installation main ten ace manual grasso 10

Refrigeration Division

Grasso

Reciprocating Compressors for industrial refrigerationSeries Grasso 10

Installation and Maintenance Manual (IMM)

Reciprocating Compressors for industrial refrigeration / Series Grasso 10IMM10/v003


Grasso

Copyright

All Rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of Grasso.This restriction also applies to the corresponding drawings and diagrams.

Legal Notice

This publication has been written in good faith. However, Grasso cannot be held responsible, neither for any errors occurring in this publication nor for their consequences.

This manual must be carefull read and understood prior to installing and servicing the compressor (package)

Safety

This manual is written with great care, but the contractor/installer is held responsible to examine this information and to care of possible additional and/ or deviated safety measures.

Safety instructions

It is the task of the contractor/installer to inform and explain his client about the operation of the compressor (Package).Do respect all federal, state or local safety regulations/legislations during installing, connecting and operating this compressor (package).

Installer oriented information

The compressor (package) is filled with nitrogen to prevent penetration of moisture. Therefore, keep the compressor closed until the compressor (package) is being installed.

The compressor is not filled with oil.

After the successful initial run of the compressor (package) the warranty chart must be filled in and returned to Grasso. A warranty chart is attached to each compressor.

Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003


Grasso

Table of Contents

Section Title Page

1 INSTALLATION AND PREPARATION FOR USE 9

1.1 INSTALLATION 11

1.1.1 Moving instructions and storage 11

1.1.2 Storage 11

1.1.3 Hoisting and moving instructions 11

1.1.4 Required free space 12

1.1.5 Foundation requirements 12

1.1.5.1 Concrete structure 12

1.1.5.2 Anchoring 13

1.1.5.3 Concrete block mounting instructions 13

1.1.5.3.1 Mounting bare compressor on a concrete block 14

1.1.5.3.2 Mounting the base frame on a concrete block 14

1.1.5.3.3 Levelling the base frame 14

1.1.5.3.4 Finishing with a self-levelling grout (See figure 1.1.5) 14

1.1.6 Connecting to refrigerating system pipework 14

1.1.7 Connecting the power supply 15

1.1.8 Earthing connections 15

1.1.9 Separately delivered components 15

1.2 PREPARATIONS FOR USE 17

1.2.1 Leak test of compressor and system 17

1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 17

1.2.3 Initial oil charge 17

1.2.4 Initial refrigerant charge 18

1.2.5 Adjustment of instruments and safety devices 18

1.2.5.1 Monitron CR 18

1.2.5.2 Pressure safety switches 18

1.2.5.3 Re-adjustment of oil pressure regulator (refer to fig. 1.2.1) 18

1.2.6 Checking direction of rotation of motor shaft 19

1.2.7 Installing the drive guards (if present) 19

1.2.8 Initial oil warm up 19

1.2.9 Initial start-up 19

1.2.9.1 Limitations of part load operation and start-up of two-stage compressors 19

1.2.9.2 Pre-start check list 19

1.2.10 Starting and stopping procedures 20

1.2.10.1 Starting for the very first time (between brackets [ ] are Monitron CR units) 20

1.2.10.2 Restart (not within 2 minutes after a stop. If Monitron Cr Controlled, refer to the Monitron CR Instruction manual) 21

1.2.10.3 Starting after a short standstill period of time (less than 1 month) 21

1.2.10.4 Starting after a seasonal standstill (1 till 6 months) or maintenance operations 21

1.2.10.5 Starting after a long standstill period of time (more than 6 months) 21

1.2.10.6 Stopping the compressor 21

2 INSPECTION, MAINTENANCE AND TROUBLE SHOOTING 23



Grasso

2.1 INSPECTION 25

2.1.1 Periodical inspection 25

2.1.2 Survey of periodical inspections ("check list") 25

2.2 MAINTENANCE (Contractor's level) 27

2.2.1 Post start-up maintenance 27

2.2.2 First maintenance 27

2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 27

2.4 LUBRICATION DATA 27

2.4.1 Topping up oil with compressor operating 27

2.5 EVACUATION OF THE COMPRESSOR 28

2.6 DRAINING AND CHANGE OF OIL 28

2.7 REPLACEMENT OF OIL FILTERS 28

2.7.1 Oil discharge filter 29

2.7.2 Oil suction filter (pos B in Fig. 1.2-1) 29

2.8 REPLACEMENT OF SUCTION GAS FILTER(S) 29

2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 29

2.10 COMPRESSOR PURGING 29

2.11 TROUBLESHOOTING TABLE 31

3 APPENDIX; Parts List 33

3.1 Partslist Grasso 10 33

4 APPENDIX; Engineering Data 35

4.1 GENERAL DATA 37

4.1.1 TECHNICAL DATA 37

4.1.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 38

4.1.3 SHAFT END COMPRESSOR 40

4.2 LIMITS OF OPERATION AND FIELDS OF APPLICATION 41

4.2.1 GENERAL LIMITS AND FIELDS OF OPERATION 41

4.2.2 FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER 42

4.2.3 FIELDS OF APPLICATION TWO STAGE 43

4.2.4 LIMITATIONS OF PART-LOAD OPERATION 45

4.2.5 STARTING UP OF TWO-STAGE COMPRESSORS 47

4.3 LUBRICATING OILS (choice and recommendations) 49

4.4 CAPACITY CONTROL SYSTEMS 50

4.4.1 SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START 50

4.4.2 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) 52

4.4.3 MANUAL CAPACITY CONTROL 54

4.5 PACKAGED BASE FRAME AND FOUNDATION BLOCK 55

4.5.1 PACKAGED BASE FRAME 55

4.5.2 BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK 57

4.6 CRANKCASE HEATER 58

Section Title Page



Grasso

Preface

This preface gives a survey of the types of documentation and software available for this Grasso compressor series.

All Grasso documentation and Grasso selection software is available on CD-Roms (Consult Grasso).

1) Grasso Refrigeration Equipment Catalogue (REC)

Contents

This catalogue contains all engineering data and all brochures of the reciprocating compressors, screw compressors, air purgers, chillers, packages, etc. This catalogue also includes the CD-Rom ´Grasso Software´ and the CD-ROM ´Documentation Navigator´.

User group

Project engineers, applications engineers, sales managers and product managers for both end-users and contractors.

Distribution

Sales Department of Grasso.

2) Grasso CD-ROM ´Grasso Software´

Contents

COMSEL programme (the Grasso COMpressor SELection programme), PURGER programme (to calculate energy savings and pay-back time) and REVALCO software (to select Revalco valves, check valves, Revalco parts etc.).

User group

Project engineers, application engineers, sales managers, product managers for both end-users and contractors.

Distribution


3) Grasso CD-ROM ´Documentation Navigator´

Contents

All Grasso documentation including a user friendly navigation system.

With this CD-rom it is possible to re-use all text, graphics, tables, etc. for various purposes (presentations, reports, ...)

User group


Distribution


4) Engineering Data Sheets (ED)

Contents

All engineering data for this series compressor and the corresponding recommended accessories. It is meant to be a guide to the selection of these components.

User group


Distribution


5) Installation and maintenance manual (IMM)

Contents

This manual will provide information on how to transport, install, start-up and maintain the compressor (package). It also contains a number of "Engineering Data Sheets" and the current "Parts List"

User group

To be used in the field by qualified personnel for both end-user and contractor.

Distribution

Supplied together with the compressor.



Grasso

6) Instructions for Accessories (IFA)

Contents

The compressor is supplied with accessories, all the relevant mounting and installation instructions and spare parts information for those accessories.

User group

To be used in the field by qualified personnel for both end-user and contractor.

Distribution

Supplied together with the compressor.

7) Parts list (PL)

Contents

All current parts of the compressor and accessories together with the design changes applicable to previous supplied components ("History").

User group

Service and parts department for both end-sure and contractor.

Distribution

Service and Parts Department of Grasso.

8) Service & Maintenance Schedules (SMS)

Contents

Complete set of service and maintenance schedules for 100 operating hours up to 48000 operating hours (inspection, renewal, measuring, cleaning, ...) of the bare shaft compressor.

User group

Service and parts department and in the field by qualified personnel for both end-user and contractor.

Distribution


9) Service and Maintenance Manual (SIM)

Contents

Description of (re)assembling, inspection, repair and part or total overhaul of the bare shaft compressor. This manual should be used together with the 'Installation and Maintenance Manual'.

User group

To be used in the field by qualified personnel of refrigeration installers or contractors.

Distribution


10) Miscellaneous

Typographic signs:

Indicates a caution, note or procedure to which you should pay special attention.READ IT CAREFULLY!

Indicates a WARNING. READ IT CAREFULLY!

Indicates an IMPORTANT note or procedure to which you should pay special attention.

Indicates a HINT.

Values between []

Values between [ ] are read-outs of Grasso's electronic control device Monitron CR.



Grasso

Main setup data Grasso 10 Table 1 Main setup data Grasso 10

Release Notes IMM Grasso 10

Descriptiona Value Remark

Start frequency max. 6 starts per hour

Time interval between stopping and re-starting min. 2 minutes

Time interval between starting and re-starting min. 10 minutes

Time interval between loading and unloading min. 3 minutes

Oil level 25-75% crankcase sight glass

Min. oil temperature warmer than surroundings and ≥ 20 °C for NH3 and ≥ 30 °C for halocarbons

Max. oil temperature [max. Toil] Refer to oil selection table/applied type of oilRequired oil viscosity;

≥ 10 cSt during operation at location of bearings

Control oil pressure suction pressure + 7 bar

Lubricating oil pressure difference [min dOil] between 1.3 and 3.0 bar Setting approx. 2.0 bar

After a mimimum of 15 minutes running time at an oil temperature of approx. 50 oC

(122 oF)

Max. discharge temperature [max. Tdis] 170 °C

Min. suction pressure [min Psuc] 0.3 bar

Max. intermediate pressure [max Pint]Max. suction pressure 8.5 bar

Pdischarge - Psuction ≤25.0 bar

Superheat [dTo] >0 K for NH3, R22>15K for R507/R404A/R134a

Oil suction filter Blue coloured filter element

Oil discharge - running in - filter Red coloured filter element Factory mounted; to be replaced after max. 100 running hours by permanent oil discharge filter element

Oil discharge - permanent - filter Grey filter elementSupplied loose; replacement for factory mounted running in filter

Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end

a. For values between [ ] brackets refer to the Instruction Manual of the Monitron CR



Grasso

Table 2 Release Notes IMM Grasso 10

Cylinder numbering of Grasso reciprocating compressors

Fig. 1 Cylinder numbering Grasso reciprocating compressors

Booster or single-stage operation

Booster operation applies if condensing temperature <5 oC.Single stage operation applies if condensing temperarture =>5oC.

