Vilter VSS Screw Compressor - 13668843-MANUAL-VILTER PDF

VPN 35391S
February 2006 Rev. 05

Price $ 60.00
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Important Note:
READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.
The following instructions have been prepared to assist in installation, operation and removal of Vilter Single
Screw Compressors. Following these instructions will result in a long life of the compressor with satisfactory
operation.
The entire manual should be reviewed before attempting to install, service or repair the compressor.
A refrigeration compressor is a positive displacement machine. It is designed to pump superheated

vapor. The compressor must not be subjected to liquid carry over. Care must be exercised in properly
designing and maintaining the system to prevent conditions that could lead to liquid carry over. Vilter
Manufacturing Corporation is not responsible for the system or the controls needed to prevent liquid
carry over and as such Vilter Manufacturing Corporation cannot warrant equipment damaged by 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 or the home office should be notified of any claim made.
All inquires should include the Vilter order number, compressor serial and model number. These can be
found on the compressor name plate on the compressor.
All requests for information, services and or parts should be directed to:
Vilter Manufacturing Corporation

Customer Service Department
5555 South Packard Ave
P.O. Box 8904
Cudahy, WI 53110-8904 USA
Telephone: 1-414-744-0111
Fax:1-414-744-3483
e-mail: vilter@execpc.com
Equipment Identification Numbers:
Vilter Order Number: __________________________Serial Number: _____________

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Table of Contents
LONG TERM STORAGE REQUIREMENTS ......................................................................................................................................... 8
DOMESTIC TERMS and CONDITIONS .............................................................................................................................................. 10

EXPORT TERMS and CONDITIONS ................................................................................................................................................... 12
STANDARD VILTER WARRANTY STATEMENT .............................................................................................................................. 14

STANDARD VILTER 5/15 WARRANTY STATEMENT ..................................................................................................................... 15
DESCRIPTION ........................................................................................................................................................................................ 16
SYMBOLS AND MEANINGS ............................................................................................................................................................... 18
Installation Section ...................................................................................................... 19
DELIVERY INSPECTION ....................................................................................................................................................................... 21

UNIT WEIGHTS ...................................................................................................................................................................................... 21
FOUNDATIONS ...................................................................................................................................................................................... 21
LOCATING UNIT - DRIVE COUPLING ALIGNMENT ....................................................................................................................... 21
SYSTEM PIPING .................................................................................................................................................................................... 21
ELECTRICAL CONNECTIONS ............................................................................................................................................................. 23
TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23

Ammonia Systems ........................................................................................................................................................................... 23
Halocarbon Refrigerant Systems ..................................................................................................................................................... 24
Evacuating The System .................................................................................................................................................................... 24
UNIT OIL CHARGING ........................................................................................................................................................................... 25

Oil For Single Screw Compressors .................................................................................................................................................. 25
SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25

Low Side Equipment ................................................................................................................................................................................ 26
Compressors ............................................................................................................................................................................................. 26
Condensers ............................................................................................................................................................................................... 26
Controls .................................................................................................................................................................................................... 26
Initial Charging – High Side Charging .................................................................................................................................................... 26
MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27

Daily ................................................................................................................................................................................................. 27
Weekly .............................................................................................................................................................................................. 27
Monthly ............................................................................................................................................................................................ 27
Trimonthly ........................................................................................................................................................................................ 27
Yearly ................................................................................................................................................................................................ 27
System Leaks .................................................................................................................................................................................... 28
Year Round Operation ...................................................................................................................................................................... 28
“STOP CHECK” INSTALLATION ......................................................................................................................................................... 29
COUPLINGS INSTALLATION AND ALIGNMENT ............................................................................................................................. 30

Hub Mounting .................................................................................................................................................................................. 30
Straight Bore .................................................................................................................................................................................... 30
Taper Bore ........................................................................................................................................................................................ 30
Shaft Alignment. .............................................................................................................................................................................. 31
Final assembly . ............................................................................................................................................................................... 32
Disc Pack Replacement. ................................................................................................................................................................... 32
SLIDE VALVE ACTUATOR ................................................................................................................................................................... 34
ACTUATOR MOTOR CONTROL MODULE CALIBRATION PROCEDURE .................................................................................... 34
SLIDE VALVE TROUBLE SHOOTING GUIDE ................................................................................................................................... 37

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Table of Contents
Operation Section ........................................................................................................ 41
OIL SYSTEM ........................................................................................................................................................................................... 43

Non-Vilter Oil Notice ...................................................................................................................................................................... 42
Oil Charge ....................................................................................................................................................................................... 43
Oil Filter ........................................................................................................................................................................................... 43
Filter Removal and Installation, all VSR Units. ............................................................................................................................. 43
Filter Removal, VSS and VSM Units .............................................................................................................................................. 44
Filter Removal, VSS and VSM Units . ........................................................................................................................................... 44
Oil Pressure Regulating ................................................................................................................................................................... 45
Oil Cooling ....................................................................................................................................................................................... 45
Water Cooled Oil Cooler .................................................................................................................................................................. 45
Liquid Injection Oil Cooling. ........................................................................................................................................................... 46
V-PLUS Oil Cooling System ............................................................................................................................................................ 46
Thermosyphon Oil Cooling .............................................................................................................................................................. 47
CONTROL SYSTEM .............................................................................................................................................................................. 47

Screw Compressor Control And Operation ..................................................................................................................................... 47
Starting, Stopping and Restarting the Compressor ......................................................................................................................... 47
Slide Valve Control .......................................................................................................................................................................... 48
Slide Valve Motor Location ............................................................................................................................................................. 49
Oil Separator Heater ......................................................................................................................................................................... 49
Econ-O-Mizer Controls ................................................................................................................................................................... 49
Safety Setpoints ................................................................................................................................................................................ 49
Oil Pressure ...................................................................................................................................................................................... 49
Discharge Pressure ........................................................................................................................................................................... 49
Suction Pressure ............................................................................................................................................................................... 50
Oil Filter Differential ....................................................................................................................................................................... 50
Oil Temperature ............................................................................................................................................................................... 50
Discharge Temperature .................................................................................................................................................................... 50
INITIAL START-UP ................................................................................................................................................................................. 50

Setting of Controls ........................................................................................................................................................................... 50
Valve Settings ................................................................................................................................................................................... 50
Oil Separator .................................................................................................................................................................................... 50
V-PLUS Oil Cooling ........................................................................................................................................................................ 51
Liquid Injection Oil Cooling ............................................................................................................................................................ 51
Compressor Pre Start-Up Check List .............................................................................................................................................. 51
Stop Check Operation ...................................................................................................................................................................... 52
Pre-Start Up ...................................................................................................................................................................................... 53
PRE START-UP CHECKLIST - FIELD PIPING AND MECHANICAL REQUIREMENTS .............................................................. 54

PRE START-UP CHECKLIST - FIELD WIRING REQUIREMENTS ................................................................................................. 55
Service Section ............................................................................................................. 56
GENERAL COMMENTS ........................................................................................................................................................................ 58
PREPARATION OF UNIT FOR SERVICING ........................................................................................................................................ 58

REMOVAL OF COMPRESSOR FROM THE UNIT ............................................................................................................................ 58
INSTALLATION OF THE COMPRESSOR ............................................................................................................................................ 59
LEAK CHECKING UNIT ........................................................................................................................................................................ 59
ANNUAL INSPECTION ......................................................................................................................................................................... 60
NORD-LOCK WASHERS ....................................................................................................................................................................... 61
GATE ROTOR ASSEMBLY .................................................................................................................................................................... 62
REMOVAL (All VSS and VSR Models) ................................................................................................................................................. 62
REMOVAL (ALL VSM MODELS) ......................................................................................................................................................... 64
INSTALLATION (All VSS and VSR Models) ........................................................................................................................................ 66
INSTALLATION (All VSM Models) ...................................................................................................................................................... 68
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Table of Contents
Service Section Cont ..............................................................................................................................................................
GATE ROTOR BLADE REMOVAL ....................................................................................................................................................... 69

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

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

OPTICAL SLIDE VALVE ACTUATOR INSTALLATION ..................................................................................................................... 79
GEAR MOTOR TO OPTICAL SLIDE VALVE ACTUATOR ................................................................................................................ 80
CONVERSION, INSTALLATION OF ACTUATOR ............................................................................................................................... 80

COMMAND SHAFT ASSEMBLY REMOVAL ..................................................................................................................................... 80
COMMAND SHAFT ASSEMBLY INSTALLATION ............................................................................................................................. 81
COMMAND SHAFT BEARING AND O-RING SEAL REPLACEMENT ........................................................................................... 81
COMMAND SHAFT BEARING AND O-RING SEAL REASSEMBLY .............................................................................................. 82
DISCHARGE MANIFOLD REMOVAL ................................................................................................................................................. 82

DISCHARGE MANIFOLD INSTALLATION ......................................................................................................................................... 82
SLIDE VALVE GEAR AND RACK INSPECTION ................................................................................................................................ 83
REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS .............................................................................................................. 83

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

RATIO ACTUATORS (PRIOR TO 11-1-01 AND AFTER 5-1-95 .......................................................................................................... 85
POTENTIOMETER REMOVAL ............................................................................................................................................................. 87

POTENTIOMETER INSTALLATION .................................................................................................................................................... 88
RETROFIT CAPACITY AND VOLUME RATIO CONTROL ............................................................................................................... 88

ASSEMBLIES ON ALL VSS AND VSR COMPRESSORS
MANUFACTURED BEFORE MAY 1, 1995. ............................................................................................................................................................ 88
REMOVAL ................................................................................................................................................................................................................... 88
INSTALLATION OF RETROFIT COMMAND SHAFT BEARING

AND O-RING SEAL ................................................................................................................................................................................ 89
REPLACEMENT FOR RETROFIT CONTROL ASSEMBLIES .......................................................................................................... 89

LIQUID INJECTION PLUG REPLACMENT ........................................................................................................................................ 91
REMOVAL OF PLUG ............................................................................................................................................................................. 91

INSTALLATION OF PLUG ................................................................................................................................................................... 91
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Table of Contents
PLUG APPLICABILITY ......................................................................................................................................................................... 92
TORQUE SPECIFICATIONS .................................................................................................................................................................. 93

OIL FILTER ELEMENTS ........................................................................................................................................................................ 94
VSS, VSM and VSR SINGLE SCREW COMPRESSORS SERVICE INTERVAL REQUIREMENTS ........................... 98
Recommended Spare Parts List ................................................................................ 99
VSS and VSR Replacement Parts Section ................................................................ 103

Gate Rotor ...................................................................................................................................................................................... 104
Shaft Seal ....................................................................................................................................................................................... 108
Main Rotor ..................................................................................................................................................................................... 110
Slide Valve Cross Shafts and End Plate ....................................................................................................................................... 114
Slide Valve Cross Shafts Prior to 5-1-95 .................................................................................................................................... 115
Slide Valve Carriage Assembly ..................................................................................................................................................... 120
Capacity Control Actuating Motor and Command Shaft ........................................................................................................... 122
Slide Valve Actuating Motor and Command shaft Before 5-1-95 ............................................................................................... 126
Volume Ratio Control Actuating Motor and Command Shaft ..................................................................................................... 128
Miscellaneous Frame Components ............................................................................................................................................... 132
Tubing and Fittings ........................................................................................................................................................................ 132
C-Flange Adapter Components ..................................................................................................................................................... 138
Replacement Parts Tools ............................................................................................................................................................... 140
VSM Replacement Parts Section .............................................................................. 143

Gaterotor Assembly ....................................................................................................................................................................... 144
Shaft Seal ....................................................................................................................................................................................... 147
Main Rotor, Slide Valve Cross Shafts and End Plate (Models 71-401) ..................................................................................... 148
Main Rotor, Slide Valve Cross Shafts and End Plate (Models 501-701 .................................................................................... 152
Actuating Motor with Optical Sensor and Command Shaft ........................................................................................................ 156
Replacement Parts Accessories ..................................................................................................................................................... 160
Replacement Tools ......................................................................................................................................................................... 162
Vendor Assessories Section ........................................................................................ 163

HAIGHT PUMPS 10-80 Pumps ................................................................................................................................................................
PARKER Inlet Pressure Regulators ..........................................................................................................................................................
CARTRIDGE HEATERS .............................................................................................................................................................................
SPORLAN Strainers ...................................................................................................................................................................................
VIKING PUMP Pumps and Pressure Relief Valves ..................................................................................................................................
FLUID POWER ENERGY Thermostatic Valves .....................................................................................................................................
SPORLAN Solenoid Valve and Thermostatic Expansion Valve ..............................................................................................................
HANSEN HA4AOAS INLET/OUTLET REGULATOR ............................................................................................................................
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Long Term Storage
Requirements
The procedure described is a general recommendation for extended storage (over one month of no operation) of
Vilter Manufacturing packages and compressors. While this procedure is intended to cover most of the commonly
encountered situations, it is the responsibility of the installation firm and end user to address any unusual condi-
tions. We suggest using the accompanying Long Term Storage Log sheet for recording purposes to validate the
appropriate procedures.
Prior to start-up, Vilter recommends that a complete system pressure check be performed. Upon verification of the
system integrity, a comprehensive evacuation procedure should be completed to ensure a dry system before refriger-
ant is introduced. The oil circuit of any compressor is to be primed at initial start-up through the oil gauge connec-
tion on reciprocating compressors and the pre-lube oil pump on screw compressors.
Warranty of the system remains in effect as described in Section 5, Product Warranty and Procedures.
* If the unit is designed for indoor duty, it must be stored in a heated building.
If the unit is designed for outdoor duty, and is to be stored outdoors, a canvas tarp is recommended for protec-
tion until installation is imminent. Adequate drainage should be provided, by placing wood blocks under the
base skid, so that water does not collect inside the base perimeter or low spots in the tarp.
* All compressor stop valves are to be closed to isolate the compressor from the remainder of the system. All
other valves, except those venting to atmosphere, are to be open. It is essential that the nitrogen holding charge
integrity be maintained.
* Cover all bare metal surfaces (coupling, flange faces, etc.) with rust inhibitor.
* Desiccant is to be installed in the control panel. If the panel is equipped with a space heater, it is to be
energized. If the panel does not have a space heater, use a thermostatically controlled 50-watt light bulb. Use
an approved electrical spray-on corrosion inhibitor for panel components (relays, switches, etc.)
* All pneumatic controllers and valves (Fisher, Taylor, etc.) are to be covered with plastic bags and sealed with
desiccant bags inside.
* System and compressor pressures (unit is shipped with dry nitrogen holding charge approximately 5 psi above
atmospheric pressure) are to be monitored, on a regular basis, for leakage. It will be necessary to add a gauge
to monitor the system holding charge pressure. If a drop in pressure occurs, the source of leakage must be found
and corrected. The system must be evacuated and recharged with dry nitrogen to maintain the package integ-
rity.
* Motors – (NOTE: The following are general recommendations. Consult the manufacturer of your motor for
specific recommendations.)
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Long Term Storage
Requirements
1) Remove the condensation drain plugs from those units equipped with them and insert silica-gel into the openings.
Insert one-half pound bags of silica-gel (or other desiccant material) into the air inlets and outlets of drip-proof
type motors.
NOTE: The bags must remain visible, and tagged, so they will be noticed and removed when the
unit is prepared for service.
2) Cover the unit completely to exclude dirt, dust, moisture, and other foreign materials.
3) If the motor can be moved, it is suggested that the entire motor be encased in a strong, transparent plastic bag.
Before sealing this bag, a moisture indicator should be attached to the side of the motor and several bags of
silica-gel desiccant put inside the bag, around the motor. When the moisture indicator shows that the desiccant
has lost its effectiveness, as by a change in color, the bag should be opened and fresh replacement desiccants
installed.
Whenever the motor cannot be sealed, space heaters must be installed to keep the motor at least 10°F above
the ambient temperature.
NOTE: There is a potential for damage by small rodents and other animals that will inhabit
motors in search of warm surroundings or food. Due to this, a possibility of motor
winding destruction exists. Sealing motor openings should restrict access to the motor.
4) Rotate motor and compressor shafts several revolutions (approximately 6) per month to eliminate flat spots on
the bearing surfaces. If the compressor unit is installed, wired and charged with oil, open all oil line valves and
run the oil pump for 10 seconds prior to rotating the compressor shaft. Continue running the oil pump while the
compressor shaft is being turned to help lubricate the surfaces of the shaft seal.
9
DOMESTIC TERMS and
CONDITIONS
Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms and
conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly re-
jected, and do not form a part of this Agreement unless Seller agrees to such terms in writing.
Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind
Seller unless this Agreement and any purported change are signed by a home office Officer of Seller.
Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyer’s
binding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unless
agreed otherwise in writing, all payments are due in full within 30 days of Seller shipping the products or providing
the services. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the
maximum allowed by law.
Security Agreement. This Agreement shall be considered a security agreement to the maximum extent allowed by
law. Seller shall have, retain, and possess a security interest in all products sold to Buyer until Seller is paid in full.
Buyer grants to Seller a power of attorney to complete, sign on Buyer’s behalf, and file all forms reasonably necessary
to perfect Seller’s security interest. If Buyer defaults, or Seller deems itself insecure of receiving payment, the full
unpaid balance shall become immediately due and payable at the option of the Seller, and Seller may retake posses-
sion of the products without Court order.
Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. All
delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’s
Order Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment
deliveries.
Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a
period of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months
from date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the
following extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal
rotating parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and recip-
rocating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties
do not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or
regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains
all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Seller
of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.
Products supplied by Seller which are manufactured by others are not warranted by Seller, but rather Seller merely
passes through the manufacturer’s warranty to Buyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WAR-
RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise agreed in writing, Buyer’s
sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or the
providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of dismantling, lost refrig-
erant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect,
consequential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REM-
EDIES ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED. Products or
parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory. Any improper
use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved by Seller, or any
alteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall void all warranties and
warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer be in default of its
payment obligations to Seller under this Agreement or any credit agreement.
10
DOMESTIC TERMS and
CONDITIONS
Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages
arising from canceling or changing this Agreement. No returns shall be allowed other than with Seller’s express
permission, and such returns shall include a reasonable restocking charge to the extent permitted by law.
Resellers and Distributors. Should Buyer resell the product to a third party, then Buyer agrees to provide a copy of
these Terms and Conditions to such third party prior to the sale, and obtain such third party’s agreement to be
bound by the relevant provisions including, but not limited to, the Warranties Section and the Limitation of
Liability Section. Buyer agrees to indemnify Seller against any and all claims, damages, or liability (including
reasonable attorney fees) arising from Buyer’s breach of the obligations set forth in this Section.
Proprietary Rights. All designs and information provided by Seller remain its property, and Buyer shall honor all
proprietary legends.
Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyer
understands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NO
LIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARY
OR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCT
LIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.
IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER IN

EXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTY
REMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCE-
ABLE FOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREE-
MENT, THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS WILL NEVERTHELESS RE-
MAIN IN EFFECT.
Governing Law. This Agreement shall be governed by the internal laws of the State of Wisconsin, without resort
to conflicts of law analysis.
Attorney fees, Collection Costs, and Indemnification. Buyer agrees to defend and indemnify Seller against any
claims, damages, or liability (including attorney fees) arising out of Buyer’s violation of any law or breach of its
obligations under this Agreement including, but not limited to, personal injury, death, or property damage. In
addition, Buyer shall reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce
its rights against Buyer under this Agreement.
Manuals and Brochures. Buyer shall communicate to Seller any special needs, pictorials, labels, warning signs,
instructions, or language required for the manuals and brochures used for the products. Buyer agrees to pay a
reasonable surcharge for additional manuals, special manuals, and brochures.
Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms
and conditions will be enforced as a whole as if such provision had not be inserted herein.
Waiver, Entire Agreement. No waiver by either party of a right under this Agreement shall waive any other rights.
These terms and conditions and any other writing signed by Seller constitute the entire agreement, and may not be
modified other than in writing signed by Seller.
11
EXPORT TERMS and
CONDITIONS
Exclusivity. Seller’s acceptance of Buyer’s order is expressly conditional upon Buyer’s agreement to these terms and
conditions. All inconsistent or additional terms, modifications, or changes are deemed material, are expressly rejected,
and do not form a part of this Agreement unless Seller agrees to such terms in writing.
Home Office Approval. Buyer understands that no agent of Seller is authorized to execute this Agreement or bind
Seller unless this Agreement and any purported change are signed by a home office Officer of Seller.
Prices and Payments. Prices are exclusive of taxes and may be modified at any time prior to Seller receiving Buyer’s
binding order. Upon acceptance, prices are firm for only three months and subject to reasonable escalation. Unless
agreed otherwise in writing, all payments are due in full upon receipt of order or Vilter’s receipt of an acceptable letter
of credit. All overdue amounts will incur finances charge of the lesser of (a) 1 ½ % per month and (b) the maximum
allowed by law.
Export Transactions. If the products provided under this Agreement are to be shipped or used outside of the United
States, then the following terms apply unless otherwise agreed by Seller in writing: (1) Buyer shall be responsible for
all export and import scheduling and financial arrangements, (2) Buyer shall be responsible for compliance with all
export and import laws and shall comply, and shall cause its agents to comply, with the Foreign Corrupt Practices Act,
(3) the United Nations Convention on the International Sale of Goods shall not apply or govern the transaction, (4)
Buyer accepts all responsibility for the products complying with any non-United States based laws, regulations, and
other legal requirements, and (5) Seller shall be entitled to condition any shipment upon Buyer obtaining an acceptable
Letter of Credit in Seller’s favor confirmed at a United States based bank of Seller’s choosing.
Delivery. Seller shall not be liable for delivery delays beyond its control, including delays caused by its suppliers. All
delivery dates and rates of production statements are merely good faith estimates. Unless otherwise stated on Seller’s
Order Acknowledgment, all shipments are F.O.B. Seller’s factory. Seller reserves the rights to make installment
deliveries.
Warranties. Seller warrants the products it manufactures to be free from defects in material and workmanship for a
period of eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months
from date of installation at the initial end users location, whichever occurs first. In addition, Seller provides the
following extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal
rotating parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and recipro-
cating compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do
not apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or
regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product contains
all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must notify Seller
of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to such claim.
Products supplied by Seller which are manufactured by others are not warranted by Seller, but rather Seller merely
passes through the manufacturer’s warranty to Buyer. SELLER EXPRESSLY DISCLAIMS ALL OTHER WAR-
RANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING THE IMPLIED WARRANTIES OF MER-
CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Unless otherwise agreed in writing, Buyer’s
sole remedy for breach of warranty is, at Seller’s option, the repair of the defect, the correction of the service, or the
providing a replacement part FOB Seller’s office. Seller will not be responsible for costs of dismantling, lost refriger-
ant, reassembling, or transporting the product. Further, Seller will not be liable for any other direct, indirect, conse-
quential, incidental, or special damages arising out of a breach of warranty. THESE WARRANTY REMEDIES
ARE EXCLUSIVE, AND ALL OTHER WARRANTY REMEDIES ARE EXCLUDED.
12
EXPORT TERMS and
CONDITIONS
Products or parts for which a warranty claim is made are to be returned transportation prepaid to Seller’s factory.
Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substitution of parts not approved
by Seller, or any alteration or repair by others which, in Seller’s judgment, adversely affects the Product, shall void
all warranties and warranty obligations. Further, Seller shall not be liable under the above warranties should Buyer
be in default of its payment obligations to Seller under this Agreement or any credit agreement.
Changes, Cancellations, and Returns. Buyer will pay reasonable charges and all associated costs and damages
arising from canceling or changing this Agreement. No returns shall be allowed other than with Seller’s express
permission, and such returns shall include a reasonable restocking charge to the extent permitted by law.
Proprietary Rights. All designs and information provided by Seller remain its property, and Buyer shall honor all
proprietary legends.
Limitation of Liability. The Seller’s price is based on the enforceability of this limitation of liability, and the Buyer
understands that the price would be substantially higher without this limitation. SELLER SHALL HAVE NO
LIABILITY TO BUYER FOR LOST PROFITS OR FOR SPECIAL, CONSEQUENTIAL, EXEMPLARY
OR INCIDENTAL DAMAGES OF ANY KIND, WHETHER ARISING IN CONTRACT, TORT, PRODUCT
LIABILITY OR OTHERWISE, EVEN IF ADVISED OF THE POTENTIAL DAMAGES IN ADVANCE.
IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER IN
EXCESS OF THE CONTRACT PRICE. IN THE EVENT THAT ANY WARRANTY OR WARRANTY
REMEDY FAILS OF ITS ESSENTIAL PURPOSE, OR IS HELD TO BE INVALID OR UNENFORCEABLE
FOR ANY REASON, IN CONSIDERATION OF THE OTHER PROVISIONS OF THIS AGREEMENT,
THE PARTIES AGREE THAT ALL LIABILITY LIMITATIONS WILL NEVERTHELESS REMAIN IN
EFFECT.
Governing Law and Dispute Resolution. This Agreement shall be governed by the internal laws of the State of
Wisconsin, U.S.A. without resort to conflicts of law analysis. The parties agree the State courts located in Milwau-
kee, Wisconsin, U.S.A. shall have exclusive venue for any dispute concerning the enforceability, interpretation, or
termination of this Agreement, and agree to bring any such action in this venue. The parties further agree to
personal jurisdiction in such courts for any such dispute.
Attorney fees, Collection Costs, and Indemnification. Buyer agrees to defend and indemnify Seller against any
claims, damages, or liability (including attorney fees) arising out of Buyer’s violation of any law or breach of its
obligations under this Agreement including, but not limited to, personal injury, death, or property damage. In
addition, Buyer shall reimburse Seller all reasonable attorney fees and collection costs incurred by Seller to enforce
its rights against Buyer under this Agreement.
Manuals and Brochures. Buyer shall communicate to Seller any special needs, pictorials, labels, warning signs,
instructions, or language required for the manuals and brochures used for the products. Buyer agrees to pay a
reasonable surcharge for additional manuals, special manuals, and brochures.
Severability. Any legally unenforceable provision may be severed from this Agreement, and the remaining terms
and conditions will be enforced as a whole as if such provision had not be inserted herein.
Waiver, Entire Agreement. No waiver by either party of a right under this Agreement shall waive any other rights.
These terms and conditions and any other writing signed by Seller constitute the entire agreement, and may not be
modified other than in writing signed by Seller.
13
STANDARD VILTER
WARRANTY STATEMENT
Seller warrants the products it manufactures to be free from defects in material and workmanship for a period of
eighteen (18) months from the date of shipment from Seller’s manufacturing plant or twelve (12) months from date
of installation at the initial end users location, whichever occurs first. In addition, Seller provides the following
extended warranties: (a) three (3) years from the date of shipment on single screw compressor internal rotating
parts, (b) two (2) years from the date of shipment on reciprocating compressors and single screw and reciprocating
compressor parts, and (c) two (2) years on all other parts on a single screw compressor unit. Such warranties do not
apply to ordinary wear and tear. Seller does not warrant that the product complies with any particular law or
regulation not explicitly set forth in the specifications, and Buyer is responsible for ensuring that the product
contains all features necessary to safely perform in Buyer’s and its customer’s plants and operations. Buyer must
notify Seller of any warranty claim within ten (10) days after such claim arises, otherwise Buyer waives all rights to
such claim. Products supplied by Seller, which are manufactured by others, are not warranted by Seller, but rather
Seller merely passes through the manufacturer’s warranty to Buyer.
SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED,

INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-
LAR PURPOSE.
Unless otherwise agreed in writing, Buyer’s sole remedy for breach of warranty is, at Seller’s option, the repair of
the defect, the correction of the service, or the providing a replacement part FOB Seller’s office. Seller will not be
responsible for costs of dismantling, lost refrigerant, reassembling, or transporting the product. Further, Seller will
not be liable for any other direct, indirect, consequential, incidental, or special damages arising out of a breach of
warranty. THESE WARRANTY REMEDIES ARE EXCLUSIVE AND ALL OTHER WARRANTY REM-
EDIES ARE EXCLUDED. Products or parts for which a warranty claim is made are to be returned transportation
prepaid to Seller’s factory. Any improper use, corrosion, neglect, accident, operation beyond rated capacity, substi-
tution of parts not approved by Seller, or any alteration or repair by others which, in Seller’s judgement, adversely
affects the Product, shall void all warranties and warranty obligations. Further, Seller shall not be liable under the
above warranties should Buyer be in default of its payment obligations to Seller under this Agreement or any credit
agreement.
14
STANDARD VILTER 5/15
WARRANTY STATEMENT
The seller extends warranty, from date of shipment, to a period of fifteen (15) years on all compressor bearings, five
(5) years on all internal compressor parts and two (2) years on the remainder of the parts on single screw compressor
units. If within such period any such product shall be proved to Seller’s satisfaction to be defective, such product
shall be repaired or replaced at Seller’s option. Such repair or replacement shall be Seller’s sole obligation and
Buyer’s exclusive remedy hereunder and shall be conditioned upon Seller’s receiving written notice of any alleged
defect within ten (10) days after its discovery and, at Seller’s option, return of such parts to Seller, F.O.B., freight
prepaid to Seller’s factory. Expenses incurred by Buyer in repairing or replacing any defective product or any lost
refrigerant will not be allowed except by written permission of Seller. This warranty is only applicable to products
properly maintained and used according to Seller’s instructions, the use of genuine Vilter replacement parts and
recommended oil in all repairs and replacements has demonstrated adherence to a scheduled maintenance program
as detailed in the Single Screw Compressor operating manual. This warranty does not apply to normal wear and
tear, or damage caused by corrosion, misuse, overloading, neglect, improper operation, accident or alteration, as
determined by Seller. Products supplied by seller hereunder, which are manufactured by someone else, are not
warranted by Seller in any way, but Seller agrees to assign to Buyer any warranty rights in such products that the
Seller may have from the original manufacturer. Labor and expenses for repair are not covered by warranty.
THE WARRANTY CONTAINED IN THIS SECTION IS EXCLUSIVE AND IN LIEU OF ALL OTHER
REPRESENTATIONS AND WARRANTIES (EXCEPT OF TITLE), EXPRESS OR IMPLIED WARRANTY
OF MERCHANTABILITY OR IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Any description of the product, whether in writing or made orally by Seller or Seller’s agents, specifications, samples,
models, bulletins, drawings, diagrams, engineering sheets or similar materials used in connection with Buyer’s
order are for the sole purpose of identifying the products and shall not be construed as an express warranty. Any
suggestions by seller or Seller’s agents regarding use, application or suitability of the products shall not be construed
as an express warranty unless confirmed to be such in writing by Seller.
The 5/15 Extended Warranty shall be applicable only if the specific maintenance guidelines as outlined in the
technical manual are followed. This includes the compressor inspections, completing periodic oil analysis and the
change out of the oil and oil filters, and related components as required with only genuine Vilter parts. The
customer is required to keep a maintenance log and receipts demonstrating the use of Genuine Vilter parts for
validation of a warranty claim, if requested.
Note; The 5/15 warranty applies to NEW compressors only, and does NOT include used or remanufactured com-
pressors.
15
Description
COMPRESSOR
The Vilter Single Screw Compressor is a positive ing is flooded with gas at suction pressure. The
displacement, capacity and volume controlled, oil gas enters the open end of the main screw flutes at
flooded, rotary compressor which uses a single the driven end, and becomes trapped in the screw
main screw intermeshed by two opposing gate ro- flute as the screw rotates and the gate rotor tooth
tors. Gas compression occurs when the individual enters the end of the flute. At this point, the com-
fingers of each gate rotor sweep through the pression process begins. Directly after the screw
grooves, or flutes, of the main screw as the screw flute is closed off by the gate rotor tooth, oil is in-
rotates. Compression occurs from the time the jected into the groove.
screw flute is first closed off by the gate rotor fin-
ger, until the time when the screw flute has ro- The oil enters the compressor through a connec-
tated to the point of lining up with the discharge tion at the top of the compressor. The purpose of
port in the compressor housing. A labyrinth type the injected oil is to absorb the heat of compres-
seal is used to prevent gas at discharge pressure sion, to seal the gate rotor tooth in the groove, and
from leaking past the end of the screw. Any dis- to lubricate the moving parts.
charge gas leakage past the labyrinth seal is vented
back to suction via four longitudinal holes drilled Additional internal oiling ports are provided at the
through the body of the screw. main and gate rotor bearings to cool and lubricate
the bearings. The mechanical shaft seal housing
By venting the discharge end of the main screw also contains oiling ports to lubricate, cool and pro-
back to suction, forces on each end of the screw vide a sealing film of oil for the mechanical shafts
are equal. This results in zero net axial forces on seal. Excess oil flows through the check valves on
the main bearings. With twin opposing gate ro- the sealing baffle plate. This oil is directed at the
tors, all radial forces are cancelled out also. Main main rotor roller bearing, which cools and lubri-
shaft bearings have no net forces except the weight cates the front roller bearing.
of the screw and the shaft assembly.
As the main screw rotates, the gate rotor is also
The compressors are comprised of three rotating driven, causing the gate rotor tooth to sweep the
assemblies: the main screw assembly and the two groove in the main screw. This sweeping action
gate rotor assemblies. Each of these rotating as- reduces the volume of the groove ahead of the gate
semblies use a common bearing configuration con- rotor tooth and causes the trapped gas and oil to be
sisting of a single, cylindrical rolling element bear- compressed in the reduced volume. As the main
ing at one end, and a pair of angular contact ball screw continues to rotate, the gate rotor tooth con-
bearings at the other end. The pair of angular tinues to reduce the groove volume to a minimum,
contact ball bearings are used to axially fix one thus compressing the trapped gas to a maximum
end of the rotating shafts, and to absorb the small pressure. A labyrinth seal arrangement prevents
amount of thrust loads on the shafts. The inner the compressed gas from leaking past the end of
races of the ball bearings are securely clamped to the screw. As the gate rotor tooth reaches the end
the rotating shafts, while the outer races are se- of the groove, the groove rotates to a position that
curely held in the bearing housing, thus fixing the lines up with the discharge port in the compressor
axial position of the shaft in relation to the bear- housing and the gas/oil mixture is discharged from
ing housings. The cylindrical roller bearings at the screw at high pressure. This completes the com-
the opposite end of the shafts allow for axial growth pression cycle for a single flute of the main screw.
of the shafts while supporting the radial loads from
the shafts. Once the gas is swept from the main screw flute
through the discharge port, it passes into the dis-
The suction gas enters the compressor housing charge manifold of the compressor. From the dis-
through the top inlet flange, at the driven end of charge manifold, the gas/oil exits the compressor
the unit. The driven end of the compressor hous- housing
16
Description
The Vilter compressors feature the exclusive continues until the screw rotates far enough for
Parallex™ Slide System, which consists of a pair the flute to pass the end of the volume ratio slide.
of slides for each gate rotor assembly. These At this point, the screw flute lines up with the
two independently operated slides are referred discharge port and the compressed gas is ex-
to as the capacity slide and the volume ratio slide. pelled from the screw flute. As the volume ra-
On the suction end of the screw, the capacity tio slide is pulled back away from the discharge
slide moves to vary the timing of the beginning end of the screw, the position of the discharge
of the compression process. With the slide port is changed and the gas is allowed to escape
moved all the way out to the suction end of the the screw flute earlier in the compression pro-
screw (the 100% position), the compression process, at a reduced pressure.
cess begins immediately after the gate rotor tooth
enters the screw flute and closes off the end of The overall volume ratio within the compressor
the groove. In this situation, the maximum vol- is determined by the distance between the front
ume of gas is trapped in the screw flute at the of the capacity slide (the start of compression)
start of the compression process. As the slide is and the back of the volume ratio slide (the
pulled back away from the suction end of the completion of compression). Therefore, the vol-
screw, the start of the compression process is ume ratio slide must respond to changes in the
delayed as some of the suction gas is allowed to downstream pressure measured in the oil sepa-
spill back out of the screw flute until the screw rator and position itself for the required com-
rotates far enough to pass the end of the capac- pression ratio based on the position of the ca-
ity slide and begin compressing. This causes a pacity slide. By only compressing the gas within
reduced volume of gas to be trapped in the screw the screw as far as required to match the pres-
flute when the compression process begins. In sure in the downstream receiver, the compres-
this way, the capacity of the compressor is re- sor efficiency is maximized. Proper position-
duced from 100% down to as low as 10% of the ing of the volume ratio slide prevents either over
full rated capacity. compressing or under compressing of the gas
within the screw flute. This allows the single
The capacity slide provides the means for con- screw compressor to efficiently handle a range
trolling specific process set points. By con- of volume ratios from as low as 1.2 up to 7.0.
tinuously adjusting the flow of gas through the
compressor, either suction or discharge pressure
in a particular process can be controlled. When
coupled with a microprocessor controller, the
adjustable capacity slide allows for precise and
continuous automatic control of any parameter
in the process to a chosen set point.
The second slide for each gate rotor is the vol-

ume ratio slide. The purpose of the volume ra-
tio slide is to maximize the efficiency of the com-
pressor by matching the gas pressure within the
screw flute at the point of discharge to the down-
stream process requirements. The volume ratio
slide operates at the discharge end of the screw,
and acts to vary the position of the discharge
port. When the slide is extended fully to the
discharge end of the screw (the 100% position),
the compression process within the screw flute
17
Symbols and Meanings
Note: The symbols that appear on this page, are used throughout the
manual to help identify any potential warnings, cautions or hazards and to
assist in avoidance of any accidents or injuries.
Electrical Hazards........................................................
Misc. Hazards...............................................................
Mechanical Hazards.....................................................
Fire Hazards..................................................................
Heat/Hot Hazards...........................................................
Mandatory Action Sign/Verification -

Communicates an action to be taken to
AVOID hazard......................................................
Prohibition Symbol......................................................
18
Installation
Section
Installation Section ...................................................................................................... 19
DELIVERY INSPECTION ....................................................................................................................................................................... 21

UNIT WEIGHTS ...................................................................................................................................................................................... 21
FOUNDATIONS ...................................................................................................................................................................................... 21
LOCATING UNIT - DRIVE COUPLING ALIGNMENT ....................................................................................................................... 21
SYSTEM PIPING .................................................................................................................................................................................... 21
ELECTRICAL CONNECTIONS ............................................................................................................................................................. 23
TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23

Ammonia Systems ........................................................................................................................................................................... 23
Halocarbon Refrigerant Systems ..................................................................................................................................................... 24
Evacuating The System .................................................................................................................................................................... 24
UNIT OIL CHARGING ........................................................................................................................................................................... 25

Oil For Single Screw Compressors .................................................................................................................................................. 25
SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25

Low Side Equipment ................................................................................................................................................................................ 26
Compressors ............................................................................................................................................................................................. 26
Condensers ............................................................................................................................................................................................... 26
Controls .................................................................................................................................................................................................... 26
Initial Charging – High Side Charging .................................................................................................................................................... 26
MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27

Daily ................................................................................................................................................................................................. 27
Weekly .............................................................................................................................................................................................. 27
Monthly ............................................................................................................................................................................................ 27
Trimonthly ........................................................................................................................................................................................ 27
Yearly ................................................................................................................................................................................................ 27
System Leaks .................................................................................................................................................................................... 28
Year Round Operation ...................................................................................................................................................................... 28
“STOP CHECK” INSTALLATION ......................................................................................................................................................... 29
COUPLINGS INSTALLATION AND ALIGNMENT ............................................................................................................................. 30

Hub Mounting .................................................................................................................................................................................. 30
Straight Bore .................................................................................................................................................................................... 30
Taper Bore ........................................................................................................................................................................................ 30
Shaft Alignment. .............................................................................................................................................................................. 31
Final assembly . ............................................................................................................................................................................... 32
Disc Pack Replacement. ................................................................................................................................................................... 32
SLIDE VALVE ACTUATOR ................................................................................................................................................................... 34
ACTUATOR MOTOR CONTROL MODULE CALIBRATION PROCEDURE .................................................................................... 34
SLIDE VALVE TROUBLE SHOOTING GUIDE ................................................................................................................................... 37
19
20
Installation
I. DELIVERY INSPECTION III. LOCATING UNIT - DRIVE

COUPLING ALIGNMENT
Vilter screw compressor components are thor-
oughly inspected at the factory, assuring the ship- The single screw compressor units are shipped
ment of a mechanically perfect piece of equip- with all major components mounted on struc-
ment. Damage can occur in shipment, however. tural steel. Place the entire unit on the floor on a
For this reason, the units should be thoroughly concrete pad and securely bolt in place. Review
inspected upon arrival. Any damage noted should local codes and ASHRAE Safety Code for Me-
be reported immediately to the transportation com- chanical Refrigeration. Bolt holes are located
pany. This way, an authorized agent can exam- in the unit’s mounting feet. When locating the
ine the unit, determine the extent of damage and unit, provide adequate space for service work.
take necessary steps to rectify the claim with no When the compressor unit is in place on the con-
serious or costly delays. At the same time, the crete pad, check both lengthwise and crosswise
local Vilter representative or the home office to assure it is level. Use shims and wedges as
should be notified of any claim made. needed under the mounting feet to adjust the level
of the unit.
TABLE 1. UNIT WEIGHTS
MODEL STANDARD ECON-O-MIZER On single screw units, the motor and compres-
UNIT (LBS)* UNIT (LBS)* sor have been roughly aligned at the factory. The
coupling center section was shipped loose to al-
VSM 71 2,750 2,750 low a check of proper electrical phasing, direc-
VSM 91 2,750 2,750 tion of rotation of the motor and final coupling
VSM 101 2,750 2,750 alignment. The dial indicator alignment method
VSM 151 2,750 2,750 is recommended. Final alignment should be
VSM 181 2,750 2,750 within 0.004 inches total indicator reading in
VSM 201 2,750 2,750 all direction for the VSS models and 0.010 inches
VSM 301 2,850 2,850 for the VSM models.
VSM 361 2,850 2,850
VSM 401 2,850 2,850 IV. SYSTEM PIPING
VSM 501 4,000 4,000
VSM 601 4,500 4,500 Refer to the ANSI/ASME B31.5 Code for Re-
VSM 701 5,000 5,000 frigeration Piping. All compressor oil supply and
VSS 451 4,000 4,000 oil return piping has been completed at the fac-
VSS 601 4,500 4,500 tory. The necessary connections to be made to
VSS 751 5,300 5,300 the screw compressor unit will vary depending
VSS 901 5,300 5,300 on the type of oil cooling method purchased.
VSS 1051 6,600 6,600 Main line refrigerant suction and discharge con-
VSS 1201 6,700 6,700 nections are always necessary.
VSS 1501 10,010 10,010
VSS 1801 10,010 10,010 Care must be taken to avoid trapping the lines
except for specific purposes. When traps are
* Does not include motor. used, the horizontal dimensions should be as
short as possible to avoid excessive oil trapping.
II. FOUNDATIONS
Lines for ammonia systems must be of steel pipe
Vilter single screw compressor units are basically with specially designed ammonia service fittings.
vibration free machines, therefore, no elaborate Common pipe fittings must NEVER be used as
foundations are necessary. The floor or founda- they will not provide the same service. Steel pipe
tion upon which the unit will be placed should be is generally used in large installations when joints
designed to support the entire operating weight are welded.
of the unit. See Table 1 for unit weights.
21
Installation
In making up joints for steel pipe, the following bon piping, only wrought copper fittings should
procedures should be followed: be used. Cast fittings as used for water service
are porous and will allow the refrigerant to es-
For threaded connections, all threads on the pipe cape. Note this exception: In larger pipe sizes,
and fitting should be carefully cleaned to remove wrought fittings are not available. However,
all traces of grease or oil. Threads should then be specially tested cast fittings are available and
wiped dry with a lintless cloth. Only thread fill- these may be used with complete safety.
ing compounds suitable for refrigeration service
should be used for making steel pipe joints. These In larger pipe sizes, wrought fittings are not avail-
compounds should be used sparingly, and on the able. However, specially tested cast fittings are
pipe only. Do not put any on the first two threads available and these may be used with complete
to prevent any of the compound from entering the safety.
piping system. Acetylene or arc welding is fre-
quently used in making steel pipe joints, however, When soldering copper tubing joints, only sil-
only a skilled welder should attempt this kind of ver solder should be used for Refrigerant-22 ser-
work. Take care to see no foreign materials are vice. Soft solder such as “50-50” should never
left in the pipes and remove all burrs formed when be used, as its melting point is to low, lacks me-
cutting pipe. chanical strength, and tends to break down
chemically in the presence of moisture.
It is important to avoid short, rigid pipe lines that
do not allow any degree of flexibility. This must A second method would be to install flex-
be done to prevent vibration being transmitted ible pipe couplings as close to the compressor
through the pipe lines to the buildings. One unit as possible with connections run in two dif-
method of providing the needed flexibility to ab- ferent directions, 90° apart. These flexible con-
sorb the vibration is to provide long lines that are nections should be installed on both the high and
broken by 90° Ells in three directions. low side lines of the compressor unit.
Smaller Halocarbon and Hydroflourocarbon in- Hangers and supports for coils and pipe lines
stallations use copper pipes with solder type fit- should receive careful attention. During pro-
tings where possible. The use of screw type fit- longed operation of the coils, they may become
tings in Halocarbon systems should be held to an coated with ice and frost, adding extra weight to
absolute minimum, as these refrigerants, due to the coil. The hangers must have ample strength
their physical properties, will leak through screw and be securely anchored to withstand the vibra-
type joints. tion from the compressor and adequately sup-
port the pipe lines.
When drawn copper tubing is used for Halocar-
bon lines, type “K” or “L” conforming to ASTM Water supply and drain connections, and equip-
B88 should be used. Soft annealed copper tubing ment using water, should be installed so all the
conforming to ASTM B280 can also be used for water may be drained from the system after the
tube sizes not larger than 1-3/8" in outside diam- plant has been shut down in cold weather. These
eter. These requirements are in accordance with precautions will avoid costly damage to the
the mechanical code for refrigeration ANSI B9.1- equipment due to freezing.
1971. The type of copper tubing to be used for a
given pressure is dependent on the strength of the This information is taken from ASHRAE 15-89
copper at the design temperature. Some local and ANSI B31.5. The installing contractor
codes forbid the use of Type “L”. Therefore, be- should be thoroughly familiar with these codes,
fore installation, be sure to check local require- as well as any local codes.
ments. Never use type “M” as it does not have
adequate wall thickness to withstand the operat-
ing pressures. In selecting fittings for Halocar-
22
Installation
V. ELECTRICAL CONNECTIONS First, if test pressures exceed the settings of the

system, relief valves or safety devices, they must
The single screw compressor units are shipped be removed and the connection plugged during
with all package mounted controls wired. The the test. Secondly, all valves should be opened
standard control power is 115 volts 60 Hertz, except those leading to the atmosphere. Then,
single phase. If a 115 volt supply is not available, open all solenoids and pressure regulators by the
a control transformer may be required. The power manual lifting stems. All bypass arrangements
source must be connected to the control panel ac- must also be opened. Because of differences in
cording to the electrical diagrams. characteristics of the various refrigerants, two
different testing methods are necessary.
The units are shipped without the compressor
motor starter. Field wiring is required between A. Ammonia Systems
the field mounted starters and package mounted
motors. Dry nitrogen may be used to raise the pressure
in an ammonia system to the proper level for the
Additional control wiring in the field is also re- test. The gas may be put into the system through
quired. Dry contacts are provided in the control the charging valve or any other suitable open-
panel for starting the screw compressor motor. ing. Adjust the pressure regulator on the bottle
These contacts are to be wired in series with the to prevent over-pressurization. Do not exceed
starter coils. A current transformer is supplied the pressure rating on the vessel with the lowest
along with the compressor unit, and is located in pressure rating.
the motor junction box. This transformer is to be
installed around one phase of the compressor Carbon Dioxide should NOT be used as a test-
motor starter. A normally open auxiliary contact ing gas in a system where ammonia is already
from the compressor motor starter is also required. dissolved in any moisture remaining. This will
cause ammonium carbonate to precipitate when
Terminal locations for this wiring can be found the CO2 is added. If heavy enough, this precipi-
on the wiring diagram supplied with this unit. tate may cause the machine to freeze and clog
Additional aspects of the electrical operation of the strainer.
the single screw units are covered in the start up
and operation section of this manual. A mixture of four parts water to one part liquid
soap, with a few drops of glycerin added, makes
VI. TESTING REFRIGERATION a good solution. Apply this mixture with a one
SYSTEM FOR LEAKS inch round brush at all flanges, threaded joints,
and welds. Repair all visible leaks. If possible,
Vilter equipment is tested for leaks at the factory. leave the pressure on over night. A small pres-
One the most important steps in putting a refrig- sure drop of 5 lbs. Over this period indicates a
eration system into operation is field testing for very tight system.
leaks. This must be done to assure a tight system Remember to note the ambient temperature, as a
that will operate without any appreciable loss of change in temperature will cause a change in
refrigerant. To test for leaks, the system pressure pressure.
must be built up. Test pressures for various re-
frigerants are listed in ANSI B9.1-1971 code bro- After the system is thoroughly tested, open all
chure entitle “Safety Code for Mechanical Refrig- valves on the lowest part of the system so the gas
eration”. These pressures will usually suffice, will float away from the compressor. This pre-
however, it is advisable to check local codes as vents any dirt or foreign particles from entering
they may differ. Before testing may proceed, sev- the compressor and contaminating the working
eral things must be done. parts. The oil should then be charged into the
compressor.
23
Installation
Charge a small amount of ammonia into the sys- condensables from the system before charging it
tem and pressurize the system to its respective with refrigerant. A combination of moisture and
design pressure. Pass a lit sulfur stick around all refrigerant, along with any oxygen in the sys-
joints and connections. Any leaks will be indi- tem, can form acids or other corrosive com-
cated by a heavy cloud of smoke. If any leaks are pounds that corrode internal parts of the system.
observed during this test, they must be repaired
and rechecked before the system can be consid- To properly evacuate the system, and to remove
ered tight and ready for evacuation. all non-condensables, air and water vapor, use a
high vacuum pump capable of attaining a
B. Halocarbon Refrigerant Systems blanked off pressure of 50 microns or less. At-
tach this pump to the system and allow it to op-
“Oil pumped” dry nitrogen, or anhydrous CO2 in erate until system pressure is reduced somewhere
this order of preference may be used to raise the below 1000 microns. Evacuation should not be
pressure to the proper level for testing. done unless the room temperature is 60F or
higher.
When the proper pressure is attained, test for leaks
with the soap mixture previously described. Af- Attach vacuum gauge(s), reading in the 20 to
ter all leaks are found and marked, relieve the 20,000 micron gauge range, to the refrigerant
system pressure and repair the leaks. Never at- system. These gauge(s) should be used in con-
tempt to repair soldered or welded joints while junction with the high vacuum pump. The read-
the system is under pressure. Soldered joints ing from the gauge(s) indicates when the system
should be opened and re soldered. has reached the low absolute pressure required
for complete system evacuation.
Do not simply add more solder to the leaking joint.
After all the joints have been repaired and the Connect the high vacuum pump into the refrig-
system is considered “tight” the system may be eration system by using the manufacturer’s in-
tested with refrigerant. structions. Connect the pump both to the high
side and low side of the system, to insure system
Attach a drum of the refrigerant to be used in the evacuation. Attach the vacuum gauge to the sys-
system and allow the gas to enter until a pressure tem in accordance with the manufacturer’s in-
of 5 psig is reached. structions.
Remove the refrigerant drum and bring the pres- A single evacuation of the system does not satis-
sure to the recommended test level with oil factorily remove all of the non-condensable, air
pumped dry nitrogen or CO2. Then check the and water vapor. To do a complete job, a triple
entire system again for leaks, using a halide torch evacuation is recommended.
or electronic leak detector. Be sure to check all
flanged, welded, screwed and soldered joints, all When the pump is first turned on, bring system
gasketed joints, and all parting lines on castings. pressure to as low a vacuum level as possible,
If any leaks are found, they must be repaired and and continue operation for 5 to 6 hours.
rechecked before the system can be considered
tight again, remembering that no repair should Stop the pump and isolate the system. Allow the
be made to welded or soldered joins while the sys- unit to stand at this vacuum for another 5 to 6
tem is under pressure. hours. After this time, break, the vacuum and
bring the system pressure up to 0 psig with dry
C. Evacuating The System nitrogen.
A refrigeration system operates best when only To begin the second evacuation, allow the pump
refrigerant is present. Steps must be taken to re- to operate and reduce the pressure again to within
move all air, water, vapor, and all other non- 50 to 1000 microns. After this reading is reached,
24
Installation
allow the pump to operate 2 or 3 hours. Stop the TABLE 2. OILCHARGE

pump and let the system stand with this vacuum.
Again using dry nitrogen, raise the system pres- Oil Separator Size Approximate Oil
sure to zero. Charge – Gallons
For the third evacuation, follow the previous pro- VSR 16” 20 to 27
cedure with the pump operating until system pres- VSR 20” 22 to 31
sure is reduced below the 1000 micron level. Run VSM 20” 20 to 25
the pump an additional 6 hours and hold the sys- VSM 30” 30 to 35
tem for approximately 12 hours at low pressure. 20” 30 to 40
After this, again break the vacuum with dry ni- 24” 40 to 50
trogen and allow the pressure in the system to 30” 60 to 75
rise slightly above zero pounds (psig). Install new 36” 95 to 105
drier cartridges and moisture indicators. Charge 42” 145 to 165
the system once more below the 1000 micron level
and use the refrigerant designed for the system.
The oil level may be above the top sight glass at
When properly evacuating the system as outlined this time. Later, when the unit is placed in op-
above, the system is dry, oxygen-free and free of eration, there will be some drop in the oil level
non-condensables. The piping should not be in- as the various oil lines, oil filter and other pip-
sulated before the evacuation process is started. ing becomes charged with the normal amount of
If moisture is in the system before evacuating, it oil that will be in circulation. This drop in oil
condenses in low places and freezes. If this hap- level should bring the level in the oil receiver/
pens, it can be removed by gently heating the trap separator into the normal operating range. Do
farthest away from the vacuum pump. This causes not mix oils.
the ice to melt and water to boil. Water vapor
collects in the next trap towards the vacuum pump. A. Oil For Single Screw Compressors
This process should be repeated until all pockets
of water have been boiled off, and the vacuum Due to the need for adequate lubrication, Vilter
pump has had a chance to remove all the water recommends only the use of Vilter lubricants,
vapor from the system. designed specifically for Vilter compressors.
With the extensive research that has been per-
VII. UNIT OIL CHARGING formed, we are able to offer refrigerant specific
lubricating oils. Use of oil not specified or sup-
The compressor unit is shipped from Vilter with plied by Vilter will void the compressor warranty.
no oil charge. The initial oil charge can be made
through the drain valve at the oil receiver/separa- Please contact your local Vilter representative or
tor. Vilter motor driven and manually operated the Home Office for further information.
oil chargers are available for this purpose. Once
the unit has been started and is operating above VIII. SYSTEM REFRIGERANT
50% capacity, oil may have to be added to bring CHARGING
the oil level to the normal operating point. With
the unit operating, oil should be added through CAUTION
the charging connection at the suction strainer.
The normal operating level is between the (2) sight When charging the system, make sure the com-
glasses on the oil separator. See Table 2 for ap- pressor unit is pressurized from the discharge
proximate oil charge requirements. side of the compressor. Pressurizing the com-
pressor from the suction side may cause rota-
tion of the compressor, without oil supply, which
could lead to internal damage.
25
Installation
the “low side”. High side charging is usually

After the system is leak-free and evacuation has used for initial charging as filling of the system is
been completed, it is ready for charging. Before much faster. Low side charging is usually reserved
actual charging, however, the entire operation of for adding only small amounts of refrigerant after
the refrigeration system should be inspected as the system is in operation.
outlined below:
High side charging of refrigerant into the sys-
A. Low Side Equipment tem is accomplished as follows:
1. Fans on air handling equipment running. 1. Connect a full drum of refrigerant to the
2. Pumps on water cooling equipment running. liquid charging valve. This valve is gener-
3. Proper location and attachment of thermo- ally located in the liquid line immediately
static expansion valve bulb to suction line. after the king or liquid line valve. Purge
4. Correct fan and pump rotation. the air from the charging line.
5. Evaporator pressure regulators and solenoid
valves open. 2. Invert the refrigerant drum if the drum is
6. Water pumps and motors correctly aligned. not equipped with “Liquid” and “Vapor”
7. Belt drives correctly aligned and tensioned. valves, and place in such a position so the
8. Proper voltage to motors. liquid refrigerant only can enter the sys-
tem. Close the liquid line or king valve, if
B. Compressors it is not already closed. Open the “Liquid”
charging valve slowly to allow refrigerant
1. Proper oil level. to enter the system. The vacuum in the
2. Voltage agrees with motor characteristics. system will draw in the refrigerant.
3. Properly sized motor fuses and heaters.
4. Direct drivers aligned and couplings tight. It is important that, during this operation,
5. All suction and discharge valves open. air handling units be running and water is
6. All transducers and RTD’s calibrated and circulating through the chillers. The low
reading correctly. pressures on the system can cause the re-
frigerant to boil at low temperature and
C. Condensers possibly freeze the water if it is not kept
circulating.
1. Water available at water cooled condensers
and supply line valve open. Water freezing in a chiller can rupture the
2. Water in receiver of evaporative condenser tubes and cause extensive damage to the
and makeup water available. system. It would be desirable to charge the
3. Correct rotation of pump and fan motors. initial amount of refrigerant without water
4. Belt drives aligned and tensioned correctly. in the shell and tube equipment to elimi-
5. Pump, fans and motors lubricated. nate the possibility of freeze up.
D. Controls 3. After some refrigerant has entered the sys-

tem, the compressor unit starting procedure
Controls should be at the initial set points. See may be followed. See Start-Up and Opera-
microprocessor manual for further information. tion Section of this manual.
E. Initial Charging – High Side Charg- 4. Continue charging refrigerant into the sys-
ing tem until the proper operating requirements
are satisfied. Then, close the liquid charg-
There are two methods of charging refrigerant into ing connection and open the liquid line
the system, through the “high side” or through valve allowing the system to operate nor-
26
Installation
mally. To check that enough refrigerant has replaced.

