service and maintenance manual gas compressor manual, 15hp 8d vrue... · this manual must be read...

This manual must be read carefully before using your Valerus Gas Compressor. Store

in a safe and convenient location for future reference.

Service and

Maintenance

Manual

15 HP 8D VRUE

Skid Auto Bypass

Gas Compressor

309876

1-30-2014 KWB

For technical support:

Phone: (713) 808-6100 (Outside USA)

Email: [email protected]

Website: http://www.valerus-co.com

2 309876

3 309876

Manual Change History................................................................................................7

1.1 Revision List....................................................................................................7

Welcome........................................................................................................................8

2.1 General Information..........................................................................................8

2.2 Overview .........................................................................................................8

Safety...................................................................................................................9-13

3.1 General Safety Overview...................................................................................9

3.2 Safety Precautions..........................................................................................10

3.3 Safety and Information Decals..........................................................................12

Specifications..............................................................................................................14

4.1 Specification Sheet.........................................................................................14

Description of Components..............................................................................15-18

5.1 Electric Motor.................................................................................................15

5.2 Drive Coupling...............................................................................................15

5.3 Compressor Gasend.......................................................................................15

5.4 Separator System..........................................................................................15

Separator Tank.........................................................................................15

Separator Element......................................................................................15

5.5 Inlet Blowcase System....................................................................................16

Inlet Blowcase...........................................................................................16

Safety Shutdown Float Switch....................................................................16

Liquid Discharge Float Switch....................................................................16

Normally Open Shutoff Valve.....................................................................16

Normally Closed Gas Discharge Valve........................................................16

Normally Closed Liquid Discharge Valve....................................................16

5.6 Pressure Relief Valves.....................................................................................16

Separator Tank Relief Valve.......................................................................16

Ienlet Scrubber Relief Valve........................................................................16

5.7 Cooling Systems.............................................................................................17

Compressor Oil Cooler...............................................................................17

5.8 Compressor Oil Filter......................................................................................17

5.9 Compressor Oil Thermal Valve......................................................................17

5.10 Compressor Inlet Valve.................................................................................17

5.11 Minimum Pressure Valve...............................................................................17

5.12 Blowdown Valve..........................................................................................17

5.13 Low Suction Bypass.....................................................................................18

Contents

4 309876

Installation..........................................................................................................19-21

6.1 System Installation Overview...........................................................................19

6.2 Placing the Machine........................................................................................19

6.3 Connecting the Gas Inlet Line...........................................................................19

6.4 Connecting the Gas Discharge Line..................................................................20

6.5 Connecting the Electrical Lines........................................................................20

6.6 Pre-Startup Inspection ...................................................................................20

6.7 Machine Documentation.................................................................................20

6.8 Check Fluid Levels.........................................................................................20

6.9 Initial Startup Preparation..............................................................................21

6.10 Initial Startup.................................................................................................21

Operation....................................................................................................................22

7.1 Operating.......................................................................................................22

Maintenance........................................................................................................23-29

8.1 Maintenance Overview....................................................................................23

8.2 Maintenance Schedule....................................................................................23

8.3 Recommended Spare Parts List..................................................................24

8.4 Parts and Service Contact Information............................................................24

8.5 Maintenance Log............................................................................................25

8.6 Separator Element Replacement......................................................................26

8.7 Compressor Oil..............................................................................................27

Specifications.......................................................................................27

Adding Compressor Oil.............................................................................28

Changing Compressor Oil..........................................................................28

8.8 Compressor Oil Cooler.................................................................................29

8.9 Compressor Oil Filter....................................................................................29

Troubleshooting...................................................................................................30-31

9.1 Troubleshooting Chart....................................................................................30

9.2 Parts and Service Contact Information............................................................31

Warranty.....................................................................................................................32

10.1 Warranty Policy............................................................................................32

Parts and Illustration Section...........................................................................34-53

11.1 Frame System...............................................................................................34

11.2 Motor System...............................................................................................36

11.3 Compressor System.....................................................................................38

11.4 Discharge System..........................................................................................40

11.5 Cooler System..........................................................................................42

Contents

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Parts and Illustration Section (continued)........................................................34-53

11.6 Blowcase System..........................................................................................44

11.7 Decal System................................................................................................46

11.8 Canopy System............................................................................................48

11.9 System Wiring Diagram.................................................................................50

11.10 Hose System...............................................................................................52

11.11 Gas/Oil Schematic......................................................................................53

Flow Charts Section....................................................................................................54

12.1 SCG8D Flow Chart......................................................................................54

Contents

6 309876

7 309876

Manual Change History

ETAD NOITACOL EGNAHCFONOITPIRCSED SLAITINI

1.1 Revision List

8 309876

Welcome

2.2 Overview

The 15 HP VRUE Skid Compressor is a compact, strategically designed system. It integrates all major

components on a single, environmentally sealed frame, which is enclosed in a tough, weather-resistant

canopy.

The 15 HP VRUE’s rotary screw design guarantees

continuous gas output, see flow charts in section 12 of this

manual. With remote fluid drains and removable doors,

virtually all components are accessible for maintenance and

service. Other features, including a spin-on compressor oil

filter and a drop-in separator element, reduce the time and

costs associated with routine maintenance.

The 15 HP VRUE also has enhanced safety features to

protect your valuable resources: minimum pressure valve,

high compressor oil temperature shutdown, low suction

pressure shutdown, high discharge pressure shutdown,

automatic blowdown device, pressure relief valves, and

clearly displayed warning/information decals.

2.1 General Information

Thank you for choosing the 15 HP VRUE Skid Compressor. Before

operating this system, read over this manual and become well ac-

quainted with your new machine. Doing this will increase your safety

and maximize the life of the machine.

While this manual is written to be as accurate as possible, Valerus

strives to continually improve the efficiency and performance of its

machines. As a result, sometimes there may be slight differences

between a given version of the manual and the machine.This manual must be read carefully before using your Valerus Gas Compressor. Store

in a safe and convenient location for future reference.

Service and

Maintenance

Manual

15 HP 8D VRUE

Skid Auto Bypass

Gas Compressor

309876

6/28/2013

For technical support:




9 309876

Safety

3.1 General Safety Overview

Indicate[s] an imminently hazardous situation, which, if

not avoided, will result in death or serious injury.

Indicate[s] a potentially hazardous situation, which, if not

avoided, could result in death or serious injury.

