• Author / Uploaded
• Сергей Конкин

Citation preview

Reciprocating Compressors for industrial refrigeration Series Grasso 12E Installation and Maintenance Manual (IMM) ca0132_0089282_imm_rc12e_v008_gbr

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 1-

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

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

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

The compressor is not filled with oil.

After the successful initial run of the compressor (package) the warranty chart must be filled in and returned to Grasso. A warranty chart is attached to each compressor. Open compressor series and (semi) hermetic compressor series; This manual includes procedures and checks for open compressors and (semi) hermetic compressors. a. Open compressor series are Grasso 12E, Grasso 12, Grasso 6, Grasso 5HP and Grasso 10. b. Semi hermetic compressor series are Grasso 7S and Grasso 8S.

Safety This manual is written with great care, but the contractor/installer is held responsible to examine this information and to take care of possible additional and/ or deviated safety measures. Safety instructions It is the task of the contractor/installer to inform and explain to his client the operation of the compressor (Package). Do respect all federal, state or local safety regulations/legislations during installing, connecting and operating this compressor (package). Construction changes In compliance with the regulations of the Pressure Equipment Directive it is mandatory that no changes be made to the construction of pressurised parts such as the crankcase housing, suction filter housing etc. 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.

- 2-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

Table of Contents Section

Title

Page

1

INSTALLATION AND PREPARATION FOR USE

11

1.1

INSTALLATION

13

1.1.1

Moving instructions and storage

13

1.1.2

Storage

13

1.1.3

Hoisting and moving instructions

13

1.1.4

Required free space

14

1.1.5

Foundation requirements

14

1.1.5.1

Concrete structure

14

1.1.5.2

Anchoring

15

1.1.5.3

Mounting the base frame on a concrete block

15

1.1.5.3.1

Levelling the base frame

16

1.1.5.3.2

Finishing with a self-levelling grout

16

1.1.5.4

Mounting bare compressor on a concrete block

16

1.1.6

Connecting to refrigerating system pipework

16

1.1.7

Connecting the power supply

16

1.1.8

Earthing connections

16

1.1.9

Separately delivered components

17

1.2

PREPARATIONS FOR USE

19

1.2.1

Leak test of compressor and system

19

1.2.2

EVACUATION/DRYING THE REFRIGERATING SYSTEM

19

1.2.3

Initial oil charge

19

1.2.3.1

Initial oil charge

19

1.2.4

Initial refrigerant charge

19

1.2.5

Adjustment of instruments and safety devices

19

1.2.5.1

Monitron CR and GSC

19

1.2.5.2

Refrigerants R717 and halocarbons

19

1.2.5.3

Re-adjustment of oil pressure regulator

20

1.2.6

Checking direction of rotation of motor shaft

20

1.2.7

Installing the drive guards (if present)

20

1.2.8

Initial oil warm up

21

1.2.9

Initial start-up

21

1.2.9.1

Limitations of part load operation and start-up

21

1.2.9.2

Wiring logic NO unloaded start solenoid

21

1.2.9.3

Frequency controlled compressor

21

1.2.9.4

Pre-start check list

21

1.2.10

Starting and stopping procedures

21

1.2.10.1

First start

21

1.2.10.2

Restart

22

1.2.10.3

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

22

1.2.10.4

Restart after a long standstill period of time

22

1.2.10.5

Stopping the compressor

22

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 3-

Section

Title

Page

2

INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

23

2.1

INSPECTION

25

2.1.1

Periodical inspection

25

2.1.2

Survey of periodical inspections

25

2.1.2.1

Check list periodical inspection

26

2.2

MAINTENANCE (REFER Chapter 5)

27

2.2.1

Post start-up maintenance

27

2.2.2

First maintenance

27

2.3

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

27

2.4

LUBRICATION DATA

27

2.4.1

Topping up oil with compressor operating

27

2.5

EVACUATION OF THE COMPRESSOR

27

2.6

DRAINING AND CHANGE OF OIL

28

2.6.1

DRAINING OIL REVERVOIR FOR MARINE USE (Optional)

28

2.7

REPLACEMENT OF OIL FILTERS

28

2.7.1

Oil discharge filter

28

2.7.2

Oil suction filter (Pos. B)

28

2.8

REPLACEMENT OF SUCTION GAS FILTER(S)

28

2.9

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

28

2.10

COMPRESSOR PURGING

28

2.11

TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS

29

3

PARTS COMPRESSOR

33

4

SUPPLEMENTARY PARTS

73

5

MAINTENANCE

81

5.1

SMS FACTOR

81

5.2

Grasso 12E

83

5.3

Checklist

85

6

APPENDIX; Product Information (PI)

87

6.1

GENERAL DATA

89

6.1.1

TECHNICAL DATA

89

6.1.2

MAIN DIMENSIONS AND SPACE REQUIREMENTS

91

6.1.3

SHAFT END COMPRESSOR

93

6.2

Electrical wiring schematic oil differential pressostat (RT260A)

95

6.2.1

Method A, two timers, recommended

95

6.2.2

Method B, one timer (method A is recommended)

96

6.3

LIMITS OF OPERATION AND FIELDS OF APPLICATION

97

6.3.1

GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 12E

97

6.3.2

PRECISE FIELD OF APPLICATION

98

6.3.3

FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER

99

6.3.3.1

DIAGRAMS Grasso 12E

100

6.3.4

FIELDS OF APPLICATION TWO STAGE

102

6.3.4.1

FIELDS OF APPLICATION DIAGRAMS

102

6.3.5

LIMITATIONS OF PART-LOAD OPERATION

104

- 4-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

Section

Title

Page

6.3.6

STARTING UP OF TWO-STAGE COMPRESSORS

104

6.4

LUBRICATING OILS (choice and recommendations)

107

6.4.1

Oil selection table

107

6.4.1.1

Remarks

107

6.4.2

Strongly recommended oil types for Grasso reciprocating compressors

107

6.4.3

Accepted NH3 and HCFC oil types for Grasso reciprocating compressorss

108

6.4.4

Accepted HCFC oil types for Grasso reciprocating compressors

108

6.5

CAPACITY CONTROL SYSTEMS

108

6.5.1

SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START

108

6.5.2

ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD)

110

6.5.2.1

GENERAL DIAGRAM OF ELECTRICALLY OPERATED CAPACITY CONTROL

110

6.5.2.2

DIAGRAMS

111

6.5.3

MANUAL CAPACITY CONTROL

115

6.6

PACKAGED BASE FRAME AND FOUNDATION BLOCK

117

6.6.1

PACKAGED BASE FRAME

117

6.6.1.1

PACKAGED BASE FRAME

117

6.6.2

BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK

119

6.6.2.1

FOUNDATION BLOCK

120

6.7

CRANKCASE HEATER

120

6.7.1

HEATER FITTING DETAIL

121

7

NOTES

123

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 5-

- 6-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

Preface

4) Installation and maintenance manual (IMM)

This preface gives a survey of the types of documentation available for reciprocating Grasso compressor series.

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

All documentation and selection software is on-line available on www.grasso-global.com 1) Product Information (PI) Contents All product information (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 Your Grasso contact only. 2) Operating manual (OM) Contents General operation guide lines; safety instructions, periodical inspections, fault analysis, periodical maintenance. User group To be used in the field by the end-user. Distribution Supplied together with the compressor. 3) Safety instructions refrigerant ammonia Contents Strict safety provisions have been defined to protect human beings and facilities. Reference is made to the main guidelines and provisions to be observed inplanning and operating refrigerating plants. With regard to their operation, the detailed operating manuals of the plant manufacturers shall be taken into account as well. Manual will be supplied with all compressors User group To be used in the field by qualified personnel for both end-user and contractor. Distribution (If applicable supplied together with the compressor)

IMM0703/v008

User group To be used in the field by qualified personnel for both end-user and contractor. Distribution Supplied together with the compressor. 5) Product Descriptions, Instructions for Accessories (PD) Contents All the relevant mounting and installation instructions and spare parts information for those accessories supplied with the compressor. User group To be used in the field by qualified personnel for both end-user and contractor. Distribution Supplied together with the compressor. 6) 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-user and contractor. Distribution Your Grasso contact only. 7) 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 Your Grasso contact only.

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 7-

8) Service Instruction Manual (SIM) Contents Description of (re)assembling, inspection, repair and part or total overhaul of the bare shaft compressor. This manual should be used together with the 'Installation and Maintenance Manual'. User group To be used in the field by qualified personnel of refrigeration installers or contractors. Distribution Your Grasso contact only. 9) Typographic signs Indicates a WARNING. READ IT CAREFULLY!

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

Indicates a HINT.

- 8-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

Main setup data Grasso 12E When operating the compressor, none of the limits of operation as stated in the table below and the product information must be exceeded. Refer Section 6.3! Table 1 Main setup data Description

Value

Start frequency

max. 6 starts per hour

Time interval between stopping and re-starting

min. 2 minutes

Time interval between starting and re-starting

min. 10 minutes

Time interval between capacity steps

min. 3 minutes

Oil level

25-75% crankcase sight glass

Min. oil temperature

warmer than surroundings and ≥ 20 °C for NH3 and ≥ 30 °C for halocarbons

Max. oil temperature

Refer to oil selection table/applied type of oil

Control oil pressure Lubricating oil pressure difference Max. discharge temperature

Remark

For continuous minimum part-load (i.e. more than 30 minutes) consult Grasso. Adjust the steps between up and down loading, in such a way that the system is running stable.

Required oil viscosity; ≥ 10 cSt during operation at location of bearings

suction pressure + 8 bar between 1.3 and 3.0 bar Setting approx. After a mimimum of 15 minutes running time at an oil 2.0 bar temperature of approx. 50 oC (122 oF) 170 °C

Min. suction pressure

0.3 bar (a)

Max. intermediate pressure Max. suction pressure

NH3 - 7.0 bar (a) R22 - 7.0 bar (a) R134a - 6.2 bar (a) R404A - 6.0 bar (a)

Pdischarge - Psuction

≤19.0 bar

Superheat

>0 K for NH3, >15 K for R404A, R507 and R134a

Oil suction filter

Blue coloured filter element

Oil discharge - running in - filter

Red coloured filter element

Oil discharge - permanent - filter

Grey filter element

Factory mounted; to be replaced after max. 100 running hours by permanent oil discharge filter element

Supplied loose; replacement for factory mounted running in filter

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

Cylinder numbering

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 9-

Fig. 1 Cylinder numbering Grasso reciprocating compressors

Legend 1, 2, 3, ...

Cylinder numbers

T

Top view of compressor

M

Motor/Drive end of compressor

O

Oil pump of compressor

- 10-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

1. INSTALLATION AND PREPARATION FOR USE

1. INSTALLATION AND PREPARATION FOR USE Table of Contents Section

Title

Page

1.1

INSTALLATION

13

1.1.1

Moving instructions and storage

13

1.1.2

Storage

13

1.1.3

Hoisting and moving instructions

13

1.1.4

Required free space

14

1.1.5

Foundation requirements

14

1.1.5.1

Concrete structure

14

1.1.5.2

Anchoring

15

1.1.5.3

Mounting the base frame on a concrete block

15

1.1.5.3.1

Levelling the base frame

16

1.1.5.3.2

Finishing with a self-levelling grout

16

1.1.5.4

Mounting bare compressor on a concrete block

16

1.1.6

Connecting to refrigerating system pipework

16

1.1.7

Connecting the power supply

16

1.1.8

Earthing connections

16

1.1.9

Separately delivered components

17

1.2

PREPARATIONS FOR USE

19

1.2.1

Leak test of compressor and system

19

1.2.2

EVACUATION/DRYING THE REFRIGERATING SYSTEM

19

1.2.3

Initial oil charge

19

1.2.3.1

Initial oil charge

19

1.2.4

Initial refrigerant charge

19

1.2.5

Adjustment of instruments and safety devices

19

1.2.5.1

Monitron CR and GSC

19

1.2.5.2

Refrigerants R717 and halocarbons

19

1.2.5.3

Re-adjustment of oil pressure regulator

20

1.2.6

Checking direction of rotation of motor shaft

20

1.2.7

Installing the drive guards (if present)

20

1.2.8

Initial oil warm up

21

1.2.9

Initial start-up

21

1.2.9.1

Limitations of part load operation and start-up

21

1.2.9.2

Wiring logic NO unloaded start solenoid

21

1.2.9.3

Frequency controlled compressor

21

1.2.9.4

Pre-start check list

21

1.2.10

Starting and stopping procedures

21

1.2.10.1

First start

21

1.2.10.2

Restart

22

1.2.10.3

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

22

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 11-

1. INSTALLATION AND PREPARATION FOR USE

Section

Title

Page

1.2.10.4

Restart after a long standstill period of time

22

1.2.10.5

Stopping the compressor

22

- 12-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

1. INSTALLATION AND PREPARATION FOR USE

1.1

INSTALLATION

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

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

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 energise the main power control cabinet until oil is added and the direction of rotation1 has been checked. 6. The compressor is to be filled with the correct type and amount of lubricating oil. 7. ‘Open compressors’ only; 1 Open compressors; The drive system should be installed. 2 (Semi) hermitic compressors; Mark R-S-T-N power supply in the terminal box of the motor. 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 "Product Information"). 10.The control cabinet should be energised to check the package controls. Do not forget to charge the oil separator (if present) initially with oil, to the level of the float assembly 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 "Product Information".

Every precaution must be taken while moving the package to its final location. Pushing, pulling or climbing on any package component or piping, can easily create damage. 1.1.2 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

Fig. 1.1-1 Hoisting a compressor package

Legend C

Compressor

M

Motor

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.

DO NOT use the compressor or motor or oil separator hoisting eyes to move the package! These hoisting eyes are intended for lifting loose components only and not for the entire package! Bare compressor or loose components: Determine the dead weight of the particular component (see "Product Information (ED)"), prior to moving a bare compressor or loose component. Use the hoisting eyes only, DO NOT sling from other compressor parts (see Fig. 1.1-2).

1. The direction of rotation of the compressor cannot be checked for (semi) hermetic compressors. For these compressors the electrical connection should be marked, to be sure that the compressor has always the same direction of rotation!

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 13-

1. INSTALLATION AND PREPARATION FOR USE

For more instalation details refer to; Section 1.1.5.1, Section 1.1.5.2Section 1.1.5.3, Section 1.1.5.3.1, Section 1.1.5.3.2. b) Frame designed for mounting on vibration dampers. For more details in case mounting base frames on vibration dampers is applied, refer to separate instruction sheet and other order documentation like package drawing, supplied with the compressor package and consult Grasso if required. 2. Bare compressor direct mounted on a concrete block via grouted machined anchors (see "Product Information (PI)"). The mounting surfaces of these machined anchors must be level without any deviation and projecting at least 10 mm above the concrete base. For more installation details refer to; Section 1.1.5.1, Section 1.1.5.2, Section 1.1.5.4 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. 1.1.4 REQUIRED FREE SPACE For easy operating, servicing and maintenance access, the compressor (package) should be installed with sufficient free space around it. Refer to “Product Information“ for minimum requirements. 1.1.5

FOUNDATION REQUIREMENTS

Compressor (package) has to be mounted on a concreted block. On request, Grasso can calculate the exact dimensions of the concrete block, based on the compressor size and operating conditions. This paragraph covers measures to be taken for a compressor (package) mounting on a concrete block. Two foundation arrangements are described: 1. Compressor package with steel base frame mounted on a concrete block. Following base frames are possible; a) Frame designed for mounting on concrete block.

- 14-

Fig. 1.1-3 Concrete block

Legend 1

Cork board

2

Concrete base

3

(Concrete) Floor

4

Sand

The concrete block for compressor and motor or compressor package should have a profile as illustrated in Table on Page 14and made according to the 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.

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

1. INSTALLATION AND PREPARATION FOR USE

Table 1.1-1 Legend A

Chemical anchor

B

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

Drilled chemical anchor (M20)

B

Grouted anchor recesses (M20)

1

Installed chemical anchor before placing the base frame

2

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

3

Drilling angle

1.1.5.3

IMM0703/v008

MOUNTING THE BASE FRAME ON A CONCRETE BLOCK

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 15-

1. INSTALLATION AND PREPARATION FOR USE

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. 1.1.5.3.1

LEVELLING THE BASE FRAME

instructions can be found in the order manual. 1.1.5.4

MOUNTING BARE COMPRESSOR ON A CONCRETE BLOCK If no base frame is applied the compressor and motor should be installed as described in the "Product Information (ED)". 1.1.6

CONNECTING TO REFRIGERATING SYSTEM PIPEWORK

DO NOT ground through the compressor when arc welding 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 "Product Information" (bare compressor) and in case of a package, the package lay out drawing.

