NF 2028A 4 8 12 16 24 32 12 24 511 Bearing Half Connecting Rod KT512 2 4 6 8 12 16 6 12 512 Bolt Connecting Rod 31955A 4 8 12 16 24 32 12 24 513 Safety Head Assy Ammonia All Speeds A32695C 1 1 2 2 3 3 2 3 Thru Safety Head Assy Halocarbon All Speeds A32695D 1 1 2 2 3 3 2 3 518 515 Diaphragm Discharge Valve Plate all speeds 31939B 6 12 18 24 36 48 18 36 518 Valve Retaining Screw 1527B 2 4 6 8 12 16 6 12 519 Valve Springs Volute 31915A 8 16 24 32 519 Valve Springs Helical 33803A 8 16 24 32 48 64 24 32 519 Valve Springs Damped Helical 1200 RPM 13556A 8 16 24 32 48 64 524 Discharge Valve Plate 1200 RPM Compressor Serial No 0 t
310. that the Stedy Mount be installed downstream of a globe valve to facilitate safe removal of the pressure gauge Materials Of Construction The standard VSM 1 Vilter Stedy Mount consists of 1 Lower Coil Fitting 304 stainless steel for FPT connection 1 Upper Coil Fitting 304 stainless steel for MPT connection 1 Spiral Tube Coil 304 stainless steel 1 Damper Neoprene oil resistant 1 Diffuser 316 stainless steel Gauge Sizes And Weights Because the Stedy Mount converts the gauge into a free standing free floating body certain size and weight limitations must be applied in order not to convert the unit into a top heavy system in which the gauge would topple over To some extent gauge sizes and weights are dependent on the make and pattern of the gauge Generally speaking pressure gauges of 377 dia or less and weigh up to 2 Ibs or 472 dia weigh ing up to 2 Ibs can be accommodated by the Stedy Mount This is providing that the Top Heavy Mo ment of the weight of the gauge is within the 30 to 140 range TOP HEAVY MOMENT is the product of the weight of the gauge ounces times the distance inches from the center of gravity of the gauge to the top of the Stedy Mount The center of gravity of the gauge must be low enough so the system does not lose its vertical stability STEDY MOUNT VILTER GAUGE STEDY MOUNT TOP HEAVY MOMENT PART NO CONNECTION PIPE SIZE RANGE Oz In
311. the shim pack will keep the shims in alignment To remove the coupling from the crankshaft remove the screw and washer if present Try to lightly tap the coupling off the shaft or apply heat to coupling A puller can be con structed out of a flat steel bar with holes that match two holes in the coupling in a straight line past the center of the crankshaft Make a hole in the center of the bar for 15 88 mm bolt thread the hole or weld a g 15 88 mm nut inline with the hole Bolt this bar loosely to holes in coupling Place a solid washer or disc a little smaller than end of the shaft between the bar and in front of the tapped hole in the crankshaft Using a g 15 88 mm bolt apply force to center crankshaft and a pulling force on the cou pling Coupling Replacement 400 Series VMC SERVICE 12 Inspect the compressor coupling bore and crankshaft to make sure they are clean and free of burrs Apply anti seize to shaft and coupling bore Place the key on the shaft and slip on the coupling Install the bolt and washer if required and tighten Reassemble shim pack and center member in correct orientation Tighten bolts and note distance between hubs per coupling manu facturer s bulletin This bulletin is located in the Installation Section Recheck alignment if necessary CAPACITY CONTROL Old Style Mushroom Type Lift Pins Ring and Springs Removal The valve lifting mechanism consists of the
312. the yoke springs and unloading the bank of cylinders This cycle is repeated whenever the load fluc tuates While the solenoid valve is open gas metered from the discharge is transferred into the suction maintaining an unloaded condition If a compressor is used a system where an other compressor is operating the pressure difference is already present so the suction plate remains lifted for a shorter period of time on startup This assumes that each compres sor has a discharge check valve Without the check valve the suction plate will not be lifted on start up C Oil Operated Unloader 400 Series Sin gle Stage Booster Integral Two Stage And 300 Series Compressors The mechanism is spring loaded and actuated