Indicate[s] a potentially hazardous situation, which, if not

avoided, could result in minor or moderate injury.

Indicate[s] a potentially unsafe situation or practice,

which, if not avoided, can result in property and/or

equipment damage only.

Remember, safety is basically common sense. While there are standard safety rules, each situation has

its own peculiarities that cannot always be covered by rules. Therefore with your experience and

common sense, you are in a position to ensure the safety of yourself and others. Lack of attention to

safety can result in: accidents, personal injury, reduction in efficiency, and worst of all – Loss of Life.

Watch for safety hazards and correct them promptly.

Understanding the proper operation of this equipment is critical to its safe operation. The owner, lessor,

and/or operator of this equipment is hereby notified and forewarned that any failure to observe the

safety and operating guidelines may result in injury and/or damage. Valerus expressly disclaims respon-

sibility or liability for any injury or damage caused by failure to observe these specified precautions or by

failure to exercise the ordinary caution and due care required while operating or handling this equipment,

even though not expressly specified.

In addition to following these safety guidelines, the operator should follow any company specific guide-

lines and procedures. Consult your immediate supervisor for specific company safety guidelines and/or

procedures.

The following safety symbols are used throughout this manual to draw attention to important information.

If the information is not carefully read and the instructions are not followed, severe injury, death, and/or

damage to property and equipment may occur.

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Safety

3.2 Safety Precautions

This is a pressurized system. Do not attempt to remove

any part of this machine without first completely relieving

entire system of pressure. Do not attempt to service any

part of the equipment while in operation. Never attempt

to repair or modify any pressure vessel or device.

The system is designed to compress gas. Do not attempt

to compress other gases. Compression of other gases

may create a situation where an explosion or fire may

occur.

Do not use flammable solvents for cleaning system com-

ponents as this can cause the unit to ignite or explode

during operation. Keep combustibles out of and away

from system inlets and any associated enclosures.

Never disable, override, or remove safeties, either tempo-

rarily or permanently.

The following safety precautions are a general guide to safe operation of the equipment.

System contains hot oil. The system must be shut off prior

to servicing. Then permit system to cool down prior to

adding compressor oil or servicing the unit.

Do not use gas from this system for breathing or food

processing. Gas from this system will cause severe injury

or death if used for breathing or food processing.

Never operate the machine in an enclosed area.

Do not modify systems to operate equipment at a higher

or lower pressure than specified.

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Safety

3.2 Safety Precautions (continued)

Never place machine on a grade more than 15 degrees.

Keep doors closed on the machine during operation.

Use only Valerus approved replacement parts.

Substitution of components may impair suitability for Class

1 Division 2.

Do not replace any components unless power has been

switched off or the area is known to be non-hazardous.

Do not disconnect equipment unless power has been

switched off or the area is known to be non-hazardous.

Always properly connect grounding terminals.

Running the electric motor less then 2900 rpm will

produce insufficient oil flow for the compressor.

Check the electric motor’s operator manual for

required service and maintenance intervals.

Read and understand this manual and all other safety

instructions before using this equipment. Failure to follow

operating instructions and/or failure to follow maintenance

procedures and intervals could result in personal injury,

death, and/or damage to equipment and property.

Tank heater can create a hazardous situation. Disconnect

power and allow tank heater to cool prior to performing

any maintenance, especially adding oil, to the system.

Failure to adhere will result in death or serious injury.

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Safety

3.3 Safety and Information Decals

Pressurized SystemHot Pressurized Oil

Close Doors Overfill

This machine is supplied with a full complement of safety and identification decals. These decals are

affixed to the unit during final assembly. These decals must be clearly visible and undamaged. Should

any of these decals become illegible or damaged, immediately replace the decal.

Oil Level

Fan Guard

Hot Oil Read Manual

13 309876

Safety

3.3 Safety and Information Decals (continued)

Serial Tag

VRU-100 Lubricant

Scrubber Drain Valve

System Inlet

By-Pass Valve

System Vent Valve

Compressor Drain Valve Direction of Rotation

Tank Heater

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Specifications

4.1 Specification Sheet

*SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE*

Running the electric motor less then 2900 rpm will

produce insufficient oil flow for the compressor.

7.81 33.00

40.50

10.18

51.21

71.70

124.10

53.70

59.34

124.47

104.75

15 309876

Description of Components

The 15 HP VRUE contains an 15 HP Variable Frequency Drive (VFD) electric motor. The motor

speed can be changed by rotating a potentiometer. When the knob is rotated clockwise, the

potentiometer increases the frequency going to the motor, and increases the motors RPM..

5.1Electric Motor

5.2Drive Coupling

The drive coupling is a jaw type coupling. This is a type of motion control coupling designed to trans-

mit torque, by connecting two shafts, while damping system vibrations, which protects other compo-

nents from damage. Jaw couplings are composed of three parts: two metallic hubs and an elastomer

insert called a spider. The three parts press fit together with a jaw from each hub fitted alternately with

the lobes of the spider. The curved jaws of the hubs reduce deformation of the spider to maintain the

zero-backlash fit.

5.3 Compressor Gasend

The Valerus compressor gasend is a positive displacement, oil flooded, rotary screw type unit employing

one stage of compression to achieve the desired pressure. Components include a housing (stator), two

screws (rotors), bearings, and bearing supports. Power from the electric motor is transferred to the

male rotor. The female rotor is driven by the male rotor. There are five lobes on the male rotor while

the female rotor has six roots. In operation, two helical grooved rotors mesh to compress gas. Inlet gas

is trapped as the male lobes roll down the female grooves, pushing trapped gas along, compressing it

until it reaches the discharge port at the end of the stator and delivers smooth-flowing, pulse-free gas.

Being an oil flooded system, the oil serves three purposes: lubricates the rotating parts and bearings,

serves as a cooling agent for the compressed gas, and seals the running clearances. Gasend must be

powered in the proper direction. Failure to rotate the gasend in the correct direction will damage

equipment and possible personal injury.

5.4 Separator System

I. Separator Tank

From the compressor gasend, the compressed gas and hot oil flow into a steel, ASME coded,

pressure vessel, rated at 250 PSI, that acts as an oil reservoir. This tank is the first of two stages in

separating the oil and compressed gas mixture. From the bottom of the separator tank, oil is forced

to the oil filter.

