Installation Main Ten Ace Manual Grasso 10

Grasso
Refrigeration Division
Reciprocating Compressors for industrial refrigeration Series Grasso 10

Installation and Maintenance Manual (IMM)
IMM10/v003
Reciprocating Compressors for industrial refrigeration / Series Grasso 10
Page 1
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.
The compressor is not filled with oil.
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. 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.
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.
Page 2
IMM10/v003
Grasso
Table of Contents
Section 1 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.5.1 1.1.5.2 1.1.5.3 1.1.5.3.1 1.1.5.3.2 1.1.5.3.3 1.1.5.3.4 1.1.6 1.1.7 1.1.8 1.1.9 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.5.1 1.2.5.2 1.2.5.3 1.2.6 1.2.7 1.2.8 1.2.9 1.2.9.1 1.2.9.2 1.2.10 1.2.10.1 1.2.10.2 1.2.10.3 1.2.10.4 1.2.10.5 1.2.10.6 2 INSTALLATION AND PREPARATION FOR USE INSTALLATION Moving instructions and storage Storage Hoisting and moving instructions Required free space Foundation requirements Concrete structure Anchoring Concrete block mounting instructions Mounting bare compressor on a concrete block Mounting the base frame on a concrete block Levelling the base frame Finishing with a self-levelling grout (See figure 1.1.5) Connecting to refrigerating system pipework Connecting the power supply Earthing connections Separately delivered components PREPARATIONS FOR USE Leak test of compressor and system EVACUATION/DRYING THE REFRIGERATING SYSTEM Initial oil charge Initial refrigerant charge Adjustment of instruments and safety devices Monitron CR Pressure safety switches Re-adjustment of oil pressure regulator (refer to fig. 1.2.1) Checking direction of rotation of motor shaft Installing the drive guards (if present) Initial oil warm up Initial start-up Limitations of part load operation and start-up of two-stage compressors Pre-start check list Starting and stopping procedures Starting for the very first time (between brackets [ ] are Monitron CR units) Restart (not within 2 minutes after a stop. If Monitron Cr Controlled, refer to the Monitron CR Instruction manual) Starting after a short standstill period of time (less than 1 month) Starting after a seasonal standstill (1 till 6 months) or maintenance operations Starting after a long standstill period of time (more than 6 months) Stopping the compressor INSPECTION, MAINTENANCE AND TROUBLE SHOOTING Title Page 9 11 11 11 11 12 12 12 13 13 14 14 14 14 14 15 15 15 17 17 17 17 18 18 18 18 18 19 19 19 19 19 19 20 20 21 21 21 21 21 23
IMM10/v003
Page 3
Grasso
Section 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.2 2.3 2.4 2.4.1 2.5 2.6 2.7 2.7.1 2.7.2 2.8 2.9 2.10 2.11 3 3.1 4 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.3 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.6 INSPECTION Periodical inspection Survey of periodical inspections ("check list") MAINTENANCE (Contractor's level) Post start-up maintenance First maintenance STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) LUBRICATION DATA Topping up oil with compressor operating EVACUATION OF THE COMPRESSOR DRAINING AND CHANGE OF OIL REPLACEMENT OF OIL FILTERS Oil discharge filter Oil suction filter (pos B in Fig. 1.2-1) REPLACEMENT OF SUCTION GAS FILTER(S)
Title
Page 25 25 25 27 27 27 27 27 27 28 28 28 29 29 29 29 29 31 33 33 35 37 37 38 40 41 41 42 43 45 47 49 50 50 52 54 55 55 57 58
DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES COMPRESSOR PURGING TROUBLESHOOTING TABLE APPENDIX; Parts List Partslist Grasso 10 APPENDIX; Engineering Data GENERAL DATA TECHNICAL DATA MAIN DIMENSIONS AND SPACE REQUIREMENTS SHAFT END COMPRESSOR LIMITS OF OPERATION AND FIELDS OF APPLICATION GENERAL LIMITS AND FIELDS OF OPERATION FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER FIELDS OF APPLICATION TWO STAGE LIMITATIONS OF PART-LOAD OPERATION STARTING UP OF TWO-STAGE COMPRESSORS LUBRICATING OILS (choice and recommendations) CAPACITY CONTROL SYSTEMS SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) MANUAL CAPACITY CONTROL PACKAGED BASE FRAME AND FOUNDATION BLOCK PACKAGED BASE FRAME BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK CRANKCASE HEATER
Page 4
IMM10/v003
Grasso
Preface
This preface gives a survey of the types of documentation and software available for this Grasso compressor series.
3) Grasso CD-ROM Documentation Navigator Contents All Grasso documentation including a user friendly navigation system.
All Grasso documentation and Grasso selection software is available on CD-Roms (Consult Grasso).
With this CD-rom it is possible to re-use all text, graphics, tables, etc. for various purposes (presentations, reports, ...) User group Project engineers, application engineers, sales managers, product managers for both end-users and contractors. Distribution Sales Department of Grasso. 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 Project engineers, application engineers, sales managers, product managers for both end-users and contractors. Distribution Sales Department of Grasso. 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.
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 Sales Department of Grasso.
IMM10/v003
Page 5
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 Service and Parts Department of Grasso. 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'.
Page 6
User group To be used in the field by qualified personnel of refrigeration installers or contractors. Distribution Service and Parts Department of Grasso. 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.
IMM10/v003
Grasso
Main setup data Grasso 10