been added, the liquid sight glass should
show no bubbles, and there will be a liquid 5. Check compressor sound for abnormal
seal in the receiver. If these two conditions noises.
are not satisfied, additional refrigerant must
be added. 6. Check shaft seals for excessive oil leakage.
A small amount of oil leakage (approxi-
5. When sufficient refrigerant has been charged mately 10 drops/min) is normal. This al-
into the system, close the charging and drum lows lubrication of the seal faces.
valves. Then remove the drum from the sys-
tem. B. Weekly
(Items 1 thru 6 above plus 7 thru 9)
6. During the charging period, observe the
gauge carefully to insure no operating diffi- 7. Check the refrigeration system for leaks
culties. Watch head pressures closely to with a suitable leak detector.
make sure the condensers are functioning
properly. 8. Check oil pressures and review micropro-
cessor log and log sheets.
Since it is usually necessary to use several drums
when charging a system, follow the procedures in 9. Check refrigerant levels in vessels.
paragraphs E1 and E2 of the above description
when attaching a new drum. After charging, the C. Monthly
refrigerant drums should be kept nearby for sev- (Items 1 thru 8 above plus 9 thru 13)
eral days as it is sometimes necessary to add more
refrigerant as the system “settles down”. 10. Oil all motors and bearings. Follow
manufacturer’s instructions on lubrication.
IX. MAINTENANCE SUGGESTIONS
11. Check calibration and operation of all con-
Careful checking of a refrigeration system for trols, particularly safety controls.
leaks and proper operation of all components upon
installation will start the system on its way to a 12. Check oil cooler for any evidence of corro-
long life of satisfactory service. To ensure the sion, scaling or other fouling.
desired trouble-free operation, however, a system-
atic maintenance program is a prerequisite. The 13. Operate compressor capacity and volume
following maintenance schedule is suggested. ratio controls through their range both au-
tomatically and manually.
A. Daily
D. Trimonthly
1. Check oil levels. (About 2000 operating hours)
2. Check all pressure and temperature readings. Check movement of compressor rotor at drive
coupling end to determine bearing float. (Refer
3. Check micronic oil filter inlet and outlet to Service Section.)
pressures for excessive pressure drop.
Change filter when pressure drop exceeds E. Yearly
45 psi or every six months, whichever oc- (Items 1 thru 13 and “D” above plus 14 thru
curs first. For proper procedure for chang- 28)
ing micronic oil filter and for charging oil
into the system, see Operation Section. 14. Check entire system thoroughly for leaks.
4. Clean strainers each time filter cartridge if 15. Remove all rust from equipment, clean and
paint.
27
Installation
16. Flush out sediment, etc. from water circuits. G. Year Round Operation
17. Clean all oil strainers. On a continual basis:
18. Clean suction strainer – compressors. 1. Guard against liquid slugging of compres-
sor.
19. Check motors and fans for shaft wear and
end play. 2. Maintain unit in clean condition and paint
as necessary.
20. Check operation and general condition of
microprocessor and other electrical controls. 3. Grease valve stems and threads for the valve
caps.
21. Clean all water strainers.
When refrigeration equipment is operated 24
22. Check drains to make sure water will flow hours a day year round, it is highly recommended
away from equipment. that a yearly check of all internal parts be made
(see Service Section). While the highest mate-
23. Drain and clean entire oil system at receiver rial standards are maintained throughout all
drain. Recharge with new clean moisture Vilter compressors, continuous operation and any
free oil. For proper procedure for changing presence of dirt may prove injurious to the ma-
micronic oil filter and charging oil into the chine. To forestall needless shutdowns or pre-
system, see Start-Up and Operation section. vent possible machine breakdowns, the side cov-
ers should be removed yearly, and a visual in-
24. Check compressor coupling. For integrity spection be made of the internal parts. In this
and alignment. way, a small amount of time spent checking
machine conditions once a year may prevent
25. Check oil pump for wear. extensive shutdowns later with subsequent prod-
uct loss and expensive repairs.
26. Check the calibration of the microprocessor
pressure transducers and RTD’s for accuracy.
27. Check mounting bolts for compressor and

motor.
F. System Leaks
There are any number of reasons why leaks de-

velop in a refrigeration system (i.e. such as dry-
ing out of valve packing, yielding of gaskets, im-
proper replacement of valve caps and loosening
of joints due to vibration). For these reasons, the
need for periodic leak testing cannot be over-em-
phasized. Similarly, when any service operations
are performed on the system, care should be exer-
cised to insure all opened flanges are tightened,
all plugs that were removed are replaced with a
suitable thread filling compound, all packing
glands on valve stems are tightened, and all valve
caps are replaced. When operation is restored,
all joints opened or any valves moved during the
servicing should be checked for leaks.
28
“Stop Check” Installation
Name
Name
Stem should always be

positioned upwards.
Correct Correct
Wrong
Wrong
Wrong
Verify the location of Spring and

note the Vilter name
Installation: The new design will apply only to the 2” thru 4” stop valves. Retrofitting a field
installation will require replacing the bonnet assembly.
The bonnet must be installed with the spring towards the bottom (see
illustrations above). The drill fixture is designed so that the hole for the spring
will always be drilled on the opposite side from the cast-in Vilter name on the
bonnet. From the outside of the valve, the casting numbers must always be
towards the top of the valve.
See Operation Section on Stop Check Operation.
29
Installation
IIV. COUPLINGS INSTALLATION

ANDALIGNMENT B. Straight Bore:
These instructions are intended to help you to 1. Install key(s) in the shaft. If the hub is an
installand align the coupling. Covered here will interference fit, heat the hub in an oil bath or
be general information, hub mounting, alignment, oven until bore is sufficiently larger than the
assembly, locknut torquing, discpack replacement, shaft. 350º F. is usually sufficient. An open
and part numbers. The coupling as received, may flame is not recommended. However, if flame
or may not be assembled. heating is necessary, use a very large rose bud
*If assembled, the locknuts are not torqued. tip to give even heat distribution. A thermal
*If coupling is assembled, remove the bolts that heat stick will help determine hub tempera-
attach the hubs to the disc packs. Remove both ture. DO NOT SPOT HEAT THE HUB OR
hubs. Leave the disc packs attached to the center DISTORTION MAY OCCUR. With the hubs
member. expanded, slide it up the shaft to the desired
axial position. A pre-set axial stop device can
A. Hub Mounting: be helpful.
1. Clean hub bores and shafts. Remove any NOTE: All DBZ hubs have pressed in bushings.
nicks or burrs. If bore is tapered, check for good Make sure the bushings are facing the disc pack.
contact pattern. If the bore is straight, mea-
sure the bore and shaft diameters to assure
proper fit. The key(s) should have a snug side- C. Taper Bore:
to-side fit with a small clearance over the top.
1. Put the hub on the shaft without key(s)
NOTE: If the DBZ hub position on the shaft does inplace. Lightly tap hub up the shaft with a
not allow enough room to install the short bolts soft hammer. This will assure a metal-to-metal
in the hub after hub mounting, install the bolts fit between shaft and hub. This is the starting
and disc pack before mounting hub on shaft. point for the axial draw. Record this position
30
Installation
Coupling Total Indicator Dimension “E” Torque

Size Reading (T.I.R.) Ft.-Lbs.
Angle Parrallel Min Max (In.-Lbs.)
50 .004 .003 1.36 1.37 (24)

62 .005 .003 1.74 1.75 (36)
75 .005 .003 1.77 1.78 (36)
101 .006 .004 2.08 2.10 (96)
126 .007 .005 2.46 2.48 (156)
163 .009 .005 2.46 2.48 (156)
201 .010 .006 2.96 2.98 25
226 .012 .007 3.83 3.83 30
263 .014 .009 4.33 4.35 40
301 .016 .010 4.90 4.93 95
351 .018 .012 5.90 5.93 175
401 .020 .013 6.71 6.75 150*
451 .024 .014 7.27 7.31 190*
Note: These torques are approximate. Bolt and locknut threads must be coated with molybdenum
disulfide grease.
* Tightening torques are cadmium plated.
between shaft and hub face with a depth mi- This means there is a minimal amount of wavi-
crometer. Mount a dial indicator to read axial ness in the disc pack when viewed from the
hub movement. Set the indicator to “0”. Re- side. This will result in a flexing element that
move hub and install key(s). Remount hub, is centered and parallel to its mating flange
drawing it up the shaft to the “0” set point. faces. Move the connected equipment to ac-
Continue to advance hub up the taper to the complish the above.
desired axial position. Use the indicator as a
guide only. A pre-set axial stop device can be NOTE: The disc pack is designed to an optimal
helpful. Check the final results with a depth thickness and is not to be used for axial adjust-
micrometer. The hub may have to be heated in ments.
order to reach the desired position on the shaft.
DO NOT SPOT HEAT THE HUB OR DIS- As a guide, maximum and minimum values for
TORTION MAY OCCUR. Install shaft lock- dimension “E” are given. These dimensions are
nut to hold hub in place. suggested for initial installation. Additional ca-
pacity is available to compensate for thermal and
D. Shaft Alignment. structural movement. Maximum axial capacity
values for these couplings are also given. See chart
Move equipment into place. above.
a. Soft Foot. The equipment must sit flat on its c. Angular Alignment. Rigidly mount a dial in-
base. Anysoft foot must be corrected now. dicator on one hub or shaft, reading the face of
the other hub flange, as shown on next page.
b. Axial Spacing. The axial spacing of the shafts Rotate both shafts together, making sure the
should be positioned so that the disc packs shaft axial spacing remains constant. Adjust
(flexing elements) are flat when the equipment the equipment by shimming and/or moving so
is running under normal operating conditions. that the indicator reading is within .002 inch
per inch of coupling flange.
31
Installation
a. If the coupling arrived assembled, the disc

d. Parallel Offset. Rigidly mount a dial indi- packs are still attached to the center ring. Be-
cator on one hubor shaft, reading the other hub fore taking the discs packs off, first install one
flange outside diameter, as shown in Figure 3. hub bolt through each disc pack and secure
Indicator set-up sag must be compensated for. with lock out. This will help when the pack is
Rotate both shafts together. Adjust the equip- reinstalled late. If the coupling was shipped
ment by shimming and/or moving so that the disassembled, the bolt through the pack is not
indicator reading is within .002 inch per inch required as the discs in the pack are factory
of the axial length between flex elements. See taped together.
drawing below.
Note: If the driver or driven equipment alignment b. Remove the long bolts. Mount the disc packs
specification is tighter than these recommenda- on the hubs with one bolt through the disc pack
tions, the specification should be used. Also, be aligned with a clearance hole in the hub. In-
sure to compensate for thermal movement in the stall the short bolts through the hub, disc pack,
equipment. The coupling is capable of approxi- bevel washer or link, and secure with a lock-
mately four time the above shaft alignment toler- out.
ances. However, close alignment at installation
will provide longer service with smoother opera- NOTE: All bolt threads should be lubricated. A
tion. clean motor oil is recommended. On size 226 and
larger, a link must be put on bolt first. Remove
Note: Alignment of C- the disc pack alignment bolt. Proceed to mount
Flange Units should be
checked when compressor
the second disc pack to the other hub in the same
or motor are replaced. way.
C.Position one set of short bolts in each hub

on top. Now slide the center ring down into
place straddling the short bolts with the cen-
ter ring bushings. If coupling is dynam-ically
balanced, the center ring match marks must
lineup with both hub match marks. When one
bushing is in-line with the hole in the disc pack,
slide one long bolt through washer or link, disc
pack, center ring, disc pack, washer or link,
and then secure with a locknut. The long bolt
requires a minimum clearance “R” for instal-
lation between back side of coupling flange
and stationary equipment. See Figure 1 and
Table l for value of “R.” On size 226 and larger
a link must be put on the bolt first. Now in-
stall the rest of the long bolts in the same man-
ner.
D.Torque the long bolt locknuts at this time.

See Table on page 31 for torque values.
E. Final assembly .
NOTE: With the coupling in good alignment, the
With the coupling in good alignment the bolts bolts will fit through the holes in the flanges and
will fit through the holes in the flanges and the the disc pack more easily. It is recommended that
disc packs more easily. all locknuts be retightened after several hours of
32
Installation
initial operation. E.For further help with the installa-

tion or alignment, consult Rexnord.
F. Disc Pack Replacement.
If it becomes necessary to replace the disc pack, it

can be done as follows:
A. Remove all the long bolts and lower the cen-

ter ring by sliding it our from between the two
disc packs.
B. Remove one short bolt from the disc pack/hub

connection and reinstall it through a hub clear-
ance hole and into the hole in the disc pack. Put
the nut on. This will keep the discs together and
maintains the disc orientation for later reinstal-
lation. Remove the rest of the short bolts and
takeoff the disc pack. Repeat for the second disc
pack.
C. Replace the pack(s) if required. Recheck align-

ment per Section D. Reassemble per Section E.
33
Installation & Calibration
SLIDE VALVE ACTUATOR 2. Completely shut off the power to the

INSTALLATIONS INSTRUCTIONS Vission/Vantage control panel com-
pletely.
Caution
3. If not already done, mount the slide
WHEN INSTALLING THE OPTICAL SLIDE valve actuator per (“Vilter Actuator set
MOTOR, LOOSEN LOCKING COLLAR up for Capacity and Volume Slide Mo-
BEFORE SLIDING THE COLLAR DOWN tors). Next, wire the actuator per the
ON THE SHAFT. DO NOT USE A SCREW- attached wiring diagrams, using the al-
DRIVER TO PRY LOCKING COLLAR INTO ready installed electrical conduit to run
POSITION. the cables. The old wiring can be used
to pull the new cables through the con-
duit to the control panel. The cables
OVERVIEW may also be externally tie-wrapped to
the conduit. Run the yellow AC power
Calibration of an optical slide valve actuator is cable(s) and the gray DC position
a two step process that must be done for each transmitter cable(s) in different con-
actuator installed of the compressor. Briefly, duit. This prevents the DC position
the steps are as follows. transmitter cable from picking up elec-
trical noise from the AC power cable.
1) The actuator motor control module, located Do not connect either of the cables to
inside the actuator housing, is calibrated so the actuators yet.
that it knows the minimum and maximum
rotational positions of the slide valve it con- In addition, if the actuators are replacing old
trols. The calibrated actuator will output 0 gearmotors on early Vission/Vantage units, you
VDC at the minimum position and 5 VDC must remove the capacitors and associated wir-
at the maximum position. ing from inside the control panel. This is neces-
sary to prevent electrical damage to the new ac-
2) After the actuator motor control module has tuator motor.
been calibrated for 0-5Volts, the controlling
channel corresponding to the actuator mo- 4. When completing the calibration of
tor (either the capacity or volume) has to be the new actuators, the motors are
calibrated. This instructs the Vission/ Van- signaled to move to below 5%. This
tage control panel to learn the rotational 0% may not completely occur when
position & rotational 100% position of the exiting the calibration screen due to a
slide valve travel. “program timer”. HOWEVER, when
the compressor actually starts, the
PLEASE NOTE: motors will travel below 5% and
Because there is an optical sensor on this function correctly. The user may see
motor, do not attempt calibration in direct that the actuators are not below 5%
sunlight. after calibration and try to find the
reason. If the calibration screen is re-
entered right away and then exited,
ACTUATOR MOTOR CONTROL the timer will allow the actuator to go
MODULE CALIBRATION PROCEDURE below the 5% on the screen. This
may be perceived as a problem; in
1. Disable the Slide Non-Movement Alarm reality,it is not.
by going to the “Setup” menu on the
Vission/Vantage and choosing “Alarm 5. Note:The 0 to 5V-position transmitter
Disable” for the Slide Non-Movement output of the actuator will fluctuate wildly
Option. (If applicable).
34
Installation & Calibration
during the calibration process. To prevent stated earlier, the actuator voltage will
damage to the actuators, do not connect the fluctuate during calibration. After the
yellow power cable or the gray position actuator has been calibrated, 0V output
transmitter cable until instructed to do so will correspond to the minimum position
later on. and 5V to the maximum position.
6. Open the plastic cover of the capacity 14. Note: The “Slide calibration” screen on
motor by removing the four #10 screws. the Vission/Vantage has a “Current”
Caution: there are wires attached to the window, which displays twice the actuator
connector on the plastic cover. Handling output voltage. This value, (the % volume
the cover too aggressively could break and the % capacity) displayed in the
the wires. “Current Vol” and Current Cap” Windows
are meaningless until calibration has been
7. Gently lift the cover and tilt it toward the completed.
Turck connectors. Raise the cover enough
to be able to press the blue calibrate button 15. Use the DEC button on the Vission/
and be able to see the red LED on the top Vantage panel to drive the slide valve to its
of assembly. minimum “mechanical stop” position. Do
not continue to run the actuator in this
8. Press “Menu” on the main screen and then direction after the slide valve has
press the “Slide Calibration” button, to reached the stop. Doing so may cause
enter the slide calibration screen. (Note: damage to the actuator or the slide
you must be in this slide calibration screen valve. When the slide has reached the
before attaching the yellow power cable or mechanical stop position, use the INC
gray position transmitter cable.) button to pulse the actuator to where the
slide is just off of the mechanical stop and
9. Now connect the yellow power cable and there is no tension on the motor shaft.
the gray position transmitter cable to the
actuator. 16. Quickly press and release the blue button
on the actuator again. The red LED will
10. Press INC and DEC to move the slide now flash at a slower rate, indication that
valve and check for the correct rotation. the minimum slide valve position (0V
See Table 1on page 48 for Actuator/ position) has been set.
command shaft rotation specifications.
17. Use the INC button on the Vission/Vantage
11. Note: If the increase and decrease buttons panel to drive the slide to its maximum
do not correspond to increase or decrease “mechanical stop” position. Do not
shaft rotation, swap the blue and brown continue to run the actuator in this
wires of the “yellow power cable”. This direction after the slide valve has
will reverse the rotation of the actuator/ reached the stop. Doing so may cause
command shaft. damage to the actuator or the slide
valve. When the slide valve has reached
12. Quickly press and release the blue push the mechanical stop position, use the DEC
button on the actuator one time. This button to pulse the actuator to where the
places the actuator in calibration mode. slide is just off of its mechanical stop and
The red LED will begin flashing rapidly. there is no tension on the motor shaft.
13. Note: When the actuator is in calibration 18. Quickly press and release the blue button
mode, it outputs 0V when the actuator is on the actuator one more time. The red
running and 5V when it is still. Thus, as LED will stop flashing. The actuator is
35
Installation
now calibrated and knows the minimum calibration and exit the “Slide Calibration”
and maximum positions of the slide valve screen. The controller will automatically
it controls. Now the capacity or volume energize the actuator and drive it back to
channel of the Vission/Vantage can be its minimum position (below 5%) for pre-
calibrated. start-up.
19. Use the Dec button to move the actuator 26. Note: Now the “Current Cap” or the
towards its minimum position while “Current Vol” value will be displayed in
watching the millivolt readout on the the window on the “Main” screen and the
Vission/Vantage screen. Discontinue “Slide Calibration” screen.
pressing the DEC button when the milli-
volt reading in the “Current” window above 27. Gently lower the plastic cover over the top
the “Set Min” button is approximately 500 of the actuator to where it contacts the base
millivolts. and o-ring seal. After making sure the
cover is seated properly, gently tighten the
20. Now use the DEC and INC buttons to four #10 screws. Caution: The plastic
position the slide valve until a value close cover will crack if the screws are over
to 300 millivolts is on the screen. Then, tightened.
press the “Set Min” button for the capacity
or volume slide valve window to tell the 28. Enable the “Slide Non-Movement Alarm”
controller that this is the minimum by going to the “Setup” menu and choosing
millivolt position. Note: The value in the “Alarm Enable” for the “Slide Non-
“Current Cap” or “Current Vol” window Movement Option”.
has no meaning right now.
29. This completes the calibration for this
21. Use the INC button to rotate the actuator channel either capacity or volume. Repeat
towards its maximum position while the same procedure to the other channel.
watching the millivolt readout on the
controller screen. Discontinue pressing the
INC button when the millivolt reading in
the “Current” window is approximately
9200 millivolts (7900 millivolts for the
2783J qualified analog boards). You are
nearing the mechanical stop position.
22. Pulse the INC button to carefully move the

slide valve until the millivolt readout
“saturates”, or stops increasing. This is
around 9500 millivolts (8400 millivolts for
2783 qualified analog boards).
23. Pulse the DEC button until the millivolts

just start to decrease. (This is the point
where the channel drops out of
saturation).Adjust millivolt value to 300
millivolts below recorded maximum milli-
volts in step #22.
24. Press the “Set Max” button.
25. Press the “Main” button to complete
36
Slide Valve Actuator Troubleshooting Guide
Slide Valve Actuator Theory of Operation the saved motor position is read from EEPROM
memory and the actuators resumes normal function
The slide valve actuator is a gear-motor with a
position sensor. The motor is powered in the for- This scheme is not foolproof. If the motor is moved
ward and reverse directions from the main com- manually while the power is off or the motor brake
puter in the control panel. The position sensor has failed, allowing the motor to free wheel for too
tells the main computer the position of the slide long after the position sensor looses power, the ac-
valve. The main computer uses the position and tuator will become lost.
process information to decide where to move the
slide valve next. A brake failure can sometimes be detected by the po-
sition sensor. If the motor never stops turning after
The position sensors works by optically counting a power loss, the position sensor detects this, knows
motor turns. On the shaft of the motor is a small it will be lost, and goes immediately into calibrate
aluminum “photochopper”. It has a 180 degree mode when power is restored.
fence that passes through the slots of two slotted
optocouplers. The optocouplers have an infra-
red light emitting diode (LED) on one side of the
slot and a phototransistor on the other. The
phototransistor behaves as a light controlled
switch. When the photochopper fence is block-
ing the slot, light from the LED is prevented from
reaching the phototransistor and the switch is
open. When photochopper fence is not blocking
the slot, the switch is closed.
As the motor turns, the photochopper fence al-

ternately blocks and opens the optocoupler slots,
generating a sequence that the position sensor
microcontroller can use to determine motor posi-
tion by counting. Because the motor is connected
to the slide valve by gears, knowing the motor
position means knowing the slide valve position.
During calibration, the position sensor records the

high and low count of motor turns. The operator
tells the position sensor when the actuator is at
the high or low position with the push button.
Refer to the calibration instructions for the de-
tailed calibration procedure.
The position sensor can get “lost” if the motor is

moved while the position sensor is not powered.
To prevent this, the motor can only be moved elec-
trically while the position sensor is powered.
When the position sensor loses power, power is
cut to the motor. A capacitor stores enough en-
ergy to keep the position sensor circuitry alive
long enough for the motor to come to a complete
stop and then save the motor position to non-vola-
tile EEPROM memory. When power is restored,
37
The actuator cannot be cali- Dirt or debris is blocking one or both Clean the optocoupler slots with
brated optocoupler slots a Q-Tip and rubbing alcohol.
The photochopper fence extends less Adjust the photochopper so that

than about half way into the the fence extends further into the
optocoupler slots optocoupler slots. Make sure the
motor brake operates freely and
the photochopper will not con-
tact the optocouplers when the
shaft is pressed down.
The white calibrate wire in the grey Tape the end of the white wire
Turck cable is grounded in the panel and make sure that
it cannot touch metal
Dirt and/or condensation on the po- Clean the boards with an elec-
sition sensor boards are causing it to tronics cleaner or compressed
malfunction air.
The calibrate button is stuck down Try to free the stuck button.
The position sensor has failed Replace the actuator.
Push button is being held down for Depress the button quickly and
more that ¾ second when going then let go. Each ¾ second the
through the calibration procedure button is held down counts as
another press.
The actuator goes into calibra- The white calibrate wire in the grey Tape the end of the white wire
tion mode spontaneously Turck cable is grounding intermit- in the panel and make sure that
tently it cannot touch metal.
A very strong source of electromag- Increase the distance between

netic interference (EMI), such as a the EMI source and the actua-
contactor, is in the vicinity of the ac- tor.
tuator or grey cable
Install additional metal shield-
ing material between the EMI
source and the actuator or cable.
There is an intermittent failure of the Replace the actuator.

position sensor
The actuator goes into calibra-

The motor brake is not working prop- Get the motor brake to where it
tion mode every time power is
erly (see theory section above.) operates freely and recalibrate.
restored after a power loss
Replace the actuator
38
The actuator does not transmit The motor was manually moved Recalibrate.
the correct position after a power while the position sensor was not
loss powered.
The motor brake is not working Get the motor brake to where it op-
properly erates freely and then recalibrate.
The position sensor’s EEPROM Replace the actuator.

memory has failed
There is a rapid clicking noise The photochopper is misaligned Try to realign or replace the ac-
with the slotted optocouplers tuator.
when the motor is operating
The photochopper is positioned too Adjust the photochopper so that
low on the motor shaft. the fence extends further into the
optocoupler slots.
A motor bearing has failed Replace the actuator.
The motor operates in one direc- There is a loose connection in the Tighten.
tion only screw terminal blocks
There is a loose or dirty connection Clean and tighten.

in the yellow Turck cable
The position sensor has failed Replace the actuator.
There is a broken motor lead or Replace the actuator.

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

motor operates in one direction
only”
The command shaft is jammed Free the command shaft.
Broken gears in the gearmotor Replace the actuator.
The motor runs intermittently, Motor is overheating and the ther- This could be caused by a malfunc-
several minutes on, several min- mal switch is tripping tioning control panel. Consult the
utes off factory.
39
The motor runs sporadically Bad thermal switch Replace the actuator.
Any of the reasons listed in “The mo- See above.

tor will not move in either direction”
The motor runs but output shaft Stripped gears inside the gear motor Replace the actuator.
will not turn or the armature has come un-pressed
from the armature shaft
40
Operation
Section
Operation Section ........................................................................................................ 41
OIL SYSTEM ........................................................................................................................................................................................... 43

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

Screw Compressor Control And Operation ..................................................................................................................................... 47
Starting, Stopping and Restarting the Compressor ......................................................................................................................... 47
Slide Valve Control .......................................................................................................................................................................... 48
Slide Valve Motor Location ............................................................................................................................................................. 49
Oil Separator Heater ......................................................................................................................................................................... 49
Econ-O-Mizer Controls ................................................................................................................................................................... 49
Safety Setpoints ................................................................................................................................................................................ 49
Oil Pressure ...................................................................................................................................................................................... 49
Discharge Pressure ........................................................................................................................................................................... 49
Suction Pressure ............................................................................................................................................................................... 50
Oil Filter Differential ....................................................................................................................................................................... 50
Oil Temperature ............................................................................................................................................................................... 50
Discharge Temperature .................................................................................................................................................................... 50
INITIAL START-UP ................................................................................................................................................................................. 50

Setting of Controls ........................................................................................................................................................................... 50
Valve Settings ................................................................................................................................................................................... 50
Oil Separator .................................................................................................................................................................................... 50
V-PLUS Oil Cooling ........................................................................................................................................................................ 51
Liquid Injection Oil Cooling ............................................................................................................................................................ 51
Compressor Pre Start-Up Check List .............................................................................................................................................. 51
Stop Check Operation ...................................................................................................................................................................... 52
Pre-Start Up ...................................................................................................................................................................................... 53
PRE START-UP CHECKLIST - FIELD PIPING AND MECHANICAL REQUIREMENTS .............................................................. 54

PRE START-UP CHECKLIST - FIELD WIRING REQUIREMENTS ................................................................................................. 55
41
Notice on using Non -Vilter Oils
Oil and its additives are crucial in refrigeration system performance. Vilter Manufacturing will NOT
APPROVE non-Vilter oils for use with Vilter compressors. Due to the innumerable choices available it is
not possible for us to test all oils offered in the market place, and their effects on our equipment, as we can
with our own lubricants.
We realize that customers may choose compressor lubricants other than Vilter branded oil. This is cer-
tainly within the customers’ right as owners of the equipment. When this choice is made, however, Vilter
is unable to accept responsibility for any detrimental affects those lubricants may have on the equipment
or system performance and durability.
Should a lubrication related system issue occur with the use of non-Vilter oils, Vilter may deny warranty
upon evaluation of the issue. This includes any parts’ failure caused by inadequate lubrication.
Certainly, there are many good refrigeration lubricants in the market place. The choice of a lubricant for
a particular application involves consideration of many aspects of the lubricant and how it and its additive
package, will react in the various parts of the entire refrigeration system. It is a complex choice that
depends on a combination of field experience, lab and field-testing, and knowledge of lubricant chosen.
Vilter will not accept those risks other than for our own compressor lubricants.
42
Operation
I. OIL SYSTEM 1. Filter Removal and installation, all

VSR Units.
A. Oil Charge
Release the pressure in the oil filter housing by
Charge the combination oil receiver/separator opening the bleed valves at the stop valve in
with the proper quantity of lubricating oil (see the block and bleed assembly, or at the bleed
Installation Section). valve for the oil filter housing. Be sure to fol-
low all Local, State and Federal ordinances re-
garding the recovery of refrigerants.
CAUTION
It is imperative you charge the oil into the
receiver/separator prior to energizing the con-
trol panel to prevent burning out the immer-
sion heater in the separator/receiver.
During operation, maintain the receiver/sepa-

rator oil level in the normal operating range
between the two bullseye sight glasses. If the
oil level is visible only in the lowest sight glass,
add oil to the operating compressor through the
connection located at the compressor suction
inlet. Pump oil into the compressor until the
oil level in the separator is between the two
bullseye sight glasses. Watch this level care-
fully to maintain proper operation. Never al-
low the oil to reach a level higher than indi-
cated on the highest sight glass, since this may
impair the operation and efficiency of the oil
FIGURE 1.
separator portion of this combination vessel.
TYPICAL CANISTER TYPE FILTER
CROSS SECTION
B. Oil Filter
Change the oil filter after the first 200 hours of

Drain the filter bowl or housing in to an appro-
operation, as noted on the hour meter. There-
priate container and dispose of the oil in a ap-
after, replace the filter every six months, or
propriate manner following all Local, State and
when the oil pressure drop through the filter
Federal ordinances regarding the disposal of
reaches 45 psi, whichever occurs first. The
used refrigeration oil.
pressure drop across the filter is read on the
microprocessor panel. Check the pressure drop
Loosen and remove the locking ring on filter
and record it daily.
tank by turning in a counter clockwise direc-
tion. Remove filter tank with the used element.
To prepare for the removal of the filter, shut
down the compressor. Isolate the filter housing
Remove the filter element from the tank. Be-
appropriate. If unit is equipped with duplex fil-
fore reassembling, thoroughly clean the tank
ter housings the unit does not have to be shut
to lengthen the life span of the filter element.
down, however the filter to be serviced must be
isolated before the tank or bowl can be opened.
Wet the threads and O-ring on the head and
the O-ring in the new element with clean re-
frigeration oil.
43
Operation
CAUTION 3. Filter Removal, VSS and VSM

Units (after 5/1/00) when using
Do not use a pipe wrench, hammer or any other Vilter Part Numbers 3109A (16”
tool to tighten the locking ring. Duplex), or 3110A (39” Duplex) oil
filter housings.
Insert new element into the filter tank with
the open end visible. Attach tank to head Isolate the bowl to be worked on by turning
and HAND TIGHTEN the locking ring. handle. The handle will cover the drain
valve of active element. Close commuter
The filter housing can be evacuated and then valve in center of handle. Release the pres-
slowly pressurized to check for leaks before sure in the isolated bowl by bleeding through
returning to service. the stop valve on the oil filter cover for Du-
plex (Vilter Part #3109A or 3110A), or
2. Filter Removal, VSS and VSM Units through the stop valve for the oil filter hous-
(after 5/1/00) when using Vilter Part ing. Be sure to follow all Local, State and
Numbers 3111A (16” Simplex), or Federal ordinances regarding the recovery
3112A (39” Simplex) oil filter of refrigerants.
housings.
Drain the filter bowl or housing in to an ap-
Release the pressure in the oil filter housing propriate container and dispose of the oil in
by opening the bleed valves at the stop valve a appropriate manner following all Local,
in the block and bleed assembly, or at the State and Federal ordinances regarding the
bleed valve for the oil filter housing. Be sure disposal of used refrigeration oil.
to follow all Local, State and Federal ordi-
nances regarding the recovery of refrigerants. Loosen and remove the cover on the bowl of
the filter tank by turning it in a counter clock-
Drain the filter bowl or housing in to an ap- wise direction. Remove the used element.
propriate container and dispose of the oil in
a appropriate manner following all Local, Wet the O-ring in the new element with clean
State and Federal ordinances regarding the refrigeration oil. Insert the new element into
disposal of used refrigeration oil. the filter tank with the close end visible and
attach the cover to the bowl. HAND
Loosen and remove the cover on the bowl of TIGHTEN the cover.
the filter tank by turning it in a counter clock-
wise direction. Remove the used element. The filter housing can be evacuated and then
slowly pressurized by opening the commuter
Wet the O-ring in the new element with clean valve on handle. This will pressurize the
refrigeration oil. Insert the new element into housing. Check for leaks. The filter can
the filter tank with the closed end visible and now be returned to service. Repeat for other
attach the cover to the bowl. HAND filter bowl if needed.
TIGHTEN the cover.
4. Filter Removal, VSS Units using
The filter housing can be evacuated and then Vilter Part Number1833C oil filter
slowly pressurized to check for leaks before elements.
returning to service.
Release the pressure in the oil filter housing
by opening the bleed valves at the stop valve
in the block and bleed assembly, or at the
bleed valve for the oil filter housing. Be sure
44
Operation
to follow all Local, State and Federal ordinances re- the cover assembly in place. On units
garding the recovery of refrigerants. equipped with dual element tanks, insert in-
ner element and make sure it fits onto the
Drain the filter bowl or housing in to an appropriate outlet connection. Put the centering piece
container and dispose of the oil in a appropriate on the outer element and slide into tank mak-
manner following all Local, State and Federal ordi- ing sure the center piece fits into the inner
nances regarding the disposal of used refrigeration element. Put spring plate on outer element
oil. and bolt the cover assembly in place.
CAUTION
Unscrew the bolts holding the cover flange to the
When changing filter, discard clogged filter
tank. Remove the cover flange and spring plate.
only. Save and reuse spring plate and center-
Pull out the filter element(s). Before reassembling,
ing piece. This filter MUST be installed with
thoroughly clean the tank and spring plate to
the spring plate. A compressor that is allowed
lengthen the life span of the filter element(s).
to operate without the spring plate is running
with unfiltered oil.
The filter housing can be evacuated and then

slowly pressurized to check for leaks before
returning to service.
C. Oil Pressure Regulating
On units with a full time oil pump, the back pres-

sure regulator, in the oil supply line from the sepa-
rator, controls upstream pressure to the compres-
sor bearings and should be adjusted to hold the
oil pressure at 50 psig above suction pressure.
Excess oil not required for bearing lubrication is
passed through the regulator and flows into the
separator.
D. Oil Cooling
1. Water Cooled Oil Cooler
In lieu of the three way oil temperature valve

to control the temperature of the oil used for
lubrication and cooling of the compressor,
it is required to install a water regulating
FIGURE 3. valve and solenoid valve combination to con-
1833C FILTER ELEMENT TANKS trol the water supply to the oil cooler. The
water inlet connection should be made on
the bottom and the outlet connection on the
To replace the filter element(s), on single element top. The water supply is controlled by the
tanks, insert the element and make sure it fits onto water regulating valve to maintain the oil
the outlet connection. Install spring plate, and bolt temperature at approximately 120°F.
45
Operation
1/4” Fine
Adjustment Valve
FIGURE 4.
TYPICAL WATER COOLED OIL COOLER FIGURE 5.
DIAGRAM TYPICAL LIQUID INJECTION OIL COOLING
SCHEMATIC DIAGRAM
The solenoid valve provides positive water
shut-off when the compressor is not in opera- Liquid injection cooling on booster compressors is
tion. handled in the following manner. Using high pres-
sure liquid, the point of injection can be the dis-
A temperature of 150°F is considered high in charge line and no horsepower penalty is paid by
most circumstances and the compressor is pro- injecting liquid into the compressor discharge line.
tected by a safety control to prevent operation The high pressure gas source normally used for the
of the compressor above this temperature. pressure regulator would be compressor discharge
Unless otherwise specified, the oil cooler is pressure. Since, on a booster unit, this intermediate
sized for an 85°F water inlet temperature and pressure is very rarely as high as the nominal set-
10°F temperature rise. ting of 70 psig, high stage discharge gas is used.
2. Liquid Injection Oil Cooling. On high stage compressors, the liquid is injected
directly into the compressor. However, there is a
The components are furnished with liquid in- horsepower penalty when the liquid is injected into
jection for a typical system. The liquid sole- the compressor. This will vary with refrigerant and
noid valve opens whenever the compressor is operating condition. The liquid is injected into the
in operation. The thermostatic expansion valve compressor at a point in the compressor cycle that
controls the flow of liquid refrigerant to the minimizes the brake horsepower penalty.
compressor injection port in response to the
discharge temperature. The discharge tempera- 3. V-PLUS Oil Cooling System
ture is maintained at a minimum of 120°F with
a maximum of 140°F. The discharge tempera- This system consists of a liquid pump, shut-off
ture can be adjusted either of two ways. First, valves, motor, solid state variable speed controller
the small outlet pressure regulator can be used and solid state temperature controller. This method
to adjust superheat. Normally, this regulator of oil cooling is not available on the VSM or VSR
should be adjusted to maintain 70 psig pres- compressor units.
sure at the external equalizing port of the ex-
pansion valve. Raising the pressure beyond The pump and solenoid valve cycle on and off in
70 psig tends to raise the discharge tempera- parallel with the compressor drive motor. The tem-
ture, while lowering the pressure lowers the perature controller receives a temperature signal
discharge temperature. Secondly, the standard from the sensor located in the discharge and oil lines
superheat adjusting screw on the thermostatic and in turn, sends a signal to the motor speed con-
expansion valve can be used to adjust the dis- troller. As the oil and desupserheating load varies,
charge temperature.
46
Operation
the temperature controller adjusts the speed sure transducers. To use the block and bleed
of the pump/motor combination to maintain valves to recalibrate the pressure transducers, the
a constant oil temperature. block valve is shut off at the unit and the pressure
is allowed to bleed off by opening the bleed valve
NOTE: near the pressure transducer enclosure. The trans-
ducer can then be calibrated at atmospheric pres-
See separate V-PLUS® instruction manual for
sure (0 psig), or an external pressure source with
detailed start-up and operation.
an accurate gauge may be attached at the bleed
valve.
4. Thermosyphon Oil Cooling
The discharge pressure transducer cannot be iso-
Using a brazed plate or an one pass shell lated from its pressure source, so it is equipped
and tube type vessel, similar to the water with only a valve to allow an accurate pressure
cooled oil cooler, oil is circulated on the shell gauge to be attached and the pressure transducer
side and liquid refrigerant from the receiver calibrated at unit pressure.
is
circulated through the tubes.Thermosyphon Recheck the transducers periodically for any drift
systems use a 3-way temperature sensing of calibration.
control valve to regulate oil at 120°F. Oil is
bypassed around the thermosyphon oil cooler. A. Screw Compressor Control And
When oil is higher than 120°F, the oil is Operation
passed through the thermosyphon oil cooler.
A 1/4” tubing line w/valve adds high pres- 1. Starting, Stopping and Restarting
sure gas to the oil to quiet the sound of injec- the Compressor
tion. Open this valve in small amounts, until
noise subsides. Before the screw compressor unit may start,
certain conditions must be met. All of the
The closed type cooling circuit is free from safety setpoints must be in a normal condi-
the fouling problems associated with open tion, and the suction pressure must be above
circuit water cooling. Since the oil cooling the low suction pressure setpoint to assure
load is rejected in the condenser, this type of that a load is present. When the “On-Off”
cooling is practical. The temperature limits switch or “Manual-Auto” button is pressed,
here are the same as those regarding the the oil pump will start. When sufficient oil
water cooled oil coolers. pressure is built up and the compressor ca-
pacity control and volume ratio slide valves
II. CONTROL SYSTEM are at or below10%, the compressor unit will
start.
Equipped for automatic operation, the screw com-
pressor unit has safety controls to protect it from If the compressor is in the automatic mode,
irregular operating conditions, an automatic start- it will now load and unload and vary the
ing and stopping sequence, capacity and volume volume ratio in response to the system de-
ratio control systems. mands.
Check all pressure controls with a remote pres- Stopping the compressor unit can be accom-
sure source, to assure that all safety and operat- plished a number of ways. Any of the safety
ing control limits operate at the point indicated setpoints will stop the compressor unit if an
on the microprocessor. abnormal operating condition exists. The
compressor unit “On-Off” or stop button will
The unit can be equipped with optional block and turn the compressor unit off as will the low
bleed valves that are used to recalibrate the pres- pressure setpoint. If any of these conditions
47
Operation
COMMAND SHAFT ROTATION NO. OF TURNS / ROTATION ANGLE / SLIDE TRAVEL
COMP. CAPACITY VOLUME CAPACITY VOLUME
MODEL INC DEC INC DEC TURNS/ANGLE/TRAVEL TURNS/ANGLE/TRAVEL
VSR 111 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSR 151 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSR 221 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSR 301 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSS 451 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSS 601 CW CCW CW CCW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSS 751 CCW CW CCW CW 1.09 / 392 / 4.283" 0.63 / 227 / 2.473"
VSS 901 CCW CW CCW CW 1.09 / 392 / 4.283" 0.63 / 227 / 2.473"
VSS 1051 CCW CW CCW CW 1.22 / 439 / 4.777" 0.74 / 266 / 2.889"
VSS 1201 CCW CW CCW CW 1.22 / 439 / 4.777" 0.74 / 266 / 2.889"
VSS 1501 CCW CW CCW CW 1.36 / 490 / 5.325" 0.82 / 295 / 3.200"
VSS 1801 CCW CW CCW CW 1.36 / 490 / 5.325" 0.82 / 295 / 3.200"
VSM 71 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 91 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 101 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 151 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 181 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 201 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 301 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 361 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 401 CW CCW CW CCW 0.80 / 288 / 3.141" 0.45 / 162 / 1.767"
VSM 501 CCW CW CCW CW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSM 601 CCW CW CCW CW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
VSM 701 CCW CW CCW CW 0.91 / 328 / 3.568" 0.52 / 187 / 2.045"
Note:These refer to the old stlye gear motors and DO NOT apply to the optical motors.
Table 1
turns the compressor unit off, the slide valve mo- 2. Slide Valve Control Gear Motors
tors will immediately energize to drive the slide
valves back to 5% limit. The control motors will Capacity and volume ratio control of the
be de-energized when the respective slide valve screw compressor is achieved by movement
moves back below 5%. If there is a power failure, of the respective slide valves, actuated by
the compressor unit will stop. If the manual start electric motors.
on power failure option is selected (see appropri-
ate Microprocessor Instruction Manual), restart- NOTE:
ing from this condition is accomplished by push- The manual operating shaft on the gear motor
ing the reset button to insure positive operator should be turned the opposite direction of the
control. If the auto start on power failure option desired command shaft rotation.
is selected (see appropriate Microprocessor In-
struction Manual), the compressor unit will start The older capacity and volume control mo-
up after a waiting period. With both options, the tors are equipped with a brake. If it is neces-
compressor slide valves must return below their sary to operate the control motors manually,
respective 5% limits before the compressor unit the brake must be disengaged. The brake
can be restarted. can be disengaged by pushing on the motor
shaft on the cone end. The shaft should be
centered in its travel. Do not use excessive
force manually operating the motor or dam-
age may result.
48
Operation
View Capacity
Instruction Manual.)
Note: Optical
Actuators CAN NOT 3. Oil Separator Heater
be manually rotated.
( VSM 501-701 will The oil separator heater keeps the oil in the
have motor locations separator from becoming too viscous and
opposite of figure #6) helps to boil off refrigerant entrained in the
oil in the receiver section of the separator.
The heater is turned on only when the com-

pressor is off. The separator heater is sup-
View plied with an integral temperature control.
Volume Ratio
4. Econ-O-Mizer Controls
FIGURE 6.
SLIDE VALVE MOTOR LOCATION Econ-O-Mizer® systems are of three types:
direct expansion, flooded or flash. Flash
When viewing the compressor from the dis- systems include a back pressure regulator to
charge end (opposite the drive end), the up- control intermediate pressure.
per motor is for capacity control. The com-
mand shaft turns (see Table 1) to decrease When a direct expansion system is used, a
the capacity to 10% and reverses to increase solenoid valve and thermostatic expansion
the capacity to 100%. The lower motor is valve are furnished to control the degree of
for volume ratio control. The command shaft subcooling. If a flooded subcooler system
turns (see Table 1) to reduce the volume ra- or flash system is supplied, it is equipped
tio to 2.0, and reverses to increase the vol- with a liquid solenoid valve and a float
ume ratio to 5.0. switch to control the liquid level in the ves-
sel.
Actuation of the electric motors can be done
manually or automatically. To actuate the B. Safety Setpoints
motors manually, place the desired mode
selector in the manual position and push the A detailed explanation of all safety setpoints can
manual Increase or Decrease buttons. In the be found in the appropriate Microprocessor In-
automatic mode, the microprocessor deter- struction Manual.
mines the direction to actuate the electric
motors. However, in the automatic mode, 1. Oil Pressure
there is an “On” and “Off” time for the ca-
pacity control motor. The “On” time is the Low oil pressure differential stops the com-
time in which the slide valve moves, and the pressor unit when there is an insufficient
“Off” time is the time in which the system is difference in pressure between the oil mani-
allowed to stabilize before another change fold and suction.
in slide valve position.
2. Discharge Pressure
The Motor Amps Load Limit protects the
compressor from overloading by decreasing High discharge pressure cutout stops the
the compressor capacity if the motor amper- compressor unit, when the discharge pres-
age is at the Maximum Amps setpoint, or pre- sure in the oil separator exceeds the setpoint.
venting an increase in capacity if the motor
amperage is above the Full Load Amps
setpoint. (See appropriate Microprocessor
49
Operation
3. Suction Pressure the valve to set it in the automatic position.
Low suction pressure cutout stops the 4. Manually open the oil isolating valve at the
compressor unit when the suction pres- oil separator outlet connection.
sure drops below the setpoint.
5. Open the isolating valve(s) before and after
4. Oil Filter Differential the oil filter housings.
High oil filter differential cutout stops 6. On packages with a full time oil pump, make
the compressor unit when the difference sure the manual opening stem on the oil
between the outlet and inlet of the filter regulating valve is in the auto position. See
exceeds the setpoint. manufacturer’s literature for details.
5. Oil Temperature C. Oil Separator
The oil temperature cutout stops the 7. Manually open the stop valve on the oil bleed
compressor unit when the oil tempera- return line from the element section and open
ture is too high or too low. the expansion valve 1/3 of a turn.
6. Discharge Temperature NOTE:

The purpose of the oil bleed return assembly
The high discharge temperature cutout is to collect any oil that passes through the oil
stops the compressor unit when the dis- separating element and returns that oil to the
charge temperature exceeds the setpoint. compressor. The hand expansion valve should
be adjusted to prevent an oil level from form-
III. INITIAL START-UP ing in the sight glass when the compressor is
at 100% capacity. Generally 1/3 to 1 turn open
A. Setting of Controls is satisfactory.
Refer to the appropriate Microprocessor Instruc-

8. A second oil bleed return valve is located in
tion Manual for a list of initial settings.
the mid section of the oil separator. This
valve should be opened about 1/2 of a turn
B. Valve Settings
to meter oil back to the compressor.
1. The suction stop/check valve is designed to
operate as a stop valve (manually open or
closed) or a check valve. The valve is nor-
mally positioned in the automatic mode dur-
ing unit operation. Please refer to the tag on
the valve to set it in the automatic position.
Stop Valve
2. The ¼” valve should be open during opera-

tion. The valve enables the unit to slowly
equalize to low side pressure during off peri-
ods. This valve must be adjusted to minimize
oil loss when compressor stops.
FIGURE 7.
3. The discharge stop/check valve is designed OIL SEPARATOR BLEED LINE
to operate as a stop valve (manually open or
closed) or a check valve. The valve is nor-
mally positioned in the automatic mode dur-
ing unit operation. Please refer to the tag on
50
“Stop Check” Operation
AUTO
In the “Auto Position”, the stop valve is
operating as a check valve, allowing
flow in the directions of the arrows.
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 conven-
tional stop valve, not allowing flow in
either direction.
OPEN
In the manually ” Open Position”, with
the valve stem fully back seated, the valve
disc is lifted slightly, allowing flow in ei-
ther direction.
Valve Size 1.5” 2” 2.5” 3” 4” 5” 6” 8”

Number of Turns
Open 2 2.25 2.75 3.25 4.5 3.75 5.75 7.75
(from closed position)
52
Pre-Start Up
Check List
53
PRE START-UP CHECKLIST
FIELD PIPING AND MECHANICAL
REQUIREMENTS
NOTE: If start-up service has been purchased, the following items should be completed before the start-up
man arrives. This will help save time and money.
_____ 1. The unit should be leveled and secured to the mounting pad or floor.
_____ 2. The suction and Discharge line must be piped and properly supported, independent of the
unit
_____ 3. The Discharge Stop/Check Valve is shipped loose and must be installed in a vertical up f
low direction or in a horizontal line with the valve stem pointing upward at a 45° angle.
During off periods, refrigerant can condense in the line downstream of the Discharge Stop/
Check Valve. It is recommended the Stop/Check Valve be located to minimize the
quantity of liquid that can accumulate downstream of the valve.
_____ 4. A Dual Safety Relief Valve is shipped loose for field installation. A connection is provided
on the oil separator for the relief valve. Refer to ASHRAE/ANSI Standard 15 (Safety
Code for Refrigeration) for proper sizing and installation of Relief Valves and Vent Lines.
_____ 5. Piping For Oil Cooling
a) Liquid Injection
An adequate, or dedicated, liquid line is required for the Liquid Injection System. A high pressure
liquid source must be piped to the stop valve at the inlet of the Thermostatic Expansion Valve. On
booster units, an additional 3/8” line must be piped to the regulator from high stage discharge gas f
or the Thermostatic Expansion Valve.
b) V-PLUS
A high pressure liquid source must be run to the V-PLUS® inlet. Some subcooling is desirable. A
high pressure float must be installed at the inlet of the pump and a 3/8” vent line must be returned to
a suction trap. Refer to the V-PLUS manual for additional information.
c) External Oil Cooler
On thermosyphon oil coolers, the refrigerant lines must be connected to the front head of the oil
cooler. On water cooled oil coolers, the water lines must be connected to the front head of the oil
cooler. Installation of water regulating and solenoid valves are recommended.
_____ 6. The oil separator should be provided with oil until the oil level is between the (2) sight
glasses. An oil charging connection is provided on the bottom of the oil separator.
_____ 7. The center member of the compressor coupling is shipped loose to help facilitate final f
ield alignment and allow for motor rotation check. The motor alignment should be within
0.004” total indicator reading in all directions.
a) Both the compressor and motor hubs should be checked for concentricity and perpendicularity.
b) The motor should be checked and shimmed for soft foot prior to attempting final alignment.
c) The center section of the coupling should be left out to allow the start-up technician to verify the
final alignment and motor rotations.
_____ 8. The unit should be pressure tested, evacuated and a system load should be available at the
time of start-up.
Order #_______________________________Compressor Serial #________________________
54
PRE START-UP CHECKLIST
FIELD WIRING REQUIREMENTS
VILTER MANUFACTURING CORPORATION
VRS SCREW COMPRESSOR, VSS/VSM SINGLE SCREW COMPRESSOR UNITS
PRESTART-UP CHECKLIST
FIELD WIRING REQUIREMENTS FOR UNITS WITH FACTORY WIRED VISSION® MICROPROCESSORS
NOTE: If startup service has been purchased, to save time and money, the following items should be completed before
the startup technician arrives.
The unit is pre-wired at the factory. The necessary field wiring connections are described below.
1. Control power of 115 VAC 50/60 HZ must be wired to the left side terminals of the digital I/O board inside the
ViSSion® cabinet. Line power (L1) is brought in to a 10-amp fuse via the terminal marked “L1” on the appro-
priate connector. The neutral (L1A) is brought in and connected to any of the “N” terminals located on left
connectors. Two separate line power feeds for the oil heaters are brought to two additional 10 amp fuses via the
terminals marked “L2” and “L3” on the same connector just below the “L1” terminal. The neutrals for these
circuits (L2A and L3A) are also connected to any of the “N” terminals. For units with V-PLUS® oil cooling, L1
must also be brought to the fuse in the V-PLUS® panel, and L1A must also be brought to the terminal #2B in the
V-PLUS® panel.
2. An auxiliary contact from the compressor motor starter is required. This isolated contact is connected to the K-
1 input relay using any of the “L” terminals on the strip of connectors, and returned to the terminal marked
“Motor Starter Aux. Safety” at the very top connector.
3. A dry contact from control relay K-22 must be wired to the compressor motor starter coil. This dry contact is
wired to terminals marked “Compressor Start – N.O. #1A” and “Compressor Start – N.O. #1B”. Control power
for this coil should come from a source, which will be de-energized with the compressor disconnect.
4. A dry contact from control relay K-19 must be wired to the oil pump motor starter coil. This dry contact is wired
to the two terminals marked “Oil Pump Starter”. Control power for this coil should come from a source, which
will be de-energized with the compressor disconnect.
5. An auxiliary safety cutout is available to shut down the compressor package using the K-2 input relay. A dry
contact must be supplied and wired to one of the “L” terminals on any of the connectors, and returned to the
terminal marked “Auxiliary #1 Safety” at the top connector. The jumper to the “Auxiliary #1 Safety” terminal
must be removed to use this cutout. The contact, if closed, will allow the compressor to run. If this contact
opens at any time, the compressor will shut down.
6. Indication of the compressor alarm or shutdown status is also available via two control relays. Relay K-20 is
provided for remote trip indication and relay K-21 is provided for remote alarm indication. Each relay has three
terminals available: a common input, a normally open contact, and a normally closed contact. For both relays,
the energized state represents a “trip” or “alarm” condition. Loss of voltage to the relay coil and the resultant
return to normal state indicates “safe” condition.
7. The current transformer supplied in the compressor motor conduit box should be checked to insure that the
motor leads of one leg are pulled through the transformer. Note that there is a dot on one side of the current
transformer. This dot must face away from the motor. Typically, a wye delta started motor should have leads 1
and 6 pulled through this transformer for a 6 lead motor. However, this should always be checked as different
motors and starting methods will require different leads to be used.
Order #_______________________________Compressor Serial #________________________
55
Service Section
Service Section ............................................................................................................. 56
GENERAL COMMENTS ........................................................................................................................................................................ 58
PREPARATION OF UNIT FOR SERVICING ........................................................................................................................................ 58

REMOVAL OF COMPRESSOR FROM THE UNIT ............................................................................................................................ 58
INSTALLATION OF THE COMPRESSOR ............................................................................................................................................ 59
LEAK CHECKING UNIT ........................................................................................................................................................................ 59
ANNUAL INSPECTION ......................................................................................................................................................................... 60
NORD-LOCK WASHERS ....................................................................................................................................................................... 61
GATE ROTOR ASSEMBLY .................................................................................................................................................................... 62
REMOVAL (All VSS and VSR Models) ................................................................................................................................................. 62
REMOVAL (ALL VSM MODELS) ......................................................................................................................................................... 64
INSTALLATION (All VSS and VSR Models) ........................................................................................................................................ 66
INSTALLATION (All VSM Models) ...................................................................................................................................................... 68
GATE ROTOR BLADE REMOVAL ....................................................................................................................................................... 69

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

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

OPTICAL SLIDE VALVE ACTUATOR INSTALLATION ..................................................................................................................... 79
CONVERSION, INSTALLATION OF ACTUATOR ............................................................................................................................... 80

COMMAND SHAFT ASSEMBLY REMOVAL ..................................................................................................................................... 80
COMMAND SHAFT ASSEMBLY INSTALLATION ............................................................................................................................. 81
COMMAND SHAFT BEARING AND O-RING SEAL REPLACEMENT ........................................................................................... 81
DISCHARGE MANIFOLD REMOVAL ................................................................................................................................................. 82

DISCHARGE MANIFOLD INSTALLATION ......................................................................................................................................... 82
SLIDE VALVE GEAR AND RACK INSPECTION ................................................................................................................................ 83
REMOVAL OF CAPACITY OR VOLUME CROSS SHAFTS .............................................................................................................. 83

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

RATIO ACTUATORS (PRIOR TO 11-1-01 AND AFTER 5-1-95 .......................................................................................................... 85
56
Service Section
POTENTIOMETER REMOVAL ............................................................................................................................................................. 87

POTENTIOMETER INSTALLATION .................................................................................................................................................... 88
RETROFIT CAPACITY AND VOLUME RATIO CONTROL ............................................................................................................... 88

ASSEMBLIES ON ALL VSS AND VSR COMPRESSORS
MANUFACTURED BEFORE MAY 1, 1995. ............................................................................................................................................................ 88
REMOVAL ................................................................................................................................................................................................................... 88
INSTALLATION OF RETROFIT COMMAND SHAFT BEARING

AND O-RING SEAL ................................................................................................................................................................................ 89
REPLACEMENT FOR RETROFIT CONTROL ASSEMBLIES .......................................................................................................... 89

LIQUID INJECTION PLUG REPLACMENT ........................................................................................................................................ 91
REMOVAL OF PLUG ............................................................................................................................................................................. 91

INSTALLATION OF PLUG ..................................................................................................................................................................... 91
PLUG APPLICABILITY .......................................................................................................................................................................... 92
TORQUE SPECIFICATIONS .................................................................................................................................................................. 93

OIL FILTER ELEMENTS ........................................................................................................................................................................ 94
VSS, VSM and VSR SINGLE SCREW COMPRESSORS SERVICE INTERVAL REQUIREMENTS ........................... 98
57
Operation
D. V-PLUS Oil Cooling F. Water Cooled Oil Cooler
* Applies only to units with V-PLUS® oil *** Applies only to units with water cooled oil
cooling. cooler.
Refer to V-PLUS manual for detailed instructions. ***9. The water supply to the cooler should
be opened.
*9. Manually open the stop valve at the inlet and
outlet of the V-PLUS system. ***10. Verify the water solenoid valve does
open with the compressor motor
*10. Open the needle valve in the ¼” oil supply starter.
line to the V-PLUS pump.
***11. Open 1/4” high pressure gas line valve
piped to oil injection line just enough
*11. The manual opening stem on the solenoid to quiet compressor at 100% capacity.
valve should be in the automatic position
(turned counter clockwise or out).
E. Liquid Injection Oil Cooling G. Compressor Pre Start-Up Check

List
** Applies only to units with Liquid Injection
Oil Cooling. Before proceeding with actual starting of the com-
pressor, the items listed on the “Pre Start-Up
**9. Open the stop valve at the inlet of the Check List” must be verified. Time and money
pressure regulator. will be saved before the Vilter start-up man ar-
rives.
**10. Open the metering valve 1/8 to 1/4 of
a turn.
**11. Adjust the manual opening stem to the

liquid line solenoid. (Refer to acces-
sory equipment section for details.)
**12. The pressure regulator may require ad

justment after the compressor is running.
(Refer to the accessory section on de-
tails of how to adjust regulator.) The reg-
ulator should be adjusted to maintain ap-
proximately 70 psig on the external equal
izing connection of the TX valve. At this
setting, the controls should maintain the
oil temperature at approximately 115°F.
To adjust oil temperature up or down,

raise or lower the pressure setting on the
regulator. It should not be necessary to
adjust the superheat setting on the TX
valve.
51
Service
0.00 GENERAL COMMENTS
When working on the compressor, care must be C) Isolate the unit by manually closing the dis-
taken to ensure that contaminants (i.e. water from charge Stop/Check valve. If the unit is
melting ice, dirt and dust) do not enter the com- equipped with a V-PLUS® or liquid injection
pressor while it is being serviced. It is essential cooling system, close the liquid supply valves
that all dust, oil or ice that has accumulated on and open all solenoid valves to prevent liq-
the outside of the compressor be removed before uid refrigerant from being trapped between
servicing the compressor. the stop valves and solenoid valves. Allow
the unit to equalize to suction pressure be-
When servicing the compressor, all gaskets, O- fore closing the Suction Bypass or Stop/
rings, roll pins and lock washers must be replaced Check valve. After the unit has equalized to
when reassembling the compressor. suction pressure and suction valve closed,
use an acceptable means to depressurize the
It is important that if the refrigerant requires the unit that complies with all Local, State and
use of a Polyolester (POE) refrigeration oil, that Federal Ordinances.
all oil is removed from the compressor unit after
D) Remove drain plugs from the bottom
the unit has been opened to the atmosphere for
ofcompressor housing and the discharge
servicing. POE refrigeration oils are highly
manifold On units equipped with Suction Oil
hydroscopic and will absorb large quantities of
Injection (SOI) manually open the SOI sole-
moisture in a short time, when exposed to the
noid valve below the compressor. Drain the
atmosphere during servicing. Once the moisture
oil into appropriate containers.
is absorbed into the oil it is nearly impossible to
remove the moisture from the oil.
0.02 REMOVAL OF COMPRESSOR
0.01 PREPARATION OF UNIT FOR
FROM THE UNIT
SERVICING
After Preparing the unit for service the following
steps should be followed when removing the com-
pressor from the unit:
A) Disconnect the motor drive coupling from the
compressor input shaft.
B) Disconnect all gas and oil piping which is
attached to the compressor. When removing
A) On Cool Compression units, while the unit is
the suction strainer on VSS/VSM units or the
running, close the main liquid ammonia line
suction line from VSR units, the suction line
(located before the thermostatic expansion
should be supported to prevent it from sag-
valve) and wait for the unit to stop by itself.
ging.
This operation will remove all the liquid am-
monia from the separator. The compressor C) Replace oil drain in compressor housing and
will stop when the superheat at discharge discharge manifold after oil has stopped
reaches 25°F. draining.
B) Shut down the unit, open the electrical dis-
connect switch and pull the fuses for the com-
pressor motor to prevent the unit from start-
ing. Put a lock on the disconnect switch and
tag the switch to indicate that maintenance All Oil must be removed from unit.
is being performed.
D) Remove all electrical connections to the com-

pressor.
58
Service
ance under the fourth compressor foot. If

CAUTION there is clearance, add the appropriate amount
of shims. Tighten down the fourth bolt and
loosen either adjacent bolt and check again
May cause an electrical shock! for clearance, adding shims accordingly.
Align the compressor and motor.
E) On VSG units, loosen and remove bolts
holding the compressor to the base. On VSR & VSM units, the compressor can be
bolted onto the C-flange adapter and the cou-
pling reinstalled.
On VSR compressors the discharge elbow
should be tightened on the separator first,
before the compressor manifold flange is tight-
ened. This should be done to prevent com-
pressor to motor misalignment.
Keep compressor alignment shims together Replace all electrical, gas and oil connections
and mark the locations with a permanent removed when servicing the compressor.
marker. On VSG with C- flange the motor/C- 0.03 LEAK CHECKING UNIT
flange/compressor assembly must be sup-
ported with a chain fall or other lifting device, Note: Unit can be leak checked before evacua-
before the bolts holding the compressor to tion.
the C-flange adapter can be removed.
F) Install appropriate lifting eye into the threaded

CAUTION
hole on the top of the compressor.
Slowly pressurize the unit from the discharge

side of the compressor. Pressurizing the com-
pressor from the suction side may cause rota-
Verify unit is properly secured to avoid tion of the compressor without oil supply, which
compressor from falling. could lead to internal damage.
Re-verify all piping and electrical are properly
disconnected prior to lifting unit. A) Use a vacuum pump to evacuate the unit.
G) Lift compressor from the base, verify the B) Break the vacuum on the unit using refriger-
amount of room needed for clearance and ant or dry nitrogen and check for leaks. Con-
weight of the bare compressor when the com- centrate on areas where work was done.
pressor is removed from the unit. C) If no leaks are found, the unit can be returned
to service if refrigerant was used for the leak
0.03 INSTALLATION OF THE detection gas.
COMPRESSOR
If dry nitrogen was used for the leak detec-
A) After the work has been completed, reinstall tion gas, the nitrogen must be purged from
the compressor on the base or C-flange the unit and step A and B should be repeated,
adapter (dependent upon compressor model). this time breaking the vacuum with refriger-
ant. The unit may now be returned to ser-
vice.
B) On the VSS units, replace the shims under the
compressor feet. Check for a soft foot. This
is accomplished by tightening down three of
the hold down bolts and checking the clear-
59
Service
0.05 ANNUAL INSPECTION
The Vilter Single Screw Compressor is designed

for long periods of trouble free operation with a
minimum of maintenance. However, a yearly in-
spection is recommended so any irregular wear is
noted and rectified. At this time, the bearing float
is measured for the main rotor and gate rotors.
The following are the procedures used in measur-
ing the main rotor and gate rotor bearing float.
CAUTION
When taking the measurements, do not exceed

300 to 500 Lbs. of force at point of contact or
damage may result to the bearings.
A) Shut down and de-pressurize the unit, as

outlined in section 0.01.
B) Main rotor bearing float.
1) Remove the coupling guard, then re-
move the center member from the cou-
pling.
2) Attach a dial indicator to the compres-
sor frame as shown and zero indicator.
Place a lever arm and fulcrum behind
the compressor coupling half and push
the coupling towards the motor (note
measurement).
TABLE 0.1MAXIMUM BEARING FLOAT
MAIN GATE
Bearing Float 0.003” 0.002”
Maximum Force 300 to 500 200 to 300
Lbs. Lbs.
3) Re-Zero indicator, now position the ful-

crum on the motor and use the lever arm
to push the input shaft towards the com-
pressor (note measurement).
4) Add both readings, the total indicator

movement is the bearing float and this
should not exceed 0.003”.
60
Service
C) Gate rotor bearing float. VSR 111 THRU VSS 601 0.045”
VSS 751 & VSS 901 0.055”
1) Remove the side covers and position a VSS 1051 & VSS 1201 0.060”
dial indicator on the gate rotor. VSS 1501 & VSS 1801 0.060”
2) Use a lever arm pivoting on a bolt with a
small block of wood against the gate ro- E) Readings could be higher than 0.020. If
tor blade to protect the blade. readings is greater than 0.030 over table
3) The maximum amount of bearing float tolerance contact Vilter’s home office.
should not exceed 0.002”. F) Inspect the main and gate rotors for
signs of abnormal wear due to dirt or
other contaminants.
G) After the inspection is complete, the
covers, coupling center member and
guard can be reinstalled and the unit can
then be evacuated and leak checked be-
fore starting.
0.06 NORD-LOCK WASHERS
A) Nord-Lock® lock washer sets are used in

many areas on the Single Screw Compres-
sor that requires a vibration proof lock
washer.
B) The lock washer set is assembled so the
course serrations that resemble ramps are
mated together.
C) Once the lock washer set is tightened down,
it takes more force to loosen the bolt then it
D) Measure the gate rotor to blade float. Some
did to tighten it. This is caused by the wash-
movement between blade and support is nec-
ers riding up the opposing serrations.
essary to prevent damage to the compressor
blade, however at no time should the blade
uncover the support. Fine serrations face out.
1) Position the blade with the gate rotor

damper pin and 90º to the main rotor.
2) Position a dial indicator at the tip of the
support. The total movement of the
damper pin in the bushing is the gate
rotor float. Refer to table 0.2 to find the
maximum blade to support float (on new
compressor parts only).
Coarse Serrations
m.apr
Coarse serrations
TABLE 0.2. GATE ROTOR FLOAT mate together
mate together.
MODEL FLOAT
VSM 71 THRU 401 0.045”

VSM 501 THRU 701 0.045”
61
Service
1.00 GATE ROTOR ASSEMBLY

CAUTION
Gate rotor removal and assembly is divided into

distinct instructions, instructions for all VSS and
VSR models and different instructions for all
VSM models. Please follow the appropriate set
of instructions.
1.01 A REMOVAL (All VSS and VSR
Models)
A) Prepare the compressor for servicing as out-

lined in section 0.01.
NOTE:
All parts must be kept with their appropriate side
and not mixed when the compressor is reas-
sembled.
B) Remove two upper bolts from the side cover,

and install guide studs in the holes. Remove
the remaining bolts and side cover. There
will be some oil drainage when the cover is
removed.
C) Turn the main rotor so a driving edge of any
one of the main rotor grooves is even with
the back of the gate rotor support.
D) Insert the gate rotor stabilizer. The side rails
are not required on VSS 451/601 and VSR
Drive End compressors. For the VSS 751/901 and VSS
1051/1201 compressors, use the side rails
and assemble to the gate rotor stabilizer as
stamped. For the VSS 1501/1801, use the
side rails and assemble to the gate rotor sta-
bilizer.
The gate rotor stabilizer is designed to hold
the gate rotor support in place and prevent
damage to the gate rotor blade as the thrust
bearings and housing is being removed.
62
Service
E) Remove the hex head and socket head bolts

from the thrust bearing cover. Insert two of
the bolts into the threaded jacking holes to 913 917
assist in removing the cover. Retain the shim
pack and keep it with the bearing housing
916
cover. 914
910
F) Hold the gate rotor support with a suitable
wrench on the flats provided near the roller
bearing housing. Remove the inner retainer 911 Use flats provided
bolts and the retainer. To remove the thrust on gaterotor
bearing housing, install the thrust bearing support to prevent
removal and installation tool with the smaller
901
rotation when
puller shoe. Turn the jacking screw clock- removing bearing
wise. The thrust bearings and housing as- retainer.
sembly will be pulled off the shaft and out of 110
the frame.
G) Remove the bolts on the roller bearing hous-
ing. Thread two bolts into the jack screw
holes provided in the housing to assist in re-
moving it.
H) To remove the gate rotor support, carefully
move the support opposite the direction of 112
rotation and tilt the roller bearing end to-
wards the suction end of the compressor. The
152
compressor input shaft may have to be turned
to facilitate the removal of the gate rotor sup-
port. On dual gate compressor units, repeat
the procedure for the remaining gate rotor
support assembly.
63
Service
1.01 B REMOVAL (ALLVSM MODELS)
The removal of the gate rotor assembly for the

VSM compressors is similar for the VSS/VSR
compressors. However, the thrust bearing outer
races are not secured in a stationary bearing hous-
ing as on the VSS/VSR compressors. On VSM
compressors the thrust bearings are located in
the gate rotor support and rotate with the sup-
port when the compressor is in operation. The
inner races are secured to the stationary bearing
spindle.