Item Description Date Changed by

1 Evaluation copy 01-Oct-2000 KK

2 Initial version 20-Oct-2000 KK

3 Translation check by Grasso UK (B.H.) 19-Dec-2000 KK

Legend

1, 2, 3, ... Cylinder numbers

T Top view of compressor

S Shaft-end of compressor

O Oil pump of compressor



Grasso1. INSTALLATION AND PREPARATION

FOR USE

1. INSTALLATION AND PREPARATION FOR USE

Table of Contents

Section Title Page

1.1 INSTALLATION 11

1.1.1 Moving instructions and storage 11

1.1.2 Storage 11

1.1.3 Hoisting and moving instructions 11

1.1.4 Required free space 12

1.1.5 Foundation requirements 12

1.1.5.1 Concrete structure 12

1.1.5.2 Anchoring 13

1.1.5.3 Concrete block mounting instructions 13

1.1.5.3.1 Mounting bare compressor on a concrete block 14

1.1.5.3.2 Mounting the base frame on a concrete block 14

1.1.5.3.3 Levelling the base frame 14

1.1.5.3.4 Finishing with a self-levelling grout (See figure 1.1.5) 14

1.1.6 Connecting to refrigerating system pipework 14

1.1.7 Connecting the power supply 15

1.1.8 Earthing connections 15

1.1.9 Separately delivered components 15

1.2 PREPARATIONS FOR USE 17

1.2.1 Leak test of compressor and system 17

1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 17

1.2.3 Initial oil charge 17

1.2.4 Initial refrigerant charge 18

1.2.5 Adjustment of instruments and safety devices 18

1.2.5.1 Monitron CR 18

1.2.5.2 Pressure safety switches 18

1.2.5.3 Re-adjustment of oil pressure regulator (refer to fig. 1.2.1) 18

1.2.6 Checking direction of rotation of motor shaft 19

1.2.7 Installing the drive guards (if present) 19

1.2.8 Initial oil warm up 19

1.2.9 Initial start-up 19

1.2.9.1 Limitations of part load operation and start-up of two-stage compressors 19

1.2.9.2 Pre-start check list 19

1.2.10 Starting and stopping procedures 20

1.2.10.1 Starting for the very first time (between brackets [ ] are Monitron CR units) 20

1.2.10.2 Restart (not within 2 minutes after a stop. If Monitron Cr Controlled, refer to the Monitron CR Instruction manual) 21

1.2.10.3 Starting after a short standstill period of time (less than 1 month) 21

1.2.10.4 Starting after a seasonal standstill (1 till 6 months) or maintenance operations 21

1.2.10.5 Starting after a long standstill period of time (more than 6 months) 21




FOR USE

1.2.10.6 Stopping the compressor 21

Section Title Page




FOR USE

1.1 INSTALLATION

The compressor is not charged with oil, therefore, DO NOT start the compressor before it has been installed and prepared according to Grasso’s instructions.

This section contains instructions for the proper installation of a Grasso compressor (package). Before the compressor (package) is ready for the initial start up, the installation instructions in the following paragraphs must be followed:

1. The Compressor (Package) should be levelled and securely anchored to the foundation.

2. All piping should be completed.3. The system and the compressor are to be

pressure tested for leaks (see. Section 1.2.1)4. The system should be evacuated to remove air

and moisture.5. The electric wiring should be completed as per

wiring diagrams. Do not energize the main power control cabinet until oil is added and the direction of rotation has been checked.

6. The compressor is to be filled with the correct type and amount of lubricating oil.

7. The drive coupling or V-belt drive system should be installed.

8. The system should be charged with the correct amount of refrigerant.

9. The oil should be warmed up above minimum start up oil temperature (see "Engineering Data").

10.The control cabinet or Monitron CR should be energized to check the package controls.

Do not forget to fill the oil separator (if present) initially.

1.1.1 Moving instructions and storageFor loose component or compressor package weights, refer either to the relevant component type plate or package lay-out or to the suppliers document. For bare compressor weights, see "Engineering Data".

Every precaution must be taken while moving the package to its final location. Pushing, pulling or climbing on any package component or piping, can easily create damage.

1.1.2 StorageThe compressor (package) is filled with dry nitrogen. Keep the system closed until the package is installed. If the compressor (package) is stored, it should be kept at all times in a dry location to prevent corrosion damage. If the compressor (package) is to be stored for a prolonged period of time, it should be checked weekly to ensure that the holding charge of dry nitrogen remains above atmospheric pressure.

1.1.3 Hoisting and moving instructions

Fig. 1.1-1 Hoisting a compressor package

Packaged base frame:

The only places that can be used for safe hoisting of the package are the four hoisting eyes on the steel base frame as shown in the above figure. Prior to hoisting a compressor package with a V-belt drive arrangement, the factory mounted drive guard has to be removed. Attach spreader bars to the slings so as to prevent damage to piping and components.

Legend

C Compressor

M Motor




FOR USE

DO NOT use the compressor or motor or oil separator hoisting eyes to move the package! These hoisting eyes are intended for lifting loose components only and not for the entire package!

Bare compressor or loose components:

Determine the dead weight of the particular component (see "Engineering Data"), prior to moving a bare compressor or loose component. Use the hoisting eyes only, DO NOT sling from other compressor parts (see Fig. 1.1-1).

Fig. 1.1-2 Hoisting angle

Moving by fork-lift truck

The bare compressor or package can be transported with a fork-lift truck with the forks spread as much as possible between the skids. To simplify moving, the 2 wooden transport beams must still be mounted underneath the base frame and stored in this way, until the package is positioned above its approximate location.

1.1.4 Required free spaceFor easy operating, servicing and maintenance access, the compressor (package) should be installed with sufficient free space around it.

Refer to Engineering Data Sheets for minimum requirements

1.1.5 Foundation requirementsThis paragraph covers measures to be taken for a compressor (package) mounting on a concrete floor.Two foundation arrangements are described:• Compressor package with steel base frame

mounted on a concrete block.• Bare compressor direct mounted on a concrete

block via grouted machined anchors (see "Engineering Data"). The mounting surfaces of these machined anchors must be level without any deviation and projecting at least 10 mm above the concrete base.

COMPRESSOR AND COMPRESSOR PACKAGE TO BE MOUNTED ON A CONCRETE BLOCK. On request, Grasso can calculate the exact dimensions of the concrete block, based on the compressor size and operating conditions.

1.1.5.1 Concrete structure

Fig. 1.1-3 Concrete block

The concrete block for compressor and motor or compressor package should have a profile as illustrated below and made according to the

Legend

1 Cork board

2 Concrete base

3 Basement floor




FOR USE

following recommendations:

• The concrete block should be set on firm footings or on a floor capable of carrying the weight of the concrete block and capable of absorbing the free forces and gas forces of the compressor during operation. The ground under the concrete block should be horizontal and flat.

• The top surface of the block should be level and even.

• There should be sufficient free space around the block to install corkboard (or similar).

• The block should be provided with anchor bolt recesses or holes according to the anchor bolt spacing as per package lay out drawing.

Table 1.1-1

It is recommended to consult a concrete specialist/ constructor for the following items:• The compound of the concrete with/without

reinforcement.• The exact grouting depth (dependent on the soil

conditions).• Installing foundation onto an existing floor, with

sealing corkboard or vibration isolators.

1.1.5.2 Anchoring

After the concrete block has cured the anchors should be installed as shown above and in case of a package in accordance with the package lay out drawing. Templates should be made to locate the anchor bolts or chemical anchors to match the holes in the bottom flange of the base frame.

Grout the mortar according to the supplier instructions. Install chemical anchors as illustrated in Fig. 1.1-4 and according to the instructions of the anchor supplier.

Fig. 1.1-4 Anchoring details

1.1.5.3 Concrete block mounting instructions

Legend

A Chemical anchor

B Grouted anchor, grounded to reinforcing steel

Legend

A Drilled chemical anchor (M20)

B Grouted anchor recesses (M20)

1 Installed chemical anchor before placing the base frame

2 Installing chemical anchor after placing the base frame (base frame cannot be removed easily)

3 Drilling angle




FOR USE

1.1.5.3.1 Mounting bare compressor on a concrete block

If no base frame is applied the compressor and motor should be installed as described in the "Engineering Data".

1.1.5.3.2 Mounting the base frame on a concrete block

General

After the space between base frame and concrete base has been filled-up with a filling grout, the package base frame must be secured tightly to the foundation block or floor.

1.1.5.3.3 Levelling the base frame

Fig. 1.1-5 Grouting details

After the anchor filling mortar has completely cured the frame should be levelled with a space between block and lower frame flange of 3 - 5 mm*. This space is necessary for levelling using the base frame adjusting bolts with metal washers (supplied separately). The base frame should be levelled on each frame side. Adjust the frame on each adjusting place until all frame sides are horizontal.

This space largely depends on the sort of grout or mortar used. Determine this space according to the instructions of the grout or mortar supplier.

1.1.5.3.4 Finishing with a self-levelling grout (See figure 1.1.5)

After levelling has been completed the adjusting bolt ends must be greased to avoid bonding to the self-levelling grout. The space between concrete block and frame must be completely filled with the self-levelling grout to ensure that the complete bottom surface of the base frame will be supported. Therefore, it is not allowed to use shims between concrete base and base frame.

Grouting must be carried out in accordance with the instructions provided by the grouting supplier. After complete de-aeration of the grouted layer, secure the base frame by tightening the anchor bolt nuts and remove all adjusting bolts. At this stage the drive system can be installed. These (accessories) installation instructions can be found in the order manual.

1.1.6 Connecting to refrigerating system pipework

After the compressor (package) has been levelled and secured to the foundation, the system piping may be connected. The suction line(s) and discharge line(s) should be installed and supported such that there is no load exerted on the compressor. The size and location of the suction and discharge connections, can be found in the "Engineering Data" (bare compressor) and in case of a package, the package lay out drawing.

Legend

1 Self-levelling grout

2 Adjusting bolts (4x)

3 Washer

4 Temporary barrier strip around and inside frame

5 Complete cured concrete block

6 Grout layer




FOR USE

If an oil rectifier system is applied in the refrigeration system, the oil return line must be connected to the oil return connection (see "Engineering Data").

Never connect the oil rectifier return line to the suction line or to the suction gas filter.

DO NOT ground through the compressor when arc welding

Suspension of system pipework

To eliminate vibration transmission to the system piping, the following is recommended:• Install all piping free of tension.• Secure the piping by clips or brackets in two

directions.• Install (stop) valves, piping and accessories such,

that there is no load exerted on the compressor.

1.1.7 Connecting the power supplyBefore leaving the factory the compressor package is completely wired.1 The connection to be made by the installer is between main power source and the Monitron CR (if ordered). Information about further electrical connections to be made (e.g. crankcase heater, drive motor starting equipment, thermal protection of drive motor, automatic start/ stop, motor current transducer and other external electrical devices) can be found in the order manual.

1.1.8 Earthing connectionsGrasso compressors and packages are equipped with litz-wires and earth connecting points.To avoid leakage current flowing through the components, disconnect all litz-wires when

arc-welding. After all installation functions are completed, reconnect the litz-wires and ground the package to earth.

1.1.9 Separately delivered components

Check whether the sets/parts/components (e.g. fly wheel) belonging to this compressor are supplied loose! (Refer to confirmation of order)

Mount these separately delivered sets, components and/or parts, according to the instruction as enclosed.