Descriptiona Start frequency Time interval between stopping and re-starting Time interval between starting and re-starting Time interval between loading and unloading Oil level Min. oil temperature Max. oil temperature [max. Toil] Control oil pressure Lubricating oil pressure difference [min dOil] Max. discharge temperature [max. Tdis] Min. suction pressure [min Psuc] Max. intermediate pressure [max Pint] Max. suction pressure Pdischarge - Psuction Superheat [dTo] Oil suction filter
Table 1 Main setup data Grasso 10

Value max. 6 starts per hour min. 2 minutes min. 10 minutes min. 3 minutes 25-75% crankcase sight glass warmer than surroundings and 20 C for NH3 and 30 C for halocarbons Refer to oil selection table/applied type of oil suction pressure + 7 bar between 1.3 and 3.0 bar Setting approx. 2.0 bar 170 C 0.3 bar 8.5 bar 25.0 bar >0 K for NH3, R22 >15K for R507/R404A/R134a Blue coloured filter element After a mimimum of 15 minutes running time at an oil temperature of approx. 50 oC (122 oF) Required oil viscosity; 10 cSt during operation at location of bearings Remark
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 element
Supplied 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
Release Notes IMM Grasso 10
IMM10/v003
Page 7
Grasso
Table 2 Release Notes IMM Grasso 10

Item 1 2 3 Description Evaluation copy Initial version Translation check by Grasso UK (B.H.) Date 01-Oct-2000 20-Oct-2000 19-Dec-2000 Changed by KK KK KK
Cylinder numbering of Grasso reciprocating compressors
Fig. 1 Cylinder numbering Grasso reciprocating compressors

Legend 1, 2, 3, ... T S O Cylinder numbers Top view of compressor Shaft-end of compressor Oil pump of compressor
Booster or single-stage operation

Booster operation applies if condensing temperature <5 oC. Single stage operation applies if condensing temperarture =>5oC.
Page 8
IMM10/v003
Grasso
1. INSTALLATION AND PREPARATION FOR USE

Table of Contents
Section 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.5.1 1.1.5.2 1.1.5.3 1.1.5.3.1 1.1.5.3.2 1.1.5.3.3 1.1.5.3.4 1.1.6 1.1.7 1.1.8 1.1.9 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.5.1 1.2.5.2 1.2.5.3 1.2.6 1.2.7 1.2.8 1.2.9 1.2.9.1 1.2.9.2 1.2.10 1.2.10.1 1.2.10.2 1.2.10.3 1.2.10.4 1.2.10.5 INSTALLATION Moving instructions and storage Storage Hoisting and moving instructions Required free space Foundation requirements Concrete structure Anchoring Concrete block mounting instructions Mounting bare compressor on a concrete block Mounting the base frame on a concrete block Levelling the base frame Finishing with a self-levelling grout (See figure 1.1.5) Connecting to refrigerating system pipework Connecting the power supply Earthing connections Separately delivered components PREPARATIONS FOR USE Leak test of compressor and system EVACUATION/DRYING THE REFRIGERATING SYSTEM Initial oil charge Initial refrigerant charge Adjustment of instruments and safety devices Monitron CR Pressure safety switches Re-adjustment of oil pressure regulator (refer to fig. 1.2.1) Checking direction of rotation of motor shaft Installing the drive guards (if present) Initial oil warm up Initial start-up Limitations of part load operation and start-up of two-stage compressors Pre-start check list Starting and stopping procedures Starting for the very first time (between brackets [ ] are Monitron CR units) Restart (not within 2 minutes after a stop. If Monitron Cr Controlled, refer to the Monitron CR Instruction manual) Starting after a short standstill period of time (less than 1 month) Starting after a seasonal standstill (1 till 6 months) or maintenance operations Starting after a long standstill period of time (more than 6 months) Title Page 11 11 11 11 12 12 12 13 13 14 14 14 14 14 15 15 15 17 17 17 17 18 18 18 18 18 19 19 19 19 19 19 20 20 21 21 21 21
IMM10/v003
Page 9
Grasso
Section 1.2.10.6 Stopping the compressor
Title
Page 21
Page 10
IMM10/v003
Grasso
1.1 INSTALLATION
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.
The compressor is not charged with oil, therefore, DO NOT start the compressor before it has been installed and prepared according to Grassos 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.
1.1.2
Storage
The 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
Do not forget to fill the oil separator (if present) initially.
Legend C M Compressor Motor
1.1.1
Moving instructions and storage
For 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".
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.
IMM10/v003
Page 11
Grasso
1.1.4
Required free space
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!
For 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 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).
1.1.5
Foundation requirements
This 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. 1.1-2 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.
Fig. 1.1-3 Concrete block

Legend 1 2 3 Cork board Concrete base Basement floor
The concrete block for compressor and motor or compressor package should have a profile as illustrated below and made according to the
Page 12 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003
Grasso
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
Legend A B Chemical anchor Grouted anchor, grounded to reinforcing steel
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

Legend A B 1 2 3 Drilled chemical anchor (M20) Grouted anchor recesses (M20) Installed chemical anchor before placing the base frame Installing chemical anchor after placing the base frame (base frame cannot be removed easily) Drilling angle
1.1.5.3
Concrete block mounting instructions
IMM10/v003
Page 13
Grasso
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
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
Fig. 1.1-5 Grouting details

Legend 1 2 3 4 5 6 Self-levelling grout Adjusting bolts (4x) Washer Temporary barrier strip around and inside frame Complete cured concrete block Grout layer
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.
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.
Page 14
IMM10/v003
Grasso
arc-welding. After all installation functions are completed, reconnect the litz-wires and ground the package to earth. 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").
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) Never connect the oil rectifier return line to the suction line or to the suction gas filter. Mount these separately delivered sets, components and/or parts, according to the instruction as enclosed.
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 supply
Before 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 connections
Grasso 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
1. If the standard recommended Monitron CR is applied.
IMM10/v003
Page 15
Grasso
Page 16
IMM10/v003
Grasso
1.2 PREPARATIONS FOR USE