by an unloader piston When the suction and oil pressures are equalized on both sides of the piston the yoke springs force the yoke lift ring and lift pins upward This lifts the suction valve plate which unloads the bank of cylinders The capacity control system is incorporated in the compressor and is actuated by oil pressure Pressure is conveyed to three way solenoid capacity control valves and is used for the op eration of the unloader assembly When the compressor is started the solenoid valves are 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor D Oil Operated Unloader 400 Series Single Stage Booster Integral Two Stage And All 300 Seri
313. tions Switch Differential Maximum Differential PSI Differential ow Pressure Pressure Range kPa Pressure Between Bellows Overrun Bellows PSI P74A P74B the Beliows PSIG Material kPa P74C P74D P74E P74F PSI kPa P74G P74H kPa 2 to 26 u 3 5 Fixed 1 2 Fixed 120 180 TOR 14 to 180 24 8 850 1241 8 to 60 6 to 20 Adj 3 8 Fixed 1 5 Fixed 120 180 Brass 50 to 400 41 to 138 26 10 830 1241 2 to 30 5 0 Fixed 2 0 Fixed 200 180 Stainless 14 to 207 34 14 1379 1241 Steel Bto70 8 to 30 Adj 5 5 Fixed 2 5 Fixed 200 180 Stainless 50 to 450 55 to 207 38 17 1379 1241 Steel Bellows overrun pressure is the pressure supplied to the low pressure side of the control Features e Heavy duty low profile elements withstand unduly high overrun pressures that may be encountered in shipment or in some machine rooms e Lockout models have a trip free manual reset e Long life contact structure with high contact force no contact bounce e Single unit mounting and wiring saves installation time and material General Description Single and double pole models are available with contacts that open on a pressure differential increase or close on a pressure differential increase Also available are models with single pole double throw enclosed contacts or with main and separate reverse acting auxiliary contacts Controls with lockout feature require manual reset to reclose circuit after lockout The trip fre
314. ton Flat AL amp Connecting Rod 2 4 6 8 12 16 6 12 3638 Present KT478 512 Assembly Kit 501 Piston Ring Compression 6 12 18 24 36 48 18 36 3638 Present 31989M 502 Piston Ring Oil 2 4 6 8 12 16 6 12 3638 Present 31989N 503 Snap Ring Piston Pin 4 8 12 16 24 32 12 24 3638 Present 33244A 504 amp Piston and Pin Assembly 2 4 6 8 12 16 6 12 3638 Present Order Kit 505 506 thru Connecting Rod Assembly with 2 4 6 8 12 16 6 12 3638 Present KT463 512 Bearings Kit 510 Bearing Half amp Lock Nut Kit std size 2 4 6 8 12 16 6 12 3638 Present KT512 511 Bearing Half amp Lock Nut Kit undersize 2 4 6 8 12 16 6 12 3638 Present KT513 506 Bushing Piston Pin 2 4 6 8 12 16 6 12 3638 Present 31896B 507 Connecting Rod and Cap 2 4 6 8 12 16 6 12 3638 Present Order Kit 509 Nut Plain Hex 24UNF 4 8 12 16 24 32 12 24 3638 Present 2027A 510 Nut Lock e 24NF 4 8 12 16 24 32 12 24 3638 Present 2028A 510 Bearing Half Conn Rod w o Groove 511 Standard Size 4 8 12 16 24 32 12 24 3638 Present KT512 0 015 Undersize 4 8 12 16 24 32 12 24 3638 Present KT513A 0 030 Undersize 4 8 12 16 24 32 12 24 3638 Present KT513 512 Bolt Connecting Rod 4 8 12 16 24 32 12 24 3638 Present 31955A 513 Safety Head Assembly Ammonia Thru for Helical Springs 2 4 6 8 12 16 6 12 3638 Present A32695C 518 Safety Head Assembly R12 and R22 for Helical Springs 2 4 6 8 12 16 6 12 3638 Present A32695D 513 Nut Lock
315. uential damages or field labor is included ORDERING INFORMATION HCK4 CHECK VALVES FLANGE CONNECTION PORT STYLE amp SIZES TYPE rasa FPT SW WN ODS STD ALSO STD 2 r es r ee oe TNCS zs HcKa9 65 2 25 2 65 2 80 3 34 3 Replaces R S CK4A 2 CK4A 3 CK4A 4 CK4A 8 amp CK4A 1 HCK4 2 close couples to HS6 amp HS8 Solenoid Valves HCK4 3 4 amp 5 close couples to HS7 Solenoid Valve available only s to 1 TO ORDER Specify valve type connection style and size and close coupling information if needed TYPICAL SPECIFICATIONS Refrigeration in line check valves shall have steel or ductile iron bodies stainless steel seat discs stainless steel closing springs and be suitable for a safe working pressure of 400 PSIG as manufactured by Hansen Technologies Corporation type HCK4 or approved equal Typical close coupling to solenoid valve HCK4 TETA ISO 9002 Hansen Technologies Corp Burr Ridge IL Cert 000472 Orlando FL Cert 001523 HANSEN TECHNOLOGIES CORPORATION 6827 High Grove Boulevard Burr Ridge Illinois 60527 U S A Telephone 708 325 1565 FAX 708 325 1572 Toll free 1 800 426 7368 1995 Hansen Technologies Corporation Printed in U S A TB Wood s