1. If the standard recommended Monitron CR is applied.




FOR USE




FOR USE

1.2 PREPARATIONS FOR USEAfter the Compressor (Package) has been installed (excluding final connection of drive device), the following actions should be followed in the order given:

1.2.1 Leak test of compressor and systemThe compressor (package) has been pressure tested prior to leaving the factory. In case an additional leak test is required, this test is should be carried out with dry nitrogen under pressure up to a max. of 10 bar(a).

DO NOT add oil to the compressor prior to pressure testing

A system leak test should be carried out over 24 hours to ensure that the system is tightly sealed.Record during the pressure test, the pressure, ambient temperature and outside temperature. During the initial 6 hours a pressure drop of 2% is permissable. With respect to temperature variations, no further pressure loss should be detected in the remaining 18 hours.If the test pressure has not decreased by more than 5% the system can be considered leak free.

1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM

For evacuation of compressor only, refer to Section 2.5

Procedure to evacuate and to dry a system:

i) STATUS: System is filled with nitrogen and no oil has been added (oil prevents any trapped moisture from boiling off).

ii) Verify that all valves in that part of the system to be evacuated are opened (refer also to the plant manual).

iii) Connect vacuum pump to the evacuation/purging valve(s) of the compressor (for location of these valves refer to the "Engineering Data" or to a connection as mentioned in the plant manual and evacuate the system to approx. 5 mm Hg (=6.6 mBar).

iv) Break vacuum by charging dry nitrogen into the system.

v) Repeat step iii, 'Connect vacuum pump ...'.vi) Wait approx. 24 hours.

vii)If pressure has increased (system still contains moisture), repeat steps iv, vand vi, otherwise, continue with the "Initial oil charge" procedure.

1.2.3 Initial oil charge

Used or filtered oil should NEVER BE added to a compressor under any circumstance.

Use only new oil as selected from the Grasso oil table.

Oil charging via the suction line of the compressor is not allowed.

Procedure:

i) STATUS: System is dried and still evacuated.ii) Fill the oil separator (if present) initially with oil .iii) Close suction and discharge stop valves of

compressor and oil return line of oil separator (if present).

iv) Fill the compressor crankcase with oil via the oil charge valve.

Pre-lubrication just before the first start is obligatory.

v) Open evacuation/purging valve(s) of the compressor to bring the compressor to atmospheric pressure.




FOR USE

Filling of the afore mentioned components is also possible by means of a separate oil filling pump via the oil charge valves mounted onto the oil pump housing.

1.2.4 Initial refrigerant chargeRefrigerant charging should be done in accordance with the plant manual by qualified refrigeration engineers.

1.2.5 Adjustment of instruments and safety devices

1.2.5.1 Monitron CR

For adjustments as given overleaf (values between brackets [ ]) refer to the Monitron CR Instruction Manual.

1.2.5.2 Pressure safety switches

1.2.5.3 Re-adjustment of oil pressure regulator (refer to fig. 1.2.1)

IT IS POSSIBLE that after the compressor(package) has been installed, the lubrication oil pressure regulator (located on the left side of the pump) needs to be re-adjusted.

Inside the oil pump two regulators are factory preset and installed; One control oil pressure regulator (right) to control the valve lifting mechanisms and one lubricating oil pressure regulator for lubrication.For settings, refer to Section 1.2.5.2.

Fig. 1.2-1 Oil pressure regulator

QUANTITY OF OIL TO BE FILLED (IN dm3)

Number of cylinders

Shaft seal housing incl.

internal circuit of crnkshaft

Oil filters

Oil pump Crankcase

2 0.6

1.5 each 0.5

6.5

3 0.7 9.0

4 0.7 6.5

6 0.8 9

8 0.9 13.5

Pressure safety limit switches

Suction pressure [Psuc]

Setting Precondition

5oC below design evaporating temp. Min. =0.3 bar(a)

Suction and intermediate

pressure [Pint]

Setting Precondition Max.= 8.5 bar(a)

Discharge pressure [Pdis]


5oC above design condensing temp. Max. =26 bar(a)

Lubrication oil pressure difference Setting Min. =1.3 bar

Oil pressure regulators

Lubrication oil pressure difference

[dOil]


2.0 bar Min. =1.3 bar Max. =3.0 bar at 50oC oil temp.

Control oil pressure difference Setting Min. =6.9 bar Max.

=7.1 bar

Legend

1 Lubricating oil pressure regulator

2 Control oil pressure regulator

A Oil suction filter

B

Oil discharge filter

REMARK: A running in filter is factory mounted; to be replaced after max. 100 running hours by permanent oil discharge filter element

Legend




FOR USE

Re-adjustment procedure:

i) Run the compressor for 15 minutes until the crankcase oil is at its stable operating temperature [Toil] of 50 oC at which:# The lubricating oil pressure difference should be 2.0 bar.# The control oil pressure difference should be approx. 7.0 bar.After the initial run the oil pressure differences should be slightly higher.

ii) Determine the lubricating oil pressure difference (difference between the pressure gauges of the oil and suction or [dOil]).

iii) Determine the control oil pressure difference (difference between the pressure gauges of oil pump discharge 1 and suction.

iv) Remove the cap nut of both oil pressure regulators if the pressures need to be re-adjusted.

v) Turn the slotted pin with a screwdriver clockwise or counter clockwise for a higher or lower oil pressure respectively, until the required control & lubricating oil pressure differences has been achieved 2.

vi) Replace both cap nuts.

REMARK: If the valve lifting fails, check the lubrication oil pressure regulator!

1.2.6 Checking direction of rotation of motor shaft

Prior to installing the intermediate coupling element or V-belts, the direction of rotation of the motor shaft must be checked either by bumping the electrical drive motor or by measuring the rotation of the field. The direction of rotation can be determined from the arrow-sticker on the oil pump.

1.2.7 Installing the drive guards (if present)Only after the compressor is ready for the initial

startup! Refer to the drive guard installing procedures included in the order documentation.

1.2.8 Initial oil warm upPrior to the initial start-up, the crankcase heater (if present) must be energized. For the min. oil temperature (min. [Toil]) refer to Engineering Data Sheets.

1.2.9 Initial start-up

1.2.9.1 Limitations of part load operation and start-up of two-stage compressors

The capacity control serves to adapt the compressor capacity at any moment as closely as possible to the refrigerating capacity. In order to adapt the capacity, a number of cylinders can be put in or out of action either individually or collectively. In this case use is made of the valve lifting mechanism fitted on each cylinder which is put in or out of action by oil pump pressure via 3-way solenoid valves.

Due to start-up limitations and to limitations of part load operation it may be that not all available part load steps are allowed under certain conditions. Use of incorrect control steps can damage compressor and/or components.

In the case of a Monitron CR Controller, all these limitations will be checked automatically.

For a detailed description about these start-up and part load limitations refer to the "Engineering Data".

1.2.9.2 Pre-start check list

The following Paragraph covers only the initial start of the compressor and not the complete refrigeration plant.

Be sure that all necessary system valves are open and that the refrigeration system is ready for start up. Use the following check to guarantee that no items of importance regarding the compressor (package) have been overlooked.

i) System is charged with refrigerant.ii) Monitron CR (if present) is properly installed

(refer to the Monitron CR Instruction Manual).

C

Oil charge valve for lubrication circuit.

REMARK: This connection to be used for pre-lubrication of the oil circuit

D Oil charge plug for oil suction filter (Hand operarated oil pump and stop valve are not included)

E Connection to measure oil control pressure

F Hand operated oil charge pump (optional).

1. To be measured by means of a special control oil pressure gauge to be connected at position E on the oil pump.

2. Re-adjusting one regulator will affect the other one, so be sure that both regulators are properly (re-)adjusted.

Legend




FOR USE

iii) Settings of safety limit switches are adjusted properly.

iv) Direction of rotation of compressor crankshaft is correct.

Different procedure for Manually operated capacity control and Electrically operated capacity control:

1. Manually operated capacity control: Set the electrical capacity control switch to the position ´1´.2. Electrically operated capacity control Monitron CR Controller: Check whether the manual control lever of each solenoid is in its lowest horizontal position. If not, the compressor may be seriously damaged.

v) Oil level established in sight glass.vi) Stop valves to the pressure gauges are open.vii)Suction stop valve is closed (in case the

evaporating temperature is much higher than the design evaporating temperature) and the discharge stop valve is open and in case of two- stage compressors that the stop valves in the intermediate circuit lines are open.

viii)Stop valve in the oil return line of the oil separator (if present) is closed.

When all items are verified, the compressor (package) is ready for the start-up.

1.2.10 Starting and stopping proceduresWhen starting the compressor a distinction should be made between:

• (Section 1.2.10.1) Starting for the very first time.• (Section 1.2.10.2) Restart (not within 2 minutes

after a stop and, if Monitron CR Controlled, refer to the Monitron CR Instruction manual)

• (Section 1.2.10.4) Starting after a short standstill period of time (less than 1 month).

• (Section 1.2.10.5) Starting after a seasonal standstill (1 till 6 months) or maintenance operations.

• (Section 1.2.10.6) Starting after a long standstill period of time (more than 6 months).

• (Section Section 1.2.10.6) Stopping the compressor.

1.2.10.1 Starting for the very first time (between brackets [ ] are Monitron CR units)

i) Notice "Pre-start check list", also consult the plant manual and verify the following items:— Check the oil temperature [Toil] (refer to the

"Engineering Data").— Check crankcase oil level (refer to Section

2.4.1).ii) Start the compressor and check whether the oil

pressure [Poil] increases.

Maximum 6 starts per hour and at least 2 minutes between stopping and starting and at least 10 minutes between starting and re-starting

i) Slowly open suction stop valve and watch suction pressure [Psuc], which may not exceed the max. value as given for each refrigerant in "Main setup data Grasso 10" on Page 7.

Refrigerant liquid hammer, will damage the compressor; Superheat is always necessary! [dTo]≥0-15K. Refer to "Main setup data Grasso 10" on Page 7.

i) In case of electrically operated capacity control or control by a Monitron CR:— Single-stage compressors: One or more

cylinders will be energized.— Two-stage compressors: 3 - 5 minutes after

starting and only when HP-cylinder(s) is (are) in operation, can the LP cylinders be energized.




FOR USE

Watch maximum allowable motor current [Imot] (refer to motor type plate).

Watch discharge temperatures LP and HP {[Tint] and [Tdis]}, max. intermediate pressure [Pint] (Refer Table 1) and max. allowable motor current (refer to motor type plate).

In the case of decreasing capacity, it is not allowed to cut out all LP-cylinders.

i) Adjust pressure gauge stop valves, in order to avoid vibration of the pointers.

ii) Open the stop valve in the oil return line from the oil separator (if present).

After 50 hours of operation retighten the coupling bolts or check and/or correct the tension of the V-belts and retighten the foundation bolts (with due respect to the torque settings given by the supplier of the fasteners!).

1.2.10.2 Restart (not within 2 minutes after a stop. If Monitron Cr Controlled, refer to the Monitron CR Instruction manual)

• Proceed to the complete starting procedure of Section 1.2.10.1, items a) through f).

1.2.10.3 Starting after a short standstill period of time (less than 1 month)

• Refer to Section 1.2.10.2.

