Piston Grasso 6 Installation and Maintenance Manual PDF

Reciprocating Compressors for industrial refrigeration
Series Grasso 6
Installation and Maintenance Manual (IMM)
ca0148_0089238_v002_gbr
Reciprocating Compressors for industrial refrigeration / Series Grasso 6
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Copyright
All Rights reserved. No part of this publication may be
copied or published by means of printing, photocopying,
microfilm or otherwise without prior written consent of
Grasso.
This restriction also applies to the corresponding
drawings and diagrams.
The compressor is not filled with oil.
Legal Notice
This publication has been written in good faith.
However, Grasso cannot be held responsible, neither for
any errors occurring in this publication nor for their
consequences.
This manual must be carefull read and understood prior

to installing and servicing the compressor (package)
Safety
This manual is written with great care, but the
contractor/installer is held responsible to examine this
information and to take care of possible additional and/
or deviated safety measures.
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 and Grasso 10.
b. Semi hermetic compressor series are Grasso 7S and
Grasso 8S.
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.
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IMM0312/v002
Table of Contents
Section
Title
Page
INSTALLATION AND PREPARATION FOR USE
1.1
INSTALLATION
1.1.1
Moving instructions and storage
1.1.2
Storage
1.1.3
Hoisting and moving instructions
1.1.4
Required free space
10
1.1.5
Foundation requirements
10
1.1.5.1
Concrete structure
10
1.1.5.2
Anchoring
11
1.1.5.3
Concrete block mounting instructions
11
1.1.5.3.1
Mounting bare compressor on a concrete block
12
1.1.5.3.2
Mounting the base frame on a concrete block
12
1.1.5.3.3
Levelling the base frame
12
1.1.5.3.4
Finishing with a self-levelling grout
12
1.1.6
Connecting to refrigerating system pipework
12
1.1.7
Connecting the power supply
13
1.1.8
Earthing connections
13
1.1.9
Separately delivered components
13
1.2
PREPARATIONS FOR USE
15
1.2.1
Leak test of compressor and system
15
1.2.2
EVACUATION/DRYING THE REFRIGERATING SYSTEM
15
1.2.3
Initial oil charge
15
1.2.3.1
Initial oil charge
15
1.2.4
Initial refrigerant charge
15
1.2.5
Adjustment of instruments and safety devices
16
1.2.5.1
Pressure safeties
16
1.2.5.2
Re-adjustment of oil pressure regulator
16
1.2.6
Checking direction of rotation of motor shaft
16
1.2.7
Installing the drive guards (if present)
16
1.2.8
Initial oil warm up
16
1.2.9
Initial start-up
16
1.2.9.1
Limitations of part load operation and start-up
16
1.2.9.2
Pre-start check list
16
1.2.10
Starting and stopping procedures
17
1.2.10.1
First start
17
1.2.10.2
Restart
17
1.2.10.3
Restart after a short standstill period of time (less than 1 month)
17
1.2.10.4
Restart after a long standstill period of time
17
1.2.10.5
Stopping the compressor
17
INSPECTION, MAINTENANCE AND TROUBLE SHOOTING
19
2.1
INSPECTION
21
IMM0312/v002
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Section
Title
Page
2.1.1
Periodical inspection
21
2.1.2
Survey of periodical inspections
21
2.1.2.1
CHECK LIST PERIODICAL INSPECTIONS
21
2.2
MAINTENANCE (REFER Chapter 5)
23
2.2.1
Post start-up maintenance
23
2.2.2
First maintenance
23
2.3
STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months)
23
2.4
LUBRICATION DATA
23
2.4.1
Topping up oil with compressor operating
23
2.5
EVACUATION OF THE COMPRESSOR
24
2.6
DRAINING AND CHANGE OF OIL
24
2.7
OIL SUCTION AND DISCHARGE FILTERS
24
2.8
DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES
24
2.9
COMPRESSOR PURGING
24
2.10
TROUBLESHOOTING TABLE
24
PARTS COMPRESSOR
27
PARTS ACCESSORIES
57
MAINTENANCE
65
5.1
SMS FACTOR
65
5.2
Grasso 6
67
5.3
Checklist
69
APPENDIX; Product Information (PI)
71
6.1
TECHNICAL DATA
71
6.2
MAIN DIMENSIONS AND SPACE REQUIREMENTS
73
6.3
SHAFT END COMPRESSOR
74
6.4
LIMITS OF OPERATION AND FIELDS OF APPLICATION
75
6.4.1
GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 6
75
6.4.1.1
FIELDS OF APPLICATION
76
6.4.2
PRECISE FIELD OF APPLICATION
77
6.4.3
LIMITATIONS OF PART-LOAD OPERATION
77
6.5
LUBRICATING OILS (choice and recommendations)
79
6.6
CAPACITY CONTROL
80
6.6.1
CYLINDER NUMBERING
81
6.7
PACKAGED BASE FRAME
82
6.7.1
PACKAGED BASE FRAME
82
6.8
CRANKCASE HEATER
83
6.8.1
DETAILS CRANKCASE HEATER
83
NOTES
85
7.1
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85
IMM0312/v002
Main setup data Grasso 6
Table 1 Main setup data
Description
Value
Start frequency
max. 4 starts per hour
Time interval between stopping and re-starting
min. 2 minutes
Time interval between starting and re-starting
min. 15 minutes
Time interval between loading and unloading
min. 3 minutes
Oil level
25-75% crankcase sight glass
Min. oil temperature
warmer than surroundings and 20 C for NH3 and 30

C for halocarbons
Max. oil temperature
Refer to oil selection table/applied type of oil
Required oil viscosity;

10 cSt during operation at
location of bearings
Lubricating oil pressure difference
Setting approx. 2.2 bar
After a mimimum of 15
minutes running time at an oil
temperature of approx. 50 oC
(122 oF)
Max. discharge temperature
155 C
Min. suction pressure
0.3 bar
Pdischarge - Psuction
24.0 bar
Superheat
>0 Kfor NH3,

>15K for R507/R404A/R134a
Remark
For continuous minimum

part-load (i.e. more than 30
minutes) consult Grasso.
Normally counterclockwise
when facing shaft end of the
compressor.
Direction of rotation of compressor drive shaft
Initially both directions are allowed
After initial run, never

change the direction of
rotaion anymore.
Cylinder numbering of Grasso reciprocating

compressors
IMM0312/v002
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Fig. 1 Cylinder numbering Grasso reciprocating compressors
Legend
1, 2, 3, ...
Cylinder numbers
Top view of compressor
Motor/Drive end of compressor
Oil pump of compressor
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IMM0312/v002
1. INSTALLATION AND PREPARATION

FOR USE
1. INSTALLATION AND PREPARATION FOR USE

Table of Contents
Section
Title
Page
1.1
INSTALLATION
1.1.1
Moving instructions and storage
1.1.2
Storage
1.1.3
Hoisting and moving instructions
1.1.4
Required free space
10
1.1.5
Foundation requirements
10
1.1.5.1
Concrete structure
10
1.1.5.2
Anchoring
11
1.1.5.3
Concrete block mounting instructions
11
1.1.5.3.1
Mounting bare compressor on a concrete block
12
1.1.5.3.2
Mounting the base frame on a concrete block
12
1.1.5.3.3
Levelling the base frame
12
1.1.5.3.4
Finishing with a self-levelling grout
12
1.1.6
Connecting to refrigerating system pipework
12
1.1.7
Connecting the power supply
13
1.1.8
Earthing connections
13
1.1.9
Separately delivered components
13
1.2
15
1.2.1
Leak test of compressor and system
15
1.2.2
EVACUATION/DRYING THE REFRIGERATING SYSTEM
15
1.2.3
Initial oil charge
15
1.2.3.1
Initial oil charge
15
1.2.4
Initial refrigerant charge
15
1.2.5
Adjustment of instruments and safety devices
16
1.2.5.1
Pressure safeties
16
1.2.5.2
Re-adjustment of oil pressure regulator
16
1.2.6
Checking direction of rotation of motor shaft
16
1.2.7
Installing the drive guards (if present)
16
1.2.8
Initial oil warm up
16
1.2.9
Initial start-up
16
1.2.9.1
Limitations of part load operation and start-up
16
1.2.9.2
Pre-start check list
16
1.2.10
Starting and stopping procedures
17
1.2.10.1
First start
17
1.2.10.2
Restart
17
1.2.10.3
Restart after a short standstill period of time (less than 1 month)
17
1.2.10.4
Restart after a long standstill period of time
17
1.2.10.5
Stopping the compressor
17
IMM0312/v002
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FOR USE
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IMM0312/v002