II. Separator Element

At the top of the separator tank is the separator element. The separator element removes the oil

mist from the gas as it is passed on to the minimum pressure valve. As the gas/oil mist passes

through the outside of the media, oil gathers on the interior walls and settles to the bottom of the

element. Collected oil is returned to the compressor gasend through the oil return line. The separa-

tor will filter the oil concentration in the gas to less than 3 parts per million.

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I. Blowcase

The blowcase is a two chambered, steel, ASME coded, pressure vessel that acts as a reservoir for

the inlet gas and helps separate moisture. Liquids from the upper chamber are drained into the

lower chamber and evacuated automatically. The gas in the upper chamber flows through a

demister pad and 1 micron filter to the inlet control valve.

II. Safety Shutdown Float Switch

The safety shutdown float switch is located in the upper chamber of the blowcase. Should the

liquid level build to the set point, the float switch sends an electrical signal to shut down the machine.

III. Liquid Discharge Float Switch

The liquid discharge float switch is mounted in the lower chamber of the blowcase. When the liquid

level reaches the float switch set point, the switch sends pressure signals to the normally open

shutoff valve, normally closed discharge liquid valve, and normally closed discharge gas valve. This

sequence pressurizes the lower chamber and pushes liquid through the normally closed discharge

liquid valve.

IV. Normally Open Shutoff Valve

The normally open shutoff valve is an angled body valve that connects the top and bottom cham-

bers of the blowcase. This line serves as a pressure equalization line until piloted by the liquid

discharge float switch.

V. Normally Closed Gas Discharge Valve

The normally closed discharge gas valve is an angled body valve. When piloted by the liquid

discharge float switch, the signal sends full system pressure to the lower chamber of the blowcase.

VI. Normally Closed Liquid Discharge Valve

The normally closed discharge liquid valve is an angled body valve. The liquid that has drained to

the lower chamber of the blowcase is forced out of this valve when the level reaches the liquid

discharge float switch set point.

5.5Blowcase System

5.6 Pressure Relief Valves

I. Separator Tank Relief Valve

This ASME coded valve vents separator tank pressure to atmosphere should the pressure inside the

tank exceed 250 PSI.

II. Inlet Scrubber Relief Valve

This ASME coded valve vents the upper chamber inlet scrubber pressure to atmosphere should the

pressure inside the vessel exceed 15 PSI.

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5.7 Cooling Systems

I. Compressor Oil Cooler

The compressor oil cooler is designed to dissipate the heat created during the compression of gas.

The oil cooler is mounted on top of the compressor aftercooler. Hot compressor oil is passed

through the interior of the cooler and heat is transferred to the air that passes across the cooling fins.

5.8 Compressor Oil Filter

The compressor oil filter is a full flow, spin-on canister. It has been specially designed to handle the full

system pressure. The oil filter is mounted downstream of the separator tank to ensure all contaminants

are prevented from being passed on to the compressor oil cooler.

5.9 Compressor Oil Thermal Valve

The compressor oil thermal valve is a thermostatically controlled by-pass valve that allows varying

amounts of oil, depending upon the temperature, to by-pass the oil cooler. The oil thermal valve directs

oil flow back to the compressor gasend until the system reaches 210°F. Once at system operating

temperature, the valve shifts directing the flow through the oil cooler before returning to the compressor

gasend.

5.11 Minimum Pressure Valve

To ensure there is adequate pressure to produce proper oil flow throughout the system, a spring loaded,

normally closed minimum pressure valve is set to maintain at least 80 PSI in the separator tank.

5.10 Compressor Inlet Valve

The compressor inlet valve is a normally open gas intake valve attached to the compressor gasend. This

valve has an NPT threaded connection. When the system is shut down, this valve also acts as a check

valve that prevents the gas/oil mixture within the compressor gasend from entering the inlet piping.

5.12 Blowdown Valve

The blowdown valve is a shuttle valve that vents system pressure to atmosphere when the system is shut

down. This is done to prevent the high torque load that would be required to overcome the static

pressure. The blowdown valve is stamped with an “I” and a “P”. The “I” side is connected to dry gas

from the separator tank, and the “P” side is the pilot signal coming from the compressor inlet valve.

18 309876


5.13 Low Suction Bypass

The unit is equipped with a low suction bypass that allows a controlled amount of gas from the higher

pressure discharge side to recirculate to the inlet blowcase vessel, this is to prevent a vacuum from being

pulled on the tank(s). The bypass consists of a normally closed pneumatic motor valve and two solenoid

valves. One solenoid valve allows gas to vent from the pneumatic valve into the suction scrubber if the

pressure in the tank(s) rises above the “HiBypassSP”, causing the motor valve to close. The other

solenoid valve allows regulated gas pressure (40 psig) to open the motor valve if the pressure in the

tank(s) falls below the “LoBypassSP”.

19 309876

6.2 Placing The Machine

The first step in installing the 15 HP VRUE is set the system on a solid, level surface. This machine is

designed to run a level surface only. If you must set the package on any grade, set across the grade so

that the machine does not tend to roll. The machine must be supplied ample ambient air, as the system

will overheat if the cooling air intake’s temperature exceeds ambient conditions.

Installation

6.1 System Installation Overview

The 15 HP VRUE should be installed only by those who have been delegated to do so, trained, and

who have read and understand this manual. Failure to follow the instructions, procedures, and safety

precautions in this manual may result in accidents and injuries.

Install, use, and operate this system only in full compliance with all pertinent O.S.H.A., Federal, State,

and Local codes or requirements, in addition to Valerus and any company’s regulations.

Do not modify this system except with written factory approval.

6.3 Connecting the Gas Inlet Line

Verify the bypass valve is in the open position prior to supplying gas to the system. Connect the cus-

tomer supplied tank vent manifold to the 4” FNPT port on the inlet scrubber (4” is recommended for

the manifold and piping to the inlet scrubber, a shutoff valve at the inlet scrubber is also recommended).

7 FOOT LG. STAINLESS

STEEL VENT TUBE

SHIPPED LOOSE

ENVIRONMENTALLY SEALED

FRAME DRAIN

COMPRESSOR OIL

DRAIN VALVE

2" FNPT

GAS DISCHARGE

1" FNPT BLOWCASE

LIQUID DISCHARGE

BLOWCASE MANUAL

DRAIN VALVE

4" FNPT

GAS INLET

BYPASS VALVE

BLOWCASE

VENT VALVE

5 FOOT LG. STAINLESS

STEEL VENT TUBE

SHIPPED LOOSE

20 309876

The machine is factory filled prior to shipment. The proper fluid levels are also listed in the maintenance

section. The Separator Tank Oil Level should be halfway on the separator tank sightglass.