After the Compressor (Package) has been installed (excluding final connection of drive device), the following actions should be followed in the order given:
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
1.2.1
Leak test of compressor and system

Used or filtered oil should NEVER BE added to a compressor under any circumstance.
The 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.
Use only new oil as selected from the Grasso oil table.
Oil charging via the suction line of the compressor is not allowed.
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.
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.
IMM10/v003
Page 17
Grasso
1.2.5.2
QUANTITY OF OIL TO BE FILLED (IN dm ) Number of cylinders 2 3 4 6 8 Shaft seal housing incl. Oil Oil internal circuit of filters pump crnkshaft 0.6 0.7 0.7 0.8 0.9 1.5 each 0.5
3
Pressure safety switches

Pressure safety limit switches
Crankcase Suction pressure [Psuc] 6.5 9.0 6.5 9 13.5 Lubrication oil pressure difference Setting Suction and intermediate pressure [Pint] Discharge pressure [Pdis] Setting Precondition Setting Precondition Setting Precondition
5oC below design evaporating temp. Min. =0.3 bar(a) Max.= 8.5 bar(a) 5oC above design condensing temp. Max. =26 bar(a) Min. =1.3 bar
Oil pressure regulators
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.
Lubrication oil pressure difference [dOil] Control oil pressure difference
Setting Precondition Setting
2.0 bar Min. =1.3 bar Max. =3.0 bar at 50oC oil temp. Min. =6.9 bar Max. =7.1 bar
1.2.4
Initial refrigerant charge
1.2.5.3
Refrigerant charging should be done in accordance with the plant manual by qualified refrigeration engineers.
1.2.5
Adjustment of instruments and safety devices
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.
1.2.5.1 Monitron CR For adjustments as given overleaf (values between brackets [ ]) refer to the Monitron CR Instruction Manual.
Fig. 1.2-1 Oil pressure regulator

Legend 1 2 A Lubricating oil pressure regulator Control oil pressure regulator Oil suction filter
Legend Oil discharge filter B
REMARK: A running in filter is factory mounted; to

be replaced after max. 100 running hours by permanent oil discharge filter element
Page 18
IMM10/v003
Grasso
Legend Oil charge valve for lubrication circuit. C
startup! Refer to the drive guard installing procedures included in the order documentation.
REMARK: This connection to be used for

pre-lubrication of the oil circuit
Oil charge plug for oil suction filter (Hand operarated oil pump and stop valve are not included) Connection to measure oil control pressure Hand operated oil charge pump (optional).
1.2.8
Initial oil warm up
D E F
Prior 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.
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!
1.2.9
1.2.9.1
Initial start-up
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).
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

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.
IMM10/v003
Page 19
Grasso
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 twostage 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.
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.
1.2.10 Starting and stopping procedures

When 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)
Page 20
IMM10/v003
Grasso
Watch maximum allowable motor current [Imot] (refer to motor type plate).
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.
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)
Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 21
IMM10/v003
Grasso
Page 22
IMM10/v003
Grasso
2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Table of Contents
Section 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.2 2.3 2.4 2.4.1 2.5 2.6 2.7 2.7.1 2.7.2 2.8 2.9 2.10 2.11 INSPECTION Periodical inspection Survey of periodical inspections ("check list") MAINTENANCE (Contractor's level) Post start-up maintenance First maintenance STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) LUBRICATION DATA Topping up oil with compressor operating EVACUATION OF THE COMPRESSOR DRAINING AND CHANGE OF OIL REPLACEMENT OF OIL FILTERS Oil discharge filter Oil suction filter (pos B in Fig. 1.2-1) REPLACEMENT OF SUCTION GAS FILTER(S) DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES COMPRESSOR PURGING TROUBLESHOOTING TABLE Title Page 25 25 25 27 27 27 27 27 27 28 28 28 29 29 29 29 29 31
IMM10/v003
Page 23
Grasso
Page 24
IMM10/v003
Grasso
2.1 INSPECTION
2.1.1 Periodical inspection
These 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.
IMM10/v003
Page 25
Grasso
Table 2.1-1 Survey of periodical inspections ("check list")

CHECK POINTSa daily FREQUENCY monthly weekly REMARKS
CHECK POINTSa daily
FREQUENCY monthly weekly
REMARKS
Oil level in crankcase
Between 25% and 75% height of the sight glass. For topping up oil, refer to Section 2.4.1. The oil should be transparently clear. A disappearing white colour points to dissolved refrigerant. Refer to Section 2.2.2 for oil analysis frequency. The indication of the oil pressure gauge should be 1.3 - 3.0 bar higher than the value shown by the suction pressure gauge. Suction pressure + 7 bar Refer to the "Engineering Data" In case of more than 1 cc/hr contact supplier. Check against design conditions. Refer to plant manual. Refer to plant manual. For the max. allowable discharge pressure refer to the technical data of compressor.
Adjustment and operation of pressure safety switches Capacity control (if provided)
Refer to Section 1.2.5 and to instructions of switch manufacturer. The time lag between the unloading and loading of one cylinder or cylinder group should generally be at least 3 - 5 minutes. 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). Check the number of operating hours in view of any maintenance operations to be carried out.
Colour of the oil
Switching frequency of the compressor
Lubricating oil pressure difference [dOil] Min. control oil pressure Oil temperature max. [Toil] Oil leakage of shaft seal max. Suction pressure [Psuc]
Number of operating hours
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.
Discharge pressure [Pdis] Suction superheat [dTo]Intermed iate superheat [dTm Discharge temperature max.
0K
170 C. During compressor standstill the lower part of the crankcase must remain warmer than the surroundings: 20 C (NH3) and 30 C (halocarbons). 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.
Oil temperature min. [Toil]
Condition of V-belts
Page 26
IMM10/v003
Grasso
2.2 MAINTENANCE (Contractor's level)