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 Grassos instructions.
This section contains instructions for the proper
installation of a Grasso compressor (package). Before
the compressor (package) is ready for the initial start up,
the installation instructions in the following paragraphs
must be followed:
1. The Compressor (Package) should be levelled and
securely anchored to the foundation.
2. All piping should be completed.
3. The system and the compressor are to be pressure
tested for leaks (see. Section 1.2.1)
4. The system should be evacuated to remove air and
moisture.
5. The electric wiring should be completed as per wiring
diagrams. Do not 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.
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
all times in a dry location to prevent corrosion damage.
If the compressor (package) is to be stored for a
prolonged period of time, it should be checked weekly to
ensure that the holding charge of dry nitrogen remains
above atmospheric pressure.
1.1.3
HOISTING AND MOVING INSTRUCTIONS
Fig. 1.1-1 Hoisting a compressor package
Do not forget to 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".
Legend
C
Compressor
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.
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!
IMM0312/v002
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FOR USE
DO NOT use the compressor or motor or oil separator

hoisting eyes to move the package! These hoisting eyes
are intended for lifting loose components only and not
for the entire package!
Bare compressor or loose components:

Determine the dead weight of the particular component
(see "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).
Refer to Product Information for minimum

requirements.
1.1.5
FOUNDATION REQUIREMENTS
This paragraph covers measures to be taken for a
compressor (package) mounting on a concrete floor.
Two foundation arrangements are described:
Compressor package with steel base frame mounted
on a concrete block.
Bare compressor direct mounted on a concrete block
via grouted machined anchors (see "Product
Information (ED)"). The mounting surfaces of these
machined anchors must be level without any
deviation and projecting at least 10 mm above the
concrete base.
COMPRESSOR AND COMPRESSOR PACKAGE TO BE

MOUNTED ON A CONCRETE BLOCK. On request, Grasso
can calculate the exact dimensions of the concrete block,
based on the compressor size and operating conditions.
1.1.5.1
CONCRETE STRUCTURE
Fig. 1.1-3 Concrete block
Legend
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.
-Page 10-
Cork board
Concrete base
(Concrete) Floor
Sand
The concrete block for compressor and motor or

compressor package should have a profile as illustrated
in Table on Page 10and 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.
IMM0312/v002

FOR USE
There should be sufficient free space around the

block to install corkboard (or similar).
The block should be provided with anchor bolt
recesses or holes according to the anchor bolt spacing
as per package lay out drawing.
Table 1.1-1
Legend
A
Chemical anchor
Grouted anchor, grounded to reinforcing steel
It is recommended to consult a concrete specialist/

constructor for the following items:
The compound of the concrete with/without
reinforcement.
The exact grouting depth (dependent on the soil
conditions).
Installing foundation onto an existing floor, with
sealing corkboard or vibration isolators.
1.1.5.2
ANCHORING
After the concrete block has cured the anchors should be
installed as shown above and in case of a package in
accordance with the package lay out drawing.
Templates should be made to locate the anchor bolts or
chemical anchors to match the holes in the bottom
flange of the base frame.
Grout the mortar according to the supplier instructions.
Install chemical anchors as illustrated in Fig. 1.1-4 and
according to the instructions of the anchor supplier.
Fig. 1.1-4 Anchoring details
Legend
A
Drilled chemical anchor (M20)
Grouted anchor recesses (M20)
Installed chemical anchor before placing the base frame
Installing chemical anchor after placing the base frame

(base frame cannot be removed easily)
Drilling angle
1.1.5.3
IMM0312/v002
CONCRETE BLOCK MOUNTING

INSTRUCTIONS
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FOR USE
1.1.5.3.1
MOUNTING BARE COMPRESSOR ON A

CONCRETE BLOCK
If no base frame is applied the compressor and motor
should be installed as described in the "Product
Information (ED)".
1.1.5.3.2
MOUNTING THE BASE FRAME ON A

CONCRETE BLOCK
General
After the space between base frame and concrete base
has been filled-up with a filling grout, the package base
frame must be secured tightly to the foundation block or
floor.
1.1.5.3.3
self-levelling grout to ensure that the complete bottom

surface of the base frame will be supported. Therefore,
it is not allowed to use shims between concrete base and
base frame.
Grouting must be carried out in accordance with the
instructions provided by the grouting supplier. After
complete de-aeration of the grouted layer, secure the
base frame by tightening the anchor bolt nuts and
remove all adjusting bolts. At this stage the drive system
can be installed. These (accessories) installation
instructions can be found in the order manual.
1.1.6
CONNECTING TO REFRIGERATING SYSTEM

PIPEWORK
LEVELLING THE BASE FRAME

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
In order to ensure that suction gas strainer can be

removed easily, special attention for pipe work is
required for (semi) hermetic compressors.
Legend
1
Self-levelling grout
Adjusting bolts (4x)
Washer
Temporary barrier strip around and inside frame
Complete cured concrete block
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.
1.1.5.3.4 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
-Page 12-
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.
IMM0312/v002

FOR USE
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
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.
IMM0312/v002
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FOR USE
-Page 14-
IMM0312/v002

FOR USE
1.2
1.2.3
INITIAL OIL CHARGE
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 under pressure up to a max. of 10 bar(a).
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 6.5)
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.
1.2.2
EVACUATION/DRYING THE REFRIGERATING

SYSTEM
For evacuation of compressor only, refer to Section 2.5
Procedure to evacuate and to dry a system:
i) STATUS: System is filled with nitrogen and no oil has
been added (oil prevents any trapped moisture from
boiling off).
ii) Verify that all valves in that part of the system to be
evacuated are opened (refer also to the plant
manual).
iii) Connect vacuum pump to the evacuation/purging
valve(s) of the compressor (for location of these
valves refer to the "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.
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.
Pre-lubrication just before the first start is obligatory.
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
crnkshaft
4
6
Crankcase
11
0.5
1.5
0.5
12
13
1.2.4
INITIAL REFRIGERANT CHARGE
Refrigerant charging should be done in accordance with
the plant manual by qualified refrigeration engineers.
IMM0312/v002
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FOR USE
1.2.5
1.2.5.1
ADJUSTMENT OF INSTRUMENTS AND

SAFETY DEVICES
PRESSURE SAFETIES
Pressure safety limit switches
Suction pressurea
5oC below design

evaporating temp.
(To - 5 K)
Setting
Min.
>= 0.3 bar(a)

o
Discharge pressurea
Lubrication oil
pressure difference
Setting
5 C above design
condensing temp.
(Tc + 5 K)
Max.
<= 26 bar(a)
Min.
>= 1.7 bar
a. Settings Pdischarge - Psuction may never exceed 24.0 bar!
Oil pressure regulator

Lubrication oil
pressure
differencea
Setting
2.0 bar
(2.2 bar at 50 oC oil temp.)
ii) Determine the oil pressure difference (difference

between the oil pressure gauge and the suction
pressure gauge).
iii) Remove the cap nut of oil pressure regulator if the
pressure needs to be re-adjusted.
iv) Turn the slotted pin with a screwdriver clockwise or
counter clockwise for a higher or lower oil pressure
respectively, until the required lubricating oil pressure
difference has been achieved.
v) Replace cap nut and sealing ring.
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.
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 <1.7 or
>2.5 bar. The re-adjustment procedure is given in section Re-adjustment of oil
pressure regulator.
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 (ED).
1.2.5.2
1.2.9
RE-ADJUSTMENT OF OIL PRESSURE

REGULATOR
It is possible that after the compressor has been installed,
the lubrication oil pressure regulator needs to be
re-adjusted.
This lubricating oil pressure regulator is factory preset
and installed.
Fig. 1.2-1 Oil pressure regulator
Lubricating oil pressure regulator
Re-adjustment procedure:
i) Run the compressor untill the crankcase oil is at its
stable operating temperature:
1 The lubricating oil pressure difference should be
according to Section 1.2.5.1.
2 After the initial run the oil pressure difference
should be slightly higher.
-Page 16-
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.
For a detailed description about start-up and part load
limitations refer to the software program Comsel.
Legend
1
INITIAL START-UP
1.2.9.2
PRE-START CHECK LIST
The following Paragraph covers only the initial start of
the compressor and not the complete refrigeration
plant.
Be sure that all necessary system valves are open and
that the refrigeration system is ready for start up. Use
the following check to guarantee that no items of
importance regarding the compressor (package) have
been overlooked.
IMM0312/v002