6.8 Check Fluid Levels

6.4 Connecting the Gas Discharge Line

Connect a customer supplied gas discharge line and check valve, designed to handle a minimum of 250

PSI continuously, to the 2” FNPT gas discharge port.

Installation

6.7 Machine Documentation

Record serial numbers for main components in the system.

I. Machine Serial Number __________________________________________

II. Compressor Gasend Serial Number __________________________________________

III. Electric Motor Serial Number __________________________________________

IV. Separator Tank Serial Number __________________________________________

V. Blowcase Serial Number __________________________________________

VI. VFD Starter Panel Serial Number __________________________________________

6.6 Pre-Startup Inspection

This inspection must be done prior to initial system startup.

I. Check all assemblies, clamps, fittings, hose connections, nuts, and bolts to ensure they are properly

tied and secured.

II. Remove all tools, rags, and installation equipment from the area.

III. Check all valves to ensure they are in the correct operating position.

A. Inlet Blowcase Vent Valve = Closed

B. Compressor Oil Drain Valve = Closed

C. Environmentally Sealed Frame Drain = Plugged

D. Inlet Blowcase Manual Drain Valve = Closed

6.5 Connecting the Electrical Lines

Connect a customer supplied electrical lines, in full compliance with all pertinent O.S.H.A., Federal,

State, and Local electrical codes or requirements. Ensure that the electrical lines are connected to the

motor, to provide proper rotation. Improper rotation will damage equipment and may cause personal

injury.

21 309876

Installation

6.10 Initial Startup

At this point the system is ready to test for functionality. Be sure to have completed all of the previous

steps prior to continuing.

I. Turn the “Manual/Off-Reset/Auto” switch to the “Manual” position. When the switch is put into

the “Manual” position, as long as there are no shutdown conditions, the compressor will immedi-

ately go into a pre run warning countdown.

II. Check the direction of rotation by quickly engaging and then disengaging the compressor. If the

compressor is rotating opposite of the arrows, turn the “Manual/Off-Reset/Auto” switch to the

“OFF” position. The machine should shut down immediately. Switch the disconnect to “OFF”.

Switch positions of the wires on TB5-1 (L1) and TB5-2 (L2).

III. Restart the machine and recheck compressor rotation.

IV. Check system for leaks.

V. After the compressor oil temperature exceeds 150°F, rotate RPM knob and verify maximum and

minimum speeds are 3600 RPM and 2900 RPM, respectively.

VI. “Manual/Off-Reset/Auto” switch to the “OFF” position.

VII. Switch the disconnect to “Off”.

VIII. Initial startup testing is complete.

6.9 Initial Startup Preparation

I. Verify the disconnect is in the OFF position. Ensure there is proper voltage on the three legs.

II. Verify the “Manual/Off-Reset/Auto” switch is in the OFF position.

III. Check the system for gas, and/or oil leaks.

Directional arrows are attached to the compressor package on

both ends and sides of the electric motor. This coupling must be

rotating in the direction the arrows are pointing. If, for some

reason, this arrows have been removed, the correct compressor

rotation is clockwise when looking directly at the compressor

shaft.

22 309876

Operation

7.1 Routine Operating Procedures

The 15 HP VRUE should only be operated by those who have been delegated to do so, trained, and

who have read and understand this manual. Failure to follow the instructions, procedures, and safety


Operate this system only in full compliance with all pertinent O.S.H.A., Federal, State, and Local codes

or requirements, in addition to Boss Industries, Inc. and any company’s regulations.

I. Routine Startup Preparation

A. Verify fluid levels and refill if necessary.

B. Check compressor oil filter’s indicator, element, and hoses.

C. Check for oil and gas leaks.

II. Routine Startup Procedure

The 15HP VRUE has two modes of operation. The system operation can be manually controlled,

or can automatically start and stop based off the suction pressure. The system will not recognize a

change in mode during operation. The system must be turned off prior to selecting the mode of

operation. Be sure to use the corresponding startup/shutdown procedure for the mode you select.

A. Manual Mode

1. Turn the “Manual/Off-Reset/Auto” switch to “Manual”.

2. Allow system to run until compressor oil temperature reaches 150°F.

3. Check for leaks and close machine doors.

4. Rotate RPM knob to the desired engine speed.

B. Automatic Mode

1. Open By-pass valve & close the discharge valve.

2. Turn the “Manual/Off-Reset/Auto” switch to the “Auto” Position.

3. If sufficient suction pressure is available the compressor will start the “Running Soon”

warning period.

4. After the “Running Soon” warning period is complete the compressor will start.

5. Allow the system to run until the compressor oil temperature reaches 150°F

6. Check for leaks and close machine doors.

7. Rotate RPM knob to the desired engine speed.

8. Open Discharge valve.

9. Close By-pass valve.

III. Routine Shutdown Procedure

A. Turn the “Manual/Off-Reset/Auto” switch to the “Off” position.

23 309876

Check electric motor’s operator manual for required service

and maintenance intervals.

Compressor oil filter is to be changed after the first 50 hours

of operation. After this, normal intervals are to be followed.

Maintenance

This section contains instructions for performing the inspection, lubrication, and maintenance procedures

required to ensure the system is in proper operating condition. The importance of performing the

maintenance described herein cannot be over emphasized. A planned program of periodic inspection

and maintenance will help avoid premature failure and costly repairs. Keep an accurate logbook for

maintenance, service, and operating hours. The maintenance schedule intervals on this system are

maximum intervals. The factory recommended maintenance schedule is based on favorable operating

conditions. For continuous duty, extreme temperature, etc., service more frequently. Neglecting routine

maintenance can result in machine failure or permanent damage.

This system should be maintained only by those who have been delegated to do so, trained, and who

have read and understand this manual. Failure to follow the instructions, procedures, and safety


8.1 Maintenance Overview

8.2 Maintenance Schedule

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24 309876

Maintenance




8.4 Parts and Service Contact Information

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8.3 Recommended Spare Parts List

When calling for technical support, please have equipment

number, equipment and compressor serial numbers and this

manual available.