B) Remove the upper bolt from the side cover

and install a guide stud in the hole. Remove
the remaining bolts and side cover. There
will be some oil drainage when the cover is
removed.
C) The side cover that contains the suction

strainer should have the suction line prop-
erly supported before the bolts securing the
line to the cover can be removed. After the
line is removed, the cover can be removed
per paragraph B.
D) Turn the main rotor so the driving edge of

the groove is between the top of the shelf or
slightly below the back of the gate rotor sup-
port. At this point install the gate rotor sta-
bilizing tool.
64
Service
E) Remove plug on the thrust bearing housing.

Loosen the socket head cap screw that is lo-
cated underneath the plug. This secures the
inner races of the thrust bearings to the
spindle.
F) Remove bolts that hold the thrust bearing

housing to the compressor. Insert two of the
bolts into the threaded jacking holes to as-
sist in removing the bearing housing from
the compressor. When the housing is re-
moved, there will be shims between the
spindle and thrust bearings. These control
the clearance between the shelf and gate ro-
tor blades. These must be kept with their
respective parts for that side of the compres-
sor.
G) Remove the bolts from the roller bearing

housing. After the bolts have been removed,
the housing can be removed from the com-
pressor.
H) To remove the gate rotor support, carefully

move the support opposite the direction of
rotation and tilt the roller bearing end to-
wards the suction end of the compressor. The
compressor input shaft may have to be turned
to facilitate the removal of the gate rotor sup-
port. On dual gate versions, repeat the pro-
cedure for the remaining gate rotor support
assembly.
65
Service
1.02 A INSTALLATION (All VSS and

152 VSR Models)
160
116 A) Install the gate rotor support by carefully tilt-
106 ing the roller bearing end of the gate rotor
143
151 support towards the suction end of the com-
pressor. The compressor input shaft may
115
142 have to be rotated to facilitate the installa-
tion of the gate rotor support.
113
Install gate rotor stabilizer. The gate rotor
stabilizer (901) will hold the gate rotor sup-
port in place as the thrust bearing housing
is being installed. If the gate rotor support
is not restricted from moving, the gate rotor
blade may be damaged.
B) Install the roller bearing housing (112) with
a new O-ring (141). Tighten the bolts (152)
to the recommended torque value.
C) When installing the thrust bearing housing
141
(113), a new O-ring (142) must be used when
112 the housing is installed. Lubricate the out-
side of the housing and bearings with clean
152 compressor oil to aid in the installation. Due
to the fit of the bearings on the gate rotor
shaft, the thrust bearing removal and instal-
lation tool with the pusher shoe must be used.
913 916 Turn the jacking screw clockwise. This will
push the thrust bearings onto the shaft and
push the housing assembly into the frame.
915 Install the inner retainer (115) and bolts
(151) using Loctite ® 242 thread locker.
910 Tighten the bolts to the recommended torque
value.
914
912
901
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Service
D) Set the clearance between the gate rotor blade

and the shelf.
1. Place a piece of 0.003”-0.004” shim

stock between the gate rotor blade and
the shelf.
2. Measure the depth from the top of the
compressor case to the top of the thrust
bearing housing. This determines the
amount of shims needed for the correct
clearance.
3. Use factory installed shim pack (106)
and bearing housing cover (116) with-
out the O-ring (143). Check the clear-
ance between the entire gate rotor blade
and the shelf, rotate the gate rotor to find
the tightest spot. It should be between
0.003”-0.004”. Make adjustments, if
necessary. It is preferable to shim the
gate rotor blade looser rather than tighter
against the shelf.
Note: Replacement blades are precisely the
same dimensionally as blades installed
originally at factory: Therefore, the same
amount of shims will be required for replace-
ment blades.
E) After clearance has been set install a new O-

ring (143) on bearing housing cover, install
cover and tighten the bolts to the recom-
mended torque value.
F) Install side cover with a new gasket. Tighten
the bolts to the recommended torque value.
The unit can then be evacuated and leak
checked as outlined in section 0.03.
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Service
1.02B INSTALLATION (All VSM Mod-

els)
A) Install the gate rotor support. Carefully tilt

the roller bearing end of the gate rotor sup-
port towards the suction end of the compres-
sor. The compressor input shaft may have
to be rotated to facilitate the installation of
the gate rotor support.
B) Install the roller bearing housing with a new
O-ring. Tighten the bolts to the recom-
C) Install the spindle with shims and o-ring,
tighten the bolts to the recommended torque
value, measure the clearance between the
shelf and blade.
D) Check the clearance between the entire gate
Gaterotor for C-flange Models rotor blade and the shelf, rotate the gate ro-
tor to find the tightest spot. It should be
between 0.003”-0.004”. Make adjustments,
if necessary. It is preferable to shim the gate
rotor blade looser rather than tighter against
the shelf.
Important: Read note on page 42.
E) Once the clearance is set remove the spindle.
Install new o-ring, apply Loctite 242 thread
locker to the socket head cap screw clamp-
ing the thrust bearings to the spindle. Torque
all bolts to the recommended torque values.
F) Install side covers with new gaskets. Tighten
bolts to the recommended torque value. The
unit can now be evacuated and leak checked
as outlined in section 0.03.
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Service
1.03 GATE ROTOR BLADE REMOVAL
A) Remove the gate rotor assembly. Refer to

130
section 1.01 or 1.01B on gate rotor assembly
119
removal.
B) Remove the snap ring and washer from the 111
gate rotor assembly. Lift gate rotor blade
assembly off the gate rotor support. 120
C) Check damper pin and bushing for exces-
sive wear. Replace if necessary. 135
1.04 GATE ROTOR BLADE
INSTALLATION 110
A) There are two sizes of damper pins and bush-
ings that have been used in single screw com-
pressors. The gate rotor supports, pins and
bushings are not interchangeable. If the gate
rotor support has a small diameter pin, only
the small diameter bushing can be used with
it. Additionally a large diameter pin cannot
be used in a gate rotor support machined for
a small diameter pin.
Small Pin=Small Damper
Large Pin= Large Damper
All new compressors and replacement gate
rotor support assemblies are provided with
the large diameter damper pins. The follow-
ing table shows the sizes of pins used.
TABLE 1.1 DAMPER PIN DIAMETERS
MODEL SMALL LARGE

PIN DIA. PIN DIA.
VSM 71 thru VSM 401 --- 0.4375”
VSM 501 thru VSM 701 --- 0.4375”
VSR 111 thru VSR 301 0.250” 0.4375”
VSS 451 & VSS 601 0.250” 0.4375”
VSS 751 & VSS 901 0.3125” 0.4375”
VSS 1051 & VSS 1201 0.375” 0.4375”
VSS 1501 & VSS 1801 0.375” 0.500”
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Service
B) Install damper pin bushing (120) in gate ro-

tor blade (111) from the back side of the
blade. Be sure the bushing is fully seated.
C) Place the blade assembly on the gate rotor
support. Locating Damper over pin.
D) Install washer (119) and snap ring (130) on
gate rotor assembly. The bevel on the snap
ring must face away from the gate rotor
blade. After the gate rotor blade and sup-
port are assembled, there should be a small
amount of rotational movement between the
gate rotor and support.
E) For installation of the gate rotor assembly
and setting of gate rotor clearance, refer to
section 1.02.
1.05 GATE ROTOR THRUST

BEARING REMOVAL
A) Refer to section 1.01 for removal of the gate

rotor bearing housings and gate rotor sup-
ports.
B) For removal of thrust bearings on VSS and
VSR units:
1) Remove bolts (150) from the clamping
ring (114).
2) Remove thrust bearing clamping ring.
3) Remove thrust bearings (126) from

housing (113).
150
C) For removal of thrust bearings on VSM units:
1) Remove retaining ring from gate rotor
114 support.
2) Remove bearings from support.

126
3) Remove bearing retainer from inner
race.
113
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Service
1.06 GATE ROTOR THRUST

BEARING INSTALLATION
A) For installation of thrust bearings on VSS

and VSR units:
1) Install bearings (126) in the housing so
the bearings are face to face.
The larger sides of the inner races are
placed together. A light application of
clean compressor lubricating oil should
be used to ease the installation of the
bearings into the housing.
2) Center the bearing retainer ring on hous-
ing, use Loctite® 242-thread locker and
evenly tighten the bolts to the recom-
3) For installation of the bearing housing

and the setting of the gate rotor blade
clearance, refer to section 1.02.
B) For installation of thrust bearings on VSM

units:
1) Install retainer in the back of the inner
race of one of the thrust bearings. The
back of the inner race is the narrower of
the two sides. Inner Retainer
2) The bearing with the retainer should be

placed in the housing first, retainer to-
wards the support. Install the second
bearing. The bearings should be posi-
tioned face to face. This means that the
larger sides of the inner races are placed
together. A light application of clean
compressor lubricating oil should be
used to ease the installation of the bear-
ings into the gate rotor support. Ball Bearings
Retaining Ring
3) Install the bearing retaining snap ring.
4) For installation of the bearing housing

and the setting of the gate rotor blade
clearance, refer to section 1.02A.
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Service
1.07 GATE ROTOR ROLLER

BEARING REMOVAL
A) Refer to section 1.01 for removal of the gate

rotor bearing housings and gate rotor sup-
ports.
B) Remove the snap ring (131), which retains

the roller bearing in the bearing housing.
C) Remove the roller bearing (125) from the

bearing housing (112).
D) Use a bearing puller to remove the roller

bearing race (125) from the gate rotor sup-
port (110).
VSM Only
1.02 GATE ROTOR ROLLER

BEARING INSTALLATION
A) Match up the part numbers on the inner race

to the part numbers outer race. Press the bear-
ing race (numbers visable) onto the gate ro-
tor support.
B) Install the outer bearing into the bearing

housing so the numbers match the numbers
on the inner race. Install the snap ring re-
tainer in the housing. The bevel on the snap
ring must face away from the roller bearing.
C) For installation of the bearing housing, re-

fer to section 1.02.
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Service
Seal with stationary mirror face (219B) and

2.00 INPUT SHAFT SEAL rotating carbon face (219C).
REPLACEMENT
Used till mid 1995. on VSG non c-flange
compressors.
281 219A 219C
There are two types of shaft seals that have been

used interchangeably in the Vilter VSS and VSR
Single Screw Compressors. The first type has a
stationary mirror face and rotating carbon. The
second type has a stationary carbon and a rotat-
ing mirror face. Either type of seal may be used
in the compressors. On Vilter VSM compressors
the type of seal utilized has a stationary carbon
and a rotating mirror face. 230 218 265 260 219B
2.01 INPUT SHAFT SEAL REMOVAL Seal with stationary carbon face (219B) and
rotating mirror face (219C).
lined in section 0.01. Current Shaft Seal and for all Replace-
ment.
B) Remove bolts (281) holding the shaft seal
cover (218). Insert two of the bolts into the
threaded jacking holes to assist in removing 281 219A 219C
the cover. There will be a small amount of
oil drainage as the cover is removed.
C) Remove the rotating portion of the shaft seal
(219C).
D) Remove oil seal (230) from cover.
E) Remove the stationary portion of the shaft

seal (219B) from the seal cover using a brass
drift and hammer to tap it out from the back
side of the seal cover.
230 218 265 260 219B

Roll pin # 265 only used
on VSS 751 and larger.
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Service
Stationary seal 2.02 SHAFT SEAL INSTALLATION

265
261
NOTE:
When replacing the stationary members of the
seal on the VSR 111 thru VSR 301, and VSS
451 and VSS 601, the roll pin in the cover is
260 used only with the seal assembly having a sta-
tionary mirror face. If a seal assembly with a
stationary carbon face is installed, the roll pin
must be removed.
A) Install new oil seal in cover.
Align slot in seal

with dowel pin or
key in shaft.
CAUTION
265
Care must be taken when handling the shaft
seal and mirror face so it is not damaged. Do
not touch the carbon or mirror face as body oil
and sweat will cause the mirror face to corrode.
B) To install the carbon cartridge part of the

seal in the seal cover; clean the seal cover,
remove protective plastic from the carbon
cartridge, do not wipe or touch the carbon
face. Lubricate the sealing O-ring with clean
Make sure that seal is
bottomed against compressor lubricating oil. If applicable,
shoulder on shaft. align the hole on the back of the carbon car-
Align slot in seal
with dowel pin or tridge with the dowel pin in the seal cover.
key in shaft.
Install cartridge using seal installation tool
or similar (see tool lists).
C) Wipe clean, the compressor input shaft and

the shaft seal cavity in the compressor hous-
ing. Apply clean compressor oil to the shaft
seal seating area on input shaft.
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Service
D) Lubricate the inside area of the rotating seal

with clean compressor lubricating oil, do not
wipe or touch the face of the rotating portion
of the seal. Align the slot in the rotating seal
with the drive pin on the compressor input
shaft. Carefully push the seal on, holding
onto the outside area of the seal until the
seal seats against the shoulder on the input
shaft. Make sure the seal is seated against
the shoulder. If the seal is not fully seated
against the shoulder, the shaft seal carbon
will be damaged when the seal cover is in-
stalled.
Maintenance Suggestion:
A spray bottle filled with clean compressor oil

may be used to lubricate the faces of the seals
without touching the seal.
E) Install a new O-ring on the seal cover, mak-

ing sure the O-ring is placed in the O-ring
groove and not the oil gallery groove. Lu-
bricate both seal faces with clean compres-
sor lubricating oil.
F) Carefully install the seal cover on the com-

pressor shaft, evenly tightening the bolts to
the recommended torque values.
G) Install the coupling and coupling guard. The

unit can then be evacuated and leak checked,
2.03 MAIN ROTOR ASSEMBLY
Due to the procedures and tools involved in the

disassembly and reassembly, the main rotor as-
sembly must be performed by qualified individu-
als. Please consult the factory if maintenance is
required.
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Service
3.00 INSPECTION OF SLIDE VALVE

ASSEMBLIES IN THE
COMPRESSOR
Prepare the compressor for servicing as outlined

in section 0.01.
A) Remove the gate rotor access covers. Using
Check for
Check for wear
excessive wear areas.
in these in these
areas. a mirror and flashlight, visually inspect the
slide valve carriage through the gas bypass
opening. Look for any significant signs of
wear on the slide valve carriage.
B) To check the clearance of the slide valve

clamps, the gate rotor support must be re-
moved. Refer to section 1.00 for removal of
the gate rotor support.
C) Using a feeler gauge, inspect the clearance

Feeler gauge Measure here between capacity and volume slide valve
clamps and slide valve carriage through the
gas bypass opening. The clearance should
be less than 0.002”.
D) If the slide valves are worn in excess of the

tolerances, the factory should be contacted.
3.10 REMOVAL SLIDE VALVE

CARRIAGE ASSEMBLIES

B) If only one of the slide valve carriages is re-

moved only the corresponding gate rotor sup-
port needs to be removed. If both carriages
are removed both gate rotors must be re-
moved. Remove the gate rotor assemblies
C) Remove the capacity and volume actuators

as outlined in section 4.01. Remove the dis-
charge manifold, capacity and volume cross
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Service
shafts and the slide valve racks as outlined in

section 4.10.
D) Locate and remove the socket head plugs

above the slide valve carriage attachment
bolts. Remove the bolts located under the
plugs.
E) The slide valve carriage may now be re-

moved. On newer carriages there is a
threaded hole in the back of the slide valve
carriage to aid in its removal. Use a threaded
tip slide hammer to aid in the removal of the
carriage.
Note: Slide Valves may be re-positioned to aid

in removal of assembly.
3.20 INSTALLATION OF SLIDE

VALVE CARRIAGE ASSEMBLIES
A) Position the slide valves to the center of the

carriage. Place the slide valve assembly in
the bore of frame and use the slide hammer
to slowly tap the carriage into position. Re-
positioning slide valves once inside bore may
aid installation. Adjust the carriage so that
the 3-holes line up.
B) Install the 3 socket head cap screws with new

Nord-Lock washers beneath the heads, but
do not tighten them.
C) Work a piece of 0.005”shim stock between

the slide valves and the main rotor to help
position the carriage.
D) Tighten, to the correct torque the hold down

bolts to secure the carriage in the frame. The
edges of the slide valves themselves should
be at or slightly below the main rotor bore.
E) Re- Install the capacity and volume slide

valve cross shafts, slide valve racks and dis-
charge manifold as outlined in section 4.01.
F) Re-install the gate rotor assemblies as out-

lined in section 1.02
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Service
4.00 CAPACITY AND VARIABLE

VOLUME RATIO CONTROL
ASSEMBLY
A) The following instructions are applicable for

most units equipped with optical gear mo-
tors built after 11-1-01. For units equipped
with potentiometer feed back gear motor
built after 5-1-95, see section 4.10. For units
built before 5-1-95, see Section 4.11.
B) On VSS units and dual gate VSM units, each

pair of volume or capacity slide valves are
mechanically connected and actuated to
move as a balanced pair. On VSR units
and single gate VSM units, there is only
one set of volume or capacity slide valves.
However, all information on removing the
volume or capacity control assemblies is
applicable to all units.
Collar 4.01 OPTICAL SLIDE VALVE

ACTUATOR REMOVAL
A) Follow appropriate lock out tag out proce-

dures to shut off the electricity to the micro-
processor. Disconnect cables from actuator.
Locking Screw
B) Remove the side covers from the bracket to
gain access to the shaft collar.
C) Loosen shaft collar locking screw. Slide the

collar onto the actuator shaft. Lightly tighten
locking screw to hold it in place.
D) Remove the (4) #10 socket head cap screws

holding the bracket to the base plate.
E) Remove slide valve actuator from the unit.

Remove key from command shaft.
78
Service
4.02 OPTICAL SLIDE VALVE

ACTUATOR INSTALLATION
A) Install the key in the command shaft keyway.
B) Slide the actuator assembly on to the com-

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

of the actuator shaft. Check to make sure
the key is fully inserted in the actuator shaft.
The key should be flush with the end of the
actuator shaft.
D) Tighten the shaft collar ¼” socket head cap

screw to 16 ft/lbs. (192 in/lbs.). Failure to
correctly torque the locking screw may re-
sult in a failure of the actuator.
E) Install the side covers to the bracket with hex

washer head self tapping screws.
79
Service
GEAR MOTOR TO OPTICAL SLIDE

VALVE ACTUATOR CONVERSION, C) The four #10 holes in the existing mounting
REMOVAL OF GEARMOTOR plate that will be utilized to attach the actua-
tor must be in good condition. A 10-24 N.C.
tap can be utilized to clean out the threaded
holes.
D) Install the key in the command shaft keyway.
E) Slide the actuator assembly on to the com-

mand shaft. Align one of the two key slots
A) Follow appropriate lock out tag out proce- in the actuator shaft with the key on the com-
dures to shut off the electricity to the mi- mand shaft. Make sure that the collar re-
croprocessor. mained on the actuator shaft. Due to the
position of the slide valve in the compres-
B) Remove the six hex head cap screws that sor, use of the other key slot may be required
secure the slide valve actuator cover. Remove to align the bracket holes with the threaded
cover and gasket. mounting plate holes.
C) Disconnect the motor and potentiometer F) Slide the collar until it is flush with the end
leads. of the actuator shaft. Check to make sure
the key is fully inserted in the actuator shaft.
D) Remove the four 5/16” hex head cap screws The key should be flush with the end of the
holding the motor support to the mounting actuator shaft.
plate. Remove the gear motor assembly.
G) Tighten the shaft collar ¼” socket head cap
E) Remove the ¼” retaining nut, washer and screw to 16 ft/lbs. (192 in/lbs.). Failure to
plastic gear from the end of the command correctly torque the locking screw may re-
shaft. Loosen the set screw securing the sult in a failure of the actuator.
large drive gear to the command shaft. Re-
tain drive key for possible re-use with new H) Install the side covers to the bracket with
actuator assembly. hex washer head self tapping screws.
I) Refer to the slide valve actuator calibration

GEAR MOTOR TO OPTICAL SLIDE instructions in the Vission/Vantage manual
VALVE ACTUATOR CONVERSION, or the instructions packed with actuators on
INSTALLATION OF ACTUATOR calibration procedures
A) Remove the four self tapping screws that

secure the side covers to the actuator bracket. 4.05 COMMAND SHAFT ASSEMBLY
This will allow access to the actuator shaft. REMOVAL
B) On certain units with economizer, the ac- The following steps can be used to remove or
tuator bracket may have to be rotated from install either the capacity or volume command
its original position with the motor. To ac- shaft assemblies.
complish this remove the four hex head cap A) Prepare the compressor for servicing as out-
screws holding the bracket to the motor. lined in section 0.01.
Rotate the motor from the original posi-
tion. Make sure the electrical connections B) Follow the appropriate instructions to re-
on the actuator are not to the top position. move control actuator as outlined in sections
This will allow enough clearance between 4.01 or 4.10.
the motor and economizer line.
80
Service
Old Style Motor Plate
457 477 C) The unit can now be leak checked as out-

415
lined in section 0.03.]
4.07 COMMAND SHAFT BEARING

AND O-RING SEAL
REPLACEMENT
A) Remove command shaft assembly as outlined

in section 4.05.
B) Remove snap ring retainer (451) from com-

mand shaft housing (412). Push the com-
C) Remove four socket head cap screws (457) mand shaft assembly out of the housing.
and Nord-Lock washers (477) securing
mounting plate (415) to manifold.
D) The command shaft and mounting plate may

now be removed from the compressor.
4.06 COMMAND SHAFT ASSEMBLY

INSTALLATION
A) Install the command shaft assembly with a

new o-ring (446) on the manifold. Make sure
that the command shaft tongue is engaged
in the cross shaft slot. Rotate the bearing
Div.2
housing so the vent holes point down, this Only
will prevent water and dust from entering
the vents.
Rotate bearing housing

so vent hole points down.
Command shaft
assembly. C) The command shaft bearing (435) is a press
Align the tongue of
the command shaft fit on the command shaft (413). Remove the
with the groove in the
cross shaft. command shaft bearing with a suitable press.
446
Vent hole.
436
Reference “Parts
445 Section” for current
Housing
D) Remove the O-ring seal (445) from the com-

B) Install the actuator mounting plate with the mand shaft housing. The command shaft
four socket head cap screws and Nord-Lock bushing (433 and 436) might have to be re-
washers securing it with proper torque. moved to gain access to o-rings. Replace
bushing if the bore is deeply scored or exces-
sively worn.
81
Service

511 512 Guide rods
AND O-RING SEAL
REASSEMBLY Discharge 519
spool
A) Install new O-ring seal in housing and lu-
bricate the O-ring with clean compressor oil.
A vent hole is provided in the command shaft
547
bearing housing to allow any refrigerant and
548
oil that may leak past the O-ring seal to vent 540
549
to atmosphere and not into the slide valve 536
550
motor housing. Install snap ring retainer and 551
washer on the command shaft.
B) Remove any burrs from the command shaft

to prevent damage to the O-ring when as- NOTE:
sembling. Press the command shaft bearing When removing the discharge manifold on VSM
onto the command shaft. Insert the com- compressor the compressor must be properly sup-
mand shaft into the housing appling pres- ported to keep the compressor from moving when
sure on outer race of bearing. Make sure the the manifold is removed.
bearing is fully seated in the command shaft
housing. Install the snap ring retainer in
the command shaft housing. C) On VSM compressors unbolt the discharge
flange from the discharge manifold.
C) Install command shaft assembly as outlined
in section 4.02. D) Remove one bolt from each side of the dis-
charge manifold and install (2) guide rods
approximately 6” long, to support the mani-
4.09 DISCHARGE MANIFOLD fold. Remove the remaining bolts (note
REMOVAL length and location of bolts) and take off the
discharge manifold.
A) Remove both control actuators and command

shaft assemblies as outlined in sections 4.01 4.10 DISCHARGE MANIFOLD
and 4.05. INSTALLATION
B) On VSS and VSR compressors, remove the A) Install (2) guide rods to position the dis-
discharge spool between the manifold and charge manifold. Install a new manifold
separator. Remove one bolt from each side gasket and the discharge manifold. Install
of the discharge manifold and install (2) the dowel pins and bolts, tighten manifold
guide rods approximately 6” long, to sup- bolts to the recommended torque value.
port the manifold. Remove the remaining
bolts (note length and location of bolts) and B) On VSS and VSR compressors install the
take off the discharge manifold. discharge spool or elbow between the dis-
charge manifold and oil separator with new
Note: Mainfold has dowel pins to locate it gaskets. When installing the discharge el-
on the compressor housing. Therefore, re- bow tighten the bolts to the correct torque
move manifold straight back approximately on the manifold flange first before tighten-
1” as not to break dowel pins. ing the separator flange bolts. Install the
drain plug in the bottom of the discharge
manifold.
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Service
C) On VSM compressors install the bolts in the F) Look for any excessive wear on all moving
discharge flange. Install the drain plug in parts and replace the worn parts.
the bottom of the discharge manifold.
G) Reassemble the manifold and discharge el-
D) Install both command shaft assemblies and bow as outlined in section 4.10.
control actuators as outlined in sections 4.05
and 4.01.
4.12 REMOVAL OF CAPACITY OR
4.11 SLIDE VALVE GEAR AND RACK VOLUME CROSS SHAFTS
INSPECTION
A) Remove the discharge manifold as outlined
A) Remove the discharge manifold as outlined in section 4.09.
in section 4.09
B) To remove the capacity or volume ratio slide
B) Check rack to rack clamp and rack clamp valve racks, remove the two jam nuts and lock
spacer clearance on all four slide valves. washers (361) securing the rack (316) to the
slide valve shafts. The racks can now be
TABLE 4.1 pulled off the slide valve shafts. Repeat the
RACK CLEARANCE VALUES procedure for the remaining pair of slide valve
racks.
MEASUREMENT CLEARANCE
Rack to clamp. 0.005 to 0.010”
Rack to clamp spacer. 0.003 to 0.005”
C) Check torque of socket heat cap screws.
D) Check for excessive movement between the

slide valve rack shafts and the rack. The
jam nuts on the end of the slide valve rack
shaft should be tight.
E) Check for loose or broken roll pins in gears.
Check
Rack to torque C) To remove the cross shafts, remove socket
clamp on cap head bolts, clamp and spacers from both
spacer screws sides.
Rack to Roll pins
clamp Loose nuts
83
Service
VSS compressors cross shafts.

4.13 INSTALLATION OF CAPACITY
269 228 221 OR VOLUME CROSS SHAFTS
268
A) To reassemble either set of capacity or vol-
ume ratio slide valve racks, install the cross
222 shaft with the pinion gear onto the back plate,
222 place the remaining pinion gear on the shaft
and drive in the roll pins. Install clamps,
228 269 268 spacers and bolts on both sides. Tighten the
bolts to the recommended torque values.
VSR compressors cross shafts.
Volume control cross shaft. B) The slide valve sets must be synchronized
on VSS and dual gate VSM units. Both slide
269 269 valve racks for either the volume ratio or
221 capacity slide valves must engage the cross
268
268 shaft gears at the same time. Push the racks
222 all the way towards the suction end of the
234
compressor until they stop. Install washers
and jam nuts on the slide valve shafts. Re-
peat the procedure for the remaining set of
slide valve racks.
Capacity control cross shaft.
228
268
222
269
268 When installing the slide
228 221 valve racks, both racks
269 must engage the axle
shaft gears at the same
time.
D) Drive the roll pins from pinion gear from one

side. Remove pinion gear. Slide the cross
shaft with the remaining pinion gear or spac-
ers out of the opposite side. Repeat the pro-
cedure for the remaining cross shaft.
C) Install (2) guide rods to position the discharge
manifold. Install a new manifold gasket and
the discharge manifold. Install the dowel pins
and bolts, tighten manifold bolts to the rec-
ommended torque value.
D) On VSS, VSM and VSR compressors install

the discharge as outlined in section 4.11.
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Service
4.20 REMOVALAND INSTALLATION 4.21 REMOVAL

OF CAPACITY OR VOLUME RA
TIO ACTUATORS (PRIOR TO 11- 1- A) Prepare the compressor for servicing as out-
01 AND AFTER 5-1-95 lined in section 0.01.
The capacity and volume ratio control assemblies

with their potentiometers are not interchangeable
and must not be switched when they are re-in-
stalled on the compressor. The following steps
are used to remove the control assemblies that
utilize a potentiometer that were manufactured
or retrofitted between 5-1-95 and 11-1-01.
NOTE:
The capacity and volume control motors are
equipped with a brake. If it is necessary to oper-
ate the control motors manually, the brake must be
disengaged. The brake can be disengaged by
pushing on the motor shaft on the cone end. The
shaft should be centered in its travel. Do not use B) Remove the six screws from the cover. Re-
excessive force manually operating the motor or move the cover for the slide valve actuator.
damage may result. Mark and disconnect the wires to the slide
valve control actuator and potentiometer.
C) Remove the four hex bolts and Nord-Lock®

washers holding the slide valve control mo-
tor assembly in place. The motor can now
be removed.
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Service
B) Install the motor plate and the four socket

D) Remove nut and Nord-Lock® washers, secur- head bolts, and Nord-Lock® washers secur-
ing the potentiometer drive gear to the com- ing it. Tighten the bolts to the recom-
mand shaft assembly. Loosen the set screw. mended torque value.
The command shaft drive gear and drive key
may now be removed from the command
shaft assembly. Remove the four socket head
bolts and Nord-Lock washers, securing the
motor plate and command shaft assembly.
The motor plate and command shaft assem-
bly can now be removed from the discharge
manifold.
4.22 INSTALLATION
A) Install the command shaft assembly with a

new O-ring on the manifold. Make sure
the command shaft tongue is engaged in the
cross shaft slot. Rotate the bearing housing
so the vent holes points down, to prevent
water and dust from entering the vents.
C) Install the drive key in the command shaft

keyway. Align the keyway on the command
shaft drive gear with the key on the com-
mand shaft, and slide the gear onto the com-
mand shaft. Tighten the set screw on the
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Service
gear. Install the spacer, potentiometer drive

gear, Nord-Lock washers and nut on the
command shaft and tighten the nut to the
recommended torque value.
477
465
D) Install the slide valve control motor assem-

bly with the four hex head bolts and Nord-
Lock washers that hold the slide valve con-
trol motor assembly to the motor plate.
Connect the wires to the slide valve control
motor and potentiometer.
E) Refer to the appropriate Microprocessor In-

struction Manual for the procedure to
recalibrate the potentiometers. The unit can C) Loosen and remove the socket head cap
now be evacuated and leak checked as out- screws (456) and Nord-Lock® (476) wash-
lined in section 0.03. ers to remove the potentiometer assembly
from the slide valve motor bracket.
4.23 POTENTIOMETER REMOVAL

(GEAR MOTOR ONLY)
A) Remove the cover for the slide valve control

assembly. Mark and disconnect the wires to
the potentiometer (419).
B) The capacity gearmotor potentiometer uses

a larger potentiometer gear and a small drive
gear on the command shaft. The volume
ratio gearmotor uses a small potentiometer
gear and a large drive gear on the command
shaft. The potentiometer bracket (428) is in-
terchangeable and can be used for either the
capacity or volume control.
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Service
C) Loosely install only one of the two mounting

screws and its set of Nord-Lock® washers.
Connect the wires to the potentiometer. Red
potentiometer lead goes to the white wire,
purple potentiometer lead goes to the red wire
and brown potentiometer lead goes to the
black wire. Recalibrate the potentiometer ac-
cording to the appropriate Microprocessor
operating manual. The remaining screw can
now be installed and both screws torqued.
Do not apply excessive force when meshing the

potentiometer gear, slide load on potientometer
D) Loosen the potentiometer gear clamp (432) shaft can cause rapid failure
and remove the gear (424 capacity and 425
volume ratio) from the potentiometer shaft. 4.30 RETROFIT CAPACITYAND VOL-
UME RATIO CONTROL ASSEMBLIES ON
ALL VSS AND VSR COMPRESSORS
MANUFACTURED BEFORE MAY 1, 1995.
This section will cover the retrofit parts required

to update units manufactured before 5-1-95, to
current capacity and volume ratio control actua-
tor assemblies.
4.31 REMOVAL
E) To remove the potentiometer (419) from the

bracket (428), loosen and remove nut (419A)
and lock washer (419B) from the potentiom-
eter.
4.24 POTENTIOMETER
INSTALLATION To change to the new style optical motors, the
command shaft and mounting plate must be re-
A) Install potentiometer in the bracket. Install placed. This will require the unit to be evacuated
the lock washer and nut on the potentiom- for servicing.
eter. Do not over tighten nut on the potenti-
ometer.
B) Install the potentiometer gear and clamp on lined in section 0.01.
the potentiometer shaft.
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Service
B) Remove the hex head cap screws (452) from Lock® washers (477) securing it. Tighten the
the cover (418) for the slide valve control bolts to the recommended torque value.
motor, and remove cover. Mark and discon- C) Install the drive key (427) in the command
nect the wires to the slide valve control motor shaft keyway.
and potentiometer (425). Remove the two hex
bolts (453) under the mounting plate (415) that D) Install the new style optical gear motor as
hold the motor bracket (405) in place. The outlined in section 4.02 Optical Slide Valve
motor can now be removed. Actuator Installation.
E) Refer to the appropriate Microprocessor op-

erating manual for the procedure to recalibrate
the actuator. The unit can now be evacuated
and leak checked as outlined in section 0.03.

AND O-RING SEAL REPLACEMENT
FOR RETROFIT CONTROL AS-
SEMBLIES
A) Remove command shaft assembly as outlined

in section 4.05.
B) With a suitable pin punch, drive out roll pins

(490) and (491). Remove coupling (414) from
the command shaft and dress out any burrs
around the roll pin hole on the command shaft.
C) Removes the four socket head cap screws

(455) securing the motor plate and command
shaft assembly. The motor plate and com-
mand shaft assembly can now be removed
from the discharge manifold.
D) Repeat the above steps to remove the oppo-

site slide valve control motor and command
shaft assembly.
4.32 INSTALLATION OF RETROFIT

CONTROLASSEMBLY
A) Install the new command shaft assembly with

a new O-ring on the manifold. Make sure the
command shaft coupling is engaged in the
C) Remove snap ring retainer (451) from com-
cross shaft gear. Rotate the bearing housing
mand shaft housing (412). Push the com-
so the vent holes points down, to prevent
mand shaft assembly out of the housing.
water and dust from entering the vent.
B) Install the new motor plate (415) and the four

socket head cap screws (457), and Nord-
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Service
align roll pin holes. Drive in roll pins.

D) The command shaft bearing (435) is a press
fit on the command shaft (413). Remove the E) Install the command shaft assembly with a
command shaft bearing with a suitable press. new o-ring (446) on the manifold. Make sure
that the command shaft tongue is engaged in
the cross shaft slot. Rotate the bearing hous-
ing so the vent holes point down, this will
prevent water and dust from entering the
vents.
E) Remove the O-ring seal (445) from the com-

mand shaft housing. The command shaft
bushing (436) should only be removed if the
bore is deeply scored or excessively worn.

AND O-RING SEAL REASSEMBLY
A) If the command shaft bushing (436) was re-

moved, install a new bushing in housing. In-
stall new O-ring seal (445) in the command F) Install the actuator mounting plate with the
shaft housing. Lubricate the O-ring with clean four socket head cap screws and Nord-Lock
compressor oil. Install snap ring retainer (450) washers securing it.
and washer (480) on the command shaft (413).
G) The unit can now be leak checked as out-
B) Remove any burrs from the command shaft to lined in section 0.03.
prevent damage to the O-ring when assem-
bling. Press the command shaft bearing (435)
onto the command shaft.
IMPORTANT
Do not press on outer bearing race when install-

ing the bearing on to the command shaft.
C) Insert the command shaft into the housing.

Make sure the bearing is fully seated in the
command shaft housing. Install the snap ring
retainer in the command shaft housing.
D) Place the coupling on the command shaft and
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Service
5.00 LIQUID INJECTION PLUG 5.02 INSTALLATION OF PLUG

REPLACMENT
A) Electrically lock out and tag out the screw A) Apply refrigerant grade thread sealant to the
compressor package. threads of the replacement plug. Install plug
into compressor frame.
B) Isolate the screw compressor package B) Rotate the compressor input shaft by hand
from the package. to make sure the compressor turns over
freely.
C) Remove the refrigerant from the screw
compressor package in an approved man- C) Pressurize the screw compressor package
ner. and check for leaks.
5.01 REMOVAL OF PLUG
A) Remove the socket head pipe plug, from

the top of VSS compressors or the bot-
tom of VSR compressors. Some of the
pipe plugs were sealed with red refriger-
ant grade thread sealing compound. This
may require a moderate amount of heat
to be applied to the plug, not to exceed
300°F.
B) Two types of inner plugs are used.
1) The first style of plug assemblies
consists of a steel plug with a
crushed Teflon® pellet on top of the
steel plug, which holds the steel
plug in position. To remove the
steel plug, the crushed Teflon pel-
let must be dug out from the top of
the steel plug. Care must be taken
that all of the Teflon is removed
from the threads.
2) After the threads are clean, the steel
plug can be removed with a ¼” x
20 threaded rod or bolt. After the
plug is removed, clean and inspect
the port in the compressor frame
for debris.
3) The second type consists of a steel

plug and O-ring assembly. The
steel plug utilized a ¼” x 20 tapped
hole to assist in removing the plug.
This plug can be removed by in-
serting a ¼” x 20 threaded rod or
bolt to pull the plug out.
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Service
TABLE 5.1 VSS AND VSR LIQUID INJECTION

PLUG APPLICABILITY
COMPRESSOR MODEL VPN
VSR 111/211 NONE

VSR 151/301 25905BC
VSS 451 25905BB
VSS 451E NONE
VSS 601 25905BA
VSS 601E 25905BA
VSS 751 25905CB
VSS 751E 25905CB
VSS 901 25905CA
VSS 901E 25905CA
VSS 1051 25905DB
VSS 1051E 25905DC
VSS 1201 25905DA
VSS 1201E 25905DA
VSS 1501 NONE
VSS 1501E NONE
VSS 1801 NONE*
* EXCEPT S/N 819, 820 & 821 25905EA
VSS 1801E NONE
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Service
Torque Specifications
HEAD OUTSIDE DIAMETER OF BOLT SHANK
TYPE BOLT MARKINGS 1/ 4 " 5/16" 3/ 8 " 7/16" 1/ 2 " 9/16" 5/ 8 " 3/ 4 "
SAE GRADE 2 6 12 20 32 47 69 96 155
SAE GRADE 5 10 19 33 54 78 114 154 257
SAE GRADE 8 14 29 47 78 119 169 230 380
SOCKET HEAD 16 33 54 84 125 180 250 400

CAP SCREW
Fine serrations face out.

A. The Nord-Lock® lock washer sets are used
in many areas in both the VSR and VSS screw
compressors that require a vibration proof lock
washer.
B. The lock washer set is assembled so the

course serrations that resemble ramps are
mated together.
C. Once the lock washer set is tightened

Coarse serrations down, it takes more force to loosen the bolt
mate together.
that it did to tighten it. This is caused by the
washers riding up the opposing ramps.
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Service
6.00 OIL FILTER ELEMENTS
The following is a description of the oil filter

elements supplied on standard VSS, VSR and
VSM single screw compressor units
6.01 1833C FILTER ELEMENTS

Vilter Part Number 1833C
Usage VSS451 to
VSS 1801
Dates All units
prior to 3-1-00
Length 18”
Diameter 6-1/8”
A) Characteristics;
1) The outside of the filter element is

covered with a perforated metal sur-
face.
2) At each end of the filter, there is a

large thick elastomeric seal.
3) The housing is a fabricated steel hous-

ing with bolted end cover. The hous-
ing can contain one or two elements.
4) Simplex filter housing is standard

with duplex filter housings with a
bypass valve arrangement is optional,
so that the filter can be changed while
unit is in operation.
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Service
6.02 KT 721 FILTER ELEMENTS

Vilter Part Number KT 721
Tank O-Ring 2176BU
Usage VSR Compres-

sors
Dates 1992 to 8-1-96
Length 8”
A) Characteristics;
1) Pleated type element with a screen cov-

ering the surface of the element.
2) One end of the element is solid while

the other has a pilot hole with a cap-
tive “o”-ring.
Vilter Part Number KT 722
Tank O-Ring 2176AJ
Usage VSR Compres-

sors
Dates 1996 to 2002
Length 16.8”
A) Characteristics;
1) Pleated type element with a screen cov-

ering the surface of the element.
2) One end of the element is solid while

the other has a pilot hole with a cap-
tive “o”-ring.
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Service
6.04 KT 773A & B FILTER ELEMENTS
Vilter Part KT 773A KT 773B

Number
Tank O-Ring 2176BY 2176BZ
Usage 3109A 3111A

Duplex Simplex
Housing Housing
Usage 1. VSM all models 4/1/00 to
present.
2. VSS 451 to 1201 models with
30” and smaller oil separators 3/
1/00 to present
Length 16”
A) Characteristics;
1) Pleated type element with a screen
covering the surface of the element.
2) One end of the element is solid while the

other has a pilot hole with a captive “o”-
ring. Simplex filter housing. Duplex filter housing.
3) On duplex models only the end cap is

removed from the filter bowl
B) Usage;
1) Used in simplex and duplex applications.
2) The O-rings for the simplex and duplex

housings are not interchangeable.
96
Service
Vilter Part KT 774

Number
Tank O-Ring 2176BY
Usage 3112A 3110A

Simplex Duplex
Housings Housings
1. VSS 1501 & 1801 3-1-00 to
present.
2. All other VSS models with 30”
and larger oil separators
3/1/00 to present.
Length 39” Simplex filter housing.
C) Characteristics;
1) Pleated type element with a screen covering

the surface of the element.
2) One end of the element is solid while the

other has a pilot hole with a captive “o”-
ring.
3) Only end cap is removed from the filter Duplex filter housing.
bowl.
D) Usage;
1) Used in simplex and duplex applications.
97
VSS, VSM and VSR SINGLE SCREW COMPRESSORS
SERVICE INTERVAL REQUIREMENTS
FOR VILTER EXTENDED WARRANTY
The following service intervals are based on the usage of Vilter Manufacturing Corporation Premium Grade refrigeration
oil in VSS, VSM and VSR Single Screw Compressor units.
Inspection SERVICE INTERVAL (HOURS)

Or
100,000
120,000
110,000
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
5,000
200
Group Maintenance
Item
OIL CIRCUIT
Oil Change (1) R R R R R R R
Oil Analysis (2) S S S S S S S S S S S S S
Oil Filters (3) R R R R R R R R R R R R R R
Oil Strainer I I I I I I I I I I I I I I
PACKAGE
Coalescing Elements R R R R
Suction Screen I I I I I I I I I I I I I I
Liquid Line Strainers I I I I I I I I I I I I I I
Coupling Alignment and
Integrity I I I I I I I I I I I I I I
CONTROL
CALIBRATION Transducers I I I I I I I I I I I I I I
RTD’s I I I I I I I I I I I I I I
COMPRESSOR
Inspect Compressor I I I I I I I
Bearings I
Key I Inspect.
R Replace.
S Sample.
Notes: (1) The oil should be changed at these intervals, unless oil analysis results exceed the allowable limits. The
frequency of changes will depend on the system cleanliness.
(2) Oil analysis should be done at these intervals as a minimum; the frequency of analysis will depend on
system cleanliness.
(3) The oil filter(s) on a minimum must be changed at these intervals or annually if not run continuously.
However, the oil filter(s) must be changed if the oil filter differential exceeds 12 psi or oil analysis requires it.
98
Recommended
Spare Parts List
99
VSS - VSR - VSM Spare Parts List
SPARE PARTS FOR: PART WHERE USED:
100
COMPONENT VSS VSM VSR V.P. # DESCRIPTION QTY DESCRIPTION MULT
Oil Separator X 2923A Defogger/Coelecent Element 1 16" Oil Separator 140A
X 2879C Defogger/Coelecent Element 1 20" Oil Separator 111R
Gaskets X 69203C Cover Gasket 1 16" Oil Separator 140A
X 93559A Cover Gasket 1 20" Oil Separator 112R
Oil Separator X X 1 20" Oil Separator
X X 2 24" Oil Saparator
X X 2879A Defogger/Coelecent Element 3 30" Oil Separator 140A
X 4 36" Oil Separator
Gaskets: X X 93559A Cover Gasket, 13" x 12" 1 20" Oil Separator 112R
choose separator X 1 24" Oil Separator
size X 1 30" Oil Separator
X 93560A Cover Gasket, 16" x 15" 1 36" Oil Separator 112R
X KT721 Oil Filter Element 1 Used on VSR compressors 111R
VSR Units manufactured Before 8-8-96
Oil Filter X KT722 Oil Filter Element 1 Used on VSR compressors 111R
+++ manufactured After 8-8-96
X 1833C Oil Filter Element 1 Single Element Filter Tank 112R
VSS Units Before April - 2000 2 Dual Element Filter Tank 112R
Oil Filter X 35197A Filter Tank Cover Gasket 1 Single or Dual Element Filter Tank 112R
+++ (Included with 1833C)
X X 3109A Duplex Housing - 16" Bowl < or = 30" Oil Separator 111R
X 3110A Duplex Housing - 39" Bowl > 30" Oil Separator 111R
VSS/VSM X X 3111A Single Housing - 16" Bowl < or = 30" Oil Separator 111R
Oil Filter X 3112A Single Housing - 39" Bowl > 30" Oil Separator 111R
+++ X X KT773A 16" Oil Filter Element (3109 B-Duplex Housing) 111R
X X KT773B 16" Oil Filter Element (3109 B-Single Housing) 111R
X KT774 39" Oil Filter Element (3110 B Single & Duplex Housing) 111R
Safety Relief X X X 1498C 300 Psig R-717 Relief Valve 2 300 Psig R-717 Dual Relief Valve 2HVF
Valves X X X 1498A 250 Psig R-717 Relief Valve 2 250 Psig R-717 Dual Relief Valve 2HVF
X X X 1528B 300 Psig Halocarbon Relief Valve, 2 300 Psig Halocarbon Dual Relief Valve 2HVF
Safety Relief 1/2"x 5/8"
Valves X X X 1528H 300 Psig Halocarbon Relief Valve, 2 300 Psig Halocarbon Dual Relief Valve 2HVF
3/4"x 3/4"
X X X 1528M 300 Psig Halocarbon Relief Valve, 2 300 Psig Halocarbon Dual Relief Valve 2HVF
1"x 1"
NOTE : RECOMMENDED SPARE PARTS MARKED BY A (+++)

Make sure to check part # with correct Model Screw Compressor marked with “X”
SPARE PARTS FOR: PART

COMPONENT VSS VSM VSR V.P. # DESCRIPTION QTY DESCRIPTION MULT
X X X 2650W Solenoid Coil, 115V/50 Hz., 1 2650 Series Solenoid Valve, 115V/50Hz 2HVF
Yellow and Blue Leads
X X X 2650X Solenoid Coil, 230V/50 Hz., 1 2650 Series Solenoid Valve, 230V/50Hz 2HVF
Replacement Yellow Leads
Solenoid X X X 2650Y Solenoid Coil, 120V/60 Hz., 1 2650 Series Soleniod Valve, 120V/60Hz. 2HVF
Valve Coils Blue leads
X X X 2650Z Solenoid Coil, 240V/60 Hz., 1 2650 Series Soleniod Valve, 240V/60Hz. 2HVF
Red Leads
X 2954B Bare 11 GPM Oil Pump 1 11 GPM Oil Pump Before 1996 111R
X KT718A Replacement Shaft Seal for 1 11 GPM Oil Pump Before 1996 111R
Viking Oil 11 GPM Oil Pump
Pump X 2954E Bare 22 GPM Oil Pump 1 22 GPM Oil Pump Before 1996 111R
& repl’mt X 2954H Bare 31 GPM Oil Pump 1 31 GPM Oil Pump Before 1996 111R
shaft seals X KT718C Replacement Shaft Seal for 1 22 and 31 GPM Oil Pumps Before 1996 111R
22 and 31 GPM Oil Pumps
X X X 3022AU 10 GPM Oil Pump w/Bracket 1 Was 3022A (Before 1995) hub OK 111R
X X X 3022CX Replacement Shaft Seal 1 10U Oil Pumps AFTER 4-19-02 111R
1548LA Flange Gasket 2
Haight X X X 3022DU 20 GPM Oil Pump w/Bracket 1 Was 3022D (Before 1995) req’s 2913E hub 111R
Oil Pump X X X 3022CU Replacement Shaft Seal 1 24U Oil Pumps AFTER 4-19-02 111R
1548AA Flange Gasket 2
(note req’d hub) X X X 3022GU 30 GPM Oil Pump w/Bracket 1 Was 3022G (Before 1995) req’s 2913E hub 111R
X X X 3022CU Replacement Shaft Seal 1 30U Oil Pumps AFTER 4-19-02 111R
& repl’mt X 3022JU 40 GPM Oil Pump w/Bracket 1 Was 3022J (Before 1995) req’s 2913S hub 111R
shaft seals X 3022CU Replacement Shaft Seal 1 40U Oil Pumps AFTER 4-19-02 111R
X 3022MU 54 GPM Oil Pump w/Bracket 1 Was 3022M (Before 1995) req’s 2913S hub 111R
X 3022CV Replacement Shaft Seal 1 54U Oil Pumps AFTER 4-19-02 111R
1548BA Flange Gasket 2
X 3022QU 80 GPM Oil Pump w/Bracket 1 Was 3022Q (Before 1995) req’s 2913R hub 111R
X 3022CV Replacement Shaft Seal 1 80U Oil Pumps AFTER 4-19-02 111R
1548BA Flange Gasket 2
X X 2545A 1.5KW/240V—375W/120V 1 before 1999 on 20" & 24" Separator 112R
Heater X 2545B 2KW/240V—500W/120V 1 before 1999 on 30" Separator 112R
(pre 1999) X 2545C 2.5KW/240V—625W/120V 1 before 1999 on 36" Separator 112R
X 2545D 3KW/240V—750W/120V 1 before 1999 on 42" Separator 112R
101
Heater(after ’99) X X 3116C 750W/120V Cartridge Heater >> after 1999 on all separators—qty 1 or 2 111R
102
Spare Parts Cont.....

