Compressor Manual P 251511 Om Ssp1 GBR 3-A4

Screw Compressor Packages
Grasso SSP1
Operating Manual (Translation of the original text)

P_251511_3
Operating Manual |
Grasso SSP1
COPYRIGHT
this document may contain or for their consequen-
All Rights reserved. ces.
No part of this publication may be copied or pub- The manufacturer reserves the right to make techni-
lished by means of printing, photocopying, microfilm cal modifications during the course of further devel-
or otherwise without prior written consent of opment of the equipment covered by these operating
• GEA Refrigeration Germany GmbH instructions.
herein after called manufacturer. This restriction Illustrations and drawings in these operating instruc-
also applies to the corresponding drawings and dia- tions are simplified representations. As a result of the
grams. improvements and changes, it is possible that the
illustrations do not exactly match the unit you are
LEGAL NOTICE operating. The technical data and dimensions are
subject to change. No claims can be made on the
These operating instructions are part of the technical basis of them.
documentation for the scope of delivery. They con-
The manufacturer cannot accept liability for damages
tain important instructions for ensuring safe and
proper transport, installation, start-up, economic • which occur during the warranty period as a
operation, maintenance and repair of the unit. Their result of
observance helps in avoiding dangers, reducing
– improper operating conditions and conditions
repair costs and down-times and increasing the relia-
of use,
bility and durability of the unit.
These operating instructions are intended for the – inadequate maintenance,
users of the equipment and are specifically intended – improper operation,
for the operating company and its operating and
maintenance personnel. – incorrect installation,
It is essential that the operating company and its – incorrect or improper connection of the main
operating and maintenance staff read these operat- electrical drive,
ing instructions prior to transport, installation, start- • or which result from or can be attributed to
up, use, maintenance, repair, disassembly and dis- improper modifications or failure to observe the
posal. This obligation to read also applies to person- instructions;
nel involved in activities in the life phases of the
machine. • through the use of accessories or spare parts
The operating company must supplement these which were not supplied or recommended by the
operating instructions with instructions regarding manufacturer.
health and safety at work and environmental protec-
tion on the basis of existing national regulations for
industrial safety.
In addition to these operating instructions and the
binding accident prevention regulations valid for the
respective country and area where the product is
used, the recognised technical regulations for safe
and professional work must also be observed.
These operating instructions are part of the unit. The
entire documentation comprises these operating
instructions and all additional operating instructions
supplied with the unit. It must be kept readily availa-
ble where the unit is installed. The entire documenta-
tion must also be forwarded if the unit is installed at
another location and if the unit is sold.
These operating instructions have been written in
good faith. However, GEA Refrigeration Germany
GmbH cannot be held responsible for any errors that
2 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

Operating Manual |
Grasso SSP1
SYMBOLS USED IN THIS MANUAL

Danger!
Stands for an immediate danger which
leads to heavy physical injuries or to
the death.
Warning!
Stands for a possibly dangerous situa-
tion which leads to heavy physical
injuries or to the death.
Caution!
Stands for a possibly dangerous situa-
tion which could lead to light physical
injuries or to damages to property.
Hint!
Stands for an important tip whose
attention is important for the designa-
ted use and function of the device.
GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 3

Operating Manual |
Grasso SSP1
LAYOUT INFORMATION
Bullet points and numbered list characters

Bullet points are used to separate logical contents within a section:
• Bullet point 1
Types of bullet point 1.
• Bullet point 2
Types of bullet point 2.
Numbered list characters are used to separate enumerations within a descriptive text:
Descriptive text with consecutive numbering:
– Numbered list point 1
– Numbered list point 2
Handling instructions
Handling instructions require you to do something. Several consecutive steps result in a handling sequence that
should be run in the specified order. The handling sequence can be divided into separate steps.
Handling sequence
1. Handling sequence step 1
– step 1,
– step 2,
– step 3.
2. Handling sequence step 2
The subsequent handling sequence is the expected result:
® Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
– Individual work steps