1.2.10.4 Starting after a seasonal standstill (1 till 6 months) or maintenance operations

• Check settings of control and safety equipment.• Proceed to the complete starting procedure.

1.2.10.5 Starting after a long standstill period of time (more than 6 months)

Consult your supplier. Monitron CR "standby" status (ready to operate during this long period of time) is not allowed! It is recommended to proceed with the "Initial start-up" procedure of Section 1.2.10.1.

1.2.10.6 Stopping the compressor

The compressor can be stopped at any moment, however, consult the supplier if further actions are required.




FOR USE



Grasso2. INSPECTION, MAINTENANCE AND

TROUBLE SHOOTING

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Table of Contents

Section Title Page

2.1 INSPECTION 25

2.1.1 Periodical inspection 25

2.1.2 Survey of periodical inspections ("check list") 25

2.2 MAINTENANCE (Contractor's level) 27

2.2.1 Post start-up maintenance 27

2.2.2 First maintenance 27

2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 27

2.4 LUBRICATION DATA 27

2.4.1 Topping up oil with compressor operating 27

2.5 EVACUATION OF THE COMPRESSOR 28

2.6 DRAINING AND CHANGE OF OIL 28

2.7 REPLACEMENT OF OIL FILTERS 28

2.7.1 Oil discharge filter 29

2.7.2 Oil suction filter (pos B in Fig. 1.2-1) 29

2.8 REPLACEMENT OF SUCTION GAS FILTER(S) 29

2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 29

2.10 COMPRESSOR PURGING 29

2.11 TROUBLESHOOTING TABLE 31




TROUBLE SHOOTING




TROUBLE SHOOTING

2.1 INSPECTION

2.1.1 Periodical inspectionThese inspections should be made during the normal shut-down periods as much as possible, so the compressor is always ready to operate when required. If, at that time, the number of running hours slightly differs from the scheduled period below, the inspection should nevertheless be carried out.

In this way it will not be necessary to stop the compressor at inconvenient times.The frequency of inspections is dependent on the type of installation and operating conditions. In the case of automatically controlled plants, the periodical inspection are particularly important. The table below sums up all the points on the compressor that have to be inspected or maintained along with inspection and maintenance frequencies.

2.1.2 Survey of periodical inspections ("check list")

Apart from the check points in the table below, the sound produced by the compressor provides an indication or its mechanical condition. If abnormal sounds are audible, their cause should be traced and removed immediately in order to prevent serious breakdowns.




TROUBLE SHOOTING

Table 2.1-1 Survey of periodical inspections ("check list")

CHECK POINTSa FREQUENCY REMARKS

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Oil level in crankcase •

Between 25% and 75% height of the sight glass.

For topping up oil, refer to Section 2.4.1.

Colour of the oil •

The oil should be transparently clear. A

disappearing white colour points to dissolved

refrigerant. Refer to Section 2.2.2 for oil analysis

frequency.

Lubricating oil pressure

difference [dOil]

•

The indication of the oil pressure gauge should be 1.3 - 3.0 bar higher than the value shown by the suction pressure gauge.

Min. control oil pressure • Suction pressure + 7 bar

Oil temperature max. [Toil]

• Refer to the "Engineering Data"

Oil leakage of shaft seal max. • In case of more than 1

cc/hr contact supplier.

Suction pressure [Psuc] •

Check against design conditions. Refer to plant

manual.

Discharge pressure [Pdis] •

Refer to plant manual. For the max. allowable

discharge pressure refer to the technical data of

compressor.

Suction superheat

[dTo]Intermediate superheat

[dTm

• ≥ 0 K

Discharge temperature

max.• 170 °C.

Oil temperature min. [Toil]

•

During compressor standstill the lower part of the crankcase must remain

warmer than the surroundings: ≥ 20 °C

(NH3) and ≥ 30 °C (halocarbons).

Condition of V-belts •

Check belts for:1) Wear (fraying, cuts etc.)

and ensure that they do not touch the groove

bottom.2) Tension. Too low a tension gives rise to excessive flapping or

oscillation in operation. For correct tension consult the instructions given by the

V-belt supplier.

Adjustment and operation

of pressure safety switches

•Refer to Section 1.2.5 and to instructions of switch

manufacturer.

Capacity control (if provided)

•

The time lag between the unloading and loading of one cylinder or cylinder

group should generally be at least 3 - 5 minutes.

Switching frequency of

the compressor

•

The time interval between stopping and starting should be at least 2

minutes and between starting and restarting 10

minutes (see Section 1.2.10.2).

Number of operating

hours•

Check the number of operating hours in view of

any maintenance operations to be carried

out.

a. During the first 50 operating hours the compressor should be checked regularly for all the points mentioned above, at least twice every 24 hours and more frequently in cases where irregularities are found.

CHECK POINTSa FREQUENCY REMARKS

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TROUBLE SHOOTING

2.2 MAINTENANCE (Contractor's level)

2.2.1 Post start-up maintenanceAfter the compressor has run for the initial 100 operating hours:i) Drain the oil and refill the compressor with the

correct amount of fresh oil.ii) Replace the red marked oil discharge filter

element with the grey marked filter element in accordance with the filter replacement instructions. Refer also to Section 2.7.

iii) Inspect suction gas filter (refer to the Compressor Service Instruction Manual).

iv) Exchange or clean oil suction filter element (refer Section 2.7).

v) Check the compressor shaft seal for leakage. If excessive (more than 1 cc/hr) replace the seal.

vi) 1) Retighten the coupling mounting bolts with the torque settings as given by the coupling manufacturer.2) Verify and if necessary, correct the tension of the V-belts as given in the V-belt supplier's instructions.

vii)Verify and if necessary, correct the torque settings of all foundation bolts as given in Compressor Service Instruction Manual.

2.2.2 First maintenanceFor complete service schedules and required service sets refer to Grasso's Service and Maintenance Schedules (SMS).

After the refrigerating plant has been modified, the suction gas filter(s). the oil filters and the oil should be changed.

2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months)

To shut down a compressor for long term periods, proceed as follows:i) Tightly shut both the suction and discharge stop

valves and the stop valve of the oil return line (if present).

ii) Disconnect the power source from the compressor drive motor and the electrical control cabinet of the Monitron CR (if present).

iii) Place a moisture absorbing compound (eg a dessicant such as silica gel) inside the control cabinet.

iv) Place warning tags on the electric system and all closed stop valves.

Prior to starting up after a shut down, change the oil (refer to Section 2.6) and exchange the oil filters (refer to Section 2.7). Determine the starting and stopping procedure from Section 1.2.10 prior to start the compressor.

2.4 LUBRICATION DATADetermine max Toil and set this value in the safety device (Monitron CR, if present).Change the oil as soon as an oil analysis (refer to Section 2.2.2 for frequency) indicates contaminated oil.

It is expressly pointed out that it is not permitted to mix different types of oil. If another type of oil is used, first remove all the stale oil in the filters, oil pump, crankcase, shaft seal, oil separator and oil drains of the installation.

2.4.1 Topping up oil with compressor operating

Topping up oil is permitted during compressor operation.

Maintenance Number of operating hours

100a

a. Time dependent on pollution.

> 100

Renewal of oil discharge filter X

refer to Service and Maintenance Schedules (SMS)

Renewal of suction gas filter(s) X

Inspection of oil suction filter X

Oil analysis bc

b. Take an oil sample every 3,000 running hours or twice a year and renew if any sign of discoloration and if the system is contaminated.

c. Consult your oil supplier.

X

Inspection leakage shaft seal X

Inspection relief valve(s)d

d. If temperature of relief valve is close to (LP/HP) discharged temp, consult your supplier.

X




TROUBLE SHOOTING

Be sure that this oil is the same as in the plant (refer to Section 2.4).

Without affecting the operation of the compressor, the oil may be topped up by means of a separate oil pump. This pump enables the oil to be forced into the crankcase via the oil charging valve, against suction pressure. If this oil pump is not available, oil can be charged by reducing the crankcase pressure to below atmospheric pressure.

The procedure is as follows:

i) Connect a hose to the oil charging valve after removing the cap nut.

ii) Fill the hose with oil and immerse its loose end in a reservoir containing sufficient oil.

iii) Close the suction stop valve so, that the suction pressure falls below the atmospheric pressure.

iv) Keep the oil charge valve open as long as the oil in the crankcase has attained the required level again. Take care that no air is being drawn into the crankcase.

v) Slowly open the suction stop valve to avoid liquid hammer which may damage the compressor.

vi) Remove the hose and replace the cap nut with gasket onto the oil charging valve.

Fig. 2.4-1 Oil level in compressor sight glass

2.5 EVACUATION OF THE COMPRESSOR

To evacuate the refrigeration system refer to Section 1.2.2, Procedure to evacuate the compressor:

i) Close the suction stop valve and the stop valve in the oil return line of the oil separator.

ii) Check that the discharge stop valve is open.1. Two-stage system A/B: shut off liquid supply

to interstage cooler.2. Two-stage system C/D: consult the plant

manual.

iii) Set suction pressure safety switch to 0.3 bar(a).iv) Start the compressor (manual).v) Wait until the compressor is cut out of operation

either by the min. suction pressure safety switch [min Psuc] or the min. oil differential pressure safety switch [dOil].

Do not start the compressor again, but close the discharge stop valve as soon as possible. Be sure the compressor will not start again!

vi) Remove the remainder of the refrigerant, via the evacuation/purging valve(s) as prescribed by local safety regulations. For the location of these valves refer to the "Engineering Data".

vii)Reset the suction pressure safety switch [Psuc].

2.6 DRAINING AND CHANGE OF OILTo top up oil see Section 2.4.1, Oil changing procedure:

i) Evacuate the compressor (refer to Section 2.5).ii) Drain the oil via the oil charging/drain valve.

Remove the cover of one or more service openings on the compressor side.

iii) Clean the inside of the crankcase with a non-fibrous cloth (do not use cotton waste!).

iv) Replace the service cover(s) with a new O-ring.v) Charge crankcase with clean or fresh oil in

accordance with the procedure of Section 1.2.3.

2.7 REPLACEMENT OF OIL FILTERS

Tools; Use the ring spanner for (dis)mounting the oil filter cups (included in set of special Grasso tools)

Evacuate (refer to Section 2.5) the compressor prior to exchange the filter(s).

Facts:Oil suction filter = BLUE colouredOil discharge - running-in - filter = RED colouredOil discharge - permanent - filter= grey.




TROUBLE SHOOTING

2.7.1 Oil discharge filter

An oil discharge (running-in) filter is factory mounted. This filter must be exchanged after max. 100 running hours. Oil filters can not be cleaned!

Replace this filter according to the schedule in Section 2.2.2 and to the replacement instructions included in the filter set (GREY = permanent) or in case of a modified plant (RED = running-in).

2.7.2 Oil suction filter (pos B in Fig. 1.2-1)The frequency of exchanging this filter depends on the condition of the refrigeration system. It is recommended to exchange this filter when the compressor is overhauled or when pressure drop exceeds 1 bar.

2.8 REPLACEMENT OF SUCTION GAS FILTER(S)

Running-in suction gas filter(s) is(are) factory mounted. This(these) filter(s) must be exchanged after max. 100 running hours. Running-in filters can not be cleaned!