FOR USE
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: Set the electrical capacity
control switch to the position of the lowest part load
step.
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.
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
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.
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
Do not restart within 15 minutes after a stop

Proceed to the complete starting procedure of Section
1.2.10.1.
1.2.10.3
Maximum 4 starts per hour and at least 2 minutes

between stopping and starting and at least 15 minutes
between starting and re-starting
iii) Slowly open suction stop valve and watch suction
pressure, which may not exceed the max. value.
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.
Refrigerant liquid hammer, will damage the compressor;

Superheat is always necessary! R404A and R507
dTo15K, other refrigerants dTo0K.
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.
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.
IMM0312/v002
-Page 17-

FOR USE
-Page 18-
IMM0312/v002
2. INSPECTION, MAINTENANCE AND

TROUBLE SHOOTING
2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Table of Contents
Section
Title
Page
2.1
INSPECTION
21
2.1.1
Periodical inspection
21
2.1.2
Survey of periodical inspections
21
2.1.2.1
21
2.2
MAINTENANCE (REFER Chapter 5)
23
2.2.1
Post start-up maintenance
23
2.2.2
First maintenance
23
2.3
STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months)
23
2.4
LUBRICATION DATA
23
2.4.1
Topping up oil with compressor operating
23
2.5
24
2.6
24
2.7
24
2.8
DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES
24
2.9
COMPRESSOR PURGING
24
2.10
TROUBLESHOOTING TABLE
24
IMM0312/v002
-Page 19-

TROUBLE SHOOTING
-Page 20-
IMM0312/v002

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 or its mechanical condition. If abnormal
sounds are audible, their cause should be traced and
removed immediately in order to prevent serious
breakdowns.
2.1.2.1
IMM0312/v002
-Page 21-

TROUBLE SHOOTING
CHECK
POINTSa
Oil level in
crankcase
Between 25% and 75%

height of the sight glass.
For topping up oil, refer to
Section 2.4.1.
Colour of the
oil
Lubricating oil
pressure
difference
REMARKS
monthly
weekly
daily
FREQUENCY
The oil should be

transparently clear. A
disappearing white colour
points to dissolved
refrigerant.
Oil
temperature
max.
Refer to the "Product

Information"
Suction
pressure
Check against design

conditions. Refer to plant
manual.
Discharge
pressure
Refer to plant manual. For

the max. allowable
discharge pressure refer to
the technical data of
compressor.
Suction
superheat
0K
Discharge
temperature
max.
155 C/175 Cb
Oil
temperature
min.
During compressor
standstill the lower part of
the crankcase must remain
warmer than the
surroundings: 20 C
Adjustment
and operation
of pressure
safety switches
Refer to Section 1.2.5.1

and to instructions of
switch manufacturer.
Capacity
control (if
provided)
Start/stop
intervals
Number of
operating
hours
Cooling water
temperature
(if present)
The time lag between the

unloading and loading of
one cylinder or cylinder
group should generally be
at least 3 - 5 minutes.
The time interval between

stopping and starting,
starting and re-starting,
loading and unloading
refer to section Starting
and stopping procedures.
Check the number of

operating hours in view of
any maintenance
operations to be carried
out.
Min. actual condensing
temperature plus 10 K
(> Tc+10)
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.
b. Only in combination with water cooling and cylinderhead temperature
protection,
-Page 22-
IMM0312/v002

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 .
iii) Inspect suction gas filter (refer to the Compressor
Service Instruction Manual).
iv) Exchange or clean oil suction filter element (refer ).
v) Check the compressor shaft seal for leakage. If
excessive (more than 1 cc/hr) replace the seal.
vi) 1) Retighten the coupling mounting bolts with the
torque settings as given by the coupling
manufacturer.
2) Verify and if necessary, correct the tension of the
V-belts as given in the V-belt supplier's instructions.
vii) Verify and if necessary, correct the torque settings of
all foundation bolts as given in Compressor Service
Instruction Manual.
2.2.2
FIRST MAINTENANCE
For complete service schedules and required service sets
refer to Grasso's Service and Maintenance Schedules
(SMS).
Maintenance
Number of operating hours

100a
Renewal of oil discharge filter
Renewal of suction gas filter(s)
Inspection of oil suction filter
Oil analysis bc
Inspection leakage shaft seal

Inspection relief valve(s)
> 100
refer to Service and

Maintenance
Schedules (SMS)
i) Tightly shut both the suction and discharge stop

valves and the stop valve of the oil return line (if
present).
ii) Disconnect the power source from the compressor
drive motor and the electrical control cabinet.
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
LUBRICATION DATA
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
TOPPING UP OIL WITH COMPRESSOR

OPERATING
Use Grassos hand-operated oil pump, part. no.

18.13.121
X
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.
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).
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.
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)
Fig. 2.4-1 Oil level in compressor sight glass
To shut down a compressor for long term periods,

proceed as follows:
IMM0312/v002
-Page 23-

TROUBLE SHOOTING
2.5
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.
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
local safety regulations. For the location of these
valves refer to the "Product Information".
2.6
To top up oil see Section 2.4.1, Oil changing procedure:

i) Evacuate the compressor (refer to Section 2.5).
ii) Drain the oil via the oil charging/drain valve. Remove
the cover of one or more service openings on the
compressor side.
iii) Clean the inside of the crankcase with a non-fibrous
cloth (do not use cotton waste!).
iv) Replace the service cover(s) with a new seal.
v) Charge crankcase with clean oil in accordance with
the procedure.
2.7
Schedule
Replace these filters according to the Service
Maintenance Schedules.
The frequency of exchanging these filters depends on
the conditions of the refrigeration system.
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.
2.9
COMPRESSOR PURGING
Procedure to purge the compressor(after maintenance

jobs):
STATUS:
Stop valves of suction, discharge and oil return line are
still closed (refer to Section 2.5) and compressor is filled
with oil (refer to Section 2.6).
i) Connect a vacuum pump to the evacuation/purging
valve(s) and evacuate as prescribed by local
regulations. For the location of these valves refer to
the "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.
It is recommended to exchange these filters when the
compressor is overhauled or when pressure drop exceeds
1.0 bar.
2.8
DISMANTLING, INSPECTION AND

RE-ASSEMBLY OF SUCTION AND
DISCHARGE VALVES
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).
2.10 TROUBLESHOOTING TABLE

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
-Page 24-
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.
IMM0312/v002

TROUBLE SHOOTING
Table 2.10-1 Troubleshooting

FAULT
CAUSE
REMEDY
1. Discharge stop valve

Open fully
not fully open
A Discharge
2. Discharge pressure
pressure too high gauge defective
FAULT
CAUSE
E Crankcase
frosted or wet
1. Liquid refrigerant in
crankcase due to:
Provide for crankcase
1a. Room temperature heating or, if provided,
too low
check it for proper
operation
Repair or replace
3. Non-condensables in Purge with a Automatic

the system
Purger
1. Discharge pressure
too high
See A
2. Too many cylinders

cut out
Cut in more cylinders
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
compressors:
Repair
temperature too
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
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 (For Grasso 12,
See J
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

separatora
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
D Suction
3. Injection control not
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 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
2. Suction gas strainer

Renew
blocked
IMM0312/v002
REMEDY
9. Oil separator is not

initially filled with oil
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
suction pressure gauge Repair or replace
(if present)
-Page 25-

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. During the initial start-up, the oil separator (if present) consumes oil before the
first oil will be returned.
-Page 26-
IMM0312/v002
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR
Table of Contents
Parts List
Page
Figure
COMPRESSOR HOUSING WITH CONNECTIONS
28
RC6-01
MAIN BEARINGS
30
RC6-02
CRANKSHAFT
32
RC6-03
PISTON AND CONNECTING ROD
34
RC6-04
SUCTION AND DISCHARGE VALVE (from mach. nr. 99061345)
36
RC6-05
ROTARY SHAFT SEAL
38
RC6-06
OIL PUMP
40
RC6-07
CAPACITY CONTROL MECHANISM
42
RC6-08
OIL DISCHARGE FILTER
44
RC6-09
FLANGED MAIN CONNECTIONS
46
RC6-10
SUCTION GAS STRAINER
48
RC6-11
OIL SUCTION FILTER
50
RC6-12
OIL PRESSURE REGULATOR
52
RC6-13
STANDARD SETS OF PARTS, SEALS AND TOOLS
54
RC6-14
The RC6, RC12 and RC12E have been rebranded and

each type number is now prefixed with the name Grasso
(ie Grasso 6, Grasso 12, Grasso 12E) However, for this
chapter, both the old and the new designations are
interchangeable and can be considered valid.
IMM0312/v002
-Page 27-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
with capacity control
Fig. RC6-01 COMPRESSOR HOUSING WITH CONNECTIONS

1
CYLINDER HEAD COVER ASSY
1.1Aa
CYLINDER HEAD COVER
RC6-2CR
2336521
with capacity control for 2 cyl.
1.1Ab
CYLINDER HEAD COVER
RC6-2CR
2336525
RC6W: with capacity control for 2 cyl.
1.1Ba
CYLINDER HEAD COVER
RC6-1CR
2336510
with capacity control for 1 cyl.