Operating Manual |
Grasso SSP1
TABLE OF CONTENTS
1 BASICS 11
1.1 Importance of the documentation 11
1.2 Requirements for personnel, obligation to exercise due care 11
1.3 Legal foundations (Germany) 12
1.4 Specified Use 13
1.5 Warning against foreseeable abusive use 13
1.6 CE mark 14
2 MANUFACTURER INFORMATION 15
3 CUSTOMER SERVICE 16
3.1 Technical customer service department 16
3.2 Spare parts 16
3.3 Training courses 16
3.4 Service contracts 16
4 SAFETY 17
4.1 General information for safety 17
4.2 Behaviour in the case of emergency 17
4.3 Possible residual hazards 17
5 TRANSPORT, STORAGE 19
5.1 General instructions 19
5.2 Delivery 19
5.3 Transport (crane transport) 19
5.4 Bearings 21
5.5 Storage (several years) 21
6 INSTALLATION 23
6.1 Basic information for installation 23
6.2 Rigid installation 23
6.3 Anti-vibration mounting 23
6.4 Electrical connection 23
6.5 Information about noise emissions 24
7 DESCRIPTION OF DESIGN AND FUNCTION 29
7.1 Product name 29
7.2 Technical specifications 30
7.3 Location of the product identification (type plate) 31
7.4 Information and safety labels on the product 33
7.4.1 Labels of the pressure and temperature sensors, heater 33
7.4.2 Label of the safety valve 33
7.4.3 Labels of the screwed connections with DiNova ring 33
7.4.4 Labels of the pipelines 34
7.4.5 Marking the direction of rotation of the compressor drive motor 34
7.4.6 Marking the direction of rotation of the oil pump motor 34
7.4.7 Labeling of the control / control cabinet 35
7.4.8 Designation of the earth connection 35
7.5 Process flow diagram 36
7.6 Main components 36
7.6.1 Screw compressors 37
7.6.2 Compressor drive motor 38
7.6.3 Coupling 38
7.6.4 Oil separator 38
7.6.5 OMC block with oil filter system 39
7.6.6 Oil cooler 39
7.6.7 Oil pump 39
7.6.8 Suction filter combination SFC 40
7.6.9 Controller 40
7.6.10 Fittings 40
7.6.11 Safety devices 41
7.6.12 Components installed by the client 42
7.7 General functional description 42
7.8 Refrigerant circuit 42
7.9 Oil System 43
7.9.1 Oil separation 43

Operating Manual |
Grasso SSP1
7.9.2 Oil heater 43

7.9.3 Oil cooling 43
7.9.4 Oil filter 43
7.9.5 Oil pump 43
7.9.6 Oil injection 43
7.9.7 Oil circuit, OMC block 44
7.10 Capacity control 44
7.11 Technical data 44
7.11.1 Basic terms 44
7.11.2 Operating media 44
7.11.2.1 Refrigerant 44
7.11.2.2 Refrigeration machine oils 45
7.11.2.3 Secondary refrigerant 45
7.11.3 Operating limits 46
7.11.4 Water quality requirements, parameters 48
8 START-UP 50
8.1 Important information for start-up 50
8.2 Basics 51
8.3 Connecting the screw compressor package 51
8.3.1 Connecting the pipes 51
8.3.2 Electrical connection 52
8.4 Paint and insulation 52
8.5 Start-up procedure 52
8.5.1 Checking the electrical connection 52
8.5.2 Leak test 52
8.5.3 Drying, vacuum 53
8.5.4 Operating position of valves 54
8.5.5 Oil charge 57
8.5.5.1 Pressure compensation with the cooling system 57
8.5.5.2 Checking the direction of rotation of the oil pump motor 57
8.5.6 Checking the fault monitoring 58
8.5.7 Adjustment of oil pressure 58
8.5.8 Checking the direction of rotation of the drive motor 59
8.5.9 Mounting the coupling 59
8.5.10 Checking the water circuits 60
8.5.11 Initial start-up 60
8.5.12 Checking the adjustment of the control slide 60
8.5.13 Checking the control slide adjustment times 60
8.5.14 Checking the oil cooler 60
8.5.15 Adjusting the amount of injection oil and the oil temperature 60
8.5.15.1 Screw compressor packages without refrigerant injection 60
8.5.15.2 Compressor units with refrigerant injection 61
8.6 Start-up after long standstill periods 61
8.7 Restarting after approx. 1 year standstill 61
9 USE, OPERATION, CONTROL 62
9.1 Important information for the operator 62
9.2 Prerequisite for switching on 62
9.2.1 Overview of the operating modes 63
9.2.2 Setting of setpoint and limiting values as well as safety devices 64
9.3 Operation of the screw compressor package 64
9.4 Guide to failures, their causes and remedies 65
10 CLEANING, MAINTENANCE, REPAIR 67
10.1 Important information for service personnel 67
10.2 Cleaning the heat exchanger 68
10.2.1 Mechanical cleaning 68
10.2.2 Chemical cleaning 68
10.3 Maintenance 69
10.3.1 General instructions 69
10.3.2 Repair work 70
10.3.2.1 Repair information 70
10.3.2.2 Repairs of pressure vessels subject to approval inspection 70
10.3.3 Maintenance intervals 70
10.3.4 Maintenance work 70