2.2.1 Post start-up maintenance
After 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. 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.
2.2.2
First maintenance
For complete service schedules and required service sets refer to Grasso's Service and Maintenance Schedules (SMS).
Maintenance Number of operating hours 100a Renewal of oil discharge filter Renewal of suction gas filter(s) Inspection of oil suction filter Oil analysis
bc
2.4 LUBRICATION DATA

Determine 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.
> 100
X X X X X X refer to Service and Maintenance Schedules (SMS)
Inspection leakage shaft seal Inspection relief valve(s)d
a. Time dependent on pollution. 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. d. If temperature of relief valve is close to (LP/HP) discharged temp, consult your supplier.
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.
IMM10/v003
Page 27
Grasso
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.
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 OIL

To 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

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.
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 coloured Oil discharge - running-in - filter = RED coloured Oil discharge - permanent - filter= grey.
Page 28
IMM10/v003
Grasso
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).
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.
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.
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 PURGING

Procedure 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.
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.
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).
Page 29
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
IMM10/v003
Grasso
Page 30
IMM10/v003
Grasso
2.11 TROUBLESHOOTING TABLE

The 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.
IMM10/v003
Page 31
Grasso
Table 2.11-1 Troubleshooting

FAULT CAUSE REMEDY 1. Discharge stop valve not fully open 1. Open fully A Discharge 2. Discharge pressure 2. Repair or replace pressure too high gauge defective 3. Purge with a Automatic 3. Non-condensables in Purger the system 1. Discharge pressure too high 2. Too many cylinders cut out 3. Suction pressure too low 4. Excessive superheat of suction gas B Discharge 5. For two-stage temperature too compressors: high interstage cooling does not operate properly 6. Room temperature too high 7. Discharge valve defective 8. Pressure relief valve is leaking 1. Capacity control does not operate 2. Compressor capacity too small 3. Suction pressure gauge defective C Suction 4. One or more suction pressure too high valves defective 5. One or more discharge valves defective 6. Pressure relief valve is leaking
FAULT
CAUSE
REMEDY
G Too high oil consumption 1. See A 2. Cut in more cylinders 3. See D 4. Eliminate excessive superheat 5. Repair 6. Ventilate engine room better 7. Repair or renew 8. Repair or renew
1. Type of oil not according to oil lubrication oil table (too thin oil) 2. Compressor operates unloaded too 1. Change oil type frequently 2. Refer to design 3. No return from oil calculations separatora 4. Restriction plug at 3. Check the operation of the bottom of suction float valve in oil separator 4. Clean plug chamber in cylinder 5. Replace ring(s) clogged 6. Repair 5. Worn out oil scraper 7. Repair shaft seal ring(s) Refer to Section 2.2 6. Loss of oil due to 8. leakage 9. 7. Leaking shaft seal (max. 1 cc/hr) 8. Oil level in crankcase too high 9. Oil separator is not initially filled with oil
1. Repair 2. Refer to plant design 3. Repair or renew 4. Renew suction valve rings 5. Repair or renew 6. Repair or renew
1. Lubricating oil H Too high oil pressure regulator not pressure during adjusted properly or normal defective operation at 2. Defective oil working pressure and/or temperature suction pressure gauge (if present)
1. Re-adjust or renew 2. Repair or replace
1. Suction stop valve not fully open 2. Suction gas strainer 1. Open fully blocked 2. Clean D Suction 3. Injection control not 3. Re-adjust control pressure too low adjusted correctly 4. Top-up with refrigerant 4. Too little refrigerant 5. Renew in installation 5. Suction pressure gauge defective E Crankcase frosted or wet 1. Liquid refrigerant in crankcase due to: 1a. Provide for crankcase 1a. Room temperature heating or, if provided, too low check it for proper 1b. Oil return from operation separator contains 1b. Consult plant manual liquid refrigerant 1c. Re-adjust installation 1c. Installation and provide for superheat operates too wet 1d. Consult plant manual 1d. Liquid separator too small
J Too low lubricating oil pressure
1. Too little oil in crankcase 2. Disturbed oil circuit: Oil suction and/or 1. Top up oil discharge filter is dirty 2. Renew the element of oil 3. Lubricating oil suction filter and/or oil pressure regulator not discharge filter adjusted properly or 3. Re-adjust or renew defective 4. See E 4. Liquid refrigerant in 5. Repair or renew crankcase 6. Renew bearings 5. Defective oil pressure and/or suction pressure gauge (if present) 6. Worn bearings 1. Failure of control oil pressure regulator in oil pump 2. A lack of oil in oil system 3. Oil pump defect 1. Re-adjust or renew regulator 2. Add oil to the system 3. Repair or renew oil pump
K Too low or no control oil pressure
a. During the initial start-up, the oil separator (if present) consumes oil before the first oil will be returned.
Stop compressor and contact installation engineer

F All cylinders inactive while compressor is operating
1. Oil pressure for valve lifting mechanism too low 2. Incorrect wiring of capacity control
1. See J 2. Refer to the "Engineering Data
Page 32
IMM10/v003
3. APPENDIX; Parts List
Grasso