RC6W: with capacity control for 1 cyl.
1.1Bb
CYLINDER HEAD COVER
RC6-1CR
2336515
1.2
HEXAGON HEAD BOLT
M10x120
0110512
GASKET
190x405x2CR
0907192
on item 1.1A
GASKET
190x405x1CR
0907191
on item 1.1B
without capacity control
1.3A
1.3B
2
CYLINDER HEAD COVER ASSY
2.1a
CYLINDER HEAD COVER
RC6-OCR
2336500
2.1b
CYLINDER HEAD COVER
RC6-OCR
2336505
2.2
GASKET
190x405x1.5OCR
0907190
3.a
HEXAGON HEAD BOLT
M10x100
0110510
20
18 on item 1 (for RC6 types only)
3.b
HEXAGON HEAD BOLT
M10x120
0110512
20
18 on item 1 (for RC6W types only)
FLAT WASHER
M10
1113501
36
CRANKCASE
RC6
GASKET
175x290x1.5
0907175
on type RC6W only
7.a
INSPECTION SIDE COVER
175x290
0530175
RC6 (2x), RC6W (1x)
7.b
175x290WK
0530178
RC6W (1x)
M10x40
0110540
16
2.62x32.99
0952284
HEXAGON HEAD BOLT
O-RING
10
SIGHT GLASS
29x60
1224029
11
HEXAGON HEAD BOLT
M6x16
0110316
12
EYE BOLT
M16
0118812
26.5G33
1249333
G13S
0136134
240V-200W
1372203
13
SPRING LOADED SAFETY
14
PLUG
15
CRANKCASE HEATER
16
STOP VALVE
TAH8-12
0607011
17
ORIFICE
G13x3x20
0123139
18
ALU.SEALING RING
21x25x1
0912021
in RC46(W) compressor only
G21
0136216
in RC46(W) compressor only

in types RC66(W) & RC86(W)
19.a
19.b
PLUG
G21
0136216
20
ALU SEALING RING
21x27x2
0914023
21
ALU SEALING RING
13.5x20x1
0912014
22
NIPPLE COUPLING
12G13
0338131
23
NIPPLE COUPLING
12G21
0338211
-Page 28-
PLUG
if connection not in use
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-1 RC6-01
IMM0312/v002
-Page 29-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
60x15x11.5
1143600
Remarks
Fig. RC6-02 MAIN BEARINGS

1
BEARING FLANGE
BEARING ASSY
RC6
2.1
PUMP HOUSING
RC6
---------
2.2
O-RING
3.53x209.14
0952365
2.3
BEARING FLANGE
60x50xM10
1143651
2.4
SOCKET HEAD SCREW
M10x100
0104510
M10
1113501
16
FLAT WASHER
HEXAGON HEAD BOLT
M10x40
0110540
HEXAGON HEAD BOLT
M10x35
0110535
-Page 30-
driving end
refer to parts list FIG. RC6-7
oil pump end (from 95.08.1648)
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-2 RC6-02
IMM0312/v002
-Page 31-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
E/K-RC6
Remarks
Fig. RC6-03 CRANKSHAFT

1.1
CRANKSHAFT
1A.a
CRANKSHAFT
E-RC6
2236400
4-cylinder compressor
1A.b
CRANKSHAFT
K-RC6
2236410
1B.a
CRANKSHAFT
E-RC6
2236600
1B.b
CRANKSHAFT
K-RC6
2236610
1C.a
CRANKSHAFT
E-RC6
2236800
1C.b
CRANKSHAFT
K-RC6
2236810
14x9x70
1102570
60x5A
1125106
M10x25
0104525
KEY
CARRIER DISC
SOCKET HEAD SCREW
-Page 32-
from 95.08.1648
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-3 RC6-03
IMM0312/v002
-Page 33-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
85RC6
2436010
Remarks
Fig. RC6-04 PISTON AND CONNECTING ROD

1
PISTON ASSY
1.1
PISTON
1.2
GUDGEON PIN
1.3
SAFETY RING
1.4
PISTON RING SET
85RC6H
26x16x68R6
2436260
85RC6
0974084
CONNECTING ROD
60x170xRC6
2436500
2.1
CONNECTING ROD
170RC6
2.2
CONNECTING ROD BOLT
MF8
0111401
2.3
LOCKING RING SET
M8
1139400
2.4
HEXAGON NUT
MF8x1
0147405
-Page 34-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-4 RC6-04
IMM0312/v002
-Page 35-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
DIN 540
Fig. RC6-05 SUCTION AND DISCHARGE VALVE (from mach. nr. 99061345)
1
HEXAGON HEAD BOLT
M10x40
0110540
2
3
FLAT WASHER
M10
1113501
PRESSURE RING
RC6
2736410
SINUSOIDAL SPRING
87x125x4
1133087
5.H
DISCHARGE VALVE ASSY
RC6
2736103
option "H" (High), refer selection table
5.L
DISCHARGE VALVE ASSY
RC6
2736113
option "L" (Low), refer selection table
5.1
LOCKING NUT
M8
0145400
5.2
FLAT WASHER
M8
1113401
5.3
DISCHARGE VALVE STROKE LIMITOR
RC6
5.4a
SINUSOIDAL SPRING
64x76x0.5
option "L" (Low), refer selection table
5.4b
SINUSOIDAL SPRING
64x76x0.5
option "H" (High), refer selection table
5.5
DISCHARGE VALVE RING
5.6
SUCTION STROKE LIMITOR
5.7
FITTED BOLT
64x76x1
RC6
M8x35
5.8H
DISCHARGE VALVE AND SPRINGS
R
(halocarbons)
1134105
5.8L
DISCHARGE VALVE AND SPRING
NH3
(ammonia)
1134110
108x87x4
DAMPER RING
SINUSOIDAL SPRING
88x103x0.7
SUCTION VALVE RING
88x103x0.7
O-RING
3.53x117.07
0952362
10
CYLINDER LINER
85RC6
2336120
11
O-RING
3.53x91.67
0952361
12
SUCTION VALVE RING, SPRING AND

DAMPER RING
RC6/GR7
1134115
-Page 36-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-5 RC6-05
IMM0312/v002
-Page 37-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6
2636100
Remarks
Fig. RC6-06 ROTARY SHAFT SEAL

1
SHAFT SEAL HOUSING
2A
PLUG
G13S
0136134
2B
PLUG
NPT13X1.5
0365513
6N10
0338810
NIPPLE COUPLING
O-RING
HEXAGON HEAD BOLT
6
7
-Page 38-
3.53x158.34
0952364
M10x35
0110535
FLAT WASHER
M10
1113501
SHAFT SEAL SET
RC6
0962900
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-6 RC6-06
IMM0312/v002
-Page 39-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6
2636700
Remarks
Fig. RC6-07 OIL PUMP

1
PUMP COVER
OIL PUMP ELEMENT
BEARING
HEXAGON HEAD BOLT
5
6
7
PUMP HOUSING
-Page 40-
RC6A
2636601
RC6x13.5
2636710
M6x16
0110316
O-RING
3.53x209.14
0952365
O-RING
3.53x136.12
0952363
RC6E
2636503
from 95.08.1647
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-7 RC6-07
IMM0312/v002
-Page 41-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6C
2736702
Remarks
Fig. RC6-08 CAPACITY CONTROL MECHANISM