Operating Manual |
Grasso SSP1
10.3.4.1 Maintenance of the screw compressor 70

10.3.4.2 Changing the block mounting filter element 71
10.3.4.3 Maintenance of suction filter combination SFC 71
10.3.4.4 Oil draining, oil filling, oil change 72
10.3.4.5 Oil pump maintenance 74
10.3.4.6 Changing the fine oil separation cartridges 74
10.3.4.7 Tightening screw fastenings 74
10.3.4.8 Coupling maintenance 75
10.3.4.9 Checking the function of check valves 75
10.3.4.10 Searching for leaks on the refrigerant side / leak test 75
10.3.4.11 Venting the refrigerant circuit 76
10.3.4.12 Refrigerant evacuation 76
10.3.4.13 Checking the bearing noise 76
10.3.4.14 Checking the solenoid valves for capacity control 76
10.3.4.15 Checking the oil heater 76
10.3.4.16 Maintenance of the compressor drive motor 76
10.3.4.17 Checking the start regime 76
10.3.4.18 Checking the safety devices 76
10.3.4.19 Checking the operating parameters 77
10.3.4.20 Maintenance of the switching cabinet 78
10.3.4.21 Checking the earth connection 78
10.3.4.22 Insulation 78
10.3.4.23 Checking the tightening torque on the base fixator 78
11 DECOMMISSIONING 79
11.1 Shut-down in the event of dangerous situations 79
11.2 Standstill for a period <48 hours 79
11.3 Standstill for a period >48 hours 79
11.4 Measures during shutdowns 79
11.4.1 Monthly measures during standstill 80
11.4.2 Four weeks before restarting 80
12 DECOMMISSIONING, DISPOSAL 81