Facts:

Filter type 1000 = installed in 2-3 cylinder compressors.Filter type 2000K = installed in 4-6-8 cylinder compressors.

Procedure:

i) Evacuate the compressor.ii) Remove and exchange the suction gas filter(s).iii) Purge the compressor.

2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES

The suction and discharge valves of a refrigeration compressor are parts that are heavily loaded both

mechanically and thermally. Wear and life time of the valves strongly depend on the working conditions of the compressor. It is recommended that valve condition is regularly checked.For dismantling, inspection and re-assembly of the valves, refer to the relevant paragraph of the Compressor Service Instruction Manual.

In order to reduce the downtime involved in the valve inspection, it is recommended to have as many complete valve assemblies in stock as there are cylinders on the compressor.These valves can be exchanged with the original valves; in this case, these original valves can be inspected and repaired or replaced if necessary later on.

2.10 COMPRESSOR PURGINGProcedure to purge the compressor(after maintenance jobs):

STATUS:

Stop valves of suction, discharge and oil return line are still closed (refer to Section 2.5) and compressor is filled with oil (refer to Section 2.6).

i) Connect a vacuum pump to the evacuation/purging valve(s) and evacuate as prescribed by local regulations. For the location of these valves refer to the "Engineering Data".

ii) When evacuation is completed open the discharge stop valve.

iii) Watch suction and discharge pressure.

If suction pressure increases quickly, the discharge valve assy is leaking.

iv) Start compressor.v) Slowly open suction stop valve.vi) Open the stop valve in the oil return line of the

oil separator (if present).1. Two-stage system A/B: open liquid supply to

interstage cooler.2. Two-stage system C/D: refer to the plant

manual.vii)If a Self-Limiting Automatic Purger is not

installed, purge the refrigerating system (refer to the plant manual).




TROUBLE SHOOTING




TROUBLE SHOOTING

2.11 TROUBLESHOOTING TABLEThe troubleshooting table on the next pages may be helpful to quickly trace and remedy failures that interfere with the proper operation of the compressor. It is emphatically pointed out that the cause of a failure must often be sought in the refrigeration installation itself. Therefore, it is necessary besides this table also to consult the plant manual.For Monitron CR controlled installations refer also to its own trouble shooting table.




TROUBLE SHOOTING

Table 2.11-1 Troubleshooting

FAULT CAUSE REMEDY

A Discharge pressure too high

1. Discharge stop valve not fully open

2. Discharge pressure gauge defective

3. Non-condensables in the system

1. Open fully2. Repair or replace

3. Purge with a Automatic Purger

B Discharge temperature too

high

1. Discharge pressure too high

2. Too many cylinders cut out

3. Suction pressure too low

4. Excessive superheat of suction gas

5. For two-stage compressors:

interstage cooling does not operate properly6. Room temperature

too high7. Discharge valve

defective8. Pressure relief valve

is leaking

1. See A2. Cut in more cylinders

3. See D4. Eliminate excessive

superheat5. Repair

6. Ventilate engine room better

7. Repair or renew8. Repair or renew

C Suction pressure too high

1. Capacity control does not operate

2. Compressor capacity too small

3. Suction pressure gauge defective

4. One or more suction valves defective5. One or more discharge valves

defective6. Pressure relief valve

is leaking

1. Repair2. Refer to plant design

3. Repair or renew4. Renew suction valve

rings5. Repair or renew6. Repair or renew

D Suction pressure too low

1. Suction stop valve not fully open

2. Suction gas strainer blocked

3. Injection control not adjusted correctly

4. Too little refrigerant in installation

5. Suction pressure gauge defective

1. Open fully2. Clean

3. Re-adjust control4. Top-up with refrigerant

5. Renew

E Crankcase frosted or wet

Stop compressor and contact installation engineer

1. Liquid refrigerant in crankcase due to:

1a. Room temperature too low

1b. Oil return from separator contains liquid refrigerant1c. Installation

operates too wet1d. Liquid separator

too small

1a. Provide for crankcase heating or, if provided,

check it for proper operation

1b. Consult plant manual1c. Re-adjust installation

and provide for superheat1d. Consult plant manual

F All cylinders inactive while compressor is

operating

1. Oil pressure for valve lifting mechanism too

low2. Incorrect wiring of

capacity control

1. See J2. Refer to the

"Engineering Data

G Too high oil consumption

1. Type of oil not according to oil

lubrication oil table (too thin oil)

2. Compressor operates unloaded too

frequently3. No return from oil

separatora

4. Restriction plug at the bottom of suction chamber in cylinder

clogged5. Worn out oil scraper

ring(s)6. Loss of oil due to

leakage7. Leaking shaft seal

(max. 1 cc/hr)8. Oil level in crankcase

too high9. Oil separator is not initially filled with oil

1. Change oil type2. Refer to design

calculations3. Check the operation of float valve in oil separator

4. Clean plug5. Replace ring(s)

6. Repair7. Repair shaft sealRefer to Section 2.2

8. -9. -

H Too high oil pressure during

normal operation at

working temperature

1. Lubricating oil pressure regulator not adjusted properly or

defective2. Defective oil pressure and/or

suction pressure gauge (if present)

1. Re-adjust or renew2. Repair or replace

J Too low lubricating oil

pressure

1. Too little oil in crankcase

2. Disturbed oil circuit: Oil suction and/or

discharge filter is dirty3. Lubricating oil

pressure regulator not adjusted properly or

defective4. Liquid refrigerant in

crankcase5. Defective oil pressure and/or

suction pressure gauge (if present)

6. Worn bearings

1. Top up oil2. Renew the element of oil

suction filter and/or oil discharge filter

3. Re-adjust or renew4. See E

5. Repair or renew6. Renew bearings

K Too low or no control oil pressure

1. Failure of control oil pressure regulator in

oil pump2. A lack of oil in oil

system3. Oil pump defect

1. Re-adjust or renew regulator

2. Add oil to the system3. Repair or renew oil

pump

a. During the initial start-up, the oil separator (if present) consumes oil before the first oil will be returned.

FAULT CAUSE REMEDY



Grasso3. APPENDIX; Parts List

3. APPENDIX; Parts List

Table of Contents

3.1 Partslist Grasso 10Data not yet released.Partslist Grasso 10 is under construction

Section Title Page

3.1 Partslist Grasso 10 33



Grasso3. APPENDIX; Parts List



Grasso4. APPENDIX; Engineering Data

4. APPENDIX; Engineering Data

Table of Contents

Section Title Page

4.1 GENERAL DATA 37

4.1.1 TECHNICAL DATA 37

4.1.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 38

4.1.3 SHAFT END COMPRESSOR 40

4.2 LIMITS OF OPERATION AND FIELDS OF APPLICATION 41

4.2.1 GENERAL LIMITS AND FIELDS OF OPERATION 41

4.2.2 FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER 42

4.2.3 FIELDS OF APPLICATION TWO STAGE 43

4.2.4 LIMITATIONS OF PART-LOAD OPERATION 45

4.2.5 STARTING UP OF TWO-STAGE COMPRESSORS 47

4.3 LUBRICATING OILS (choice and recommendations) 49

4.4 CAPACITY CONTROL SYSTEMS 50

4.4.1 SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START 50

4.4.2 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) 52

4.4.3 MANUAL CAPACITY CONTROL 54

4.5 PACKAGED BASE FRAME AND FOUNDATION BLOCK 55

4.5.1 PACKAGED BASE FRAME 55

4.5.2 BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK 57

4.6 CRANKCASE HEATER 58




4.1 GENERAL DATA

4.1.1 TECHNICAL DATA

Table 4.1-1 Technical Data of Grasso 10 compressors

COMPRESSOR TYPE Grasso Single-stage Two-stage

210 310 410 610 810 2110 3110 4210 6210

Number of cylinderszL

2 3 4 6 82 3 4 6

zH 1 1 2 2

Cylinder arrangement 1xL 1xL 2xV 2xV 4xV 1xL 2xV 2xV 4xV

Cylinder bore D mm 110

Piston stroke S mm 85

Swept volume at full-load and: n=1500 min-1 Vs m3/h 145 217 290 435 580 145 217 290 435

Standard direction of rotation counter-clockwise when facing shaft end

Standard compressor speeds (with

V-belt drive) at motor speed:

1475 min-1 (50 Hz) n min-1 1475-1328-1180-1047-929-826-738-661-625

1775 min-1 (60 Hz) n min-1 1416-1257-1115-991-885-793-750-708-637

Standard steps of capacity control (expressed in %

of full-load swept volume):

manual and electric control:

%

100-50 100-67- 33

100-75- 50

100-83- 67-50 -33

100-87- 75-62- 50-37-

25

100 100-67 100-75- 50

100-83- 67-50-

33

incl. Fast Pull Down(FPD)a - 100-50 100-67

33

100- 75(1.5)- 75(3.0)- 50(1.0)- 50(2.0)-

25

100-83- 67-

50(1.5)- 50(3.0)- 33(1.0)- 33(2.0)

Mass of bare compressor (without flywheel and other accessories) kg 510 585 610 725 990 590 615 730 998

Shipping mass (approx.) kg 560 635 660 775 1040 640 665 780 1048

Shipping volume m3 0.3 0.4 0.7 0.8 1.1 0.4 0.7 0.8 1.1

Oil charge in crankcase and oil circuit (centre line of sight glass) dm3 9.5 12 9.5 12 16.5 12 9.5 12 16.5

Mass moment of inertia of crank mechanism (without flywheel) Id kg.m2 0.0776 0.1491 0.0776 0.1491 0.1673 0.1491 0.0776 0.1491 0.1673

a. Volume ratio between brackets




4.1.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS

Fig. 4.1-1 Main dimensions, space requirements Table 4.1-2 Main dimensions and space requirements

COMPRESSOR TYPE Grasso 210 310 410 610 810 2110 3110 4210 6210

Length A 925 1105 925 1105 1455 1105 925 1105 1455

Width B 536 536 888 888 888 536 888 888 888

High C 765 765 815 815 815 765 815 815 815

D 579 579 782 777 782 577 782 782 777

E - - - - - 685 709 722 722

F - - - - - 513 595 600 600

G - - 787 824 824 709 709 709 709

H - 516 - - - 516 315 345 735

J 343 402 301 372 821 519 315 481 845

K - - - - - 152 152 134 134

L - - - - - 30 38 68 68

M 152 134 0 0 0 152 152 152 152

N 68 68 77 100 98 70 77 77 98




O 555 735 555 735 1085 735 555 735 1085

R 240 240 240 240 240 240 240 240 240

S 211 211 0 0 0 210 0 0 0

MINIMUM REQUIRED FREE SPACE for removal of:

T - - - - - 519 326 470 860

flywheela U 335 355 335 335 335 335 335 335 335

crankshafta V 750 925 750 925 1270 925 750 925 1270

piston and cylinder linera W 1000 1000 790 790 790 1000 790 790 790

X 300 300 530 530 530 300 530 530 530

LOCATION OF CENTRE OF GRAVITY

length Yon request

width Z

MAIN CONNECTIONS DN (mm)b

(LP) suction 1 50 65 65 80 100 50 65 65 80

LP dicharge/HP suction 2/3 - 32 32 50 50

(HP) discharge 4 32 50 50 65 80 32 32 32 32

AUXILIARY CONNECTIONS

Temperature 5

1/4” BSP

LP discharge pressure/ temperature 6

HP suction pressure/ temperature 7

HP dicharge pressure/ temperature 8

Crankcase 9

Oil lubrication pressure 10

Oil temperature 11

Oil drain 12

1/2’ BSPOil return oil separator 13

Crankcase heater 14

Oil leakage drain of rotary shaft seal 15 clamp coupling provided width Ø6 x 1.5 mm steel precision tube

Oil control pressure 16 1/2” BSP

Crankcase pressure equalizing 17 1/4” BSP

Oil charge valve 18 1/2’ bsp (TAH 8)

a. Minimum required free spaceb. connection 45 degr. for Grasso 210, 2110 and 310, refer to

COMPRESSOR TYPE Grasso 210 310 410 610 810 2110 3110 4210 6210




4.1.3 SHAFT END COMPRESSOR




4.2 LIMITS OF OPERATION AND FIELDS OF APPLICATION

4.2.1 GENERAL LIMITS AND FIELDS OF OPERATION

When operating the compressor, none of the limits of operation as stated in the table below must be exceeded.1

The diagrams overleaf represent the overall fields of application in which the individual operation limits are taken into account.