1
FLANGE
CYLINDER HEAD SCREW
PISTON CAPACITY CONTROL
PRESSURE SPRING
PISTON FITTING RING
FLAT WASHER
HEXAGON HEAD BOLT
GASKET
CYLINDER CAPACITY CONTROL
10
PISTON FITTING RING
11.1A
VALVE BODY
11.1B
VALVE BODY
M4x10
0168210
RC6
2736600
1.25x10x11.5
x51
1131132
56x51.3x2
0970056
M10
1113501
M10x40
0110540
87x94x1.5
0907087
RC6
2736500
40x36.6x2
0970040
11.2A
VALVE COIL
110-120/5060
11.2B
VALVE COIL
220-240/5060
1316311
1316322
per controlled cylinder cover
11A
SOLENOID VALVE
110/120V
11B
SOLENOID VALVE
220FA
0680111
NH3
12.a
CONNECTOR
DIN
1316610
without LED
for valves 11A/11B, without LED
12.b
CONNECTOR
220/240 V AC,
DIN incl. LED
1316611
with 220V-AC/DC LED

`with 220V-AC/DC LED
12.c
CONNECTOR
24/48 V
AC/DC, DIN
incl. LED
1316615
with 48V-AC/DC LED

with 48v-AC/DC LED
6G10
0337106
13
SOCKET COUPLING
14
SET SCREW
M5x10
0123010
15
PLUG
M8x1
0365708
16
O-RING
9.3
0951093
-Page 42-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-8 RC6-08
IMM0312/v002
-Page 43-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6
0711900
3.53x136.12
0952363
480x15
M6
0145300
M6x20
0151320
130
0702130
M10x75
0110575
M10
1113501
Remarks
Fig. RC6-09 OIL DISCHARGE FILTER

1
FILTER SET
1.1
O-RING
1.2
FILTER CARTRIDGE
LOCKING NUT
STUD
FILTER HOUSING
HEXAGON HEAD BOLT
FLAT WASHER
-Page 44-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-9 RC6-09
IMM0312/v002
-Page 45-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
Fig. RC6-10 FLANGED MAIN CONNECTIONS

1A
SHOULDER FLANGE
RC46
0539045
1B
SHOULDER FLANGE
RC66
0539051
1C
SHOULDER FLANGE
RC86
0539063
M16x40
0110840
per flanged connection
67x81x1.5
0903067
per flanged connection
26.5G33
1249333
HEXAGON HEAD BOLT
GASKET
SPRING LOADED SAFETY
-Page 46-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-10 RC6-10
IMM0312/v002
-Page 47-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
SHOULDER FLANGE
RC46
0539048
Remarks
Fig. RC6-11 SUCTION GAS STRAINER

1A
1B
SHOULDER FLANGE
RC66/RC86
0539060
GASKET
67x81x1.5
0903067
STRAINER ELEMENT
544x100
0716544
-Page 48-
IMM0312/v002
3. PARTS COMPRESSOR
a a a a a a a a a
aaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaa
a a a a a a a a a
aaaaaaaaaaaaaaaaa
a aaaaaaaaaaaaaaa
Fig. 3-11 RC6-11
IMM0312/v002
-Page 49-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
Fig. RC6-12 OIL SUCTION FILTER

1
STRAINER ELEMENT
149x16
0716164
from machine nr. 95.08.1648
SWIVEL COUPLING
16G21
0339216
from machine nr. 95.08.1648
-Page 50-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-12 RC6-12
IMM0312/v002
-Page 51-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
PRESS. REGULATOR SET
SAM RC6
1241140
1.1
STEEL PRECISION PIPE WITH VALVE

HOUSING
K12x1.5
1241012
1.2
ALU SEALING RING
21.5x27x1
0912022
1.3
BEAMING BALL
W16
1119010
1.4
PRESSURE SPRING
1.25x14x9x35
.5
1131134
1.5
THRUST BOLT
G21x60S
0135218
1.6
O-RING
1.78x8.73
0952184
1.7
NIPPLE
G21CxG21
0304921
1.8
ALU SEALING RING
10x18x1
0912010
1.9
CAP NUT
GK21R
0117021
NIPPLE COUPLING
12G13
0338131
refer to fig. RC6-6
NIPPLE COUPLING
12G21
0338211
refer to fig. RC6-1
Fig. RC6-13 OIL PRESSURE REGULATOR

1
-Page 52-
lubricating oil pressure regulator included. To

replace the internal regulator for an external
regulator, conversion kit 12.41.145 should be
applied.
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-13 RC6-13
IMM0312/v002
-Page 53-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
0990046
for RC46
Fig. RC6-14 STANDARD SETS OF PARTS, SEALS AND TOOLS

1a
GASKETS (SET)
RC46/GR47
1b
GASKETS (SET)
RC66/GR67
0990066
for RC66
1c
GASKETS (SET)
RC86/GR87
0990086
for RC86
2a
DISCHARGE VALVE AND SPRINGS
R
(halocarbons)
1134105
2b
DISCHARGE VALVE AND SPRING
NH3
(ammonia)
1134110
SUCTION VALVE RING, SPRING AND

DAMPER RING
RC6/GR7
1134115
for R ( halocarbons ) and NH3 ( ammonia )
SET OF SPARE PARTS
RC6/GR7
2036011
for all types
5a
TIRE CLAMP
232
1508232
for coupling element 42
5b
TIRE CLAMP
244
1508244
5c
TIRE CLAMP
280
1508280
-Page 54-
IMM0312/v002
3. PARTS COMPRESSOR
Fig. 3-14 RC6-14
IMM0312/v002
-Page 55-
3. PARTS COMPRESSOR
-Page 56-
IMM0312/v002
4. PARTS ACCESSORIES
Table of Contents
Parts List
Page
Figure
PRESSURE GAUGES AND SAFETY SWITCH CABINET (Use 0337136 if your current pressure gauge connections differs from
fig. RC6-1A
58
RC6-A1
DIRECT DRIVE
60
RC6-A2
COOLING WATER DEVICE
62
RC6-A3
The RC6, RC12 and RC12E have been rebranded and

each type number is now prefixed with the name Grasso
(ie Grasso 6, Grasso 12, Grasso 12E) However, for this
chapter, both the old and the new designations are
interchangeable and can be considered valid.
IMM0312/v002
-Page 57-
Item
Description
Dims.
Ref. No.
Qty
Remarks
Fig. RC6-A1 PRESSURE GAUGES AND SAFETY SWITCH CABINET (Use 0337136 if your current
pressure gauge connections differs from fig. RC6-1A
1.1a
PRESSURE GAUGE
NH3 - R-P-63
1210065
1.1b
PRESSURE GAUGE
R22 - 63
1212065
1.1c
PRESSURE GAUGE
R134a - 63
1212066
1.1d
PRESSURE GAUGE DISCHARGE

PRESSURE
R404A
1212067
1.2a
PRESSURE GAUGE
NH3 - R-Z-63
1210066
1.2b
PRESSURE GAUGE
R22 - Z-63-12
1212068
1.2c
PRESSURE GAUGE SUCTION PRESSURE
R134a Z-63-12
1212069
1.2d
PRESSURE GAUGE SUCTION PRESSURE
R404A Z-63-12
1212070
1.3
PRESSURE GAUGE
R-O-63
1215065
1.4a
PRESSURE SAFETY SWITCH
MP55A
1260232
1.4b
MP55
1261232
1.5a
PRESSOSTAT
NH3 KP15A
1260615
1.5b
COMBINED SUCTION/DISCHARGE
R KP15
1261615
1.5c
PRESSOSTAT
NH3 KP7ABS
1260618
1.5d
COMBINED DISCHARGE PRESSURE

LIMITOR AND SAFETY SWITCH
R KP7BS
1261618
1.6a
SUCTION PRESSURE SAFETY SWITCH
NH3 KP1A
1260608
1.6b
SUCTION PRESSURE SAFETY SWITCH
R KP1
1261608
1a.1
PRESSURE GAUGE AND SAFETY SWITCH

CABINET
NH3 - std
1208301
with 2 safety switches
1a.2

CABINET
R22 - std
1208601
with an additional safety switch to meet

German UVV-VBG20 regulations
1a.3

CABINET
R134a - std
1208701
1a.4

CABINET
R404A
1208801
1b.1

CABINET
NH3 UVV-VB420
1208302
1b.2

CABINET
NH3 UVV-VB420
1208602
1b.3

CABINET
NH3 UVV-VB420
1208702
1b.4

CABINET
NH3 UVV-VB420
1208802
-Page 58-
IMM0312/v002
Fig. 4-1 RC6-A1
IMM0312/v002
-Page 59-
Item
Description
Dims.
Ref. No.
Qty
42
1918842
Remarks
Fig. RC6-A2 DIRECT DRIVE