Fig. 1.1-5 Grouting details

Legend 1

Self-levelling grout

2

Adjusting bolts (4x)

3

Washer

4

Temporary barrier strip around and inside frame

5

Complete cured concrete block

6

Grout layer

After the anchor filling mortar has completely cured the frame should be levelled with a space between block and lower frame flange of 3 - 5 mm*. This space is necessary for levelling using the base frame adjusting bolts with metal washers (supplied separately). The base frame should be levelled on each frame side. Adjust the frame on each adjusting place until all frame sides are horizontal. This space largely depends on the sort of grout or mortar used. Determine this space according to the instructions of the grout or mortar supplier. 1.1.5.3.2 FINISHING WITH A SELF-LEVELLING GROUT 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

- 16-

In order to ensure that suction gas strainer can be removed easily, special attention for pipe work is required for (semi) hermetic compressors.

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

Never connect the oil rectifier return line to the suction line or to the suction gas filter. 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 Information about further electrical connections to be made (e.g. crankcase heater, drive motor starting equipment, thermal protection of drive motor, automatic start/ stop and other external electrical devices) can be found in the plant manual (not supplied by Grasso).

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

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

1. INSTALLATION AND PREPARATION FOR USE

components, disconnect all litz-wires when arc-welding. After all installation functions are completed, reconnect the litz-wires and ground the package to earth. 1.1.9

SEPARATELY DELIVERED COMPONENTS

Check whether the sets/parts/components belonging to this compressor are supplied loose! (Refer to confirmation of order) Mount these separately delivered sets, components and/or parts, according to the instruction as enclosed.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 17-

1. INSTALLATION AND PREPARATION FOR USE

- 18-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

1. INSTALLATION AND PREPARATION FOR USE

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: 1.2.1 LEAK TEST OF COMPRESSOR AND SYSTEM 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.

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. EVACUATION/DRYING THE REFRIGERATING SYSTEM For evacuation of compressor only, refer to Section 2.5

1.2.3

INITIAL OIL CHARGE

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

Use only new oil as selected from the Grasso oil table.(Section 6.4)

Oil charging via the suction line of the compressor is not allowed. Procedure: i) STATUS: System is dried and still evacuated. ii) Charge 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) Charge the compressor crankcase with oil via the oil charge valve.

1.2.2

Pre-lubrication just before the first start is obligatory.

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 "Product Information" or to a connection as mentioned in the plant manual and evacuate the system to approx. 5 mm Hg (=6.6 mBar). iv) Break vacuum by charging dry nitrogen into the system. v) Repeat step iii, 'Connect vacuum pump ...'. vi) Wait approx. 24 hours. vii) If pressure has increased (system still contains moisture), repeat steps iv, vand vi, otherwise, continue with the "Initial oil charge" procedure.

Filling of the afore mentioned components is also possible by means of a separate oil filling pump via the oil charge valves mounted onto the oil pump housing. 1.2.3.1

INITIAL OIL CHARGE QUANTITY OF OIL TO BE FILLED (IN dm3)

Number of cylinders

Shaft seal housing incl. Oil Oil internal circuit of filters pump crankshaft

Crankcase

2 and 3

0.6

7.8

4

0.7

13.6

6

0.7

1.5 each

0.5

14.7

9

0.8

21.7

12

0.9

28.7

1.2.4 INITIAL REFRIGERANT CHARGE Refrigerant charging should be done in accordance with the plant manual by qualified refrigeration engineers. 1.2.5

ADJUSTMENT OF INSTRUMENTS AND SAFETY DEVICES

1.2.5.1 MONITRON CR AND GSC Refer to the Monitron CR resp. GSC Instruction Manual(s). 1.2.5.2

IMM0703/v008

REFRIGERANTS R717 AND HALOCARBONS

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 19-

1. INSTALLATION AND PREPARATION FOR USE

Legend Pressure safety limit switches for R717 and halocarbons Setting

5oC below design evaporating temp.

Precondition

Min. =0.3 bar(a)

Suction and intermediate pressure

Setting

Max.= depends on rotational speed, refer to Product Information (PI)

Discharge pressure

Setting

5oC above design condensing temp.

Precondition

Max. =24 bar(a)

Setting

Min. =1.3 bar

Suction pressurea

Lubrication oil pressure difference

a. Settings Pdischarge - Psuction must never exceed max. value as mentioned in Product Information

Oil pressure regulators for R717 and halocarbons Lubrication oil pressure differencea Control oil pressure difference

Setting

2.0 bar

Precondition, at 50 oC oil temp.

Min. =1.3 bar Max. =3.0 bar

Setting

8.0 bar

a. The oil pressure regulator is adjusted at the works, but it may occur that this setting should be corrected during the initial run and also if the value 2.5 bar. The re-adjustment procedure is given in section “Re-adjustment of oil pressure regulator.

1.2.5.3

RE-ADJUSTMENT OF OIL PRESSURE REGULATOR 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.

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 Oil charge valve for lubrication circuit.

C

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

D

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

E

Connection to measure oil control pressure

F

Hand operated oil charge pump (optional).

Re-adjustment procedure: REMARK: For settings, refer . 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 (A) according to . # The control oil pressure difference should be approx. (B) according to . 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 have been achieved 2. vi) Replace both cap nuts. REMARK: If the valve lifting fails, check the control oil pressure regulator! 1.2.6

CHECKING DIRECTION OF ROTATION OF MOTOR SHAFT Prior to installing the intermediate coupling element or V-belts, the direction of rotation of the motor shaft must be checked. The direction of rotation can be determined from the arrow-sticker on the oil pump. 1.2.7

INSTALLING THE DRIVE GUARDS (IF PRESENT) Only after the compressor is ready for the initial startup! Refer to the drive guard installing procedures included in the order documentation.

Fig. 1.2-1 Oil pressure regulator

Legend 1

Lubricating oil pressure regulator

2

Control oil pressure regulator

A

Oil suction filter

- 20-

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.

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

1. INSTALLATION AND PREPARATION FOR USE

1.2.8 INITIAL OIL WARM UP Prior to the initial start-up, the crankcase heater (if present) must be energised. For the min. oil temperature refer to “Product Information (PI)“. 1.2.9

INITIAL START-UP

1.2.9.1

LIMITATIONS OF PART LOAD OPERATION AND START-UP The capacity control serves to adapt the compressor capacity at any moment as closely as possible to the refrigerating capacity. In order to adjust the capacity, a number of cylinders can be put in or out of action either individually or collectively by means of 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.

1. Set the electrical capacity control switch to the position of the lowest part load step. 2. Check whether the manual control lever of each solenoid is in its lowest horizontal position. If control lever of each solenoid is not in its lowest position, the compressor may be seriously damaged. v) Oil level established in sight glass. vi) Stop valves to the pressure gauges are open. vii) Suction stop valve is closed (in case the evaporating temperature is much higher than the design evaporating temperature) and the discharge stop valve is open and in case of two- stage compressors that the stop valves in the intermediate circuit lines are open. viii)Stop valve in the oil return line of the oil separator (if present) is closed. When all items are verified, the compressor (package) is ready for the start-up. 1.2.10

STARTING AND STOPPING PROCEDURES

For a detailed description about start-up and part load limitations refer to the software program “Comsel”. 1.2.9.2 1 2 3 4 5

WIRING LOGIC NO UNLOADED START SOLENOID If compessor is NOT running then NO-solenoid is not energised. Energise the NO-solenoid 10 seconds before starting. If compressor starts then NO-solenoid is energised and de-energised by means of an auxiliary time relay. Ensure that the NO-solenoid valve is not de-energised until full speed has been achieved and the specified lubrication oil pressure has been established. Energise the NO-solenoid 5 seconds before stopping untill the compressor is stopped for 60 seconds.

1.2.9.3

FREQUENCY CONTROLLED COMPRESSOR

In case of frequency controlled compressors, a separate instruction 00.87.041 is required. If you don’t have this instruction consult Grasso. 1.2.9.4 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) Settings of safety limit switches are adjusted properly. iii) Direction of rotation of compressor crankshaft is correct. iv) Check capacity control:

IMM0703/v008

For all limitations refer to "Main setup data Grasso 12E" on Page 9! The values in the main setup data tables, overrules the values as mentioned in the text. When starting the compressor a distinction should be made between: 1.2.10.1 FIRST START i) Notice "Pre-start check list", also consult the plant manual and verify the following items: — Check the oil temperature (refer to the "Product Information"). — Check crankcase oil level (refer to Section 2.4.1). ii) Start the compressor and check whether the oil pressure increases. The time interval between stopping and starting should be at least 2 minutes and between starting and re-starting 10 minutes. iii) Slowly open suction stop valve and watch suction pressure, which may not exceed the max. value. Refrigerant liquid hammer, will damage the compressor; Superheat is always necessary! R404A and R507 dTo≥15K, other refrigerants dTo≥0K. iv) In case of electrically operated capacity control: a. Single-stage compressors: One or more cylinders will be energized. b. Two-stage compressors: 3 - 5 minutes after starting and only when HP-cylinder(s) is (are) in operation, the LP cylinders can be energised.

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 21-

1. INSTALLATION AND PREPARATION FOR USE

In the case of decreasing capacity for two stage compressors, it is not allowed to cut out all LP-cylinders. v) Watch maximum allowable motor current (refer to motor type plate). vi) Watch discharge temperatures LP and HP, max. intermediate pressure and max. allowable motor current (refer to motor type plate). vii) Adjust pressure gauge stop valves, in order to avoid vibration of the pointers. viii)Open the stop valve in the oil return line from the oil separator (if present). ix) Open compressors only; 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

The time interval between stopping and starting should be at least 2 minutes and between starting and re-starting 10 minutes. Proceed to the complete starting procedure of Section 1.2.10.1. 1.2.10.3

RESTART AFTER A SHORT STANDSTILL PERIOD OF TIME (LESS THAN 1 MONTH) • Refer to Section 1.2.10.2. 1.2.10.4

RESTART AFTER A LONG STANDSTILL PERIOD OF TIME

After a seasonal standstill (1 till 6 months) or maintenance operations; • Check settings of control and safety equipment. • Proceed to the complete starting procedure. Restarting compressor after a standstill period of time more than 6 months, consult your supplier. It is recommended to proceed with the initial start up procedure. 1.2.10.5 STOPPING THE COMPRESSOR The compressor can be stopped at any moment, however, consult the supplier if further actions are required.

- 22-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING Table of Contents Section

Title

Page

2.1

INSPECTION

25

2.1.1

Periodical inspection

25

2.1.2

Survey of periodical inspections

25

2.1.2.1

Check list periodical inspection

26

2.2

MAINTENANCE (REFER Chapter 5)

27

2.2.1

Post start-up maintenance

27

2.2.2

First maintenance

27

2.3

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

27

2.4

LUBRICATION DATA

27

2.4.1

Topping up oil with compressor operating

27

2.5

EVACUATION OF THE COMPRESSOR

27

2.6

DRAINING AND CHANGE OF OIL

28

2.6.1

DRAINING OIL REVERVOIR FOR MARINE USE (Optional)

28

2.7

REPLACEMENT OF OIL FILTERS

28

2.7.1

Oil discharge filter

28

2.7.2

Oil suction filter (Pos. B)

28

2.8

REPLACEMENT OF SUCTION GAS FILTER(S)

28

2.9

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

28

2.10

COMPRESSOR PURGING

28

2.11

TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS

29

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 23-

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

- 24-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

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

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 25-

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

CHECK POINTSa

FREQUENCY

CHECK POINTSa

Oil level in crankcase

Adjustment and operation of pressure safety switches Between 25% and 75% height of the sight glass. For topping up oil, refer to Section 2.4.1.

•

Colour of the oil

Lubricating oil pressure difference

REMARKS monthly

weekly

daily

FREQUENCY

•

The oil should be transparently clear. A disappearing white colour points to dissolved refrigerant. Refer to Section 2.2.2 for oil analysis frequency.

•

Oil temperature max.

•

Oil leakage of shaft seal max.

•

•

Refer "Main setup data Grasso 12E" on Page 9.

•

•

Refer to plant manual. For the max. allowable discharge pressure refer to the technical data of compressor.

Suction superheat Intermediate superheat

•

≥15 K required for R404A and R507, for other refrigerants ≥0 K

Discharge temperature max.

•

170 °C.

Oil temperature min.

Check the number of operating hours in view of any maintenance operations to be carried out.

In case of more than 1 cc/hr contact supplier.

Discharge pressure

- 26-

Switching frequency of the compressor

Refer to the "Product Information"

Check against design conditions. Refer to plant manual.

Condition of V-belts

•

Refer also to instructions of switch manufacturer.

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.

•

Cooling water temperature (if present)

•

Capacity control (if provided)

Number of operating hours

REMARKS

•

Min. control oil pressure

Suction pressure

daily

Table 2.1-1 Check list periodical inspection

monthly

CHECK LIST PERIODICAL INSPECTION

weekly

2.1.2.1

•

During compressor standstill the lower part of the crankcase must remain warmer than the surroundings: ≥ 20 °C (NH3) and ≥ 30 °C (halocarbons). Min. Actual condensing temperature + 10 K (≥ Tc + 10 K)

•

•

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.

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

2.2

MAINTENANCE (REFER CHAPTER 5)

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.

ii) Disconnect the power source from the compressor drive motor and the electrical control cabinet. 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 ) and exchange the oil filters. Determine the starting and stopping procedure from prior to start the compressor.

2.4

Determine max Toil and set this value in the safety device. Change the oil as soon as an oil analysis indicates contaminated oil.

It is expressly pointed out that it is not permitted to mix different types of oil. If another type of oil is used, first remove all the stale oil in the filters, oil pump, crankcase, shaft seal, oil separator and oil drains of the installation. 2.4.1

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

X

Renewal of suction gas filter(s)

X

Inspection of oil suction filter

X

Oil analysis bc

X

Inspection leakage shaft seal

X

Inspection relief

valve(s)d

> 100

LUBRICATION DATA

TOPPING UP OIL WITH COMPRESSOR OPERATING

Use Grasso’s hand-operated oil pump, part. no. 18.13.121 Topping up oil is permitted during compressor operation. Be sure that this oil is the same as in the plant (refer to Section 2.4).

refer to Service and Maintenance Schedules (SMS)

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.

X

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.

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).

IMM0703/v008

Fig. 2.4-1 Oil level in compressor sight glass

2.5

EVACUATION OF THE COMPRESSOR

Use always a vacuum pump to evacuate the compressor. To evacuate the refrigeration system refer to Section 1.2.2, Procedure to evacuate the compressor: i) Switch off main control panel. ii) Remove main fuses. iii) Remove the refrigerant by means of a vacuum pump, via the evacuation/purging valve(s) as prescribed by

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 27-

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

local safety regulations. For the location of these valves refer to the "Product Information".

2.6

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 seal. v) Charge crankcase with clean oil in accordance with the procedure. DRAINING OIL REVERVOIR FOR MARINE USE (OPTIONAL)

In case an oil reservoir for marine use is applied, this oil reservoir has also to be drained via the oil drain plug of the oil reservoir.

2.7

REPLACEMENT OF OIL FILTERS

Tools; Use the ring spanner for (dis)mounting the oil filter cups (included in set of special Grasso tools) Evacuate (refer to Section 2.5) the compressor prior to exchange the filter(s). Facts: Oil suction filter = BLUE coloured Oil discharge - running-in - filter = RED coloured Oil discharge - permanent - filter= GREY coloured. 2.7.1

REPLACEMENT OF SUCTION GAS FILTER(S)

DRAINING AND CHANGE OF OIL

To top up oil see Section 2.4.1, Oil changing procedure:

2.6.1

2.8

OIL DISCHARGE FILTER

An oil discharge (running-in) filter is factory mounted. This filter must be exchanged after max. 100 running hours. Oil filters can not be cleaned! Replace this filter according to the schedule in Section 2.2.2 and to the replacement instructions included in the filter set (GREY = permanent) or in case of a modified plant (RED = running-in). 2.7.2 OIL SUCTION FILTER (POS. B) 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.

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 2000 = installed in 2-3-4-6 cylinder compressors. Filter type 3000 = installed in 9 and 12 cylinder compressors. Procedure: i) Evacuate the compressor. ii) Remove and exchange the suction gas filter(s). iii) Purge the compressor.

2.9

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

A high working temperature and rapid temperature variations shorten the life time of the valves, which, for this reason, require regular inspection. The suction and discharge valves of a refrigeration compressor are parts that are heavily loaded both mechanically and thermally. Wear and life time of the valves strongly depend on the working conditions of the compressor. It is recommended that valve condition is regularly checked.For dismantling, inspection and re-assembly of the valves, refer to the relevant paragraph of the Compressor Service Instruction Manual.