Table 4.2-1 General limits and fields of operation

1. In practice, it is not so much the individual operation limits as combinations of them that are decisive for the conditions under which a compressor may operate. To check the various possibilities in this respect, use should be made of the "fields of application" ).

REFRIGERANT NH3 R22 R134a R404A R507

Compressor speed n min-1min. 600

max. 1500

Suction pressure = evaporating pressure =crankcase pressure

a po bar(a)min. 0.3

max. 8.5

Intermediate pressure pm bar(a)min. 0.3

max. 8.5

Evaporating temperature = saturation temperature at suction pressure to °C

min. -55 -63 -50 -68 -68

max. 19 17 33 10 10

Actual suction temperature ta °C min. -50

Discharge pressure = condensing pressure b pc bar(a) max. 26.0

Condensing temperature = saturation temperature at discharge pressure tc °C max. 60 63 110 55 54

Discharge temperature c te °C max. +170

Pressure ratio per stage (pc/po or pc/pm or pm/po) d j -min. 1.5

max. 10

Pressure difference e ∆p bar max. 25.0

Oil temperature in crankcase f toil °C

min. +20 +30

max. depending on type of oil (Required oil viscosity > 10 cSt)

a. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.b. This pressure is also the maximum allowable pre-set value of the HP safety switch. CAUTION!: When adjusting the HP and/or LP safety switch, care

should be taken that the pressure difference ∆p=(PC-po) never exceeds 25.0 bar.c. This is the actual discharge temperature, measured directly in the gas flow just before the discharge connection. The given value also applies to the LP

stage of two-stage compressors.d. Pressure ratio limits are not absolute but arbitrary values based on practical considerations.e. The standard built-in overflow safety valve(s) between suction and discharge side has been factory-set to 26.0 ≤ 1.5 bar to prevent advanced opening

during normal operation at ∆p = (pc - po) ≤25.0 bar.f. Indicated minimum value is the lowest oil temperature at which the compressor is allowed to be started. The maximum oil temperature depends on

the operating conditions of the compressor, the oil type used and (for halocarbon refrigerants only) the solubility of the refrigerant in the oil. A minimum actual oil viscosity of 10 cSt is always required.




4.2.2 FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER

General

Application of part-load operation for a long period of time and/or superheat > 0 K results into higher discharge temperatures. Consequently the fields of application for single-stage and booster compressors will be reduced. So line te-max will shift downwards for NH3.

Symbols used in diagrams

to = evaporating temperaturepo = evaporating pressuretc = condensing temperaturepc = condensing pressure∆to = suction superheatj = pressure ratio = (pc / po)∆p = pressure difference = (pc - po)te,max = maximum discharge temperature↓ = Line shift downwards for ∆to > 0 K and/or part-load operation

Procedure and data

• Diagrams in Section 4.2.2 are based on continuous full-load operaton, suction superheat = 0K.

• For continuous minimum part-load (i.e. more than 30 minutes) consult Grasso.

Fig. 4.2-1 Field of application NH3




Fig. 4.2-2 Field of application R404A/R507

Fig. 4.2-3 Field of application R22

Fig. 4.2-4 Field of application R134a

Table 4.2-2 Fields of Appication

4.2.3 FIELDS OF APPLICATION TWO STAGE

General

The fields of application for two stage compressors are (besides superheat and part-load operation) very dependant on ϕ(ratio LP/HP swept volume; full-load and part-load can have different values). Because each capacity control step can have a different ϕ, it is very important to check for every

Legend

A

These parts of the general fields of application are not covered by the compressor selection software COMSEL.

Please consult Grasso to make a selection for those applications

Po Suction pressure (evaporating)

Pc Discharge pressure (condensing)

j Pressure ratio (Pc/Po)

te,max Max. discharge temperature at full-load and superheat 0K




control step (especially during starting up!) that the compressor will run with-in its limits of operation.

Refer to Starting Up Procedure and Limitations of Partload Operation

Symbols used in diagrams

to = evaporating temperaturepo = evaporating pressuretc = condensing temperaturepc = condensing pressuretm = saturation intermediate temperaturej = pressure ratio = (pc / po, pc / pm or pm / po)∆p = pressure difference = (pc - po)te,max = maximum discharge temperatureteH,max = maximum discharge temperature HPϕ = ratio LP/HP swept volume (full-load and part-load can have different values)↓ = Line shift downwards for ∆to > 0 K and/or part-load operation

Procedure and Data

• Two stage fields of application are not valid for all types of compressors and/or all part-load steps. All compressor types are included within the total field of application.

• Diagrams overleaf are based on LP and HP suction superheat 0K resp. 10K.

For continous part-load (i.e. more than 30 minutes) consult Grasso.

• The Dummy diagram shows field of application for different ϕ's.

• Shaded areas are fields of single-stage operation (used and allowed only during starting up compressor).

• Each ϕ has its own field of application (Example; see dummy diagram ϕ= X area)

• ϕ = 1 is "Fast Pull Down" capacity control step (option), to be used during starting up compressor only. Refer to starting up procedure

Fig. 4.2-5 Dummy diagram

Table 4.2-3 Dummy Diagram; Explanation two stage field of application

Legend

Jmax / te,max

Area on the right side of this line indicates the single stage field of operation (starting up). This line shifts down in case of continuous part-load

operation and/or (intermediate) superheat. Superheat also results in limited part-load

operation.

teH,max* / te,max

Maximum HP-discharge temperature (not applicable for halocarbons). This line shifts down in case of continuous part-load operation and/or (intermediate) superheat. Superheat also results

in limited part-load operation.

ϕEach ϕ (phi) has its own field of appication. The higher this value, the lower possible evaporating temperature. For each capacity control step field of application must be verified in relation with ϕ.

Po,min Minimum suction pressure (evaporating)

tm,max Maximum intermediate pressure.




Fig. 4.2-6 Field of application two-stage NH3

Fig. 4.2-7 Field of application two-stage R404A and R507

Fig. 4.2-8 Field of application two-stage R22

4.2.4 LIMITATIONS OF PART-LOAD OPERATION

General

The Monitron CR will control automatically all full-load and part-load limitations (motor current, optimum ϕ etc.) for booster, single- and two-stage compressors.

Limitations of part-load operation for single-stage compressors

In the case of continuous single-stage part-load operation of Grasso compressors with the refrigerant NH3, not all standard capacity control steps can be used under all operating conditions. There is a limitation with respect to minimum capacity, which, depending on the amount of suction superheat, is determined by the maximum discharge temperature of 170 °C. This means that the full-load field of application as shown in the NH3- diagram, is reduced at top-left for part-load operation in a way as indicated by the arrows in the the relevant diagram.This part-load restriction cannot be eliminated by applying a cooling system on the cylinder head.

When, on the contrary, the refrigerants R134a, R22, R404A and R507 are used for continuous single-stage part-load operation of all standard capacity control steps, the same operating conditions are allowed as for full-load operation with all cylinders energized. In other words, the full-load fields of application, also remain valid for




part-load operation down to and including the standard minimum capacity step.Only under very extreme conditions with respect to ambient temperature (e.g. above approx. +40 °C) and/or suction superheat (e.g. more than approx. 30 K) the situation may occur that during part-load operation the maximum discharge temperature of 170 °C and/or the maximum oil temperature are/is exeeded, which implies that in these cases it is not permitted to switch off cylinders down to the standard minimum capacity.In such a case the oil temperature is the decisive factor, the limitation mentioned before can be avoided by applying an oil cooler. For these special cases, always consult Grasso.

In general the rule is that, irrespective of refrigerant and conditions of operation, it is never allowed to run a compressor during a prolonged period of time fully unloaded, i.e. with all cylinders switched off.

When using a Grasso compressor equipped with a standard capacity control such a situation is impossible because then, apart from the starting period, always one or more cylinders are permanently connected to the control oil pressure.

Limitations of part-load operation for two-stage compressors

From the diagrams, it appears that for two-stage compressors the field of application depends not only on the kind of refrigerant but also on the ratio ϕ of L.P. and H.P. swept volume.This involves (since the standard capacity control steps of the individual two-stage types have not always the same ϕ-value) that for the successive capacity control steps of a certain compressor type different fields of application may be valid. If this is the case, the situation may occur that, when cylinders are switched on or off under constant (design) conditions of operation, the corresponding working point (= combination of condensing temperature tc and evaporating temperature to) lies outside one or more of the relevant fields of application.This implies that it is not allowed to use the part load steps concerned, either on account of too high a H.P. discharge temperature in case of NH3 only (working point lies to the left of the field of

application), or on account of too high a saturation intermediate temperature / intermediate pressure (working point to the right of the field of application). In the case of electrical capacity control, such disallowed part-load steps can easily be avoided in actual practice for once and forever by adapting accordingly the wiring diagram for energizing the three-way solenoid valves.

Should hand-operated capacity control be applied, however, the operator in the engine room has to be well informed about the part-load steps that are not allowed to be used and consequently about the positions of the oil distributor handle that must be avoided. It will be clear that ignorance and/or negligence in this respect may easily lead to failures and/or breakdowns. This is one of the reasons that for two-stage compressors hand-operated capacity control is forbidden.

Apart from the above-mentioned inadmissibility of certain standard part-load control steps, care should always be taken to ensure that the capacity of two-stage compressors is never reduced to such an extent that only H.P. cylinders remain operative.

For then the compressor would operate as a single- stage machine, but under two-stage conditions, which would result, in particular for NH3, in an unacceptably high discharge temperature. This restriction means that the three-way solenoid valves should be wired so that, when the compressor is running under design conditions, at least one solenoid valve remains energized. Here again the undesirability of hand-operated capacity control becomes evident, for it would mean that, as long as the compressor in running, one has to be sure that the handle of the oil distributor is never set to (starting) position 1.