VILTER OIL X X X 2939A 717— 5 GALLON CAN FOR ALL SCREW & RECIP COMP 2HVF
+++ X X X 2939B 717— 55 GALLON DRUM FOR ALL SCREW & RECIP COMP 2HVF
X X X 3100A HALOCARBON — 5 GAL CAN FOR ALL SCREW & RECIP COMP 2HVF
X X X 3100B HALOCARBON — 55GAL. DRUM FOR ALL SCREW & RECIP COMP 2HVF
Shaft Seal X X KT709A Shaft Seal Kit 1 VSR111-VSS601 & VSM 501-701 111R
Ammonia X KT709B Shaft Seal Kit 1 VSS751 - 1201 111R
+++ X KT709C Shaft Seal Kit 1 VSS1501 - 1801 111R
X KT709D Shaft Seal Kit 1 VSM 71-401 111R
Shaft Seal X X KT781A Shaft Seal Kit 1 VSR111-VSS601 & VSM 501-701 111R
Other Refrig. X KT781B Shaft Seal Kit 1 VSS751 - 1201 111R
+++ X KT781C Shaft Seal Kit 1 VSS1501 - 1801 111R
X KT781D Shaft Seal Kit 1 VSM 71-401 111R
Slide Valve X X X KT720A Gearmotor/ Capacity Slide Valve 1 All Single Screw Compressors 111R
Motors X X X KT720C Gearmotor/ Volume Slide Valve 1 All Single Screw Compressors 111R
+++ X X X 25972A NEW Capacity & Volume 1 Complete Retrofit for all Viss/Vant
Optical Actuator Assembly panels & Compressors after 1/01/02 111R
Shaft Seal X X A25931A VSR’S & 451 & 601 1 2-Checks, Baffle, Teflon Seal 111R
Baffle X A25942AA VSM 1 & Retainer Ring 111R
Assembly X A25932A 751-1201 1 “ “ 111R
X A25933A 1501-1801 1 “ “ 111R
X A26034B VSM 501-701 1
Hubbel X X X 2803
VSS and VSR Replacement
Parts Section
VSS and VSR Replacement Parts Section ................................................................ 103

Gate Rotor ...................................................................................................................................................................................... 104
Shaft Seal ....................................................................................................................................................................................... 108
Main Rotor ..................................................................................................................................................................................... 110
Slide Valve Cross Shafts and End Plate ....................................................................................................................................... 114
Slide Valve Cross Shafts Prior to 5-1-95 .................................................................................................................................... 115
Capacity Control Actuating Motor and Command Shaft ........................................................................................................... 122
Slide Valve Actuating Motor and Command shaft Before 5-1-95 ............................................................................................... 126
Volume Ratio Control Actuating Motor and Command Shaft ..................................................................................................... 128
Tubing and Fittings ........................................................................................................................................................................ 132
C-Flange Adapter Components ..................................................................................................................................................... 138
Replacement Parts Tools ............................................................................................................................................................... 140
V
S
S
&
V
S
R
Parts
List
103
Gate Rotor
104
Gate Rotor
MODEL NUMBER
ITEM DESCRIPTION VSR 111 & VSR 221 VSR 151 & VSR 301 VSS 451 VSS 601
QTY VPN QTY VPN QTY VPN QTY VPN
GATE ROTOR BLADE AND BEARING
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126, 130,
131, 141, 142 & 143. 1 KT712A 1 KT712B 2 KT712A 2 KT712B
GATE ROTOR BLADE REPLACEMENT
KIT, 111, 118, 120A, 120B, 121, 122, 123,
124, 130, 141, 142 & 143. 1 KT713A 1 KT713B 2 KT713A 2 KT713B
100 SUPPORT ASSEMBLY 110 & 135B. 1 A25159BB 1 A25159BA 2 A25159BB 2 A25159BA
102 GATE ROTOR SUPPORT ASSEMBLY
100, 111, 120B, 119 & 130. 1 A25161BB 1 A25161BA 2 A25161BB 2 A25161BA
105 GATE ROTOR GASKET SET 118, 141,
142 & 143. 1 A25164B 1 A25164B 2 A25164B 2 A25164B
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 1 A25165B 1 A25165B 2 A25165B 2 A25165B
110 SUPPORT. 1 25606A 1 25520A 2 25606A 2 25520A
111 GATE ROTOR. 1 25557A 1 25534A 2 25557A 2 25534A
112 SMALL BEARING HOUSING. 1 25518A 1 25518A 2 25518A 2 25518A
113 LARGE BEARING HOUSING. 1 25517A 1 25517A 2 25517A 2 25517A
114 RETAINER. 1 25008A 1 25008A 2 25008A 2 25008A
115 RETAINER. 1 25009A 1 25009A 2 25009A 2 25009A
116 BALL BEARING COVER. 1 25258A 1 25258A 2 25258A 2 25258A
117 GATE ROTOR COVER. 1 25519A 1 25519A 2 25519A 2 25519A
118 GATE ROTOR COVER GASKET. 1 25259A 1 25259A 2 25259A 2 25259A
119 WASHER. 1 25007A 1 25007A 2 25007A 2 25007A
120A BUSHING, SMALL DOWEL PIN. 1 25006A 1 25006A 2 25006A 2 25006A
120B BUSHING, LARGE DOWEL PIN. 1 25760A 1 25760A 2 25760A 2 25760A
121* SHIM 0.002". ar 25010AA ar 25010AA ar 25010AA ar 25010AA
122* SHIM 0.003". ar 25010AB ar 25010AB ar 25010AB ar 25010AB
123* SHIM 0.005". ar 25010AC ar 25010AC ar 25010AC ar 25010AC V
124* SHIM 0.010". ar 25010AD ar 25010AD ar 25010AD ar 25010AD S
125 ROLLER BEARING. 1 2864B 1 2864B 2 2864B 2 2864B S
126 BALL BEARING. 2 2865B 2 2865B 4 2865B 4 2865B
130 RETAINING RING. 1 2866A 1 2866A 2 2866A 2 2866A &
131 RETAINING RING. 1 2867A 1 2867A 2 2867A 2 2867A
135A DOWEL PIN, SMALL, 0.250" O.D.. 1 2868B 1 2868B 2 2868B 2 2868B V
135B DOWEL PIN, LARGE, 0.4375" O.D.. 1 25910A 1 25910A 2 25910A 2 25910A S
141 O-RING ROLLER BRG HSG. 1 2176M 1 2176M 2 2176M 2 2176M R
142 O-RING BALL BRG HSG. 1 2176R 1 2176R 2 2176R 2 2176R
143 O-RING BRG HSG COVER. 1 2176N 1 2176N 2 2176N 2 2176N Parts
150 HEX HEAD CAP SCREW. 6 2796AJ 6 2796AJ 12 2796AJ 12 2796AJ List
151 HEX HEAD CAP SCREW. 3 2796B 3 2796B 6 2796B 6 2796B
152 HEX HEAD CAP SCREW. 20 2796CJ 20 2796CJ 40 2796CJ 40 2796CJ
153 HEX HEAD CAP SCREW. 16 2796E 16 2796E 32 2796E 32 2796E
160 SOCKET HEAD CAP SCREW. 6 2795E 6 2795E 12 2795E 12 2795E
NOTE: * Not pictured

ar = As required
105
Gate Rotor
ITEM DESCRIPTION VSG 751 VSG 901 VSG 1051 VSG 1201
REPLACEMENT KIT, 111, 118, 120A,
120B, 121, 122, 123, 124, 125, 126, 130,
131, 141, 142 & 143. 2 KT712C 2 KT712D 2 KT712E 2 KT712F
KIT, 111, 118, 120A, 120B, 121, 122, 123,
124, 130, 141, 142 & 143. 2 KT713C 2 KT713D 2 KT713E 2 KT713F
100 SUPPORT ASSEMBLY 110 & 135B. 2 A25159CB 2 A25159CA 2 A25159DB 2 A25159DA
100, 111, 120B, 119 &130 2 A25161CB 2 A25161CA 2 A25161DB 2 A25161DA
142 & 143. 2 A25164C 2 A25164C 2 A25164D 2 A25164D
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 2 A25165C 2 A25165C 2 A25165C 2 A25165C
110 SUPPORT. 2 25612A 2 25553A 2 25614A 2 25587A
111 GATE ROTOR. 2 25608A 2 25554A 2 25610A 2 25588A
112 SMALL BEARING HOUSING. 2 25281A 2 25281A 2 25313A 2 25313A
113 LARGE BEARING HOUSING. 2 25282A 2 25282A 2 25333A 2 25333A
114 RETAINER. 2 25084A 2 25084A 2 25084A 2 25084A
115 RETAINER. 2 25085A 2 25085A 2 25085A 2 25085A
116 BALL BEARING COVER. 2 25284A 2 25284A 2 25335A 2 25335A
117 GATE ROTOR COVER. 2 25285A 2 25285A 2 25311A 2 25311A
118 GATE ROTOR COVER GASKET. 2 25088A 2 25088A 2 25132A 2 25132A
119 WASHER. 2 25086A 2 25086A 2 25086A 2 25086A
120A BUSHING, SMALL DOWEL PIN. 2 25087A 2 25087A 2 25104A 2 25104A
120B BUSHING, LARGE DOWEL PIN. 2 25760B 2 25760B 2 25760B 2 25760B
121* SHIM 0.002". ar 25089AA ar 25089AA ar 25089AA ar 25089AA
122* SHIM 0.003". ar 25089AB ar 25089AB ar 25089AB ar 25089AB
123* SHIM 0.005". ar 25089AC ar 25089AC ar 25089AC ar 25089AC
124* SHIM 0.010". ar 25089AD ar 25089AD ar 25089AD ar 25089AD
125 ROLLER BEARING. 2 2864C 2 2864C 2 2864G 2 2864G
126 BALL BEARING. 4 2865A 4 2865A 4 2865A 4 2865A
130 RETAINING RING. 2 2866B 2 2866B 2 2866B 2 2866B
131 RETAINING RING. 2 2867E 2 2867E 2 2867L 2 2867L
135A DOWEL PIN, SMALL, 0.3125" O.D.. 2 2868F 2 2868F 2 2868H 2 2868H
135B DOWEL PIN, LARGE, 0.4375" O.D.. 2 25910B 2 25910B 2 25910B 2 25910B
141 O-RING ROLLER BRG HSG. 2 2176N 2 2176N 2 2176AJ 2 2176AJ
142 O-RING BALL BRG HSG. 2 2176V 2 2176V 2 2176AM 2 2176AM
143 O-RING BRG HSG COVER. 2 2176U 2 2176U 2 2176U 2 2176U
151 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796N 8 2796N
152 HEX HEAD CAP SCREW. 26 2796Q 26 2796Q 26 2796Q 26 2796Q
153 HEX HEAD CAP SCREW. 32 2796R 32 2796R 36 2796R 36 2796R
160 SOCKET HEAD CAP SCREW. 12 2795H 12 2795H 12 2795H 12 2795H
ar = As required
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Gate Rotor
ITEM DESCRIPTION VSG 1501 VSG1801

QTY VPN QTY VPN
REPLACEMENT KIT, 111, 118, 120A, 120B,
121, 122, 123, 124, 125, 126, 130, 131, 141,
142 & 143. 2 KT712G 2 KT712H
KIT, 111, 118, 120A, 120B, 121, 122, 123, 124,
130, 141, 142 & 143. 2 KT713G 2 KT713H
100 SUPPORT ASSEMBLY 110 & 135B. 2 A25159EB 2 A25159EA
101 GATE ROTOR ASSEMBLY 111 & 120. 2 A25160EB 2 A25160EA
100, 111, 120B, 119 &130. 2 A25161EB 2 A25161EA
142 & 143. 2 A25164E 2 A25164E
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 2 A25165E 2 A25165E
110 SUPPORT. 2 25687A 2 25665A
111 GATE ROTOR. 2 25647A 2 25645A
112 SMALL BEARING HOUSING. 2 25667A 2 25667A
113 LARGE BEARING HOUSING. 2 25669A 2 25669A
114 RETAINER. 2 25141A 2 25141A
115 RETAINER. 2 25789A 2 25789A
116 BALL BEARING COVER . 2 25351A 2 25351A
117 GATE ROTOR COVER. 2 25354A 2 25354A
118 GATE ROTOR COVER GASKET. 2 25790A 2 25790A
119 WASHER. 2 25788A 2 25788A
120A BUSHING, SMALL DOWEL PIN. 2 25104A 2 25104A
120B BUSHING, LARGE DOWEL PIN. 2 25760C 2 25760C
121* SHIM 0.002". ar 25791AA ar 25791AA V
122* SHIM 0.003". ar 25791AB ar 25791AB S
123* SHIM 0.005". ar 25791AC ar 25791AC S
124* SHIM 0.010". ar 25791AD ar 25791AD
125 ROLLER BEARING. 2 2864K 2 2864K &
126 BALL BEARING. 4 2865K 4 2865K
130 RETAINING RING. 2 2866G 2 2866G V
131 RETAINING RING. 2 2867R 2 2867R S
135A DOWEL PIN, SMALL, 0.375" O.D.. 2 2868H 2 2868H R
135B DOWEL PIN, LARGE, 0.500" O.D.. 2 25910C 2 25910C
141 O-RING ROLLER BRG HSG. 2 2176U 2 2176U Parts
142 O-RING BALL BRG HSG. 2 2176BD 2 2176BD List
143 O-RING BRG HSG COVER. 2 2176P 2 2176P
150 HEX HEAD CAP SCREW. 12 2796CJ 12 2796CJ
151 HEX HEAD CAP SCREW. 8 2796N 8 2796N
152 HEX HEAD CAP SCREW. 32 2796CJ 32 2796CJ
153 HEX HEAD CAP SCREW. 44 2796R 44 2796R
160 SOCKET HEAD CAP SCREW. 16 2795G 16 2795G
ar = As required
107
Shaft Seal
Shaft Seal With Stationary Carbon Face
Important:
Item # 244- Tappered
ID Faces Outward.
Shaft Seal Baffle Assemmbly
108
Shaft Seal
MODEL NUMBER
ITEM DESCRIPTION VSR 111 & VSR 151& VSS 751-1201 VSS 1501-1801
VSR 221 VSR 301
VSS 451 VSS 601

SHAFT SEAL AMMO KIT; 219, 230 & 260. 1 KT709A 1 KT709A 1 KT709B 1 KT709C
SHAFT SEAL HALO KIT 219,230 & 230 1 KT781A 1 KT781A 1 KT781B 1 KT781C
203 BAFFLE SHAFT SEAL 1 25931A 1 25931A 1 25932A 1 25933A
218 SEAL HOUSING. 1 25269A 1 25269A 1 25269B 1 25670A
219.# SHAFT SEAL. (Ammonia) 1 25043A 1 25043A 1 25043B 1 25378A
219.# SHAFT SEAL (Halo) 1 25432B 1 25432B 1 25432C 1 25432E
230 OIL SEAL. 1 25040A 1 25040A 1 25064A 1 2930B
244.> TEFLON SEAL 1 25939B 1 25939B 1 25939C 1 25939D
252> RETAINER RING 1 2928N 1 2928N 1 2928N 1 2928P
260 O-RING. 1 2176F 1 2176F 1 2176AC 1 2176BH
264 ROLL PIN. 1 1193RR 1 1193RR 1 1193RR 1 1193RR
265 DOWEL PIN . n/a n/a 1 2868A 1 2868A
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109
Main Rotor
VSS
110
Main Rotor
VSS
MODEL NUMBER
ITEM DESCRIPTION VSS 451 VSS601 VSS751 VSS901 VSS1051 VSS1201 VSS1501 VSS1801
QTY PART# QTY PART# QTY PART# QTY PART# QTY PART# QTY PART# QTY PART# QTY PART#
201 ROTOR ASSY 1 A25168BB 1 A25168BA 1 A25168CB 1 A25168CA 1 A25168DB 1 A25168DA 1 A25168EB 1 A25168AE
206 SHIM PACK 1 A25173B 1

A25173B 1 A25173C 1 A25173C 1 A25173D 1 A25173D 1 A25173E 1 A25173E
207 SHIM PACK 1 A25177B 1
A25177B 1 A25177C 1 A25177C 1 A25177D 1 A25177D 1 A25177E 1 A25177E
213 ROTOR SEAL 1 25509A 1
25509A 1 25273A 1 25273A 1 25322A 1 25322A 1 25359A 1 25359A
214 HOUSING BALL BRG 1 25531A 1
25531A 1 25272A 1 25272A 1 25321A 1 25321A 1 25358A 1 25358A
215 RET, OUTER RING BRG 1 25001A 1
25001A 1 25061A 1 25061A 1 25141A 1 25141A 1 25795A 1 25795A
216 RET, INNER BEARING 1 25000A 1
25000A 1 25062A 1 25062A 1 25142A 1 25142A 1 25796A 1 25796A
220 END PLATE 1 25530A 1
25530A 1 25543A 1 25543A 1 25593A 1 25593A 1 25661A 1 25661A
245 BALL BEARING 2 2865A 2
2865A 2 2865E 2 2865E 2 2865G 2 2865G 2 2865J 2 2865J
246 ROLLER BEARING 1 2864A 1
2864A 1 2864D 1 2864D 1 2864D 1 2864D 1 2864J 1 2864J
250 RETAINING RING n/a n/a 1 2867M 1 2867M 1 2867M 1 2867M 1 2867P 1 2867P
251 RETAINING RING 2 2867B 2 2867B 1 2867N 1 2867N 1 2867N 1 2867N 1 2867Q 1 2867Q
264 ROLLPIN 1 1193RR 1 1193RR 1 1193RR 1 1193RR 1 1193RR 1 1193RR 1 1193RR 1 1193RR
275 HEX HD CAP SCREW 6 2796AE 6 2796AE 10 2796B 10 2796B 6 2796Q 6 2796Q 6 2796Q 6 2796Q
276 HEX HD CAP SCREW 3 2796B 3 2796B n/a n/a 5 2796B 5 2796B 5 2796B 5 2796B
277 HEX HD CAP SCREW 4 2796CL 4 2796CL 10 2796EL 10 2796EL 10 2796EL 10 2796EL n/a n/a
278 HEX HD CAP SCREW 2 2796CT 2 2796CT 2 2796EU 2 2796EU 2 2796EU 2 2796EU 2 2796EU 2 2796EU
279 HEX HD CAP SCREW 2 2796CZ 2 2796CZ 2 2796EX 2 2796EX 2 2796EX 2 2796EX 2 2796EX 2 2796EX
280 HEX HD CAP SCREW 6 2796EL 6 2796EL n/a n/a n/a n/a 14 2796R 14 2796R
281 HEX HD CAP SCREW 8 2796B 8 2796B 8 2796B 8 2796B 8 2796B 8 2796B 13 2796B 13 2796B
282 SOC HD CAP SCREW 2 2795D 2 2795D 2 2795D 2 2795D 2 2795AL 2 2795AL 2 2795AK 2 2795AK
285 SOC HD CAP SCREW 12 2795R 12 2795R 12 2795F 12 2795F 12 2795K 12 2795K 16 2795AE 16 2795AE
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Main Rotor
VSR
112
Main Rotor
VSR
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301
QTY PART # QTY PART #

201 MAIN ROTOR ASSY 1 A25168BD 1 A25168BC
206 SHIM PACK 1 A25173C 1 A25173C
207 SHIM PACK 1 A25177B 1 A25177B
203 BAFFLE, SHAFT SEAL 1 A25931A 1 A25931A
213 SEAL 1 25630A 1 25630A
214 SUPPORT BEARING 1 25649B 1 25630A
215 OUTER BEARING RET 1 25001C 2 25001C
216 INNER BEARING RET 1 25062B 1 25062B
220 ENDPLATE ASSY 1 A25851BC 1 A25851BC
245 BEARING BALL 2 2865E 2 2865E
246 BEARING ROLLER CYL. 1 2864A 1 2864A
251 RETAINING RING 2 2867B 2 2867B
275 SOC HD CAP SCREW 6 2795E 6 2795E
276 HEX HD CAP SCREW 3 2796B 3 2796B
277 HEX HD CAP SCREW 4 2796CL 4 2796CL
278 HEX HD CAP SCREW 2 2796CT 2 2796CT
279 HEX HD CAP SCREW 2 2796CZ 2 2796CZ
280 HEX HD CAP SCREW 6 2796EL 6 2796EL
282 SOC HD CAP SCREW 2 2795D 2 2795D
285 SOC HD CAP SCREW 12 2795R 12 2795R
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113
Slide Valve Cross Shafts and End Plate
114
ITEM DESCRIPTION MODEL NUMBER

VSR111-221 VSR 151-301 VSS 451 VSS 601

220 END PLATE 1 25530A 1 25530A 1 25530A 1 25530A
221 SHAFT. 2 25843A 2 25843A 2 25843A 2 25843A
222 GEAR. 2 25027A 2 25027A 4 25027A 4 25027A
226 RACK CLAMP. 1 25913A 1 25913A 2 25913A 2 25913A
227 RACK CLAMP. 1 25913B 1 25913B 2 25913B 2 25913B
228 SPACER. 1 25847A 1 25847A 2 25847A 2 25847A
229 SPACER. 1 25234A 1 25234A 0 n/a 0 n/a
234 SPACER 1 25873A 1 25873A 0 n/a 0 n/a
267 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B
268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D
269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA
270 PIPE PLUG. 2 2606E 2 2606E 2 2606E 2 2606E
286 SOCKET HEAD CAP SCREW. 4 2795F 4 2795F 8 2795F 8 2795F
297 SET SCREW 2 2060J 2 2060J 2 2060J 2 2060J
298 SET SCREW 2 2060H 2 2060H 2 2060H 2 2060H
Slide Valve Cross Shafts Prior to 5-1-95
MODEL NUMBER
VSR111-221 VSR 151-301 VSS 451 VSS 601
ITEM DESCRIPTION QTY VPN QTY VPN QTY VPN QTY VPN
V
221 SHAFT. 2 25031A 2 25031A 2 25031A 2 25031A S
222 GEAR. 2 25027A 2 25027A 2 25027A 2 25027A S
223 GEAR. 2 25028A 2 25028A 2 25028A 2 25028A
228 SPACER. 2 25033C 2 25033C 2 25033C 2 25033C &
229 SPACER. 0 n/a 0 n/a 0 n/a 0 n/a
268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D 4 1193D V
269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA 4 2981AA S
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MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201
220 END PLATE 1 25543A 1 25543A 1 25593A 1 25593A
221 SHAFT. 2 25844A 2 25844A 2 25845A 2 25845A
222 GEAR. 4 25027A 4 25027A 4 25027A 4 25027A
226 RACK CLAMP. 4 25913C 4 25913C 4 25913C 4 25913C
228 SPACER. 4 25033C 4 25033C 4 25033C 4 25033C
267 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B
270 PIPE PLUG. 2 2606E 2 2606E 2 2606E 2 2606E
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F 8 2795F
297 SET SCREW 2 2060J 2 2060J 2 2060J 2 2060J
298 SET SCREW 2 2060H 2 2060H 2 2060H 2 2060H
Slide Valve Cross Shafts Prior to 5-1-95

MODEL NUMBER
220 END PLATE 1 25543A 1 25543A 1 25543A 1 25543A
221 SHAFT. 2 25068A 2 25068A 2 25139A 2 25139A
222 GEAR. 2 25027A 2 25027A 2 25027A 2 25027A
223 GEAR. 2 25028A 2 25028A 2 25028A 2 25028A
228 SPACER. 2 25033B 2 25033B 2 25033B 2 25033B
229 SPACER. 2 25033C 2 25033C 2 25033C 2 25033C
NOTE: Three piece rack spacers and clamp are obsolete, use VPN 25913C instead.
116
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS1801
QTY VPN QTY VPN
220 END PLATE 1 25661A 1 25661A
221 SHAFT. 2 25793A 2 25793A
222 GEAR. 4 25027A 4 25027A
226 RACK CLAMP. 4 25913C 4 25913C
228 SPACER. 4 25033C 4 25033C
267 DOWEL PIN. 2 2868B 2 2868B
268 EXPANSION PIN. 4 1193D 4 1193D
269 EXPANSION PIN. 4 2981AA 4 2981AA
270 PIPE PLUG. 2 2606A 2 2606A
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F
297 SET SCREW 2 2060J 2 2060J
298 SET SCREW 2 2060H 2 2060H
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117
118
Volume Slide
Capacity Slide
Carriage Assembly
Slide Valve Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS601

300 CARRIAGE ASSEMBLY. 1 A25179B 1 A25179B 2 A25179B 2 A25179B
304 CAPACITY PISTON 340, 341, 350 & 355. 1 A25183B 1 A25183B 2 A25183B 2 A25183B
305 VOLUME PISTON 340, 342, 350 & 355. 1 A25184B 1 A25184B 2 A25184B 2 A25184B
307 GASKET SET 345B. 0 n/a 0 n/a 2 A25200B 2 A25200B
316 RACK. 1 25024A 1 25024A 2 25024A 2 25024A
323 RACK. 1 25023A 1 25023A 2 25023A 2 25023A
340 PISTON. 2 25017A 2 25017A 4 25017A 4 25017A
341 CAPACITY PISTON SHAFT. 1 25019A 1 25019A 2 25019A 2 25019A
342 VOLUME PISTON SHAFT. 1 25018A 1 25018A 2 25018A 2 25018A
343A COVER, SEPARATE VOL. & CAP. 0 n/a 0 n/a 4 25022A 4 25022A
343B COVER, ONE PIECE CAST. 0 n/a 0 2 25399A 2 25399A
345A GASKET, SEPARATE VOL. & n/a
CAP COVERS. 0 n/a 0 n/a 4 25021A 4 25021A
345B GASKET, ONE PIECE CAST COVER. 0 n/a 0 n/a 2 25900A 2 25900A
350 PISTON RING SET. 2 2953AA 2 2953AA 4 2953AA 4 2953AA
355 EXPANSION PIN. 2 1193PP 2 1193PP 4 1193PP 4 1193PP
359 PIPE PLUG. 3 2606D 3 2606D 6 2606D 6 2606D
360 LOCK WASHER (PAIR). 2 3004C 2 3004C 4 3004C 4 3004C
361 WASHER. 2 13265B 2 13265B 4 13265B 4 13265B
363 NUT. 4 2797A 4 2797A 8 2797A 8 2797A
366A HEX HEAD CAP SCREW, SEPARATE
VOL. & CAP COVERS. 0 n/a 0 n/a 24 2796N 24 2796N
366B HEX HEAD CAP SCREW, ONE PIECE
CAST COVER. 0 n/a 0 n/a 24 2796B 24 2796B
372 SOCKET HEAD CAP SCREW. 0 n/a 0 n/a 2 2795M 2 2795M
373 SOCKET HEAD CAP SCREW. 3 2795V 3 2795V 4 2795N 4 2795N V
374 LOCK WASHER (PAIR). 3 3004C 3 3004C 3 3004C 3 3004C S
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119
MODEL NUMBER
300 CARRIAGE ASSEMBLY. 2 A25179C 2 A25179C 2 A25179D 2 A25179D
304 CAPACITY PISTON 340, 341, 350 & 355. 2 A25183C 2 A25183C 2 A25183D 2 A25183D
305 VOLUME PISTON 340, 342, 350 & 355. 2 A25184C 2 A25184C 2 A25184D 2 A25184D
307 GASKET SET 345B & 378**. 2 A25200C 2 A25200C 2 A25200D 2 A25200D
316 RACK. 2 25080A 2 25080A 2 25080C 2 25080C
323 RACK. 2 25080B 2 25080B 2 25080D 2 25080D
340 PISTON. 4 25076A 4 25076A 4 25138A 4 25138A
341 CAPACITY PISTON SHAFT. 2 25078A 2 25078A 2 25078E 2 25078E
342 VOLUME PISTON SHAFT. 2 25078B 2 25078B 2 25078F 2 25078F
343A COVER, SEPARATE VOL. & CAP. 2 25123B 2 25123B 4 25123C 4 25123C
343B COVER, ONE PIECE CAST. 2 25279A 2 25279A 2 25401A 2 25401A
344 COVER, SEPARATE VOL. & CAP. 2 25123A 2 25123A n/a n/a n/a n/a
345A GASKET, SEPARATE VOL. &
CAP COVERS. 2 25124B 2 25124B 4 25124C 4 25124C
345B GASKET ONE PIECE CAST COVER. 2 25902A 2 25902A 2 25901A 2 25901A
346 GASKET, SEPARATE VOL. & CAP
COVERS. 2 25124A 2 25124A n/a n/a n/a n/a
347 PISTON SLEEVE. 2 25079A 2 25079A n/a n/a n/a n/a
350 PISTON RING SET. 4 2953AB 4 2953AB 4 2953AC 4 2953AC
355 EXPANSION PIN. 4 1193PP 4 1193PP 4 1193PP 4 1193PP
359 PIPE PLUG. 6 2606D 6 2606D 6 2606E 6 2606E
361 WASHER. 4 13265B 4 13265B 4 13265B 4 13265B
363 NUT. 8 2797A 8 2797A 8 2797A 8 2797A
366A HEX HEAD CAP SCREW. 12 2796B 12 2796B 24 2796B 24 2796B
366B HEX HEAD CAP SCREW. 12 2796P 12 2796P 24 2796P 24 2796P
367 HEX HEAD CAP SCREW. 12 2796BN 12 2796BN n/a n/a n/a n/a
373 SOCKET HEAD CAP SCREW. 6 2795N 6 2795N 6 2795P 6 2795P
374 LOCK WASHER (PAIR). 6 3004C 6 3004C 6 3004D 6 3004D
378 0-RING. 2 2176Y 2 2176Y n/a n/a n/a n/a
380 RETAINER RING. 2 2866C 2 2866C n/a n/a n/a n/a
120
MODEL NUMBER
ITEM DESCRIPTION VSS 1501 VSS 1801
QTY VPN QTY VPN
300 CARRIAGE ASSEMBLY. 2 A25179E 2 A25179E
304 CAPACITY PISTON 340, 341, 350 & 355. 2 A25183E 2 A25183E
305 VOLUME PISTON 340, 342, 350 & 355. 2 A25184E 2 A25184E
307 GASKET SET 345 & 378. 2 A25200E 2 A25200E
316 RACK. 2 25779A 2 25779A
323 RACK. 2 25780A 2 25780A
325 SHAFT. 2 25778A 2 25778A
340 PISTON. 4 25782A 4 25782A
341 CAPACITY PISTON SHAFT. 2 25784A 2 25784A
342 VOLUME PISTON SHAFT. 2 25783A 2 25783A
343B COVER. 2 25690A 2 25690A
345B GASKET. 2 25384A 2 25384A
347 PISTON SLEEVE. 4 25786A 4 25786A
350 PISTON RING SET. 4 2953AD 4 2953AD
355 EXPANSION PIN. 4 1193PP 4 1193PP
359 PIPE PLUG. 6 2606E 6 2606E
360 LOCK WASHER (PAIR). 4 3004C 4 3004C
361 WASHER. 4 13265B 4 13265B
363 NUT. 8 2797A 8 2797A
366B HEX HEAD CAP SCREW. 28 2796BL 28 2796BL
373 SOCKET HEAD CAP SCREW. 6 2795AG 6 2795AG
374 LOCK WASHER (PAIR). 6 3004D 6 3004D
378 0-RING. 4 2176AG 4 2176AG
380 RETAINER RING. 4 2755AG 4 2755AG
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121
Capacity Control Actuating Motor and
Command Shaft
Note: Steel Bushing until 10/25/04

then modified housing
New housing design

starting 10/25/04 for all
command shaft assemblies.
Optical Actuator
See note
above
122
Command Shaft
MODEL NUMBER
GEAR MOTOR REPLACEMENT

(410, 440, 455, 475). 1 KT720A 1 KT720A 1 KT720A 1 KT720A
(DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B 1 KT720B 1 KT720B
RETROFIT GEAR MOTOR ASSEMBLY
FOR UNITS BUILT BEFORE 5-1-95. * 1 A25819B 1 A25819B 1 A25819B 1 A25819B
FOR UNITS BUILT BEFORE 5-1-95
(DIV. 2). * 1 A25860B 1 A25860B 1 A25860B 1 A25860B
410 GEAR MOTOR. 1 25380A 1 25380A 1 25380A 1 25380A
410A GEAR MOTOR (DIV. 2). 1 25868A 1 25868A 1 25868A 1 25868A
411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A
412 BEARING HOUSING. 1 25364A 1 25364A 1 25364A 1 25364A
413 COMMAND SHAFT. 1 25382A 1 25382A 1 25375A 1 25375A
413A COMMAND SHAFT, RETROFIT. 1 25803A 1 25803A 1 25803A 1 25803A
414 COUPLING, RETROFIT 1 25032A 1 25032A 1 25032A 1 25032A
415 MOUNTING PLATE. 1 25805A 1 25805A 1 25805A 1 25805A
416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A
416A COVER STEEL (DIV. 2). 1 25535A 1 25535A 1 25535A 1 25535A
419 POTENTIOMETER. 1 2935D 1 2935D 1 2935D 1 2935D
420 MOTOR SHAFT GEAR. 1 25029A 1 25029A 1 25029A 1 25029A
421 COMMAND SHAFT GEAR. 1 25806A 1 25806A 1 25806A 1 25806A
422 GEAR. 1 25832A 1 25832A 1 25832A 1 25832A
424 GEAR. 1 2107B 1 2107B 1 2107B 1 2107B
426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A
432 CLAMP FOR ITEM 424. 1 2013A 1 2013A 1 2013A 1 2013A
433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A
436** SLEEVE BEARING. 1 25853B 1 25853B 1 25853B 1 25853B 1V
440 PUSH-ON RETAINER. 1 2866F 1 2866F 1 2866F 1 2866F
S
445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W
445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W S
446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X
450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D &
451 RETAINING RING. 1 2867C 1 2867C 1 2867C 1 2867C
455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN 4 2795AN 4 2795AN V
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ S
457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M 4 2795M 4 2795M R
465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE 4 2796BE 4 2796BE
466 HEX HEAD CAP SCREW. 6 2583C 6 2583C 6 2583C 6 2583C
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F Parts
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT List
475 LOCK WASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A
476 LOCK WASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B
480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA
485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A
490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D
491 ROLL PIN. 1 2981AA 1 2981AA 1 2981AA 1 2981AA
492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J
497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to
new style gear drive potentiometer. Less items 416, 429 & 466.
** Item 412 was modified to remove sleeve bearing.

123
Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS 901 VSS 1051 VSS 1201
(410, 440, 455, 475). 1 KT720A 1 KT720A 1 KT720A 1 KT720A
(DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B 1 KT720B 1 KT720B
FOR UNITS BUILT BEFORE 5-1-95. * 1 A25819C 1 A25819C 1 A25819D 1 A25819D
FOR UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25860C 1 A25860C 1 A25860D 1 A25860D
410 GEAR MOTOR. 1 25380A 1 25380A 1 25380A 1 25380A
411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A
416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A
422 GEAR. 1 25832A 1 25832A 1 25832A 1 25832A
424 GEAR. 1 2107B 1 2107B 1 2107B 1 2107B
426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A
433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A
436** SLEEVE BEARING. 1 25853B 1 25853B 1 25853B 1 25853B
445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W
445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W
446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X
450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D
455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN 4 2795AN 4 2795AN
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ
457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M 4 2795M 4 2795M
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT
475 LOCK WASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A
476 LOCK WASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B
480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA
485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A
490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D
492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J
497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to
new style gear drive potentiometer. Less items 416, 429 & 466.
** Item 412 was modified to remove the sleeve bearing.
124
Command Shaft
MODEL NUMBER
QTY VPN QTY VPN
(410, 440, 455, 475). 1 KT720A 1 KT720A
(DIV. 2) (410, 440, 455, 475). 1 KT720B 1 KT720B
410 GEAR MOTOR. 1 25380A 1 25380A
410A GEAR MOTOR (DIV. 2). 1 25868A 1 25868A
411 MOTOR MOUNT. 1 25374A 1 25374A
412 BEARING HOUSING. 1 25364A 1 25364A
413 COMMAND SHAFT. 1 25369A 1 25369A
415 MOUNTING PLATE. 1 25805A 1 25805A
416 COVER PLASTIC. 1 25697A 1 25697A
416A COVER STEEL (DIV. 2). 1 25535A 1 25535A
419 POTENTIOMETER. 1 2935D 1 2935D
420 MOTOR SHAFT GEAR. 1 25029A 1 25029A
421 COMMAND SHAFT GEAR. 1 25806A 1 25806A
422 GEAR. 1 25832A 1 25832A
424 GEAR. 1 2107B 1 2107B
426 KEY. 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A
432 CLAMP FOR ITEM 424. 1 2013A 1 2013A
433 BUSHING (DIV. 2). 1 25853A 1 25853A
435 BALL BEARING. 1 2908A 1 2908A
436** SLEEVE BEARING. 1 25853A 1 25853B
440 PUSH-ON RETAINER. 1 2866F 1 2866F
445 O-RING. 1 2176W 1 2176W
445A O-RING (DIV. 2). 1 2176W 1 2176W
446 O-RING. 1 2176X 1 2176X
450 RETAINING RING. 1 2866D 1 2866D
451 RETAINING RING. 1 2867C 1 2867C V
455 SOCKET HEAD CAP SCREW. 4 2795AN 4 2795AN S
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ
S
457 SOCKET HEAD CAP SCREW. 4 2795M 4 2795M
465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE
466 HEX HEAD CAP SCREW. 6 2583C 6 2583C &
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT V
475 LOCK WASHER (PAIR). 4 3004A 4 3004A S
476 LOCK WASHER (PAIR). 3 3004B 3 3004B R
480 WASHER. 1 2906AA 1 2906AA
Parts
485 JAM NUT. 1 13283A 1 13283A
492 DOWEL PIN. 1 2868J 1 2868J List
497 PIPE PLUG. 1 2606E 1 2606E
** Note: Item 412 was modified to remove the sleeve bearing.
125
Slide Valve Actuating Motor
and Command shaft
Before 5-1-95
418
408 452
425
408
451
463
459
407
450
403
458
405
416
404 420 OR 421
419 443
463 454
458
443
417
455
419
415
429
453 435
439
438
440
411
446
447
410 2 O-RINGS ONLY
IF SPECIFIED.
430
431
412
126
Slide Valve Actuating Motor
and Command shaft
Before 5-1-95
MODEL NUMBER
ITEM DESCRIPTION
VSR 111-301 VSS 451-601 VSS 751-901 VSS 1201
403 GEAR MOTOR. n/a n/a n/a n/a n/a n/a n/a n/a
404 MOUNTING BLOCK. n/a n/a n/a n/a n/a n/a n/a n/a
405 MOTOR BRACKET. n/a n/a n/a n/a n/a n/a n/a n/a
406 CLIP. n/a n/a n/a n/a n/a n/a n/a n/a
407 COLLAR. n/a n/a n/a n/a n/a n/a n/a n/a
408 LOCKING TAB. n/a n/a n/a n/a n/a n/a n/a n/a
410 BEARING HOUSING. n/a n/a n/a n/a n/a n/a n/a n/a
411 SHAFT. n/a n/a n/a n/a n/a n/a n/a n/a
412 COUPLING. 2 25032A 2 25032A 2 25032A 2 25032A
415 PLATE. n/a n/a n/a n/a n/a n/a n/a n/a
416 GEAR. 2 25029A 2 25029A 2 25029A 2 25029A
417 GEAR. n/a n/a n/a n/a n/a n/a n/a n/a
418 COVER. 2 25697A 2 25697A 2 25697A 2 25697A
419 KEY. 4 25039BC 4 25039BC 4 25039BC 4 25039BC
420 POSITION INDICATOR, CAPACITY. n/a n/a n/a n/a n/a n/a n/a n/a
421 POSITION INDICATOR, VOLUME. n/a n/a n/a n/a n/a n/a n/a n/a
425 POTENTIOMETER. n/a n/a n/a n/a n/a n/a n/a n/a
429 GASKET. 2 25757A 2 25757A 2 25757A 2 25757A
430 O-RING. 2 2176W 2 2176W 2 2176W 2 2176W
431 O-RING. 2 2176X 2 2176X 2 2176X 2 2176X
438 RETAINER RING. 2 2866D 2 2866D 2 2866D 2 2866D
439 RETAINER RING. 2 2867C 2 2867C 2 2867C 2 2867C
440 WASHER. 2 2906AA 2 2906AA 2 2906AA 2 2906AA
443 PUSH ON RETAINER. 4 2866F 4 2866F 4 2866F 4 2866F
V
S
450 NUT. 4 1393E 4 1393E 4 1393E 4 1393E
S
451 SOCKET HEAD CAP SCREW. 8 2795Z 8 2795Z 8 2795Z 8 2795Z
&
454 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB 4 2795AB 4 2795AB
V
455 SOCKET HEAD CAP SCREW. 8 2795L 8 2795L 8 2795L 8 2795L
S
R
459 SOCKET HEAD SET SCREW. 2 2060E 2 2060E 2 2060E 2 2060E
463 WASHER. 8 2880E 8 2880E 8 2880E 8 2880E
Parts
List
n/a No longer available, contact Home Office.
127
Volume Ratio Control Actuating Motor
and Command Shaft
Note: Steel Bushing until 10/25/04

then modified housing
New housing design

starting 10/25/04 for all
command shaft assemblies.
Optical Actuator
See Note
above
See page 122 for assembly
128
and Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS 601

(410, 440, 455, 475). 1 KT720C 1 KT720C 1 KT720C 1 KT720C
(DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D 1 KT720D 1 KT720D
FOR UNITS BUILT BEFORE 5-1-95. * 1 A25820B 1 A25820B 1 A25820B 1 A25820B
FOR UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25861B 1 A25861B 1 A25861B 1 A25861B
410 GEAR MOTOR. 1 25379A 1 25379A 1 25379A 1 25379A
411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A
416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A
423 GEAR. 1 25831A 1 25831A 1 25831A 1 25831A
425 GEAR. 1 2107A 1 2107A 1 2107A 1 2107A
426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A
433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A
V
445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W S
445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W S
446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X
450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D &
455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN 4 2975AN 4 2975AN V
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ S
R
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F 1 2060F 1 2060F Parts
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT List
475 LOCKWASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A
476 LOCKWASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B
477 LOCKWASHER (PAIR). 8 3004C 8 3004C 8 3004C 8 3004C
480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA
485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A
490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D
492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J
497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer to new
style gear drive potentiometer. Less items 416, 429 & 466.

129
and Command Shaft
MODEL NUMBER
ITEM DESCRIPTION VSS 751 VSS 901 VSS 1051 VSS 1201
(410, 440, 455, 475). 1 KT720C 1 KT720C 1 KT720C 1 KT720C
(DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D 1 KT720D 1 KT720D
RETROFIT GEAR MOTOR ASSEMBLY FOR
UNITS BUILT BEFORE 5-1-95. * 1 A25820C 1 A25820C 1 A25820D 1 A25820D
RETROFIT GEAR MOTOR ASSEMBLY FOR
UNITS BUILT BEFORE 5-1-95 (DIV. 2). * 1 A25861C 1 A25861C 1 A25861D 1 A25861D
410 GEAR MOTOR. 1 25379A 1 25379A 1 25379A 1 25379A
411 MOTOR MOUNT. 1 25374A 1 25374A 1 25374A 1 25374A
416 COVER. 1 25697A 1 25697A 1 25697A 1 25697A
423 GEAR. 1 25831A 1 25831A 1 25831A 1 25831A
425 GEAR. 1 2107A 1 2107A 1 2107A 1 2107A
426 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A 1 25830A 1 25830A
433 BUSHING (DIV. 2). 1 25853A 1 25853A 1 25853A 1 25853A
445 O-RING. 1 2176W 1 2176W 1 2176W 1 2176W
445A O-RING (DIV. 2). 1 2176W 1 2176W 1 2176W 1 2176W
446 O-RING. 1 2176X 1 2176X 1 2176X 1 2176X
450 RETAINING RING. 1 2866D 1 2866D 1 2866D 1 2866D
455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN 4 2975AN 4 2975AN
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ 2 2795AJ 2 2795AJ
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT 1 13255TT 1 13255TT
475 LOCKWASHER (PAIR). 4 3004A 4 3004A 4 3004A 4 3004A
476 LOCKWASHER (PAIR). 3 3004B 3 3004B 3 3004B 3 3004B
477 LOCKWASHER (PAIR). 8 3004C 8 3004C 8 3004C 8 3004C
480 WASHER. 1 2906AA 1 2906AA 1 2906AA 1 2906AA
485 JAM NUT. 1 13283A 1 13283A 1 13283A 1 13283A
490 ROLL PIN. 1 1193D 1 1193D 1 1193D 1 1193D
492 DOWEL PIN. 1 2868J 1 2868J 1 2868J 1 2868J
497 PIPE PLUG. 1 2606E 1 2606E 1 2606E 1 2606E
Notes *. Complete retrofit control actuating motor and command shaft assembly, used to convert pre 5-1-95 unit with direct drive potentiometer
to new style gear drive potentiometer. Less items 416, 429 & 466.
130
and Command Shaft
MODEL NUMBER
QTY VPN QTY VPN
(410, 440, 455, 475). 1 KT720C 1 KT720C
(DIV. 2) (410, 440, 455, 475). 1 KT720D 1 KT720D
410 GEAR MOTOR. 1 25379A 1 25379A
410A GEAR MOTOR (DIV. 2). 1 25867A 1 25867A
411 MOTOR MOUNT. 1 25374A 1 25374A
413 COMMAND SHAFT. 1 25369A 1 25369A
415 MOUNTING PLATE. 1 25805A 1 25805A
416 COVER. 1 25697A 1 25697A
416A COVER STEEL (DIV. 2). 1 25535A 1 25535A
419 POTENTIOMETER. 1 2935D 1 2935D
420 MOTOR SHAFT GEAR. 1 25029A 1 25029A
421 COMMAND SHAFT GEAR. 1 25806A 1 25806A
423 GEAR. 1 25831A 1 25831A
425 GEAR. 1 2107A 1 2107A
426 KEY. 1 25039BC 1 25039BC
427 KEY. 1 25039BC 1 25039BC
428 BRACKET. 1 25804A 1 25804A
429 GASKET. 1 25757A 1 25757A
430 BUSHING. 1 25809A 1 25809A
431 SPACER. 1 25830A 1 25830A
432 CLAMP FOR ITEM 424. 1 2013A 1 2013A
433 BUSHING (DIV. 2). 1 25853A 1 25853A
435 BALL BEARING. 1 2908A 1 2908A
436** SLEEVE BEARING. 1 25853B 1 25853B
440 PUSH-ON RETAINER. 1 2866F 1 2866F
445 O-RING. 1 2176W 1 2176W
445A O-RING (DIV. 2). 1 2176W 1 2176W
446 O-RING. 1 2176X 1 2176X
451 RETAINING RING. 1 2867C 1 2867C
455 SOCKET HEAD CAP SCREW. 4 2975AN 4 2975AN
456 SOCKET HEAD CAP SCREW. 2 2795AJ 2 2795AJ V
S
465 HEX HEAD CAP SCREW. 4 2796BE 4 2796BE
466 HEX HEAD CAP SCREW. 6 2583C 6 2583C S
470 SOCKET HEAD SET SCREW. 1 2060F 1 2060F
471 SOCKET HEAD SET SCREW. 1 13255TT 1 13255TT &
475 LOCKWASHER (PAIR). 4 3004A 4 3004A
476 LOCKWASHER (PAIR). 3 3004B 3 3004B V
477 LOCKWASHER (PAIR). 8 3004C 8 3004C S
480 WASHER. 1 2906AA 1 2906AA R
485 JAM NUT. 1 13283A 1 13283A
492 DOWEL PIN. 1 2868J 1 2868J
497 PIPE PLUG. 1 2606E 1 2606E Parts
List
131
Miscellaneous Frame Components
Tubing and Fittings
Gate Rotor Bearing Supply Lines

VSR 111&VSR 301 VSS 451-VSS 1801
555
556 OR 555
567
568 555
558
558
555
Seal Chamber Oil Line

VSS 451&VSS1201 VSS 1501&VSS 1801
567
559 560 561 559 560

Slide Valve Piston Equalizing Lines
VSS 451&VSS 601 VSS 751&VSS 901 VSS 1051&VSS1201
555 555
564
555 566
565 563
555
555
132
Tubing and Fittings
MODEL NUMBER
ITEM DESCRIPTION VSR 111-VSR 221 VSR 151-VSR 301 VSS 451 VSS 601
555 ELBOW . 2 13375D 2 13375D 5 13375D 5 13375D
556 STRAIGHT. n/a n/a n/a n/a 1 13229D 1 13229D
557 TEE, RUNNING. n/a n/a n/a n/a 1 1509A 1 1509A
558 HEX BUSHING. 1 13231AA 1 13231AA 1 13231AA 1 13231AA
560 ELBOW. n/a n/a n/a n/a 1 13375Z 1 13375Z
561 ELBOW. n/a n/a n/a n/a 1 13375F 1 13375F
562 PLUG. n/a n/a n/a n/a 1 2606E 1 2606E
MODEL NUMBER
555 ELBOW. 5 13375D 5 13375D 3 13375D 3 13375D
556 STRAIGHT. 1 13229D 1 13229D 2 13229D 2 13229D
557 TEE, RUNNING. 1 1509A 1 1509A 1 1509A 1 1509A
558 HEX BUSHING. 1 13231AA 1 13231AA 1 1101H 1 1101H
559 HEX BUSHING. 0 n/a 0 n/a 1 1101K 1 1101K
560 ELBOW. 1 13375Z 1 13375Z 1 13375Z 1 13375Z
561 ELBOW. 1 13375F 1 13375F 1 13375F 1 13375F
562 PLUG. 1 2606E 1 2606E 1 2606A 1 2606A
563 TEE. n/a n/a n/a n/a 2 13376D 2 13376D
564 TEE. n/a n/a n/a n/a 1 13239C 1 13239C V
565 TEE. 2 1884A 2 1884A n/a n/a n/a n/a S
566 NIPPLE. 2 13181D 2 13181D n/a n/a n/a n/a S
&
V
S
MODEL NUMBER R
QTY VPN QTY VPN Parts
555 ELBOW. 2 13375D 2 13375D List
557 TEE, RUNNING. 1 13376D 1 13376D
558 HEX BUSHING. 1 13231AA 1 13231AA
559 HEX BUSHING. 1 1101H 1 1101H
560 ELBOW. 1 13375Z 1 13375Z
567 CONNECTOR. 1 13299C 1 13299C
568 REDUCING BUSHING. 1 1101M 1 1101M
133
VSR Mini Screw Compressor
VSS Screw Compressor
134
MODEL NUMBER

GASKET AND O-RING KIT; n/a n/a n/a n/a 1 KT710A 1 KT710A
504 FLANGE SET 513, 514 & 547A. 1 A25190A 1 A25190A 1 A25190A 1 A25190A
ECON-O-MIZER PORT. n/a n/a n/a n/a 2 A25190B 2 A25190B

506 ECON-O-MIZER PLUG. 1 A25243BD 1 A25243BC
511 DISCHARGE MANIFOLD. 1 25634A 1 25634A 1 25502A 1 25502A

512 MANIFOLD GASKET. 1 25648A 1 25648A 1 25503A 1 25503A
513 FLANGE OIL. 1 25058A 1 25058A 1 25058A 1 25058A
513A FLANGE ECON-O-MIZER. n/a n/a n/a n/a 2 25058A 2 25058A
514 FLANGE GASKET OIL. 1 11323D 1 11323D 1 11323D 1 11323D
514A FLANGE GASKET ECON-O-MIZER. n/a n/a n/a n/a 2 11323D 2 11323D
515 KEY. 1 25039AA 1 25039AA 1 13396R 1 13396R
518 SUCTION FLANGE GASKET. 1 11323L 1 11323L 1 25199C 1 25199C
519 DISCHARGE FLANGE GASKET. 1 11323J 1 11323J 1 25199B 1 25199B
522 LOCKING WASHER. n/a n/a n/a n/a 1 25004A 1 25004A
523 LOCKING TAB. n/a n/a n/a n/a 1 25005A 1 25005A
524 COVER. 1 25346A 1 25346A n/a n/a n/a n/a
525 GASKET. 1 11323L 1 11323L n/a n/a n/a n/a
527 INLET SCREEN. 1 2881E 1 2881E n/a n/a n/a n/a
528 ECON-O-MIZER PLUG. 1 25240B 1 25240A n/a n/a n/a n/a
530 O-RING 2 2176AB 2 2176AB 2 2176AB 2 2176AB
532 O-RING. 2 2176BA 2 2176BA n/a n/a n/a n/a
535 PIPE PLUG 1/ 4 " MPT. 1 2606C 1 2606C n/a n/a n/a n/a
535 PIPE PLUG 3/ 8 " MPT. 1 2606D 1 2606D 2 2606D 2 2606D
536 PIPE PLUG 1/ 2 " MPT. 6 2606E 6 2606E 11 2606E 11 2606E
537 PIPE PLUG 1-1/4" MPT. n/a n/a n/a n/a 2 13163G 2 13163G
539 PIPE PLUG. 1 13264F 1 13264F n/a n/a n/a n/a
540 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B
541 SET SCREW. n/a n/a n/a n/a 1 13298G 1 13298G
545 HEX HEAD CAP SCREW FOR OIL n/a n/a n/a n/a n/a n/a n/a n/a
SUPPLY FLANGE. 2 2796C 2 2796C 2 2796C 2 2796C
545 HEX HEAD CAP SCREW FOR n/a n/a n/a n/a n/a n/a n/a n/a
ECON-O-MIZER FLANGE. n/a n/a n/a n/a 4 2796C 4 2796C
V
547 HEX HEAD CAP SCREW. 15 2796F 15 2796F 8 2796C 8 2796C
548 HEX HEAD CAP SCREW. n/a n/a n/a n/a 4 2796GQ 4 2796GQ
S
549 HEX HEAD CAP SCREW. 2 2796GZ 2 2796GZ 2 2796GZ 2 2796GZ S
550 HEX HEAD CAP SCREW. 2 2796GAF 2 2796GAF 2 2796GAF 2 2796GAF
551 HEX HEAD CAP SCREW. 2 2796GP 2 2796GP 2 2796GP 2 2796GP &
552 HEX HEAD CAP SCREW. 8 2796C 8 2796C n/a n/a n/a n/a
552 HEX HEAD CAP SCREW. 2 2796HJ 2 2796HJ n/a n/a n/a n/a V
553 HEX HEAD CAP SCREW. 4 2796HM 4 2796HM n/a n/a n/a n/a S
554 HEX HEAD CAP SCREW. n/a n/a n/a n/a 1 2796U 1 2796U
R
569 PIPE PLUG 1/4" MPT. n/a n/a n/a n/a 2 2606C 2 2606C
650 O-RING. 2 2176AZ 2 2176AZ n/a n/a n/a n/a
651 O-RING. 1 2176AB 1 2176AB n/a n/a n/a n/a Parts
List
135
MODEL NUMBER
GASKET AND O-RING KIT; 1 KT710B 1 KT710B 1 KT710C 1 KT710C
504 FLANGE SET 513, 514 & 547. 1 A25190A 1 A25190A 1 A25190B 1 A25190B
504 FLANGE SET 513A, 514A & 547
ECON-O-MIZER PORT. 2 A25190B 2 A25190B 2 A25190B 2 A25190B
511 DISCHARGE MANIFOLD. 1 25540A 1 25540A 1 25597A 1 25597A
512 MANIFOLD GASKET. 1 25541A 1 25541A 1 25324A 1 25324A
513 FLANGE OIL. 1 25058A 1 25058A 1 25058B 1 25058B
513A FLANGE ECON-O-MIZER. 2 25058A 2 25058A 2 25058B 2 25058B
514 FLANGE GASKET OIL. 1 11323D 1 11323D 1 11323E 1 11323E
514A FLANGE GASKET ECON-O-MIZER. 2 11323D 2 11323D 2 11323E 2 11323E
515 KEY. 1 13396S 1 13396S 1 13396S 1 13396S
518 SUCTION FLANGE GASKET. 1 25199C 1 25199C 1 25199D 1 25199D
519 DISCHARGE FLANGE GASKET. 1 25199B 1 25199B 1 25199C 1 25199C
522 LOCKING WASHER. 1 25004A 1 25004A 1 25004A 1 25004A
523 LOCKING TAB. 1 25005A 1 25005A 1 25005A 1 25005A
526 ORIFICE PLATE. 1 25223CB 1 25223CA 1 25223DB 1 25223DB
529 WAVE SPRING. 1 2912E 1 2912E 1 2912E 1 2912E
530 O-RING 2 2176J 2 2176J 2 2176J 2 2176J
535 PIPE PLUG 3/8" MPT. 2 2606D 2 2606D 2 2606D 2 2606D
536 PIPE PLUG 1/2" MPT. 8 2606E 8 2606E 4 2606E 4 2606E
537 PIPE PLUG 1-1/4" MPT. 2 13163G 2 13163G 2 13163G 2 13163G
538 PIPE PLUG 3/4" MPT. 6 2606A 6 2606A
540 DOWEL PIN. 2 2868B 2 2868B 2 2868B 2 2868B
541 SET SCREW. 1 13298G 1 13298G 1 13298G 1 13298G
545 HEX HEAD CAP SCREW FOR OIL
SUPPLY FLANGE. 2 2796C 2 2796C 2 2796C 2 2796C
545 HEX HEAD CAP SCREW FOR
ECON-O-MIZER FLANGE. 4 2796C 4 2796C 4 2796C 4 2796C
547 HEX HEAD CAP SCREW. 21 2796GP 21 2796GP 24 2796GP 24 2796GP
548 HEX HEAD CAP SCREW. 2 2796GAB 2 2796GAB 2 2796GAB 2 2796GAB
549 HEX HEAD CAP SCREW. 2 2796GAE 2 2796GAE 2 2796GAE 2 2796GAE
554 HEX HEAD CAP SCREW. 1 2796U 1 2796U 1 2796U 1 2796U
569 PIPE PLUG 1/4" MPT. 2 2606C 2 2606C 2 2606C 2 2606C
NOTE: ** For VSS 1051 Econ-o-Mizer model.
136
MODEL NUMBER
QTY VPN QTY VPN
GASKET AND O-RING KIT; 1 KT710D 1 KT710D
504 FLANGE SET 513, 514 & 547. 1 A25190C 1 A25190C
504 FLANGE SET 513A, 514A & 547
ECON-O-MIZER PORT. 2 A25190D 2 A25190D
511 DISCHARGE MANIFOLD. 1 25663A 1 25663A
512 MANIFOLD GASKET. 1 25676A 1 25676A
513 FLANGE OIL. 1 12477C 1 12477C
513A FLANGE ECON-O-MIZER.
514 FLANGE GASKET OIL. 1 11323F 1 11323F
514A FLANGE GASKET ECON-O-MIZER.
515 KEY. 1 25039AC 1 25039AC
518 SUCTION FLANGE GASKET. 1 25199D 1 25199D
519 DISCHARGE FLANGE GASKET. 1 25199C 1 25199C
522 LOCKING WASHER. 1 25004C 1 25004C
523 LOCKING TAB. 1 25005C 1 25005C
530 O-RING 2 2176J 2 2176J
536 PIPE PLUG 1/2" MPT. 3 2606E 3 2606E
537 PIPE PLUG 1-1/4" MPT. 2 13163G 2 13163G
538 PIPE PLUG 3/4" MPT. 3 2606A 3 2606A
540 DOWEL PIN. 2 2868K 2 2868K
541 SET SCREW. 1 13298G 1 13298G
542 PIPE PLUG 3/4" MPT. 1 13163F 1 13163F
OIL SUPPLY FLANGE. 4 11397E 4 11397E
ECON-O-MIZER FLANGE.
548 HEX HEAD CAP SCREW. 26 2796HR 26 2796HR
549 HEX HEAD CAP SCREW. 2 2796HAB 2 2796HAB
550 HEX HEAD CAP SCREW. 2 2796HAF 2 2796HAF V
554 HEX HEAD CAP SCREW. 1 2796U 1 2796U S
569 PIPE PLUG 1/4" MPT. 2 2606C 2 2606C S
NOTE: * Not pictured &