316. uid line from the intercooler must be in sulated or the liquid will pick up heat as it passes through a warm room and the resultant efficiency could be lower than if no subcooling were provided The intercooler and the line from the intercooler to the compressor should be insulated Factory insulation of the inter cooler and intercooler line consist of layers of sheet insulation 2 01 REPLACES ALL PREVIOUS ISSUES VILTER MANUFACTURING CORPORATION VILTER MultiCylinder Compressor A Intercooler cont d Liquid line and intercooler insulation results in more efficient operation and eliminates prob lems caused by dripping condensate If factory insulation is not ordered we strongly recom mend insulation be applied at time of installation If the subcooling feature of the two stage inter cooler is not desired or subcooling is provided elsewhere in the system a desuperheater which desuperheats the gas from the low stage without subcooling liquid refrigerant from re ceiver is available in place of the standard inter cooler The operation of the desuperheater is very similar to the intercooler The refrigerant gas from the low temperature evaporator enters the compressor through the low stage suction con nection and is compressed to the intermediate pressure The gas is then discharged into each end of the desuperheater where it is desuper heated It then enters the h
317. umber be certain to include letters i e A AH R22S R12H etc which precedes the actual serial number This will establish whether the compressor is built for 1000 RPM or 1200 RPM The serial number is stamped on the nameplate and the compressor frame On 2 cylinder compressors the frame serial number location is directly below the cylinder cover on the crankcase handhole side On 4 thru 16 cylinder compressors the frame serial number location is directly above the suction flange or directly above the rear bearing cover The rear bearing is located on the oil pump filter end of the compressor 2 Always give the name of the part as well as the corresponding part number and or item number Also include the number of parts required 3 Should there be a doubt regarding the part number or name send a sketch of the part required or return the old part as a sample transportation charges prepaid Orders on which part numbers and description do not agree will be filled according to our best interpretation 4 f parts that appear on the parts list do not appear on the price list it is because they are sold only as an assembly All prices shown on the list are F O B factory Minimum domestic parts order is 75 00 net price Prices are for a single item unless otherwise specified in the price list 5 Please indicate on the order the preferred method of shipment We will follow your instructions unless it is to your best interest to change routi
318. upper 2 4 6 8 12 16 Order KT575 508 Bearing Half Connecting Rod lower 2 4 6 8 12 16 Order KT575 509 Spring Safety Head 2 4 6 8 12 16 35252A 510 Safety Head Yoke Kit includes 4 of item 513 2 4 6 8 12 16 KT543 520 Booster Safety Head Yoke 2 4 6 8 12 16 31941B 2 Stage Low side Safety Head Yoke 4 8 31941B 511 Spring Valve 16 32 48 64 96 128 33803A 512 Plate Discharge Valve 2 4 6 8 12 16 3508055 Valve Diaphragm Discharge Booster 6 12 18 24 36 48 aise 2 Stage Low Side 12 24 31939B Safety Hd amp Pins Assy Std Ammonia 2 4 6 8 12 16 A35082A 513 Safety Pins Assy 2 Stage High Side Comp 2 4 514 Safety Hd amp Pins Assy Halo 2 4 6 8 12 16 A35272A Safety Hd amp Pins Assy 2 Stage High Side Comp 2 4 513 Pin Roll 0 187 dia x 4 Ig t 8 16 24 32 48 64 1712F 514 Safety Head STD XL 2 4 6 8 12 16 pd 515 Spring Valve 8 16 24 32 48 64 33803A Booster Safety Head Ammonia 2 4 6 8 12 16 A32695C 513 thru Booster Safety Head Halo 2 4 6 8 12 16 A32695D 518 2 Stage Low Side Safety Head Ammonia 4 8 A32695C 2 Stage Low Side Safety Head Halo 4 8 A32695D Spring Valve Booster 16 24 32 48 64 919 2 Stage Low Side 16 32 3980314 NOTES Patents Pending asi Piston wrist pin and connecting rod sold only as a kit ds Shown for disassembly purposes only order assembly 1 Install with pin s outside longitudinal seam facing outside diameter of safety head This