Table of Contents
Section 3.1 Partslist Grasso 10 Title Page 33
3.1 Partslist Grasso 10

Data not yet released. Partslist Grasso 10 is under construction
IMM10/v003
Page 33
Grasso
Page 34
IMM10/v003
4. APPENDIX; Engineering Data
Grasso

Table of Contents
Section 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.3 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.6 GENERAL DATA TECHNICAL DATA MAIN DIMENSIONS AND SPACE REQUIREMENTS SHAFT END COMPRESSOR LIMITS OF OPERATION AND FIELDS OF APPLICATION GENERAL LIMITS AND FIELDS OF OPERATION FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER FIELDS OF APPLICATION TWO STAGE LIMITATIONS OF PART-LOAD OPERATION STARTING UP OF TWO-STAGE COMPRESSORS LUBRICATING OILS (choice and recommendations) CAPACITY CONTROL SYSTEMS SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) MANUAL CAPACITY CONTROL PACKAGED BASE FRAME AND FOUNDATION BLOCK PACKAGED BASE FRAME BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK CRANKCASE HEATER Title Page 37 37 38 40 41 41 42 43 45 47 49 50 50 52 54 55 55 57 58
IMM10/v003
Page 35
Grasso
Page 36
IMM10/v003
Grasso
4.1 GENERAL DATA

4.1.1 TECHNICAL DATA
Table 4.1-1 Technical Data of Grasso 10 compressors

COMPRESSOR TYPE Grasso 210 Number of cylinders Cylinder arrangement Cylinder bore Piston stroke Swept volume at full-load and: n=1500 min-1 D S Vs mm mm m3/h 145 217 290 435 zL zH 1xL 1xL 2xV 2xV 4xV 110 85 580 145 217 290 435 2 310 3 Single-stage 410 4 610 6 810 8 1 1xL 1 2xV 2 2xV 2 4xV 2110 2 Two-stage 3110 3 4210 4 6210 6
Standard direction of rotation Standard compressor speeds (with V-belt drive) at motor speed: 1475 min-1 (50 Hz) 1775 min-1 (60 Hz) manual and electric control: % incl. Fast Pull Down(FPD)a n n min-1 min-1
counter-clockwise when facing shaft end 1475-1328-1180-1047-929-826-738-661-625 1416-1257-1115-991-885-793-750-708-637 100-8367-50 -33 100-8775-6250-3725 100-8367-5033 100-836750(1.5)50(3.0)33(1.0)33(2.0) 998 1048 1.1 16.5 0.1673
100-50
Standard steps of capacity control (expressed in % of full-load swept volume):
100-6733
100-7550
100
100-67
100-7550 10075(1.5)75(3.0)50(1.0)50(2.0)25 730 780 0.8 12 0.1491
100-50
100-67 33
Mass of bare compressor (without flywheel and other accessories) Shipping mass (approx.) Shipping volume Oil charge in crankcase and oil circuit (centre line of sight glass) Mass moment of inertia of crank mechanism (without flywheel)
a. Volume ratio between brackets
kg kg m
3
510 560 0.3 9.5 0.0776
585 635 0.4 12 0.1491
610 660 0.7 9.5 0.0776
725 775 0.8 12 0.1491
990 1040 1.1 16.5 0.1673
590 640 0.4 12 0.1491
615 665 0.7 9.5 0.0776
dm3 Id kg.m2
IMM10/v003
Page 37
Grasso
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

410 925 888 815 782 787 301 0 77 610 1105 888 815 777 824 372 0 100 810 1455 888 815 782 824 821 0 98 2110 1105 536 765 577 685 513 709 516 519 152 30 152 70 3110 925 888 815 782 709 595 709 315 315 152 38 152 77 4210 1105 888 815 782 722 600 709 345 481 134 68 152 77 6210 1455 888 815 777 722 600 709 735 845 134 68 152 98
COMPRESSOR TYPE Grasso Length Width High A B C D E F G H J K L M N
210 925 536 765 579 343 152 68
310 1105 536 765 579 516 402 134 68
Page 38
IMM10/v003
Grasso
COMPRESSOR TYPE Grasso O R S
210 555 240 211
310 735 240 211
410 555 240 0
610 735 240 0
810 1085 240 0
2110 735 240 210
3110 555 240 0
4210 735 240 0
6210 1085 240 0
MINIMUM REQUIRED FREE SPACE for removal of: T flywheel

a
335 750 1000 300
355 925 1000 300
335 750 790 530
335 925 790 530
335 1270 790 530
519 335 925 1000 300
326 335 750 790 530
470 335 925 790 530
860 335 1270 790 530
U V
a
crankshafta piston and cylinder liner
W X
LOCATION OF CENTRE OF GRAVITY length width Y Z MAIN CONNECTIONS DN (mm)b (LP) suction LP dicharge/HP suction (HP) discharge 1 2/3 4 32 50 50 65 65 50 65 80 80 100 50 32 32 65 32 32 65 50 32 80 50 32 on request
AUXILIARY CONNECTIONS Temperature LP discharge pressure/ temperature HP suction pressure/ temperature HP dicharge pressure/ temperature Crankcase Oil lubrication pressure Oil temperature Oil drain Oil return oil separator Crankcase heater Oil leakage drain of rotary shaft seal Oil control pressure Crankcase pressure equalizing Oil charge valve 5 6 7 1/4 BSP 8 9 10 11 12 13 14 15 16 17 18 clamp coupling provided width 6 x 1.5 mm steel precision tube 1/2 BSP 1/4 BSP 1/2 bsp (TAH 8) 1/2 BSP
a. Minimum required free space b. connection 45 degr. for Grasso 210, 2110 and 310, refer to
IMM10/v003
Page 39
Grasso
4.1.3
SHAFT END COMPRESSOR
Page 40
IMM10/v003
Grasso
4.2 LIMITS OF OPERATION AND FIELDS OF APPLICATION