** For VSS 1801 Serial Numbers 819, 820 & 821 only.
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137
C-Flange Adapter Components
630
620
610 601
641 640
601 610 620 630
640
650
641
651
642
138
C-Flange Adapter Components
MODEL NUMBER
ITEM DESCRIPTION VSR 111 & VSR 221 VSR 151 & VSR 301
QTY VPN QTY VPN
601 C-FLANGE ADAPTER.
610 KEY. 1 25039AA 1 25039AA
620 HEX HEAD CAP SCREW. 8 2796C 8 2796C
630 LOCKWASHER (PAIR). 8 3004H 8 3004H
640 CONNECTOR. 1 13229C 1 13229C
641 TUBE 1/4" O.D. x 6" LONG. 0.5 Ft. S1589AA 0.5 Ft. S1589AA
642 PIPE PLUG. 1 2606C 1 2606C
650 O-RING. 2 2176AZ 2 2176AZ
651 O-RING. 1 2176AB 1 2176AB
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139
Replacement Parts
Tools
140
Replacement Parts
Tools
MODEL NUMBER
ITEM DESCRIPTION VSR 111-221 VSR 151-301 VSS 451 VSS 601
900 GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917). 1 A25205B 1 A25205B 1 A25205B 1 A25205B
901 GATEROTOR STABILIZER SET
(901A, 901B & 901C). 1 A25698A 1 A25698A 1 A25698A 1 A25698A
901A GATEROTOR STABILIZER. 1 A25698B 1 A25698B 1 A25698B 1 A25698B
901B HEX HEAD CAP SCREW. 4 2796A 4 2796A 4 2796A 4 2796A
901C RAIL, SIDE. 2 25698A 2 25698A 2 25698A 2 25698A
910 PULLER BAR. 1 25204A 1 25204A 1 25204A 1 25204A
911 PULLER SHOE. 1 25157A 1 25157A 1 25157A 1 25157A
912 PUSHER SHOE. 1 25157B 1 25157B 1 25157B 1 25157B
913 JACKING SCREW. 1 A25156B 1 A25156B 1 A25156B 1 A25156B
914 GUIDE STUD. 1 25908A 1 25908A 1 25908A 1 25908A
915 GUIDE STUD. 2 25908B 2 25908B 2 25908B 2 25908B
916 STUD. 3 25908C 3 25908C 3 25908C 3 25908C
917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W 2 2795W 2 2795W
918 HEX NUT 3 13228F 3 13228F 3 13228F 3 13228F
MODEL NUMBER V
ITEM DESCRIPTION VSS 751 VSS901 VSS 1051 VSS 1201 S
QTY VPN QTY VPN QTY VPN QTY VPN S
900 GATEROTOR TOOLS (901, 910, 911,
912, 913, 914, 915, 916 & 917). 1 A25205C 1 A25205C 1 A25205C 1 A25205C &
901 GATEROTOR STABILIZER SET
(901A, 901B & 901C). 1 A25698A 1 A25698A 1 A25698A 1 A25698A V
901A GATEROTOR STABILIZER. 1 A25698B 1 A25698B 1 A25698B 1 A25698B S
901B HEX HEAD CAP SCREW. 4 2796A 4 2796A 4 2796A 4 2796A R
901C RAIL, SIDE. 2 25698A 2 25698A 2 25698A 2 25698A
910 PULLER BAR. 1 25204B 1 25204B 1 25204B 1 25204B Parts
911 PULLER SHOE. 1 25157C 1 25157C 1 25157C 1 25157C List
912 PUSHER SHOE. 1 25157D 1 25157D 1 25157D 1 25157D
913 JACKING SCREW. 1 A25156B 1 A25156B 1 A25156B 1 A25156B
914 GUIDE STUD. 1 25908A 1 25908A 1 25908A 1 25908A
915 GUIDE STUD. 2 25908B 2 25908B 2 25908B 2 25908B
916 STUD. 2 25908C 2 25908C 2 25908C 2 25908C
917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W 2 2795W 2 2795W
918 HEX NUT 2 13228F 2 13228F 2 13228F 2 13228F
141
Replacement Parts
Tools
MODEL NUMBER
QTY VPN QTY VPN
900 GATEROTOR TOOLS (901, 910,
911, 912, 913, 914, 915, 916 & 917). 1 A25205E 1 A25205E
901 GATEROTOR STABILIZER SET (
901A, 901B, 901C & 901D). 1 A25699A 1 A25699A
901A GATEROTOR STABILIZER. 1 A25699B 1 A25699B
901B HEX HEAD CAP SCREW. 4 2796A 4 2796A
901C RAIL, SIDE. 2 25698C 2 25698C
901D LOCK WASHER. 4 13165B 4 13165B
910 PULLER BAR. 1 25204C 1 25204C
911 PULLER SHOE. 1 25157E 1 25157E
912 PUSHER SHOE. 1 25157F 1 25157F
913 JACKING SCREW. 1 A25156B 1 A25156B
914 GUIDE STUD. 1 25908A 1 25908A
915 GUIDE STUD. 2 25908B 2 25908B
916 STUD. 2 25908C 2 25908C
917 SOCKET HEAD CAP SCREW. 2 2795W 2 2795W
918 HEX NUT 2 13228F 2 13228F
142
VSM Replacement
Parts Section
VSM Replacement Parts Section .............................................................................. 143

Gaterotor Assembly ....................................................................................................................................................................... 144
Shaft Seal ....................................................................................................................................................................................... 147
Main Rotor, Slide Valve Cross Shafts and End Plate (Models 71-401) ..................................................................................... 148
Main Rotor, Slide Valve Cross Shafts and End Plate (Models 501-701 .................................................................................... 152
Actuating Motor with Optical Sensor and Command Shaft ........................................................................................................ 156
Replacement Parts Accessories ..................................................................................................................................................... 160
Replacement Tools ......................................................................................................................................................................... 162
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143
Gaterotor Assembly
144
Gaterotor Assembly
Part totals indicated are for one gate rotor assembly, machines with two gate rotors will require double the
components listed below.
MODEL NUMBER
ITEM DESCRIPTION VSM-71, 151, 301 VSM-91, 181, 361 VSM-101, 201, 401
QTY VPN QTY VPN QTY VPN
100 SUPPORT ASSEMBLY 110 & 135B. 1 A25222AB 1 A25222AA 1 A25222AC
101 GATE ROTOR & DAMPER ASSEMBLY
111,120. 1 A25160AB 1 A25160AA A25160AC
100, 101, 119 & 130. 1 A25161AB 1 A25161AA A25161AC
105 GATE ROTOR GASKET SET
141 & 143. 1 A25164A 1 A25164A A25164A
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 1 A25165A 1 A25165A A25165A
110 SUPPORT. 1 25723D 1 25723C 1 25723B
111 GATE ROTOR. 1 25718B 1 25718C 1 25718D
112 SMALL BEARING HOUSING. 1 25407B 1 25407B 1 25407B
114 SNAP RING. 1 2867L 1 2867L 1 2867L
115 RETAINER BALL BEARING 1 25935A 1 25935A 1 25935A
116 BALL BEARING SUPPORT. 1 25408B 1 25408B 1 25408B
117 GATE ROTOR COVER. 1 25416B 1 25416B 1 25416B
118 GATE ROTOR COVER GASKET. 1 25259B 1 25259B 1 25259B
119 WASHER WAVE SPRING. 1 3203A 1 3203A 1 3203A
120 DAMPER. 1 25760A 1 25760A 1 25760A
121* SHIM 0.002". ar 25921AA ar 25921AA ar 25921AA
122* SHIM 0.003". ar 25921AB ar 25921AB ar 25921AB
123* SHIM 0.005". ar 25921AC ar 25921AC ar 25921AC
124* SHIM 0.010". ar 25921AD ar 25921AD ar 25921AD
125 ROLLER BEARING. 1 2864F 1 2864F 1 2864F
126 BALL BEARING. 2 2865L 2 2865L 2 2865L
130 RETAINING RING. 1 2866H 1 2866H 1 2866H
131 RETAINING RING. 1 2867S 1 2867S 1 2867S
132 RETAINING RING. 1 2866J 1 2866J 1 2866J
135 DOWEL PIN 1 25910A 1 25910A 1 25910A
141 O-RING ROLLER BRG HSG. 1 2176L 1 2176L 1 2176L
143 O-RING BALL BRG SUPPORT. 1 2176F 1 2176F 1 2176F
151 SOC HEAD CAP SCREW. 1 2795AP 1 2795AP 1 2795AP
152 HEX HEAD CAP SCREW. 11 2796CG 11 2796CG 11 2796CG
155 SHIM ar 25977D ar 25977D ar 25977D
156 SHIM ar 25977C ar 25977C ar 25977C
170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C
176 PIPE PLUG. 1 2606D 1 2606D 1 2606D
ar = As required
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Gaterotor Assembly
Part totals indicated are for one gate rotor assembly, dual gate machines will require double the components.
MODEL NUMBER
ITEM DESCRIPTION VSM-501 VSM-601 VSM-701
100 SUPPORT ASSEMBLY 110 & 135B. 1 A26011BB 1 A26011BA 1 A26011BA
101 GATE ROTOR & DAMPER ASSEMBLY
111,120. 1 A26002BB 1 A26002BA 1 A26002BC
100, 101, 119 & 130. 1 A26003BB 1 A26003BA 1 A26003BC
105 GATE ROTOR GASKET SET 118,
141 & 143. 1 A26005B 1 A26005B 1 A26005B
106 SHIM PACK SET (2) 121, (2) 122,
(1) 123, (1) 124. 1 A26035B 1 A26035B 1 A26035B
110 SUPPORT. 1 26030BB 1 26030BA 1 26030BA
111 GATE ROTOR. 1 26032A 1 26031A 1 26033A
112 SMALL BEARING HOUSING. 1 25518B 1 25518B 1 25518B
114 SNAP RING. 1 2867U 1 2867U 1 2867U
115 RETAINER BALL BEARING 1 25935B 1 25935B 1 25935B
116 BALL BEARING SUPPORT. 1 26019B 1 26019B 1 26019B
117 GATE ROTOR COVER. 1 26021B 1 26021B 1 26021B
118 GATE ROTOR COVER GASKET. 1 25259C 1 25259C 1 25259C
119 WASHER. 1 25007A 1 25007A 1 25007A
120 DAMPER. 1 25760A 1 25760A 1 25760A
121* SHIM 0.002". ar 26027AA ar 26027AA ar 26027AA
122* SHIM 0.003". ar 26027AB ar 26027AB ar 26027AB
123* SHIM 0.005". ar 26027AC ar 26027AC ar 26027AC
124* SHIM 0.010". ar 26027AD ar 26027AD ar 26027AD
125 ROLLER BEARING. 1 2864B 1 2864B 1 2864B
126 BALL BEARING. 1 2865B 1 2865B 1 2865B
130 RETAINING RING. 1 2866A 1 2866A 1 2866A
131 RETAINING RING. 1 2867A 1 2867A 1 2867A
132 RETAINING RING. 1 2866K 1 2866K 1 2866K
135 DOWEL PIN 1 25910A 1 25910A 1 25910A
141 O-RING ROLLER BRG HSG. 1 2176M 1 2176M 1 2176M
143 O-RING BALL BRG SUPPORT. 1 2176R 1 2176R 1 2176R
151 SOC HEAD CAP SCREW. 1 2795AAA 1 2795AAA 1 2795AAA
152 HEX HEAD CAP SCREW. 12 2796CG 12 2796CG 12 2796CG
155 SHIM ar 25977G ar 25977G ar 25977G
156 SHIM ar 25977H ar 25977H ar 25977H
170 LOCK WASHER (PR). 1 3004C 1 3004C 1 3004C
176 PIPE PLUG. 1 2606D 1 2606D 1 2606D

ar = As required
146
Shaft Seal
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71- 401 ALL VSM 501-701
QTY VPN QTY VPN
* SHAFT SEAL KIT Ammon Kit
219, 230, & 260. 1 KT709D 1 KT709A
* SHAFT SEAL KIT Halo Kit
219, 230 & 260. 1 KT781D 1 KT781A
218 SEAL HOUSING. 1 25410B 1 25269A
219 SHAFT SEAL. 1 A 1 A
230 OIL SEAL. 1 2930C 1 25040A
244- TEFLON SEAL 1 25939A 1 25939A
252- RETAINER RING 1 2928M 1 2928M
260 O-RING 1 2176U 1 2176F
261 O-RING. (205 Only) 1 2176AE n/a
264 ROLL PIN. 1 1193RR 1 1193RR
281 HEX HEAD CAP
SCREW. 6 2796N 8 2796B
NOTE * Not pictured.

A Sold only as kit.
- See recommended spare parts lists for complete assembly.
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List
147
Main Rotor, Slide Valve Cross Shafts
and End Plate
(Models 71-401 Only Counter-clockwise)
148
and End Plate
(Models 71-201 Only CounterClockwise)
MODEL NUMBER
ITEM DESCRIPTION VSM 71 AND 151 VSM 91 AND 181 VSM 101 AND 201
201 MAIN ROTOR ASSEMBLY. 1 A25266AB 1 A25266AA 1 A25266AC
203 OIL BAFFLE ASSEMBLY (1) 217,
(1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA
207 SHIM ASSORTMENT (2) 240,
(2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A
217 OIL BAFFLE PLATE. 1 25719D 1 25719D 1 25719D
220 END PLATE. 1 25719B 1 25719B 1 25719B
221 SHAFT. 2 25941A 2 25941A 2 25941A
222 GEAR. 4 25027A 4 25027A 4 25027A
227 CLAMP. 4 25913A 4 25913A 4 25913A
228 SPACER. 4 25847A 4 25847A 4 25847A
240 SHIM 0.002” A 25409AA A 25409AA A 25409AA
241 SHIM 0.003” A 25409AB A 25409AB A 25409AB
242 SHIM 0.005” A 25409AC A 25409AC A 25409AC
243 SHIM 0.010” A 25409AD A 25409AD A 25409AD
244 TEFLON RING. 1 25939A 1 25939A 1 25939A
248 CHECK VALVE. 1 3120A 1 3120A 1 3120A
249 CHECK VALVE. 1 3120B 1 3120B 1 3120B
250 RETAINING RING. 2 2867T 2 2867T 2 2867T
252 RETAINING RING 1 2829M 1 2829M 1 2829M
254 WAVE SPRING. 1 2912G 1 2912G 1 2912G
267 DRILL BUSHING. (See item 271) 2 3121A 2 3121A 2 3121A
268 EXPANSION PIN. 4 1193D 4 1193D 4 1193D
269 EXPANSION PIN. 4 2981AA 4 2981AA 4 2981AA
270 PIPE PLUG. 3 2606B 3 2606B 3 2606B
271** PLUG SOLID 1 25422A 1 25422A 1 25422A
277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ
278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR
279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A
280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q
281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N
286 SOCKET HEAD CAP SCREW. 4 2795F 4 2795F 4 2795F
297 SET SCREW. 2 2060J 2 2060J 2 2060J
298 SET SCREW. 2 2060H 2 2060H 2 2060H

** Required at top locate single gaterotor only.
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149
and End Plate
(Models 301-401 Only Counter-clockwise)
MODEL NUMBER
ITEM DESCRIPTION VSM 301 VSM 361 VSM 401
201 MAIN ROTOR ASSEMBLY. 1 A25226AB 1 A25226AA 1 A25226AC
203 OIL BAFFLE ASSEMBLY (1)
217, (1) 244, (1) 248, (1) 249, (1) 252. 1 A25942AA 1 A25942AA 1 A25942AA
(2) 241, (1) 242, (1) 243 1 A25177A 1 A25177A 1 A25177A
217 OIL BAFFLE PLATE . 1 25938A 1 25938A 1 25938A
220 END PLATE. 1 25719D 1 25719D 1 25719D
221 SHAFT. 2 25941A 2 25941A 2 25941A
222 GEAR. 4 25027A 4 25027A 4 25027A
227 CLAMP. 4 25913A 4 25913A 4 25913A
228 SPACER. 4 25847A 4 25847A 4 25847A
240 SHIM 0.002” A 25409AA A 25409AA A 25409AA
241 SHIM 0.003” A 25409AB A 25409AB A 25409AB
242 SHIM 0.005” A 25409AC A 25409AC A 25409AC
243 SHIM 0.010” A 25409AD A 25409AD A 25409AD
244 TEFLON RING. 1 25939A 1 25939A 1 25939A
248 CHECK VALVE. 1 3120A 1 3120A 1 3120A
249 CHECK VALVE. 1 3120B 1 3120B 1 3120B
250 RETAINING RING. 2 2867T 2 2867T 2 2867T
252 RETAINING RING 1 2829M 1 2829M 1 2829M
254 WAVE SPRING. 1 2912G 1 2912G 1 2912G
267 DRILL BUSHING. (See item 271) 2 3121A 2 3121A 2 3121A
270 PIPE PLUG. 3 2606B 3 2606B 3 2606B
271** PLUG SOLID 1 25422A 1 25422A 1 25422A
277 SOCKET HEAD CAP SCREW. 2 2795AQ 2 2795AQ 2 2795AQ
278 SOCKET HEAD CAP SCREW. 2 2795AR 2 2795AR 2 2795AR
279 SOCKET HEAD CAP SCREW. 4 2795A 4 2795A 4 2795A
280 HEX HEAD CAP SCREW. 8 2796Q 8 2796Q 8 2796Q
281 HEX HEAD CAP SCREW. 6 2796N 6 2796N 6 2796N
286 SOCKET HEAD CAP SCREW. 8 2795F 8 2795F 8 2795F
297 SET SCREW. 2 2060J 2 2060J 2 2060J
298 SET SCREW. 2 2060H 2 2060H 2 2060H

** Required at top locate single gaterotor only.
A As required.
150
See Next Page for Models 501-701
and End Plate
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151
and End Plate
(Model 501-701 Only Clockwise)
152
and End Plate
(Model 501-701 Only Clockwise)
MODEL NUMBER
ITEM DESCRIPTION VSM 501 VSM 601 VSM 701
201 MAIN ROTOR ASSEMBLY. 1 A26010BB 1 A26010BA 1 A26010BC
203 OIL BAFFLE ASSEMBLY (1) 217,
(1) 244, (1) 248, (1) 249, (1) 252. 1 A26034B 1 A26034B 1 A26034B
(2) 241, (1) 242, (1) 243 1 A25177B 1 A25177B 1 A25177B
217 OIL BAFFLE PLATE. 1 A26034B 1 A26034B 1 A26034B
220 END PLATE. 1 26025B 1 26025B 1 26025B
221 SHAFT. 2 25843A 2 25843A 2 25843A
222 GEAR. 4 25027A 4 25027A 4 25027A
228 SPACER. 4 25847A 4 25847A 4 25847A
240 SHIM 0.002” A 25255AA A 25255AA A 25255AA
241 SHIM 0.003” A 25255AB A 25255AB A 25255AB
242 SHIM 0.005” A 25255AC A 25255AC A 25255AC
243 SHIM 0.010” A 25255AD A 25255AD A 25255AD
244 TEFLON RING. 1 25929B 1 25929B 1 25929B
248 CHECK VALVE. 1 3120A 1 3120A 1 3120A
249 CHECK VALVE. 1 3120B 1 3120B 1 3120B
250 RETAINING RING. 2 2867B 2 2867B 2 2867B
252 RETAINING RING 1 2928N 1 2928N 1 2928N
255 WASHER 2 25977E 2 25977E 2 25977E
256 WASHER 2 25977F 2 25977F 2 25977F
267 DRILL BUSHING. 2 3121A 2 3121A 2 3121A
270 PIPE PLUG. 3 2606B 3 2606B 3 2606B
277 HEX HEAD CAP SCREW. 2 2796CL 2 2796CL 2 2796CL
278 HEX HEAD CAP SCREW. 2 2796CT 2 2796CT 2 2796CT
279 HEX HEAD CAP SCREW. 2 2796CZ 2 2796CZ 2 2796CZ
280 HEX HEAD CAP SCREW. 6 2796EL 6 2796EL 6 2796EL
281 HEX HEAD CAP SCREW. 8 2796B 8 2796B 8 2796B
282 SOCKET HEAD CAP SCREW 2 2795D 2 2795D 2 2795D
297 SET SCREW. 2 2060J 2 2060J 2 2060J
298 SET SCREW. 2 2060H 2 2060H 2 2060H

A As required.
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153
154
Volume Ratio
Capacity Slide
Carriage Assembly
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501 - 701
QTY VPN QTY VPN
300 CARRIAGE ASSEMBLY. 1 A25179A 1 A26012B
304 CAPACITY PISTON 340, 341, 350 & 355. 1 A25183A 1 A25183B
305 VOLUME PISTON 340, 342, 350 & 355. 1 A25184A 1 A25184B
316 CAPACITY RACK. 1 25023D 1 25024A
318 CAPACITY RACK SHAFT. 1 25772C 1 25772A
323 VOLUME RATIO RACK. 1 25023C 1 25023A
325 VOLUME RATIO RACK SHAFT. 1 25772D 1 25772B
340 PISTON. 2 25017B 2 25017A
341 CAPACITY PISTON SHAFT. 1 25018B 1 25019A
342 VOLUME PISTON SHAFT. 1 25018C 1 25018A
350 PISTON RING SET. 2 2953AE 2 2953AA
355 EXPANSION PIN. 2 1193PP 2 1193PP
359 PIPE PLUG. 3 2606D 3 2606D
361 WASHER. 2 13265B 2 13265B
363 NUT. 4 2797A 4 2797A
372* SOCKET HEAD CAP SCREW. N/A 1 2795M
373 SOCKET HEAD CAP SCREW. 3 2795A 3 2795N
Notes: There are two slide valve carriages per compressor. Each one each has its own Volume
Ratio and Capacity slide valves. The above totals are per side of the compressor, double
the quantities if both slide valve carriages are being worked on.
*. Not Pictured.
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155
Actuating Motor with Optical Sensor
and Command Shaft
Kit assemblies are as follows:

A25975A VSM71-401
A25975B VSM 501-701
156
Actuating Motor with Optical Sensor
and Command Shaft
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501- 701
QTY VPN QTY VPN

413 COMMAND SHAFT. 1 25417A 1 25375A
415 MOUNTING PLATE. 1 25805B 1 25805B
416 COVER. 1 15653E 1 15653E
427 KEY. 1 25039BC 1 25039BC
433 BUSHING. 1 25853A 1 25853A
435 BALL BEARING. 1 2908A 1 2908A
436* SLEEVE BEARING. 1 25853B 1 25853B
445 O-RING. 1 2176W 1 2176W
445A O-RING. 1 2176W 1 2176W
446 O-RING. 1 2176X 1 2176X
451 RETAINING RING. 1 2867C 1 2867C
466 SOCKET HEAD CAP SCREW. 4 2795AB 4 2795AB
475 LOCKWASHER (PAIR). 4 3004A 4 3004A
477 LOCKWASHER (PAIR). 4 3004C 4 3004C
480 WASHER. 1 2906AA 1 2906AA
Notes: There are two slide valve actuators per compressor. One each for the control of the
Volume Ratio and Capacity slide valves. If both actuators or parts are to be replaced
double the quantities above.
* Bearing changed to steel until 10/25/04, then removed due to housing being modified.
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157
Model VSM 71-401
Model VSM 501-701
158
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71-401 ALL VSM 501 - 701
QTY VPN QTY VPN
511 DISCHARGE MANIFOLD. 1 25734B n/a
511 240 mm DISCHARGE MANIFOLD
WITH DOWN DISCHARGE. n/a 1 25024BC
WITH HORIZONTAL DISCHARGE. n/a 1 25024BB
WITH UP DISCHARGE. n/a 1 25024BA
512 MANIFOLD GASKET. 1 25737A 1 26037A
514 ECON-O-MIZER GASKET. 2 11323GG 2 11323D
515 KEY. 1 13396R 1 13396R
522 COUPLING LOCK PLATE n/a 1 25004D
523 LOCK WASHER n/a 1 3004H
528 ECON-O-MIZER PLUG. 2 25419A 2 25397K
530 O-RING n/a 2 2176BF
535 PIPE PLUG. 7 2606E 2 2606D
536 PIPE PLUG. 1 13163F 6 2606E
537 PIPE PLUG. 1 13163G 1 13163G
538 PIPE PLUG. 9 2606B 2 2606B
540 DOWEL PIN 2 2868B 2 2868B
542 PIPE PLUG 3 2606C 10 2606B
545 HEX HEAD CAP SCREW 4 2796EL 4 2796C
546 SOCKET HEAD CAP SCREW 7 2795AK 6 2795GD
547 HEX HEAD CAP SCREW 3 2796EN 4 2796F
548 SOCKET HEAD CAP SCREW n/a 3 2795GH
549 CAP SCREW 3 2796EY 1 2795GP
550 CAP SCREW 2 2796AB 2 2795GS
551 HEX HEAD CAP SCREW n/a 2 2796C
570 BEARING OIL PLUG 1 25978A n/a
571 PLUG 1 25979A n/a
572 SPRING 1 3148A n/a
Notes *. Not Pictured.
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160
Housing Accessories
C-Flange Assembly
Replacement Parts Accessories
Replacement Parts Accessories
Housing Accessories
MODEL NUMBER
ITEM DESCRIPTION VSM 71 - 701
QTY VPN
117 GATE ROTOR COVER. 1 25416B
118 COVER GASKET. 2 25259B
127 SUCTION TEE. 1 25735B
128 BLIND FLANGE WITH TAP. 1 25967A
129 GASKET. 1 11323T
153 HEX HEAD CAP SCREW. 32 2796DC
154 HEX HEAD CAP SCREW. 8 1139BE
171 LOCKWASHER (PAIR). 8 3004J
180 INLET SCREEN. 1 25920A
190 PIPE PLUG. 2 2606C
191 PIPE PLUG. 1 2606E
343 PISTON COVER. * 1 25724B
C-Flange Assembly
MODEL NUMBER
ITEM DESCRIPTION VSM 71 - 401 VSM 501 - 701
QTY VPN QTY VPN
1 C-FLANGE. 1 A 1 A
2 ADAPTER. 1 A 1 A
3 HEX HEAD CAP SCREW. 8 2796F 8 2796F
4 HEX HEAD CAP SCREW. 4 2796EL 4 A
5 LOCKWASHER (PAIR). 8 3004H 8 3004H
6 LOCKWASHER (PAIR). 4 3004F 4 A
7 PORT COVER. 2 25685A 2 25685B
8 HEX HEAD CAP SCREW. 2 2796AC 2 2796AC
9 CONNECTOR 1 13229C 1 13229C
10 TUBE (CUT TO LENGTH) 1 S1589A 1 S1589A
345 O-RING. 4 2176BX 4 2176CA
346 O-RING. 2 2176BG 2 2176BG
NOTE: A. Contact Home Office for part number and quantity.
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Replacement Tools
MODEL NUMBER
ITEM DESCRIPTION ALL VSM 71 - 401 ALL VSM 501 - 701
QTY VPN QTY VPN
901 GATEROTOR STABILIZER. 1 25742A 1 25742B
902 SEAL INSTALLATION TOOL 1 25455A 1 25455B
162
Vendor Assessories
Section
Vendor Assessories Section ........................................................................................ 163

HAIGHT PUMPS 10-80 Pumps ................................................................................................................................................................
PARKER Inlet Pressure Regulators ..........................................................................................................................................................
CARTRIDGE HEATERS .............................................................................................................................................................................
SPORLAN Strainers ...................................................................................................................................................................................
VIKING PUMP Pumps and Pressure Relief Valves ..................................................................................................................................
FLUID POWER ENERGY Thermostatic Valves .....................................................................................................................................
SPORLAN Solenoid Valve and Thermostatic Expansion Valve ..............................................................................................................
HANSEN HA4AOAS INLET/OUTLET REGULATOR ............................................................................................................................
Note: See spare parts lists for Vilter’s Part numbers.
163
Haight Pumps
10-80 GPM OIL PUMPS face of the seal will need to be inspected for crack-
VILTER PART NUMBER ing or excessive wear. If they are damaged the seal
3022UB, EU and HU must be replaced at this time.
HAIGHT MODEL 10-80U Series
3. Replace cap "o"-ring (3) at this time.
PREPARATION OF OIL PUMP 4. If the shaft seal is to be replaced, remove

FOR MAINTENANCE the stationary portion of the seat from the
inside of the cap. The stationary portion of the seal
1 Prepare compressor unit for servicing is pressed in finger tight and is held in place by an
as outlined in the service section of the manual. "o"-ring.
2. Remove the refrigerant from the unit in IMPORTANT

an appropriate manner and equalize to atmospheric
pressure. Care must be taken when installing the seal as
not to touch or scratch the polished side or the
3. Isolate the oil pump in the oil circuit. carbon portion of the seal.
4. Make sure that the electricity is turned 5. Install the new stationary portion of the
off to the oil pump motor and remove the 4 bolts seal in the cap with the polished surface faces the
and washers from the oil pump mounting face (25 rotating portion of the seal when assembled. Lu-
and 26), remove bolts securing the motor to the bricate the "o''-ring of the stationary portion of the
unit and slide the oil pump motor from the oil pump. seal with clean compressor oil to facilitate the in-
stallation.
5. Remove the set screw from the coupling
half and slide the coupling off of the oil pump shaft. 6. Remove the rotating portion of the seal
Remove the key (1) from shaft. from the oil pump shaft Oil the shaft to aid in the
removal of the seal. The bellows may stick to the
6. Using fine emery paper remove any burrs shaft, this is a normal, this wilt require a little pres-
from the key way area and the end of the sure to start it moving. After the rotating portion
shaft. of the seal is removed, inspect the shaft (22) for
damage and replacd if necessary.
SHAFT SEAL INSPECTION.
REMOVAL AND INSTALLATION. 7. Lubricate the shaft with dean com-
pressor oil and push the replacement seal on to the
1. Prepare the pump for servicing as stated shaft taking care not to touch the carbon face of the
in the previous paragraph. seal.
2. Remove the seal housing by unscrewing 8. Screw the cap back on to the pump hous-
the cap (2) using care as the seal in compressed ing and torque 40 to 60 ft.lbs.
with a spring, therefore the cap may release towards
the key way as the cap is unscrewed. With the cap 9. Re-install the key and coupling, tighten
unscrewed, slide it off of the shaft. The seal (21) the set screw after it is determined that the cou-
will now be visible, but possibly under compres- plings mate up correctly. Pressurize and leak check
sion as the bellows of the the unit concentrating on areas that repairs were
seal may be sticking to the shaft. made.
Carefully, rotate the shaft and inspect the bellows 10. It is normal for the seal to weep a small
of the seal for damage. If it is damaged the seal amount of oil on start-up until the bellows takes a
must be replaced at this time. If the bellows is in set on the shaft.
good shape, then the carbon face and the matting
164
Haight Pumps
Note:
Effective 2002, the ‘D” Series has been discontinued and upgraded to the “U” series.
When placing an order for a new pump and had the “D” (old) series pump you will be
required to upgrade to an “U” and a new Hub will also need to be purchased.
Vilter Part # 3022BU ,EU,and HU

Vilter Shaft Seal Part # 3022C
165
Haight Pumps
166
10U through 40U Haight Pump w/o Relief Valve
10U through 40U Haight Pump with Relief Valve
Item Qty. Item Qty.

Number Description Required Number Description Required
1 Screw on O-ring gland 1 11 Shaft 1
2 O-Ring 1 12 Key 1
-Buna 13 Rotor*-C.I. Standard 1
-Viton® 14 Case 1
-Neoprene -1" ports
-Kalrez® -1-1/4" ports
-Teflon -1-1/2" ports
3 Thurst Washer Kit 1 15 Lip Seal 1
Nut -Buna
Washer -Viton®
Washer -Neoprene
Washer 15A Mechanical Seal 1
Bearing -Buna
Washer -Viton®
4 Screw 8 -Neoprene
5 Cover 1 15B Packing Seal 1
6 & 6A Bearing 2 -Graphoil
-Bronze -Teflon
-Iron 16 Set Screw 1
-Graphite 17 Gland 1
-DU 18 Set Screw 1
7 Wiper Seal 2 19 Roll Pin 1
-Buna 20 O-Ring 1
-Neoprene -Buna
-Viton® -Viton®
8 O-Ring 1 -Neoprene
-Buna 21 O-Ring 2
-Viton® -Buna
-Neoprene -Viton®
-Kalrez® -Neoprene
-Teflon -Teflon
9 Shaft & Pinion Assy-std. 1 22 Screw 4
9 Shaft & Pinion Assy-OBB 1 23 Cover Plate 1
10 Pinion 1 24 Valve Body 1
12
CHECK VALVE BULLETIN 50-16C
Type CK4A
Port Size 13 - 100mm (1/2” - 4”)
FOR AMMONIA, R12, R22, R502
AND OTHER COMMON REFRIGERANTS
FEATURES
• UL Listed (Thru 3" Size)
September 1990
• Installs in any position Installation, Service and Parts Information
• Compact
• Lightweight
Purpose
• In-Line The Type CK4A Check Valves prevent backward flow of fluid
• Design Pressure (MRP): 34.5 bar (500 psi) in refrigerant suction, hot gas or liquid lines. The most frequent
use for these valves is in recirculating (overfeed) systems.
They are especially suited for high speed compressor
discharge, pump discharge, suction - down to -50°C (-60°F)
and hot gas lines (pan to evaporator).
Description Certain refrigerant flows pulsate sufficiently or with a
These compact valves are spring closing with a lapped, frequency in harmony with the valve’s natural frequency,
stainless steel or chrome plated seat for positive closing which can cause “slapping” or even wholesale failure. These
action and low leakage. A minimum pressure difference of valves are not recommended for slow speed compressor
0.05 bar (0.75 psi) is required to hold the valve in the open discharge lines (See CK-1, Bulletin 50-10B) or for any
position. Removable seat plate with combination O-ring and compressor discharge where a low speed machine
metal-to-metal knife edge seal allows the valve to be discharges into the same downstream header, or for use on
disassembled for maintenance. They may be ordered with side-port suction lines on a screw compressor installation.
male adapter rings for close-coupling to other Refrigerating
Specialties valves and may be installed in any position. Operation
These are light spring-closing check valves. An increase in
the pressure drop across the valve overcomes the force of
the closing spring and the disc is forced away from its seat
permitting flow. As the flow decreases, the disc is forced
back against its seat by the expansion of the closing spring.
Flow is then stopped.
Installation
Keep dirt from entering the valve. Do not remove protective
packaging until ready to install.
Install the valve where it can be serviced easily. DO NOT
INSTALL AT THE INLET OF A SOLENOID VALVE, OR A
REGULATOR WITH AN ELECTRIC SHUT-OFF FEATURE; DO
NOT INSTALL AT THE INLET OF AN OUTLET PRESSURE
REGULATOR IN A SYSTEM WHERE LIQUID MAY BE
TRAPPED BETWEEN TWO VALVES. Check Valves when used
with such valves should always be installed at the outlet of
the valves.
NOTE: THE ODS COPPER FLANGES AVAILABLE ARE ONLY
FOR INSTALLATIONS WHERE R-12, R-22, AND R-502 OR
OTHER HALOCARBON REFRIGERANTS ARE USED. DO
NOT USE THESE FLANGES FOR AMMONIA. FOR
INSTALLATIONS USING AMMONIA THE FPT, SOCKET WELD
OR WELD NECK FLANGES SHOULD BE USED.
The Type CK4A Valves may be installed in any position. The
valve must be installed with the arrow pointing in the direction
of flow. After installing the valve, tighten the flange bolts evenly.
Fig. 1
The CK4A Check Valves may be closed-coupled to
Refrigerating Specialties Refrigerant Valves and most hand
valves by using a Refrigerating Specialties Male Adapter Ring.
Refrigerating Specialties Division 1 I S O 9 0 0 1 C E R T I F I E D

050280
Repair Kits for Type CK4A Check Valves
ITEM POR
PORT T SIZE
NO. DESCRIPTION QTY 50mm (2") 65mm (2-1/2") 75mm (3") 100mm (4")
6 Valve Seat 1
7 O-Ring 1
8 Disc Assembly 1 Available Only With Kit
9 Comp. Spring 1
4 Flange Gasket 2
4,6,7,8,9 Repair Kit — 202089 202090 202091 202092
4 Flange Gasket Pkg. 12 202081 202082 202083 202084
Note: 13-32mm (½” - 1¼”) do not have Repair Kits available.
Dimensional Data
PORT SIZE
Dimension 13mm 20-25mm 32mm 50mm 65mm 75mm 100m
(1/2”) (3/4 - 1”) (1-1/4”) (2”) (2-1/2”) (3”) (4”)
mm 75 113 95 114 148 148 179
A
inch 29.3 4.43 3.75 4.50 5.81 5.81 7.06
mm 38 62 95 114 148 148 179
B
inch 1.50 2.43 3.75 4.50 5.81 5.81 7.06
mm 27 32 50 60 70 81 89
C
inch 1.06 1.25 2 2.37 2.75 3.19 3.50
D mm 63 59 79 114 145 157 177
(FPT, SW) inch 2.47 2.32 3.10 4.47 5.72 6.16 6.97
Conn.
Size 3/8, 1/2, 3/4 3/4” 1” 1-1/4” 1-1/4” 1-1/2” 1-1/2” 2” 2-1/2” 3” 4”
mm 82 97 117 117 126 136 171 177 215 245 298
E
inch 3.22 3.82 4.61 4.61 4.97 5.35 6.72 6.97 8.47 9.66 11.72
Conn.
Size 1/2 5/8 7/8 7/8 1-1/8 1-3/8 1-5/8 1-3/8 1-5/8 2-1/8 1-5/8 2-1/8 2-5/8 2-5/8 3-1/8 3-1/8 3-5/8 4-1/8
mm 76 82 98 99 193 99.5 111 119 130 159 193 177 205 203 250 228 248 285
F
inch 2.98 3.22 3.85 3.88 4.07 3.91 4.36 4.69 5.12 6.26 7.57 6.95 8.08 7.98 9.82 8.95 9.76 11.2
mm 9 13 29 20 24 25 28 25 28 34 28 34 37 37 42 42 48 55
N
inch .37 .50 .75 .75 .93 .96 1.09 .96 1.09 1.34 1.09 1.34 1.46 1.46 1.65 1.65 1.90 2.15
mm 13 13 15 15 25 29 32
P
inch .50 .50 .60 .60 1.0 1.1 1.3
Refrigerating Specialties Division 2

Service factory. Warranty does not cover products which have been
Dirt or other foreign material in the system is the greatest altered, or repaired in the field; damaged in transit, or have
single cause of valve malfunction. suffered accidents, misuse, or abuse. Products disabled by
dirt or other foreign substances will not be considered
Before disassembling a check valve for servicing, read and defective.
become familiar with the Safe Operation Instructions in this
bulletin as well as in the current issue of Safety Bulletin RSB. THE EXPRESS WARRANTY SET FORTH ABOVE
CONSTITUTES THE ONLY WARRANTY APPLICABLE TO
Check the following chart for possible symptoms and REFRIGERATING SPECIALTIES PRODUCTS, AND IS IN LIEU
corrections. OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,
Symptom Probable Reason Correction WRITTEN OR ORAL, INCLUDING ANY WARRANTY OF
Valve does not Dirt or chips Disassemble valve MERCHANTABILITY, OR FITNESS FOR A PARTICULAR
close or there under valve seat. and clean PURPOSE. No employee, agent, dealer or other person is
is leakage thoroughly. authorized to give any warranties on behalf of Refrigerating
through valve. Replace any Specialties, nor to assume, for Refrigerating Specialties, any
damaged parts. other liability in connection with any of its products.
Valve chatters. Valve is Replace with
oversized. smaller port size or Safe Operation (See also Bulletin RSB)
use Type CK-1. People doing any work on a refrigeration system must be
qualified and completely familiar with the system and the
Refrigerating Specialties Division valves involved, or all other
Disassembly precautions will be meaningless. This includes reading and
Caution - If the valve to be disassembled or removed is understanding pertinent Refrigerating Specialties Division
close-coupled to a solenoid operated valve make sure that product Bulletins, and Safety Bulletin RSB prior to installation
the power supply to the valve is de-energized and all or servicing work.
refrigerant is pumped out of the line. Refer to Page 3 as
necessary. After removing the valve from between the flanges Where cold refrigerant liquid lines are used, it is necessary
remove the parts in the numerical order shown in the that certain precautions be taken to avoid damage which
applicable exploded view. In all CK4A Valves the seat plates could result from liquid expansion. Temperature increase in
with the O-rings are removed by gently tapping out the seat a piping section full of solid liquid will cause high pressure
from the opposite end of the valve body. Use a wooden dowel due to the expanding liquid which can possibly rupture a
for this purpose. gasket, pipe or valve. All hand valves isolating such sections
should be marked, warning against accidental closing, and
must not be closed until the liquid is removed. Check valves
Assembly must never be installed upstream of solenoid valves, or
Before assembling all parts must be clean, dry and lightly regulators with electric shut-off, nor should hand valves
coated with refrigerant oil. If an existing valve or strainer is upstream of solenoid valves or downstream of check valves
close-coupled to the check valve, either one should be be closed until the liquid has been removed. It is advisable
opened, inspected and cleaned before putting it and the to properly install relief devices in any section where liquid
check valve back in service. expansion could take place.
Refer to Page 3 as applicable. Assemble the valve in the Avoid all piping or control arrangements which might produce
reverse numerical order shown in the exploded view. Make thermal or pressure shock.
sure the O-ring is firmly seated and permanently retained by For the protection of people and products, all refrigerant must
the seat plate when reassembled. be removed from the section to be worked on before a valve,
strainer, or other device is opened or removed.
Flanges with ODS connections are not suitable for ammonia
Warranty service.
All Refrigerating Specialties products are warranted against
defects in workmanship and materials for a period of one
year from date of shipment from originating factory. This
warranty is in force only when products are properly installed,
field assembled, maintained, and operated in use and service
as specifically stated in Refrigerating Specialties Catalogs
or Bulletins for normal refrigeration applications, unless
otherwise approved in writing by Refrigerating Specialties
Division. Defective products, or parts thereof returned to the
factory with transportation charges prepaid and found to be
defective by factory inspection will be replaced or repaired
at Refrigerating Specialties option, free of charge, F.O.B.
Parker Hannifin Corporation • Refrigerating Specialties Division 4

2445 South 25th Avenue • Broadview, IL 60155-3891
Telephone: (708) 681-6300 • Fax (708) 681-6306
INLET PRESSURE BULLETIN 23-05B
Type A4A, A4AK, A4AE, A4AR
REGULATORS
Type A4A, A4AK, A4AE, A4AR
Port Size 20 - 100 mm (3/4" - 4")
FOR AMMONIA, R-12, R-22, R-502
OTHER REFRIGERANTS AND OIL
FEATURES
• Pilot operated characterized Modulating Plug
for precise control
• Suitable for all common refrigerants and oil
• 27.6 bar (400 psig) design pressure (MRP)
• Flanges for threaded or welded steel pipe and
copper tube (copper not for ammonia)
A4A, A4AE
• Interchangeable parts
• Easy to service
• Close coupled strainers, optional
• Many control variations are possible with the
use of a few Modules and kits. (See
Adaptomode Pressure Regulator Bul. 23-06)
• Stainless Steel Diaphragm
• Chrome Plated Pilot Seat
• Manual Opening Stem
A4A INLET PRESSURE REGULATOR

A4AK A4AR
SEAL CAP
ADJUSTING January 2003

STEM
Installation, Service and Parts Information
RANGE SPRING
PILOT SEAT
Description
GAUGE PORT
These compact, heavy duty, pilot operated, iron alloy
DIAPHRAGM
(ASTM A126 Class B) Inlet Pressure Regulators are
suitable for Ammonia, R-12, R-22, R-502 and other
POWER PISTON common refrigerants and fluids approved for use in
refrigeration systems.
All A4 Regulators are pilot operated using upstream
pressure for the opening force and requires a minimum
0.14 bar (2 psig) pressure drop to fully open.
These valves are generally ordered with close coupled
upstream strainer to prevent entrance of foreign material
into the valve and the rest of the system. (See current Bul
MODULATING
PLUG 00-10 for strainer information.)
CLOSING Purpose
SPRING
Modulates flow of refrigerant gas or liquid to maintain
DIRT WIPER constant upstream (or inlet) pressure as set-for, despite
load fluctuations. The A4AR is a main valve only and will
MANUAL
control pressures as determined by the remote pilot(s)
OPENING piped to it.
STEM
The fluid temperature range for the A4 Series of
Fig. 1 Regulators is -45°C to 105°C (-50°F to 220°F).

I S O 9 0 0 0-2 0 0 0 C E R T I F I E D
050274
The A4A Series of Regulators will give optimum
Principles of Operation (See Fig. 1)
performance if mounted in a horizontal line in a vertical
The inlet pressure enters the space under the diaphragm
position with the manual opening stem on bottom. Where
through passage N. When the force created by the
other positions are desired, the factory should be
pressure exceeds the force of the range spring, the
consulted; please give application and piping details. The
diaphragm is lifted off the pilot seat allowing pressure to
regulator must be installed with the arrow on the valve
enter on top of the power piston. This causes the power
body pointing in the direction of the fluid flow for the
piston to move downward forcing the modulating plug to
regulator to function properly. Backward flow through the
open and modulate to maintain constant inlet pressure.
regulator is uncontrolled and will vary with the valve model
An increase in inlet pressure lifts the diaphragm further,
and the reverse pressure drop encountered. The regulator
allowing more pressure on top of the power piston and
is not a check valve.
opening the valve wider. A decrease in inlet pressure
causes the diaphragm to move closer to the pilot seat Tighten the flange bolts and nuts evenly to provide proper
reducing the pressure on the top of the power piston and seating of the flange gasket and to avoid damage to
causing the closing spring to reduce the valve opening. gaskets or flanges. (See Flange Bolt Torque Table, p. 12)
The pressure on top of the power piston is controlled by Avoid using the regulator flange bolts to stretch or align
the flow through the pilot seat and the bleed off through pipe. Even the heavy-duty iron alloy body of an A4A can
the bleed hole in the power piston and through the be distorted, causing the precision parts to bind.
clearance between the piston and cylinder. A minimum of The regulator should be installed in a location where it is
0.14 bar (2 psig) pressure drop across the valve is required easily accessible for adjustment and maintenance. The
to open it fully. location should be such that the regulator can not be easily
The A4A Inlet Pressure Regulator therefore opens on a damaged by material handling equipment. When it is
rise in the inlet pressure above its set point and closes on necessary to insulate the regulator (and companion
a drop in inlet pressure below its set point. The inlet strainer), the insulation should be installed to provide
pressure set point is not appreciably affected by variations access to the regulator (and companion strainer) for
in the outlet pressure. adjustment and maintenance. Proper indicating gauges
should be installed to be easily visible to the operating
engineer for system checking and adjusting purposes.
Manual Opening Stem
All Type A4A Regulators are provided with a manual
opening stem. To open the regulator manually, back the Disassembly and Assembly
stem out (turn counter-clockwise) until it stops. To put the Refer to the exploded view (Fig. 2) for parts discussed in
regulator into automatic operation, turn the stem in this section.
(clockwise) until only the flats on the stem protrude from Before disassembling any A4A type regulator, read the
the packing nut. Always retighten packing nut after information in this bulletin and Bulletin RSB, Safety
changing position of the manual opening stem. Procedures for Refrigerating Specialties Division
Refrigeration Control Valves.
Installation Before a regulator is removed from the line or
All regulators are packed for maximum protection. Unpack disassembled in the line, make sure that all refrigerant
carefully. Check the carton to make sure all flanges and has been removed from the regulator, including the
other items are unpacked. Save the enclosed instructions bonnet, where applicable, and the close coupled strainer.
for the installer and eventual user. The regulator must be isolated from the rest of the system
in a safe manner. When pumping down to remove the
Do not remove the protective coverings from the inlet and refrigerant, the manual opening stem 33A must be turned
outlet of the regulator until the regulator is ready to be out (counter clockwise) to make sure the valve is open.
installed. Protect the inside of the regulator from moisture,
dirt and chips before and during installation. When welded
or brazed flange connections are used, all slag, scale and All A4A Regulators
loose particles should be removed from the flange interior General Procedure
before the regulator is installed between the flanges. It is The construction of the regulator and the method of
advisable to install a close-coupled companion strainer disassembly are relatively simple, but some procedures
(RSF) at the inlet of the regulator to help protect it from must be followed to avoid damage. The following describes
any foreign material in the system. the procedure for the basic A4A; special instructions for
other styles will be included in other appropriate sections.

Disassembly - Take care when removing Seal Caps 1 Remove seat from valve body and clean, lap on a flat
and 44 in case some refrigerant may be trapped inside. plate or replace as necessary. Examine the diaphragm
Back the Adjusting Stem 6 all the way out to remove any region which contacts the seat surface, look for dirt, heavy
pressure from Range Spring 13 otherwise damage to scratches or corrosion. If the diaphragm cannot be easily
Diaphragm 17 or Pilot Seat 18 may occur. Remove Bonnet wiped clean, it should be replaced. Reassemble the
8 by carefully removing Cap Screws 11. Take care not to regulator following the General Procedure.
damage Diaphragm Follower 15. Remove Adapter 28 by
removing Cap Screws 31. Turn the Manual Opening Stem
33A all the way in until the flats on the stem barely protrude A4AK
from the stuffing box nut. Push Piston 30 down against For disassembly and assembly follow the General
the spring force. The piston should move freely down and Procedure and the procedure for A4A. This regulator has
be returned by the spring force. If the piston is jammed or a sealed wire connection to keep the seal cap from being
sticky, remove Bottom Cap Assembly, which includes removed. This wire must be removed before the regulator
Items 33 through 42, by removing Cap Screws 39 or can be disassembled. Please Note: Removal of the seal
unscrewing Bottom Cap, 20mm through 32mm (3/4" voids any Refrigerating Specialties Division factory
through 1-1/4"). Using a hard wood dowel rod inserted responsibility for the regulator pressure set-point.
through the bottom of the valve, tap the piston upward Adjustment
and out. Thoroughly clean all parts. If jamming has taken Install an accurate pressure gauge in the gauge port. Back
place and the piston and bore are scored, remove all burrs the adjusting stem all the way out to stop. This will reduce
by polishing the piston, bore and modulating plug with the set point to its lowest level and cause the valve to
fine crocus cloth. Inspect the seating area of the open wide. Start the system, and when suction pressure
Modulating Plug 33 for damage or erosion. If damaged it is about the desired pressure, turn the adjusting stem in
should be replaced. It would be advisable to replace the until the pressure gauge shows a slight rise in the inlet
entire bottom cap assembly. Inspect all gaskets and “O” pressure. At this point the adjusting stem may be turned
rings for damage and replace where necessary. in (clockwise) to raise the pressure further, or backed out
Assembly - When reassembling the valve, all internal (counterclockwise) to lower it; but the final adjustment
parts should be clean, dry and lightly oiled with refrigerant should be made after the system has been operating for
oil, except “O” rings. Apply silicone grease to the “O” rings. a period of time.
Care must be taken especially when the parts are cold INLET PRESSURE SETTING RANGES
since moisture can condense on parts and cause rapid
rusting. When replacing gaskets, they should be oiled very Approx. Pressure Change Factory Set Point
Set Point Ranges per Turn of (unless otherwise)
lightly with refrigerant oil before assembly. Install bottom
Adjusting Screw specified)
cap assembly first and tighten in place. Carefully replace
the piston; never try to force it in place. Align the Adapter A: 0 to 10.3 bar 1 .7 bar (25 psi) 2.8 bar (40 psig)
(0 to 150 psig)
Gasket 29 carefully with the proper holes in the adapter
and valve body and fasten adapter in place. Before V: 500mm hg to 8.3 bar 1 .7 bar (25 psi) 1 . 0 bar (15 psig)
(20in hg to 120 psig)
assembling the bonnet be sure the Adjusting Stem 6 is
turned all the way out. Place Gasket 19, Diaphragm 17 D: 5.2 to 19.3 bar 3.7 bar (53 psi) 9.7 bar (140 psig)
(75 to 280 psig)
and Gasket 16 in Adapter 28. The raised center of the
diaphragm must be towards the bonnet. Stack Diaphragm
Follower 15, Lower Spring Rest 14, Spring 13 and Upper A4AE Inlet Pressure Regulator,
Spring Rest 12 on top of diaphragm and carefully lower Remote Sensing Connection
bonnet in place and tighten Screws 11 in place. For range This regulator allows control of upstream pressure at a
“D” use two diaphragms. Tighten Cap Screws 11 evenly. point remote from the regulator inlet. Gasket 19 has no
The ideal tightening torque is 1.5 Kg-m (11 ft. lbs.). Valve hole, thus blocking flow of upstream pressure to under
is now ready to be adjusted for normal operation. the diaphragm. The sensing pressure from the desired
If close coupled strainer is used, it may be cleaned before control point, upstream of the regulator, is connected to
putting the valve back in operation. The regulator must be the gauge port leading to under the diaphragm. Thus the
tested for leaks with refrigerant gas or other appropriate regulator will control the pressure at this point. The
gas before the system is put into operation. regulator operation and adjustment is the same as for
A4A.
(continued on page 8)
A4A
After the General Procedure for disassembly, inspect the
Pilot Seat 18 top seating surface for dirt, wear or damage.

Repair Kits for A4A, A4AE, A4AK and A4AR
1 20mm (3/4") 25mm (1 “)
2 Item No. Description Kit No. Qty Kit No. Qty
3 1 Seal Cap Only Avail. with Kit 1 Only Avail with Kit 1
4 2 Seal Cap Gasket Only Avail with Kit 1 Only Avail. with Kit 1
5 1-2 Cap Kit, Seal 202110 1 202110 1
6 3 Nut, Packing Only Avail. with Kit 1 Only Avail. with Kit 1
4 Packing, Stem Only Avail. with Kit 1 Only Avail. with Kit 1
5 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 1
9 3-5 Packing Kit, Stem 202100 1 202100 1
11 8
6 Stem, Adjusting Only Avail. with Kit 1 Only Avail. with Kit 1
4-6 Stem Kit, Adjusting 202120 1 202120 1
10 12 Plate, Spring, Upper Only Avail with Kit 1 Only Avail. with Kit 1
13 Spring, Comp. Only Avail. with Kit 1 Only Avail. with Kit 1
12 14 Plate, Spring, Lower Only Avail. with Kit 1 Only Avail. with Kit 1
15 Follower, Diaphragm Only Avail. with Kit 1 Only Avail. with Kit 1
13 3-5, 6, Spring/ Range A/V 202006 1 202006 1
14 12-15 Stem Kit Range D 202007 1 202007 1
15
8 Bonnet Only Avail. with Kit 1 Only Avail. with Kit 1
16 17
11 Screw, Hx. Hd. Only Avail. with Kit 8 Only Avail. with Kit 8
112 18
16 Bonnet Gasket Only Avail. with Kit 1 Only Avail. with Kit 1
19
1-6, 8, Spring Kit Range A/V 202008 1 202008 1
28
11-16 with Bonnet Range D 202009 1 202009 1
27
12-14, Spring Kit, Range A/V 202481 1 202481 1
29 16 Less Bonnet Range D 202482 1 202482 1
A4AR
30 17 Diaphragm Only Avail. with Kit 1 Only Avail. with Kit 1
Cover
19 Gasket Only Avail. with Kit I Only Avail. with Kit 1
31
See 16,17, 19 Diaphragm Kit Range A/V 200770 1 200770 1
45 Note 17 Diaphragms Range D Only Avail. with Kit 2 Only Avail, with Kit 2
16,17, 19 Diaphragm Kit Range D 200771 1 200771 1
16-19 VC Vacuum Cartridge 202004 1 202004 1
Pilot Seat/ Range A 202000 1 202000 1
16-19 Diaphragm Kit Range V 202004 1 202004 1
(Not A4AO) Range D 202002 1 202002 1
27 Plug Pkg, 1/4" NPT 202552 5 202552 5
28 Adapter Only Avail. with Kit 1 Only Avail. with Kit 1
29 Gasket Only Avail. with Kit 1 Only Avail. with Kit 1
Modulating Plug 19,28, 29 Adapter Kit 200703 1 200703 1
for Port Sizes
30 Piston/Stem Assembly Only Avail. with Kit 1 Only Avail. with Kit 1
3/4" to 1-1/4" only 33
29,30 Piston Kit 200760 1 200760 1
33B 32 Valve Body Not Available Not Available
46 34 Spring, Comp. Only Avail. with Kit 1 Only Avail. with Kit 1
33A 35 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 1
47 34 36 Wiper, Dirt Only Avail. with Kit 1 Only Avail. with Kit 1
Bottom Cap 35 37 “O” Ring Only Avail. with Kit 1 Only Avail. with Kit 1
for Port Sizes 34-37 Spring Kit, (A4A) 202300 1 202300 1
20mm thru 32mm 36
(3/4" thru 1-1/4")
Closing (A4AK) 202298 1 202298 1
37 37
only. 38 33 Plug/Stem Assembly Only Avail. with Kit 1 Only Avail. with Kit 1
40 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 1
38
40 42 Nut, Packing Only Avail. with Kit 1 Only Avail. with Kit 1
41 33, 34-37, Full Cap. Plug (A4A) 202021 1 202022 1
42 40-42 Kit, Modul. (A4AK) 202037 1 202038 1
43 33, 34-37, 50% Cap. Plug (A4A) 202029 1 (*)
39 44 40-42 Kit, Modul. (A4AK) 202036 1 (*)
33, 34-37, 35% Cap. Plug (A4A) Not Available Not Available
40-42 Kit, Modul. (A4AK) Not Available Not Available
A4A, A4AK A4AE, A4AR 33, 34-37, 17% Cap. Plug (A4A) 202030 1 (*)
40-42 Kit, Modul. (A4AK) 202030 1 (*)
Fig. 2
Note: Piston for port sizes 3/4” thru 1-1/4” only.

(*) All Plug Kits and Bottom Assembly Kits for 3/4" Port Size Valves can be used in the 1" Port Size
Valves for reducing capacity.

32mm (1-1/4") 40mm (1-5/8") 50mm (2") 65mm (2-1/2") 75mm (3") 100mm (4")
Item No. Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty
1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
1-2 202110 1 202110 1 202110 1 202110 1 202110 1 202110 1
3 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
4 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
3-5 202100 1 202100 1 202100 1 202100 1 202100 1 202100 1
6 Only Avail. with Kit 1 Only Avail with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
4-6 202120 1 202120 1 202120 1 202120 1 202120 1 202120 1
14 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit I Only Avail. with Kit 1
15 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
3-5, 6, 202006 1 202006 1 202006 1 202006 1 202006 1 202006 1
12-15 202007 1 202007 1 202007 1 202007 1 202007 1 202007 1
8 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1
1-6, 8, 202008 1 202008 1 202008 1 202008 1 202008 1 202008 1
11-16 202009 1 202009 1 202009 1 202009 1 202009 1 202009 1
12-14, 202481 1 202481 1 202481 1 202481. 1 202481 1 202481 1
16 202482 1 202482 1 202482 1 202482 1 202482 1 202482 1
17 Only Avail with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
19 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
16,17, 19 200770 1 200770 1 200770 1 200770 1 200770 1 200770 1
17 Only Avail with Kit 2 Only Avail with Kit 2 Only Avail. with Kit 2 Only Avail. with Kit 2 Only Avail. with Kit 2 Only Avail. with Kit 2
16,17, 19 200771 1 200771 1 200771 1 200771 1 200771 1 200771 1
16-19 202004 1 202004 1 202004 1 202004 1 202004 1 202004 1
202000 1 202000 1 202000 1 202001 1 202001 1 202001 1
16-19 202004 1 202004 1 202004 1 202004 1 2020 4 1 202004 1
202002 1 202002 1 202002 1 202003 1 202003 1 202003 1
27 202552 5 202552 5 202552 5 202552 5 202552 5 202552 5
19.28,29 200700 1 200725 1 200725 1 200685 1 200713 1 200716 1
29,30 200767 1 200389 1 200389 1 200391 1 200393 1 200227 1
32 Not Available Not Available Not Available Not Available Not Available Not7vailable
34 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1
35 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Onlv Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
37 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
34-37 202301 1 202302 1 202302 1 202303 1 202304 1 202305 1
202299 1 202302 1 202302 1 202303 1 202304 1 202305 1
33,34-37, 202023 1 202024 1 202025 1 202026 1 202027 1 202028 1
40-42 202039 1 202024 1 202025 1 202026 1 202027 1 202028 1
33, 34-37, Not Available Not Available Not Available Not Available Not Available Not Available
40-42 Not Available Not Available Not Available Not Available Not Available Not Available
33, 34-37, 202031 1 202032 1 (**) 202033 1 202034 1 202035 1
40-42 202031 1 202032 1 (**) 202033 1 202014 1 202035 1
33, 34-37, Not Available Not Available Not Available Not Available Not Available Not Available
(**) All Plug Kits and Bottom Assembly Kits for 1-5/8" Port Size Valves can be used in the 2 “ Port Size Valves for reducing capacity.