25 309876

8.5 Maintenance Log

Maintenance

Accum.

Hours Date Service Performed Parts Replaced Service Work By

26 309876

Maintenance

When the oil vapor in the discharge gas becomes excessive, the separator element may need replacing.

This should not be necessary more than once a year under normal operating conditions.

I. Replacement Procedure.

A. Shut down machine and allow to cool for approximately 10 minutes.

B. Verify entire system pressure is relieved before proceeding.

8.6 Separator Element Replacement

C. Disconnect the 1” hose from the minimum pressure valve.

D. Disconnect the two 1/4” hoses from the blowdown valve.

E. Disconnect the 1/4” hose from the oil return line.

F. Remove the eight 5/8” bolts holding the separator tank lid in place.

G. Lift and remove the lid from the package.

H. Remove the separator element.

I. Install a new element.

J. Reinstall the separator tank lid.

K. Reinstall the eight 5/8” bolts.

L. Uniformly tighten the bolts in a crisscross pattern to a torque of 220ft-lb.

M. Reconnect all hoses and ensure they are correctly located and tightened properly.

N. Start machine and check for any leaks.

Substitute filters may have inadequate working pressure

limits, resulting in filter leakage or rupture. Replacement

filters must be the same quality and type as the original

Valerus separator element.

When disconnecting hoses, be sure to note the location to

ensure there is no confusion when reconnecting.

Note the location of the separator tank lid so that it can

be reinstalled in the same orientation.

The separator tank lid has a scavenage line pick-up tube

installed and damaging or moving the tube will affect the

machines functionality.

The separator element flange must have a gasket on each side

to seal the lid on one side and the vessel on the other. The

staple in each gasket acts as a static ground and must not be

removed.

27 309876

Maintenance

The life and proper operation of the system is dependent on adequate and clean oil. Valerus VRU–100

Synthetic Oil is supplied with the machine from the factory and should be used for proper level mainte-

nance and oil changes. It is advantageous to use VRU–100 Synthetic Oil as it is an ideal oil for this

application.

8.7 Compressor Oil

I. Specifications

liOcitehtnyS001-URV dohteMtseT stluseR

edarGytisocsiVOSI 2242DMTSA 001

tsc,C°04@ytisocsiV 544DMTSA 001

tsc,C°001@ytisocsiV 544DMTSA 4.91

SUS,F°001@ytisocsiV 544DMTSA 105

SUS,F°012@ytisocsiV 544DMTSA 8.79

xednIytisocsiV 0722DMTSA 812

F°06,ytivarGcificepS 8921DMTSA 540.1

F°,tniopruoP 79DMTSA 94-

F°,tniophsalF 29DMTSA 005

retcarahCevitneverPtsuR 566DMTSA ssaP

mm,gk04,F°761,mpr0021,raeWllaBruoF 6622DMTSA 75.

noisorroCreppoC 031DMTSA A1

It is important that the system oil be of the recommended type,

inspected, and replaced as stated in this manual.

Mixing different types or brands of lubricants is not recom-

mended due to the possibility of a dilution of the additives or a

reaction between additives of different types.

28 309876

Maintenance

F. Replace fill cap and tighten immediately.

A. Verify the machine is level to assure oil level sightglass will be accurate.

B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the

system.

C. Remove the separator tank fill cap.

D. Inspect and clean the fill cap. Replace if necessary.

E. Drain oil from the bottom of the separator tank.

F. If compressor oil filter change is required, proceed to section 8.9, “Compressor Oil Filter”.

Do not remove caps, plugs, or other components when the

system is running or pressurized. Stop system and relieve all

internal pressure before doing so. Failure to comply with this

warning will cause damage to property and serious bodily

harm.

8.7 Compressor Oil (continued)

C. Remove the separator tank fill cap.

D. Inspect and clean the fill cap. Replace if necessary.

E. VRU-100 Synthetic Oil can then be added until the oil level reaches halfway in the sightglass.

Do not over fill the separator tank. This will cause oil carryover in the discharge line and at

blowdown.

II. Adding Compressor OilA. Verify the machine is level to assure oil level in sightglass will be accurate.

B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the

system.

Do not remove caps, plugs, or other components when the

system is running or pressurized. Stop system and relieve

all internal pressure before doing so. Failure to comply

with this warning will cause damage to property and serious

bodily harm.

Do not replace fill cap with a pipe cap; serious injury or dam-

age could result. Replacement filters must be the same

quality and type as the original Valerus fill cap.

III. Changing Compressor Oil

Initially the compressor oil and oil filter should be replaced after the first 50 hours of operation then

every 500 hours or as required based on strict oil analysis. Change oil at least annually or as

needed based on a strict oil analysis program or when contamination is apparent. Change oil filter

element at least annually or as needed based on differential pressure indication (maximum of 25 psi)

or operator experience. Life expectancy of compressor oil may vary from site to site. If the oil

appears dirty or has a foul smell, it should be replaced immediately.

Tank heater can create a hazardous situation. Disconnect power and

allow tank heater to cool prior to performing any maintenance,

especially adding oil, to the system. Failure to adhere will result in

death or serious injury.

29 309876

Maintenance

Initially the filter should be replaced after the first 50 hours of operation, then every 500 hours or as

required based on strict oil analysis. Change oil at least annually or as needed based on a strict oil

analysis program or when contamination is apparent. Change oil filter element at least annually or as

needed based on differential pressure indication (maximum of 25 psi) or operator experience. Life

expectancy of compressor oil may vary from site to site. A dirty filter can restrict oil flow, causing high

oil temperature, which will result in a system shutdown.

I. Compressor Oil Filter Replacement

A. Verify the compressor oil system is drained, and the system has fully blown down.

B. Using a strap wrench, remove the oil filter and o-ring.

C. Clean o-ring seating surface on the oil filter head.

D. Apply a light film of oil to the new o-ring.

E. Hand tighten new filter until o-ring is seated in o-ring groove.

F. Continue tightening filter by hand an additional 1/2 to 3/4 turn.

G. Continue with Changing the Compressor Oil steps.

8.9 Compressor Oil Filter

Substitute filters may have inadequate working pressure

limits, resulting in filter leakage or rupture. Replacement

filters must be the same quality and type as the original

Valerus oil filter.

Mechanical over-tightening may distort the threads or damage

the filter element seal.