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

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

- 28-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

regulations. For the location of these valves refer to the "Product Information". ii) When evacuation is completed open the discharge stop valve. iii) Watch suction and discharge pressure. If suction pressure increases quickly, the discharge valve assy is leaking. iv) Start compressor. v) Slowly open suction stop valve. vi) Open the stop valve in the oil return line of the oil separator (if present). vii) For two stage compressor only; a. Two-stage system A/B: open liquid supply to interstage cooler. b. Two-stage system C/D: refer to the plant manual. viii)If a Self-Limiting Automatic Purger is not installed, purge the refrigerating system (refer to the plant manual).

2.11 TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS The troubleshooting table shown overleaf 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.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 29-

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Table 2.11-1 Troubleshooting FAULT

CAUSE

FAULT REMEDY

1. Discharge stop valve Open fully not fully open A Discharge 2. Discharge pressure pressure too high gauge defective

1. Discharge pressure too high

See A

2. Too many cylinders cut out

Cut in more cylinders

E Crankcase frosted or weta

Stop compressor and contact installation engineer

3. Suction pressure too See D low 4. Excessive superheat Eliminate excessive of suction gas superheat 5. For two-stage B Discharge Repair temperature too compressors: interstage cooling does high not operate properly 6. Room temperature too high

Ventilate engine room better

7. Discharge valve defective

Repair or renew

F All cylinders inactive while compressor is operating

Provide for crankcase 1a. Room temperature heating or, if provided, too low check it for proper operation 1b. Oil return from separator contains liquid refrigerant

Consult plant manual

1c. Installation operates too wet

Re-adjust installation and provide for superheat

1d. Liquid separator too small

Consult plant manual

1. Oil pressure for valve lifting mechanism too low See J (For Grasso 12, Grasso 12E and Grasso10 only) 2. Incorrect wiring of capacity control

Refer to the "Product Information”

1. Type of oil not according to oil lubrication oil table (too thin oil)

Change oil type

8. Pressure relief valve Repair or renew is leaking

2. Compressor operates unloaded too Refer to design calculations frequently

9. Water cooling is not Repair working properly

3. No return from oil separatorb

Check the operation of float valve in oil separator

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

Clean plug

1. Capacity control does not operate

Repair

G Too high oil consumption

2. Compressor capacity Refer to plant design too small C Suction pressure too high 3. Suction pressure gauge defective

5. Worn out oil scraper Replace ring(s) ring(s)

Repair or renew

4. One or more suction Renew suction valve rings valves defective 5. One or more discharge valves defective

Repair or renew

6. Pressure relief valve Repair or renew is leaking 1. Suction stop valve not fully open

3. Injection control not D Suction Re-adjust control pressure too low adjusted correctly 4. Too little refrigerant Top-up with refrigerant in installation 5. Suction pressure gauge defective

Renew

6. Loss of oil due to leakage

Repair

7. Leaking shaft seal (max. 1 cc/hr) (For Grasso 5HP, Grasso 12, Grasso 12E and Grasso10 and Grasso 6 only)()

Repair shaft seal Refer to Section 2.2

8. Oil level in crankcase Drain/Refill with oil too high

Open fully

9. Oil separator is not initially filled with oil

2. Suction gas strainer Renew blocked

- 30-

REMEDY

1. Liquid refrigerant in crankcase due to:

Repair or replace

3. Non-condensables in Purge with a Automatic the system Purger

CAUSE

H Too high oil pressure during normal operation at working temperature

Refer to section “Initial oil charge”

1. Lubricating oil pressure regulator not Re-adjust or renew adjusted properly or defective 2. Defective oil pressure and/or Repair or replace suction pressure gauge (if present)

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

FAULT

CAUSE

REMEDY

1. Too little oil in crankcase

Top up oil

2. Disturbed oil circuit: Renew the element of oil Oil suction and/or suction filter and/or oil discharge filter is dirty discharge filter J Too low lubricating oil pressure

3. Lubricating oil pressure regulator not Re-adjust or renew adjusted properly or defective 4. Liquid refrigerant in See E crankcase 5. Defective oil pressure and/or Repair or renew suction pressure gauge (if present) 6. Worn bearings

K Too low or no control oil pressure (For Grasso 12, Grasso 12E and Grasso10 only)

Renew bearings

1. Failure of control oil Re-adjust or renew pressure regulator in regulator oil pump 2. A lack of oil in oil system

Add oil to the system

3. Oil pump defect

Repair or renew oil pump

a. In case of R744 applications only, crankcase can be frosted or wet, during normal operating conditions. b. During the initial start-up, the oil separator (if present) consumes oil before the first oil will be returned.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 31-

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

- 32-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

3. PARTS COMPRESSOR Table of Contents Parts List

Page

Figure

COMPRESSOR HOUSING WITH CONNECTIONS AND MAIN COMPONENTS

34

Grasso 12E-01

BEARING COVER DRIVE SIDE AND INTERMEDIATE BEARINGS

36

Grasso 12E-02A

BEARING COVER OIL PUMP SIDE: BRONZE SLIDE THRUST BEARING ( from serial number 03071378 )

38

Grasso 12E-02B

CRANKSHAFT

40

Grasso 12E-03

PISTON AND CONNECTING ROD

42

Grasso 12E-04

CYLINDER AND VALVE-LIFTING MECHANISM ( from serial no. 03091531 )

44

Grasso 12E-05

SUCTION AND DISCHARGE VALVE - Application: NH3 / in Single & HP two-stage compressors

46

Grasso 12E-06A

SUCTION AND DISCHARGE VALVE - Application: NH3 / in Booster & LP two-stage compressors

48

Grasso 12E-06B

SUCTION AND DISCHARGE VALVE ( Application: R22 / R134A

50

Grasso 12E-06C

SUCTION AND DISCHARGE VALVE ( Application: R404 / R507

52

Grasso 12E-06D

SUCTION AND DISCHARGE VALVE OVERVIEW

54

Grasso 12E-06E

ROTARY SHAFT SEAL

56

Grasso 12E-07

OIL PUMP

58

Grasso 12E-08

OIL FILTERS

60

Grasso 12E-09

LUBRICATING OIL LINES

62

Grasso 12E-10

SUCTION GAS STRAINER

64

Grasso 12E-11

High / Low PRESSURE RELIEF VALVES

66

Grasso 12E-12

MAIN FLANGE SEALING RINGS

68

Grasso 12E-13

STANDARD SETS OF PARTS, SEALS AND TOOLS

70

Grasso 12E-14

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 33-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-01 COMPRESSOR HOUSING WITH CONNECTIONS AND MAIN COMPONENTS 1 2

HEXAGON NUT

M16

FLAT WASHER

0115810

-

M16

1113801

-

3.A

CYLINDER COVER

298.5P

0531997

-

Without temp. sensor plug

3.B

CYLINDER COVER

298.5P-13G

0531999

-

With temp. sensor plug

4

GASKET

225X242X1.5

0903226

-

5

STUD

M16x60

0151860

-

6

STUD

M16x35

0151835

-

7

RESTRICTION

NPTF13x0.5

0123020

-

NON-RETURN VALVE

NPTF -18-Lx1.5

0123138

-

9.a

STUD

M16x35

0151835

23

9.B

STUD

M16x55

0151856

3

10

O-RING

3.53x145

0955257

-

11

SERVICE COVER

195X16

0530196

-

12

HEXAGON HEAD BOLT

M12x35

0110635

8

8

All cylinders single stage compressors and LP-cylinders two-stage compressors

13

OIL CONNECTING LINE

*

-

Refer to fig. Grasso12E-10

14

OIL SUCTION LINE

*

-

Refer to fig. Grasso12E-10

15

ALU SEALING RING

0914023

1

16

PLUG

21x27x2

0136216

1

17.a

POCKET

0385333

-

For 2 and 3 cylinder compressors

17.b

POCKET

0385335

-

For 4 .. 12 cylinder compressors

33x39x2

0914033

1

18

G21

ALU SEALING RING

19

HEXAGON NUT

G33

0148331

1

20

HEXAGON HEAD BOLT

M6x20

0110320

4

21

O-RING

2.5X52

0952256

1

SIGHT GLASS

46X80

1224046

1

23.a

22

SUCTION GAS STRAINER

2000

*

-

Refer to fig. Grasso 12E-11

23.b

SUCTION GAS STRAINER

3000

*

-

Refer to fig. Grasso 12E-11

24

ALU SEALING RING

25

PLUG

13.5x20x1

0912014

2

G13S

0136134

2

26

STOP VALVE

TAH8-12

0607011

1

27

NIPPLE COUPLING

12G21

0338211

1

28

CONNECTION LINE

12X150

0412120

1

29

NIPPLE COUPLING

12

0336012

1

- 34-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-1 Grasso 12E-01

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 35-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-02A BEARING COVER DRIVE SIDE AND INTERMEDIATE BEARINGS 1

BEARING COVER ASSY GRASSO12(E) (DRIVE SIDE)

1.1

BEARING COVER

1.2

BEARING BUSH

1.3

ALU SEALING RING

1.4 1.5 3

1

RC12

2138812

1

90X96X103

1146291

1

21x27x2

0914023

1

PLUG

G21-BZK

0365821

1

O-RING

3.53x21.8

0955212

1

90M

1169901

-

BEARING BLOCK

3.1

BEARING BLOCK HALVES

3.2

BEARING SHELL

3.3

HEXAGON HEAD BOLT

3.4

FLAT WASHER

3.5

DOWEL PIN

- 36-

*

4

O-RING

5

LOCKING RING

6

HEXAGON HEAD BOLT

7

FLAT WASHER

8

HEXAGON NUT

Oil groove pointing at 12 O'clock

90M

*

1

4, 6,9 and 12 cylinder compressor

90x81

1144900

-

In two pieces

M16 x 100

0110810

4

M16

1113801

4

12x26

1106226

2

5.33X240.67

0955375

2

M20

1139100

2

M20x60

0110160

3

M16

1113801

24

M16

0115810

24

For each intermediate bearing

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-2 Grasso 12E-02A

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 37-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-02B BEARING COVER OIL PUMP SIDE: BRONZE SLIDE THRUST BEARING ( from serial number 03071378 ) 1

BEARING COVER ASSY RC12 BRONZE

*

1

RC12 BRONZE

2138825

1

M6x16

0110316

3

1.1

BEARING COVER

1.10

HEXAGON HEAD BOLT

1.11

ALU SEALING RING

21x27x2

0914023

3

1.12

PLUG

G21-BZK

0365821

3

1.13

DOWEL PIN

6x12

1106612

1

1.14

RESTRICTION

M6x10x2

0123311

1

1.15

SETSCREW

M12 X 16 X 2

0123617

1

1.2

BEARING BUSH

90x96x107A

1146195

1

1.3

THRUST RING

RC12 BRONZE

1142013

1

1.4

NIPPLE COUPLING

8G13

0338138

1

1.5

DOWEL PIN

1.6

STUD

1.7

DOWEL PIN

1.8

OIL BAFFLE

1.9

TOOTHED SPRING WASHER

2 3

O-RING HOLD DOWN DISC

1 7

4x8

1106408

1

1926200

1

M6

1113303

3

5.33X240.67

0955375

2

149S

1125249

1

*

1

DOWEL PIN

8x28

*

2

DOWEL PIN

5x20

*

1

M10X40

0104540

4

CARRIER DISC

3.2 3.3

- 38-

1106612 0151610

149M10

3.1

4

6x12 M12x110

SOCKET HEAD SCREW

From 03071378

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-3 Grasso 12E-02B

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 39-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

E/K-RC12E

*

1

*

-

2x for 2-, 3-, 4- and 6-cyl. compressors, 6x for 9 cyl. compressors and 8x for 12 cyl. compressors -

M16 / 13-ST-G.V.

1139800

-

in two pieces

M16x55

0104855

-

Fig. Grasso 12E-03 CRANKSHAFT 1.1

CRANKSHAFT

1.2

COUNTERBALANCE WEIGHT

1.3

LOCKING RING SET

1.4

SOCKET HEAD SCREW

1.5

SPACER ASSY

90X116X60S M

1112990

1

1.5.1

FITTED BOLT

M8X10X10

0124410

2

1.5.2

SPACER

90x116x60E

*

1

1.5.3

LOCKING NUT

M8

0145400

2

1A.a

CRANKSHAFT

E-RC212ES

2271201

1

2-cyl. compressor

1A.b

CRANKSHAFT

K-RC211ES

2271211

1

2-cilinder compressor, with approval

1B.a

CRANKSHAFT

E-RC312ES

2271300

1

3-cylinder Compressor

1B.b

CRANKSHAFT

K-RC311ES

2271310

1

3 cylinder compressor, with approval

1C.a

CRANKSHAFT

E-RC412ES

2271400

1

4-cylinder compressor

1C.b

CRANKSHAFT

K-RC411ES

2271410

1

4 cylinder compressor, with approval

1D.a

CRANKSHAFT

E-RC612ES

2271600

1

6-cylinder compressor

1D.b

CRANKSHAFT

K-RC611ES

2271610

1

6 cylinder compressor, with approval

1E.a

CRANKSHAFT

E-RC912ES

2271901

1

9-cyinder. Compressor

1E.b

CRANKSHAFT

K-RC911ES

2271911

1

9 cylinder compressor, with approval

1F.a

CRANKSHAFT

E-RC1212ES

2271001

1

12-cylinder compressor

1F.b

CRANKSHAFT

K-RC1211ES

2271011

1

12 cylinder compressor, with approval

2

KEY

22X14X120

1102012

1

3

HUB FIXING

M24X108

1915211

1

4

LOCKING PLATE

M24xM12

1114248

1

5

FLAT WASHER

M12

1113601

1

6

HEXAGON HEAD BOLT

M12x35

0110635

4

- 40-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-4 Grasso 12E-03

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 41-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

PISTON ASSY

160X40X145 RC12E

2471012

1

1.1

GUDGEON PIN

26X40X120-R C12E

2470040

1

1.2

PISTON

Grasso 10

*

1

1.3

LOCKING RING

40

1104040

2

1.4

SET OF PISTON RINGS

160X40X145R C12E

0974163

1

2.4

BEARING SHELL

90x53

1144590

1

2.5

CONNECTING ROD BOLT

MF16

0111810

2

2.6

LOCKING RING SET

M16 / 13-ST-G.V.