4.2.5 STARTING UP OF TWO-STAGE COMPRESSORS

General

The Monitron CR will control automatically all full-load and part-load limitations (motor current, optimum ϕ etc.) for booster, single- and two-stage compressors.

Procedure for starting from compressor standstill

In the case of two-stage compressors it is very important that immediately after the period of automatic fully unloaded start (ensured by the corresponding three-way solenoid valve in the control pressure supply line from the oil pump; only one or more H.P. cylinders become operative, viz. only those cylinders of which the suction valve lifting mechanism is directly and permanently connected to the control pressure supply of the oil pump via the starting solenoid valve mentioned. This means that during starting none of the three-way solenoid valves for the capacity control are allowed to be energized.

Procedure to move on to two-stage operation and to increase capacity.

Once properly started, as indicated in the previous paragraph, the compressor has to be switched over to two-stage operation with minimum capacity, followed, if and when required, by gradual stepping up to maximum capacity.The procedure thereby to be applied depends on the installation operating conditions during starting which give rise to two distinct possibilities, viz.:

1. The compressor is started at low evaporating temperatures, this being approx. the (design) value during normal (full-load) operation.This situation occurs after the compressor has been stopped for a certain period of time because of low capacity requirements of the installation. Under these circumstances it is permitted to switch over to the two-stage part-load step of minimum capacity immediately after proper starting with H.P. cylinders in operation.In the case of NH3, this is even a necessity, for otherwise the compressor would be running in

single-stage under two-stage conditions, resulting in too high a discharge temperature.

2. The compressor is started at a relatively high evaporating temperature, that is to say much higher than under design conditions and in any case not suitable for two-stage operation.Such a situation may occur after a prolonged period of compressor standstill or when the compressor operates on a batch type freezing tunnel, just loaded with warm products. Under these circumstances it is not permitted to switch over to two-stage operation with minimum capacity until the H.P. cylinders already in operation have lowered (in single-stage) the evaporating temperature to so much that the corresponding working point at the condensing temperature tc, lies inside the field of application of the two-stage minimum part-load step concerned. Only then, after this step has been energized, the saturation intermediate temperature tm will be below its maximum value. Consequently, the maximum value of to at which it is allowed to switch over to two-stage operation, is determined by the intersection of the near-vertical line which represents the right hand limitation of the relevant field of application and the horizontal line which represents the condensing temperature tc.Likewise, during further stepping up to maximum capacity, the evaporating temperature has to be pulled down by each intermediate part-load step so far that the corresponding working point at given condensing temperature lies each time just inside the field of application of the next part-load step of higher capacity, before that step is energized.

Fast pull-down part-load control steps

When using the standard capacity control steps of the two-stage compressor types, the pull-down procedure to achieve full-load operation at design conditions, as described in the previous paragraph, is rather often very time consuming. This is due to the fact that all compressor types are always started with only one HP cylinder in operation and that the minimum LP/HP swept volume ratio for any part-load step is ϕ = 2.Therefore, for all Grasso two-stage types a fast pull- down electric capacity control system has been developed, which allows the compressors to be started with two or more HP cylinders in operation and which includes one or more part-load steps with volume ratio ϕ = 1.




4.3 LUBRICATING OILS (choice and recommendations)

For lubrication of refrigeration compressors, several brands and types of specially developed lubricating oils are on the market. The choice of oil depends not only on its good lubrication properties (viscosity) and chemical stability at the operating conditions of the compressor, but also on the operating conditions of the refrigerating plant (solidifying and floc point, solubility).

Grasso has tested and approved for use in its reciprocating-compressors the brands and types of oil as listed in Table 4.3-2.The choice of the viscosity of the lubricating oil depends on the operating conditions of the compressor.The oil viscosity should always be more than 10 cSt (based on bearing construction requirements of the compressor). For the selection of the oil viscosity grade number, refer to Table 4.3-1 below.A higher viscosity should be chosen, when a high oil temperature is expected, due to arduous operating condition such as:• high evaporating temperature;• large superheat of the refrigerant suction

vapour;• prolonged part-load operation with a large

number of cylinders cut-out;• a high surrounding temperature;• large pressure ratio.

Remark

For the oil types mentioned below, applied with the refrigerants R22, NH3 and R134a, the minimum requirement of the actual oil viscosity of 10 cSt is fulfilled, but only when the maximum oil temperature as mentioned in the Table 4.3-1 below is not exceeded.

Table 4.3-1 Oil selection table

Example: R22, to,max = 0oC): recommended oil type is ISO VG100. NH3 under normal operating conditions, oil type with ISO VG68 is recommended.

Table 4.3-2 Recommended oil types for Grasso reciprocating compressors - NH3

Some of the oil types listed in this table may be marketed under other names and/or designations; these oils can also be used, provided their identity can be proved beyond any doubt. Application of other oils is not permitted without the written consent of Grasso.

Max. allowable evaporating temperature to,max (°C)

Maximum allowable crankcase oil temperaturea

a. Data based on minimum oil viscosity of 10 cSt at the bearing surfaces, which is derived from the oil type, solubility of the regrigerant in the oil (halocarbon refrigerants only) and operating conditions. Assumed is that the oil temperature at the bearing surfaces = 6 K above crankcase oil temperature.

ISO VG-number

46 68 100

Ref

rig

eran

t u

sed

b

b. In case of other refrigerants always contact the oil supplier in advance for advise

NH3 - 73 80c

c. Recommended ISO VG-numbered oil.

88

R22

-64 72 80c 88

-30 69 78c 86

-20 67 76c 84c

-10 65 74c 82c

0 60 71 78c

+10 52 65 74c

R134a, R507, R404A

-50 - 88c 94

-30 - 85c 92

-20 - 83c 91

-10 - 81c 90c

0 - 76 87c

+10 - 68 84c

Refrigerant used Brand Type designation ISO VG

numbera

a. Viscosity grade number designation according to ISO Standard 3448.

NH

3

CPI CP-1009-68b

b. For NH3 only! Strongly recommended for NH3 with discharge temp. > 120 oC

100-68

PETRO CANADAReflo 68ab

68Reflo 68Ab




Table 4.3-3 Accepted oil types for Grasso reciprocating compressors

Some of the oil types listed in this table may be marketed under other names and/or designations; these oils can also be used, provided their identity can be proved beyond any doubt. Application of other oils is not permitted without the written consent of Grasso.

4.4 CAPACITY CONTROL SYSTEMS

4.4.1 SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START

General

Capacity control of the compressor will be enabled by lifting the suction valves, by means of the control oil pressure from the oil pump. One of the options mentioned below is compulsory.

One of the options must be applied;

• Electric (compulsory for two-stage compressors);• Standard (recommended for single-stage and

booster compressors)


numbera

NH

3 an

d R

22

AVIA Avilub FC 46/68 b

BPEnergol LPT-F 46 46

Energol LPT-F 68 68

CASTROL Icematic 299 b

CPI Recommeded! CP-1009-68c b(NH3 only!)

ELF Elfrima FR 68 b

ESSO

Zerice 46 46

Zerice 68 68

Zerice 46 46

Zerice 68 68

FINA Purfrigol MP 68 68

FUCHSKC 46 46

KC 68 68

KROON OIL Carsinus FC 46/68 b

MOBIL Arctic oil 300 b

PETRO CANADA Recommended!

Reflo 68ab

(NH3 only!)Reflo 68Ab

Q 8StravinksyB b

Stravinsky C b

SHELL

Clavus 46 46

Clavus 68 68

Clavus G 46 46

Clavus G 68 68

Clavus G 100 100

SUN-OIL

Suniso 3.5 GS b

Suniso 4 GS b

Suniso 5 GS b

Suniso 4 SA b(NH3 only!)

TEXACO Capella WF 68 68

TOTAL Lunaria S 46/68 b

R13

4a/R

404A

/R50

7

CASTROLIcematic SW 68 68

Icematic SW 100 100

CPISolest 68 b

Solest 120 b

DEA

Triton SE 55 b

Triton SE 80 b

Triton SE 120 b

ELFPlanetelf ACD 68 b

Planetelf ACD 100 b

FINAPurfrigol ST VG 68 b

Purfrigol ST VG 100 b

FUCHSReniso E 68 68

Reniso E 100 100

ICIEmkarte RL 685 b

Emkarte RL 100S b

MOBILEAL Arctic 68 b

EAL Arctic 100 b

SHELLClavus R68 b

Clavus R100 b

SUN-OIL Suniso Excel b

TEXACOCapella HFC 68 68

Capella HFC 100 100

a. Viscosity grade number designation according to ISO Standard 3448.b. Consult your oil supplier to determine the maximum allowable oil

temperature at an oil viscosity of 10 cSt, under prevailing operating conditions and refrigerant used.

c. For NH3 only! Strongly recommended for NH3 with discharge temp. > 120 oC


numbera




• 'Fast pull down' (FPD); obligatory for R404A and R507 applications; recommended for all two-stage compressors

• Manual (Not allowed for two-stage compressors)

In case manual or electric capacity control is applied, fully unloaded starting of the compressor is ensured.

Unloaded start

Fully unloaded compressor starting is enabled by energizing the three-way solenoid valve for unloaded starting, which is an Normally Open valve in contrast with the solenoid valves for capacity control which are Normally Closed.This NO-solenoid valve has to be energized when starting the electric motor and has to be DE-energized by means of the start delta switch of electric motor when electric motor switches from star to delta or by means of an auxiliary time relay.

Time relay and/or star-delta switch are not included (time relay is built-in in Monitron CR).

After fully unloaded compressor starting, this solenoid valve must be DE-engergized allowing control oil pressure to the control pistons of these cylinders and causing these cylinders to become operative automatically.In the case of single-stage compressors, they are at the same time the minimum number of cylinders that must always remain energized during continuous operation.For two-stage compressors only HP cylinders are involved, which, however, do not at the same time represent the minimum capacity.The other cylinders can be energized or de-energized in one or more steps in a standard sequence for each type of compressor.

Summary wiring logic NO-unloaded start solenoid:

• If compessor is NOT running then NO-solenoid is not energized.

• If compressor starts then NO-solenoid is energized until start-delta switch switches from start to delta or by means of an auxiliary time relay.

• If compressor is running then solenoid is NOT energized.




4.4.2 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD)

General

Electric capacity control is compulsory if Monitron CR is applied and is included in the standard scope of supply for two stage compressors.

Procedure and data

• Refer to diagrams and figures below.• The possible control steps and the number of

three-way solenoid valves depends on type of compressor

Standard scope of supply

• One three-way NO-solenoid valve (with LED indicator) for unloaded starting (mounted).

• A number of NC-three-way solenoid valves (each with LED indicator; mounted).

• Oil pressure lines (mounted).

Options (for two-stage compressors only)

• Fast Pull Down control system

FPD is compulsory for R404A and R507.

The standard starting procedure which is contained in the standard electrical capacity control, is only suitable if the compressor is being started at design evaporating temperature.In case the compressor has to start frequently with high evaporating temperatures (batch freezing, etc), fast pull down capacity control is necessary to avoid that the compressor runs continuously in part-load.