H. Replace fill cap and tighten immediately.

I. Run system briefly to see if more oil needs to be added and to ensure there are no leaks.

Do not replace fill cap with a pipe cap; serious injury or dam-

age could result. Replacement filters must be the same

quality and type as the original Valerus fill cap.

8.8 Compressor Oil Cooler

Any sign of leakage from the compressor oil cooler justifies a pressure test to assure its integrity.

Cooler leaks should only be repaired by qualified service technicians. Dirt that clogs the cooling fins of

the cooler should be removed. The use of an air stream or high-pressure steam cleaner should be done

with caution so as to not damage the delicate fins. Bent cooling fins will reduce the cooling capability of

the compressor oil cooler.

8.7 Compressor Oil (continued)

III. Changing Compressor Oil (continued)

G. VRU-100 Synthetic Oil can now be added until the oil level reaches halfway in the sightglass.

Do not over fill the separator tank. This will cause oil carryover in the discharge line and at

blowdown.

30 309876

Troubleshooting

9.1 Troubleshooting Chart

melborP esuaC ydemeR

detcepxenU

nwodtuhSderrucconwodtuhsytefaS esuacroflenaplortnockcehC

evissecxE

noitarbiV

rotomesoolrodegamaD

tnuomecalperroriapeR

deepsrotomwoL MPR009fomuminimdeepsrotomyfireV

edalbnafnekorbrotneB yletaidemmiecalperroriapeR

tonlliwenihcaM

erusserppudliub

nepoevlavnwodwolBecalper;skaelrofevlavfeilererusserpkcehC

dedeensa

rosserpmocnroW rosserpmocecalpeR

gnilpuocevirdytluaF gnilpuocecalpeR

sagtneiciffusnI

yreviled

rofdezisrednurosserpmoC

tnemeriuqersagtnemeriuqersagmumixamyfireV

deepsrotomwoL yrassecenfitsujda/deepsrotomkcehC

nepoevlavnwodwolBrofsnoitcennocdna,sgnittif,senilsagllakcehC

yrassecensariaper;skael

evlavtelniytluaF yletaidemmiecalperroriapeR


gnilpuocevirdytluaF gnilpuocecalperroriapeR

evissecxE

liorosserpmoc

noitpmusnoc

dellifrevoknatrotarapeS levelreporpotlioniarD

metsysliorosserpmocnikaeLriaper;snoitcennocdnasenilgnipipllakcehC

yrassecensa

liognivomertonenilnruterliO

tnemelerotarapesmorf

riaper;snoitcennocdnasenilgnipipllakcehC

yrassecensa

degamadtnemelerotarapeS tnemeleecalpeR

rosserpmoC

gnitaehrevo

htiwaeranignitarepotinU

riahserfdetimiltnemenifnocpuneporotinunoitisopeR

snifrelooclionopu-dliubtriDottonluferaceb;ylhguorhtrelooclionaelC

snifegamad

wollevelliorosserpmoC levelreporpotllifdnakcehC

31 309876

Troubleshooting

9.1 Troubleshooting Chart (continued)

9.2 Parts and Service Contact Information




melborP esuaC ydemeR

rosserpmoC

gnitaehrevo

liorosserpmocninoitcirtseR

senilsenilecalperronaelC

detcirtseryllanretnireloocliO reloocfosebutlanretninaelC

ytridretlifliorosserpmoC retlifecalpeR

gninoitcnuflamevlavlamrehT evlavecalperroriapeR


sroodhtiwmetsysgnitarepO

neposroodesolC

When calling for technical support, please have equipment

number, equipment and compressor serial numbers and this

manual available.

32 309876

WARRANTYWarranty

10.1 Warranty

CONTACT VALERUS

FOR WARRANTY!