4.2.1 GENERAL LIMITS AND FIELDS OF OPERATION
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" ).
When operating the compressor, none of the limits of operation as stated in the table below must be exceeded.1
REFRIGERANT Compressor speed Suction pressure = evaporating pressure =crankcase pressure Intermediate pressure Evaporating temperature = saturation temperature at suction pressure Actual suction temperature Discharge pressure = condensing pressure Condensing temperature = saturation temperature at discharge pressure Discharge temperature Pressure ratio per stage (pc/po or pc/pm or pm/po) Pressure difference Oil temperature in crankcase
c b
NH3 n min-1 min. max.

a
R22
R134a 600 1500 0.3 8.5 0.3 8.5
R404A
R507
min. po bar(a) max. min. max. min. to ta pc tc te j p toil C max. C bar(a) C C bar C max. min. max. max. max. min. max. max. min. +20 60 63 19 17 -55 -63
pm
bar(a)
-50 33 -50 26.0 110 +170 1.5 10 25.0 +30
-68 10
-68 10
55
54
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.
IMM10/v003
Page 41
Grasso
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 temperature po = evaporating pressure tc = condensing temperature pc = condensing pressure to = suction superheat j = 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
Page 42
IMM10/v003
Grasso
Fig. 4.2-2 Field of application R404A/R507
Fig. 4.2-4 Field of application R134a
Table 4.2-2 Fields of Appication

Legend A Po Pc j te,max 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 Suction pressure (evaporating) Discharge pressure (condensing) Pressure ratio (Pc/Po) Max. discharge temperature at full-load and superheat 0K
4.2.3
FIELDS OF APPLICATION TWO STAGE
Fig. 4.2-3 Field of application R22
General The fields of application for two stage compressors are (besides superheat and part-load operation) very dependant on (ratio LP/HP swept volume; full-load and part-load can have different values). Because each capacity control step can have a different , it is very important to check for every
IMM10/v003
Page 43
Grasso
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 temperature po = evaporating pressure tc = condensing temperature pc = condensing pressure tm = saturation intermediate temperature j = pressure ratio = (pc / po, pc / pm or pm / po) p = pressure difference = (pc - po) te,max = maximum discharge temperature teH,max = maximum discharge temperature HP = 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.
Fig. 4.2-5 Dummy diagram
Table 4.2-3 Dummy Diagram; Explanation two stage field of application

Legend 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.
Jmax / te,max
Maximum HP-discharge temperature (not applicable for halocarbons). This line shifts down teH,max* / te,max in case of continuous part-load operation and/or (intermediate) superheat. Superheat also results in limited part-load operation. Po,min Each (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 . Minimum suction pressure (evaporating) Maximum intermediate pressure.
For continous part-load (i.e. more than 30 minutes) consult Grasso. The Dummy diagram shows field of application for different 's. Shaded areas are fields of single-stage operation (used and allowed only during starting up compressor). Each has its own field of application (Example; see dummy diagram = X area) = 1 is "Fast Pull Down" capacity control step (option), to be used during starting up compressor only. Refer to starting up procedure
tm,max
Page 44
IMM10/v003
Grasso
Fig. 4.2-6 Field of application two-stage NH3
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 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
IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 45
Fig. 4.2-7 Field of application two-stage R404A and R507
Grasso
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.
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.
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 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 -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
Page 46
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 singlestage 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.
IMM10/v003
Grasso
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 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 = 2. Therefore, for all Grasso two-stage types a fast pulldown 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 = 1.
Page 47
IMM10/v003
Grasso
Page 48
IMM10/v003
Grasso
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

Max. allowable evaporating temperature to,max (C) NH3 -64 -30 -20 R22 Refrigerant usedb -10 0 +10 -50 -30 R134a, R507, R404A -20 -10 0 +10 Maximum allowable crankcase oil temperaturea ISO VG-number 46 73 72 69 67 65 60 52 68 80c 80c 78
c
100 88 88 86 84c 82c 78c 74c 94 92 91 90c 87c 84c
76c 74c 71 65 88c 85 83

c c
81c 76 68
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. b. In case of other refrigerants always contact the oil supplier in advance for advise c. Recommended ISO VG-numbered oil.
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
Refrigerant used NH3 Brand CPI PETRO CANADA Type designation CP-1009-68b Reflo 68ab 68 ISO VG numbera 100-68
Reflo 68Ab
a. Viscosity grade number designation according to ISO Standard 3448. b. For NH3 only! Strongly recommended for NH3 with discharge temp. > 120 oC
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.
IMM10/v003
Page 49
Grasso
Table 4.3-3 Accepted oil types for Grasso reciprocating compressors