1139800

2

2.7

HEXAGON NUT

MF16

0147805

2

2A

CONNECTING ROD

S 275 RC12E LD

2471510

-

2A.1

CONNECTING ROD

(aluminium alloy)

*

1

2A.2

BEARING BUSH

40X50X58

1146640

1

For single stage compressors and LP-cylinders in two stage compressors only ( will be replaced by p/n 1146641 ) For HP-cylinders of two stage compressors only

Fig. Grasso 12E-04 PISTON AND CONNECTING ROD 1

2B

CONNECTING ROD

S275 RC12E HD

2471520

-

2B.1

CONNECTING ROD

(aluminium alloy)

*

-

2B.2

NEEDLE BEARING

NK 40/30

1163430

2

- 42-

in two pieces

For single stage compressors and LP-cylinders in two stage compressors only

For HD-cylinders two stage compressors only

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-5 Grasso 12E-04

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 43-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-05 CYLINDER AND VALVE-LIFTING MECHANISM ( from serial no. 03091531 ) 1.1.A

CYLINDER LINER ASSY

RC12ES - SL

2371013

1.1.B

CYLINDER LINER ASSY

NH3 / R22 / R134A

RC12ES - SH

2371213

1.1

CYLINDER LINER

RC12E S

2370013

1

1.2.A

CYLINDRICAL PIN

RC12E - SL

1106587

8

NH3 / R22 / R134A

1.2.B

CYLINDRICAL PIN

RC12E - SH

1106588

8

for R404A / R507

1.3

PRESSURE SPRING

0,63X 6,3X 12,5X 36,5

1131059

8

1.4

FLAT WASHER

M 5B

1113001

8

1.5

LOCKING RING

R404 / R507

5

1103205

8

1.6.A

CAM RING

GR12E - L

2771190

1

NH3 / R22 / R134A

1.6.B

CAM RING

GR12E - H

2771195

1

R404 / R507

1,78 x 212,5

0952198

1

2

O-RING

3

VALVE LIFTING MECHANISM

RC12E

2070136

-

3.1

LEVER

RC12ES

2770113

1

3.2

SET SCREW

G27x15

1116113

1

3.3

HEXAGON NUT

3.4

SOCKET HEAD SCREW

G27

0148027

1

M6x25

0104325

1

3.5

LOCKING RING

M6

1113064

1

3.6

CARRIER DISC

46x12NS

1125015

1

3.7

CYLINDRICAL PIN

8X45

1106845

1

3.8

O-RING

3.53x59

0952376

1

2070134

1

9

CONTROL PISTON ASSY

9.1

O-RING

9.2

CONTROL PISTON

2.62x32.99

0952284

1

N GR12E

2770671

1

9.3

O-RING

2.62x32.99

0952284

1

9.4

PRESSURE SPRING

4,0x 32x 3,5x 53,5

1131340

1

10

PISTON HOUSING

RC12E

2770013

1

11

FLAT WASHER

M10

1113501

4

M10x75

0110575

4

40

0533040

1

M5x20

0110220

4

6G13

0338136

1

12

HEXAGON HEAD BOLT

13

COVER

14

HEXAGON HEAD BOLT

15

NIPPLE COUPLING

- 44-

For compressors up to serial no. 03091531 this item has to be ordered in combination with item 9 and 10

For compressors up to serial no. 03091531 this item has to be ordered in combination with item 3 and 10

For compressors up to serial number 03091531 this item has to be ordered in combination with item 3 and 9

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-6 Grasso 12E-05

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 45-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-06A SUCTION AND DISCHARGE VALVE - Application: NH3 / in Single & HP two-stage compressors 1

PRESSURE SPRING

2

DISCHARGE VALVE ASSY

19x 88.75x 4.75x 135

1131190

1

12E-FF-L

2771220

1

2.1

LOCKING NUT

M12

0145600

1

2.2

LOCKING NUT

M6

0145300

6

2.3

SOCKET HEAD SCREW

M6 X 40

0104340

3

2.4

VALVE PLATE

12E-FF-INW

2770410

1

2.5

VALVE PLATE

12E-FF-MID

2770420

1

2.6

VALVE PLATE

12E-FF-UITW-L

2770440

1

2.7

SET OF DISCHARGE VALVE RINGS

12E FF

2070040

1

2.7.1

VALVE RING

129,8x153,8x 4

*

1

2.7.2

VALVE RING

69,8x93,8x4

*

1

2.7.3

SINUSOIDAL SPRING

129,8x154,1x 0,8x11,5

*

1

2.7.4

SINUSOIDAL SPRING

69,8x93,0x0,8 x4,2

*

1

12E-FF-L

2770470

1

2.8

STROKE LIMITOR

SINGLE & HP TWO STAGE

2.9

FLAT WASHER

M12

1113601

1

2.10

WASHER

M6

1113301

9

2.11

STUD

M12x80

0151680

1

2.12

SOCKET HEAD SCREW

M6x60

0106360

6

3.A

SET OF SUCTION VALVE RINGS & SPRINGS

RC12E - FF - L

2070036

1

in combination with p/n 2371013 / cylinder liner with "slots"

3.A.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

2

Not loose available, only in a set.

3.A.2

VALVE RING

162 x 199 x 4

1134163

1

Not loose available, only in a set.

RC12E

2070032

1

in combination with p/n 2371012 / cylinder liner with "holes".

3.B

SET SUCTION VALVE RINGS

3.B.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

2

Not loose available, only in a set.

3.B.2

VALVE RING

162 x 199 x 4

1134162

1

Not loose available, only in a set

RC12E

7343170

1

For correct disassembly and assembly of the "free flow" discharge valve

4

- 46-

SPECIAL TOOL "FREE-FLOW VALVE"

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-7 Grasso 12E-06A

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 47-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-06B SUCTION AND DISCHARGE VALVE - Application: NH3 / in Booster & LP two-stage compressors 1 2

PRESSURE SPRING DISCHARGE VALVE ASSY

19x 88.75x 4.75x 135

1131190

1

12E-FF-B

2771210

1

2.1

LOCKING NUT

M12

0145600

1

2.2

LOCKING NUT

M6

0145300

6

2.3

SOCKET HEAD SCREW

M6 X 40

0104340

3

2.4

VALVE PLATE

12E-FF-INW

2770410

1

2.5

VALVE PLATE

12E-FF-MID

2770420

1

2.6

VALVE PLATE

12E-FF-UITWB

2770430

1

2.7

SET OF DISCHARGE VALVE RINGS

12E FF

2070040

1

2.7.1

VALVE RING

129,8x153,8x 4

*

1

2.7.2

VALVE RING

69,8x93,8x4

*

1

2.7.3

SINUSOIDAL SPRING

129,8x154,1x 0,8x11,5

*

1

2.7.4

SINUSOIDAL SPRING

69,8x93,0x0,8 x4,2

*

1

12E-FF-L

2770470

1

2.8

STROKE LIMITOR

BOOSTER & LP TWO STAGE

2.9

FLAT WASHER

M12

1113601

1

2.10

WASHER

M6

1113301

9

2.11

STUD

M12x80

0151680

1

2.12

SOCKET HEAD SCREW

M6x60

0106360

6

3.A

SET OF SUCTION VALVE RINGS & SPRINGS

RC12E A3-S-LP

2070039

1

in combination with p/n 2371013 / cylinder liner with "slots".

3.A.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

2

Not loose available, only in a set.

3.A.2

VALVE RING

162 x 199 x 4

1134163

1

Not loose available, only in a set.

3.A.3

VALVE RING

170,6x198,7x 3

1134165

1

Not loose available, only in a set.

RC12E A3-G-LP

2070031

1

in combination with p/n 2371012 / cylinder liner with "holes"

3.B

SET OF SUCTION VALVE RINGS & SPRINGS

3.B.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

1

Not loose available, only in a set.

3.B.2

VALVE RING

162 x 199 x 4

1134162

1

Not loose available, only in a set

VALVE RING

170,6x198,7x 3

1134165

1

Not loose available, only in a set.

RC12E

7343170

1

For correct disassembly and assembly of the "free flow" discharge valve

3.B.3 4

- 48-

SPECIAL TOOL "FREE-FLOW VALVE"

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-8 Grasso 12E-06B

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 49-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-06C SUCTION AND DISCHARGE VALVE ( Application: R22 / R134A 1

PRESSURE SPRING

2

DISCHARGE VALVE ASSEMBLY

2.1

SOCKET HEAD SCREW

2.2

LOCKING NUT

2.3

FLAT WASHER

2.4

SET OF DISCHARGE RINGS & SPRINGS

19x 88.75x 4.75x 135

1131190

1

RC12E S - LH

2771135

1

M16x80

0104880

1

M16

0145800

1

M16

1113801

1

RC12E (3)

2070035

1

2.4.1

SINUSOIDAL SPRING

71,4 x 55,4 x 0,7

*

1

2.4.2

SINUSOIDAL SPRING

126,1 x 110 x 0,7

*

1

2.4.3

SINUSOIDAL SPRING

98,8 x 82,8 x 0,7

*

1

2.4.4

SET OF VALVE RINGS

RC12E

*

1

3-RINGS, marked on top/bottom with "H", for refrigerant FREON only.

2.5

VALVE SEAT

RC12E L

2770270

1

2.6

STROKE LIMITOR

RC12E H

2770370

1

3.A

SET OF SUCTION VALVE RINGS & SPRINGS

RC12E - FF - L

2070036

1

in combination with p/n 2371013 / cylinder liner with "slots"

3.A.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

2

Not loose available, only in a set.

3.A.2

VALVE RING

162 x 199 x 4

1134163

1

Not loose available, only in a set.

RC12E

2070032

1

in combination with p/n 2371012 / cylinder liner with "holes".

3.B

SET SUCTION VALVE RINGS

3.B.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

2

Not loose available, only in a set.

3.B.2

VALVE RING

162 x 199 x 4

1134162

1

Not loose available, only in a set

- 50-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-9 Grasso 12E-06C

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 51-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-06D SUCTION AND DISCHARGE VALVE ( Application: R404 / R507 1 2

PRESSURE SPRING DISCHARGE VALVE ASSY

2.1

SOCKET HEAD SCREW

2.2

LOCKING NUT

2.3

FLAT WASHER

2.4

SET OF DISCHARGE RINGS & SPRINGS

19x 88.75x 4.75x 135

1131190

RC12E S - HH

2771136

1

M16x80

0104880

1

M16

0145800

1

1

M16

1113801

1

RC12E (3)

2070035

1

3-RINGS

2.4.1

SINUSOIDAL SPRING

71,4 x 55,4 x 0,7

*

1

2.4.2

SINUSOIDAL SPRING

126,1 x 110 x 0,7

*

1

2.4.3

SINUSOIDAL SPRING

98,8 x 82,8 x 0,7

*

1

2.4.4

SET OF VALVE RINGS

RC12E

*

1

2.5

VALVE SEAT

RC12 H

2770275

1

2.6

STROKE LIMITOR

RC12E H

2770370

1

3.A

SET OF SUCTION VALVE RINGS & SPRINGS

RC12E - SH

2070037

1

in combination with p/n 2371013 / cylinder liner with "slots".

for R404A / R507

3.A.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

3

Not loose available, only in a set.

3.A.2

VALVE RING

162 x 199 x 4

1134163

1

Not loose available, only in a set.

RC12E

2070030

1

in combination with p/n 2371012 / cylinder liner with "holes".

3.B

SET SUCTION VALVE RINGS

3.B.1

SINUSOIDAL SPRING

171 x 200 / E

1133273

3

Not loose available, only in a set.

3.B.2

VALVE RING

162 x 199 x 4

1134162

1

Not loose available, only in a set

- 52-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-10 Grasso 12E-06D

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 53-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-06E SUCTION AND DISCHARGE VALVE OVERVIEW NAN

- 54-

OVERVIEW GRASSO 12E VALVES

*

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-11 Grasso 12E-06E

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 55-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-07 ROTARY SHAFT SEAL 1

SHAFT SEAL HOUSING

RC12

2638012

1

2

HEXAGON HEAD BOLT

M12x35

0110635

8

3

FLAT WASHER

M12

1113601

8

4

ALU SEALING RING

13.5x20x1

0912014

1

5

PLUG

G13S

0136134

1

6

SHAFT SEAL SET

085B

2038100

1

*

1

6.1 6.1.1 6.2

COUNTER-SLIP RING ASSEMBLY O-RING

101.1x3.53

SLIP RING ASSEMBLY

0952390

1

*

1

6.2.1

O-RING

84.95x4.0

0952340

1

6.3

O-RING

3.53x145

0955257

1

- 56-

7

NIPPLE COUPLING

12G13

0338131

1

8

BENT STEEL PRECISION TUBE

12x530

4405012

1

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-12 Grasso 12E-07

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 57-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-08 OIL PUMP

OIL PUMP SET

RC12

2038116

1

Important: In case the direction of rotation of the oil pump is counter clockwise, when facing the (mounted] oil pump housing, the non-standard oil pump assembly 2028117 is required.

1.1.A.

OIL PUMP HOUSING

RC12

2638520

1

Standard

1.1.B.

OIL PUMP HOUSING

Mark 1

2638521

1

1.2

PUMP ELEMENT

1.3

HEXAGON HEAD BOLT

1.4

WASHER

1.5

CARRIER DISC

1.6

DOWEL PIN

1.7

GASKET

2

ALU SEALING RING

2.2

ALU SEALING RING

2.3

O-RING

1

M6x20

0110320

8

M6

1113301

8

55x8

1125006

1

6x18x3

1106617

1

83x115x0.5

0903083

1

2038120

1

0912010

1

CONTROL OIL PRESSURE REGULATOR SET

2.1

3

2638130

For Mark 1 design For use with heavy duty thrust bearing

10x18x1 33x39x2

0914033

1

3.53x21.8

0955212

1

2038118

1

LUBRICATION OIL PRESSURE REGULATOR SET

3.1

ALU SEALING RING

10x18x1

0912010

1

3.2

ALU SEALING RING

33x39x2

0914033

1

3.3

O-RING

3.53x21.8

0955212

1

4

ALU SEALING RING

21x27x2

0914023

5

5

PLUG

G21-BZK

0365821

5

6

T-COUPLING

6x6x6

0340406

1

7

NIPPLE COUPLING

6G13

0338136

1

8

SOCKET NIPPLE

9

MEASURING COUPLING

G13xG21

0302213

1

8 mm

0645608

1

10

O-RING

3.53x21.8

0955212

2

11

O-RING

3.53x145

0955257

1

12

FLAT WASHER

M12

1113601

7

13

HEXAGON NUT

M12

0115610

7

- 58-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-13 Grasso 12E-08

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 59-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

24

*

1

Remarks

Fig. Grasso 12E-09 OIL FILTERS 1A/B

OIL FILTER HOUSING

1.1

FILTER UPPER HOUSING

1.2

SET OF SEALS

*

1

0990030

1

1.3

FILTER CUP

*

1

1.4

RING NUT

*

1

1.5

SUCTION OIL FILTER SET (BLUE MARKED)

24

2038128

1

1.6A

DISCHARGE OIL FILTER SET (GREY MARKED)

24

2038124

1

1.6B

HIGH CAPACITY OIL FILTER SET (GREY MARKED)

- 60-

2038125

1

M10x80

0110581

4

M10

1113501

4

0365821

2

2

HEXAGON HEAD BOLT

3

FLAT WASHER

4

PLUG

G21-BZK

5

ALU SEALING RING

21x27x2

0914023

2

6

O-RING

2.65x25

0952281

4

7

SWIVEL COUPLING

12G21

0339212

1

8

STOP VALVE

TAH8-12

0607011

1

for both suction and discharge side and without filter

Check if the length of the oil charge filter is equal to the length of the oil suction filter cup of the compressor involved, if si, a longer oil discharge filter cup with Ref. Nr. 07.02.675 is also required!

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-14 Grasso 12E-09

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 61-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

OIL CONNECTING LINE

22x2x535

0412253

1

For 2 and 4 cylinder compressors

13.b

OIL CONNECTING LINE

22x2x865

0412286

1

For 4 cylinder compressor

13.c

OIL CONNECTING LINE

22x2x925

0412292

1

For 6 cylinder compressors

13.d

OIL CONNECTING LINE

22x2x1315

0412213

1

For 9 cylinder compressors

OIL CONNECTING LINE

22x2x1705

0412217

1

For 12 cylinder compressors

*

-

22x2x35x320

0438290

1

Fig. Grasso 12E-10 LUBRICATING OIL LINES 13.a

13.e 14 14.1

OIL INTAKE LINE BENDED STEEL PRECISION PIPE

14.2

NIPPLE COUPLING

22G22x1

0338273

1

14.3

O-RING

3.53x21.8

0955212

1

14.4

CONNECTION LINE

22x2x32

0412232

1

O-RING

3.53x21.8

0955212

1

15

- 62-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-15 Grasso 12E-10

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 63-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

RC12-2000

2038130

-

Remarks

Fig. Grasso 12E-11 SUCTION GAS STRAINER 1A

SUCTION GAS FILTER SET

1A.1

OILIT SEALING RING

170x230x1.5

0903168

1

1A.2

GAUZE FILTER ELEMENT

2000

*

1

1B

SUCTION GAS FILTER SET

RC12-3000

2038131

-

195x255x1.5

0903195

1

3000

*

1

2.65x13.95

0952269

1

1B.1

OILIT SEALING RING

1B.2

GAUZE FILTER ELEMENT

1B.3

O-RING

1B.4

CIRCLIP RING

1.3

O-RING

1.4

CIRCLIP RING

14

1103014

1

2.65x13.95

0952269

1

14

1103014

1

1 piece for RC2112(E) / 4212(E) - 2 for RC212(E) / 312(E) / 412(E) / 3112(E) / 5112(E) / 612(E)

1 piece for RC6312(E) / 8412(E) - 2 for RC912(E) / 7212(E) / 1212(E) / 9312(E) / 10212(E)

2A.1

SUCTION HOUSING COVER

236x118

0530240

-

2x for RC312(E) / 612(E) / 5112(E) and 1 for RC2112(E) / 4212(E)

2A.2

SUCTION HOUSING COVER

236x74.5

0530239

2

For RC212(E) / 412(E) / 3112(E)

2A.3

SUCTION HOUSING COVER

236

0530241

1

For RC211(2)E / 4212(E)

2B.1

SUCTION HOUSING COVER

260x118

0530263

-

1 piece for RC6312(E) / 8412(E) - 2 for RC912(E) / 7212(E) / 1212(E) / 9312(E) / 10212(E)

2B.2

SUCTION HOUSING COVER

260

0530262

1

3

SPRING RETAINER

14.5x45

4836015

-

1 piece for RC12(E) 2112/4212/6312/8412 - 2 for RC12(E) 212/312/412/612/912/3112/5112/7212/1212/ 9312/10212