33 309876

34 309876

Parts and Illustration Section

11.1 Frame System

Parts List

ITEM QTY PART NUMBER DESCRIPTION

1 1 309517 SKID

2 4 305349-100 PLUG

3 1 302633 VALVE

4 1 305349-050 PLUG

5 2 937806-094 WASHER

6 6 938206-071 WASHER

7 4 929806-100 BOLT

8 2 305357-100 BUSHING

9 2 305356-000 NIPPLE

10 1 305343-200 TEE

11 1 960016-100 ELBOW

12 1 305341-200 ELBOW

13 1 961816-100 TEE

14 1 300111 CLAMP

15 1 929705-100 BOLT

16 1 305511-000 NIPPLE

17 1 960108-050 CONNECTOR

18 1 309728 BRACKET

19 1 309821 THERMOSTAT

20 2 924304-145 NUT

21 2 938604-071 WASHER

22 2 929104-125 BOLT

23 2 305012 CONNECTOR

24 1 309067 GAUGE

25 1 309068 BRACKET

26 2 925506-198 NUT

27 1 922208-000 NIPPLE

28 1 904415-020 TEE

35 309876

11.1 Frame System (continued)


19

20

22

17

316

7

5

6

18

4

14

15

6

7

2523

24

26

6

2

2

13

11

8

10

9

2

12

9

2

8

1

21

27

28

36 309876

11.2 Motor System


Parts List

DESCRIPTIONPART NUMBERQTYITEM

MOTOR30987411

NUT925508-26242

WASHER938208-112163

BOLT929808-20044

WASHER937808-125105

BOLT929808-15046

BRACKET30924517

BOLT929808-12548

CLAMP30011119

FAN309884110

ADAPTER309890111

BOLT929808-175212

37 309876

11.2 Motor System (continued)


COUNTER-CLOCKWISE

ROTATION

12

5

11

8

53

3

10

3

5

43

4

3

1

9

6

3

6

3

3

2

2

57

38 309876

11.3 Compressor System


Parts List


GASEND30170911

ADAPTER970804-02512

ADAPTER970816-10013

WASHER938908-18044

WASHER938808-20045

BOLT928008-25046

ELBOW30540117

CONNECTOR973112-05018

GASKET30246719

TEE961804-025110

ELBOW960704-025111

VALVE304012112

CONNECTOR303920113

TEE309760114

TEE964804-025115

ADAPTER307968116


HUB309891118

HUB309892119

SPIDER301267120

ADAPTER309531121

WASHER938806-160622

BOLT929306-200623

TRANSDUCER309881124

NIPPLE305356-240-MOD125


VALVE304771127

PLUG902915-010228

COUPLING305355-200129

39 309876

11.3 Compressor System (continued)


OIL

FLOW

COUNTER-CLOCKWISE

ROTATION

914

4

5

613

12

11

1 3

10

8

7

15

221

22

23

19

2018

17

16

24

25

28

28

26

27

29

40 309876

11.4 Discharge System


Parts List


1 1 308846 TANK

2 1 300107 SIGHTGLASS

3 1 960124-150 CONNECTOR

4 1 301466-150 CAP

5 4 960204-025 ELBOW

6 1 308087 VALVE

7 1 304022 CONNECTOR

8 1 304210 TUBE

9 1 960304-025 ELBOW

10 2 960404-025 NIPPLE

11 3 960104-025 CONNECTOR

12 1 305518 VALVE

13 2 304592-031 ORIFICE

14 1 305343-150 TEE

15 1 124-22414 ELEMENT

16 4 938208-112 WASHER

17 4 929808-150 BOLT

18 4 937808-125 WASHER

19 1 984124-150 ELBOW

20 1 308907 HEATER

21 1 960116-125 CONNECTOR

22 1 960724-150 ELBOW

23 1 305344-125 BUSHING

24 1 305345-050 NIPPLE

25 1 307968 ADAPTER

26 1 306075-250 VALVE

27 1 303450 VALVE

28 1 902915-005 PLUG

Parts List


29 1 910216-100 CONNECTOR

30 7 ft 309360 TUBE

31 1 305357-100 BUSHING

32 1 960116-100 CONNECTOR

33 2 305343-075 TEE

34 1 305359-050 BUSHING

35 2 305358-000 NIPPLE

36 1 960208-075 ELBOW

37 1 960012-075 ELBOW

38 2 960212-075 ELBOW

39 1 309430 HEAD

40 1 984109-075 ELBOW

41 1 309313 VALVE

42 2 964816-100 TEE

43 1 960416-100 NIPPLE

44 2 983016-131 ADAPTER

45 1 305350-075 BUSHING

46 2 305350-025 BUSHING

47 1 309875 BRACKET

48 2 938605-071 WASHER

49 2 938005-078 WASHER

50 2 929105-075 BOLT

51 1 309880 TRANSDUCER

52 1 309822 BULBWELL

53 1 977608-050 ELBOW

54 1 960408-050 NIPPLE

55 1 960716-100 ELBOW

56 1 304022M CONNECTOR

41 309876

11.4 Discharge System (continued)


DETAIL A

A

A

B

C

3633

34

32 31

30

15

10

565

5

5

12

13

1128

29

5

"I"

"P"