1
20mm (3/4") 25mm (1")
2
3 Item No. Description Kit No. Qty Kit No. Qty
4 37 O-Ring/Gasket Only Avail. with Kit 1 Only Avail. with Kit 1
5 38 Cover, Bottom Only Avail. with Kit 1 Only Avail with Kit 1
6 40 Washer, Flat Only Avail. with Kit 1 Only Avail. with Kit 1
37,38,40,41 Cover Kit 200761 1 200761 1
42 Nut, Packing Only Avail. with Kit 1 Only Avail. with Kit 1
8 9
11 40-42 Packing Kit, Stem 202100 1 202100 1
43 Gasket Only Avail. with Kit 1 Only Avail. with Kit 1
10 44 Seal Cap Only Avail. with Kit 1 Only Avail. with Kit 1
43, 44 Seal Cap Kit 202110 1 202110 1
33-38, Full Cap. Bottom A4A 202010 1 202011 1
12
40-44 Assembly Kit A4AK 202018 1 202019 1
13 33-38, 50% Cap. Bottom A4A 202347 1 (*) 1
14 40-44 Assembly Kit A4AK Not Available Not Available
15 33-38, 17% Cap. Bottom A4A 202346 1 (*) 1
16 17 40-44 Assembly Kit A4AK Not Available Not Available
112 18 3-6, 12-19, Full Cap. Repair Rge. A 202041 1 202044 1
19
29, 30, 33-37, Kit, Reg, (All Rge. V 202040 1 202043 1
28
40-42 except A4AK) Rge. D 202042 1 202045 1
27 3-6, 12-19, 50% Cap. Repair Rge. A 202352 1 (*) 1
29 29-30, 33-37, Kit, Reg. (All Rge. V 202354 1 (*) 1
A4AR
30 40-42 except A4AK) Rge. D 202353 1 (*) 1
Cover
3-6, 12-19, 17% Cap, Repair Rge. A 202349 1 (*) 1
31 29-30, 33-37, Kit, Reg. (All Rge. V 202351 1 (*) 1
See
45 Note 40-42 Except A4AK) Rge. D 202350 1 (*) 1
112 Cover, Top Only Avail. with Kit 1 OnIy Avail. with Kit 1
29,112 A4AR Cover Kit 200680 1 200680 1
2, 16(2), 19(2), Gasket Kits (includes complete set of gaskets plus “O” Rings if applicable)
25,26,29,37,
43, 45(3) Gasket Kit A4/S4 202112 1 202112 1
lndv’l Gaskets, “0” Rings & Valve Pk’g sold & pkgd in qtys only as indicated.
29 Gasket Pkg, Adapter 202406 5 202406 5
37 ‘’0'’ Ring/Gasket Pkg, Bottom Cap 202384 3 202384 3
Modulating Plug 43 Gasket Pkg, Seal Cap (Bottom) 202408 12 202408 12
for Port Sizes 2 Gasket Pkg, Seal Cap (Top) 202408 12 202408 12
3/4" to 1-1/4" only 33
45 Gasket Pkg, Flange 202079 12 202079 12
33B 4 Packing Pkg, Stem (Top) 202478 25 202478 25
41 Packing Pkg, Stem (Bottom) 202478 25 202478 25
46
33A Bolt Package Kits
47 11 Bolt Package, A4A Bonnet 202246 8 202246 8
34
Bottom Cap 31 Bolt Package, Adapter 202248 8 202249 8
35
for Port Sizes 39 Bolt Package, Bottom Cap Not Required Not Required
20mm thru 32mm 36 Flange Bolt Package includes bolts and nuts; no gaskets
(3/4" thru 1-1/4") 37
37 46 Nut 5/8"-11 2 5/8” –11 2
only. 38
47 Bolt 5/8"-11x 3” 2 5/8" -11x3” 2
38
46, 47 Bolt Kit, Flange 201585 1 201585 1
40
41
42
43
39 44
Flange Kit FK-25 FK-25
Specify Flange, Style, FPT, SW, ODS FPT, SW, ODS
A4A, A4AK A4AE, A4AR Connection, Size WN WN
Kit includes 2 Flanges only Std Also Std Also Std Also Std Also
Connections Available Avail. Avail. Avail. Avail.
Fig. 2 Sizes in Inches 3/4 1, 7/8 1-1/8, 1 3/4 1-1/8 1-3/8
1-1/4 1-3/8 1-1/4 1-5/8
Note: Piston for port sizes 3/4” thru 1-1/4” only. (*) All Plug Kits and Bottom Assembly Kits for 3/4" Port Size Valves can be used in the 1" Port Size
Valves for reducing capacity.

32mm (1-1/4") 40mm (1-5/8") 50mm (2") 65mm (2-1/2") 75mm (31) 100mm (4")
Item No. Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty Kit No. Qty
37 Only Avail. with Kit 1
37,38,40,41 200761 1 Not Available Not Available Not Available Not Available Not Available
40-42 202100 1 202100 1 202100 1 202100 1 202101 1 202101 1
43 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail, with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit 1
44 Only Avail. with Kit 1 Only Avail. with Kit 1 Only Avail. with Kit I Only Avail. with Kit 1 Only Avail with Kit 1 Only Avail with Kit 1
43, 44 202110 1 202110 1 202110 1 202110 1 202111 1 202111
33-38 202012 1 202013 1 202014 1 202015 1 202016 1 202017 1
40-44 202020 1 1 202014 1 202015 1 202016 1 202017 1
33-38,
33-38,
3-6, 12-19, 202047 1 202050 1 202053 1 202056 1 202059 1 202062 1
29, 30, 33-37 202046 1 202049 1 202052 1 202055 1 202058 1 202061 1
40-42 202048 1 202051 1 202754 1 202057 1 202060 1 202063 1
3-6, 12-19, NOTE: 50% Capacity Repair Kit is not available for port sizes 1-1 /4" to 4". Capacity reduction can be obtained through use of
29-30, 33-37, field installing ‘’Reduced Capacity Plug Kits’’. See description and contents of these kits elsewhere this section.
40-42
3-6, 12-19, NOTE: 17% Capacity Repair Kit is not available for port sizes 1-1 /4" to 4". Capacity reduction can be obtained through use of
29-30, 33-37, field installing ‘’Reduced Capacity Plug Kits’’. See description and contents of these kits elsewhere this section,
40-42
29,112 200669 1 200673 1 200673 1 200690 1 200676 1 200677 1
2, 16(2), 19(2), Gasket Kits (includes complete set of gaskets plus “O” Rings if applicable)
25, 26, 29, 37
43, 45(3) 202113 202114 202114 202115 202116 202117
Individual Gaskets, “O” Rings and Valve Packing sold and packaged in quantities only as indicated.
29 202407 5 202397 3 202397 3 202396 3 202399 3 202400 3
37 202384 3 202374 6 202374 6 202374 6 202382 3 202383 3
43 202408 12 202408 12 202408 12 202408 12 202404 5 202404 5
2 202408 12 202408 12 202408 12 202408 12 202408 12 202408 12
45 202080 12 202081 12 202081 12 202082 12 202083 12 202084 12
4 202478 25 202478 25 202478 25 202478 25 202478 25 202478 25
41 202478 25 202478 25 202478 25 202478 25 202479 5 202479 5
Bolt Package Kits
11 202246 8 202246 8 202246 8 202246 8 202246 8 202246 8
31 202248 8 202249 8 202249 8 202249 8 202250 6 202250 6
39 Not Required 202251 6 202251 6 202251 6 202252 6 202252 6
Flange Bolt Package includes bolts and nuts; no gaskets
46 5/8"-11 4 5/8"-11 4 5/8"-11 4 3/4"-10 4 3/4"-10 4 7/8"-9 4
47 5/8"-11x2-3/4” 4 5/8"-11x3-1/4 “ 4 5/8”-11x3-1/4" 4 ¾”-10x3-3/4" 4 ¾” – 10x3-3/4” 4 7/8” –9x4-1/2” 4
46,47 201595 1 201604 1 201604 1 201611 1 201611 1 201620 1
FK-32 FK-40 FK-50 FK-65 FK-75 FK-100

FPT, SW ODS FPT, SW ODS FPT, SW ODS FPT, SW ODS FPT, SW ODS FPT, SW ODS
WN WN WN WN WN WN
Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also Std. Also
Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail. Avail.
1-1/4 1-1/2 1-3/8 1-5/8, 1-1/2 2 1-5/8 2-1/8, 2 1-1/2 2-1/8 2-5/8 2-1/2 2-5/8 3-1/8 3 3-1/8 3-5/8 4 4-1/8
2-1/8 2-5/8

A4AK Reseating Relief Regulator strainers are used, maintain according to instructions in
This regulator is adjusted at the factory for a given inlet Bulletin 00-10. Moisture in halocarbon systems in
pressure. The seal cap is wired to a bonnet cap screw particular can cause corrosion or form ice, causing the
and the wires are sealed with a lead seal. The relief piston to freeze in position. Filter-driers should be used
pressure setting is stamped on the seal. Breaking or and maintained for halocarbon systems.
removal of the seal voids the factory responsibility for the Before deciding to disassemble a regulator for servicing,
relief setting of the regulator. Normal set-point is 4.8 bar the following investigations should be made:
(70 psig)
• Check the manual opening stem; it should be
The operation and other construction features are similar turned in for automatic operation.
to A4A, except that sizes 20mm (3/4") through 32mm • Check the regulator setting to make sure it is
(1-1/4") use a PTFE seat in the modulating plug. properly adjusted. Turn adjusting screw slowly to
Because of slight leakage tolerance, this regulator is not see if regulator responds. Check regulator pressure
range; if wrong, range spring must be replaced.
intended for use as a safety relief valve to the atmosphere,
• Check other system components for proper
but rather to a lower pressure section of that system.
operation.
Because of large diaphragm to seat area ratio, setting is
• Check hand valves in the system to make sure they
affected only slightly by outlet pressure.
are open or closed as required and the system is
The A4AK Regulator is often used as a defrost pressure receiving liquid or gas as the case may be.
relief regulator.
Before disassembly of regulator, make certain that
For atmospheric relief, use Type H high capacity safety all refrigerant has been removed (pumped out) from
relief valve. (See Bul. 70-01 for information and selection). the regulator and its companion strainer where one
is used. Read Safety Bulletin RSB.
A4AR Main Regulator for Remote Pilot
The A4AR is the main regulator only, without the pressure
pilot being an integral part thereof. Instead, the main valve Safe Operation (See also Bulletin RSBCV)
has a valve cover tapped 3/8" NPT. With this arrangement, People doing any work on a refrigeration system must be
external pressure pilot and solenoid, if positive electric qualified and completely familiar with the system and the
shut-off is required, may be connected to control the main Refrigerating Specialties Division valves involved, or all
valve. These items can be remotely located from the main other precautions will be meaningless. This includes
valve where they may be more convenient to adjust, reading and understanding pertinent Refrigerating
service or perhaps be in a non-corrosive or non-explosive Specialties Division product Bulletins, and Safety Bulletin
area. RSB prior to installation or servicing work.
Remote pilot piping should not exceed 6m (20 ft.) in total Where cold refrigerant liquid lines are used, it is necessary
length and should be 3/8" pipe or equivalent tube size. that certain precautions be taken to avoid damage which
The remote piping must originate in the upstream pipe, could result from liquid expansion. Temperature increase
not at the A4AR valve itself. in a piping section full of solid liquid will cause high
pressure due to the expanding liquid which can possibly
See current issue of Bul. 21-02 for details of A2B Inlet rupture a gasket, pipe or valve. All hand valves isolating
Pressure Pilot. Use A2B2 with 20-50mm (3/4" - 2") A4AR. such sections should be marked, warning against
Use A2B Inlet Pressure Pilot with 65-100mm (2-1/2"- 4") accidental closing, and must not be closed until the liquid
A4AR. is removed. Check valves must never be installed
If main valve is to perform as an Outlet Pressure upstream of solenoid valves, or regulators with electric
Regulator, use Outlet Pressure Pilots A2BO2E for shut-off, nor should hand valves upstream of solenoid
20-50mm (3/4" - 2") A4AR, or A2BO4E for 65-100mm valves or downstream of check valves be closed until the
(2-1/2" - 4") A4AR. liquid has been removed. It is advisable to properly install
relief devices in any section where liquid expansion could
For positive electric shut-off, for all sizes A4AR Main Valve,
take place.
use direct operated pilot solenoid Type S6N. See Bul.
30-90C for details. Avoid all piping or control arrangements which might
produce thermal or pressure shock.
Maintenance and Service For the protection of people and products, all refrigerant
GENERAL PROCEDURE: must be removed from the section to be worked on before
Dirt in the system is the greatest single cause of regulator a valve, strainer, or other device is opened or removed.
malfunction. All screens or filters must be cleaned or
Flanges with ODS connections are not suitable for
replaced when they become dirty. At start up it is especially
ammonia service.
important that these items are cleaned or changed
frequently. When the RSF close-coupled companion

SERVICE POINTERS (Check General Procedure)
SYMPTOM PROBABLE REASON CORRECTION
Regulator does not Diaphragm or seat dirty, damaged or frozen. Clean or replace. Clean strainer.
shut off flow.
Diaphragm follower stuck or damaged. Clean or replace. Install follower carefully.
Piston jammed with excess dirt. Remove and polish piston and bore with
crocus cloth. Clean valve and strainer.
Throttling plug leaking due to excess Clean or replace. If used on liquid, check for
dirt or damage. erosion due to excessive flash gas. Reduce
flash gas by sub-cooling or by reducing
pressure drop across valve by providing
restriction at valve outlet.
Diaphragm and seat eroded due to flash gas. Replace. Reduce flash gas by sub-cooling or by
reducing pressure drop across regulator by
providing restriction at valve outlet.
Regulator does not A4A (inlet) Pressure Regulator Diaphragm Replace. If Range D make sure has 2
open. ruptured or badly deformed. diaphragms.
Diaphragm follower stuck, damaged Clean or replace. Install follower carefully.
or frozen.
Piston worn, too much clearance. Replace piston. Check for reason. If used on
liquid, check for flash gas.
Regulator Operation Diaphragm or seat dirty or damaged. Clean or replace. Clean strainer.
erratic.
Diaphragm follower has dirt on the outside Clean or replace.
diameter or outside diameter is damaged.
Other system components, line controllers, Adjust, repair or replace.
thermostats, etc. , erratic.
Regulator too far oversized. Check load. Replace with smaller regulator or
investigate use of Reduced Capacity Plug Kit.
Pressure drop across Inlet or outlet restricted. Check for restriction. Clean strainer.
regulator too high.
Regulator too small. Replace with proper size regulator.
Large amount of flash gas in liquid line. Reduce flash gas by sub-cooling. Reduce line
restriction by increasing line size, particularly
at the regulator outlet. Replace with larger
regulator.
High pressure drop causes high rate of Increase pipe size at the outlet of the
expansion of gas at regulator outlet. regulator.
Regulator does not open all the way. Check piston for wear. Replace, if needed.

Allow 25mm (1”) below valve
to operate manual opening stem.
A4A, A4AE
Fig. 3
PIPING AND LAYOUT FOR STANDARD A4A BACK PRESSURE REGULATOR

PORT SOCKET (E) WELD (F)
A B C PIPE F.P.T. (D)
WELD NECK
SIZE mm INCHES mm INCHES mm INCHES SIZE mm INCHES mm INCHES mm INCHES
¾” ¾” 216 8.5” 216 8.5" 254 10.0”
& 164 6 2" 244 9.6” 392 15.4” 1” 216 8.5" 216 8.5” 261 10.3”
1” 1-1 / 4” 216 8.5” 216 8.5” 261 10.3”
1-1 / 4” 256 10.1” 256 10.1” 300 11.8”
1-1/4” 203 8 0" 248 9.8” 410 16.1” 1-1/2" 256 10.1” 256 10.1” 304 12.0"
1-5/8" 1-1/2" 307 12.1” 307 12.1” 364 14 .3"

& 251 9.9” 287 11.3" 464 18.2” 2” 307 12.1” 307 12.1” 371 14.6"
2”
2-1/2” 331 13.0” 331 13.0” 401 15.8”
2-1/2” 252 9.9” 302 11.9” 483 19.0”
3” 389 15.3” 389 15.3” 478 18.8”
3” 311 12.2" 324 12.8” 597 23.5”
4” 359 14.1” 361 14.2” 653 25.7” 4” 450 17.7” 450 17.7” 571 22.5”

Allow 25mm (1”) below valve
to operate manual opening stem.
A4AR
Fig. 4
PIPING AND LAYOUT FOR STANDARD A4A BACK PRESSURE REGULATOR

PORT SOLDER O.D. SOLDER (G)
H J K L M
TUBE O.D.S.
SIZE mm INCHES mm INCHES mm INCHES mm INCHES mm INCHES mm INCHES mm INCHES
¾" 28.57 1-1/8" 286 11.3"
& 34.92 1-3/8" 285 11.2" 117 4.6" 98 5.9" 241 9.5" 71 2.8" 97 3.8"
1" 41.27 1-5/8" 299 11.8"
34.92 1-3/8" 324 12.8"
1-1/4" 41.27 1-5/8" 339 13.3" 117 4.6" 178 7.0" 254 10.0" 76 3.0" 102 4.0"
53.97 2-1/8" 370 14.6"
1-5/8" 41.27 1-5/8" 414 16.3"
& 53.97 2-1/8" 404 15.9" 140 5.5" 251 9.9" 307 12.1" 114 4.5" 140 5.5"
2” 66.67 2-5/8" 429 16.9"
66.67 2-5/8" 432 17.0"
159 6.2" 314 12.4" 325 12.8" 130 5.1" 155 6.1"
2-1/2" 79.37 3-1/8" 468 18.4"
79.37 3-1/8" 496 19.5"
3" 176 7.0" 314 12.4" 432 17.0" 152 6.0" 178 7.0"
92.07 3-5/8" 542 21.3"
4" 104.78 4-1/8" 613 24.1" 222 8.9" 363 14.3" 478 18.8" 157 6.2" 183 7.2"

FLANGES
VALVE À FPT FLANGES WELDING FLANGES Ã FLANGES
SIZE Nominal Sock Weld Weld Neck Flange Package Tubing Fitting
Nom. Flange Pipe Size Sock t I.D. Neck O.D. Number(2/Pkg) O.D. I.D. Flge Pkg.
Pipe Size Pkg. No. Á Socket Weld Â No. (2/Pkg)
mm Inches Inches (2/Pkg) Inches NW No. Inches mm Inches mm Weld Neck Inches mm Inches mm
20 3/4 3/4 200016 3/4 20 1.070 27.81 1.050 26.67 200020 200023 1-1/8 28.57 1.130 28.70 200027
and and 1 200017 1 25 1.365 34.67 1.315 33.40 200021 200024 1-3/8 34.92 1.380 33.05 200028
25 1 1-1/4 200018 1-1/4 32 1.705 43.31 1.660 42.16 200022 200025 1-5/8 41.27 1.631 41.43 200029
1-1/4 200030 1-1/4 32 1.705 43.31 1.660 42.16 200032 200034 1-3/8 34.92 1.380 35.05 200036
32 1-1/4 1-1/2 200031 1-1/2 40 1.930 49.02 1.900 48.26 200033 200035 1-5/8 41.27 1.631 41.43 200037
2-1/8 53.97 2.131 54.13 200038
40 1-5/8 1-1/2 200039 1-1/2 40 1.930 49.02 1.900 48.26 200041 200043 1-5/8 41.27 1.631 41.43 200045
and and 2 200040 2 50 2.445 62.10 2.375 60.33 200042 200044 2-1/8 53.97 2.131 54.13 200046
50 2 2-5/8 66.67 2.631 66.83 200047
65 2-1/2 2-1/2 200048 2-1/2 65 2.945 — 2.875 73.03 200049 200050 2-5/8 66.67 2.631 66.83 200051
3-1/8 79.37 3.131 79.53 200052
75 3 3 200053 3 80 3.575 90.81 3.500 88.90 200054 200055 3-1/8 79.37 3.131 79.53 200056
3-5/8 92.07 3.631 92.23 200057
100 4 4 200062 4 100 4.575 116.20 4.500 114.30 200063 200064 4-1/8 104.77 4.132 104.95 200065
À FPT: Internal NPT (USA Standard Taper Pipe Thread). Flange Bolt Torque Requirements
Á NW: Metric equivalent nominal size for steel tubing. Bolt Diameter Valve Port Size Torque
Â Metric copper tubing used for refrigeration. 11 mm (7/16") 13mm (1/2 ") 3.9 mkg (28 ft lb)
Ã ODS connections to fit copper tubing of given outside
16m m (5/8") 20-50mm (3/4 "- 2") 11.8 mkg (85 ft lb)
diameter. (Not for use with ammonia)
19m m (3/4") 65-75mm (2-1/2 "- 3") 14.5 mkg (105 ft lb)
Definitions: 22mm (7/8") 100mm (4") 22.1 mkg (150 ft lb)
ODS - Outside Diameter Sweat
I.D. - Inside Diameter
O.D. - Outside Diameter
N.A. - Not Available
Warranty
All Refrigerating Specialties Products are warranted including any warranty of merchantability or warranty
against defect in workmanship and materials for a period of fitness for a particular purpose and in no event is
of one year from date of shipment from factory. This Refrigerating Specialties responsible for any
warranty is in force only when products are properly consequential damages of any nature whatsoever. No
installed, field assembled, maintained and operated in use employee, agent, dealer or other person is authorized to
and service as specifically stated in Refrigerating give any warranties on behalf of Refrigerating Specialties,
Specialties Catalogs or Bulletins for normal refrigeration nor to assume, for Refrigerating Specialties, any other
applications, unless otherwise approved in writing by liability in connection with any of its products.
Refrigerating Specialties Division. Defective products, or
parts thereof, returned to the factory with transportation
charges prepaid and found to be defective by factory Factory Repair and Rebuilding
inspection will be replaced or repaired at Refrigerating For the convenience of our customers, we have a standard
Specialties’ option, free of charge, F.O.B. factory. Warranty factory repair and rebuilding service. Repairable returned
does not cover products which have been altered or Regulators are disassembled, cleaned, sandblasted, worn
repaired in the field; damaged in transit, or have suffered parts replaced, reassembled and re-painted. For quickest
accidents, misuse, or abuse. Products disabled by dirt, service, it is advisable that this be done during the off
or other foreign substances will not be considered peak season.
defective.
The express warranty above constitutes the only warranty
of Refrigerating Specialties products, and is in lieu of all
other warranties, expressed of implied, written or oral,
Parker Hannifin Corporation • Refrigerating Specialties Division 12

2445 South 25th Avenue • Broadview, IL 60155-3891
Telephone: (708) 681-6300 • Fax (708) 681-6306
C A R T R I D G E H E AT E R S
Hi-Temp Cartridge heaters are designed for

optimum performance above and beyond
the norm.
®
CARTRIDGE
HEATERS
HI-TEMP OPEN AIR TEST WATT DENSITY CALCULATIONS: The subtraction of 3/4” from the overall
length in the above equations is a general
This test was conducted using a 5/8” dia. x 6” Watt density of a Hi-Temp Cartridge is
allowance for the watt density calculations
(15.8 mm x 152 mm) long, 750 watt 240 volt simply the total heater wattage divided by
on Standard Cartridge heaters only.
Hi-Temp Cartridge heater. The test was con- the heated area of the cartridge in square
ducted in ambient air 70º F (21º C). A type ‘J’ inches. Hi-Temp Cartridge heaters, heated length
thermocouple was attached to the heater at varies depending upon heater diameter
the center of the sheath. The voltage was Watt Total Heater Wattage and length.
=
varied through a variac to obtain proper Density
(Heated Length) x Cartridge Dia. x 3.14 For specific unheated sections contact
power input for corresponding watt density. Fast Heat.
Heated Length = OAL – Unheated Sections
(OAL - Overall Length)
1600º F (871º C)
APPROXIMATE TEMPERATURE IN DEGREES AT THE
1500º F (815º C)
1400º F (760º C)
CENTER OF THE HEATER
1300º F (704º C)
1200º F (649º C)
1100º F (593º C)
1000º F (538º C)
900º F (482º C)
800º F (427º C)
10 w/in2 20 w/in2 30 w/in2 40 w/in2 45 w/in2

(1.6 w/cm2) (3.1 w/cm2) (4.7 w/cm2) (6.2 w/cm ) (7 w/cm2)
2
WATTS PER SQUARE INCH / WATTS PER SQUARE CM SHEATH; HI-TEMP CARTRIDGE
HEATER (THIS GRAPH FOR REFERENCE ONLY)
FAST HEAT, INC. 21

STANDARD
CARTRIDGE HEATERS
STANDARD CARTRIDGES MATERIAL AND CONSTRUCTION • U.L. approved and C.S.A. certified flexible
nickel conductor with fiberglass insulated
Our Standard Cartridge heaters are • Computer designed specifications.
lead wire 482º F, (250º C) is standard.
designed as an economical, quality heater • 304 stainless steel sheath for oxidation Mica tape/fiberglass insulated 842º F,
for lower temperature use (typically 40 resistance. (450º C) available when requested
watts per square inch, depending on the
• Ceramic insulator spaces helically wound as dictated by the application.
application). Standard Cartridges can meet
U.L./C.S.A. approval, use the chart on page resistor inside the sheath. • Disc end of the heater rests on a mica
151 for reference and consult factory. • Helically wound nickel chromium resistor insulator and is held in position when
is of a conservative design for each the sheath is rolled over onto it. This is a
The Standard Cartridge Heater is made to
application and evenly stretched through standard assembly procedure unless the
withstand internal temperatures of up to
the ceramic insulators. application requires moisture or water-
1000º F (538º C) and features a stainless
proof sealing, at which time the end cap
steel sheath for resistance to oxidation. • Fine grain high purity magnesium oxide can be sealed by brazing or welding.
High-purity magnesium oxide (MgO) fills (MgO) fills any voids around the resistor
any space around the resistor wire in order wire to optimize heat transfer, dielectric • Ceramic cap standard; cement, epoxy or
to optimize heat transfer and increase the strength and life of the heater. RTV seal also available.
life of the heater.
• Resistor wire is joined to the leads by
For faster shipment, Standard Cartridges are placing each end into nickel chromium
available through our Fast Track delivery which, upon crimping, affords a positive
program. Refer to page 2 for a complete and consistent junction.
description of these rapid delivery programs. Crimped tubing
Core
APPLICATIONS MgO
Standard Cartridge heaters can be used in
virtually any application involving lower
temperatures and relatively little vibration or Spacer
impact. Some examples include sealing bars,
heating platens, heating fluids and forming.
Standard Cartridges can also be modified to
meet the demands of special applications.
Our engineers can utilize a variety of alterna- Ceramic cap
tive features and options to customize the
heater to your specific needs.
Lead wire
FEATURES AND BENEFITS

• Wide range of diameters.
• Many termination styles.
• Voltage variations.
• U.L. approved and C.S.A. recognized.
• Top quality ceramic element support.
• Unique winding design allows faster
heating and longer life.
• High purity MgO packing for even
heat distribution. THE STANDARD CARTRIDGE HEATER
• Fiberglass insulated lead wire is standard.
Other lead wire insulation available
upon request.
8 FAST HEAT, INC.

STANDARD
CARTRIDGE HEATERS
SPECIFICATIONS DIAMETER TOLERANCE There may be applications where, due to

the wattage requirement, it would be
Wattage Tolerances: +5% – 10% based on ENGLISH SIZES METRIC EQUIVALENT
appropriate to specify a Standard Cartridge
Nema standards. 3/16” (0.1875) = .183 ± .001 4.6 mm ± .02 heater but the application dictates that a
Resistance Tolerances: +10% – 5% to give 1/4” (0.250) = .245 ± .002 6.3 mm ± .05 Hi-Temp be considered. Such applications
above power tolerances. Note that above are where distributed wattage is required or
5/16” (0.312) = .308 ± .002 7.8 mm ± .05
tolerances are based on internal operating the heater would be subjected to extreme
temperature since the room temperature 3/8” (0.375) = .370 ± .002 9.4 mm ± .05 vibration or impact in operation.
resistance of an element wire is normally
7/16” (0.437) = .432 ± .002 11.0 mm ± .05 Contact Fast Heat for higher voltage and
8.5% lower than when operating.
1/2” (0.500) = .494 ± .003 amperage ratings, and special diameters
12.6 mm ± .07
Standard voltages are 120V or 240V. 120V or tolerances.
max. for short length units 3/16”, 1/4”, and 9/16” (0.562) = .562 ± .003 14.3 mm ± .07
5/16” dia. (4.7, 6.3, 7.9 mm).
5/8” (0.625) = .620 ± .003 14.3 mm ± .07
11/16” (0.687) = .681 ± .003 15.8 mm ± .07
SPECIAL NOTE ON WARRANTY 3/4” (0.750) = .744 ± .003 17.3 mm ± .07
Heaters with an operating voltage higher 13/16” (0.812) = .812 ± .003 20.6 mm ± .07
than 250 Volts must be larger than or
7/8” (0.875) = .869 ± .003 22.2 mm ± .07
equal to 5/8” diameter to be eligible for
a warranty. 15/16” (0.937) = .932 ± .002 23.7 mm ± .07
1” (1.000) = .992 ± .005 25.2 mm ± .12
1 1/4” (1.250) = 1.244 ± .003 31.6 mm ± .12 AVOIDING COMMON HEATER
FAILURE MODES
METRIC SIZES Use recommended maximum watt
10 mm = 9.8 ± .05 ENGLISH EQUIVALENT density range to avoid excessive watt
.394” = .389” ± .003 densities which result in the internal
overheating of the heater.
Sheath A clean and properly bored hole in rela-
Length Tolerances: ± .062” (1.6 mm). tion to heater diameter is required for
For closer tolerances contact Fast Heat. good heat transfer.
End disc
The Fast Heat Standard Cartridge heater is Be aware that moisture/contamination
Resistor computer designed and specified to include
coil will reduce the life expectancy of a heater.
components that are equal to the wide Consider specifying that either the disc or
variety of applications to which this style of lead end or both be sealed, depending
heater will be subjected. upon the specific conditions to which the
As with the Hi-Temp Cartridge heater, a heater is being subjected.
variety of termination styles can be adapted Review lead exit variations and select the
to this style of heater. When there are style that best suits your particular
termination requirements other than the application. Consider such conditions as
ones illustrated, please contact Fast Heat. contamination, abrasion, flexing and
sharp bending of the leads as they exit
the heater.
It is recommended that watt density be
reduced by 20% for those heaters
subjected to frequent cycling.
To avoid burn-out by operating in open
air, heated length must always be fully
inserted. In addition, an exposed heated
section of the heater may cause a
hazardous condition.
FAST HEAT, INC. 9

HI-TEMP/STANDARD
CARTRIDGE HEATERS
FLEXIBLE LEADS Internally connected leads.

Overall length Hi-Temp For applications requiring maximum
flexibility at lead exit.
10” (25.4 cm) leads standard, other lengths
are available.
Standard
EXTERNALLY CONNECTED LEADS Hi-Temp Cartridges are provided with

approx. 1” (25.4 mm) sleeving over lead
Overall length Hi-Temp junction as standard.
are available.
Standard
STRAIGHT LEADS W/SILK AND PAINT Repairable silk and paint leads for Standard
Cartridges.
Overall length Hi-Temp
Hi-Temp Cartridges are provided with
approx. 1” (25.4 mm) sleeving as standard.
Silk and paint leads are optional on
Hi-Temps.
are available.
Standard
STRAIGHT LEADS W/CLIP SUPPORT Clip support helps to minimize lead

Hi-Temp breakage where leads exit heater.
Overall length
are available.
Standard
10 FAST HEAT, INC.

HI-TEMP/STANDARD
CARTRIDGE HEATERS
STRAIGHT STRAIN RELIEF SPRING Straight strain relief spring minimizes

bending strain on lead wires.
Overall length Hi-Temp Spring extends approximately 3” (76.2 mm)
beyond end of sheath.
Standard
BRAID OVER PAIR OF LEADS Stainless steel braid over lead wires.
For applications requiring small radius
bending and lead wire abrasion protection.
10” (25.4 cm) braid standard, other lengths
are available.
Standard
SQUARE-LOCK ARMOR STRAIN RELIEF Straight stainless steel armor cable protects
leads from abrasion.
Armor sizes include:
Square-lock - 1/4”, 5/16”, 1/2”, and 5/8”.
Convoluted - 3/8”, and 5/8” only.
(Moisture-resistant)
10” (25.4 cm) standard, other lengths
are available.
Standard
CONVOLUTED ARMOR STRAIN RELIEF
?
POTTING SYSTEMS AVAILABLE
1. Cement 1000º F (538º C)
2. Epoxy 300º F (149º C)
3. RTV® 500º F (260º C)
4. Teflon® Cap 500º F (260º C)
• Cement seal can be wiped with a
Silicon® varnish to inhibit moisture
penetration.
CONVOLUTED ARMOR Standard • Teflon® Cap requires an extended
• Used in situations that require moisture resistant armor.
• Available in most instances in which armor is utilized. lead time.
• Some size restrictions apply.
FAST HEAT, INC. 11

HI-TEMP/STANDARD
CARTRIDGE HEATERS
N.P.T. BUSHING Hex head N.P.T. bushing attached.

Insert length Hi-Temp Must specify insert length and bushing
material.
Sheath material types: stainless steel, cold
rolled or galvanized.
Bushing material types: brass, stainless steel
or steel.
are available.
For immersion applications, specify sealed
Standard end. Up to 3⁄4” (19 mm) dia. Octagonal
box available.
HEX CENTER BUSHING Hex head N.P.T. bushing attached.

Must specify insert length and bushing
material.
Insert length Hi-Temp
Sheath material types: stainless steel, steel
or brass.
or steel.
Contact Fast Heat for available NPT Bushing sizes. are available.
For immersion applications, specify sealed end.
Octagonal or explosion-proof boxes can be
adapted to both Standard and Hi-Temp
Cartridge heaters.
Standard
Consult Fast Heat for details.
ADAPTERS Must specify insert length and bushing
material.
rolled or galvanized.
or steel.
are available.
Contact Fast Heat for available Adapter sizes. Standard end. 5⁄8” to 1” (15.8 mm to 25.4 mm) dia.
ADAPTERS WITH HEX HEAD Must specify insert length.

Insert length Hi-Temp Bushing material is copper.
are available.
end. Up to 3⁄4” (19 mm) dia.
Contact Fast Heat for available Adapter sizes. Standard
12 FAST HEAT, INC.

HI-TEMP/STANDARD
CARTRIDGE HEATERS
ARMOR WITH PLUG Armor cable with power plug attached.

Must specify armor length and Hubbell®
power plug number.
Moisture-resistant armor available.
Other Plugs are available, contact Fast Heat
or see page 26 of our QuickShip catalog.
Armor length
Standard
BUSHING, ARMOR AND PLUG Hex head N.P.T. bushing and armor cable
with power plug attached.
rolled or steel.
Must specify insert length, bushing material,
armor length and Hubbell® power plug
number.
Armor length
Standard
BOLT HEATER Fast Heat bolt heaters are designed to
heat drilled metal surfaces quickly while
Insert length minimizing heat loss to surrounding areas.
Each is designed to expand drilled bolts or
studs while maintaining a uniform heat
throughout its heated length. Typically, after
a bolt is heated (expanded) the holding nut
is tightened. The shrink tightness is obtained
when the heater is removed and the bolt
cools. This process is frequently used in the
Standard assembly and/or servicing of heavy duty
equipment such as compressors, steam
turbines, pressure vessels, etc.
FAST HEAT, INC. 13

HI-TEMP/STANDARD
CARTRIDGE HEATERS
RIGHT ANGLE ELBOW Hi-Temp Right angle copper elbow for applications
requiring right angle lead exit.
B Insert length
Moisture-resistant seal is optional.
A
are available.
C Both Hi-Temp and Standard Cartridges are
also available with stainless steel braid over
the leads (See Standard at left).
Standard
Standard leads
Braid over leads
RIGHT ANGLE ELBOW W/SPRING Hi-Temp

Right angle copper elbow with spring for
B Insert length applications requiring right angle lead exit
A and reduced bending strain on lead wire.
Spring approximately 3” (76.2 mm) long.
C 10” (25.4 cm) leads standard, other lengths

are available.
ELBOW DIMENSIONS
A B C
Standard IN MM IN MM IN MM
3/8 9.5 1 25.4 1 25.4
1/2 12.8 1 1⁄4 31.8 1 1⁄4 31.8
5/8 15.9 1 1⁄4 31.8 1 1⁄2 38.1
3/4 19.1 1 5⁄8 41.3 1 1⁄2 38.1
RIGHT ANGLE ELBOW W/ARMOR Hi-Temp

Right angle copper elbow with armor cable
for applications requiring right angle lead
B Insert length
exit and lead wire abrasion protection.
A
Moisture-resistant armor and seal are
optional.
C 10” (25.4 cm) armor standard, other lengths
are available.
Both Hi-Temp and Standard Cartridges
are available with either Convoluted or
Square-Lock Armor over the leads.
Standard
Convoluted Armor
NOTE: Convoluted armor is available in
Square-Lock Armor 3/8” and 5/8” diameters.
14 FAST HEAT, INC.

HI-TEMP/STANDARD
CARTRIDGE HEATERS
90º LEADS W/CLIP Hi-Temp

Clip support helps to minimize lead
breakage where leads exit heater.
Insert length
are available.
Standard
90º LEADS Hi-Temp Leads exit at 90º angle for applications

requiring small radius bends, lead wire
D protection and where space is limited.
Overall length
A 10” (25.4 cm) braid standard, other lengths
are available.
Order by overall length.
Standard
90º LEADS W/S. ST. BRAID Hi-Temp Braided leads exit at 90º angle for applica-
D tions requiring small radius bends, lead wire
Overall length
protection and where space is limited.
A 10” (25.4 cm) braid standard, other lengths
are available.
Standard
90º S. ST. ARMOR Hi-Temp Armor cable exit at 90º angle for applications
D where space is limited and lead wire
Overall length abrasion protection is required.
A 10” (25.4 cm) armor standard, other lengths
are available.
A D (min.)
Standard IN MM IN MM
3/8 9.5 3/8 9.5

1/2 12.7 1/2 12.8
5/8 15.9 5/8 15.9
3/4 19.0 3/4 19.0
FAST HEAT, INC. 15

HI-TEMP/STANDARD
CARTRIDGE HEATERS
SCREW TERMINALS Screw terminals for applications with high

Hi-Temp
amps and requiring universal connection
capability. Screw terminals are attached to
Overall length 1“ external pins.
Standard Cartridge 10-32 screw terminal on
3⁄8” to 15⁄16” (9.5 mm - 23.8 mm) dia.
3⁄4“ Hi-Temp 1⁄2” to 3⁄4“ (12.7 mm - 19 mm) dia.

NOTE: The Terminal dimensions shown are
approximate size.
Standard
SCREW TERMINALS Screw terminals are flush with cap.

Overall length 3⁄4“ Standard Cartridge 10-24 screw terminal 1”
to 11⁄4” (25.4 mm - 31.8 mm) dia.
approximate size.
1/2” -
5/8”
Standard
SCREW TERMINALS Screw terminals for applications with high

Hi-Temp amps and requiring universal connection
capability.
Overall length 3⁄4“
Standard Cartridge 10-32 screw terminal 1⁄2”
to 11⁄4” (12.7 mm - 31.7 mm) dia.
Hi-Temp 10-32 screw terminal 1⁄2” to 3⁄4“
(12.7 mm - 19 mm) dia.
approximate size.
Standard
16 FAST HEAT, INC.

THERMOCOUPLE LOCATION
CARTRIDGE HEATERS
T/C AT BOTTOM BOTTOM GROUNDED

For fast response, heater is positioned in a
blind hole or where material flows past or
encompasses the heater.
The end disk is always welded in place.
Machined flat up to 1⁄2“ (12.7 mm) dia.
Hi-Temp
BOTTOM UNGROUNDED
Where circumstances are such that an
ungrounded thermocouple is required.
Hi-Temp
T/C AT CENTER CENTER GROUNDED

Selected when a fast response is required.
The thermocouple can be located in any
position along the length of the heater.
Standard location is midway along the
length with approximately 1⁄4” (6.4 mm)
cold section on either side of the junction.
Hi-Temp
Not available on 1/4” diameter heaters.
CENTER UNGROUNDED
The thermocouple is positioned internally
and ungrounded to monitor the heater
temperature.
Generally used in research and
Hi-Temp
development applications.
REMOVEABLE THERMOCOUPLE REMOVEABLE THERMOCOUPLE

The thermocouple is inserted down a
hypotube for easy removal.
HI-TEMP T/C LOCATION AVAILABILITY

Hi-Temp HTR GROUNDED UNGROUNDED
DIA. BOTTOM CENTER BOTTOM CENTER
1/4” (6.4 mm) Y N Y Y
5/16” (7.9 mm) Y N Y Y
? T/C AVAILABILITY
All heaters shown are Hi-Temp
10” leads, type “J” T/C standard,
T/C available in all Standard Cartridge
heaters. Located at bottom ungrounded
and center ungrounded.
3/8” (9.5 mm)
1/2” (12.7 mm)
Y
Y
Y
Y
Y
Y
Y
Y
type “K” T/C is available. 5/8” (15.9 mm) Y Y Y Y
FAST HEAT, INC. 17

SQUARE
CARTRIDGE HEATERS
FLEXIBLE LEADS Internally connected leads.

For applications requiring maximum
Overall length flexibility at lead exit.
are available.
BRAID Stainless steel braid over lead wires.

For applications requiring small radius
Overall length bending and lead wire abrasion protection.
are available.
ARMOR Straight stainless steel armor cable protects

leads from abrasion.
Overall length
10” (25.4 cm) armor standard, other lengths
are available.
Square-Lock Armor 3/8” and 5/8” diameters.
Convoluted Armor
SPRING Straight strain relief spring minimizes bend-

ing strain on lead wires.
Overall length Spring extends approx. 3“ (76.2 mm) beyond

end of sheath.
are available.
NOTE: All of the Square Cartridge heaters

are available in either Hi-Temp (85 to 90
watts per square inch, depending on the
application) or Standard (35 to 40 watts per
square inch, depending on the application).
18 FAST HEAT, INC.

SQUARE
CARTRIDGE HEATERS
STRAIGHT CLIP SUPPORT Clip support helps to minimize lead

Overall length 10” (25.4 cm) leads standard, other lengths
are available.
90º CLIP SUPPORT Clip support helps to minimize lead

Overall length 10” (25.4 cm) leads standard, other lengths
are available.
WIDTH
SIZE TOLERANCE DIM. A MAX.
3/8” x 3/8” .370” ±.002” 7/16”

(9.5 mm x 9.5 mm) (9.4 mm ±.05 mm) (11.1 mm)
1/2” x 1/2” .495” ±.002” 9/16”
(12.7 mm x 12.7 mm) (12.6 mm ±.05 mm) (14.3 mm)
5/8” x 5/8” .620” ±.002” 11/16”
(15.9 mm x 15.9 mm) (15.7 mm ±.05 mm) (17.5 mm)
90º ARMOR Armor cable exit at 90º angle for applica-
A tions where space is limited and lead wire
abrasion protection is required.
Overall length
10” (25.4 cm) armor standard, other lengths
are available.
3/8” and 5/8” diameters.
Square-Lock
Armor
Convoluted Armor
90º BRAID Braided leads exit at 90º angle for applica-

A tions requiring small radius bends, lead wire
protection and where space is limited.
Overall length
are available.
FAST HEAT, INC. 19

CARTRIDGE
HEATERS
PRECISION STANDARD SQUARE APPLICATIONS APPLICATION FOR SELECTION OF

CARTRIDGE HEATERS Square Cartridge heaters can be used in CARTRIDGE HEATERS IN PLATENS
Our Square Cartridge heaters, 3/8” (9.5 mm), virtually any application involving average Whether round or square cartridges are
1/2” (12.7 mm), and 5/8” (15.9 mm) square, temperatures and vibration. Some examples used, close contact of the heater to the
provide more surface area contact than include sealing bars, heating platens, component being heated is important.
cylindrical types. Square Cartridge heaters heating fluids and forming. When the application is such that the hole
are normally inserted in a milled slot, there- Square Cartridges can also be modified to into which a round heater is to be inserted is
fore permitting greater lengths than would meet the demands of virtually any special too long for practical drilling and reaming, a
be practically feasible with a drilled or application. Our engineers can utilize a vari- Square Cartridge can be selected.
reamed hole. ety of alternative features and options to By considering a split plate design, platen
As with our Standard Cartridge, Fast Heat’s customize the heater to your specific needs. recesses for the Square heater can be milled
Square Cartridge heater features a stainless for greater lengths or to keep the machine
steel sheath for resistance to oxidation and in-house.
can withstand internal temperatures of up
to 1000º F (538º C). In order to optimize heat For even heating along the length of the
transfer and lengthen the life of the heater, heaters, consider distributed wattage.
high-purity magnesium oxide (MgO) insula- If terminations are protected by a wire
tion fills any space around the resistor wire. enclosure box and the platen is operating in
excess of 450º F (232º C), consider specifying
high temperature mica tape leads.
To leads that are flexing, add clip supports;
where there is abrasion, cover the leads with
stainless steel braid. For possible contamina-
tion, request armor.
20 FAST HEAT, INC.

HI-TEMP/STANDARD CARTRIDGE
IMMERSION HEATERS
CARTRIDGE IMMERSION HEATER Attention must be given to selecting SPECIFICATIONS

the proper watts per square inch for the
Immersion cartridge heaters may be TOLERANCES:
material to be heated. Refer to the watt
selected when a tubular style heater may
density chart on page 150. Wattage: + 5% -10% based on NEMA standards
be too large for the application.
There are applications, because of the MAX. VOLTAGES:
Heaters are constructed using the Fast Heat
surrounding exterior of the container, in
Hi-Temp design allowing for higher watt 1/2” (12.7 mm) diameter & below: . . 240 V AC
which a terminal box will not be required.
densities, thus making it possible to concen- 5/8” (15.9 mm) diameter: . . . . . . . . . . . 480 V AC
trate more heat into a smaller package. Most standard immersion heater designs 3/4” (19.1 mm) diameter: . . . . . . . . . . . 480 V AC
can be adapted to fit special applications.
Standard designs are listed in this section; 1” (25.4 mm) diameter: . . . . . . . . . . . . . 480 V AC
however, heaters of other diameters,
lengths and fitting sizes for similar BUSHING MATERIALS:
FEATURES AND BENEFITS
applications can be designed. Stainless steel, Brass, and CRS
• Durable sheath material designed for
Disc end of heater opposite the lead end is LEADS:
welded. Lead end is sealed against moisture. water or oil immersion.
• Magnesium oxide provides an excellent Conductor and insulation selected with
heat transfer medium. respect to the design and environment
APPLICATIONS exterior to the heater.
• Resistance wire is precision wound to
This type of immersion heater can be found SHEATH MATERIALS:
provide long heater life.
in applications where hot water for
food/beverage vending, hot water for • N.P.T. fitting provides easy installation. Stainless steel
processing applications, etc. is required. Incoloy®
• BX Box isolates lead wires.
Optimum utilization of heat is experienced
when an immersion heater can be adapted
to a fluid heating application.
Durable sheath material designed for Magnesium oxide provides an

water or oil immersion. excellent heat transfer medium.
N.P.T. fitting provides easy

installation.
Resistance wire is precision wound to BX Box isolates lead wires.

provide long heater life.
CARTRIDGE IMMERSION HEATER
FAST HEAT, INC. 39

HI-TEMP/STANDARD CARTRIDGE
IMMERSION HEATERS
5/8” (15.9 MM) DIA. OIL/WATER

FIBERGLASS LEADS
5⁄8" (15.9 mm) dia.
Insert Length 10" (25.4 cm) fiberglass leads inside

octagonal terminal box.
1⁄2" (12.7 mm) N. P. T. brass bushing.
FIBERGLASS LEADS 3/4” (19.1 MM) DIA. OIL/WATER
3⁄4" (19.1 mm) dia.
Insert Length 10" (25.4 cm) fiberglass leads inside

octagonal terminal box.
3⁄4" (19.1 mm) N. P. T. steel bushing.
5/8” (15.9 MM) DIA. OIL/WATER

SCREW TERMINALS
5⁄8" (15.9 mm) dia.
Insert Length Screw terminals inside octagonal

terminal box.
SCREW TERMINALS 3/4” (19.1 MM) DIA. OIL/WATER
3⁄4" (19.1 mm) dia.

Insert Length
Screw terminals inside octagonal
terminal box.
FITTING CHART
MALE PIPE N.P.T. FITTINGS FOR CARTRIDGE HEATERS

N.P.T. SIZE 1/8" (3.2 mm) 1/4 (6.4) 3/8 (9.5) 1/2 (12.7) 3/4 (19.1)
CART. DIA. 1/4" (6.4 mm) 3/8 (9.5) 1/2 (12.7) 5/8 (15.9) 3/4 (19.1)
Brass, steel or stainless steel fittings are avail-

able for liquid immersion applications. Other
heater N.P.T. combinations available.
40 FAST HEAT, INC.

STOP / STRAINER VALVE BULLETIN 86-00
Port Size 13-100mm (1/2”- 4”)
FOR AMMONIA, R12, R22, R502
AND OTHER COMMON REFRIGERANTS
FEATURES
• Handwheel or Seal Cap
• Replaceable PTFE seat disc
• Full-ported angular seat allows washing action
• Positive shut-off
• Low pressure drop
• 50 & 100 mesh stainless steel screen
• Stainless steel stem with positive back seating
• Drain connection for safe cleaning
• Maximum Safe Working Pressure 400 PSIG March 2003
• Fluid Temperature Range -65°F to +350°F Installation, Service and Parts Information
Description
Safe Operation (See also Bulletin RSB)
The Refrigerating Specialties combination stop/strainer People doing any work on a refrigeration system must be qualified
shut-off valves are designed to provide all the benefits of a and completely familiar with the system and the Refrigerating
typical valve and strainer assembly within a single valve Specialties Division valves involved, or all other precautions will
be meaningless. This includes reading and understanding
body. This unique combination valve decreases the pertinent Refrigerating Specialties Division product Bulletins and
effects of pressure drop in a system by eliminating the Safety Bulletin RSB prior to installation or servicing work.
need for a separate strainer, while reducing system and
Where cold refrigerant liquid lines are used, it is necessary that certain
installation costs. precautions be taken to avoid damage that could result from liquid
expansion. Temperature increase in a piping section full of solid liquid
will cause high pressure due to the expanding liquid that can possibly
rupture a gasket, pipe or valve. All hand valves isolating such sections
should be marked, warning against accidental closing, and must not be
HANDWHEEL SEAL CAP closed until the liquid is removed. Check valves must never be installed
upstream of solenoid valves, or regulators with electric shut-off, nor
should hand valve upstream of solenoid valves or downstream of check
valves be close until the liquid has been removed. It is advisable to
properly install relief devices in any section where liquid expansion
could take place.
Avoid all piping or control arrangements that might produce thermal or

STAINLESS pressure shock. For the protection of people and products, all
STEEL STEM refrigerant must be removed from the section to be worked on before a
valve, strainer, or other device is opened or removed. Flanges with
ODS connections are not suitable for ammonia service.
PTFE SEAT Warranty

DISC All Refrigerating Specialties products are warranted against defects in
workmanship and materials for a period of one year from date of shipment
from originating factory. This warranty is in force only when products are
properly installed, field assembled, maintained, and operated in use
and service as specifically stated in Refrigerating Specialties Catalogs
or Bulletins for normal refrigeration applications, unless otherwise
approved in writing by Refrigerating Specialties Division. Defective
products, or parts thereof returned to the factory with transportation
charges prepaid and found to be defective by factory inspection will be
replaced or repaired at Refrigerating Specialties option, free of charge
F.O.B. factory. Warranty does not cover products that have been aftered,
or repaired in the field; damaged in transit, accidents, misuse, or abuse.
Products disabled by dirt or other foreign substances will not be
considered defective.
ANGULAR SEAT The express warranty above constitutes the only warranty of Refrigerating
SCREEN Specialties products, and is in lieu of all other warranties, expressed or
ASSEMBLY implied, written or oral, including any warranty of merchantability or
warranty of fitness for a particular purpose and in no event is Refrigerating
Specialties responsible for any consequential damages of any nature
DRAIN CONNECTION whatsoever. No employee, agent, dealer or other person is authorized
to give any warranties on behalf of Refrigerating Specialties nor to
assume for Refrigerating Specialties any other liability in connection
Fig. 1 with any of it products.
Refrigerating Specialties Division 1 I S O 9 0 0 1 C E R T I F I E D
310604
SPARE PARTS
ITEM DESCRIPTION PORT SIZE
1/2 & 3/4 * 1/2 & 3/4 1* 1 1-1/4 1-1/2 2 2-1/2 3
20-24 Handwheel 204268 204268 204268 204268 204269 204269 204269 204269 204270
Seal Cap 204273 204273 204273 204273 204274 204274 204274 204274 204275
10-13 Packing Kit 204471 204471 204471 204471 204472 204472 204472 204472 204473
5-14 Bonnet Asm 206865 206865 206866 206866 206867 206868 206869 206870 206871
15, 18 Screen Asm 206873 206873 206874 206874 206874 206875 206876 206877 206878
6-8 Disc Kit 204321 204322 204323 204324 204325
2 Gasket Pkg Bonnet 204281 204281 204282 204282 204283 204283 204284 204285 204286
Gasket Pkg Seal Cap 204292 204292 204292 204292 204292 204292 204292 204292 204293
* 2 Bolt body construction 20

ITEM DESCRIPTION
22 21
1 Body
2 Gasket, Bonnet 23
3 Bonnet
24
4 Stem, Valve
5 Disc Carrier
6 Seat Disc
7 Washer, Retaining
8 Ring, Retaining 13
9 Roll Pin
11 10
10 Packing Cartridge
11 O-ring, Bonnet
12 O-ring, Stem 12 3
13 Packing Nut
14 Bolt, Bonnet
14
15 Screen
16 Bottom Cap
17 Gasket
18 Spring
19 Bolt, Cover
20 Plug 4
5 9
7 6
8
1
15
16 17
18
19
20
OV E RA LL V A LV E DIM E NS IONS
1/2" & 3/4"* 1/2" & 3/4" 1"* 1" 1-1/4" 1-1/2" 2" 2-1/2" 3" 4"
(13 & 20 (13 & 20
P ORT S IZE (25 M M ) (25 M M ) (32 M M ) (40 M M ) (50 M M ) (65 M M ) (75 M M ) (100 M M )
MM) MM)
M M INCH M M INCH M M INCH M M INCH M M INCH M M INCH M M INCH M M INCH MM INCH MM INCH
Aw 197 7.75 197 7.75 235 9.25 235 9.25 200 7.87 204 8.03 233 9.18 231 9.12 290 11.43 231 13.03
As 216 8.50 216 8.50 230 9.03 230 9.03 212 8.37 220 8.68 231 9.12 324 12.75 324 12.75 354 13.93
B 57 2.25 57 2.25 82 3.25 82 3.25 89 3.50 108 4.25 125 4.93 149 5.87 162 6.37 212 8.37
C 85 3.37 165 6.50 108 4.25 192 7.56 216 8.50 235 9.25 260 10.25 260 10.25 324 12.75 406 16.00
W 85 3.37 85 3.37 108 4.25 98 3.87 104 4.12 109 4.31 113 4.56 130 5.12 180 7.12 238 9.37
* 2 Bolt body construction

** Dimension AW is for the stem in wide open (back seated position)

June 2000 / BULLETIN 50-10
TYPE 6000 SERIES
STRAINERS
TYPE 8000 SERIES
for REFRIGERANTS / BRINE / WATER / OIL
All cleanable strainers have an access for easy re-

moval of the screen assembly. This facilitates clean-
TYPE XD ing and inspection, without breaking the line con-
nections.
TYPE 9000
SERIES MESH SIZES
Depending upon the type of application, screen as-
sembly mesh sizes of 80 and 100 are recommended
in strainers for refrigerant liquid line applications
up to and including 1-1/8 line sizes. A 60 mesh
Sporlan Strainers are designed for either liquid or screen is recommended for strainers on lines larger
suction line applications. They provide free flow than 1-1/8 OD.
with negligible pressure drop and can be used for a
variety of liquids. Screen assemblies of 40 mesh size are recommended
for refrigerant suction line applications, and for the
All Sporlan Strainers contain the maximum effec- majority of applications involving water, brine, and
tive screen area. Screen assemblies are seam other liquids. Excessive pressure drop develops in
welded, and the ends reinforced or capped with seal screen assemblies of 80 and 100 mesh are used for
rings. This construction reduces the possibility of such applications.
bursting the screen assembly. The end of the screen
assembly seats against the flange plate to form a The mesh size of the screen assembly in a strainer
tight seal, thereby preventing dirt from bypassing is stamped on the flange cap and/or seal plug of
the strainer screen. each strainer.
“ Y ”TYPE FORGED BRASS STRAINER
TYPE 6000 STRAINER suitable for brine and water applications, and other
liquids where a strainer made of nonferrous material is desirable.
These strainers have a forged brass body, and stainless steel wire cloth
screen. Types 6022 through 6088 have a knife edge seal plug. The maxi-
mum safe working pressure is 500 psig.
CONNEC- SCREEN WEIGHT - Lbs. DIMENSIONS - Inches

TYPE MESH
TIONS
NO. AREA PART SIZE SHIP-
Inches NET A B C
Sq. In. NO. PING
6022 4 FPT
2 4385-2 2.25 1.00 2.06
6023 a FPT 80 1 1-2
6034 2 FPT 3 4395-2 2.50 1.00 2.50
6056 w FPT 5 4405-1 1-2 2-2 3.25 1.44 3.13
40
6088 1 FPT 8 4415-1 4 5 4.13 1.75 3.88
Bulletin 50-10, June 2000 supersedes Bulletin 50-10 dated July 1996 and all prior publications.
© Copyright 2000 By Sporlan Valve Company, Washington, Missouri.
Page 2 / Bulletin 50-10
SPECIAL PURPOSE STRAINER
TYPE XD STRAINER is for use with Ammonia and

other liquids where a steel construction is suitable. May
be used with companion flange or can be bolted di-
rectly to Type D Thermostatic Expansion Valves and
Type MA5A3 Solenoid Valves.
Semi-cast steel body with FPT inlet and flanged outlet connections. Strainer screen
is stainless steel with a seal plug for screen removal. Complete unit is zinc plated
and painted. The maximum safe working pressure is 500 psig.
CONNECTIONS
SCREEN WEIGHT - Lbs. DIMENSIONS - Inches
TYPE Inches MESH
NO. AREA PART SIZE SHIP-
INLET *OUTLET NET A B C E F G H K L
Sq. In. NO. PING
XD 074 2 FPT Flange 6.6 635-3 100 1-w 3 4.19 1.50 2.25 2.88 2.00 0.78 1.09 0.50 0.13
* Strainers are supplied with female companion flange. Available without flange when so ordered.
“ Y ”TYPE CAST SEMI-STEEL STRAINERS
TYPE 8000 STRAINER is TYPE 9000 STRAINERS for

used primarily for Ammonia large Ammonia (R-717) instal-
(Refrigerant 717), but can lations are also adaptable to
also be used for halocarbon large halocarbon refrigerant
refrigerants (R-22, R-134a (R-22, R-134a and R-404A)
and R-404A) and other liquids where a steel construc- applications, and other liquids where a steel construc-
tion is applicable. FPT inlet, standard two bolt York tion is suitable. The strainer is zinc plated. The maxi-
flange outlet connection. Types 8004 and 8006 strain- mum safe working pressure is 400 psig.
ers can be bolted direct to the inlet of Type A Thermo- FPT inlet, standard four bolt York flange outlet con-
static Expansion Valves or Type MA17A3 Solenoid nections. The Type 9008 and 9010 strainers bolt di-
Valves on Ammonia applications. The unit is zinc rectly to inlet of Types MA32P3 and DMA32P3 Sole-
plated. The maximum safe working pressure is 500 psig. noid Valves.
WEIGHT
SCREEN DIMENSIONS - Inches
TYPE CONNECTION MESH Lbs.
NO. Inches AREA PART SIZE SHIP-
NET A B C D E F G H K L
Sq. In. NO. PING
8004 2 FPT*
15 4097-3 80 5 7 5.69 2.75 5.06 2.06 3.81 2.69 1.28 1.75 0.56
8006 w FPT*
0.13
9008 1 FPT** 11
23 4110-3 60 13 7.56 3.13 7.50 2.44 3.75 1.81 2.31 0.75
9010 1-4 FPT** 10-2
* Strainers are supplied without companion flange. Female companion flange, bolts, and gasket can be supplied when ordered.
** Strainers are supplied without companion flange. Male companion flange, bolts and gasket can be supplied when ordered.
15-600 www.sporlan.com Printed in U.S. of A.