Refrigerant used Brand AVIA BP Energol LPT-F 68 CASTROL CPI Recommeded! ELF Icematic 299 CP-1009-68c Elfrima FR 68 Zerice 46 Zerice 68 ESSO Zerice 46 Zerice 68 FINA FUCHS KC 68 KROON OIL MOBIL PETRO CANADA Recommended! Q8 Stravinsky C Clavus 46 Clavus 68 SHELL Clavus G 46 Clavus G 68 Clavus G 100 Suniso 3.5 GS Suniso 4 GS SUN-OIL Suniso 5 GS Suniso 4 SA TEXACO TOTAL Capella WF 68 Lunaria S 46/68
b b
Refrigerant used
Brand CASTROL
Type designation Icematic SW 68 Icematic SW 100 Solest 68 Solest 120 Triton SE 55
ISO VG numbera 68 100

b b b b b b b b b
Type designation Avilub FC 46/68 Energol LPT-F 46
ISO VG numbera
b
CPI 46 68
b
DEA
Triton SE 80 Triton SE 120 Planetelf ACD 68
(NH3 only!)
b
ELF R134a/R404A/R507 Planetelf ACD 100 Purfrigol ST VG 68 FINA Purfrigol ST VG 100 Reniso E 68 Reniso E 100 Emkarte RL 685 ICI Emkarte RL 100S EAL Arctic 68 MOBIL EAL Arctic 100 Clavus R68 Clavus R100 SUN-OIL TEXACO Suniso Excel Capella HFC 68 Capella HFC 100
46 68 46 68 68 46 68
b b
FUCHS
68 100
b b b b b b b
Purfrigol MP 68 KC 46
NH3 and R22
Carsinus FC 46/68 Arctic oil 300 Reflo 68ab Reflo 68Ab StravinksyB
SHELL (NH3 only!)

b b
68 100
46 68 46 68 100
b b b
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
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
(NH3 only!) 68
b
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)
Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003
Page 50
Grasso
'Fast pull down' (FPD); obligatory for R404A and R507 applications; recommended for all two-stage compressors Manual (Not allowed for two-stage compressors)
If compressor is running then solenoid is NOT energized.
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.
IMM10/v003
Page 51
Grasso
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
Fig. 4.4-1 General diagram of electrically operated capacity control

Legend A B C D Top view of compressor Valve lifting mechanism oil return to crankcase oil pump electrical wiring to start/delta switch of the motor three-way solenoid valve for unloaded starting (NO) supply of oil pressure three-way solenoid valve(s) for capacity control (NC) Normally Open Normally Closed
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.
E G H J NO NC
Table 4.4-1 Solenoid valve/cylinder numbering for capacity control

HP cilinders No. Compr. type Grasso Cylinder number FPDa (NC) 3 Sol. valve unloaded Sol valve Sol valve Sol valve no. 1 no. 2 no. 3 starting (NC) (NC) (NC) (NO) 1 1 1+2 1+2 1+2 1 1 2 3 3 5 6 2+3 2 2 4 3+4 3+4 6 5 + 7 +8 -
210 310 410 610 810 2110 2110FPD
1 1
Page 52
IMM10/v003
Grasso
HP cilinders No.
Compr. type Grasso
Cylinder number FPD (NC) 1 4 4

a
Compr. type Grasso
Sol. valve Sol valve Sol valve Sol valve unloaded no. 1 no. 2 no. 3 starting (NC) (NC) (NC) (NO) 2 2 2 2 2 2 1+3 3 1+3 1+3 1+6 1+6 4 4 4+5 5 4+5+7 +8 5+7+8 6 6 3 3
Capacity %a
Remarks
Cylinders
Solenoids
0 3110 67 100 0 3110+ FPD 33 67 100 0
3110 3110FPD 4210 4210FPD 6210 6210FPD
2 2 2-4 2-4 2-4 2-4
starting only starting only FPD only starting only starting only FPD onlyd FPD only FPD only starting only starting only FPD only FPD only FPD only -
2 1+2+3 1+2+3+4 2 1+2 1+2+3 1+2+3+4 2 1+2+3 1+2+3+6 1+2+3+4 2 2+4 1+2+3+4 1+2+3 1+2+3+4+5 1+2+3+6 1+2+3+4+5+6 2 1+2+6 1+2+3+6 2+3+4+5+7+8 1+2+4+5+6+7+8 1+2+3+4+5+6+7+8 2 2+4 1+2+4+6 1+2+6 1+2+3+4+6 1+2+3+6 2+3+4+5+7+8 1+2+4+5+6+7+8
1 1+2 FPD 1+FPD 1+2+FPD 1 1+3 1+2+3 FPD 1+FPD 1 1+3+FPD 1+3
0.0 2.0 3.0 0.0 1.0 2.0 3.0 0.0 2.0 3.0 2.0 0.0 0.0 1.0 2.0 1.5 3.0
a. FPD=Fast Pull Down
Table 4.4-2 Capacity control steps

Compr. type Grasso 4210 Capacity %a Remarks Cylinders Solenoids b 50 75 100 0 50 210 100 33 310 67 100 50 410 75 100 33 50 610 67 83 100 25 37 50 810 62 75 87 100 0 2110 100 0 2110+ FPDc 50 100 starting only starting only FPD only 1+2 1 1+2 1+2+3 1+2 1+2+4 1+2+3+4 1+2 1+2+5 1+2+3+4 1+2+3+4+5 1+2+3+4+5+6 1+2 1+2+6 1+2+3+4 1+2+3+4+6 1+2+5+6+7+8 1+2+3+4+5+7+8 1+2+3+4+5+6+7+8 1 1+2+3 1 1+3 1+2+3 1 1 1+2 1 1+2 1 2 1+2 1+2+3 1 2 1+2 1+3 2+3 1+2+3 1 FPD 1+FPD 0.0 2.0 0.0 1.0 2.0 6210+ FPD 0 33 33 50 50 67 83 100 6210 0 33 50 67 83 100 0 4210+ FPD 1 25 50 50 75 75 100
1+2+3+FPD 2.0 1 1+3 2+3 1+2 1+2+3 FPD 1+FPD 1 1+3+FPD 1+3 2+3+FPD 1+2+FPD 0.0 2.0 3.0 2.0 2.5 3.0 0.0 0.0 1.0 2.0 1.5 3.0 2.0 2.5
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 cylinders c. FPD compressor; incl. Fast Pull Down (optional) d. FPD=Fast Pull Down step only;
IMM10/v003
Page 53
Grasso
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.
Fig. 4.4-2 Diagram of manually operated capacity control system