1.1a
COUPLING ELEMENT
1.1b
COUPLING ELEMENT
61
1918861
1.1c
COUPLING ELEMENT
91
1918891
1a
FLEXIBLE COUPLING
type 42
(complete)
1b
FLEXIBILE COUPLING
type 61
(complete)
1c
FLEXIBLE COUPLING
type 91
(complete)
CLAMPING SLEEVE
-Page 60-
IMM0312/v002
Fig. 4-2 RC6-A2
IMM0312/v002
-Page 61-
Item
Description
Dims.
Ref. No.
Qty
Remarks
19W
1518019
per cylinder head cover connection
19-28 mm
1508600
twice per hose, per cylinder head cover

connection
19xG21
1555419
per cyl. head cover connection
Fig. RC6-A3 COOLING WATER DEVICE

1
HOSE, RUBBER
HOSE CLAMP
SPIGOT NIPPLE
ANGLE SOCKET NIPPLE
G21xG21
0372441
SOCKET NIPPLE
G21xG42
0302471
NIPPLE COUPLING
16G21
0338212
per coil connection
6.1
CLAMPING SLEEVE
P16
0334516
per coil connection
16x1.5x64x28
0
0410364
COIL COOLER
CYLINDER HEAD COVER
RC6-OCR
2336505
CYLINDER HEAD COVER
RC6-1CR
2336515
10
175x290WK
0530178
-Page 62-
IMM0312/v002
Fig. 4-3 RC6-A3
IMM0312/v002
-Page 63-
-Page 64-
IMM0312/v002
5. MAINTENANCE
5. MAINTENANCE
Table of Contents
Section
Title
Page
5.1
SMS FACTOR
65
5.2
Grasso 6
67
5.3
Checklist
69
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.
IMM0312/v002
-Page 65-
5. MAINTENANCE
-Page 66-
IMM0312/v002
5. MAINTENANCE
5.2
GRASSO 6
SERVICE AND MAINTENANCE SCHEDULES GRASSO 6
Actions
Description
0.1
YEARLY
Item
Running hours * 1000a

3
12
15
18
21
24
27
30
33
36
Checkpoint
CL
CL
CL
CL
CL
CL
CL
Oil suction filter
RE
RE
RE
RE
RE
RE
Oil discharge filter
ME
ME
ME
ME
ME
ME
Oil analysis
RE
RE
RE
RE
RE
RE
Oil refreshment (If hygroscopical oil is used replace this always

after each opening of compressor or installation)
Oil
4
5
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
Housing and element
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
Control and lubrication oil pressure regulator
7a
IC/ME IC/ME
Main and intermediate bearing bushes
IC/ME IC/ME
Main and intermediate bearing surfaces crankshaft
Oil pump
7b
Crankshaft
8
9
Shaft seal
10
Conrod
11
12
Pistons
13
14
Thrust bearing
IC/ME
IC
IC
IC/ME IC/ME IC/ME IC/ME

IC
IC
IC
IC
Running surfaces con. rods/Axial play

Oil/refrigerant leakage
IC/ME
IC
IC
IC
IC
IC
Big and small end bearings

Piston
IC
IC
IC
IC
IC
Piston rings
Gudgeon pin
IV/ME
IV/ME IV/ME IV/ME IV/ME
Running surfaces/axial play
IC/IV
IC/IV
IC/IV
15
16
IC/IV
IC/IV
IC/IV
IC/IV
Solenoid valves and coils
Capacity control
17
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
Cap. Control mechanism
18
IV/CL
IV/CL
IV/CL
IV/CL
IV/CL
IV/CL
IV/CL
Crankcase heater
CL
CL
CL
CL
CL
Crankcase
19
20
Compressor
housing
IC
IC
IC
IC
Throttle valves
21
IV
IV
IV
IV
IV
Relief valves
22
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
Suction gas filter
IC
IC
RE
RE
RE
RE
Valves, springs and damper rings
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
Stroke limitor/Discharge valve seat
IC
IV
IC
RE
IC
RE
IV
IV
IV
IV
IV
Cap. Control lifting mechanism
27
IV/ME
28
IC
IC
IC
IC
IC
IC
IC
Alignment
IC
IC
IC
IC
IC
IC
IC
V-belts
23
Discharge valves
24
25
Suction valvesb
26
Cylinder liners
IV/ME IV/ME IV/ME IV/ME
Dimension and running profile
Drive
29
30
Electric motor
IMM0312/v002
Refer to specification of motor supplier
-Page 67-
5. MAINTENANCE
SERVICE AND MAINTENANCE SCHEDULES GRASSO 6

Actions
Running hours * 1000a
Description
0.1
YEARLY
Item
12
15
18
21
24
27
30
Checkpoint
33
36
31
IC
IC
IC
IC
IC
CL/IC
CL/IC
Oil level switch
32
IC
IC
IC
IC
IC
IC
IC
Safety switches
33
IC
IC
IC
IC
IC
IC
IC
Gauges
34
IC
IC
IC
IC
IC
IC
IC
Thermostats
IC
IC
IC
IC
IC
IC
IC
Thermometers
36
IC
IC
IC
IC
IC
IC
IC
Electrical control system
37
IC
IC
IC
IC
IC
CL/IC
CL/IC
Valve oil return protection
39
IC
IC
IC
IC
IC
IC
IC
Vibration dampers and bolts
41
CL
CL
IC
IC
IC
IC
Oil separator refreshing oil and cleaning/testing of float valve
42
ME
35
Optionals
ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL
Cylinder head water cooling, incl. oil cooler
a. Check after every maintenance job the settings and working of all safety devices, regulators and the running condition according to the service instruction manual
(SIM)
b. Suction valves for compressors < june 1999 (machine number < 9906****) must be changed every 6000 running hours in case not converted to latest standard
Legend for service and maintenance schedules (SMS)

Item
Code/Action
Description
IC
Inspection / Alternatively renewal - correcting / Testing
IV
Inspection Visual / Alternatively electrical testing
RE
Renewal
ME
Measure
CL
Clean
-Page 68-
IMM0312/v002
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
Oil suction filter
2
3
Oil discharge filter

Oil
Oil analysis
Oil refreshment (If hygroscopic oil is used replace this always after each
opening of compressor or installation)
4
5
Housing and element

Oil pump
Control and lubrication oil pressure regulator
Main and intermediate bearing bushes and running surfaces

Crankshaft
Running surfaces con. rods
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
IMM0312/v002
Seals of cap. control piston

Cap. Control mechanism
-Page 69-
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
Checkpoint/Setting/Value
Suction gas filter

Discharge
valves
24
Stroke limitor/Discharge valve seat
25 Suction valves
26
Cap. Control lifting mechanism

Cylinder liners
27
Dimension and running profile
28
Alignment
Drive
29
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
Thermistors
Optionals
39
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
Suction pressure
LP discharge pressure (safety)
two stage only
LP discharge pressure (limitor)
two stage only, TUV
High pressure suction (safety)
two stage only
High pressure (safety)
High pressure (limitor)
OIl differential pressure
-Page 70-
Value
TUV only
IMM0312/v002
6. APPENDIX; Product Information (PI)

Table of Contents
Section
Title
Page
6.1
TECHNICAL DATA
71
6.2
MAIN DIMENSIONS AND SPACE REQUIREMENTS
73
6.3
74
6.4
LIMITS OF OPERATION AND FIELDS OF APPLICATION
75
6.4.1
GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 6
75
6.4.1.1
76
6.4.2
77
6.4.3
77
6.5
LUBRICATING OILS (choice and recommendations)
79
6.6
CAPACITY CONTROL
80
6.6.1
CYLINDER NUMBERING
81
6.7
PACKAGED BASE FRAME
82
6.7.1
PACKAGED BASE FRAME
82
6.8
CRANKCASE HEATER
83
6.8.1
83
6.1
TECHNICAL DATA
Table 6.1-1 Technical Data of Grasso 6 compressors