4

PRESSURE SPRING

6x40x2.7x42

1131601

-

1 piece for RC12(E) 2112/4212/6312/8412 - 2 for RC12(E) 212/312/412/612/912/3112/5112/7212/1212/ 9312/10212

5A

HEXAGON HEAD BOLT

M16x40

0185840

8

5B

HEXAGON HEAD BOLT

M16x45

0185845

8

- 64-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa

aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa aaaaaaaaaa

Fig. 3-16 Grasso 12E-11

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 65-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-12 High / Low PRESSURE RELIEF VALVES 1A

(14.0 BAR) RELIEF VALVE - PRESSURE DEPENDENT

RC12-14

2839814

-

On LP-side of two-stage compr. RC12(E) 2112/311E/4212/5112/6312/7212/8412/9312/ 10212

1B

(22 BAR) RELIEF VALVE - PRESSURE DEPENDENT

RC12E-22

2839822

-

For single stage compr./booster compr. RC12(E) 212/312/412/612/912/1212

1.1

VALVE GROUP

48

4827048

-

RC12-23

2839823

-

2

(23.0 BAR) RELIEF VALVE - PRESSURE INDEPENDENT

2.1

RELIEF VALVE HOUSING

2.2

O-RING

2.3

RELIEF VALVE ASSY

48

1249212

1

3.53x66.27

0955231

1

4827423

1

M12x45

0110645

4

M12

1113601

4

3

HEXAGON HEAD BOLT

4

FLAT WASHER

5

HEXAGON HEAD BOLT

M12X95

0110696

2

6

HEXAGON HEAD BOLT

M12X110

0110609

2

7

HEXAGON HEAD BOLT

M12X120

0110612

2

8

FLAT WASHER

M12

1113601

6

9

O-RING

3.53x59

0952376

2

10

HEX. HEAD BOLT

11

BLIND FLANGE

- 66-

M12X40B

0110641

3

90X102

0504890

2

On HP-side of two-stage compr./ single stage compr. and booster compr. acc. to DIN 8975 (whole range)

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-17 Grasso 12E-12

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 67-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-13 MAIN FLANGE SEALING RINGS 1.a

GASKET

106x120x2

0904106

1

RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/ 8412/ 9312/ 10212/ 412

1.b

GASKET

129x149x2

0904129

1

RC12(E) 412/ 4212/ 6312/ 7212/ 8412/ 9312/ 10212/ 612/ 912/ 1212

1.c

GASKET

155x175x2

0904155

1

RC12(E) 612/ 912/ 1212/ 5112

1.d

GASKET

95x109x2

0904095

1

RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/ 8412/ 9312/ 10212

2.a

GASKET

61x75x2

0904061

1

RC12(E) 2112/ 3112

2.b

GASKET

95x109x2

0904095

1

RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/ 8412/ 9312/ 10212

3.a

GASKET

73x87x2

0904073

1

RC12(E) 2112/ 3112

3.b

GASKET

106x120x2

0904106

1

RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/ 8412/ 9312/ 10212/ 412

4.a

GASKET

95x109x2

0904095

1

RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/ 8412/ 9312/ 10212

4.b

GASKET

106x120x2

0904106

1

RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/ 8412/ 9312/ 10212/ 412

4.c

GASKET

129x149x2

0904129

1

RC12(E) 412/ 4212/ 6312/ 7212/ 8412/ 9312/ 10212/ 612/ 912/ 1212

4.d

GASKET

73x87x2

0904073

1

RC12(E) 2112/ 3112

- 68-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-18 Grasso 12E-13

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 69-

3. PARTS COMPRESSOR

Item

Description

Dims.

Ref. No.

Qty

Remarks

2038017

1

2038018

-

for every two cylinders 1 set / for three cyl. compr. 2 sets, for nine cyl. compr. 5 sets

2038021

1

for whole range

085B

2038100

1

Grasso 12E

2070010

1

Fig. Grasso 12E-14 STANDARD SETS OF PARTS, SEALS AND TOOLS A

BASIC GASKET / O-RING SET

B

ADDITIONAL GASKET / O-RING SET

C

SET OF SPARE PARTS

D

SHAFT SEAL SET

E

SET OF TOOLS GRASSO 12E

- 70-

RC12(E)

GRASSO 12E

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

3. PARTS COMPRESSOR

Fig. 3-19 Grasso 12E-14

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 71-

3. PARTS COMPRESSOR

- 72-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

4. SUPPLEMENTARY PARTS

4. SUPPLEMENTARY PARTS Table of Contents Parts List

Page

Figure

THRUST BEARING MARK1.1. (from serial no. 03071378)

74

Grasso 12E-E01

COMPRESSOR HOUSING MARK1.1.

76

Grasso 12E-E02

OIL COOLER

78

Grasso 12E-E03

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 73-

4. SUPPLEMENTARY PARTS

Item

Description

Dims.

Ref. No.

Qty

Remarks

Fig. Grasso 12E-E01 THRUST BEARING MARK1.1. (from serial no. 03071378) Mark 1

2638521

1

140 x 95 x 23,5 MARK1

2738700

1

RC12(E) MARK1

1135225

6

BEARING COVER

P.Z. RC12(E) MARK1

2138824

1

5

HOUSING RING

152 x 135 x 37,5 MARK1

0938135

1

6

THRUST WASHER

RC12(E) MARK1

1148004

1

7

CYLINDRICAL ROLLER THRUST BEARING

RC12(E) MARK1

1148008

1

8

SHAFT WASHER

133 x 90 x 76 x 15,5

1138090

1

9

NEEDLE THRUST BEARING

RC12(E) MARK1

*

1

10

HOUSING WASHER

RC12(E) MARK1

1148006

1

11

CARRIER DISC

100 x 76 x 36 S

1125176

1

12

BEARING BUSH

90 x 96 x 93 RC12(E) MARK1

1146093

1

13

SETSCREW

M12 x 16

0123616

1

X

SET OF SPARE PARTS THRUST BEARING MARK1

2038104

1

Y

COMPLETE SET THRUST BEARING MARK1

2038105

1

- 74-

1

OIL PUMP HOUSING

2

SPRING RETAINER

3

DIE SPRING

4

For Mark 1 design For use with heavy duty thrust bearing

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

4. SUPPLEMENTARY PARTS

Fig. 4-1 Grasso 12E-E01

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 75-

4. SUPPLEMENTARY PARTS

Item

Description

Dims.

Ref. No.

Qty

22 x G27

0341322

1

Remarks

Fig. Grasso 12E-E02 COMPRESSOR HOUSING MARK1.1.

- 76-

1

STUD ELBOW

2

STUD ELBOW

22 x G21

0341323

1

3

SERVICE COVER

RC12(E) S MARK1

0530193

1

4

BEARING COVER

P.Z. RC12(E) MARK1

2138824

1

5

PIPE STEEL

22 x 2

6105022

1

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

4. SUPPLEMENTARY PARTS

Fig. 4-2 Grasso 12E-E02

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 77-

4. SUPPLEMENTARY PARTS

Item

Description

Dims.

Ref. No.

Qty

G33 x G27

0302228

2

Remarks

Fig. Grasso 12E-E03 OIL COOLER

- 78-

1

SOCKET NIPPLE

2

STUD ELBOW

22 x G27

0341322

3

3

STUD ELBOW

22 x G21

0341323

1

4

SERVICE COVER

RC12(E) S MARK1

0530193

1

5

OIL COOLER

6

OIL COOLER VAN

LKI 110

0726015

1

LKI 110 230V

0726014

1

7

THERMOSTAT

RT 101

1256415

1

8

PIPE STEEL

22 x 2

6105022

2

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

4. SUPPLEMENTARY PARTS

Fig. 4-3 Grasso 12E-E03

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 79-

4. SUPPLEMENTARY PARTS

- 80-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

5. MAINTENANCE

5. MAINTENANCE Table of Contents Section

Title

Page

5.1

SMS FACTOR

81

5.2

Grasso 12E

83

5.3

Checklist

85

5.1

SMS FACTOR

General The running hours mentioned in the SMS tables should only be used as a reference for maintenance intervals.

The running hours mentioned in the tables are based on a single stage compressor running at -10oC/+35oC, NH3 at nominal speed. In this case the SMS factor = 1, in all other cases the maintenance intervals have to be adjusted accordingly.

The number of running hours mentioned in the SMS tables have to be adjusted accordingly depending on the operating conditions of the compressor (speed, evaporating temperature, condensing temperature, refrigerant, start frequency, capacity control steps, etc.. This means that the service intervals could be significantly different.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 81-

5. MAINTENANCE

- 82-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

5. MAINTENANCE

5.2

GRASSO 12E SERVICE AND MAINTENANCE SCHEDULES GRASSO 12E Actions

Item

Running hours * 1000a

Description 0.1

YEARLY

3

6

-

-

-

9

-

12

-

-

15

-

18

-

21

-

-

-

-

27

30

-

24

-

-

33

-

-

-

36

Checkpoint

1

CL

RE

CL

RE

RE

RE

RE

RE

Oil suction filter

2

REb

RE

RE

RE

RE

RE

RE

RE

Oil discharge filterc

-

ME

ME

ME

ME

ME

ME

ME

Oil analysis

RE

RE

-

RE

RE

RE

RE

RE

Oil refreshment (If hygroscopical oil is used replace this always after each opening of compressor or installation)

3

Oil

4 5 6

Oil pump

7a 7b

Crankshaft

8

-

IC/CL

-

IC/CL

IC/CL

IC/CL

IC/CL

IC/CL

Housing and element

-

IC/CL

-

IC/CL

IC/CL

IC/CL

IC/CL

IC/CL

Control and lubrication oil pressure regulator

-

-

-

-

-

-

IC/ME IC/ME

Main and intermediate bearing bushes

-

-

-

-

-

-

IC/ME IC/ME

Running surfaces main and intermediate bearings crankshaft

-

IC/ME

-

IC/ME IC/ME IC/ME IC/ME IC/ME

9

Shaft seal

-

IC

IC

10

Conrod

-

IC/ME

-

-

IC

-

IC

IC

IC

IC

IC

Piston

-

IC

-

IC

IC

IC

IC

IC

Piston rings

-

IC/ME

-

IC/ME IC/ME IC/ME IC/ME IC/ME

Gudgeon pin

IV/ME IV/ME IV/ME IV/ME IV/ME

Running surfaces/Axial play

11 12

Pistons

13 14

Thrust bearing

15 16

Capacity control

IC

IC

IC

IC

IC

Running surfaces con. rods

IC/ME IC/ME IC/ME IC/ME IC/ME

Oil/refrigerant leakage Big and small end bearings

-

IV/ME

-

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

Solenoid valves and coils

-

RE

-

RE

IV

IV

RE

RE

Seals of cap. control piston

17

-

IC

-

IC

IC

IC

IC

IC

Cap. Control mechanism

18

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

IC/IV

Crankcase heater

CL

CL

-

CL

CL

CL

CL

CL

Crankcase

-

-

-

-

IC

IC

IC

IC

Non return valves LP/Restrictions HP

-

IV

-

IV

IV

IV

IV

IV

Relief valves

RE

IC/CL

IC/CL

IC/CL

IC/CL

IC/CL

IC/CL

IC/CL

Suction gas filter

-

IC

-

IC

RE

RE

IC

RE

Valves, springs and damper rings

-

IC/CL

-

IC/CL

IC/CL

IC/CL

IC/CL

IC/CL

Stroke limitor/Discharge valve seat

-

IC

-

IC

RE

RE

IC

RE

Valves, springs and damper rings

-

IV

-

IV

IV

IV

IV

IV

Cap. Control lifting mechanism

19 20

Compressor housing

21

d

22 23 Discharge valvese 24 25 26 27 28 29 30

Suction valvesf Cylinder liners

Drive Electric motor

IMM0703/v008

-

IV/ME

-

IC

IC

IC

IV/ME IV/ME IV/ME IV/ME IV/ME IC

IC

IC

IC

IC

Dimension and running profile Alignment

IC

IC

IC

IC

IC

IC

IC

IC

V-belts

Refer to specifications of motor manufacturer

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 83-

5. MAINTENANCE

SERVICE AND MAINTENANCE SCHEDULES GRASSO 12E Actions

Item

Running hours * 1000a

Description 0.1

YEARLY

3

6

12

9

-

15

-

21

-

-

27

30

-

-

24

-

-

-

18

-

-

-

-

-

Checkpoint

33

-

-

-

36

31

IC

IC

IC

IC

IC

IC

CL/IC

CL/IC

Oil level switch

32

IC

IC

IC

IC

IC

IC

IC

IC

Safety switches

33

IC

IC

IC

IC

IC

IC

IC

IC

Gauges

34

IC

IC

IC

IC

IC

IC

IC

IC

Thermostats

35

IC

IC

IC

IC

IC

IC

IC

IC

Thermometers

36

IC

IC

IC

IC

IC

IC

IC

IC

Electrical control system

37

IC

IC

IC

IC

IC

IC

CL/IC

CL/IC

Valve oil return protection

IV

IV

IV

IV

IV

IV

IV

IV

Thermistors

IC

IC

IC

IC

IC

IC

IC

IC

Vibration dampers and bolts

38 Optionals

39 40

IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME

Intermediate cooler and injection valve

41

CL

CL

-

CL

CL

CL

CL

CL

Oil separator refreshing oil and cleaning/testing of float valve

42

-

IC

IC

IC

IC

RE

IC

IC

Heavy duty thrust bearing

43

CL

CL

CL

CL

CL

CL

CL

CL

Oil cooler, air side

44

RE

RE

-

RE

RE

RE

RE

RE

Oil cooler, oil side, refrigeration oil

45

Refer to specifications of motor manufacturer

46

ME

Oil cooler, electic motor (fan)

ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL

Cylinder head water cooling system

a. Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to the Service Instruction Manual (SIM) b. A running-in oil discharge filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter is supplied togehter with the compressor. c. Oil discharge filter change every 3000 hours or check optional pressure drop indicator d. A running-in suction gas filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter is supplied together with the compressor e. Discharge valves for compressors < machine number 00081502 must be changed every 6000 running hours in case not converted to latest standard f. If the machine is running on refrigerant R507 or 404A suction valves must always be changed every 3000 running hours

Legend for service and maintenance schedules (SMS) Item

Code/Action

Description

1

IC

Inspection / Alternatively renewal - correcting / Testing

2

IV

Inspection Visual / Alternatively electrical testing

3

RE

Renewal

4

ME

Measure

5

CL

Clean

- 84-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

5. MAINTENANCE

5.3

CHECKLIST

Item

SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS Description

Checked/Remarks/Notes

Checkpoint/Setting/Value

A Compressor type B Machine number C Date D Running hours E Refrigerant E Evaporating temperature/pressure To/Po F Intermediate temperature/pressure Tm/Pm G Discharge temperature/pressure Tc/Pc H Oil lubricating pressure I Oil control pressure

J General Notes

1

Oil suction filter

2 3

Oil discharge filter Oil

Oil refreshment (If hygroscopic oil is used replace this always after each opening of compressor or installation)

4 5 6 7 8

Oil analysis

Oil pump

Crankshaft

Housing and element Control and lubrication oil pressure regulator Main and intermediate bearing bushes and running surfaces Running surfaces con. rods

9

Shaft seal

Oil/refrigerant leakage

10

Conrod

Big and small end bearings

11 12

Piston Pistons

13 14 Thrust bearing 15 16

Piston rings Gudgeon pin Running surfaces/Axial play Solenoid valves and coils

Capacity control

17

IMM0703/v008

Seals of cap. control piston Cap. Control mechanism

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 85-

5. MAINTENANCE

Item

SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS Description

Checked/Remarks/Notes

18

Crankcase heater

19 20

Crankcase Compressor housing

Non return valves LP/HP

21

Relief valves

22 23 24

Suction gas filter Discharge valves

Valves, springs and damper rings Stroke limitor/Discharge valve seat

25 Suction valves 26 27 28 29

Checkpoint/Setting/Value

Valves, springs and damper rings Cap. Control lifting mechanism

Cylinder liners

Dimension and running profile Alignment

Drive

V-belts

30 Electric motor

Consult motor manufacturer

31

Oil level switch

32

Safety switches

33

Gauges

34

Thermostats

35

Thermometers

36

Electrical control system

37

Valve oil return protection

38 39

Thermistors

Optionals

Vibration dampers and bolts

40

Intermediate cooler and injection valve

41

Oil separator refreshing oil and cleaning/testing of float valve

42

Heavy duty thrust bearing

43

Oil cooler, air side

44

Oil cooler, oil side, refrigeration oil

45

Consult motor manufacturer

46

Oil cooler, electric motor (fan) Cylinder head water cooling system

Table 5.3-1 Settings pressure safeties Safety

Remark

1

Suction pressure

2

LP discharge pressure (safety)

two stage only

3

LP discharge pressure (limitor)

two stage only, TUV

4

High pressure suction (safety)

two stage only

5

High pressure (safety)