Legend
Procedure and data Monitron CR is not applied. Standard scope of supply Standard electric capacity control. Electric capacity control switch.
A B C D E G H J NO NC ES
Top view of compressor Valve lifting mechanism oil return to crankcase oil pump electrical wiring to start/delta switch of the motor three-way solenoid valve for unloaded starting (NO) supply of oil pressure three-way solenoid valve(s) for capacity control (NC) Normally Open Normally Closed Electric capacity control switch
Page 54
IMM10/v003
Grasso
4.5 PACKAGED BASE FRAME AND FOUNDATION BLOCK

4.5.1 PACKAGED BASE FRAME
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.
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.
Fig. 4.5-1 Grasso 10 package, direct drive with oil separator
IMM10/v003
Page 55
Grasso
Fig. 4.5-2 Packaged base frame for mounting on vibration dampers for direct drive
Approx. dimensions and weights Direct driven Grasso 10 compressor at NH3 -10/+35, 1475 min-1, incl. oil separator and stop valves Number of cylinders 2 3 4 6 8 (kg) 1010 1200 1230 1630 1940 L(mm) 1695 1910 1730 2095 2445 940 W(mm) H(mm) 1020 1020 1095 1130 1130
Fig. 4.5-3 Packaged base frame for mounting on concrete block for V-belt drive
Approx. dimensions and weights V-belt driven Grasso 10 compressor at NH3 -10/+35, 1475 min-1, incl. oil separator and stop valves Number of cylinders 2 3 4 6 8 (kg) 1060 1250 1280 1700 2020 L(mm) 1715 1715 1785 1855 1855 W(mm) 1060 1180 1100 1255 1530 H(mm) 1020 1020 1095 1130 1130
Page 56
IMM10/v003
Grasso
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
IMM10/v003
Page 57
Grasso
4.6 CRANKCASE HEATER

Legend dg FW MP CLC CLM fa fb fc cc Dimensions in mm Drive guard Fly wheel Motor pulley Centre line compressor Centre line motor Foundation anchor (number of foudation anchors for compressor = 4) Foundation block Filling compound Concrete Compressor dimension O Grasso 210/410/3110 C-O Grasso 310/610/2110/4210 Grasso 810/6210 e h 555 735 1085
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'. Standard scope of supply Heater element (mounted). Table 4.6-1 Crankcase heater
Number of compressor cylinders 2-4 3-6-8 Installed power of heater element 325 525 Dimension L (mm) 380 600
2.5 x diameter of foundation anchor (= 50 mm for Grasso10-compressor; only valid when using filling compound) Total height of concrete block (consult Grasso)
General In 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.
Page 58
IMM10/v003
Grasso
Fig. 4.6-1 Crankcase heater

Legend CE RC M Cable entry Removable cap to protect connections Male
Fig. 4.6-2 Location of crankcase heater sleeve
IMM10/v003
Page 59
Grasso
Language of this document English German French Spanish Italian Dutch
Ref. Nr. Grasso IMM10 0089286 0089386 0089486 0089586 0089686 0089186
Grasso Products B.V. P.O. Box 343 5201 AH s-Hertogenbosch The Netherlands Phone: +31 (0)73 - 6203 911 Fax: +31 (0)73 - 6231 286 E-Mail: products@grasso.nl URL: www.grasso.nl Grasso GmbH Refrigeration Technology Holzhauser Strae 165 13509 Berlin Germany Phone: +49 (0)30 - 43 592 6 Fax: +49 (0)30 - 43 592 777 E-Mail: info@grasso.de URL: www.grasso.de
Please contact the technical department of your supplier for extra information.
Page 60
IMM10/v003

Installation Main Ten Ace Manual Grasso 10

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Installation Main Ten Ace Manual Grasso 10

Uploaded by

Copyright:

Available Formats

Grasso

Reciprocating Compressors for industrial refrigeration Series Grasso 10

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

The compressor is not filled with oil.

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

Indicates a WARNING. READ IT CAREFULLY!

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

Main setup data Grasso 10

Table 1 Main setup data Grasso 10

Oil discharge - running in - filter

Red coloured filter element

Oil discharge - permanent - filter

Grey filter element

Supplied loose; replacement for factory mounted running in filter

Release Notes IMM Grasso 10

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

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

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

1. INSTALLATION AND PREPARATION FOR USE

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

Section 1.2.10.6 Stopping the compressor

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

Hoisting and moving instructions

Fig. 1.1-1 Hoisting a compressor package

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

Legend C M Compressor Motor

Moving instructions and storage

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

Required free space

Fig. 1.1-2 Hoisting angle

Fig. 1.1-3 Concrete block

1. INSTALLATION AND PREPARATION FOR USE

Fig. 1.1-4 Anchoring details

Concrete block mounting instructions

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

Connecting to refrigerating system pipework

Fig. 1.1-5 Grouting details

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

Separately delivered components

DO NOT ground through the compressor when arc welding

Connecting the power supply

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE

1.2 PREPARATIONS FOR USE

Initial oil charge

Leak test of compressor and system

EVACUATION/DRYING THE REFRIGERATING SYSTEM

Reciprocating Compressors for industrial refrigeration / Series Grasso 10

1. INSTALLATION AND PREPARATION FOR USE