Fig. 4.4-1 General diagram of electrically operated capacity control

Table 4.4-1 Solenoid valve/cylinder numbering for capacity control

Legend

A Top view of compressor

B Valve lifting mechanism

C oil return to crankcase

D oil pump

E electrical wiring to start/delta switch of the motor

G three-way solenoid valve for unloaded starting (NO)

H supply of oil pressure

J three-way solenoid valve(s) for capacity control (NC)

NO Normally Open

NC Normally Closed

Co

mp

r. t

ype

Gra

sso

HP

cilin

der

s N

o.

Cylinder number

FPDa (NC)

Sol. valve unloaded starting

(NO)

Sol valve no. 1 (NC)



210 - - 1 2 - -

310 - - 1 3 2 -

410 - - 1 + 2 3 4 -

610 - - 1 + 2 5 3 + 4 6

810 - - 1 + 2 6 3 + 4 5 + 7 +8

2110 1 - 1 2 + 3 - -

2110FPD 1 3 1 2 - -




Table 4.4-2 Capacity control steps

3110 2 - 2 1 + 3 4 -

3110FPD 2 1 2 3 4 -

4210 2-4 - 2 1 + 3 4 + 5 6

4210FPD 2-4 4 2 1 + 3 5 6

6210 2-4 - 2 1 + 6 4 + 5 + 7 + 8 3

6210FPD 2-4 4 2 1 + 6 5 + 7 + 8 3

a. FPD=Fast Pull Down

Co

mp

r. t

ype

Gra

sso

Capacity%a Remarks Cylinders Solenoids ϕb

21050 - 1 - -

100 - 1+2 1 -

310

33 - 1 - -

67 - 1+2 1 -

100 - 1+2+3 1+2 -

410

50 - 1+2 - -

75 - 1+2+4 1 -

100 - 1+2+3+4 1+2 -

610

33 - 1+2 - -

50 - 1+2+5 1 -

67 - 1+2+3+4 2 -

83 - 1+2+3+4+5 1+2 -

100 - 1+2+3+4+5+6 1+2+3 -

810

25 - 1+2 - -

37 - 1+2+6 1 -

50 - 1+2+3+4 2 -

62 - 1+2+3+4+6 1+2 -

75 - 1+2+5+6+7+8 1+3 -

87 - 1+2+3+4+5+7+8 2+3 -

100 - 1+2+3+4+5+6+7+8 1+2+3 -

21100 starting

only 1 - 0.0

100 - 1+2+3 1 2.0

2110+ FPDc

0 starting only 1 - 0.0

50 FPD only 1+3 FPD 1.0

100 - 1+2+3 1+FPD 2.0

Co

mp

r. t

ype

Gra

sso

HP

cilin

der

s N

o.

Cylinder number

FPDa (NC)

Sol. valve unloaded starting

(NO)




3110


67 - 1+2+3 1 2.0

100 - 1+2+3+4 1+2 3.0

3110+ FPD



67 - 1+2+3 1+FPD 2.0

100 - 1+2+3+4 1+2+FPD 3.0

4210


50 - 1+2+3 1 2.0

75 - 1+2+3+6 1+3 3.0

100 - 1+2+3+4 1+2+3 2.0

4210+ FPD


25 FPD onlyd 2+4 FPD 0.0

50 FPD only 1+2+3+4 1+FPD 1.0

50 - 1+2+3 1 2.0

75 FPD only 1+2+3+4+5 1+3+FPD 1.5

75 - 1+2+3+6 1+3 3.0

100 - 1+2+3+4+5+6 1+2+3+FPD 2.0

6210


33 - 1+2+6 1 2.0

50 - 1+2+3+6 1+3 3.0

67 - 2+3+4+5+7+8 2+3 2.0

83 - 1+2+4+5+6+7+8 1+2 2.5

100 - 1+2+3+4+5+6+7+8 1+2+3 3.0

6210+ FPD



33 FPD only 1+2+4+6 1+FPD 1.0

33 - 1+2+6 1 2.0

50 FPD only 1+2+3+4+6 1+3+FPD 1.5

50 - 1+2+3+6 1+3 3.0

67 - 2+3+4+5+7+8 2+3+FPD 2.0

83 - 1+2+4+5+6+7+8 1+2+FPD 2.5

100 - 1+2+3+4+5+6+7+8 1+2+3+FPD 3.0

a. Refers to the swept volume expressed as a percentage of the full-load swept volume for single stage compressors, resp. LP full-load swept volume for two-stage compressors.

b. Number of LP/ Number of HP cylindersc. FPD compressor; incl. Fast Pull Down (optional)d. FPD=Fast Pull Down step only;

Co

mp

r. t

ype

Gra

sso

Capacity%a Remarks Cylinders Solenoids ϕb




4.4.3 MANUAL CAPACITY CONTROL

General

Instead of the recommended electric capacity control in combination with the Monitron CR, a manual operated capacity control system can be delivered for single stage and booster compressors.

Electrical supply still required for three-way solenoid valve(s).

Manual capacity control system is equal to standard electric control system with as extra an electric capacity control switch.

Capacity control steps are equal to electric capacity control.

Procedure and data

• Monitron CR is not applied.


• Standard electric capacity control.• Electric capacity control switch.

Fig. 4.4-2 Diagram of manually operated capacity control system

Legend

A Top view of compressor

B Valve lifting mechanism

C oil return to crankcase

D oil pump

E electrical wiring to start/delta switch of the motor

G three-way solenoid valve for unloaded starting (NO)

H supply of oil pressure

J three-way solenoid valve(s) for capacity control (NC)

NO Normally Open

NC Normally Closed

ES Electric capacity control switch




4.5 PACKAGED BASE FRAME AND FOUNDATION BLOCK

4.5.1 PACKAGED BASE FRAME

General

For mounting on a concrete foundation block, Grasso can supply a standard welded steel base frame to support compressor, motor and accessoiries.Especially for vibration free operation on floors and on roof tops, a base frame with vibration dampers can be delivered (concrete foundation block can be omitted).

A. Base frame for mounting on concrete block

Design Data

• Base frame to be placed on concrete foundation block. For foundation block dimensions consult Grasso.

• There should never be a direct rigid connection whatsoever between the foundation block and the floor or any other main part of the building.

• The concrete block should be extend down to any subsoil.

Scope of supply

• Steel base frame, incl mounting of compressor, electric motor and accessories.

B. Base frame for mounting on vibration dampers

Design Data

• Frame to be placed direct on floors and on roof tops (every structural floor should be designed to take the weight of the packaged unit).

• Concrete foundation block can be omitted.• The first two pipe supports must be secured to a

solid foundation.• Horizontal piping must be arranged parallel to

the crankshaft of the compressor.• Consult always Grasso.

Scope of supply

• Steel closed box profile base frame, including mounting of compressor, electric motor and accessories.

• Set of vibration dampers.

Fig. 4.5-1 Grasso 10 package, direct drive with oil separator




Fig. 4.5-2 Packaged base frame for mounting on vibration dampers for direct drive

Fig. 4.5-3 Packaged base frame for mounting on concrete block for V-belt drive

Approx. dimensions and weightsDirect driven Grasso 10 compressor at NH3

-10/+35, 1475 min-1, incl. oil separator and stop valves

Number of cylinders (kg) L(mm) W(mm) H(mm)

2 1010 1695

940

1020

3 1200 1910 1020

4 1230 1730 1095

6 1630 2095 1130

8 1940 2445 1130

Approx. dimensions and weightsV-belt driven Grasso 10 compressor at NH3

-10/+35, 1475 min-1, incl. oil separator and stop valves

Number of cylinders (kg) L(mm) W(mm) H(mm)

2 1060 1715 1060 1020

3 1250 1715 1180 1020

4 1280 1785 1100 1095

6 1700 1855 1255 1130

8 2020 1855 1530 1130




4.5.2 BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK

For direct driven compressors, a packaged base frame is strongly recommended

Fig. 4.5-4 Foundation top




GeneralIn case a base frame is not applied, a V-belt driven compressor can be mounted direct on a concrete foundation block.

This Data Sheet should not be considered to be a guide to the design and lay-out of the foundation block as such.

This matter requires practical experience and a detailed knowledge of the situation on the spot. Therefore it is strongly recommended to leave the disign and carrying out of foundations entirely to qualified firms, which, at the same time, are prepared to take full responsiblility for the job.

Selection and Data

• Consult grasso to determine dimensions of concrete foundation block

• There should never be a direct rigid connection whatsoever between the foundation block and the floor or any other main part of the building.

• The concrete block should extend down to any subsoil.

• Dimensions in the table below are directly related to the compressor and the drive. Other dimensions are determined by amongst other the electric motor.

4.6 CRANKCASE HEATER

Recommended for all types of refrigerant and all types of compressors.

General

During standstill of the compressor, refrigerant may dissolve in the oil charge of the crankcase or it may even condense, both due to an increase of crankcase pressure, a decrease of crankcase temperature and/or possible temperature differences between crankcase and evaporator.

Excessive foaming of oil in crankcase, can occur when starting the compressor after a long period of standstill with relatively low oil temperature which may result in damaging the compressor by a lack of lubrication.

Low oil temperatures may also cause a high oil viscosity, which may result in troublesome starting.

Selection and Data

• Refer to table.• Engine room temperatures between 15 and

20 °C.• Heater fitted into a sleeve so can be exchanged

while compressor is in operation.• Wiring: If 'compressor NOT running' then

'element is energized'.


• Heater element (mounted).

Table 4.6-1 Crankcase heater

Legend Dimensions in mm

dg Drive guard

FW Fly wheel

MP Motor pulley

CLC Centre line compressor

CLM Centre line motor

fa Foundation anchor (number of foudation anchors for compressor = 4)

fb Foundation block

fc Filling compound

cc Concrete

C-O

Compressor dimension O

Grasso 210/410/3110 555

Grasso 310/610/2110/4210 735

Grasso 810/6210 1085

e2.5 x diameter of foundation anchor (= 50 mm for Grasso10-compressor; only valid when using filling

compound)

h Total height of concrete block (consult Grasso)

Number of compressor

cylinders

Installed power of heater element Dimension L (mm)

2-4 325 380

3-6-8 525 600




Fig. 4.6-1 Crankcase heater

Fig. 4.6-2 Location of crankcase heater sleeve

Legend

CE Cable entry

RC Removable cap to protect connections

M Male



Grasso

Grasso Products B.V. • P.O. Box 343 • 5201 AH ‘s-Hertogenbosch • The NetherlandsPhone: +31 (0)73 - 6203 911 • Fax: +31 (0)73 - 6231 286E-Mail: [email protected] • URL: www.grasso.nlGrasso GmbH Refrigeration Technology • Holzhauser Straße - 165 • 13509 Berlin • GermanyPhone: +49 (0)30 - 43 592 6 • Fax: +49 (0)30 - 43 592 777E-Mail: [email protected] • URL: www.grasso.de

Please contact the technical department of your supplier for extra information.

Language of this document Ref. Nr. Grasso IMM10

English 0089286

German 0089386

French 0089486

Spanish 0089586

Italian 0089686

Dutch 0089186


installation main ten ace manual grasso 10

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