25

26

8

20

7

9

2223

21

4

3

14

192

24 6

1

17

18

16

47

43

42

46

11

44

39 44

11

46

42

40

45

50 49 48

38

4135

38

33

37

51

5235

SHIPPED

LOOSE

Drill 1/8" Drain

54

53

55

13

42 309876

11.5 Cooler System


Parts List


COOLER30933211

BULKHEAD30988512

WASHER938604-071203

WASHER938004-062164

BOLT929104-100105

WASHER938206-071186

WASHER937806-09467

BOLT929806-100128

ELBOW960212-10029

NUT925506-198610

NUT924304-145211

GUARD309535212

SHROUD309886113

BOLT929104-075814

GUARD309887115

43 309876

11.5 Cooler System (continued)


12

12

8

6

153

4

14

2

13

9

1

5

8

610

5

3

11

3

43

8

6

76

2

5

4

3

44 309876

11.6 Blowcase System


Parts List


1 1 40057-2-BK BLOWCASE

2 1 303060 SWITCH

3 7 305348-000 NIPPLE

4 4 960116-100 CONNECTOR

5 6 938208-112 WASHER

6 3 925508-262 NUT

7 3 929808-150 BOLT

8 1 305343-100 TEE

9 1 305348-060 NIPPLE

10 1 306830-015 VALVE

11 2 305341-100 ELBOW

12 3 304551-100 VALVE

13 1 305229 FILTER

14 3 960204-025 ELBOW

15 2 960216-100 ELBOW

16 1 305348-030 NIPPLE

17 1 960016-100 ELBOW

18 1 305401 ELBOW

19 1 305356-000 NIPPLE

20 1 305348-050 NIPPLE

21 1 305348-040 NIPPLE

22 1 309277 VALVE

23 2 309278 SOLENOID

24 3 960104-025 CONNECTOR

25 1 305352-020 NIPPLE

26 1 305349-025 PLUG

27 1 307968 ADAPTER

28 1 960404-025 NIPPLE

29 1 985200-040 CROSS

30 1 305350-025 BUSHING

31 1 910216-100 CONNECTOR

32 1 300107 SIGHTGLASS

33 5 ft 309360 TUBE

34 2 305347-100 ELBOW

35 2 305732 VALVE

36 1 961704-025 TEE

37 1 305348-020 NIPPLE

38 1 960116-075 CONNECTOR

39 1 305421 VALVE

40 1 305261 VALVE

41 1 984116-100 ELBOW

42 1 304509 VALVE

43 1 961804-012 TEE

44 1 300605 ORIFICE

45 2 960204-012 ELBOW

46 2 960716-100 ELBOW

47 1 964816-100 TEE

48 3 970804-025 ADAPTER

45 309876

11.6 Blowcase System (continued)


GAS

FLOW

13

7

5

56

123

8

9

11

16

15

174

12

3

12 311

3

18

10

22

4

24

25

23

2827

24

3029

31

26

14

32

19

33

NC

NO

1

2

37

15

44

4

14

40

41

43 42

45

45

20

24

3

39

38

3514

21

34

34

4

35

3

36

SHIPPED

LOOSE

Drill 1/8" Drain

46

47

48

48

48

46 309876

11.7 Decal System


Parts List


DECAL, VALERUS LOGO30878521

DECAL, SERIAL TAG BOSS30576112

DECAL, DANGER HOT OIL30003813

DECAL, WARNING READ MANUAL30003914

DECAL, BGB ALL IN ONE SHEET30721015

DECAL, VENT BGB30721215A

DECAL, INLET BGB30721415B

DECAL, BY-PASS BGB30721315C

DECAL, SCRUBBER DRAIN BGB30586015D

DECAL, DOORS CLOSED104-9002925E

DECAL, COMPRESSOR OIL DRAIN BGB30525415F

DECAL, WARNING FAN GUARD30004125G

DECAL, OIL RESERVOIR104-9011515H

DECAL, HOT OIL104-9011215I

DECAL, DO NOT OVERFILL104-9012015J

DECAL, COMPR SIGHT GLASS30256815K

DECAL, DIRECTION OF ROTATION30004826

DECAL, TEMP. COMPR.- 250 F30159417

DECAL, FACTORY FILLED VRU-100 OIL30886918

DECAL, DANGER TANK HEATER31002419

DECAL, 240 VAC310064110

47 309876

DETAIL A DETAIL B

DETAIL C

DETAIL D

DETAIL G

DETAIL E

DETAIL F

DETAIL H

DETAIL I

DETAIL J

5B

5A

5C

5D

5E

2

5F 5H

5I

5J

4 3

8

5K

5G

6

1

5E

5E

5G

7

1

6

10

9

11.7 Decal System (continued)


48 309876

11.8 Canopy System


Parts List


CANOPY30987711

LATCH30138382

PANEL30883913

DOOR30884324

COVER30989315

RIVET994204-025206

WASHER977004-062247

WASHER984004-071448

BOLT983904-075219

ROOF309889110

DOOR308844211

WASHER938206-071812

WASHER937806-094813

BOLT929806-125814

WASHER938604-071315

NUT924304-145316

BOLT983904-100317

49 309876

11.8 Canopy System (continued)


DETAIL A

8-PLACES

A

16

15

17

1

11

2

11

2

3

6

8

78

9

5

79

8

10

4

2

2

4

12

13

14

50 309876


11.9 System Wiring Diagram

51 309876


11.9 System Wiring Diagram (continued)

52 309876

11.10 Hose System


REBMUNTRAP NOITPIRCSED

061-719303

DAEHRETLIFLIOFOTUO&NIOTEGUAGERUSSERPLAITNEREFFID.1

REBBURCSTELNINOSSORCOTDIONELOS.C.N.2

EVLAVEGRAHCSIDDIUQIL.C.NOTEVLAVEGRAHCSIDSAG.C.N.3

HCTIWSTAOLFEGRAHCSIDDIUQILOTEVLAVFFOTUHS.O.N.4

204503

EVLAVFEILERYTEFASESACWOLBOTEVLAVTNEVESACWOLBTELNI.1

NIARDRETAW.2

REBMAHCREPPUOTEETEGRAHCSIDDIUQILESACWOLB.3

064903 RELOOCRETFAOTEVLAVERUSSERPMUMINIM

073-719303 ROSSERPMOCFORAEROTNRUTERLIO

533-719303 TROPTOLIPNWODWOLBOTEVLAVTELNIFOEDIS

477803 KNATROTARAPESFOEDISOTEGRAHCSIDROSSERPMOC

930903 RELOOCNOTROPMOTTOBOTEVLAVLAMREHTFOPOT

040903 EVLAVLAMREHTNOEETOTRELOOCNOTROPPOT

240903 EVLAVNIARDETOMEROTKNATROTARAPESFOMOTTOB

634503 TROPNOITCEJNILIOOTEVLAVLAMREHTNOEET

941403 EETEGRAHCSIDOTEVLAVSSAPYB

340903 EVLAVTELNIOTREBBURCSTELNIFOPOT

0321-719303 HCTIWSTAOLFEGRAHCSIDDIUQILOTKNATROTARAPESFOPOT

003-719303 EVLAVTELNINOEETOTEVLAVNWODWOLB

054-719303TNEVNWODWOLBLAUNAM.1

EVLAVEGRAHCSIDSAG.C.NOTHCTIWSTAOLFEGRAHCSIDDIUQIL.2

838703 EVLAVEGRAHCSIDSAG.C.NOTEETEGRAHCSID

063-719303 DIONELOS.O.NOTHCTIWSTAOLFEGRAHCSIDDIUQIL

53 309876


11.11 Gas/Oil Schematic

54 309876

Flow Chart Section

12.1 SCG8D Flow Chart

Horsepower (HP) shown is the compressor input shaft

ONLY. The cooling fan requires 1.5 horsepower. Add

the cooling fan HP to the chart above for total HP.

MSCFD @ 3550 RPM

DISCHARGE PRESSURE (PSI)

50 60 70 80 90 100 125 150 175 190 200

0 33 33 33 33 32 32 31 30 29 29 28

.5 34 34 34 34 33 33 32 31 30 30 29

1 35 35 35 35 35 34 34 33 32 31 30

1.5 36 36 36 36 36 35 35 34 33 32 31

2 38 38 38 38 38 37 37 36 35 34 33

2.5 39 39 39 39 39 38 38 37 36 35 34

3 41 41 41 41 41 40 40 39 38 37 36

3.5 42 42 42 42 42 41 41 40 39 38 37

4 43 43 43 43 43 42 42 41 40 39 38

4.5 44 44 44 44 44 43 43 42 41 40 39

SUCTION PRESSURE (PSI)

5 46 46 46 46 46 45 45 44 43 42 41

H.P. @ 3550 RPM

DISCHARGE PRESSURE (PSI)

50 60 70 80 90 100 125 150 175 190 200

0 5.1 5.2 5.3 5.5 5.6 5.8 6.0 7.0 7.5 8.5 9.5

.5 5.2 5.3 5.4 5.6 5.7 5.9 6.1 7.1 7.6 8.6 9.6

1 5.3 5.4 5.5 5.7 5.8 6.0 6.2 7.2 7.7 8.7 9.7

1.5 5.4 5.5 5.6 5.8 5.9 6.1 6.3 7.3 7.8 8.8 9.8

2 5.5 5.6 5.7 5.9 6.0 6.2 6.4 7.4 7.9 8.9 9.9

2.5 5.6 5.7 5.8 6.0 6.1 6.3 6.5 7.5 8.0 9.0 10.0

3 5.7 5.8 5.9 6.1 6.2 6.4 6.6 7.6 8.1 9.1 10.1

3.5 5.8 5.9 6.0 6.2 6.3 6.5 6.7 7.7 8.2 9.2 10.2

4 5.9 6.0 6.1 6.3 6.4 6.6 6.8 7.8 8.3 9.3 10.3

4.5 6.0 6.1 6.2 6.4 6.5 6.7 6.9 7.9 8.4 9.4 10.4

SUCTION PRESSURE (PSI)

5 6.1 6.2 6.3 6.5 6.6 6.8 7.0 8.0 8.5 9.5 10.5

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