319. ure regulators or strainers by using a Male Adapter Ring and longer bolts supplied when so specified on order INSTALLATION DIMENSIONS A gt D 1 D Socket Weld Depth J Weld Neck K ODS Solder DIMENSION HCK4 2 HCK4 3 HCK4 4 HCK4 5 HCK4 7 HCK4 8 HCK4 9 HCK4 0 4 1 LETTER 24 PORT 1 PORT 114 PORT 112 PORT 2 PORT 2 PORT 3 PORT 4 PORT 2 50 3 25 3 25 3 25 5 06 5 06 6 06 6 06 6 39 64 mm 83 mm 83 mm 83 mm 129 mm 129 mm 154 mm 154 mm 162 mm 3 19 4 50 4 50 4 50 4 56 4 56 6 00 6 00 7 13 81 mm 114 mm 114 mm 114 mm 116 mm 116 mm 152 mm 152 mm 181 mm 3 50 4 50 4 50 4 50 6 38 6 38 7 50 7 50 8 00 89 mm 114 mm 114 mm 114 mm 162 mm 162 mm 191 mm 191 mm 203 mm 0 38 0 50 0 50 0 50 0 75 0 75 1 00 1 00 1 00 10 mm 13 mm 13 mm 13 mm 19 mm 19 mm 25 mm 25 mm 25 mm 1 03 1 22 1 22 1 22 2 56 2 56 2 92 2 92 3 50 26 mm 31 mm 31 mm 31 mm 65 mm 65 mm 74 mm 74 mm 89 mm 1 50 2 37 2 37 2 37 3 62 3 62 4 84 4 84 6 06 38 mm 60 mm 60 mm 60 mm 92 mm 92 mm 123 mm 123 mm 154 mm 1 56 2 50 2 50 2 50 4 56 4 56 6 00 6 00 743 40 mm 64 mm 64 mm 64 mm 116 mm 116 mm 152 mm 152 mm 181 mm 2 19 3 12 3 12 3 12 3 06 3 06 4 00 4 12 5 00
320. used to any great extent to unload the com pressor to facilitate starting Single Compressor System Pressures shown below for example poses only PRESSURE RANGES AND OP ERATING PRESSURES MUST BE BASED ON 1 ACTUAL SYSTEM PARAMETERS To illustrate setting these controls on a fluctuat ing load consider this hypothetical case A 30 F 1 1 C room with varying loads is maintained by a 6 cylinder VMC Compressor three cylinder banks one bank without capacity reduction Unloader control A should be set to cut out at 20 psig 137 9 kPa control B at 19 psig 131 00 kPa and the low pressure action of the pressure section of the dual pressure switch should be set at 18 psig 124 11 kPa These switches operate with a differential of 6 to 50 psig 41 37 to 344 74 kPa The range and operation of each is as follows TABLE 1 SINGLE COMPRESSOR RANGE amp OPERATION Dual Pressure Switch 23 psig 158 58 kPa Compr Starts Low Pressure Switch 18 psig 124 11 kPa Compr Stops Control 24 psig 165 48 kPa Loaded One Bank of Cytinders 19 psig 131 00 kPa Untoaded Control A 25 psig 172 37 kPa Loaded One Bank of Cylinders 20 psig 137 9 kPa Unloaded When the compressor is started balanced pres sures exist between the high side and low side VMC OPERATION and the two banks of cylinders are unloaded It is
321. w o unloading 6 12 0 14203 KT071 401 Cylinder Liner Assy w o unloading 3 6 14204 Present A33179A Thru 402B Oylinder Liner Assy w o unloading 6 12 14204 Present A33179A 401 Liner Cylinder 2 4 6 8 pe ae 0 Present 32687A 401 Liner Cylinder si zm 12 16 0 2655 A32609A 401 Liner Cylinder E 12 16 2656 Present 32687A 401 Liner Cylinder ae 6 12 0 14203 32687A 401 Liner Cylinder Eus 6 12 14204 Present 33179A 402 Seal O Ring upper 2 4 6 8 12 16 6 12 0 Present 2176BH 402 Pin Roll 8 16 24 32 48 64 24 48 7000 Present 1193Q 402B Seal O Ring Lower 6 12 14204 Present 2176BL 403 Lift Ring amp Spring Post Assembly 1 2 4 4 5 3 6 1607 Present A33351A 403 Lift Ring amp Spring Post Assembly 2x 2E 8 8 2656 Present A33351A 405 Spring Lift 4 8 16 16 12 24 1607 Present 33352A 405 Spring Lift 16 16 0 2655 33428A 405 Spring Lift 32 32 2656 Present 33352A 406 Pin Lift 4 8 16 16 12 24 150t Present 33350A 406 Pin Lift 32 32 Es 2656 Present 33350A 407 Plate Suction Valve 2 4 6 8 6 12 0 Present 31909A 407 Plate Suction Valve a aa CE 12 16 0 2655 33422 407 Plate Suction Valve 12 16 2656 Present 31909 408 Springs Valve Helical shown 48

VMC 400 Series Compressor - Emerson Climate Technologies

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