Bulletin C401d
March, 2002
HANSEN TECHNOLOGIES
CORPORATION
Specifications, Applications,
Service Instructions & Parts
HCK4 IN-LINE
CHECK VALVES
5 / 8 " thru 4" PORT
(16 thru 100 mm)
Flanged
3 8
/ " thru 4"
FPT, SW, WN, ODS
for refrigerants
HCK4-4 Check Valve
INTRODUCTION KEY FEATURES

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, ADDITIONAL FEATURES
compressor discharge lines, suction lines, and hot Mounts in any position
gas heated drain pans. Less than 1 PSID wide opening pressure
Can be close-coupled
These valves are not recommended for use with Low bubble leakage tolerance
pulsating loads such as low speed compressor For Ammonia, R22, R134a, and other approved
discharge and screw compressor side port refrigerants
applications. For applications such as these, use Dimensionally replaces R/S CK4A-2, -3, -4, -8, & -1
Hansen HCK1 piston type check valves. U.L. Listed
MATERIAL SPECIFICATIONS INSTALLATION
Body: Valve may be located in any position. Arrow on
5 / 8 " thru 1¼": Steel, ASTM A108, zinc chromate valve body should match direction of flow. Secure
plated valve with gaskets between flanges and tighten
1½" thru 4": Ductile iron, ASTM A536, zinc bolts evenly. Do not use this valve or any component
chromate plated to align pipes or tighten gap between flanges.
Seat Disc: Stainless steel
Seat Cartridge: Do not install on inlet side of solenoid valves or
5 / 8 " thru 1¼": Stainless steel, ASTM A582 control valves with electric shut-off or shut-off valves
1½" thru 4": Steel, ASTM A108, zinc chromate unless a relief valve is used from therein between
plated piping. Do not install on inlet side of outlet pressure
Spring: Stainless steel regulators where liquid may become trapped.
Safe Working Pressure: 400 PSIG (27 bar) Instead, check valves should be located on outlet
Operating Temperature: -60F to 240F (-50 to 115°C) side of these valves. Check valves can be close-
coupled to other matching solenoid valves, pressure
regulators, or strainers by using a Male Adapter
Ring and longer bolts supplied when so specified
on order.
INSTALLATION DIMENSIONS
D = Socket Weld Depth

J = Weld Neck
K = ODS Solder
5 8
/ "
2.50" 3.25" 3.25" 3.25" 5.06" 5.06" 6.06" 6.06" 6.39"
A
(64 mm) (83 mm) (83 mm) (83 mm) (129 mm) (129 mm) (154 mm) (154 mm) (162 mm)
3.19" 4.50" 4.50" 4.50" 4.56" 4.56" 6.00" 6.00" 7.13"
B
3.50" 4.50" 4.50" 4.50" 6.38" 6.38" 7.50" 7.50" 8.00"
C
0.38" 0.50" 0.50" 0.50" 0.75" 0.75" 1.00" 1.00" 1.00"
D
1.03" 1.22" 1.22" 1.22" 2.56" 2.56" 2.92" 2.92" 3.50"
E=
1.50" 2.37" 2.37" 2.37" 3.62" 3.62" 4.84" 4.84" 6.06"
F
1.56" 2.50" 2.50" 2.50" 4.56" 4.56" 6.00" 6.00" 7.13"
G
2.19" 3.12" 3.12" 3.12" 3.06" 3.06" 4.00" 4.12" 5.00"
H
3.26" 4" 4" 4" 6.06" 6.06" 7.06" 7.06" 9.89"
J
0.33" 0.49" 0.59" 0.62" 0.71" 0.87" 0.96" 1.08" 1.40"
K
Valve Cv (Kv) 5.8 (5) 8.2 (7) 11.7 (10) 14.0 (12) 39 (33) 50 (43) 74 (63) 93 (80) 210 (180)
Pipe Size ½", ¾" ¾" 1" 1¼" 1½" 2" 2½" 3" 4"
*Dimensionally replaces R/S check valve models CK4A-2, -3, -4, -8, and -1. = "E" dimension is check valve body outside
edge to outside edge. Flange groove depth: nominal 0.12" each of two; gasket thickness: nominal 0.06" each of two.
2
PARTS LIST
HCK4-2 (2-BOLT) HCK4-2 (2-BOLT)
Above Kit Consists of:

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 Bolt ( 7/ 16" - 14 x 3.25") 2 70-0225

8 Nut (7/ 16 " - 14) 2 70-0055
9 Flange (FPT, SW, WN, ODS) 2 FACTORY
Socket weld shown. FPT, weld neck, ODS: available.

HCK4-3, -4, -5 (2-BOLT)
Above Kit Consists of:

HCK4-3, -4, -5 (2-BOLT)
1 Seat Disc 1 72-0006
2 Closing Spring 1 70-0204
3 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 72-0001
7 Bolt ( 5/ 8" -11 x 4") 2 72-0005

8 Nut ( 5/ 8" -11) 2 70-0136
9 Flange (FPT, SW, WN, ODS) 2 FACTORY
HCK4-7, -8, -9, -0, -1 (4-BOLT)
1a Seat Disc 1½", 2" 1 72-0016

1b Seat Disc 2½", 3" 1 72-0034
1c Seat Disc 4" 1 72-0053 Socket weld shown. FPT, weld neck, ODS: available.
2a Closing Spring 1½", 2" 1 72-0021
2b Closing Spring 2½", 3" 1 72-0032
2c Closing Spring 4" 1 72-0048
3a Seat Cartridge 1½", 2" 1 72-0020 HCK4-7, -8, -9, -0, -1 (4-BOLT)
3b Seat Cartridge 2½" 1 72-0029
3c Seat Cartridge 3" 1 72-0028
3d Seat Cartridge 4" 1 72-0047
4a Seat Cartridge O-ring 1½", 2" 1 72-0017
4b Seat Cartridge O-ring 2½", 3" 1 72-0027
4c Seat Cartridge O-ring 4" 1 72-0049
5a Flange Gasket 1½", 2" 2 75-0138
5b Flange Gasket 2½" 2 75-0125
5c Flange Gasket 3" 2 75-0137
5d Flange Gasket 4" 2 75-0253
6a Body, HCK4-7 1 72-0042
6b Body, HCK4-8 1 72-0019
6c Body, HCK4-9 1 72-0025
6d Body, HCK4-0 1 72-0026
6e Body, HCK4-1 1 72-0046
7a Bolt, HCK4-7, -8 (5/8" - 11 x 6") 4 70-0268
7b Bolt, HCK4-9, -0 (¾" - 10 x 7") 4 72-0033
7c Bolt, HCK4-1 ( 7/ 8" - 9 x 7.5") 4 72-0051
8a Nut, HCK4-7, -8 ( 5/ 8" - 11) 4 70-0136
8b Nut, HCK4-9, -0 (¾" - 10) 4 75-0210
8c Nut, HCK4-1 (7/ 8" - 9) 4 75-0280
9 Flange (FPT, SW, WN, ODS) 2 FACTORY Socket weld shown. Weld neck, ODS: available.
3
OPERATION WARRANTY
HCK4 check valves are normally closed valves. As Hansen valves are guaranteed against defective
inlet pressure increases, it overcomes the closing materials or workmanship for one year F.O.B. our
spring force. As the seat disc is pushed back and plant. No consequential damages or field labor is
away from the seat cartridge, flow through the valve included.
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 ORDERING INFORMATION,
will close against the seat cartridge, preventing HCK4 CHECK VALVES
reverse flow.
SIZING
Check valves are normally selected on the basis of HCK4-2* 5 8
/" (16) ½" 3 8
/ ", ¾" 5 8
/ "
line size. However, for gas flow applications at low HCK4-3* ¾" (20) ¾" 1", 1¼" 7 8
/ "
load conditions, a minimum of 1 psid across the 1 8
HCK4-4* 1" (25) 1" ¾", 1¼" 1 /"
valve is essential. This will maintain valve at full
open position. Valve Cv (Kv) is listed in the HCK4-5 1¼" (32) 1¼" ¾", 1" 1 3/ 8"
installation dimension table on page 2. Factory valve HCK4-7 1½" (40) 1½" 2" 1 5/ 8"
sizing assistance is available. HCK4-8* 2" (50) 2" 1½" 2 1/ 8"
HCK4-9 2½" (65) 2½" 3" 2 5/ 8"
HCK4-0 3" (80) 3" -- 3 1/ 8"
SERVICE AND MAINTENANCE HCK4-1* 4" (100) 4" -- 4 1/ 8"
These valves are a reliable part of a refrigeration
system. However, if valve does not appear to be * Replaces R/S CK4A-2, CK4A-3, CK4A-4, CK4A-8, & CK4A-1.
HCK4-2 close-couples to HS6 & HS8 Solenoid Valves.
operating satisfactorily, isolate it from the refrigeration
HCK4-3, -4, & -5 close-couples to HS7 Solenoid Valve.
system. Remove all refrigerant from associated piping FPT available only 3/ 8" to 1¼".
and valves. Follow the guidelines in the caution
section. Loosen each flange nut on the check valve. TO ORDER: Specify valve type, connection style and
Break each flange gasket seal. Carefully loosen size, and close-coupling information if needed.
flange bolts one at a time, being cautious to avoid
any refrigerant which still may be present. Remove
check valve from flanges and inspect. Lapped seating TYPICAL SPECIFICATIONS
surfaces should be smooth and free of pits or
"Refrigeration in-line check valves shall have steel
scratches.
or ductile iron bodies, stainless steel seat discs,
To confirm valve operation, move seat disc with stainless steel closing springs, and be suitable for
eraser end of pencil. Movement should be free from a safe working pressure of 400 PSIG, as manufactured
friction. If not, disassemble and visually inspect for by Hansen Technologies Corporation type HCK4 or
dirt in valve or burrs on seat disc. Clean or replace approved equal."
parts as necessary. Valve discs and seats can be
restored by lapping on a flat plate. Typical close-coupling to solenoid valve.
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 ISO 9002
Hansen Technologies Corp.
also Safety Precautions in current List Price Bulletin Burr Ridge, IL Cert. # 000472
Orlando, FL Cert. # 001523
and Safety Precautions Sheet supplied with product.
Escaping refrigerant might cause personal injury, HANSEN TECHNOLOGIES
particularly to the eyes and lungs. CORPORATION
6827 High Grove Boulevard
Burr Ridge, Illinois 60527 U.S.A.
Telephone: (708) 325-1565 FAX: (708) 325-1572
Toll-free: 1-800-426-7368
© 1995 Hansen Technologies Corporation Printed in U.S.A.
TECHNICAL SERVICE MANUAL
HEAVY DUTY PUMPS SECTION TSM 144
SERIES 4195 and 495 PAGE 1 OF 9
SERIES GG - AL ISSUE B
CONTENTS
Introduction 1
Special Information 2
Special Mechanical Seals 2
Maintenance 2
Disassembly 3
Assembly 5
Thrust Bearing Adjustment 7
Installation of Carbon Graphite Bushings 7 FIGURE 1
Pressure Relief Valve Instructions 7 GG. HJ and HL 4195 SERIES
Foot Type Unmounted Pump with Tapped
INTRODUCTION
The illustrations used in this manual are for identification
purposes only and cannot be used for ordering parts. Obtain
a parts list from the factory or a Viking® representative.
Always give complete name of part, part number and
material with model number and serial number of pump
when ordering repair parts. The unmounted pump or pump
unit model number and serial number are on the nameplate
secured to the pump.
In the Viking model number system, basic size letters are
combined with series number (4195 and 495), indicating both
the unmounted or mounted pump units.
Model Number Chart FIGURE 2

AS, AK and AL 4195 SERIES
Foot Type Unmounted Pump with Tapped Ports
UNMOUNTED PUMP UNITS
Foot Mounted
GG 4195 Units Are Designed By The
HJ 4195 Un-Mounted Pump Model
HL 4195 Numbers Followed By A
AS 4195 Letter(s) Indicating Drive Style.
AK 4195
D = Direct Drive
AL 4195
Flange Mounted
GG 495 M = Horizontal Direct Drive FIGURE 3
GG. HJ and HL SIZE 495 SERIES
HJ 495 Unmounted Pump with Tapped Ports
HL 495 IM = Vertical In Line Direct Drive
AS 495
AK 495
AL 495
This manual deals only with Series 4195 and 495 Heavy
Duty Pumps. Refer to Figures 1 thru 14 for general
configuration and nomenclature used in this manual. Pump
specifications and recommendations are listed in Catalog
Section 144, Series 4195 and 495 Heavy Duty Pumps.
FIGURE 4
AS, AK and AL SIZE 495 SERIES
VIKING PUMP INC. • Unmounted Pump with Tapped Ports
A Unit of IDEX Corporation •
SPECIAL INFORMATION SPECIAL MECHANICAL SEALS
This bulletin illustrates the mechanical seal which is
standard in the catalog pump. A Seal Installation
DANGER Drawing will be furnished with a pump fitted with a non-
standard mechanical seal. Consult this Seal Installation
BEFORE OPENING ANY VIKING PUMP LIQUID Drawing before disassembling pump.
CHAMBER (PUMPING CHAMBER,
Modifications are required to install Teflon seals in
RESERVOIR, RELIEF VALVE ADJUSTING CAP
these pumps. Contact factory for specific information.
FITTING ETC.) BE SURE:
1. THAT ANY PRESSURE IN CHAMBER RELIEF VALVE ADJUSTING SCREW CAP
HAS BEEN COMPLETELY VENTED
THROUGH SUCTION OR DISCHARGE
LINES OR OTHER APPROPRIATE
OPENINGS OR CONNECTIONS.
2. THAT THE DRIVING MEANS (MOTOR,
TURBINE, ENGINE, ETC.) HAS BEEN SUCTION DISCHARGE
“LOCKED OUT” OR MADE NON-
OPERATIONAL SO THAT IT CANNOT BE
STARTED WHILE WORK IS BEING DONE
ON PUMP.
3. THAT YOU KNOW WHAT LIQUID THE FIGURE 5
PUMP HAS BEEN HANDLING AND THE
PRECAUTIONS NECESSARY TO SAFELY MAINTENANCE
HANDLE THE LIQUID. OBTAIN A
Series 4195 and 495 pumps are designed for long, trouble-
MATERIAL SAFETY DATA SHEET
free service life under a wide variety of application
(MSDS) FOR THE LIQUID TO BE SURE
conditions with a minimum of maintenance. The points
THESE PRECAUTIONS ARE
SPECIAL INFORMATION
UNDERSTOOD.
listed below will help provide long service life.
CLEANING PUMP: Keep pump as clean as possible. This
FAILURE TO FOLLOW ABOVE LISTED will facilitate inspection, adjustment and repair work and
PRECAUTIONARY MEASURES MAY RESULT help prevent overlooking a dirt covered grease fitting.
IN SERIOUS INJURY OR DEATH.
STORAGE: If pump is to be stored, or not used for six
months or more, pump must be drained and a light coat of
non-detergent SAE 30 weight oil must be applied to all
ROTATION: Viking pumps operate equally well in a internal pump parts. Lubricate fittings and apply grease to
clockwise or counterclockwise rotation. Shaft rotation pump shaft extension. Viking suggests rotating pump shaft
determines which port is suction and which is discharge. by hand one complete revolution every 30 days to circulate
Suction Port is where pumping elements (gear teeth) come the oil.
out of mesh.
SUGGESTED REPAIR TOOLS: The following tools must
PRESSURE RELIEF VALVES: be available to properly repair Series 4195 and 495 pumps.
1. Viking pumps are positive displacement pumps and These tools are in addition to standard mechanics’ tools
such as open end wrenches, pliers, screw drivers, etc.
must be provided with some sort of pressure protection.
Most of the items can be obtained from an industrial supply
This may be a relief valve mounted directly on the
house.
pump, an inline pressure relief valve, a torque limiting
device or a rupture disk. 1. Soft Headed hammer
2. There are relief valve options available on those pump 2. AlIen wrenches (set screws & special mechanical seals)
models designed to accept a relief valve. Options may 3. Snap Ring Pliers
include a return to tank relief valve and a jacketed relief INTERNAL – Viking Part No. 2-810-047-999
valve. Pumps equipped with a jacketed head plate are GG-HJ-HL 4195-495
generally not available with a relief valve. EXTERNAL – Viking Part No. 2-810-029-375
3. If pump rotation is reversed during operation, pressure GG-HJ-HL 4195-495
protection must be provided on both sides of pump. 4. Mechanical Seal Installation Sleeve
2-751-001-900 for 0.75 inch seal; GG 4195-495
4. Relief valve adjusting screw cap must always point
2-751-004-900 for 1.25 inch seal; AS-AL 4195-495
towards suction side of pump. If pump rotation is
reversed, remove pressure relief valve and turn end for 5. Bearing Locknut Spanner Wrench
end. Refer to Figure 5. (Source: #471 J.H. Williams & Co. or equal)
5. Pressure relief valves should not be used to control 6. Spanner Wrench, adjustable pin type for use on bearing
housing end cap.
pump flow or regulate discharge pressure.
(Source: #482 J.H. Williams & Co. or equal)
For additional information on pressure relief valves, refer to 7. Brass bar
Technical Service Manual TSM 000 and Engineering
8. Arbor press
Service Bulletin ESB-31.
SECTION TSM 144 ISSUE B PAGE 2 OF 9

DISASSEMBLY 1. Refer to figures 7 & 8 page 4 for model to be
disassembled and name of parts. Models 4195 & 495 are
disassembled and assembled the same. The difference
DANGER between these models is the casings.
2. Mark head and casing before disassembly to insure
BEFORE OPENING ANY VIKING PUMP LIQUID proper reassembly. The idler pin, which is offset in the
CHAMBER (PUMPING CHAMBER, pump head, must be positioned up an equal distance
RESERVOIR, RELIEF VALVE ADJUSTING CAP between port connections to allow for proper flow of liquid
FITTING ETC.) BE SURE: through the pump.
1. THAT ANY PRESSURE IN CHAMBER 3. Remove the head capscrews.
NOTE: The four valve capscrews, valve and gasket must
be removed from the GG 4195-495 model before the six
LINES OR OTHER APPROPRIATE head capscrews are removed.
4. Tilt top of head back when removing to prevent idler from
2. THAT THE DRIVING MEANS (MOTOR, falling off idler pin.
TURBINE, ENGINE, ETC.) HAS BEEN
“LOCKED OUT” OR MADE NON- 5. Remove idler and bushing assembly. If idler bushing
OPERATIONAL SO THAT IT CANNOT BE needs replacing, see “Installation of Carbon Graphite
STARTED WHILE WORK IS BEING DONE Bushings”, page 7.
ON PUMP. 6. Insert a brass bar or piece of hardwood in the port
opening and between the rotor teeth to keep the shaft
3. THAT YOU KNOW WHAT LIQUID THE from turning. Turn the locknut counterclockwise and
PUMP HAS BEEN HANDLING AND THE remove locknut. See Figure 9 or 10.
PRECAUTIONS NECESSARY TO SAFELY
HANDLE THE LIQUID. OBTAIN A 7. Loosen two setscrews in face of bearing housing and turn
MATERIAL SAFETY DATA SHEET thrust bearing assembly counterwise and remove from
(MSDS) FOR THE LIQUID TO BE SURE casing. See Figure 9 or 10.
8. GG, HJ, HL: Remove snap ring from shaft. See Figure 9.
UNDERSTOOD.
AS, AK, AL: Remove bearing spacer from shaft. See
FAILURE TO FOLLOW ABOVE LISTED Figure 10.
PRECAUTIONARY MEASURES MAY RESULT 9. Remove brass bar or piece of hardwood from port
IN SERIOUS INJURY OR DEATH. opening.
MECHANICAL SEAL
HEAD IDLER ROTOR

BALL BEARINGS
PRESSURE RELIEF VALVE
SHAFT
SNAP RINGS
IDLER PIN
CASING
HEAD GASKET
FIGURE 6 - CUTAWAY OF MODELS GG, HJ, or HL 4195

Modifications to pump casing and rotor are required for installation
of optional Teflon® Mechanical Seal. Consult the factory.
FIGURE 7 – EXPLODED VIEW MODELS GG, HJ and HL 4195 and 495
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART
1 Locknut 7 Ball Bearing, Inner 12 Idler Bushing 18 Gasket for Relief Valve
2 Snap Ring, Outer 8 Casing (4195) 13 Idler and Bushing 19 Relief Valve
3 Ball Bearing, Outer 8A Casing (495) 14 Head Gasket 20 Capscrew for Valve
4 Snap Ring for Shaft * 9 Pipe Plug 15 Idler Pin
5 Bearing Housing 10 Mechanical Seal 16 Head and Idler Pin
6 Snap Ring, Inner 11 Rotor and Shaft 17 Capscrew for Head
* NOT USED ON “GG” SIZE PUMPS
Modifications to pump casing and rotor are required for installation

of optional Teflon® Mechanical Seal. Consult the factory.
FIGURE 8 – EXPLODED VIEW MODELS AS, AK and AL 4195 and 495
ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART ITEM NAME OF PART
1 Locknut 7 Bearing Spacer 12 Relief Valve 18 Idler and Bushing

2 Bearing Spacer Collar 8 Ball Bearing, Inner 13 Pipe Plug 19 Head Gasket
3 End Cap for Bearing Housing 9 Bearing Retainer Washer 14 Capscrew for Valve 20 Idler Pin
4 Lip Seal for Bearing Housing 10 Casing (4195) 15 Rotor and Shaft 21 Check Valve
5 Ball Bearing, Outer 10A Casing (495) 16 Mechanical Seal 22 Head and Idler Pin
6 Bearing Housing 11 Gasket for Relief Valve 17 Idler Bushing 23 Capscrew for Head
Teflon® - Registered Trademark of DuPont Dow Elastomers L.L.C.

INNER BALL BEARING
BALL BEARING
INNER SNAP RING
OUTER SNAP RING
LOCKNUT
SHAFT SHAFT SNAP RING
BEARING HOUSING
BALL BEARING
FIGURE 9 – THRUST BEARING ASSEMBLY GG, HJ and HL SIZES
BALL BEARING BEARING RETAINER WASHER
SETSCREW INNER BALL BEARING
NYLON INSERT
END CAP
LIP SEAL
SHAFT BEARING SPACER
LOCKNUT
BEARING HOUSING
SETSCREW
FIGURE 10 – THRUST BEARING ASSEMBLY AS, AK and AL SIZES
10. The rotor and shaft can now be removed by tapping on 13. GG, HJ, HL: Remove inner snap ring and single row
end of shaft with a lead hammer or, if using a regular ball bearing from casing.
hammer, use a piece of hardwood between shaft and AS, AK, AL: Remove single row ball bearing from
hammer. The rotary member of the seal will come out casting.
with rotor and shaft.
14. Remove seal seat or stationary part of seal from casing.
11. AS,AK,AL: Remove bearing retainer washer. The
15. Disassemble thrust bearing assembly.
washer may have stayed with Rotor and
Shaft when removed or is against ball GG, HJ, HL: Remove outer snap ring from bearing
bearing. See Figure 10. housing and remove ball bearing. See
12. Remove the mechanical seal rotary member and spring Figure 9.
AS, AK, AL: Loosen two set screws in flange outside
from rotor and shaft assembly.
diameter. Rotate end cap and lip seal
counterclockwise and remove. Remove
ball bearing. See Figure 10.

The casing should be examined for wear, particularly in the SPRING
MECHANICAL SEAL (ROTARY MEMBER)
area between ports. All parts should be checked for wear
before pump is put together.
When making major repairs, such as replacing a rotor and
shaft; it is advisable to also install a new mechanical seal,
head and idler pin, idler and bushing. See "Installation of
Carbon Graphite Bushings" page 7.
Clean all parts thoroughly and examine for wear or
damage. Check lip seals, ball bearings, bushing and idler TAPERED SLEEVE
pin and replace if necessary. Check all other parts for
nicks, burrs, excessive wear and replace if necessary.
COAT WITH LIGHT OIL BEFORE ASSEMBLY
Wash bearings in clean solvent. Blow out bearings with FIGURE 11
compressed air. Do not allow bearings to spin; turn them
slowly by hand. Spinning bearings will damage race and
balls. Make sure bearings are clean, then lubricate with ROTOR HUB
non-detergent SAE 30 weight oil and check for roughness. SPRING
Roughness can be determined by turning outer race by MECHANICAL SEAL
(ROTARY MEMBER)
hand. Replace bearings if bearings have roughness.
Be sure shaft is free from nicks, burrs and foreign particles SHAFT
that might damage mechanical seal. Scratches on shaft in
seal area will provide leakage paths under mechanical
seal. Use fine emery cloth to remove scratches or sharp
edges.
ASSEMBLY
Assembly Notes On Standard Mechanical Seal
(Synthetic Rubber Bellows Type) FIGURE 12
READ CAREFULLY BEFORE REASSEMBLING PUMP

4. Place tapered installation sleeve on shaft, refer to Figure
The seal used in this pump is simple to install and good 11. Sleeve is furnished with GG, AS, AK and AL
performance will result if care is taken during installation. replacement mechanical seals. Coat rotor shaft, tapered
The principle of mechanical seal is contact between the installation sleeve and inner diameter of mechanical seal
rotary and stationary members. These parts are lapped to rotary member with a generous amount of non-detergent
a high finish and their sealing effectiveness depends on SAE 30 weight oil. Petrolatum may be used but grease is
complete contact. not recommended.
Prior to installing rotary portion of mechanical seal, prepare 5. Place seal spring on shaft against rotor hub. Refer to
and organize rotor shaft, head and idler assemblies and Figure 12.
appropriate gaskets for quick assembly. 6. Slide rotary member, lapped contact surface facing away
Once rotary portion of mechanical seal is installed on rotor from spring, over installation sleeve on shaft until just
shaft, it is necessary to assemble parts as quickly as contacting the spring. Do not compress spring. Remove
possible to insure the seal does not stick to shaft in wrong installation sleeve.
axial position. The seat will stick to the shaft after several 7. Coat rotor shaft with non-detergent SAE 30 weight oil.
minutes setting time. Install shaft slowly pushing until the ends of rotor teeth
Never touch sealing faces with anything except clean are just below the face of the casing.
hands or clean cloth. Minute particles can scratch the seal 8. Leave the rotor in this position. Withdrawal of rotor and
faces and cause leakage. shaft may displace the carbon seal rotating face and
1. Coat idler pin with non-detergent SAE 30 weight result in damage to the seal.
oil and place idler and bushing on idler pin in 9. Place O-ring gasket on head and install head and idler
head. If replacing a carbon graphite bushing, refer assembly on pump. Pump head and casing were marked
to Installation of Carbon Graphite Bushings, page before disassembly to insure proper reassembly. If not,
7. be sure idler pin, which is offset in pump head, is
2. Clean rotor hub and casing seal housing bore. positioned up and equal distance between port
Make sure both are free from dirt and grit. Coat connections to allow for proper flow of liquid through
outer diameter of seal seat and inner diameter of pump.
seal housing bore with non-detergent SAE 30 10. Tighten head capscrews evenly.
weight oil.
11. If pump was equipped with a relief valve and was
3. Start seal seat in seal housing bore. If force is removed during disassembly, install on head with new
necessary protect seal face with a clean gaskets. Relief valve adjusting screw cap must always
cardboard disc and gently tap i1 in place with a point towards suction port. Refer to Figure 5 page 2. For
piece of wood. Be sure seal seat is completely relief valve repair or adjustments, see PRESSURE
seated in the bore. RELIEF VALVE INSTRUCTIONS, Page 7.

12. Pack inner ball bearing with multi-purpose grease, THRUST BEARING ADJUSTMENT
NLGI #2. See Figures 9 and 10.
GG, HJ, HL: Install bearing in casing with sealed side Loosen two screws in face of thrust bearing assembly.
towards head end of pump. Drive the
bearing into the bore. Tap the inner race If shaft cannot be rotated freely, turn thrust bearing
with a brass bar and lead hammer to assembly counterclockwise until shaft can be turned
position bearing.Install inner snap ring. easily.
AS, AK, AL: Install bearing retainer washer over the To set end clearance:
shaft before installing ball bearing. Install
ball bearing in casing with sealed side 1. While turning rotor shaft, rotate thrust bearing
towards head end of pump. Drive the assembly clockwise until noticeable drag occurs.
bearing into the bore. Tap the inner race This is zero end clearance.
with a brass bar and lead hammer to 2. Mark position of bearing housing with respect to the
position bearing. casing.
13. GG, HJ, HL: Install shaft snap ring in groove in the 3. Rotate thrust bearing assembly counterclockwise the
shaft. See Figure 9. distance listed below as measured on outside of
AS, AK, AL: Install bearing spacer over shaft and bearing housing.
against single row ball bearing. See 4. Tighten two setscrews in face of bearing housing
Figure 10. after adjustment is made to secure thrust bearing
14. Pack lubrication chamber between inner ball bearing assembly position.
and double row ball bearing in the thrust bearing
assembly approximately one-half full of multi-purpose For viscosities above 2500 SSU, add additional end
grease, NLGI #2. The thrust bearing assembly will take clearance (0.004” for GG, HJ and HL size pumps
the remaining space. See Figure 9 and 10. and 0.005” for AS, AK and AL size pumps).
15. Pack double row ball bearing with multi-purpose
grease, NLGI #2.
GG, HJ, HL: Install ball bearing into bearing housing
with shield side toward coupling end of shaft. See Distance In Inches On End
Pump Size
O.D. Of Bearing Housing Clearance
Figure 9. Install snap ring into bearing housing to
retain ball bearing. This snap ring has a tapered edge GG 0.44” .003
to fit tapered groove in bearing housing. The tapered HJ, HL 0.56” .003
edge is located away from ball bearing.
AS, AK, AL 0.5” .003
AS, AK, AL: Install ball bearing into bearing housing.
Install lip seal in bearing housing end cap. The lip
should face towards end of shaft. Put bearing spacer
collar in lip seal and install in bearing housing and
tighten set screws securely. See Figure 10.
16. Insert brass bar or hardwood through port opening
between rotor teeth to keep shaft from turning.
INSTALLATION OF CARBON
17. Start thrust bearing assembly into casing. Turn by
hand until tight. This forces rotor against head.
GRAPHITE BUSHINGS
Replace and tighten locknut or shaft.
When installing carbon graphite bushings, extreme care
18. Remove brass bar or hardwood from port opening. must be taken to prevent breaking. Carbon graphite is a
19. Adjust pump end clearance, refer to page 7. brittle material and easily cracked. If cracked, the bushing
will quickly disintegrate. Using a lubricant and adding a
chamfer on the bushing and the mating part will help in
installation. The additional precautions listed below must
be followed for proper installation:
DANGER 1. A press must be used for installation.
2. Be certain bushing is started straight.
BEFORE STARTING PUMP, BE SURE ALL
DRIVE EQUIPMENT GUARDS ARE IN PLACE. 3. Do not stop pressing operation until bushing is in
proper position, starting and stopping will result in a
FAILURE TO PROPERLY MOUNT GUARDS cracked bushing.
MAY RESULT IN SERIOUS INJURY OR DEATH. 4. Check bushing for cracks after installation.

PRESSURE RELIEF VALVE DISASSEMBLY
INSTRUCTIONS
DANGER
BEFORE OPENING ANY VIKING PUMP LIQUID
CHAMBER (PUMPING CHAMBER,
RESERVOIR, RELIEF VALVE ADJUSTING CAP
FITTING ETC.) BE SURE:
1. THAT ANY PRESSURE IN CHAMBER
LINES OR OTHER APPROPRIATE
2. THAT THE DRIVING MEANS (MOTOR,
TURBINE, ENGINE, ETC.) HAS BEEN
“LOCKED OUT” OR MADE NON-
OPERATIONAL SO THAT IT CANNOT BE
STARTED WHILE WORK IS BEING DONE
FIGURE 13 ON PUMP.
VALVE - GG, HJ, and HL SIZES
3. THAT YOU KNOW WHAT LIQUID THE
PUMP HAS BEEN HANDLING AND THE
VALVE - LIST OF PARTS PRECAUTIONS NECESSARY TO SAFELY
1. Valve Cap 6. Valve Body HANDLE THE LIQUID. OBTAIN A
2. Adjusting Screw 7. Valve Spring MATERIAL SAFETY DATA SHEET
3. Lock Nut 8. Poppet (MSDS) FOR THE LIQUID TO BE SURE
4. Spring Guide 9. Cap Gasket
UNDERSTOOD.
5. Bonnet
FAILURE TO FOLLOW ABOVE LISTED
PRECAUTIONARY MEASURES MAY RESULT
IN SERIOUS INJURY OR DEATH.
Mark valve and head before disassembly to insure proper

reassembly.
1. Remove valve cap.
2. Measure and record length of extension of adjusting
screw. Refer to “A” on Figures 13 and 14.
3. Loosen locknut and back out adjusting screw until
spring pressure is released.
4. Remove bonnet, spring guide, spring and poppet from
valve body. Clean and inspect all parts for wear or
damage and replace as necessary.
FIGURE 14 ASSEMBLY
VALVE – AS, AK and AL SIZES
Reverse procedures outlined under Disassembly. If valve
is removed for repairs, be sure to replace in same
VALVE - LIST OF PARTS position. Relief valve adjusting screw cap must always
1. Valve Cap 6. Valve Body point towards suction side of pump. If pump rotation is
2. Adjusting Screw 7. Valve Spring reversed, remove relief valve and turn end for end. Refer
to Figures 5, page 2.
3. Lock Nut 8. Poppet
4. Spring Guide 9. Cap Gasket
5. Bonnet 10. Bonnet

TECHNICAL SERVICE MANUAL
HEAVY DUTY PUMPS SECTION TSM144
SERIES 4195 and 495 PAGE 9 OF 9
SERIES GG - AL ISSUE B
DANGER
BEFORE STARTING PUMP, BE SURE ALL

DRIVE EQUIPMENT GUARDS ARE IN PLACE.
FAILURE TO PROPERLY MOUNT GUARDS WARRANTY

MAY RESULT IN SERIOUS INJURY OR DEATH.
Viking warrants all products manufactured by it to be
free from defects in workmanship or material for a
period of one (1) year from date of startup, provided
that in no event shall this warranty extend more than
eighteen (18) months from the date of shipment from
Viking. If, during said warranty period, any products
PRESSURE ADJUSTMENT sold by Viking prove to be defective in workmanship or
material under normal use and service, and if such
If a new spring is installed or if pressure setting of pressure products are returned to Viking’s factory at Cedar Falls,
relief valve is to be changed from that which the factory has Iowa, transportation charges prepaid, and if the
set, the following instructions must be carefully followed. products are found by Viking to be defective in
workmanship or material, they will be replaced or
1. Carefully remove valve cap which covers adjusting repaired free of charge, FOB. Cedar Falls, Iowa.
screw. Viking assumes no liability for consequential
damages of any kind and the purchaser by acceptance
Loosen locknut which locks adjusting screw so of delivery assumes all liability for the consequences of
pressure setting will not change during operation of the use or misuse of Viking products by the purchaser,
pump. his employees or others. Viking will assume no field
expense for service or parts unless authorized by it in
2. Install a pressure gauge in discharge line for actual advance.
adjustment operation. Equipment and accessories purchased by Viking
from outside sources which are incorporated into any
3. Turn adjusting screw in to increase pressure and out to
Viking product are warranted only to the extent of and
decrease pressure. by the original manufacturer’s warranty or guarantee, if
4. With discharge line closed at a point beyond pressure any.
gauge, gauge will show maximum pressure valve will THIS IS VIKING’S SOLE WARRANTY AND IS IN
allow while pump is in operation. LIEU OF ALL OTHER WARRANTIES,
EXPRESSED OR IMPLIED, WHICH ARE
HEREBY EXCLUDED, INCLUDING IN
PARTICULAR ALL WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A
IMPORTANT PARTICULAR PURPOSE. No officer or employee
of IDEX Corporation or Viking Pump, Inc. is
In ordering parts for pressure relief valve, always give authorized to alter this warranty.
model number and serial number of pump as it appears on
nameplate and name of part wanted. When ordering
springs, be sure to give pressure setting desired.
VIKING PUMP INC. • VIKING PUMP INC. •

A Unit of IDEX Corporation • Copyright© 2000 •
Model 2010
Three-Way
Thermostatic Valve
2010 2” NPT
2010-1 1 1/2” NPT
2010J24 1 1/2” SAE O-Ring
A2010J32 2” SAE O-Ring
F2010 2” 125# FF Flange
SF2010 2” 150# RF Flange
SF2010X 2” 300# RF Flange
Fluid Power Energy (FPE) Thermostatic Valves utilize the principle of

expanding wax, which in the semi-liquid state undergoes large expansion Features
rates within a relatively narrow temperature range. The self-contained ele-
ment activates a stainless steel sleeve, which directs flow. All FPE
Thermostatic Valves are factory set at predetermined temperatures: no fur-
ther adjustments are necessary. A wide range of temperatures are avail-
Wide Range of Temperatures
able for water and oil temperature control applications.
When used in a diverting application, on start-up the total fluid flow is rout- Heavy Duty
ed back to the main system. As fluid temperature rises to the control
range, some fluid is diverted to the cooling system. As fluid temperature Self-Contained
continues to increase, more flow is diverted. When the thermostat is in a
fully stroked condition, all fluid flow is directed to the cooling system. FPE Replaceable Element
Thermostatic Valves may also be used in a mixing application.
In a mixing application, hot fluid enters the “B” port and colder fluid enters Non-Adjustable
the “C” port. The flows mix and the thermostat adjusts to reach the desired
temperature, exiting the “A” port. Rugged Construction
Standard FPE thermostatic valve housings are made from aluminum and Tamper-Proof
grey iron castings, however, ductile iron, bronze, steel and stainless steel
housings are available.
Operate in Any Position
Available Connections: NPT, SAE O-Ring, 125# FF Flange, 150# and
300# RF Flange. Compact
Optional features: High over temperature element, plated element. Other Available for Refrigeration Service
options available upon request.
FLUID POWER ENERGY, INC. MADE IN

W229 N591 Foster Court • Waukesha, WI 53186
262 • 548 • 6220 Fax 262 • 548 • 6239

ISO 9001-2000 U. S. A
www.fpevalves.com
Model 2010
* (Replace * with body material type; A=Cast Iron, B=Bronze, D=Ductile, S=Steel, SS=Stainless Steel)
PRESSURE RATINGS
MATERIAL PSI
A, B 150
D 250
S, SS 500
SF, SSF 275
SFX, SSFX 720
*2010-1, *2010, *2010J *F2010, *F2010X
Flow vs. Pressure Drop PART # DESCRIPTION

1 1/2” *2010 VALVE BODY (*See table for material)
*2020 VALVE COVER (*See table for material)
2” 1570** O-RING (Standard material is Buna-N)
2071 LIP SEAL
2050-Temp THERMOSTAT (Temp to follow dash)
1600 HEX BOLT
1601 LOCK WASHER
FPE Model 2000** Replacement Kit (Includes the following:)

1570** BUNA O-RING (Standard material is Buna-N)
2071 LIP SEAL
FLOW IN U.S. GPM
SAE 10 @ 100° F
2050-Temp THERMOSTAT (Temp to follow dash)
(For Viton® (V) or Neoprene (E) O-Ring material, replace ** with V or E)
Recommended Pressure Drop is 2 to 7 PSI
Viton® is a registered trademark of Dupont Dow Elastomers
To Order
FLUID POWER ENERGY, INC. Specify Model Number, nominal
temperature desired, and housing
W229 N591 Foster Court • Waukesha, WI 53186 material. For Model coding information,
visit our website or consult your
262 • 548 • 6220 Fax 262 • 548 • 6239 factory representative.
www.fpevalves.com
FPE-2010-050803
August 2003 / BULLETIN 30-11
SOLENOID VALVES
Installation and Servicing Instructions
NOT FOR USE ON HAZARDOUS OR CORROSIVE FLUIDS

■ The molded MKC-1 coil fits the A3, E3,W3, S4, E5, B6, E6, S6, The tip of the soldering torch should be large enough to avoid
W6, S7, R183, R184 and R246 series normally closed solenoid prolonged heating of the connection during the soldering operation.
valves. Overheating can also be minimized by directing the flame away from
the valve body.
■ The OMKC-1 coil fits the XWG, XUP and XXF series rapid
cycle solenoid valves. Type A3S1, S4S1, S6S1, S7S1
1. Remove the coil assembly.
■ The MKC-2 coil fits the B9, E9, B10, E10, B14, E14, W14, B19, 2. Locate the word IN or the directional arrow on the valve body.
E19, W19, B25, E25, W25, B33, E33, E34, E42 series normally 3. Place the valve in the line, in the proper direction of flow, and
closed solenoid valves and the 180 solenoid pilot control...
and all solenoid valves in the field that are equipped with
solder.
the old style KC-2 coil. 4. Replace the coil assembly and tighten coil hex screw.
■ When changing from the old KC model coils to the current Types B6, B9, B10, B14, B19, B25 Series (Brass Connections)
MKC molded model coils, discard the coil housing, coil 1. Remove the coil assembly, enclosing tube and nut, all internal
housing bottom plate, two coil sleeves (not used with KC-1 parts, and manual lift stem assembly.
coil) AND THE SPACER. 2. Locate the word IN or the directional arrow on the valve body.
3. Place the valve in the line in the proper direction of flow and
■ The OMKC-2 coil fits the OB9, OE9, OB10, OE10, OB14, OE14, solder.
OB19, OE19, OB25, OE25, OB33, OE33, OE34, OE42 series
normally open solenoid valves and the XRN, XRM, XPO
series rapid cycle solenoid valves.
■ Figure 1
Enclosing
■ Other Sporlan Valve products using a molded coil are as Tube Locknut
follows: Enclosing Tube
MKC-1 — OM-1, SORIT, 8D, 12D, 10G, SORIT-PI, 5D, SHGB(E)-8. Enclosing
MKC-2 — 16D, DDR-20, SHGB(E)-15, OLDR-15 and OLDR-20. Kickoff Spring Tube Gasket
OMKC-2 — LDR-15, LDR-20, XTM and XTO. Stem and Plunger
To insure peak performance, solenoid valves must be selected and Valve Body Seat Disc
applied correctly; however, proper installation procedures are equally
important. The following instructions list the essential points for
correct installation.
Manual Lift Stem
An exploded view of a typical solenoid valve is illustrated in Figures (if required)
5, 5A and 6, page 4.
Position — All standard solenoid valves may be mounted 4. Re-assemble as follows, see Figures 1, 5, and 5A:
horizontal, on its side or in a vertical line with the exception of the a. Place the seat disc into the valve body with the smaller
following: A3 dated 6-86 or before, MA32, B33, OB33, MA42, diameter end facing up.
MA50, MA5A, MA17A, XWG, XUP, XRN, XRM and XPO series. b. Place the enclosing tube gasket onto the valve body above the
These valves MUST be installed in horizontal lines with the coil threads.
housing no more than 45° from vertical, see table on page 2. The c. Hold the plunger with one hand so that the pointed end is
direction of flow is indicated by an arrow or the word IN on the inlet resting in the pilot port of the disk. Make sure the small spring
of the valve body. For heat pump applications, valve types C(M)E is in place on the top of the plunger. (NOTE: Does not
and C(M)B are typically installed with the directional arrow pointing apply to normally open and rapid cycle series.)
toward the outdoor coil. Or, the IN connection toward the indoor coil. d. With the other hand, place the enclosing tube over the plunger,
making sure the enclosing tube gasket is in position.
NOTE: Solenoid valves having a type number starting with the letter e. Replace the enclosing tube locknut and tighten. (See
"X" are Special Solenoid Valves (non-standard). Contact Sporlan recommended torque in the table on page 2.) Do not over
Valve Company, Washington, MO if valve mounting is in question. tighten.
f. Replace manual lift stem. Tighten lift stem assembly and seal cap.
SOLDER CONNECTIONS g. Replace the coil assembly. (NOTE: For normally open and
Because of possible damage to valve components due to the high rapid cycle valves replace spacer and spacer cup
temperatures of soldering and brazing, "B" Series Solenoid Valves with coil assembly.)
with brass connections are shipped handtight to facilitate
disassembly, with the exception of the (M)B33S2 & OB33S2. It is NOTE: Excessive tightening of the enclosing tube locknut can
necessary to completely disassemble these valves before any heat is damage the valve body bore. Please observe the torques listed on
applied to the valve body. The following steps outline recommended page 2.
procedures when installing these valves.
Types: All E Series (Extended Copper Connections)
Soldering Precautions — Solder connections on Sporlan Solenoid Brazed into the line without disassembly because the valve contains
Valves are either copper or brass. Any of the commonly used types of extended connections. Use caution by placing a wet cloth or chill
solder are satisfactory with these materials. Regardless of the type of block on the extensions at the body to prevent excessive overheating.
solder used, it is important to avoid overheating the valve. Follow Type A3S1 installation instructions.
© COPYRIGHT 2003 BY SPORLAN VALVE COMPANY, WASHINGTON, MISSOURI
BULLETIN 30-11, AUGUST 2003 SUPERSEDES BULLETIN 30-11, NOVEMBER 2000 AND ALL PRIOR PUBLICATIONS.
Page 2 / BULLETIN 30-11
RECOMMENDED TORQUE (ft.–lbs.)

FLANGE VALVE MOUNTING POSITION
ENCLOSING ENCLOSING PILOT VALVE LOWER COIL COIL PLATE FLANGE MANUAL LIFT
VALVE SERIES1 TUBE TUBE ASSEMBLY BODY SCREW LOCKNUT BOLTS/ CONNECTION STEM SEAL CAP VERTICAL HORIZONTAL ON
LOCKNUT5 SCREWS LOCKNUT LOCKNUT BOLTS ASSEMBLY LINE3 LINE SIDE3
SCREWS
YES
A3, S4, S6, S7 --- --- --- --- 2.3 --- --- --- --- --- dated 7-86 YES
or later
E3, E5 ---
YES YES
W3 --- 1.5 – 1.67 --- --- 2.3 --- --- --- --- ---
XWG --- NO YES2
B6, E6, W6 YES YES
10 – 15 --- --- --- 2.3 4.0 --- --- 11 – 12 4–6
X UP NO YES2
B9, E9, OB9, OE9 YES YES
25 – 30 --- --- --- 2.3 4.0 --- --- 11 – 12 4–6
XRN NO YES2
B10, E10, OB10, OE10
B14, E14, W14, YES YES
20 – 40 --- --- --- 2.3 4.0 --- --- 11 – 12 4–6
OB14, OE14
XRM NO YES2
B19, E19, W19,
YES YES
OB19, OE19 35 – 45 --- --- --- 2.3 4.0 --- --- 11 – 12 4–6
XPO NO YES2
B25, E25, W25
60 – 65 --- --- --- 2.3 4.0 --- --- 11 – 12 4–6 YES YES
OB25, OE25
B 33 37 NO YES2
E34 --- YES YES
25 – 30 --- --- --- 2.3 4.0 8 – 12 11 – 12 4–6
OB33 37 NO YES2
O E 34 --- YES YES
E42, OE42 25 – 30 --- --- --- 2.3 4.0 13 – 20 --- 11 – 12 10 – 15 YES YES
MA5A3 24
25 – 50 --- --- --- --- 4.0 --- 11 – 12 10 – 15 NO YES NO
MA17A3 37
MA32 8 – 12
MA42 --- --- --- --- --- 4.0 12 – 20 74 11 – 12 10 – 15 NO YES NO
MA50 25 – 35
R183, R184, R246 --- 6 --- --- 2.3 --- --- --- --- --- YES YES
8D 60 – 65 ---
10 – 15 --- 60 – 65
1 2D --- 15 – 18
2.3 --- --- --- --- YES YES
16D 30 – 35 --- 4 --- 20 – 24
10G 10 – 1 5 --- 60 – 65 60 – 65 ---
1Valves with mounting holes use a #8-32 screw torqued not more than 15 in.-lb. Note: Standard torque charts do not apply. 2Coil housing to be no more than 45° from the vertical. 3Coil
housing must not be below horizontal. 4The 16D pilot assembly is connected to the body with a pipe connection. Apply a light coat of #242 (Blue) Loctite to the male pipe thread and torque
to 30-60 ft.-lb. 5Do not over tighten the enclosing tube locknut. Damage to the enclosing tube assembly could result from over tightening.
PIPE CONNECTIONS These valves have male flange connections on the inlet of the valve;
therefore, the flange and bushing for the inlet must be the female pair.
Types A3, W3, B6, W6, B9, B10, B14, W14, B19, W19, B25,
W25, (K)(B)R183, (K)(B)R184, (K)(B)R246 Series
These valves can be installed without disassembly. Avoid excessive INSTALLATION—ALL VALVES
amounts of pipe sealing compounds. It will interfere with the valve Mounting — A Type 1216-1 universal mounting bracket, Figure 2,
operation if it comes in contact with the valve's internal parts. is available, when ordered. It fits all standard Sporlan Solenoid
Valves except the Types W3, MA32, B33, E33, E34, E42, MA42,
NOTE: When pipe type solenoid valves are installed with pipe to MA50, (K)(B)R183, (K)(B)R184, (K)(B)R246 series and the Type
ODF adaptors, the valve must be disassembled prior to brazing the 180 Solenoid Pilot Control. The slots in the bracket match the tapped
ODF adaptors. holes in the standard solenoid valves so that they may be secured by
two screws supplied with the bracket. A locknut is also furnished for
use with Types MA5A3 and MA17A3. Both types of installations are
FLANGED CONNECTIONS— shown in Figure 2. The manual lift stem seal cap is replaced after the
PIPE or SOLDER locknut is tightened against the bracket.
Solenoid valves with flanged connections may be installed without
disassembly. In most cases the flanges are packed disassembled from 1.50 1.50
the valve body. Therefore, they may be installed in the line before the ■ Figure 2 Hole through
which solenoid
valve is installed. Be certain that the correct flange is installed on the is screwed to
inlet line in order to properly match the flow direction of the valve. If bracket
1.75 2.16
the valve is installed backwards, it will not function properly.
1.16
Types MA5A3, MA17A3, MA32P3, MA42P3, MA50P3
1.
06
Avoid the use of excessive amounts of pipe sealing compounds. It

will interfere with the valve operation if it comes in contact with the FRONT VIEW BOTTOM VIEW
1.
31
valve's internal parts.

Installation
Types B33S2, MB33S2, OB33S2, MA42S3, MA50S3 using locknut on
These valves are supplied with a two piece flange assembly, a semi- manual stem for
steel flange ring and a brass solder bushing. The flange should be MA5 & MA17
placed on the pipe before the bushing is soldered or brazed. The
soldering discussion given under "Solder Connections" applies for
these valves except where the discussion deals with non-flanged
valves only.
Installation for Types A3, E3*, E5*, B6, E6*, W6, B9, E9*,
B10, E10, B14, E14, W14, B19, E19, W19, B25, E25, W25,
With Types MA42S3 and MA50S3, use the correct flange and Series & Types MA5A, MA17A Solenoid Valves.
bushing that corresponds with its mating flange on the valve to insure *Are not supplied standard with mounting holes.
correct flow direction.
BULLETIN 30-11 / Page 3
Wiring — Check the electrical specifications of the coil to be sure operating conditions are such that the reduced MOPD causes
they correspond to the available electrical service. stalling of the plunger, which results in excessive current draw.
4. Incomplete magnetic circuit due to the omission of parts such
The 1/2" BX conduit connection or junction box on the coil may be as: coil housing, coil sleeves, coil spring, coil housing bottom
rotated to any position by loosening the coil hexscrew. Solenoid plate or plunger on the KC model coil and coil yoke, coil
valves with four-wire dual voltage coils have a wiring diagram decal, backplate or plunger on the MKC molded model coils.
Figure 3, on the coil housing or bracket. This illustrates which wires 5. Mechanical interference with plunger movement which may be
to connect for either 120, 208 or 240 volt operation. Wiring and caused by a deformed enclosing tube.
fusing (when used) must comply with prevailing local and national 6. Voltage spike.
wiring codes and ordinances. 7. Valve ambient exceeds 120°F.
8. Fluid or gas temperatures greater than 240°F, while the valve
■ Figure 3 ambient is 120°F.
2. FAILURE TO OPEN (Normally Closed Types)
1. Coil burned out or an open circuit to coil connections.
2. Improper electrical characteristics.
3. In pilot operated valves, dirt, scale or sludge may prevent the
piston, disc or diaphragm from lifting. This could also be
caused by a deformed body.
4. High differential pressure that exceeds the MOPD rating of the
valve.
Direct Current Valves — A surge protector is supplied with each 5. Diameter reduction of synthetic seating material in pilot port
solenoid valve with a 115 volt DC coil. The surge protector is because of high temperatures and/or pressures, or severe
necessary to absorb the high counter-voltage generated when the pulsations. Contact Sporlan Valve Co., Washington, MO.
circuit is broken, thereby protecting the electrical contacts of the
thermostat. It should be wired as shown in Figure 4. The problem of dirt can be avoided by installing a Sporlan
Catch-AIl® Filter-Drier upstream from the solenoid valve. The
■ Figure 4 D. C. Line
Catch-AII® Filter-Drier will retain much smaller particles than a
conventional strainer.
Use a Sporlan strainer for water applications upstream of every
Thermostat industrial solenoid valve.
Surge Protector 3. FAILURE TO CLOSE
1. Valve is oversized. Pilot operated valves may fail to close due
to low pressure drop.
2. In pilot operated valves, dirt, scale or sludge may prevent the
piston, disc or diaphragm from closing. This could also be
caused by a deformed body.
TRANSFORMER SELECTION 3. Held open by the manual lift stem.
4. In pilot operated valves only, a damaged pilot port may prevent
24v/50-60c 120v/50-60c 240v/50-60c Transformer
Rating closing.
COIL Current Current Current Volt-Amperes 5. A floating disc due to severe discharge pulses, contact Sporlan
KIT Amperes Amperes Amperes Valve Co., Washington, MO.
For 100% of 6. Have voltage feedback to the coil after the coil de-energizes.
In- Hold- In- Hold- In- Hold- rated MOPD
rush ing rush ing rush ing of Valve
MKC-1 1. 9 .63 .39 .1 4 .19 .09 60 MISCELLANEOUS
1. Liquid Hammer — Industrial solenoid valves, or other liquid
OMKC-1 1.9 .94 .42 .21 .20 .10 60 line valves, may cause liquid hammer when installed on liquid
MKC-2
3.1 1.4 .60 .26 .31 .1 3 100 lines with high liquid velocities. If this occurs, it can be minimized
OMKC-2 by the use of larger pipes, (i.e. lower velocities), or a standpipe
KC-3 7.9 1.9 1.7 .41 .83 .21 250 installed in the piping near the solenoid valve inlet. Commercially
available shock absorbers may also be used to reduce this noise.
SERVICING INSTRUCTIONS Recommended maximum velocity is approximately 300 fpm.
CAUTION — Dangerous hydraulic pressures may develop if a hand
valve is installed in the liquid line ahead of the solenoid valve and the 2. AC Hum — This problem may be caused by a loose coil housing
hand valve is closed while the solenoid valve is closed. This may on a KC model coil. On rare occasions this may be caused by
cause extrusion of the teflon seat in the disc. Extrusion may cause the loose coil sleeves, in which case deforming them slightly will
valve to fail to open, fail to close and/or have excessive seat leakage. eliminate the hum. A loose coil hex screw or coil locknut may
Also the line between these two valves should be pumped down cause this problem on the MKC molded model coils.
completely before disassembling the solenoid valve for service.
Foreign material between the magnetic top plug and the plunger
in the Types A3, E3, W3, E5, B6, E6, W6, B9, E9, B10, E10, B14,
NOTE: The optional manual lift stem is designed to prevent damage to E14, W14, B19, E19, W19, B25, E25, W25, B33, E33, E34 and
the disc. If the stem is turned in too far, the threads become disengaged. E42 Series Solenoid valves may cause AC hum also.
These threads can be re-engaged by applying slight outward force
while turning counterclockwise. A thread stop is provided to prevent On water applications, deposits may accumulate in the valve
the stem from backing all the way out of the assembly. Back the stem which could cause AC hum. This may be eliminated by cleaning
to the stop and replace the seal cap when service is complete. or flushing the valve.
TYPICAL MALFUNCTIONS 3. Leak Testing — Special care should be taken when leak testing
There are only three possible malfunctions: 1. Coil burnout. valves with synthetic gaskets. Gasket materials are slightly
2. Failure to open. 3. Failure to close. Each is discussed. permeable. Leak rates of 0.5 oz. per year should be acceptable.
Note the sensitivity of electronic leak detectors. Most have the
1. COIL BURNOUT capability of finding a leak smaller than 0.05 oz. per year. Double
Coil burnouts are extremely rare unless caused by one of the check small seal leaks with soap bubbles or a halide torch if
following: possible. Do not over tighten the enclosing tube locknut. If a
1. Improper electrical characteristics. leak occurs, change the gasket and verify the metal surfaces have
2. Continuous over-voltage, more than 10%. a clean smooth finish.
3. Under-voltage of more than 15%. This applies only if the
Screw or Lock Nut (normally Enclosing Tube Screw

■ Figure 5 (normally open & rapid cycle) Assembly ■ Figure 5a
closed) Spacer Cup
Typical View of B6, E6,W6, B9, (normally open &
E9, OB9, OE9, B10, E10, OB10, rapid cycle only) Nameplate
OE10, B14, E14, W14, OB14,
OE14, B19, E19, W19, OB19, Nameplate
OE19, B25, E25, W25, OB25,
OE25, XUP, XRN, XRM, & XPO Coil
Series Solenoid Valves.
Coil
Plunger
Assembly
Enclosing
Tube
Spacer Diaphragm
(normally open & Assembly
Typical View of rapid cycle only) Enclosing
E34 & E42 Series Tube O-Ring
Solenoid Valves Enclosing Enclosing
Tube Tube O-Ring Plunger
Lock Nut Assembly
Pilot Assembly
Enclosing Tube Enclosing Tube Body
or (normally open & Body
(normally closed)
rapid cycle)
Enclosing *Enclosing Typical View of W3, XOF

Tube Tube Gasket & XJH Solenoid Valve
Gasket Typical View of
Stem & Stem & Diaphragm Industrial ■ Figure 6
Spring Solenoid Valves Lock Nut
Plunger or Plunger
Assembly Assembly (K)(B)R183, (K)(B)R184
(normally (rapid cycle) & (K)(B)R246. Voltage Tag
Piston closed)
Valve
Disc Nameplate
Body
(A & B Coil Housing
Series)
Body
(E Series)
Body
(E34 & E42 Coil Sleeve
Series)
Manual Lift Stem Assembly
(if required) Coil Spring
*Tetraseal
*B and E Series Solenoid Valves have been redesigned. The new design can be easily identified as a thin, synthetic Gasket
coated metal gasket, known as a Wolverine gasket. The old gasket is a thicker type of O-ring with a square cross or
section, known as a tetraseal. See the partial cross sections of the valve body at right. The gaskets and the
enclosing tubes of the two designs are not interchangeable. The new enclosing tube assembly is included in the
*Wolverine
Gasket Coil
replacement parts kits.
■ Figure 7 Manual Lift B25, E25

Figure 7 contains a full size Coil
Stem Gauge plunger gauge, and a manual Housing
B19, E19, W19 lift stem gauge for easy identi- Bottom Plate
B14, E14, W14, (full size)
E10, B19, fication of parts. Be sure to
B25, E25, W25, B10, E10 place stem on Coil Sleeve
E19, B33, gauge from the end of the
drawing
CB19, CE19 E33, E34 manual lift stem. Do not gauge
B9, E9, E34, E42 B10, B14 from the packing gland
CB14, CE14 CB10, CE10 Typical View of KC-3 Coil used
assembly.
B6, E6, CB9, CE9 E14 on valve types: MA5A, MA17A,
B6, E6, E9 MA32, MA42 & MA50.
B9
For installation and service instructions on

Stem Diameter Three-Way Heat Reclaim Valves Type 8D,
Plunger (see stem .165 12D & 16D, request Form SD-114.
Gauge diameter)
(full size) E10, B10, E14, B14,
place plunger B19, E19, B25, E25,
Align at this B33, E33, E34
on drawing
point to gauge
Align at this
point to gauge .125
E6, B6, E9, B9
Printed in U.S. of A. 35-803
October 2003 / BULLETIN 10-11
Thermostatic
Expansion Valves
Installation, Field Service, and Assembly
See Bulletin 20-10 for application and selection information on

Table of Contents refrigerant distributors.
Installation While not always convenient or possible, valve Types BI, F, FB, and
O are easier to service if mounted in a vertical and upright position.
Valve Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
If mounted in a horizontal position, the internal parts must be
Solder Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
carefully reassembled to prevent damage to them. Also, some consid-
Bulb Location and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
eration should be taken in mounting larger sized expansion valves.
External Equalizer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
They must be adequately supported since system vibration and the
Driers, Strainers, and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 4
weight of the valve may cause valve connections to fracture.
Test Pressures and Dehydration Temperatures . . . . . . . . . . . . . . . 4
Expansion Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
If a hand valve is located on the outlet side of the TEV it should have
How to Determine Superheat Correctly . . . . . . . . . . . . . . . . . . . . 5
a full sized port. No restrictions should appear between the TEV and
How to Change the Superheat Setting . . . . . . . . . . . . . . . . . . . . . 5
the evaporator, except a refrigerant distributor if one is used.
Field Servicing Sporlan TEVs having Selective Charges C, Z, L, or X may be