6

High pressure (limitor)

7

OIl differential pressure

- 86-

Value

TUV only

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6. APPENDIX; Product Information (PI) Table of Contents Section

Title

Page

6.1

GENERAL DATA

89

6.1.1

TECHNICAL DATA

89

6.1.2

MAIN DIMENSIONS AND SPACE REQUIREMENTS

91

6.1.3

SHAFT END COMPRESSOR

93

6.2

Electrical wiring schematic oil differential pressostat (RT260A)

95

6.2.1

Method A, two timers, recommended

95

6.2.2

Method B, one timer (method A is recommended)

96

6.3

LIMITS OF OPERATION AND FIELDS OF APPLICATION

97

6.3.1

GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 12E

97

6.3.2

PRECISE FIELD OF APPLICATION

98

6.3.3

FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER

99

6.3.3.1

DIAGRAMS Grasso 12E

100

6.3.4

FIELDS OF APPLICATION TWO STAGE

102

6.3.4.1

FIELDS OF APPLICATION DIAGRAMS

102

6.3.5

LIMITATIONS OF PART-LOAD OPERATION

104

6.3.6

STARTING UP OF TWO-STAGE COMPRESSORS

104

6.4

LUBRICATING OILS (choice and recommendations)

107

6.4.1

Oil selection table

107

6.4.1.1

Remarks

107

6.4.2

Strongly recommended oil types for Grasso reciprocating compressors

107

6.4.3

Accepted NH3 and HCFC oil types for Grasso reciprocating compressorss

108

6.4.4

Accepted HCFC oil types for Grasso reciprocating compressors

108

6.5

CAPACITY CONTROL SYSTEMS

108

6.5.1

SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START

108

6.5.2

ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD)

110

6.5.2.1

GENERAL DIAGRAM OF ELECTRICALLY OPERATED CAPACITY CONTROL

110

6.5.2.2

DIAGRAMS

111

6.5.3

MANUAL CAPACITY CONTROL

115

6.6

PACKAGED BASE FRAME AND FOUNDATION BLOCK

117

6.6.1

PACKAGED BASE FRAME

117

6.6.1.1

PACKAGED BASE FRAME

117

6.6.2

BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK

119

6.6.2.1

FOUNDATION BLOCK

120

6.7

CRANKCASE HEATER

120

6.7.1

HEATER FITTING DETAIL

121

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 87-

6. APPENDIX; Product Information (PI)

- 88-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.1 6.1.1

GENERAL DATA TECHNICAL DATA

Table 6.1-1 Technical Data of Grasso 12E compressors COMPRESSOR TYPE Grasso 12E zL

Number of cylinders

zH

Piston stroke

S

LP Swept volume at full-load and:

3

4

6

9

12

2

3

4

6

9

12

1xV

1xW

2xV

2xW

3xW

4xW

Vs

Ratio LP/HP swept volume (ZL/ZH) at full load

63

72

84

93

102

5

6

7

8

9

10

1

1

2

1

3

2

4

3

2

1xW

2xV

2xW

2xW

3xW

3xW

4xW

4xW

4xW

597

796

1194

1792

2389

398

597

796

995

1194

1393

1592

1792

1991

318

478

637

955

1433

1911

318

478

637

795

955

1115

1274

1433

1592

2

3

2

5

2

3.5

2

3

5

counter-clockwise when facing shaft end

585-656-738-831-937-1054-1171-1316a-1475a min-1

1775 min-1 1475 min-1 (60 Hz) (50 Hz) manual control:

IMM0703/v008

51

4

398

n

563-631-704-789-888-1000-1127-1268a-1409a

Sb

10050

100100100100100- 83- 67- 89- 67- 83- 6767- 33 75- 50 50 - 33 44- 33 50- 25

Bc

10050

10010010010010067- 33 75- 50 83- 67- 67- 44 75- 5842 50

10050

100100- 89- 7810010083- 6767- 33 75- 50 50- 33 67- 5644- 33

10050

100100100100- 83- 67- 100- 75- 5867- 44 67- 33 75- 50 42 50

Bc

%

10092- 8375- 6758- 5042- 3325

Td Mass of bare compressor (without flywheel and other accessories)

42

3

110

ϕ

Sb electrical control

Standard steps of capacity control (expressed in % of full-load swept volume):

31

2

160

Standard direction of rotation

Standard compres-sor speeds (with V-belt drive) at motor speed:

21

m3/h

D

n= 1200/min-1 n= 1500/min-1 (Halocarbons) (NH3)

Cylinder bore

2

Two-stage

mm

Cylinder arrangement

Single-stage

kg

553

660

810

1050

1390

1630

100

10067

100100100100100100- 80- 60- 100- 86- 72- 75- 50- 78- 67- 80- 7056- 45- 60- 5067- 33 57- 4375- 50 25 40 33 30 29

660

885

1100

1100

1440

1440

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

1700

1700

1700

- 89-

6. APPENDIX; Product Information (PI)

6

9

12

21

31

42

51

63

72

84

93

102

623

730

880

1150

1505

1760

730

955

1200

1200

1555

1555

1830

1830

1830

1.75

2.2

2.5

3.5

4.0

1.75

2.2

2.5

2.5

3.5

3.5

4.0

4.0

4.0

7.7

13.6

14.7

21.7

28.6

7.7

13.6

14.7

14.7

21.7

21.7

28.6

28.6

28.6

0.4167

0.5018

0.7171

0.8939

0.3527

0.4167

0.5018

0.5018

0.7171

0.7171

0.8939

0.8939

0.8939

Shipping volume

1.75

Oil charge in crankcase and oil circuit (centre line of sight glass)

7.7

0.3094

4

m3

3

dm3

kg

Mass moment of inertia of crank mechanism (without flywheel) a. b. c. d.

Id

Two-stage

2

kg.m2

Shipping mass (approx.)

Single-stage

0.3527

COMPRESSOR TYPE Grasso 12E

not applicable for halocarbons Single stage Booster Two stage

- 90-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.1.2

MAIN DIMENSIONS AND SPACE REQUIREMENTS

Table 6.1-2 COMPRESSOR 212 TYPE

312

412

612

912

1212

2112

3112

4212

5112

6312

7212

8412

9312

10212

Length

A

977

987

1307

1377

1792

2182

987

1307

1377

1377

1792

1792

2182

2182

2182

Width

B

1077 1171

1077

1171

1171

1171

1171

1110

1171

1171

1171

1171

1171

1171

1171

Height

C

881

884

931

931

931

931

876

931

931

931

931

931

931

931

IMM0703/v008

931

D

876

848

876

848

848

848

848

876

848

848

848

848

848

848

848

E

881

688

884

871

871

871

871

864

871

871

871

871

871

871

871

F

316

522

316

548

560

950

786

790

795

795

795

795

795

795

795

G

0

406

0

189

189

189

648

745

688

688

688

688

688

688

688

H

530

541

548

548

560

560

950

950

950

J

509

903

913

913

1315

1315

1705

1705

1705

K

149

224

163

163

163

163

163

163

163

L

195

108.5

195

195

195

195

195

195

195

M

406

331

406

406

406

406

406

406

406

217

217

217

N

205

205

205

205

217

217

205

205

205

205

217

217

O

295

295

625

685

1075

2x732.5

295

625

685

685

1075

1075

P

345

345

345

345

369

369

345

345

345

345

369

369

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

2x732.5 2x732.5 2x732.5 369

369

369

- 91-

6. APPENDIX; Product Information (PI)

COMPRESSOR 212 TYPE

312

412

612

912

1212

2112

3112

4212

5112

6312

7212

8412

9312

10212

MINIMUM REQUIRED FREE SPACE for removal of: flywheel

U

700

700

700

700

700

700

700

700

700

700

700

700

700

700

700

crankshaft

V

875

875

1205

1265

1655

2045

875

1205

1265

1265

1655

1655

2045

2045

2045

1010 1160

1010

1160

1160

1160

1160

1010

1160

1160

1160

1160

1160

1160

1160

460

460

595

595

595

595

460

595

595

595

595

595

595

595

piston and cylinder liner

Wa X

595

LOCATION OF CENTRE OF GRAVITY length

Y

197

197

280

405

600

width

Z

405

423

423

435

440

795

197

280

405

405

600

600

795

795

795

445

423

423

435

435

440

440

445

445

445

MAIN CONNECTIONS DN (mm) (LP) suction

1

LP dicharge/ HP suction

2/3

(HP) discharge

4

80

65

80

65

100

80

125

100

125

100

125

100

65

65

100

125

100

100

100

100

100

50

50

80

80

80

80

80

80

80

40

40

65

65

65

65

65

65

65

AUXILIARY CONNECTIONS b

suction pressure

5

LP discharge pressureb

6

HP suction pressure

7

dicharge pressureb

8

Crankcase pressure

9

lubricating oil pressure

10

Oil temperature

11

1/4” BSP (plugged off)

Oil charge and 12 drain valve

1/2” BSP (plugged off; separate stop valve, type TAH8, supplied loose with the compressor)

Return from oil separator or 13 rectifier

1/2” BSP (plugged off; separate swivel coupling, supplied loose with the compressor)

Crankcase heater

14

Oil leakage drain of rotary 15 shaft seal Control oil pressure

16

1/2” BSP (plugged off) to suit thread of heating element clamp coupling provided with ø12x1.5 mm steel precision tube T-coupling

a. Minimum required free space for interstage cooling system A or B. b. When a microprocessor is applied (see also the relevant Data Sheet), these auxiliary connections are provided with a swivel coupling with two connections. The straight-through and side connection of this swivel coupling are provided with a clamp coupling for ø6x1 mm steel precision tube, in order to accomodate the temperature sensor element and the steel precision tube for the pressure transducer respectivily.

- 92-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.1.3

SHAFT END COMPRESSOR

Fig. 6.1-1 Shaft end compressor

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 93-

6. APPENDIX; Product Information (PI)

- 94-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.2

ELECTRICAL WIRING SCHEMATIC OIL DIFFERENTIAL PRESSOSTAT (RT260A)

General The oil differential pressure switch should be overridden: i) during starting (to allow the compressor to achieve the required oil pressure) ii) during normal operation (to avoid nuisance trips due to system fluctuations

There are 2 methods by which to protect the compressor, method A and method B, as described below. If timer 1 (T1) has expired and the required oil pressure has not been reached then the compressor must be stopped inmediately 6.2.1

METHOD A, TWO TIMERS, RECOMMENDED

Fig. 6.2-1 Recommended wiring diagram, incl. start-up delay timer

By the use of 2 timers: 1 Timer 1 (T1) for the avoidance of nuisance trips during running. Set time is a maximum of 10 seconds 2 Timer 2 (T2) for start-up override. Set time is a maximum of 30 seconds and is active once from start-up. This timer overrides Timer 2

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 95-

6. APPENDIX; Product Information (PI)

6.2.2

METHOD B, ONE TIMER (METHOD A IS RECOMMENDED)

Fig. 6.2-2 Alternative wiring diagram method B, without start-up delay timer

By the use of one timer (T1) set at a maximum of 15 seconds for both starting and running.

- 96-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.3

LIMITS OF OPERATION AND FIELDS OF APPLICATION

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

6.3.1

GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 12E When operating the compressor, none of the limits of operation as stated in the table below must be exceeded.1

Table 6.3-1 General limits and fields of operation 1. In practice, it is not so much the individual operation limits as combinations of them that are decisive for the conditions under which a compressor may operate. To check the various possibilities in this respect, use should be made of the "fields of application" ).

REFRIGERANT

NH3

Compressor speed

n

min-1

R22

min.

c

po bar(a)

1500

max.

to ∆t

Suction superheat/intermediate superheat

°C

0.3 >= 1100 min

°C

7.0

< 1100 min-1

c

pm bar(a)

>= 1100 min < 1100 min

-1

-63.8

-50

+13.8

+10.9

+22.6

min.

tm

Actual suction temperature Discharge pressure = condensing pressure Design

ta cd

°C

max.

>= 1100 min

7.0

< 1100 min-1

max.

-

tc

°C

max. max.

Pressure ratio per stage (pc/po or pc/pm or pm/po)

g

j

-

Pressure difference

ch

∆p

bar

Oil temperature in crankcase

i

toil

°C

3.7

-55.1

-63.8

-50

>= 1100 min

< 1100 min-1

+13.8

+10.9

+22.6

+56.5

+59.5

-68.5

-14.0

-15.0

-7.0

-8.0

+75.8

+52.0

+52.8

+170

min.

1.5 10

max. min.

-68.1

26.5

max.

max.

-8.0

4.7

-1

bar(a)

°C

-7.0

6.2

24.0

te

-15.0

0.3

pc bar(a) max.

f

-14.0

-1

-50

Discharge temperature

-68.5

15

min.

pressuree

Condensing temperature = saturation temperature at discharge pressure

°C

-68.1

0

min. Intermediate temperature

4.7

-55.1

min. Intermediate pressure

3.7

6.2

-1

max.

R507a

1200

-1

min. Evaporating temperature = saturation temperature at suction pressureb

R404Aa

500

max. min.

Suction pressure = evaporating pressure =crankcase pressureb

R134a

15 19.0

+20

+30

depending on type of oil, refer Section 6.4

a. Minimum superheat 15 K. Grasso advises a condensing temperature > +35 oC, to avoid condensation of refrigerant in the compressor. b. For halocarbon refrigerants the maximum values of p0 and t0 are based on a density of the suction gas of 30 kg/m3. In single stage operation during start-up and immediately thereafter, t0, max may be exceeded slightly and only temporarily. In any case p0 should drop to at least given value in table within 5 minutes after starting. c. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi. d. 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 19.0 bar. e. This pressure deviates from the so called max. discharge pressure=condensing pressure (allowed during operation) as stated in the table. f. 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. g. Pressure ratio limits are not absolute but arbitrary values based on practical considerations. h. The standard built-in overflow safety valve(s) between suction and discharge side has been factory-set to 22.0 ≤ 1.5 bar to prevent advanced opening during normal operation at ∆p = (pc - po) ≤19.0 bar. i. 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.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 97-

6. APPENDIX; Product Information (PI)

6.3.2

PRECISE FIELD OF APPLICATION

The field of application diagrams as shown in this manual can vary slightly from the actual field of application for each particular selection.

The actual field of application is dependent on refrigerant, type of compressor, speed, suction superheat, partload steps (different pressure ratios) and interstage cooling system.

Always consult Grasso's software program, COMSEL, to determine the precise field of application for an actual compressor selection.

- 98-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.3.3

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 in 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 6.3.3 are based on continuous full-load operation, suction superheat = 0 K.(15 K for R404A and R507) • For continuous minimum part-load (i.e. more than 30 minutes) consult Grasso. Hatched section ‘A’; These parts of the general field of application are not covered by the compressor selection software COMSEL. Please consult Grasso to make a selection of those applications.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 99-

6. APPENDIX; Product Information (PI)

6.3.3.1

DIAGRAMS GRASSO 12E

Fig. 6.3-1 Fields of application NH3

- 100-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

Fig. 6.3-2 Fields of application

REMARK: A) not allowed for speeds > 1100 min-1

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 101-

6. APPENDIX; Product Information (PI)

6.3.4

FIELDS OF APPLICATION TWO STAGE

General The fields of application for two stage compressors are (besides superheat and part-load operation) very dependant on ϕ(ratio LP/HP swept volume; full-load and part-load can have different values). Because each capacity control step can have a different ϕ, it is very important to check for every 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 (Section 6.3.5/Section 6.3.6) 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 ϕ = 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 variable depending on types of compressors and/or part-load steps. All compressor types are included within the total field of application. • Diagrams overleaf are based on LP and HP suction superheat 0 K resp. 15 K1. For continous part-load (i.e. more than 30 minutes) consult Grasso.

Fig. 6.3-3 Dummy diagram Table 6.3-2 Dummy Diagram; Explanation two stage field of application Legend

Jmax / te,max

Area on the right side of this line indicates the single stage field of operation (starting up). This line shifts down in case of continuous part-load operation and/or (intermediate) superheat. Superheat also results in limited part-load operation.

teH,max / te,max

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

ϕ

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

Po,min

Minimum suction pressure (evaporating)

tm,max

Maximum intermediate pressure.