COMPRESSOR TYPE
Number of cylinders
Cylinder arrangement
46
66
86
2xV
2xW
2 x VV
Cylinder bore
mm
85
Piston stroke
mm
66
Vs
Swept volume at full-load:
n = 1450/min
m /h
Standard direction of rotation
Standard compressor speeds (with V-belt drive) at motor

speed:
130.3
195.5
260.7
counter-clockwise when facing shaft end (both

directions permitted)
1450 min-1
(50 Hz)
min-1
810- 855- 905- 1015- 1140- 1215- 1285- 1450
1750 min-1
(60 Hz)
min-1
800- 875- 980- 1030- 1095- 1225- 1380- 1465
Standard steps of capacity control (expressed in percentage

of full load swept volume)
100-50
100-67-33
100-75-50-25
Mass of bare compressor (without flywheel and other

accessories)
kg
280
345
400
Oil charge in crankcase and oil circuit (centre line of sight

glass)a
dm3
9.2 (8.5)
10.0 (9.3)
10.8 (10.1)
kW
1.10
1.58
2.22
0.0361
0.0421
0.0478
Friction power at an 55 C oil temperature

Mass moment of inertia of crank mechanism (without
flywheel)b
n= 1450/min
Pw
Id
kg.m
a. The figures between brackets indicate the smaller oil charge for the Grasso 6W compressors due to the presence of an oil cooler.
b. The mass moment of inertia Id expressed in SI units, is required to determine the so-called coefficient of speed fluctuation.
IMM0312/v002
-Page 71-
-Page 72-
IMM0312/v002
6.2
MAIN DIMENSIONS AND SPACE

REQUIREMENTS
Table 6.2-1
COMPRESSOR
TYPE
Length
Width
IMM0312/v002
46
46W
66
66W
86
86W
696
696
721
721
746
746
840
893
929
46
46W
66
66W
86
86W
MINIMUM REQUIRED FREE SPACE for removal of:

crankshaft
661
661
673
673
711
711
piston and
cylinder liner
260
260
325
325
360
360
626
700
748
748
725
725
316
316
379
379
395
395
316
316
352
352
363
363
202
202
202.5
202.5
length
225
225
250
250
270
270
width
72
72
77
77
67
67
Height
COMPRESSOR
TYPE
189.5 189.5
LOCATION OF CENTRE OF GRAVITY
300
300
248
248
228
228
544
544
644
644
619
619
394
394
432
432
444
444
suction
40
40
50
50
50
50
60
60
65
65
62
62
discharge
32
32
40
40
50
50
444
444
482
482
494
494
69
69
69
155
173
180
388
430
446
435
328
247
680
660
696
MAIN CONNECTIONS DN
(mm)a
-Page 73-
COMPRESSOR
TYPE
46
46W
66
66W
86
86W
AUXILIARY CONNECTIONS
suction
pressure
discharge
pressure
Oil pressure
Crankcase
pressure
Return from oil

separator or
rectifier
Oil charge and

drain valve
Oil
temperature
Crankcase
heater
10
1/4 BSP (plugged off)
1/2 BSP female to suit thread of heating

element
Oil leakage
drain of rotary 11 clanp coupling provided with dia. 6x1 mm steel
precision pipe
shaft seal
Water
inlet/outlet
12
(W-types) only
dia. 19 mm hose connector
a. Provided with a purging and evacuation stop valve type TAH8 (standard on
discharge connection and optional on suction connection.
6.3
Fig. 6.3-1 Shaft end compressor
-Page 74-
IMM0312/v002
6.4
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.
6.4.1
GENERAL LIMITS AND FIELDS OF OPERATION

GRASSO 6
When operating the compressor, none of the limits of
operation as stated in the table below must be
exceeded.1
REFRIGERANT
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" ).
speed
Compressor speed
Suction pressure = evaporating pressure

=crankcase pressure
Table 6.4-1 General limits and fields of operation
po
min-1
800
max.
1500
min.
Suction superheat
Discharge pressure = condensing pressure
Design
ta
min.
Dt
min.
pc bar(a) max.
pressuree
Condensing temperature = saturation

temperature at discharge pressure
bar(a)
tc
max.
max.
Discharge temperature
te
Pressure ratio per stage (pc/po)
Pressure difference (pc-po)
Dp
bar
Oil temperature in crankcase
toil
min-1
>=1140 min
<1140
Actual suction temperature
R507
6.0
5.8
-1
max.
R404A
0.3
>=1140 min
max.
<1140
to
R134a
min.
Evaporating temperature = saturation
temperature at suction pressure
R22
min.
bar(a)
b
NH3
6.2
6.8
6.2
-55.1
-63.8
-50
+10.2
+10.0
+22.6
6.8
-68.1
-68.5
-0.1
-2.0
+3.8
+3.0
-1
min-1
-50
15
5
24.0
26.5
min.
max.
max.
min.
max.
+59.8
+63.2
+79.5
+55.6
+54.4
+155
1.5
10
15
24
+20
+30
depending on type of oil, refer Section 6.5
a. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.

b. The minimum values of po and to are only of importance for booster applications. In that case the maximum value of to also applies to the saturation intermediate
temperature (tm).For halocarbon refrigerants the maximum values of po and to are based on a density of the suction gas of 30 kg/m3. During start-up and
immediately thereafter, po,max. may be exceeded slightly [up to 11 bar(a) max.] and temporarily, but no longer than about 5 minutes. The maximum static crankcase
pressure during compressor standstill is 21.5 bar(a).
c. Only of importance for booster application.
d. This pressure is also the maximum allowable pre-set value of the HP safety switch.
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 above the valves.
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 24.5 (+ 10%) bar to prevent advanced opening during normal
operation at Dp = (pc - po) 24.0 bar.
i. Indicated minimum value is the lowest oil temperature at which compressors are 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 15
cSt is always required. When using ammonia as refrigerant, the maximum oil temperature will be exceeded only when a combination occurs of high ambient
temperature, high suction superheat and part-load operation. In that case an oil cooler is required. A water-cooled oil cooler always forms part of the standard delivery
of a RCA6W-compressor.
IMM0312/v002
-Page 75-
6.4.1.1
Fig. 6.4-1
Legend
A
This part of the general field of application is not covered by COMSEL. Consult Grasso to make a selection
for this applicaction
-Page 76-
IMM0312/v002
6.4.2
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 and partload steps.
Always consult Grasso's software program, COMSEL, to

determine the precise field of application for an actual
compressor selection.
6.4.3
General
If a compressor operates continuously at the minimum

part-load, the manufacturer should be consulted first to
check whether this is allowed under the expected design
conditions.
Fig. 6.4-2 Field of applications for compressor type Grasso 6 with NH3
(upper graphic) and Grasso 6 with NH3 and water
cooled cylinder heads (lower graphic)
In the case of an Grasso 6-compressor and NH3,

operating continuously at part-load, the general field of
application is reduced in the sense that for each step of
capacity reduction the limit line for Te = 155 oC moves to
the right as shown in Fig. 6.4-2, by four Vs-indications in
percentage.
In case the of an Grasso 6-compressor and NH3 and
cylinder head water cooling can be applied (optional),
and there are no part-load restrictions. In other words,
the general field of application as shown in Fig. 6.4-2,
also remains valid for part-load operation down to and
including the standard minimum capacity control step of
Vs = 25%.
IMM0312/v002
-Page 77-
-Page 78-
IMM0312/v002
6.5
LUBRICATING OILS (CHOICE AND

RECOMMENDATIONS)
Table 6.5-1 Oil selection table

Max. allowable
evaporating
temperature to,max
(C)
Refrigerant
used
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.
NH3
ISO VG-number, according

to ISO 3448
46
68
100
-50
-30
-20
-10
R22
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 HCFCs and HFCs.
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.
R134a, R507,
R404A
+10
-50
-30
v
v
-20
-10
+10
For all other

refrigerants
please contact
Grasso
v = Approved
Table 6.5-2 Strongly recommended oil types for Grasso reciprocating

compressors - operating on NH3.
Refrigerant
used
NH3
Brand
Type designation
ISO VG
numbera
CPI
CP-1009-68
68
PETRO CANADA
Reflo 68A
68
68
Mobil
SHC-326
a. Viscosity grade number designation according to ISO Standard 3448.

b. Recommended for evaporating temperatures below -37 oC
Some of the oil types listed in this table may be marketed under other
names and/or designations; these oils can also be used, provided their
identity can be proved beyond any doubt. Application of
other/alternavive oils is not permitted without the written consent of
Grasso.
IMM0312/v002
-Page 79-
Table 6.5-3 Accepted oil types for Grasso reciprocating compressors