Complaint: installed and operated in most locations. The amount of thermostatic
A - Valve does not feed enough refrigerant . . . . . . . . . . . . . . . . . 6 charge and the bulb size are such that the bulb retains control despite
B - Valve feeds too much refrigerant . . . . . . . . . . . . . . . . . . . . . . 8 a colder valve body or diaphragm case. The exception is when the
C - Valve feeds too much refrigerant at start-up only . . . . . . . . . 8 element is subjected to sub-zero temperatures for extended periods of
D - Valve doesn't feed properly . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 time during an off-cycle. In this case, start-up may be prolonged until
E - System hunts or cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 the bulb and element are warmed sufficiently to open the valve.
F - System won't perform properly . . . . . . . . . . . . . . . . . . . . . . 10
To minimize the possibility of charge migration, the Sporlan MOP
type charges (CP series, ZP series, and VGA) should be installed so
Field Assembly Instructions . . . . . . . 10
the diaphragm case is warmer than the bulb. Special non-condensable
charges without MOP and double diaphragm hydraulic elements with
MOP are available for system manufacturers to overcome this
Installation potential problem.
For peak performance, it is important to select a Sporlan Occasionally, TEVs are located in corrosive atmospheric conditions
Thermostatic Expansion Valve (TEV) with correct capacity, selective that can damage the valve and/or the element assembly. Due to this
charge, external or internal equalizer, etc. See Bulletins 10-9 and 10-10 possibility, the valve must be protected with appropriate materials to
for complete application information. Equally important is the proper prevent premature failure. Consult specialists in protective coatings.
installation, which can determine the success or failure of the entire
system.
Precautions:
When the evaporator and TEV are located above the
Valve Location receiver, there is a static pressure loss in the liquid line. This is due
TEVs may be mounted in any position, but they should be installed to the weight of the column of liquid refrigerant, and this weight may
as close to the evaporator as possible. If a refrigerant distributor is be interpreted in terms of pressure loss in pounds per square inch as
used with the expansion valve, best performance is obtained if the shown in Table 3, Bulletin 10-9. If the vertical lift is great enough,
distributor is mounted directly to the valve outlet. If the distributor vapor or flash gas will form in the liquid line causing a serious
cannot be mounted directly to the valve outlet, the distance between reduction in the capacity of the TEV.
the valve outlet and distributor should not exceed 24 inches or refrig-
erant distribution problems may occur. Also, the tube connecting the When an appreciable vertical lift is unavoidable, precautions should
valve outlet and distributor can be sized smaller to maintain refrig- be taken to prevent the accompanying pressure loss from producing
erant velocity and better distribution. Elbows located between the liquid line vapor. This can be accomplished by providing enough
expansion valve and distributor will hinder proper distribution and subcooling to the liquid refrigerant, either in the condenser or after
therefore, are not recommended. the liquid leaves the receiver. Subcooling is determined by
subtracting the actual liquid temperature from the condensing
Best distribution is usually obtained if the expansion valve feeds temperature (corresponding to the condensing pressure). A
vertically up or down into the distributor. System manufacturers, subcooling calculation example is provided in the "subcooling"
however, have successfully applied distributors in other orientations. section of Bulletin 10-9.
© Copyright 2003 by Sporlan Valve Company, Washington, Missouri

Bulletin 10-11, October 2003 Supersedes Bulletin 10-11, September 1996 and all prior publications.
Liquid subcooling is provided by the following
methods:
1. In the condenser
2. Suction – liquid heat exchanger
3. Special devices
Method 1 – will provide sufficient subcooling for the simple short-

coupled system that has only moderate liquid line pressure drop.
Method 2 – will usually not provide more than 20°F subcooling on

air conditioning systems operating at normal head pressures. The
amount of subcooling will depend on the design and size of the heat
exchanger and on the operating suction and discharge pressures. Figure 2
Method 3 – may be used to provide considerable subcooling Solder Techniques

required for systems with excessive vertical lift. The following
It is not necessary to disassemble solder type valves when soldering
special devices are the most commonly used methods:
to the connecting lines. Any of the commonly used types of solders,
■ Water coils in heat exchange relationship with the liquid line. e.g., 95-5, Sil-Fos, Easy-Flo, Phos-Copper, Stay Brite 8 or equiva-
■ Separate refrigeration system. lents may be used for copper to copper connections. When soldering
a brass refrigerant distributor to the valve, appropriate solders for
■ Special heat exchanger which uses a portion of the refrigerant to
these connections, such as 95-5, Easy-Flo, Stay Brite 8 or equivalents
cool the main body of liquid. See Figure 1.
must be used. It is important however, regardless of the solder used,
to direct the flame away from the valve body and avoid excessive
heat on the diaphragm, Figure 2. As an extra precaution, a wet cloth
may be wrapped around the body and element during the soldering
operation.
Main Liquid Line
This precaution will prevent overheating the valve body which could
damage the superheat spring and result in flood back problems. In
addition, the Type O, EBF/SBF, and EBS valve contain synthetic
parts which can be damaged due to overheating, resulting in poor
valve performance.
Receiver
Bulb Location and Installation

Insulation The location and installation of the bulb is extremely important to the
proper performance of the system and care should be taken with its
final location.
Main Suction Line Accepted principles of good suction line piping should be followed
to provide a bulb location that will give the best possible valve
To Compressor control. When system manufacturers have piping recommendations
that differ from the general industry recommendations and Sporlan’s
Figure 1 suggestions shown in this section, those recommendations should be
used. When specific recommendations are not available, the sugges-
Ordinarily the conventional suction-liquid heat exchanger is installed tions below should be used.
near the evaporator, where the suction vapor is the coldest, to re-
condense any vapor in the liquid line. When the primary purpose of The bulb should be attached to a horizontal suction line at the
the heat exchanger is to prevent the formation of flash gas – particu- evaporator outlet (See Figures 3, 4, and 5) If the bulb cannot be
larly on systems that have a long liquid line or excessive vertical lift located in that manner, it may be located on a descending vertical
– install the heat exchanger near the receiver before the vertical line only (as shown in Figure 5 for “pumpdown control”). The bulb
lift occurs. (This also applies to the special devices described in should never be located in a trap or downstream of a trap in the
Method 3). Because vapor in the liquid line considerably increases suction line. Liquid refrigerant or mixture of liquid refrigerant and oil
friction losses, the total pressure drop available across the expansion boiling out of the trap will falsely influence the temperature of the
device on these types of systems is reduced. Also, the suction line and bulb and result in poor valve control.
liquid line should be carefully insulated to minimize heat gain if
subcooled below ambient temperature. On suction lines 7/8” OD and larger, the surface temperature may
vary slightly around the circumference of the line. On these lines, it
Important is generally recommended that the bulb be installed at 4 or 8 o’clock
Preventing the formation of vapor in liquid lines having high pressure on the side of the horizontal line, and parallel with respect to the
losses does not eliminate the requirement that an adequate pressure direction of flow. On smaller lines the bulb may be mounted at any
drop must be available across the TEV. The capacity tables show point around the circumference, however locating the bulb on the
valve capacities at pressure drops lower than normal. For TEV bottom of the line is not recommended as an oil-refrigerant mixture
application data and capacities at pressure drops below those listed, is generally present at that point. Certain conditions peculiar to a
consult Sporlan Valve Company. particular system may require a different bulb location than normally
insures individual control for each valve without the influence of

refrigerant and oil flow from other evaporators.
Compressor
ABOVE For recommended suction line piping when the compressor is located
below the evaporator see Figure 5. The vertical riser extending to the
Evaporator height of the evaporator prevents refrigerant from draining by gravity
into the compressor during the off-cycle. When a pumpdown control
is used the suction line may turn immediately down without a trap.
On commercial and low temperature applications requiring

Sporlan Selective Charges C, Z, or X the bulb should be clamped on
the suction line at a point where the bulb temperature will be the same
as the evaporator temperature during the off-cycle. This will insure
tight closing of the valve when the compressor stops. If bulb insula-
Liquid and oil drains tion is used on lines operating below 32°F, use non-water absorbing
away from bulb... insulation to prevent water from freezing around the bulb.
On brine tanks and water coolers, the bulb should be below the liquid
Short as possible to minimize amount of oil. surface where it will be at the same temperature as the evaporator
during the off-cycle. When locating the bulb in a brine tank, paint it
and the capillary tubing with pitch or other corrosion resistant paint.
Figure 3
recommended. In these cases the proper bulb location may be If, for practical reasons, the bulb must be located where its tempera-
determined by trial. ture will be higher than the evaporator during the off-cycle, a
solenoid valve must be used ahead of the TEV.
For satisfactory expansion valve control, good thermal contact
between the bulb and suction line is essential. The bulb should be
securely fastened with two bulb straps, supplied with each expansion Compressor BELOW
valve, to a clean straight section of the suction line.
Evaporator
Recommended suction line piping usually includes a horizontal line
leaving the evaporator to which the TEV bulb is attached. This line is Without
pitched slightly downward, and when a vertical riser follows, a short Pumpdown
trap is placed immediately ahead of the vertical line, see Figure 3.
The trap will collect any liquid refrigerant or oil passing through the
suction line and prevent it from influencing the bulb temperature.
On multiple evaporator installations the piping should be

arranged so that the flow from any valve cannot affect the bulb of
another. Approved piping practices including the proper use of traps
Multiple Evaporators
Pumpdown
Above and Below Main Suction Line Control
Figure 5
On air conditioning applications having TEVs equipped with

VCP100 or VGA elements, the bulb may be located inside or outside
Flow from upper valve cannot the cooled space or duct. The valve body should not be located in the
affect bulb. . . . line free draining. air stream leaving the evaporator. Avoid locating the bulb in the
return air stream unless it is well insulated.
Inverted trap to External Equalizer Connection

avoid oil draining For a complete explanation of when an externally equalized valve
into idle evaporator. should be used, refer to "equalization method," Bulletin 10-9. Valves
supplied with an external equalizer will not operate unless this
connection is made.
Free draining. The equalizer connection should be made at a point that will most
accurately reflect the pressure existing in the suction line at the bulb
location. See Figure 6. Generally, the connection is immediately
downstream of the bulb. However, equipment manufacturers
Figure 4 sometimes locate them in return bends or suction headers that are
Test Pressures and Dehydration

External Equalizer Temperatures
Connection Inert dry gases such as nitrogen, helium or CO2 are often
used for leak detection.
CAUTION: Inert gases must be added to the system

carefully through a pressure regulator. Unregulated gas
pressure can seriously damage the system and endanger
human life. Never use oxygen or explosive gases.
Excessive test pressures can shorten the life of the TEV diaphragm.
Table 1 lists the maximum pressure that can safely be applied with
the expansion valve connected to the evaporator. These maximum
pressures are well above the minimum field leak test pressures for
low sides, listed by the ANSI/ASHRAE Standard 15-2001 or latest
revision.
It must be connected - NEVER CAPPED!
Must be free of crimps, solder, etc. The external equalizer line should be disconnected if there is any
possibility of exceeding the recommended maximum pressures
listed below.
Figure 6
If elevated temperatures are used to assist in dehydrating the system,
compatible with their specific design requirements. The difference
the TEV should not be exposed to temperatures exceeding those
between the pressure at the equalizer connection and the suction
shown in Table 2.
pressure at the bulb location should not exceed reasonable pressure
drop values. The values shown in Table 1 of Bulletin 10-9 can be Table 2 refers to the maximum dehydration temperatures when the
used as a guide in determining the value. bulb and valve body are subjected to the same temperature. On L, C,
Z, and X charges, 250°F maximum valve body temperature is
If any evaporator pressure or temperature control valves are located permissible if the bulb temperature does not exceed those
in the suction line at or near the evaporator outlet, the equalizer must shown in the table.
be connected on the evaporator side of these valves.
Driers, Strainers, and Accessories Table 1

Most Sporlan TEVs are equipped with built-in screens of varying Maximum Low Side Test Pressures
mesh sizes depending on the valve size and type. These strainers are
effective only in removing particles of scale, solder, etc. which could Valve Type psig
obstruct the closure of the pin and seat. (B)I, X, NI, F, FB, (E)BF/SBF, RI, G, EG, C, S, EBS, Small O 450
D, P, H, Large O 425
A, M, V, W 400
Table 2
Maximum Dehydration Temperatures – Degrees F
Figure 7 Thermostatic Charge
Refrigerant
L C Z X VGA P Type, ZP Series
Moisture and smaller particles of foreign materials are equally
harmful to the system and must be removed for peak system perfor- 12, 134a 190 190 250 - --
mance. Field experience has proven that, without a doubt, most 22 160 160 185 210 250 250
expansion valve failures are due to the presence of dirt, sludge, and
404A, 502, 507 150 150 170 ---
moisture in the system. Furthermore, the performance and life of
other system components are also seriously affected by these foreign 717 (Ammonia) 150 190 235 --- - -- ---
materials. The Sporlan Catch-All Filter-Drier® removes dirt,
moisture, acids, and sludge, and insures the circulation of clean, dry
refrigerant through the system at all times.
Expansion Valve Adjustment
For all refrigeration and air conditioning applications we recommend Each Sporlan TEV is thoroughly tested and set at the factory before
that a Sporlan Catch-All Filter-Drier be installed in the liquid line shipment. This factory superheat setting will be correct and no
ahead of the TEV. See Bulletin 40-10 for complete Catch-All Filter- further adjustment is required for the majority of applications.
Drier specifications. However, there are many factors which can affect the performance of
a TEV. These factors are independently variable and all of them
Further system protection is easily and inexpensively provided with cannot be compensated for in the design of a valve. When the
the installation of a Sporlan See-All®. The See-All is a combination application or operating conditions require a different valve setting
liquid and moisture indicator that visually indicates if there is a due to one or more of the factors listed below, the valve may be
shortage of refrigerant in the liquid line, or if the moisture content of adjusted to obtain the required operating superheat. Therefore, an
the refrigerant is at a dangerous level. See Bulletin 70-10 for adjusting stem is provided on all standard valves. The valve should
complete See-All specifications. be set with the system as near as possible to design conditions.
Factors which affect valve performance and may make it necessary the estimated pressure drop will equal the approximate
to adjust the valve are: suction line pressure at the bulb.
1. Low temperature difference (TDs) between the refrigerant and 3. Convert the pressure obtained in 2a or 2b above to saturated
the air evaporator temperature by using a temperature-pressure chart.
2. TEV bulb location 4. Subtract the two temperatures obtained in 1 and 3 – the differ-
3. Balance between compressor and evaporator ence is superheat.
4. Ratio of load to TEV capacity Figure 8 illustrates a typical example of superheat measurement on
5. Condenser capacity an air conditioning system using Refrigerant 22. The temperature of
6. Operation of several fixtures on multiple installation the suction line at the bulb location is read at 52°F. The suction
pressure at the compressor is 66 psig and the estimated suction line
7. Seasonal variation in head pressure caused by extreme changes in pressure drop is 2 psi …66 psig + 2 psig = 68 psig at the bulb, which
ambient air temperature. is equivalent to a 40°F saturation temperature. (Use dew point
temperature for refrigerant blends.) 40°F subtracted from 52°F =
Note: Valve Types F, (E)BF/SBF, Q, A, M, V, K, and W have non- 12°F superheat.
rising adjusting stems and a change in adjustment does not change
the stem position. Note: Refrigerated case manufacturers frequently use a “tempera-
ture difference” method to approximate superheat. This procedure
When setting valves on multi-evaporator refrigeration systems with consists of measuring the temperature of a location on the evaporator
pressure or temperature sensitive evaporator control valves, the which is representative of saturated vapor temperature; and, then
following procedure is recommended: subtracting that temperature from the outlet evaporator temperature
1. Evaporator Pressure Regulating Valve (ORI Type): the ORI valve which is measured at the bulb location.
is set first at the minimum load condition. Then, if necessary, the
expansion valve is adjusted to the desired superheat setting while While this method of reading “superheat” is acceptable on those
under the normal operating load condition. manufacturer’s cases where the pressure drop through the evaporator
is low, Sporlan does not recommend the “temperature difference”
2. Temperature Sensitive Evaporator Regulating Valves (CDS
method for other types of systems.
Type): The CDS valve is forced into a fully open position first.
Then the expansion valve is adjusted to the desired superheat
setting at full load condition. Finally, the controller for the CDS
is set to the desired temperature. Contact Sporlan Valve
Company, or the case manufacturer, for additional details on What's Your
setting the CDS controller. Superheat?
When the adjustment is completed on the TEV, always tighten the
adjusting stem packing nut and replace the seal cap tightly.
Temperature
Many expansion valves are made non-adjustable for use on here reads
Original Equipment Manufacturer’s units, particularly those valves 52°
used on residential air conditioning and heat pump systems. These
valves are set at a superheat predetermined by the manufacturer’s OBTAIN SUCTION PRESSURE 40°
laboratory tests and cannot be adjusted in the field. 68 PSIG (at bulb) 12°
SUPERHEAT
Some non-adjustable models are modifications of standard
adjustable type valves. This is done by using a solid bottom cap
instead of one equipped with an adjusting stem and seal cap. These
valves can be identified by an N preceding the standard valve designa-
tion. Adjustable bottom cap assemblies are available for converting
most non-adjustable valves to the adjustable type. However, this is Figure 8
rarely required. If symptoms indicate that a valve adjustment is
needed, carefully check the other possible causes of incorrect
superheat, pages 6 through 10, before attempting an adjustment. How to Change the Superheat
Setting
How to Determine Superheat Note: There are some valve bodies (G, EG, C, S, EBS
and EMC) that have a packing nut around the adjust-
Correctly ment stem. It may be necessary to loosen the packing
1. Measure the temperature of the suction line at the bulb location. nut slightly to turn the adjusting stem. Do not forget
2. Obtain the suction pressure that exists in the suction line at the to retighten the nut after the superheat is set.
bulb location by either of the following methods:
a. If the valve is externally equalized, a gauge in the external To reduce the superheat, turn the adjusting stem counter-
equalizer line will indicate the desired pressure directly and clockwise. To increase the superheat, turn the adjusting stem
accurately. clockwise. When adjusting the valve, make no more than one turn
b. Read the gauge pressure at the suction valve of the of the stem at a time and observe the change in superheat closely to
compressor. To the pressure add the estimated pressure drop prevent over-shooting the desired setting. As much as 30 minutes
through the suction line between bulb location and may be required for the new balance to take place after an adjust-
compressor suction valve. The sum of the gauge reading and ment is made.
If in doubt about the correct superheat setting for a particular system, The primary cause of difficulty with either the BP or RPB feature is
consult the equipment manufacturer. As a general rule, the proper dirt and other foreign materials that restrict or plug them. And if the
superheat setting will depend on the amount of temperature differ- system purpose intended for either feature is not being satisfied, the
ence (TD) between refrigerant temperature and the temperature of the valve probably needs cleaning or replacing.
air or other substance being cooled. Where high TD’s exist, such as
on air conditioning applications, the superheat setting can be made as As stated in Bulletin 10-9, the RPB type valve is not to be applied on
high as 15°F without noticeable loss in evaporator capacity. Where systems using high starting torque compressors or “hard-start”
low TD’s exist, such as in low temperature blower coil applications, electrical components, on outdoor coils of heat pumps, or on any
a superheat setting of 10°F or below is usually recommended for refrigeration system, and it should not be used to replace BP type
maximum evaporator capacity. It is these applications that the TEV valves that are applied on those types of systems. On systems other
will more than likely need to be adjusted. than those described above, the RPB type valve can replace the BP
type valve when necessary. Usually it is advisable to replace a valve
For the correct valve setting on factory built equipment, manufac- with one of the same specification unless advised differently. Consult
turers’ recommendations should be followed. Some manufacturers with the system manufacturer for assistance.
specify the superheat directly; others may recommend valve adjust-
ment to a given suction pressure at certain operating conditions, or
until a certain frost line is observed. Such recommendations, however
they are stated, represent the results of extensive laboratory testing to
Complaint "A"
determine the best possible operation. “Valve does not feed enough refrigerant.”
SYMPTOMS:
■ Load temperature (air or water leaving
Field Servicing evaporator) too high.

■ Superheat too high.
■ Suction pressure lower than normal with

The TEV is erroneously considered by some to be a mysterious and compressor unloaders locked out or hot gas
complex device. As a result, many valves are needlessly replaced bypass shut off.*
when the cause of the system malfunction is not immediately
recognized.
THE CAUSE MAY BE:
Actually the TEV performs only one very simple function – it keeps 1. Moisture — Water or a mixture of water and oil frozen in the
the evaporator supplied with enough refrigerant to satisfy valve port or working parts of the valve will prevent proper
all load conditions. It is not a temperature control, suction operation. This is a common source of trouble on expansion
pressure control, a control to vary the compressor’s running time, or valves. Since the valve is the first cold spot in the system,
a humidity control. moisture will freeze and block the valve open, closed, or any
position in between. If the valve is frozen in the intermediate
How effective the valve performs is easily determined by measuring position so that flow is restricted, the superheat will be high.
the superheat as outlined in Figure 8. Observing the frost on the
suction line, or considering only the suction pressure may be Remedy — Install a Sporlan Catch-All Filter-Drier in the
misleading. Checking the superheat is the first step in a liquid line for removal of moisture from the refrigerant and oil.
See Bulletin 40-10.
simple and systematic analysis of TEV performance.
To determine a safe level of moisture in the system, install a
■ If not enough refrigerant is being fed to the evaporator— Sporlan See•All Moisture and Liquid Indicator. See Bulletin
the superheat will be high. 70-10.
■ If too much refrigerant is being fed to the evaporator — Excessive moisture has a damaging effect on all
the superheat will be low. system components regardless of the evaporating
temperature. Moisture must be removed for trouble-
Although these symptoms may be attributed to improper TEV
free performance.
control, more frequently the origin of the trouble lies elsewhere.
2. Dirt or foreign material — Contaminants such as copper
Note: TEVs with permanent bleed ports (BP) or Rapid Pressure
oxide scale, metal chips, oil breakdown sludge, etc. will restrict
Balancer (RPB) construction are applied on many air conditioning
the flow of refrigerant when it collects in strainers or other liquid
and refrigeration systems by original equipment manufacturers. Each
line accessories. This produces a shortage of refrigerant at the
application is tested and approved by the manufacturer. The primary
TEV port. Conventional strainers frequently allow the material
function of these devices is to equalize high-to-low side pressures
to pass through the screen and obstruct the flow at the valve
during the off cycle on systems equipped with low starting torque
port. If a See•All is installed downstream of the restriction,
compressors.
bubbles will be visible. This should not be confused, however,
with a refrigerant shortage or excessive liquid line pressure loss
However, some BP type valves are applied to allow small amounts of
which are also indicated by bubbles in the See•All.
liquid refrigerant to pass for compressor motor cooling. The specific
function of the feature on a given unit must be determined from the Remedy — Locate and remove the foreign material creating
system manufacturer. Once that is determined, it is easier to the restriction. Install a Sporlan Catch-All Filter-Drier to
troubleshoot the system. provide effective filtration of the refrigerant. See Bulletin 40-10.
* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
3. Wax — Certain systems are contaminated with small amounts 7. Insufficient pressure drop across valve — One of the
of wax which will precipitate at low temperatures in systems factors that influence expansion valve capacity is the pressure
with Refrigerants 22 or 502. Since the TEV represents the first drop that exists between the inlet and outlet. Anything
cold point in the refrigeration cycle, wax is most likely to form contributing to a reduction in this pressure drop will reduce valve
at the valve port. capacity. Abnormally low condensing pressures, excessive liquid
It is sometimes difficult to observe the wax in a valve because it line pressure losses (even with adequate subcooling), undersized
may exist in solid form only at very low temperatures. By the distributor nozzle or distributor tubes may also be responsible for
time the valve has been taken apart, the temperature has a very low net pressure drop across the valve port.
increased enough to cause the wax to melt and thus become Remedy — Remove source of pressure loss, or install valve
difficult to detect. When wax is suspected, it can usually be with adequate capacity at the reduced pressure drop. If inlet
detected on the pin and seat by packing the valve in dry ice pressure to valve is low due to low condensing pressure, raise
while disassembling. pressure.
Remedy — Clean the valve with solvent before reassembling If the refrigerant distributor nozzle is undersized replace with
the valve. The Sporlan HH style Catch-All Filter-Driers have a correct size. See Bulletin 20-10.
special activated charcoal desiccant that is designed to remove
wax in the liquid line before it causes trouble. Therefore, to 8. Dead thermostatic element or wrong thermo-
prevent wax problems, use these HH style driers (e.g., C-415- static charge — If the element has partially or completely
S-HH) on all low temperature systems using Refrigerants 22 or lost its thermostatic charge, the valve will be unable to feed
502. sufficient refrigerant or will remain closed. A wrong charge may
cause insufficient feed also.
4. Refrigerant shortage — See•All or sight glass in the Remedy — Replace the element if it is dead. If charge is
liquid line will show bubbles when the system is short of refrig- incorrect, replace with proper selective charge. See Bulletin 10-9.
erant charge. Before adding more refrigerant however, be sure
the bubbles are not produced by other causes (See Paragraphs 9. Charge migration (CP series, ZP series, and VGA
A-2 and A-5). charges only) — In order for valves with these charges to
A lack of refrigerant charge may also be detected by a hissing maintain control at the bulb, the bulb must be kept at a lower
sound at the TEV. Some systems not equipped with a liquid line temperature than the element (diaphragm case). If the thermo-
sight glass will have test cocks or other devices for checking the static charge does migrate to the element because of a lower
refrigerant level in the receiver. element temperature, the valve will throttle.
Remedy — Add enough refrigerant to obtain desired result. Detection — Warm the element with a cloth saturated with
hot water. If this produces more refrigerant feed and reduces the
5. Gas in the liquid line — As explained in Paragraphs A-2 superheat to normal, charge migration is responsible for the
and A-4, liquid line vapor can be produced by a partially starved evaporator.
plugged strainer or drier and by a shortage of refrigerant charge. Causes —
In addition, gas in the liquid line can be caused by air or other ■ Insufficient pressure drop between the valve outlet and bulb
non-condensable gases in the system or by excessive pressure location, possibly due to an oversized distributor nozzle or no
losses in the liquid line as a result of: nozzle at all.
■ Long or undersized line. ■ Excessive pushrod leakage, which allows the leaking refrig-
■ Liquid line vertical lift. erant to cool the diaphragm case before passing into the
Remedy — Verify the correct liquid line size for the equiva- equalizer line. This is a rare occurrence and should be
carefully checked before arriving at this conclusion.
lent length and system tonnage. Consult liquid line sizing data
■ Cold location of TEV, or condensate drippage on the
published in many manufacturers’ catalogs and in textbooks. If
diaphragm case.
undersized, repipe with the correct size.
Remedies —
Determine amount of vertical lift, and obtain the resulting
pressure loss from Table 3, Bulletin 10-9. Using the subcooling
■ Install distributor nozzle correctly sized in accordance with
calculation example provided in the "subcooling" section of nozzle sizing procedure given in Sporlan Bulletin 20-10.
■ On valves with packed pushrod construction, remove element
Bulletin 10-9, find required subcooling necessary to prevent
gasification with the existing pressure losses. Provide the and tighten the pushrod packing nuts.
■ Relocate the TEV away from cold outlet air, or condensate
necessary subcooling by using one of the methods described on
Page 1. drippage.
6. Misapplication of internally equalized valve or 10. Undersized valve

incorrect location of external equalizer — If the Remedy — Install valve sized in accordance with procedure
pressure drop through the evaporator exceeds the predetermined given in Bulletin 10-9, or Bulletin 10-10.
values shown in Table 1, Bulletin 10-9, an externally equalized
valve must be used. When an externally equalized valve is used, 11. High Superheat adjustment
the equalizer connection should be made at a point in the suction Remedy — Turn the adjusting stem counter clockwise until
line that will reflect the pressure existing in the line at the bulb the correct superheat is indicated.
location.
Remedy — Replace internally equalized valve with one 12. Feed-back from another valve — Review instructions
having an external equalizer. for Bulb Location and Installation, Page 2.
If external equalizer is installed incorrectly, change to correct Remedy — Check the bulb temperature and calculate the
location. See Page 3. superheat. If superheat is normal but too little refrigerant is
flowing through the evaporator, check the piping for possible Disassemble the valve to be certain that dirt or foreign material
refrigerant flow from another evaporator affecting the bulb. Re- is not responsible (see B-2). If the pin and seat are worn or
pipe if necessary. See Figure 4. damaged and an internal parts kit is available, replace the parts.
When parts are not available, the valve must be replaced.
13. High pressure drop through evaporator
Remedy — Check the pressure at the evaporator inlet and 4. Oversized valve — Check valve ratings considering all the
outlet with gauges. If pressure difference is greater than the factors which affect its capacity. See Page 16, Bulletin 10-9, or
values shown in Table 1, Bulletin 10-9, use an externally Page 3, Bulletin 10-10.
equalized valve. Remedy — Install correctly sized valve.
14. Restricted, plugged, or capped external equalizer — 5. Incorrect bulb installation — The bulb should be securely
If the pressure under the diaphragm builds up due to pushrod fastened to a straight, clean, section of the suction line using two
leakage and cannot escape through the external equalizer line, bulb straps for good thermal contact. Also, the temperature of the
the valve will remain closed. bulb should not be influenced by ambient temperature — an
Remedy — Check the external equalizer line to be sure it is external heat source such as a steam pipe or heating coil.
open or not capped. Remedy — Install bulb correctly. See Bulb Location and
Installation, Page 2.
Complaint "B" 6. Low superheat adjustment

“Valve feeds too much refrigerant.” Remedy — Turn the adjusting stem clockwise until the correct
SYMPTOMS: superheat is indicated. See Page 4.
■ Liquid returns to compressor.
■ Superheat is low. 7. Incorrect thermostatic charge

■ Suction pressure is normal or higher than
Remedy — Select and install the correct selective charge. See
normal. Bulletin 10-9.
8. Incorrectly located external equalizer

THE CAUSE MAY BE:
1. Moisture — Water or a mixture of water and oil frozen in the Remedy — Relocate external equalizer or the connection
valve port or working parts of the valve will prevent proper between evaporator and any other temperature or pressure
operation. This is the most common source of trouble on TEVs. sensitive evaporator control valve near bulb location. See Page
Since the valve is the first cold spot in the system, moisture will 3 for recommendations.
freeze and block the valve open, closed, or any position in
between. If the valve is held in the open position by ice, liquid 9. Inefficient compressor — If the compressor is inefficient
flood-back will occur. or for some other reason lacks capacity, the suction pressure will
Remedy — Install a Sporlan Catch-All Filter-Drier in the operate higher than normal. This may or may not be accompa-
liquid line for removal of moisture from the refrigerant and oil. nied by low superheats.
See Bulletin 40-10. Remedy — Consult with compressor manufacturer.
For additional protection, install a Sporlan See•All Moisture and
Liquid Indicator for a positive indication of when a safe
moisture level is reached. See Bulletin 70-10. Complaint "C"
“Valve feeds too much refrigerant at start-up only.”
2. Dirt or foreign material — Contaminants such as copper
oxide scale, metal chips, oil breakdown sludge, etc. may pass SYMPTOMS:
through ordinary strainers and lodge at the TEV port and prevent ■ Liquid returns to compressor.
the valve from closing. ■ No superheat.
■ Suction pressure higher than normal.

Remedy — Disassemble the valve and remove all foreign
material from the internal parts. Install a Sporlan Catch-All
Filter-Drier in the liquid line. The Catch-All filters out the
THE CAUSE MAY BE:
smallest particles of foreign material that might interfere with
1. Refrigerant drainage — Drainage of refrigerant from the
the operation of any system component.
evaporator (during the off-cycle) when installed at a higher level
than the compressor.
3. Expansion valve seat leak — When the valve port does
not seat tightly, refrigerant will pass through during the off-cycle Remedy — Install a trap-riser to top of evaporator or use
and fill the evaporator with refrigerant. If the seat leak is severe, pump-down control. See Figure 5.
the valve will feed too much refrigerant during the operating
cycle as well. (Not applicable to valves with permanent bleed 2. Compressor or suction line in cold location —
ports or RPB feature.) During the period when the system is not in operation, liquid
Remedy — If the valve seat is leaking, a gurgling or hissing refrigerant will condense at the coldest point in the system. Liquid
sound can usually be heard during the off-cycle. Also, a sight will condense in the compressor or suction line, if they are located
glass or See•All in the liquid line may indicate continued refrig- in an ambient temperature below that of the evaporator during the
erant flow for a long period after the compressor has stopped. off-cycle. Upon re-starting, this liquid will slug the compressor.
Make certain however, that the bubbles are not the result of Remedy — Keep compressor or suction line warm during the
back-flow through a vertical liquid line. off-cycle. Some compressors are equipped with crankcase heaters
for this purpose. Another corrective measure is to install a suction 3. Low load— Low evaporator load may be caused by insuffi-
line solenoid valve that is de-energized during the off-cycle. cient air over the coil as a result of an undersized blower, dirty
air filters, or an obstruction in the air stream. In addition, frost
3. Restricted or plugged external equalizer — A formation on the coil or low entering air temperatures will
momentary flood can occur when the load increases suddenly, reduce the evaporator load.
such as at start-up because the higher suction pressure cannot
Remedy — Correct the condition responsible.
reach the underside of the diaphragm and help close the valve.
If the pressure under the diaphragm increases due to any
4. Flow from one coil affecting TEV bulb of another
pressure leakage around the pushrods, the valve will eventually
(Multiple evaporator systems only) — The tempera-
throttle.
ture of the bulb may be falsely influenced by flow from another
Remedy — Remove the restriction or plugged portion of the evaporator usually because of incorrect piping.
external equalizer.
Remedy — Correct the piping. See Figure 4, Page 3.
4. Liquid line solenoid valve seat leak or interrupted
5. Improper compressor-evaporator balance — If the
pumpdown — Liquid refrigerant can continue to feed the
compressor is too large for the load and evaporator capacity, the
TEV and/or remain in evaporator upon shut-down causing
low suction pressure which results will cause poor system
flood-back to the compressor upon start-up.
performance.
Remedy — Disassemble and clean solenoid valve and/or
Remedy — Consult with the manufacturer or consulting
replace damaged internal parts if seat leakage is the problem. If
engineer, or the ASHRAE Handbook on component balancing.
the pumpdown cycle isn’t completed before the compressor
cycles off, or the thermostat calls for cooling and reopens the If necessary, change or correct the improperly sized component.
liquid line solenoid before the evaporator has been properly Hot gas bypass may be used to balance properly.
evacuated, check the low pressure cut-off setting or the
electrical controls for possible causes. 6. Evaporator oil-logged — Poor heat transfer occurs and
unpredictable performance takes place. If erratic performance is
observed over a period of time, and other causes are omitted
from consideration, review the amount of oil in the system.
Complaint "D" Turbulent compressor oil level with little or no return to the
“Valve doesn't feed properly.” compressor sump indicates oil problems.
SYMPTOMS: Remedy — Remove excessive oil from evaporator and
■ Poor system performance. connecting piping. Many times the evaporator temperature will
■ Superheat normal or lower than normal. be too low for the oil to be removed. Therefore, the system must
■ Suction pressure lower than normal with be allowed to warm sufficiently to get cold oil to drain. Analyze
compressor unloaders locked out or hot gas system components for possible causes of oil problem before
bypass shut off.* restarting the system. Consult with the compressor manufacturer
for specific details on their compressor.
THE CAUSE MAY BE:

1. Unequal circuit loading (Multi-circuit evaporators Complaint "E"
and parallel evaporators connected to a single
“System hunts or cycles.”
refrigerant distributor) — When each circuit is not
subjected to the same heat load, the lightly loaded circuits will SYMPTOMS:
allow unevaporated refrigerant or low temperature vapor to ■ Suction pressure fluctuates*
enter the suction line and throttle the valve. This will cause ■ Superheat fluctuates.
normally loaded circuits to be deprived of their share of ■ Valve does not feed enough, and then too much
refrigerant. The net result is a loss of refrigerated evaporator refrigerant.

surface.
Remedy — Make necessary modifications which will allow
each evaporator circuit to receive the same percentage of the THE CAUSE MAY BE:
total load. See Bulletin 20-10 for application information on 1. System characteristics — Certain design characteristics of
multi-circuit evaporators using a refrigerant distributor. the system may have an effect on the system’s tendency to hunt
or cycle. As an example, after the valve admits refrigerant to the
2. Poor refrigerant distribution (Multi-circuit evapora- evaporator inlet, there is a time delay before the bulb senses the
tors and parallel evaporators connected to a single effect at the evaporator outlet. This time delay is dependent on
refrigerant distributor) — If the refrigerant distribution is evaporator length, tube size, and load. Generally, there is more
faulty, the circuits receiving the largest portion of refrigerant likelihood for hunting to occur when this time interval is long.
will have the controlling influence on the TEV. The result is the Other influencing factors are circuit arrangement, load per
same as in paragraph 1 above. circuit, and temperature difference.
Remedy — Correct refrigerant distribution. See Bulletin 20-10 Remedy — When hunting is moderate particularly with no
for complete information on Refrigerant Distributors. floodback, the effect on the system is insignificant and correc-
* When system has some form of capacity reduction — cylinder unloaders or hot gas bypass, a low suction pressure will not exist. Therefore, when checking TEV
performance, a better analysis is possible when these devices are locked out or shut off so the suction pressure will respond to variations in load or valve feed.
tions are not necessary. If hunting is severe with floodback to 5. System is hunting or cycling. See Section E on Page 9.
the compressor, check the possible remedies shown in
paragraphs below. 6. The TEV has been physically abused in an effort
to make the valve work properly. This is usually the
2. Valve size — An over-sized valve usually aggravates hunting. result of a mistaken analysis. It is frequently assumed that if a
Carefully check the valve rating considering all the factors valve does not feed properly, it is stuck (either opened or
affecting its capacity. See Bulletin 10-9, or Bulletin 10-10. closed). Beating the valve body with a hammer will only distort
Remedy — Replace valve with one correctly sized. On the body and make it impossible for the valve to work once the
multiple circuit evaporators using a refrigerant distributor, the real cause is determined.
capacity of the valve can be reduced, within certain limits, by If a valve “sticks,” it is usually due to moisture freezing in the
installing a smaller distributor nozzle. See Bulletin 20-10. port, dirt and other foreign material restricting or plugging the
internal parts, wax forming on the internal parts at low temper-
3. Bulb location — If the bulb is located in a suction line trap, atures, or the valve has been physically abused so it cannot
its temperature will be affected by liquid oil and refrigerant function.
alternately collecting and evaporating at this point. This Remedy — Inspect the valve and its internal parts, including
condition frequently results in severe hunting. the inlet strainer. If plugged or restricted in any way, clean the
Remedy — As a temporary measure relocate the bulb away parts thoroughly, oil the parts with a good grade of refrigerant
from the trap, and any turbulent areas created by elbows, tees, oil, and reassemble the parts. Complete details on this subject
etc. Also remove the bulb from the air stream or insulate. Re- are found on Pages 10 through 12.
pipe if necessary. Sometimes another position around the If the valve is beyond normal cleaning processes, or if it is
circumference of the suction line will minimize hunting. Follow physically damaged in any way, replace the valve with its proper
the Bulb Location and Installation instructions given on Page 2 replacement model.
for the best TEV control.
4. Refrigerant and load distribution — In addition to the

effects of poor distribution explained in paragraphs D-1 and D- Field Assembly
2, hunting also frequently results. This is caused by liquid
refrigerant from the overfed circuits occasionally reaching the Instructions
bulb of the valve.
Remedy — Correct the faulty distribution. Sporlan valves my be opened easily for inspection.
5. Superheat adjustment — All Sporlan TEVs are preset at

the factory to give the best performance on the average system. Thermostatic
A valve should not be adjusted unnecessarily, but occasionally Element
another setting may prove to be better.
Remedy — Turn the adjusting stem clockwise a turn at a time.
If the hunting stops or is reduced, turn the adjusting stem Pushrods
counter clockwise a turn at a time to obtain the lowest superheat
with stable operation.
6. Moisture — As ice forms in a TEV from excessive moisture, Inlet

a very erratic hunt may result. Outlet
Remedy — Remove the moisture with the installation of a
Sporlan Catch-All Filter-Drier. A safe moisture level can be
determined by installing a Sporlan See•All. Body
Seat
Complaint "F"
Pin Carrier
“System won't perform properly.”
SYMPTOM:
■ Cannot get valve to react or regulate at all. Spring
Spring Guide
THE CAUSE MAY BE: Bottom Cap
1. No refrigerant being fed to evaporator. See Section Assembly
A on Pages 6 & 7.
2. Too much refrigerant being fed to evaporator. See Adjusting Stem

Section B on Page 8. Seal Cap
3. Too much refrigerant being fed to evaporator at
start-up only. See Section C on Page 8.
4. Refrigerant control is erratic. See Section D on Page 9. Figure 9

Note: These Field Assembly Instructions apply in part to all Sporlan exerting too much pressure in tightening the element or in
TEVs. See Figure 9 for an “exploded” view of those models that can clamping the body in the vise. Also, do not use a wrench on the
be completely disassembled. When a TEV is to be disassembled for outer welded edge of the element.
inspection and cleaning, or for replacement of the thermostatic
element or the internal parts, the following information should be 4. Inspect parts, element, and body for any foreign materials or
reviewed for assistance. physical damage.
Types F dated approximately C84 or earlier and Types I, BI, NI, RI, 5. On valves with replaceable elements and/or internal parts,
FB manufactured prior to 1994 do not have replaceable elements nor replace any items that appear damaged.
internal parts kits, but can be disassembled for inspection and
cleaning. Type F dated D84 or later, Type S valves dated B69 or later, 6. Clean all parts with solvent, preferably by applying and then
Type C valves dated C70 or later, and ALL Type G, X, (E)BF/SBF blowing off with clean dry compressed air.
and EBS valves employ packless pushrod construction and internal
parts are NOT available for use with them. However, their elements
can be replaced and they can be disassembled for inspection and
cleaning. Due to the single pushrod construction of the Type RIGHT WRONG
(E)BF/SBF and EBS valves, only the bottom cap assembly, pin
guide, and superheat spring may be removed for inspection and
cleaning.
Early production of the Type F valve with the replaceable element

requires a 15/16" thin jaw, open end type element wrench such as a
Bonney 1230. Subsequent production of the Type F valve and all
Types (E)BF/SBF, I, BI, NI, RI, and FB valves require a 1" thin jaw,
open end type element wrench such as the one available from
Sporlan wholesalers. An open end wrench is necessary because of
Figure 10
limited space between the body and element of these valves.
Precautions must be taken in removing the KT-43 element (F) so the
element, body, or connections are not damaged by the wrenches. 7. To reassemble valves with replaceable seats, screw seat into
body with a fairly light pressure since it does not require a heavy
While standard open end or adjustable wrenches fit the other element pressure to make this small knife-edge joint.
sizes, the thin jaw type wrenches are also available for the other Caution: Be sure hexagon corners of seat do not protrude into
element sizes: Bonney 1236 (1-1/8") for KT-53 elements, Bonney pushrod holes (see Figure 10).
1240 (1-1/4") for KT-83 elements, Bonney 1248 for KT-33 elements,
For valves that do not have replaceable elements or for Type O
and Bonney 1252 for KT-63 and 7 elements.
valves, place the pushrod(s) into the body now.
Replaceable elements and internal parts kits are available for current 8. Next, slip the pin and carrier (which have been pressed
valves with packed pushrod construction: together at the factory) into the body and tap the pin into the
Types P, H, M, D, and A. seat to form a true seating surface. It is generally advisable,
before tapping these parts together, to check the concentricity
Replaceable elements for Types O, V, W, and U are also available. of both the pin and seat by engaging the parts by pressing them
However, special field assembly instructions are included with their lightly together with one finger and noting that there is no
internal parts kits. tendency to stick together. This should be repeated several
times after rotating the pin carrier a quarter of a turn. In
Assembling Instructions assembling valves with port sizes of 1/4" and larger which use
The following steps are necessary in properly disassembling, the flat disc instead of the tapered pin, DO NOT TAP THE
inspecting, cleaning, and reassembling a TEV whether the valve is in DISC AGAINST THE SEAT.
or out of the refrigerant piping.
9. Now place the spring guide stamping (when used), and spring,
1. Before disassembling the valve, be sure the refrigerant pressure in the pin carrier, place the lower spring guide on the opposite
end of the spring and screw the bottom cap in place. (Replace
in the system has been reduced to a safe level (0 psig).
the pin guide, spring, and bottom cap assembly together on Type
(E)BF/SBF and EBS valves.) After screwing bottom cap
2. Remove the seal cap and turn the adjustment stem counter-
assembly in place, carefully tighten, preferable with two 10"
clockwise to relieve the spring force. Count and record the
wrenches, to seal the metal-to-metal knife edge joint. The
number of turns so adjustment can be returned to its original
sealing surfaces should be free of any foreign material or nicks
position.
that might prevent a leak-tight joint.
3. Using appropriate wrenches or a vise to properly support the
10. On valves with replaceable elements (except Types O,
valve body, remove the element (if a replaceable type), the
(E)BF/SBF and EBS), place the pushrods into the body and
bottom cap assembly, and the internal parts. (Only remove the
open the valve several times by pressing down on the pins with
bottom cap, pin guide, and superheat spring on Type (E)BF/SBF
a flat metal surface. This will help seat the pin properly.
and EBS valves. DO NOT remove the single pushrod from
these valves.)
11. Check the height of the pushrod(s) above the element sealing
Caution: Regardless of whether the valve is in the system or surface with the pushrod gauge (see Figure 11). The gauge is
in a vise, care must be taken to prevent distorting the body by supplied with internal parts kits or can be obtained at no charge
upon request. (Since the internal parts of the Type (E)BF/SBF
Table 3 and EBS valves cannot be replaced, it is not necessary to check
Valve TypeQ Gauge the pushrod height of these valves.)
Current Obsolete Number The appropriate gauge numbers for the various TEV’s are given
AA(E), LMC-AA(E) --- 1 in Table 3.
DA(E), LMC-DA(E) --- 2
Caution: If the element-to-body joint utilizes a gasket, the
PFE or HFE-11/2, 3, 4, 5, 8, 12 PFE or HFE-6, 71/2, 10, 11
PVE or HVE-21/2, 51/2, 7, 11, PVE or HVE-2, 5, 8, 10, 12,
gasket must be removed before checking pushrod height.
16, 20 15, 17, 18 If the pushrod(s) are too long, they must be carefully ground off
PDE or HDE-5, 8, 14 PDE or HDE-6, 71/2, 9, 12, 13 to the proper length. Clean the pushrod(s) of all dirt and
PRE or HRE-11/2, 4, 61/2, 9, 12 PRE or HRE-6, 71/2, 11, 13 3 grindings and place them into the body.
UFE-12, 17
UVE-22, 30
---
UDE-15, 21
URE-16, 22
OFE-23, 32, 40 UFE-23 Check Height
OVE-40, 55, 70 UVE-40
ODE-28, 40, 50 UDE-28
3A of Pushrod(s)
Pushrod(s) should just
ORE-30, 35, 45 URE-30 clear here. with Gauge
All F ModelsW except
FF(E)-1/8, FV(E)-1/4, --- 4 Gauge
FD(E)-1/8, FR(E)-1/8
All G Models except
GF(E)-1/8, GV(E)-1/4, All small K models
GR(E)-1/8 5 Pushrod(s)
All X Models ---
MFE-5, 71/2, 11, 13, 15, 20 MFE-12, 17
Valve
MVE-8, 12, 18, 21, 26, 34 MVE-30
MDE-6, 9, 13, 15, 18, 25 MDE-14, 20 Figure 11
6
MRE-9, 15, 20, 25
KFE or VFE-45, KVE or VVE-70 ---
12. Element Replacement — If the element is damaged or has
KDE or VDE-55, KRE or VRE-50
MFE-25 MFE-22
lost its thermostatic charge, replace it with the same type.
MVE-42 MVE-40 To properly replace the element without damaging the element
MDE-30 MDE-26 or the valve body on valves which utilize a gasketed joint, be
MRE-30 --- sure only one gasket is used before assembling the element. In
6A
KFE or VFE-35, 55 VFE-50 assembling gasketed elements held in place by two cap screws,
KVE or VVE-52, 100 VVE-90 be sure to pull up the cap screws evenly.
KDE or VDE-40, 65 VDE-42, 60
KRE or VRE-38, 70 - -- On valves which utilize the threaded type of element with metal-
WFE-80, 110 WFE-75, 100 to-metal knife edge joints, always use an appropriate wrench
WVE-135, 180 --- (10") on the wrench flats. DO NOT use a wrench on the outer
7
WDE-95, 130 WDE-90, 120 welded edge of the element. The sealing surfaces should be free
WRE-100, 130 --- of any foreign materials or nicks that might prevent a leak-tight
CF(E) or SF(E)-1/4, 1/2, 1, 11/2, joint. A few drops of refrigerant oil on the element threads will
2, 21/2, 3
facilitate easy assembling and removal.
CV(E) or SV(E)-1/2, 1, 11/2,
2, 3, 4, 5 R and T Models
8 13. Return the superheat spring adjustment to its original position.
CD(E) or SD(E)-1/4, 1/2, 1, 11/2, with 83 elements
2, 21/2, 3, 31/2 Replace the seal cap tightly.
CR(E) or SR(E)-1/4, 1/2, 1, 11/2,
2, 3, 4
CFE-5, SFE-5, 6
CVE-8, SVE-8, 10
CDE-6, SDE-6, 7
CRE-6, SRE-6, 7
-- - 8A
OFE-6, 9, 12 Q Type F (internally and externally equalized) valves dated D84 or later,
OVE-10, 15, 20 Type S valves dated B69 or later, Type C valves dated C70 or later, and
ODE-7, 11, 14 all Type G (externally equalized only) and X valves have packless
ORE-6, 9, 12 pushrod construction and internal parts kits are not available for use
OFE-16, OVE-30 with them.
--- 8B W Applies only to Type F valves with a replaceable element.
ODE-20, ORE-21E
E Formerly used the KT-33-8 element and gauge number 33-8 (redesig-
nated 8B). The KT-33-8 element has been replaced by the KT-83.
Printed in U.S. of A. 1003

Vilter Mfg. Corp. Drwn By: SDP Date: 11/27/02
3186 R0
Cudahy Wi. 53110 Redrwn By: Approv. By:
STRAINER ST HANSEN (FILTERS)
STRAINERS
HANSEN VALVE VILTER

CATALOG SIZE FLANGE STYLE AND SIZE DESCRIPTION PART
NO. (INCHES) NO.
ST050 ½ ½ FPT FLANGE CONNECTIONS 3186AF
½ SOCKET WELD FLANGE CONNECTIONS 3186AS
¾ FPT FLANGE CONNECTIONS 3186BF
¾
¾ SOCKET WELD FLANGE CONNECTIONS 3186BS
ST100 1 FPT FLANGE CONNECTIONS 3186CF
1
1 SOCKET WELD FLANGE CONNECTIONS 3186CS
1-¼ FPT FLANGE CONNECTIONS 3186DF
1-¼
1-¼ SOCKET WELD FLANGE CONNECTIONS 3186DS
1-½ FPT FLANGE CONNECTIONS 3186EF
1-½
1-½ SOCKET WELD FLANGE CONNECTIONS 3186ES
ST200
2 FPT FLANGE CONNECTIONS 3186FF
2
2 SOCKET WELD FLANGE CONNECTIONS 3186FS
ST250 2-½ 2-½ WELD NECK FLANGE CONNECTIONS 3186GW
REPLACEMENT SCREEN KITS
SCREEN KIT FOR: VALVE SIZES HANSEN VILTER PART NO.

KIT PART NO.
ST050 ½ 78-1001 3186AK
ST100 ¾, 1, 1-¼ 78-1003 3186BK
ST200 1-½, 2 78-1005 3186CK
ST250 2-½ 78-1006 3186DK
NOTES:
1. TO ORDER, SPECIFY CATALOG NO AND IF STRAINER WILL BE CLOSED-COUPLED TO
VALVE OR INSTALLED AS SEPERATE UNIT. (IF SEPERATE UNIT, SPECIFY FLANGE
CONN. STYLE AND SIZE)
2. WHEN ORDERING; SPECIFY “WITH COMPANION FLANGES, BOLTS & GASKETS”.
3. MATERIAL: BODY: DUCTILE IRON A536 65,000 PSI TENSILE
SCREEN: STAINLESS STEEL 60 MESH (ST050 IS 100 MESH)
4. MANUFACTURER: HANSEN TECHNOLOGIES CORPORATION
Revisions:
R0: NEW ISSUE. SDP 11/27/02 ECN: M020087
Drawn By: JDA Date: 6-14-04
5555 S. Packard Ave.
Redrawn By: Approved By: RPK
3214 R0
Cudahy, WI 53110
DANFOSS REGULATING/MIXING VALVES
NOTE:
PORT A IS FOR THE OUTLET
PORT B IS FOR THE HOT INLET
PORT C IS FOR THE COLD INLET
VILTER BODY OIL FLOW NOMINAL NO OF

DANFOSS
PART HOUSING (GPM) PIPE THERMOSTATIC VALVE TYPE
CODE NO.
NO. TYPE 2 PSID 7PSID DIAMETER ELEMENTS
3214A H1 20 40 1” SW 1 ORV 25 SOC H1 49qC/120qF 148H3229
3214B H2 42 71 1-1/2” SW 1 ORV 40 SOC H2 49qC/120qF 148H3232
3214C H2 44 83 2” SW 1 ORV 50 SOC H2 49qC/120qF 148H3235
3214D H3 80 150 2-1/2” BW 2 ORV 65 A H3 49qC/120qF 148H3237
SPARE/REPLACEMENT NOTES:
THERMOSTAT 49qC/120qF AND GASKET + GUIDE RING -FLAMMABLE HYDROCARBONS ARE NOT
VILTER RECOMMENDED.
SPARE PARTS FOR CODE NO. -CAN BE MOUNTED IN ANY DIRECTION
PART NO.
ORV 25 AND ORV 40 H1 148H3243 3214X -DESIGNED FOR MAX WORKING PRESSURE 580 PSIG
ORV 40 AND ORV 50 H2 148H3244 3214Y -STAINLESS STEEL NICKEL PLATED THERMOSTATIC
ORV 65 AND ORV 80 H3 148H3245 3214Z ELEMENT
Revisions
HA4AOAS - Inlet/Outlet Economizer Port / Side Load Pressure
Regulator
Purpose: To maintain an operating pressure in the economizer or side load vessel, while providing a means
of protecting the compressor motor from overloading from high economizer loads during start-up, or from
high side loads.
Construction: This valve is made up of an Outlet Pressure Regulator Base, an Inlet Pressure Regulator
Module, and a Shut Off Solenoid.
Operation: The Shut Off Solenoid must be energized to activate the HA4AOAS valve. For a flash type or
shell & coil type economizer, or for side load applications, the solenoid must be activated when the
compressor starts. For a direct expansion type, the solenoid is generally activated when the compressor
reaches 30% to 70% compressor capacity, depending on the system.
Adjusting the Inlet / Economizer or Side Load Pressure
The estimated economizer operating pressure of the valve will be as shown on the performance printout for
the compressor unit. Side load pressure settings would be set as required for the system. By means of a
pressure gauge, the actual economizer operating pressure can be determined by placing the Inlet Pressure
Regulator module range spring at minimum force (control module stem should be fully turned counter-
clockwise). Leaving the regulator in this position, the actual economizer compressor port pressure can be
read. NOTE: The compressor must be at 100% capacity and at normal operating suction and discharge
pressures before the actual port pressure can be determined. Once this pressure is known, the module stem
should be turned clockwise until there is a slight increase in pressure shown on the gauge. Increasing the
turns on the module stem will raise the inlet pressure.
Adjusting the Outlet / Maximum Port Pressure
The Outlet Pressure setting is a maximum pressure setting that will allow the compressor to load to 100%.
If too much economizer or side port gas flow occurs, port pressure increases resulting in a motor amperage
increase, which may result in amp limiting and the compressor will not load to 100%. In order to adjust the
Outlet Pressure Module, its range spring should be set near maximum force (control module stem should be
fully turned clockwise). If the compressor is not able to fully load because of Amp limiting, the outlet
pressure needs to be decreased by turning the stem counter-clockwise until there is a decrease in pressure
shown on the gauge. Reduce outlet pressure until motor amperage drops and the compressor is able to load
to 100% capacity. Make sure that the Outlet Pressure setting is at least 10 psig higher than the inlet pressure
to prevent a conflict in operation of the inlet and outlet features of the valve. NOTE: There must be
abnormally high gas flow to set the outlet feature. It may not be necessary to use the outlet feature if the
compressor motor has been sized large enough so that the unit does not amp limit on high economizer or
side load gas flow.
Hansen HA4AOAS
Inlet/Outlet Regulator for Screw Compressor Economizer
(Controls Pressure of accumulator or other types of vessels that is economized and controls
outlet pressure to economizer port on screw compressor)
Inlet Module Range A

Turn CW to increase back pressure
Turn CCW to decrease back pressure
Electric Shutoff
HS2 HA2B Outlet Module Range B

Turn CW to decrease outlet pressure
Turn CCW to increase outlet pressure
M3S Stopping Plug
M3E25
168

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VPN 35391S

February 2006 Rev. 05

READ CAREFULLY BEFORE INSTALLING AND STARTING YOUR COMPRESSOR.

A refrigeration compressor is a positive displacement machine. It is designed to pump superheated

Vilter Manufacturing Corporation

Vilter Order Number: __________________________Serial Number: _____________

DOMESTIC TERMS and CONDITIONS .............................................................................................................................................. 10

STANDARD VILTER WARRANTY STATEMENT .............................................................................................................................. 14

DELIVERY INSPECTION ....................................................................................................................................................................... 21

TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23

UNIT OIL CHARGING ........................................................................................................................................................................... 25

SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25

MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27

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

COUPLINGS INSTALLATION AND ALIGNMENT ............................................................................................................................. 30

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

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

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

OIL SYSTEM ........................................................................................................................................................................................... 43

CONTROL SYSTEM .............................................................................................................................................................................. 47

INITIAL START-UP ................................................................................................................................................................................. 50

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

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

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

PREPARATION OF UNIT FOR SERVICING ........................................................................................................................................ 58

GATE ROTOR BLADE REMOVAL ....................................................................................................................................................... 69

CARRIAGE ASSEMBLIES .................................................................................................................................................................... 76

OPTICAL SLIDE VALVE ACTUATOR REMOVAL .............................................................................................................................. 78

CONVERSION, INSTALLATION OF ACTUATOR ............................................................................................................................... 80

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

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

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

REMOVAL AND INSTALLATION OF CAPACITY OR VOLUME

POTENTIOMETER REMOVAL ............................................................................................................................................................. 87

RETROFIT CAPACITY AND VOLUME RATIO CONTROL ............................................................................................................... 88

INSTALLATION OF RETROFIT COMMAND SHAFT BEARING

REPLACEMENT FOR RETROFIT CONTROL ASSEMBLIES .......................................................................................................... 89

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

TORQUE SPECIFICATIONS .................................................................................................................................................................. 93

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

VSS and VSR Replacement Parts Section ................................................................ 103

VSM Replacement Parts Section .............................................................................. 143

Vendor Assessories Section ........................................................................................ 163

IN NO EVENT SHALL SELLER BE LIABLE TO BUYER FOR ANY DAMAGES WHATSOEVER IN

SELLER EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED,

The second slide for each gate rotor is the vol-

Mandatory Action Sign/Verification -

DELIVERY INSPECTION ....................................................................................................................................................................... 21

TESTING REFRIGERATION SYSTEM FOR LEAKS .......................................................................................................................... 23

UNIT OIL CHARGING ........................................................................................................................................................................... 25

SYSTEM REFRIGERANT CHARGING ................................................................................................................................................ 25

MAINTENANCE SUGGESTIONS ......................................................................................................................................................... 27

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

COUPLINGS INSTALLATION AND ALIGNMENT ............................................................................................................................. 30

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

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

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

I. DELIVERY INSPECTION III. LOCATING UNIT - DRIVE

V. ELECTRICAL CONNECTIONS First, if test pressures exceed the settings of the

allow the pump to operate 2 or 3 hours. Stop the TABLE 2. OILCHARGE

the “low side”. High side charging is usually

D. Controls 3. After some refrigerant has entered the sys-

mally. To check that enough refrigerant has replaced.

Vilter Order Number: ______________Serial Number: _

Order #_______Compressor Serial #

Order #_______Compressor Serial #