6.3.4.1

FIELDS OF APPLICATION DIAGRAMS

• The Dummy diagram shows field of application for different ϕ's. • Shaded areas are fields of single-stage operation (used and allowed only during starting up compressor). • Each ϕ has its own field of application (Example; see dummy diagram ϕ= X area) • ϕ = 1 is "Fast Pull Down" capacity control step (option), to be used during starting up compressor only. Refer to starting up procedure (Section 6.3.6)

1. Minimum superheat R404A and R507; 15K

- 102-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

Fig. 6.3-4 Field of application two-stage NH3

Fig. 6.3-5 Field of application two-stage R404A and R507

Fig. 6.3-6 Field of application two-stage R22

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 103-

6. APPENDIX; Product Information (PI)

6.3.5

LIMITATIONS OF PART-LOAD OPERATION

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

In general the rule is that, irrespective of refrigerant and conditions of operation, it is never allowed to run a compressor during a prolonged period of time fully unloaded, i.e. with all cylinders switched off. When using a Grasso compressor equipped with a standard capacity control such a situation is impossible because then, apart from the starting period, always one or more cylinders are permanently connected to the control oil pressure. Limitations of part-load operation for two-stage compressors From the diagrams, it appears that for two-stage compressors the field of application depends not only on the kind of refrigerant but also on the ratio ϕ of L.P. and H.P. swept volume. This means (since the standard capacity control steps of the individual two-stage types have not always the same ϕ-value) that for the successive capacity control steps of a certain compressor type different fields of application may be valid. If this is the case, the situation may occur

- 104-

that, when cylinders are switched on or off under constant (design) conditions of operation, the corresponding working point (= combination of condensing temperature tc and evaporating temperature to) lies outside one or more of the relevant fields of application. This implies that it is not allowed to use the part load steps concerned, either on account of too high a H.P. discharge temperature in case of NH3 only (working point lies to the left of the field of application), or on account of too high a saturation intermediate temperature / intermediate pressure (working point to the right of the field of application). In the case of electrical capacity control, such disallowed part-load steps can easily be avoided in actual practice by adapting accordingly the wiring diagram for energising the three-way solenoid valves.

Electrical capacity control is mandatory for two-stage compressors.

Apart from the above-mentioned inadmissibility of certain standard part-load control steps, care should always be taken to ensure that the capacity of two-stage compressors is never reduced to such an extent that only H.P. cylinders remain operative. For then the compressor would operate as a single- stage machine, but under two-stage conditions, which would result, in particular for NH3, in an unacceptably high discharge temperature. This restriction means that the three-way solenoid valves should be wired so that, when the compressor is running under design conditions, at least one solenoid valve remains energised. 6.3.6

STARTING UP OF 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

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

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 so that the corresponding working point at the condensing temperature tc, lies inside the field of application of the two-stage minimum part-load step concerned. Only then, after this step has been energized, the saturation intermediate temperature tm will be below its maximum value. Consequently, the maximum value of to at which it is allowed to switch over to two-stage operation, is determined by the intersection of the near-vertical line which represents the right hand limitation of the relevant field of application and the horizontal line which represents the condensing temperature tc. Likewise, during further stepping up to maximum capacity, the evaporating temperature has to be pulled down by each intermediate part-load step so far that the corresponding working point at given condensing temperature lies each time just inside the field of application of the next part-load step of higher capacity, before that step is energized. Fast pull-down part-load control steps When using the standard capacity control steps of the two-stage compressor types, the pull-down procedure to achieve full-load operation at design conditions, as described in the previous paragraph, is rather often very time consuming. This is due to the fact that all compressor types are always started with only one HP cylinder in operation and that the minimum LP/HP swept volume ratio for any part-load step is ϕ = 2. Therefore, for all Grasso two-stage types a fast 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 ϕ = 1.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 105-

6. APPENDIX; Product Information (PI)

- 106-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.4

LUBRICATING OILS (CHOICE AND RECOMMENDATIONS)

a. to,max is the saturated temperature, corresponding to maximum crankcase pressure where at the usual oil temperatures the oil/refrigerant mixture has a viscosity of > 10 cSt. b. Refer to Section 6.4.1.1.

The choice of oil for a refrigeration compressor should be made by taking into account the entire refrigeration system design and operation as well as the operating conditions of the compressor. 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 tables below. The choice of the lubricating oil depends on type of refrigerant and the operating conditions of the compressor. The oil viscosity should always be more than 10 cSt. A higher ISO-VG number should be chosen when refrigerant solubility in crankcase is expected to be high especially in case of HCFC’s and HFC’s. OIL SELECTION PROCEDURE: Use the oil viscosity selection table to select oil viscosity required. The following page lists all oils approved by Grasso for reciprocating compressors. 6.4.1

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

HCFC’s (R22)

HFC’s (R134a, R507, R404A)

6.4.2

STRONGLY RECOMMENDED OIL TYPES FOR GRASSO RECIPROCATING COMPRESSORS

Refrigerant used

Table 6.4-1 Oil selection table

NH3

Some of the oil types listed in the tables 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/alternavive oils is not permitted without the written consent of Grasso.

Table 6.4-2 Strongly recommended oil types for Grasso reciprocating compressors

OIL SELECTION TABLE

Refrigerant used

6.4.1.1 REMARKS 1. Using ISO VG100 oils to increase viscosity at high expected cranckcase-temperatures makes no sense as the friction-heat will increase that much, that the oil-temperature limit related to the minimum viscosity of 10 cSt will also be exceeded. Only in case of expected high refrigerant-concentrations in the cranckcase this viscosity-gradeoil is an alternative! 2. Using ISO VG46 oils to meet low pour point requirements is only acceptable if coupled to a high viscosity-index of at least 100, otherwise the working limits are so limited (again concerning the minimum required oil-viscosity of 10 cSt) that it can be used in medium evaporation-pressures, making no sense to use them als a low pourpoint alternative!

ISO VG-number, according to ISO 3448 46

68

100

-

vb

v

vb

-50

v

-30

v

v

-20

v

-10

v

v v

-30

v

CPI

CP-1009-68

PETRO CANADA

Reflo 68A

EXXON MOBIL

SHC NH68a

Klüber

Summit RHT-68

TEXACO

Capella Premium 68

SHELL

Clavus S-68

v

0

v

Type designation

a. Recommended for evaporating temperatures below -37 oC

+10 -50

NH3

Brand

v v

-20

v

v

-10

v

v

0

v

+10

v

For all other refrigerants contact Grasso Legend

IMM0703/v008

v

Approved by Grasso

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 107-

6. APPENDIX; Product Information (PI)

6.4.3

ACCEPTED NH3 AND HCFC OIL TYPES FOR GRASSO RECIPROCATING COMPRESSORSS

Table 6.4-3 Accepted NH3 and HCFC (e.g. R22) oil types for Grasso reciprocating compressors Brand AVIA

BP

Type designation

ISO VG numbera

FC 46

44

FC 68

65

Energol LPT-F 46

54

68b

68

Energol LPT

CASTROL

Icematic 299

56

CPI

CP-1009-68

69

Zerice S46

48

Zerice S68

68

Arctic 300

68

SHC NH68

68

Reniso KS 46

47

Reniso KC 68

68

KROON OIL

Carsinus FC 46/68

46

PETRO CANADA

Reflo 68Ac

58

Kuwait Petroleum

Q8 Stravinsky C

55

Clavus 46

46

Clavus 68

68

Clavus G 46d

46

Clavus G 68d

68

Clavus G 100d

95

Suniso 3.5 GSc

43

Suniso 4 GSc

55

Suniso 5 Gc

94

SAc

57

EXXON MOBIL

FUCHS

SHELL

SUN-OIL

Suniso 4 TEXACO

a. b. c. d.

Capella WF 68

ACCEPTED HCFC OIL TYPES FOR GRASSO RECIPROCATING COMPRESSORS

Table 6.4-4 Accepted HFC (e.g. R134a, R404A, R407c, R507) oil types for Grasso reciprocating compressors Brand CASTROL

CPI

TOTAL

FUCHS

ICI EXXON MOBIL SHELL

TEXACO

Type designation

ISO VG numbera

Icematic SW 68

67

Icematic SW 100

100

Solest 68

64

Solest 120

131

ACD 68 M

70

ACD 100 FY

98

Reniso E 68

68

Reniso E 100

100

Emkarate RL 68H

68

Emkarate RL 100H

100

EAL Arctic 68

63

Clavus R68

66

Clavus R100

94

Capella HFC 55

52.5

Capella HFC 80

80

Capella HFC 120

118

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

65

Capella Premium 68

67

TOTAL

Luneria FR 68

68

Klüber

Summit RHT-68

68

Viscosity grade number designation according to ISO Standard 3448. Not miscible with R22 at low temperatures NH3 only For NH3 only possible if water and air are not present!

- 108-

6.4.4

6.5 6.5.1

CAPACITY CONTROL SYSTEMS SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START

General Capacity control of the compressor will be enabled by raising and lowering 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) • 'Fast pull down' (FPD); obligatory for R404A and R507 applications; recommended for all two-stage compressors • Manual (Not allowed for two-stage compressors)

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

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 energising the solenoid valve for unloaded starting. This is a Normally Open valve in contrast with the solenoid valves for capacity control which are Normally Closed. This NO-solenoid valve has to be energised when starting the electric motor and has to be De-energised when the compressor is running (and the specified lubricating oil pressure is reached), by means of an auxiliary time relay. Time relay is not included within the scope of supply. After fully unloaded compressor starting, this solenoid valve must be DE-engergised allowing control oil pressure to the control pistons of the 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 energised during continuous operation. For two-stage compressors only HP cylinders are initialised, which, however, do not at the same time represent the minimum capacity. The other cylinders can be energised or de-energised in one or more steps in a standard sequence for each type of compressor. It is possible that control oil pressure can remain in the capacity control loading system even after the compressor has been de-activated. On re-starting this can cause the compressor to have partially loaded cylinders.To prevent this, the remaining oil pressure has to be released from the control system. Therefore, the “NO” solenoid valve should be activated a minimum of 10 seconds before the compressor is started to ensure all cylinders are fully unloaded. Furthermore, for a smooth stopping characteristic, the “NO” solenoid valve can be activated a maximum of 5 seconds before stopping the compressor.

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 109-

6. APPENDIX; Product Information (PI)

6.5.2

ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD)

General Electric capacity control is compulsory 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 solenoid valves depends on type of compressor Standard scope of supply • One NO-solenoid valve (with LED indicator) for unloaded starting (mounted). • A number of NC- solenoid valves (each with LED indicator; mounted). • Oil pressure lines (mounted). Options (for two-stage compressors only) • Fast Pull Down control system FPD is compulsory for R404A and R507. The standard starting procedure which is contained in the standard electrical capacity control, is only suitable if the compressor is being started at design evaporating temperature. In case the compressor has to start frequently with high evaporating temperatures (batch freezing, etc), fast pull down capacity control is necessary to avoid that the compressor runs continuously in part-load. 6.5.2.1

- 110-

GENERAL DIAGRAM OF ELECTRICALLY OPERATED CAPACITY CONTROL

Legend A

Top view of compressor

B

Valve lifting mechanism

C

Oil return from valve lifting mechanisms to crankcase

D

Oil pump

E

Electrical wiring to star/delta switch of the motor

H

Supply of oil (control pressure)

NO

Normally Open; 3-way solenoid valve for unloaded starting

NC

Normally Closed; 3-way solenoid valve for capacity control

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.5.2.2

DIAGRAMS

HP cilinders No.

Table 6.5-1 Solenoid valve/cylinder numbering for electric capacity control

Compressor typea

a. b. c. d. e.

Solenoid FPDb c NC

UNLd e NO

No. 1 NC

No. 2 NC

No. 3 NC

No. 4 NC

Cylinder number / solenoid valves

4

-

-

1+2

3

4

-

-

6 Single stage

-

-

1+3

6

4

5

2

6 Booster

-

-

2+3+ 5

6

4

1

-

9 Single stage

-

-

1+2+ 3

8

5+6

4+7+ 9

-

9 Booster

-

-

1+3+ 5+8

2+6

4+7+ 9

-

-

12 Single stage

-

-

1+2+ 3

11

5+8

4 + 10 6 + 7 + + 12 9

12 Booster

-

-

1+2+ 3+4+ 9

5+8

6 + 11

7 + 10 + 12

-

31

2

-

2

1+3

4

-

-

31 + FPD

2

1

2

3

4

-

-

42

3+6

-

3

1+2

5

4+6

-

42 + FPD

3+6

6

3

1+2

5

4

-

51

3

-

3

1+2

6

5

4

51 + FPD

3

1

3

2

6

5

4

63

3+6 +9

-

63 + FPD

3+6 +9

72

3

1+ 2 5+8+ 4+7+ 9 6

-

6

3

1+ 2 5+8+ 9

4+7

-

3+6

-

3

1+2

7

5+6+ 8

4+9

72 + FPD

3+6

6

3

1+2

7

5+8

4+9

84

3+6 +9+ 12

-

3

1+2

84 + FPD

3+6 +9+ 12

12

3

1+2

5+7

8+9+ 4+6+ 11 10

93

3+6 +9

-

3

1+5+ 7

8

2 + 4 + 6 + 11 9 + 10 + 12

93 + FPD

3+6 +9

6

3

1+5+ 7

8

2+4+ 9 + 10

11 + 12

102

3+6

-

3+6

1+2+ 9

4+5

10 + 12

7+8+ 11

102 + FPD

3+6

9

3+6

1+2

4+5

10 + 12

7+8+ 11

5+7+ 8+9+ 4+6+ 12 11 10

Explanation; 2=Grasso 12(E), 21=Grasso 2112(E) FPD= Fast Pull-Down NC= Normally closed UNL= Unloaded starting NO= Normally open