Brand
Type designation
ISO VG
numbera
AVIA
Avilub FC 46
44
Avilub FC 68
65
Energol LPT-F 46
54
Energol LPT-F 68
68
CASTROL
Icematic 299
56
CPI
CP-1009-68
69
ELF
Elfrima FR 68,
NH3 only!
54
Refrigerant
used
Brand
Icematic SW 68
67
Icematic SW 100
100
Solest 68
64
CASTROL
CPI
Solest 120
131
Triton SE 55
52.5
Triton SEZ 80
80
Triton SE 120
118
Planetelf ACD 68 M
70
Planetelf ACD
100LT
98
Purfrigol ST VG 68
69
BP
44
Zerice 68
65
Zerice S46
48
Zerice S68
64
Purfrigol MP 68
71
Reniso KC 46
47
Reniso KC 68
68
Carsinus FC 46/68
55
Arctic oil 300
57
SHC 326
65
PETRO CANADA
Reflo 68Ab
58
Kuwait
Petroleum
Q8 StravinksyB
ESSO
FINA
DEA
ELF
Zerice 46
HFC
(e.g. R134a /
R404A /
R407c /
R507)
FINA
KROON OIL
Purfrigol ST VG 100
95
Reniso E 68
68
Reniso E 100
100
FUCHS
FUCHS
Emkarte RL 68S
68
Emkarte RL 100S
100
EAL Arctic 68
63
EAL Arctic 100
96
ICI
MOBIL
MOBIL
SHELL
SUN-OIL
Q8 Stravinsky C
68
Clavus 46
46
Clavus 68
68
Clavus G 46
46
Clavus R68
66
Clavus R100
94
SHELL
Suniso Excel
TEXACO
Capella HFC 68
62
a. Viscosity grade number designation according to ISO Standard 3448.

b. NH3 only
Some of the oil types listed in this table may be marketed under other
names and/or designations; these oils can also be used, provided their
identity can be proved beyond any doubt. Application of
other/alternavive oils is not permitted without the written consent of
Grasso.
Clavus G 68
68
Clavus G 100
95
Suniso 3.5 GS
NH3 Only!
43
6.6
Suniso 4 GS
NH3 Only!
55
For description of the design details of the capacity

control systems, refer to
Suniso 5 G
NH3 Only!
94
Suniso 4 SA
NH3 Only!
57
TEXACO
Capella WF 68
65
TOTAL
Lunaria S 46/68
55
66
Solenoids
Remarks
Table 6.6-1 Capacity control steps

Capacity %
SUN-OIL
CAPACITY CONTROL
Qyt Cylinders
NH3 and
HCFC
(e.g. R22)
ISO VG
numbera
Type designation
Cylinders
Refrigerant
used
1+3
1+2+3
1+3
1+2+4
1+2+3+4
A+B
3
100
25 a
4
optional
50
75
optional
100
-Page 80-
IMM0312/v002
40
2+5
80
1+2+4+5
100
1+2+3+4+5
A+B
33
2+5
66
1+2+4+5
100
1+2+3+4+5+6
A+B
29
3+7
57
2+3+6+7
1+2+3+5+6+7
B+C
Remarks
Solenoids
6.6.1
Cylinders
Capacity %
Qyt Cylinders
CYLINDER NUMBERING
7
86
100
1+2+3+4+5+6+7 A+B+C
25
3+7
50
2 + 3 + 6+ 7
1 + 2 + 3 + 5+ 6 + 7
B+C
8
75
100
1+3+4+5+6+7+8 A+B+C
a. Optional (refer to )
Fig. 6.6-1 Cylinder numbering
Legend
W
IMM0312/v002
Water cooled
25%
Incl. 25% cap. control step
-Page 81-
6.7
PACKAGED BASE FRAME
6.7.1
PACKAGED BASE FRAME
General
For mounting on a concrete foundation block, Grasso
can supply a standard welded steel base frame to
support compressor, motor and accessoiries.
Especially for vibration free operation on floors and on
roof tops, a base frame with vibration dampers can be
delivered (concrete foundation block can be omitted).
A. BASE FRAME FOR MOUNTING ON CONCRETE BLOCK
(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. 6.7-1 Grasso 6 package, 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.
Scope of supply
Steel closed box profile base frame, including
mounting of compressor, electric motor and
accessories.
Set of vibration dampers.
-Page 82-
Fig. 6.7-2 Packaged base frame for mounting on concrete block for
V-belt drive
Approx. dimensions and weights

V-belt driven compressor at NH3
-10/+35 (single stage) ), 1450 min-1, incl. oil separator and stop
valves
Compressor
type
(kg)
L(mm)
W(mm)
H(mm)
46
649
1569
881
804
66
766
1651
906
908
86
860
1664
931
883
IMM0312/v002
condense, both due to an increase of crankcase pressure,

a decrease of crankcase temperature and/or possible
temperature differences between crankcase and
evaporator.
Excessive foaming of oil in crankcase, can occur when
starting the compressor after a long period of standstill
with relatively low oil temperature which may result in
damaging the compressor by a lack of lubrication.
Low oil temperatures may also cause a high oil viscosity,
which may result in troublesome starting.
Selection and Data 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).
Fig. 6.8-1 Standard crankcase heater
Legend
CE
Cable entry
RC
Removable cap to protect connections
Fig. 6.7-3 Packaged base frame for mounting on vibration dampers for
direct drive (Dimensions B, H and V can be determined
by Grasso on request)
Approx. dimensions and weights

Direct driven compressor at NH3
-10/+35 (single stage) , 1450 min-1, incl. oil separator and stop valves
6.8.1
Compressor
type
(kg)
L(mm)
W(mm)
H(mm)
46
574
1527
632
804
66
691
1617
731
908
86
785
1642
758
883
6.8
Mentioned power in Watt; Standard voltages are

110-120 V and 220-240 V.
This standard crankcase heater is thermostatically

controlled.
CRANKCASE HEATER
Installed power of heater
element
Dimension L (mm)
400
400
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
IMM0312/v002
-Page 83-
-Page 84-
IMM0312/v002
7. NOTES
7. NOTES
Table of Contents
Section
Title
7.1
Page
85
7.1
IMM0312/v002
-Page 85-

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Reciprocating Compressors for industrial refrigeration

Reciprocating Compressors for industrial refrigeration / Series Grasso 6

The compressor is not filled with oil.

This manual must be carefull read and understood prior

After the successful initial run of the compressor

Open compressor series and (semi) hermetic

In compliance with the regulations of the Pressure

Installer oriented information

Reciprocating Compressors for industrial refrigeration / Series Grasso 6

INSTALLATION AND PREPARATION FOR USE

Moving instructions and storage

Hoisting and moving instructions

Required free space

Concrete block mounting instructions

Mounting bare compressor on a concrete block

Mounting the base frame on a concrete block

Levelling the base frame

Finishing with a self-levelling grout

Connecting to refrigerating system pipework

Connecting the power supply

Separately delivered components

PREPARATIONS FOR USE

Leak test of compressor and system

EVACUATION/DRYING THE REFRIGERATING SYSTEM

Initial oil charge

Initial oil charge

Initial refrigerant charge

Adjustment of instruments and safety devices

Re-adjustment of oil pressure regulator

Checking direction of rotation of motor shaft

Installing the drive guards (if present)

Initial oil warm up

Limitations of part load operation and start-up

Pre-start check list

Starting and stopping procedures

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

Restart after a long standstill period of time

Stopping the compressor

INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Reciprocating Compressors for industrial refrigeration / Series Grasso 6

Survey of periodical inspections

CHECK LIST PERIODICAL INSPECTIONS

MAINTENANCE (REFER Chapter 5)

Post start-up maintenance

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

Topping up oil with compressor operating

EVACUATION OF THE COMPRESSOR

DRAINING AND CHANGE OF OIL

OIL SUCTION AND DISCHARGE FILTERS

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

APPENDIX; Product Information (PI)

MAIN DIMENSIONS AND SPACE REQUIREMENTS

SHAFT END COMPRESSOR

LIMITS OF OPERATION AND FIELDS OF APPLICATION

GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 6

PRECISE FIELD OF APPLICATION

LIMITATIONS OF PART-LOAD OPERATION

LUBRICATING OILS (choice and recommendations)

PACKAGED BASE FRAME

PACKAGED BASE FRAME

DETAILS CRANKCASE HEATER

Reciprocating Compressors for industrial refrigeration / Series Grasso 6