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 111-

4 single stage & Booster

6 single stage

6 Booster

9 single stage

9 Booster

Cylinders

ϕ

50

-

1+2

-

-

75

-

1+2+3

1

-

100

-

1+2+3+4

1+2

-

33

-

1+3

-

-

50

-

1+3+6

1

-

67

-

1+3+4+6

1+2

-

83

-

1+3+4+5 1+2+ +6 3

-

1+2+3+4 1+2+ +5+6 3+4

b

-

Compressor type

Cylinders

ϕb

25

-

1+2+3

-

-

33

-

1 + 2 + 3 + 11

1

-

42

-

1+2+3+5 +8

2

-

50

-

1+2+3+5 + 8 + 11

1+2

-

58

-

1+2+3+4 + 10 + 11 + 12

1+3

-

67

-

1+2+3+4 + 5 + 8 + 10 + 12

2+3

-

75

-

1+2+3+5 +6+7+8+ 1+2+ 4 9 + 11

-

83

-

1+2+3+4 1+3+ +6+7+9+ 4 10 + 11 + 12

-

92

-

1+2+3+4 2+3+ +6+7+8+ 4 9 + 10 + 12

-

100

-

1+2+3+4 +5+6+7+ 1+2+ 8 + 9 + 10 + 3 + 4 11 + 12

-

42

-

1+2+3+4 +9

-

-

58

-

1+2+3+4 +5+8+9

1

-

75

-

1+2+3+4 +5+6+8+ 9 + 11

1+2

-

1+2+3+4 +5+6+7+ 1+2+ 8 + 9 + 10 + 3 11 + 12

-

12 single stage

100

-

50

-

2+3+5

-

-

67

-

2+3+5+6

1

-

83

-

2+3+4+5 +6

1+2

-

100

-

1+2+3+4 1+2+ +5+6 3

-

33

-

1+2+3

-

-

44

-

1+2+3+8

1

-

56

-

1+2+3+5 +6

2

-

67

-

1+2+3+5 +6+8

1+2

-

78

-

1+2+3+4 +7+8+9

1+3

-

89

-

1+2+3+4 +5+6+7+ 9

2+3

-

100

-

1+2+3+4 +5+6+7+ 1+2+ 3 8+9

-

100

-

44

-

1+3+5+8

-

-

0

Starting only

2

-

0.0

67

-

1+2+3+5 +6+8

1

-

67

-

1+2+3

1

2.0

-

1+2+3+4

1+2

3.0

-

1+2+3+4 +5+6+7+ 8+9

100

100

1+2

-

12 booster

31

31 + FPD

42

0

Starting only

2

-

0.0

33

Starting only

1+2

FPD

1.0

67

-

1+2+3

1+ FPD

2.0

100

-

1+2+3+4

1+2+ FPD

3.0

0

Starting only

3

-

0.0

50

-

1 + 2+ 3

1

2.0

75

-

1+2+3+5

1+2

3.0

-

1+2+3+4 1+2+ +5+6 3

2.0

100

- 112-

Remarks

Solenoids

Remarks

Solenoids

Compressor type

Capacity %a

Table 6.5-2 Capacity control steps

Capacity %a

6. APPENDIX; Product Information (PI)

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

ϕb

Capacity %a

Remarks

Solenoids

42 + FPD

Remarks

Solenoids

Compressor type

Capacity %a

6. APPENDIX; Product Information (PI)

ϕb

0

Starting only

3

-

0.0

0

Starting only

3

-

0.0

0

Starting only

3+6

FPD

0.0

29

-

1+2+3

1

2.0

50

-

1+2+3

1

2.0

43

-

1+2+3+7

1+2

3.0

50

Starting only

1+2+3+6

1+ FPD

1.0

57

-

1+2+3+5 +6+8

1+3

2.0

75

-

1+2+3+5

1+2

3.0

72

-

2.5

-

1+2+3+5 1+2+ +6 FPD

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

1.5 86

-

1+2+3+4 +5+6+8+ 1+3+ 4 9

3.0

100

-

1+2+3+4 1+2+ +5+6+7+ 3+4 8+9

3.5

75 100

-

IMM0703/v008

2.0

3

-

0.0

40

-

1+2+3

1

2.0

0

Starting only

3

-

0.0

60

-

1 + 2 +3 + 6

1+2

3.0

0

Starting only

3+6

FPD

0.0

80

-

1+2+3+5 1+2+ +6 3

4.0

29

-

1+2+3

1

2.0

100

-

1+2+3+4 1+2+ +5+6 3+4

5.0

29

Starting only

1+2+3+6

1+ FPD

1.0

0

Starting only

3

-

0.0

43

-

1+2+3+7

1+2

3.0

20

Starting only

1+3

FPD

1.0

43

-

1+2+3+6 1+2+ +7 FPD

1.5

40

-

1+2+3

1+ FPD

2.0

57

-

1+2+3+5 1+3+ +6+8 FPD

2.0

60

-

1+2+3+6

1+2+ FPD

3.0

72

-

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

2.5

80

-

1+2+3+5 +6

1+2+ 3+ FPD

1+2+ 3+ FPD

4.0 86

-

3.0

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

1+2+3+4 1+3+ +5+6+8+ 4+ 9 FPD

5.0 100

-

1+2+3+4 1+2+ +5+6+7+ 3+4+ 8+9 FPD

3.5

-

0

Starting only

3

-

0.0

33

-

1+2+3

1

2.0

67 100

63 + FPD

72

Cylinders

Starting only

100

63

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

Compressor type

0

51

51 + FPD

Cylinders

-

1+2+3+5 +8+9

-

1+2+3+4 1+2+ +5+6+7+ 3 8+9

1+2

72 + FPD

0

Starting only

3

-

0.0

25

-

1+2+3

1

2.0

50

-

1+2+3+5 + 7 + 12

1+2

2.0

75

-

1+2+3+5 1+2+ +7+8+9+ 3 11 + 12

2.0

100

-

1+2+3+4 +5+6+7+ 1+2+ 8 + 9 + 10 + 3 + 4 11 + 12

2.0

2.0 2.0

0

Starting only

3

-

0.0

0

Starting only

3+6

FPD

0.0

33

-

1+2+3

1

2.0

33

Starting only

1+2+3+6

1+ FPD

1.0

67

-

1+2+3+5 +8+9

1+2

2.0

67

-

1+2+3+5 1+2+ +6+8+9 FPD

1.3

100

-

1+2+3+4 1+2+ +5+6+7+ 3+ 8+9 FPD

2.0

84

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 113-

0

Starting only

3

-

0.0

0

Starting only

3 + 12

FPD

0.0

25

-

1+2+3

1

2.0

25

Starting only

1 + 2 + 3 + 12

1+ FPD

1.0

50

-

1+2+3+5 1+2+ + 7+ 12 FPD

2.0

75

-

1+2+3+5 1+2+ +7+8+9+ 3+ 11 + 12 FPD

2.0

70

-

1+2+3+4 +5+6+9+ 1+2+ 3 10 + 12

3.5

100

-

1+2+3+4 1+2+ +5+6+7+ 3+4+ 8 + 9 + 10 + FPD 11 + 12

2.0

80

-

1+2+3+6 1+2+ +7+8+9+ 4 10 + 11 + 12

4.0

0

Starting only

3

-

0.0

100

-

5.0

33

-

1+3+5+7

1

3.0

1+2+3+4 +5+6+7+ 1+2+ 8 + 9 + 10 + 3 + 4 11 + 12

45

-

2+3+4+8 + 9 + 10

2+3

2.0

93

1+3+5+6 1+4 + 7 + 11 + 12

2.5

67

-

1+2+3+4 +5+7+9+ 10

1+3

3.0

78

-

1+2+3+4 1+2+ +5+7+8+ 3 9 + 10

3.5

-

1+2+3+4 +5+6+7+ 1+2+ 8 + 9 + 10 + 3 + 4 11 + 12

100

93 + FPD

- 114-

Remarks

Cylinders

ϕb

0

Starting only

3+6

-

0.0

30

-

1+2+3+6 +9

1

1.5

50

-

1+2+3+6 1+2 + 9 + 10 + 12

2.5

60

-

1+2+3+6 +7+8+9+ 11

1+4

3.0

102

-

56

Compressor type

Solenoids

ϕb

Cylinders

Capacity %a

84 + FPD

Remarks

Solenoids

Compressor type

Capacity %a

6. APPENDIX; Product Information (PI)

0

Starting only

3+6

-

0.0

20

Starting only

1+2+3+6

1

1.0

30

-

1+2+3+6 +9

1+ FPD

1.5

40

-

1+2+3+6 + 10 + 12

1+2

2.0

50

-

1+2+3+6 1+2+ + 9 + 10 + 12 FPD

2.5

60

-

1+2+3+6 1+4+ +7+8+9+ FPD 11

3.0

70

-

1+2+3+4 1+2+ +5+6+9+ 3+ 10 + 12 FPD

3.5

80

-

1+2+3+6 1+2+ +7+8+9+ 4+ 10 + 11 + 12 FPD

4.0

90

-

1+2+3+4 +5+6+7+ 1+2+ 8 + 10 + 11 + 3 + 4 12

4.5

100

-

1+2+3+4 1+2+ +5+6+7+ 3+4+ 8 + 9 + 10 + FPD 11 + 12

5.0

3.0 102 + FPD

0

Starting only

3

-

0.0

0

Starting only

3+6

FPD

0.0

33

-

1+3+5+7

1

3.0

33

-

1+3+5+6 +7

1+ FPD

1.5

44

-

2+3+4+8 + 9 + 10

2+3

2.0

56

-

1+3+5+6 1+4+ + 7 + 11 + 12 FPD

2.5

67

-

1+2+3+4 +5+7+9+ 10

1+3

3.0

78

-

1+2+3+4 +5+7+8+ 1+2+ 3 9 + 10

3.5

100

-

1+2+3+4 1+2+ +5+6+7+ 3+4+ 8 + 9 + 10 + FPD 11 + 12

3.0

a. Refer 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

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.5.3

MANUAL CAPACITY CONTROL

General Instead of the recommended electric capacity control, a manual operated capacity control system can be delivered for single stage and booster compressors. Electrical supply still required for the NO three-way solenoid valve.

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

Capacity control steps are equal to electric capacity control. Procedure and data • Refer to figure (oil distributor positioned in unloaded start). • Depending on type of compressor one or more of the distributor ports may not be in use. • Survey of capacity control steps for each position of oil distributor handle refer to the relevant table in this chapter. • Electrical supply required for three-way solenoid valve for unloaded starting. Standard scope of supply • Three-way NO-solenoid valve for unloaded starting (mounted on suction housing, not wired; refer to Section 6.5.1. • Oil distributor (mounted on suction filter housing). • Oil pressure lines (mounted). Fig. 6.5-1 Diagram of manually operated capacity control system

Legend

IMM0703/v008

A

Top view of compressor

B

Valve lifting mechanism

C

Oil return to crankcase

D

Oil pump

E

Electrical wiring to star/delta switch of the motor

G

Solenoid valve for unloaded starting (NO)

H

Supply of oil pressure

J

Solenoid valve(s) for capacity control

NO/NC

Normally Open/Normally Closed

ES

Manual capacity control switch

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 115-

6. APPENDIX; Product Information (PI)

Compressor type

212

Capacity %

Table 6.5-3 Solenoid valve/cylinder numbering for standard capacity control steps

50 100

Cylinder number Remarks

single stage and booster

33 312

67

single stage and booster

100 50 412

3

4

5

2

-

-

-

-

-

1-2

3

-

-

-

-

-

1-3

-

-

-

-

-

1-2-3

-

-

-

-

-

-

-

1-2-3

-

-

-

100

-

-

1-2-3-4

-

-

33

1-3

-

4

5

2

50

-

1-3-6

-

-

-

-

-

1-3-4-6

-

-

single stage and booster

single stage

83

-

-

-

1-3-4-5-6

-

100

-

-

-

-

1-2-3-4-5-6

50

2-3-5

-

-

-

-

-

2-3-5-6

-

-

-

67 83

booster

-

-

2-3-4-5-6

-

-

100

-

-

-

1-2-3-4-5-6

-

38

1-2-3

-

-

-

-

-

1-2-3-8

-

-

-

-

-

1-2-3-5-6-8

-

-

-

-

-

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

-

100

-

-

-

-

1-2-3-4-5-6-7-8-9

44

1-3-5-8

-

-

-

-

-

1-2-3-5-6-8

-

-

-

100

-

-

1-2-3-4-5-6-7-8-9

-

-

25

1-2-3

-

-

-

-

50

-

1-2-3-5-8-11

-

-

-

-

-

1-2-3-4-5-7-8--1112

-

-

83

-

-

-

1-2-3-4-5-6-7-8--9 -11

-

100

-

-

-

-

1-2-3-4-5-6-7-8-910-11-12

42

1-2-3-4-9

-

-

-

58

-

1-2-3-4-5-8-9

44 67 912

2

1-2

75

67

612

Position of handle of oil distributor 1

single stage

88

67

booster

67 single stage

1212

75 100

- 116-

booster

-

-

1-2-3-4-5-6-8-9-1 1

-

-

-

-

-

-

-

1-2-3-4-5-6-7-8-910-11-12

-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

6.6 6.6.1

PACKAGED BASE FRAME AND FOUNDATION BLOCK PACKAGED BASE FRAME

General For mounting on a concrete foundation block, Grasso can supply a standard welded steel base frame to support compressor, motor and accessoiries. Especially for vibration free operation on floors and on roof tops, a base frame with vibration dampers can be delivered (concrete foundation block can be omitted). A. BASE FRAME FOR MOUNTING ON CONCRETE BLOCK (“TRANSPORT BASE FRAME“) Design Data • Base frame to be placed on concrete foundation block. For foundation block dimensions consult Grasso. • There should never be a direct rigid connection whatsoever between the foundation block and the floor or any other main part of the building. • The concrete block should be extended down to any subsoil.

Fig. 6.6-1 Packaged base frame, direct drive with oil separator

Scope of supply • Steel base frame, incl mounting of compressor, electric motor and accessories. B. BASE FRAME FOR MOUNTING ON VIBRATION DAMPERS (TORSIONAL STIFF) Design Data • Frame to be placed direct on elevated floors and on roof tops (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. • Always consult Grasso for installation advice.

Fig. 6.6-2 Packaged base frame, V-belt drive with oil separator

Scope of supply • Steel closed box profile base frame, including mounting of compressor, electric motor and accessories. • Set of vibration dampers. 6.6.1.1

PACKAGED BASE FRAME

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 117-

6. APPENDIX; Product Information (PI)

Fig. 6.6-3 Packaged base frame (DD=Direct driven, VD=V-belt driven)

- 118-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

Dimensions

Frames on vibration dampers

All dimensions and weights as mentioned are estimated values. Consult Grasso to determine exact values.

Packaged base frame for mounting on vibration dampers can be determined by Grasso on request.

Table 6.6-1 Weights and dimensions, direct driven

6.6.2

Approx. dimensions and weights Direct driven Compressor type

(kg)

L(mm)

W(mm)

H(mm)

4

2120

2750

1400

1850

6

2760

2830

1500

2200

9

3400

3370

12

4020

3760

1660

2330

31

1915

2570

1600

1850

2400

2830

3230

3330

3700

3640

42 51

2200 1500

63 72 84

2330

93

1550

BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK

For direct driven compressors, a packaged base frame is strongly recommended 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 design and carrying out of foundations entirely to qualified firms, which, at the same time, are prepared to take full responsiblility for the job.

102 Table 6.6-2 Weights and dimensions, V-belt driven Approx. dimensions and weights V-belt driven Compressor type

(kg)

4

2220

6

2860

L(mm) 2300

W(mm)

H(mm)

1750

1750

1960

2100

9

3500

2330

2150

12

4120

2450

2580

31

2015

2240

1640

1750

2500

2350

1880

2100

42 51 63 72

3330

84 93

1980 2560

3860

2230

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 table below are directly related to the compressor and the drive. Other dimensions are determined by amongst others, the electric motor.

2230 2450

102

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 119-

6. APPENDIX; Product Information (PI)

6.6.2.1

FOUNDATION BLOCK

Legend

Dimensions in mm Compressor dimension O (Section 6.1.2)

C-O

bb

c

2 /3 /21a

295

4 /31

625

6 /42 /51

685

9 /63 /72

1075

12 /84 /93 /102

2x732.5

2 /3 /21 /4 /31

--

6 /42 /51 /9 /63 / 72 /12 /84 /93 /102

660

2 /3 /21 /4 /31 /6 /42 /51

85

9 /63 /72 /12 / 84 /93 /102

110 (for 3-, 6- and 8-groove flywheel) 60 (for 10-groove flywheel)

e

2.5 x diameter of foundation anchor (= 50 mm for Grasso 12-compressor; only valid when using filling compound)

h

Total height of concrete block (consult Grasso)

a. 21 is compressor with 2 low stage cylinders and 1 high stage cylinder b. Measure b applies to L-shaped foundation blocks only. The blocks for 2-, 3- and 4-cylinder compressors are always rectangular. The blocks for 6-, 9- and 12-cylinder compressors may be L-shaped or rectangular.

6.7

CRANKCASE HEATER

Recommended for all compressors and all conditions of operation. 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.

Fig. 6.6-4 Foundation top Table 6.6-3 Legend

Dimensions in mm

FW

Flywheel

MP

Motor pulley

CLC

Centre line compressor

CLM

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.

Centre line motor Foundation anchor

fa

Compressor model:

number of foundation anchors:

2 /3 /21( a)/4 /31 / 6 /42 /51 /9 /63 /72

4

12 /84 /93 /102

6

fb

Foundation block

fc

Filling compound

cc

Concrete

- 120-

Low oil temperatures may also cause a high oil viscosity, which may result in troublesome starting. Selection and Data standard heater • Refer to table. • Engine room temperatures below 20 °C. • Wiring: If 'compressor NOT running' then 'element is energised'. Standard scope of supply • Heater element (mounted, not wired).

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

6. APPENDIX; Product Information (PI)

Not included: • Auxiliary relais K1 (refer Fig. 6.7-4) Table 6.7-2 Max. number of special cranckcase heaters, each 600 Watt Number of cylinders

Max. number of heating elements

4-6

2

9

3

12

4

Fig. 6.7-1 Standard crankcase heater

Legend CE

Cable entry

RC

Removable cap to protect connections

Mentioned power in Watt; Standard voltages are 110-120 V and 220-240 V. 6.7.1

HEATER FITTING DETAIL

The standard crankcase heater is fitted into a sleeve so can be exchanged while compressor is in operation.

Fig. 6.7-3 Alternative crankcase heating element

Table 6.7-1 Number of compressor cylinders

Installed power of heater element

Dimension L (mm)

4 - 6 -9 - 12

525

600

Fig. 6.7-4 Electrical wiring schematic

Legend Fig. 6.7-2 Locations of crankcase heaters (Std=standard; Alt=alternavive)

E1, 2, 3

Heater element

XY45

Temperature controlled relay

K1

Relay

Options Grasso can supply alternative crankcase heating elements, recommended for low ambient or engine room temperatures below +15 oC. Included are: • Up to 4 alternative crankcase heating elements, 600W each (mounted on special service covers). • Thermostat and sensor PT100, supplied loose. IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 121-

6. APPENDIX; Product Information (PI)

- 122-

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

IMM0703/v008

7. NOTES

7. NOTES

IMM0703/v008

Reciprocating Compressors for industrial refrigeration / Series Grasso 12E

- 123-