Operating Manual |
Grasso SSP1

Operating Manual |
Grasso SSP1
TABLE OF FIGURES
fig. 1 CE mark 14
fig. 2 Designation of the lifting points 19
fig. 3 Limit stop 20
fig. 4 Transportation with a wire rope hoist 20
fig. 5 Transportation with a cross-arm 20
fig. 6 Product code Smart ScrewPack SSP1 29
fig. 7 Location of the product identification (type plate) 31
fig. 8 Type plate 32
fig. 9 Safety labels of the pressure and temperature sensors, heater 33
fig. 10 Label of the safety valve 33
fig. 11 Labels of the screwed connections 33
fig. 12 Labels of the pipelines 34
fig. 13 Marking the direction of rotation of the compressor drive motor 34
fig. 14 Marking the direction of rotation of the oil pump motor 34
fig. 15 Test verification for the control system 35
fig. 16 Designation of the earth connection 35
fig. 17 Process flow diagram Grasso SSP1 36
fig. 18 Grasso Smart ScrewPack SSP1 37
fig. 19 Grasso SSP1, position of the screw compressor 38
fig. 20 Grasso SSP1, position of the compressor drive motor 38
fig. 21 Grasso SSP1, position of the coupling 38
fig. 22 Grasso SSP1, position of the oil separator 38
fig. 23 Grasso SSP1, position of the OMC-block with oil filter system 39
fig. 24 Grasso SSP1, position of the oil cooler 39
fig. 25 Grasso SSP1, position of the oil pump 39
fig. 26 Grasso SSP1, position of the suction filter combination SFC 40
fig. 27 Grasso SSP1 Large, position of the controller 40
fig. 28 Corrosion resistance in presence of chlorides 49
fig. 29 Vacuum required to remove moisture from refrigerating plants 53
fig. 30 Stop valve open 54
fig. 31 Stop valve closed 54
fig. 32 Check valve 54
fig. 33 Shuttable check valve 54
fig. 34 Control valve 55
fig. 35 Shuttable check valve 55
fig. 36 Solenoid valve 55
fig. 37 Change-over valve 55
fig. 38 Oil pressure control valve 55
fig. 39 Overflow valve, safety valve 56
fig. 40 Pressure controlled check valve 56
fig. 41 Quick acting valve, spring-loaded 56
fig. 42 Charging valve, draining valve 56
fig. 43 Service valve 56
fig. 44 Oil temperature limiter 57
fig. 45 Temperature controlled valve 57
fig. 46 Motor direction of rotation 59
fig. 47 Arrangement of MIN / MAX sight glasses 73
fig. 48 Operating position of the fine oil separation cartridges 74

Operating Manual |
Grasso SSP1

Operating Manual | Basics
Grasso SSP1
1 BASICS
– applicable international and national standards,
1.1 Importance of the documentation – applicable occupational safety regulations,
These operating instructions are part of the technical – applicable accident prevention regulations,
documentation for the Grasso scope of delivery. It – applicable environmental protection regulations,
contains advice for operating the package/chiller
safely, properly and economically. The observance – the construction and functioning of the unit,
of the operating manual helps in avoiding dangers, – recognised technical regulations for safe work
reducing repair costs and down-times and increasing according to good professional practice.
the reliability and durability of the package/chiller.
The technical personnel must:
This operating manual is directed at the users of the
package/chiller and is specifically intended for the – be able to assess the work assigned to them,
operating company and its operating and mainte- recognise and avoid possible dangers,
nance personnel. This operating manual must be – be authorised by those responsible for the safety
read prior to transport, installation, commissioning, of the system to carry out the requisite work and
maintenance, repair, disassembly/disposal. activities.
All work explained in this operating manual must only
be carried out by technical personnel. Caution!
This operating manual must be supplemented with No arbitrary changes may be made to
instructions based on prevailing national regulations the control or other components
regarding industrial safety, health protection and belonging to the unit. Maintenance
environmental protection. work may only be done by authorised
In addition to this operating manual and the manda- service staff.
tory accident prevention regulations applicable for
the respective place of installation, the accepted Special requirements for the electrical techni-
technical regulations for safe work according to good cians
professional practices must also be observed. Work on electrical components and modules may
The operating manual is a part of the total product. only be carried out by an electrical technician
The entire documentation, consisting of this operat- according to the rules relevant to electrical engineer-
ing manual as well as all supplied additional instruc- ing. Furthermore the operator has to take care that
tions, is to be always kept easily accessible at the the electrical systems, tools and fixtures are oper-
place of installation of the package/chiller. The com- ated according to the rules relevant to electrical engi-
plete set of documentation must also accompany the neering and applicable standards and serviced prop-
package/chiller if it is sold. erly.
– In principle it is prohibited to carry out work on
parts under voltage.
1.2 Requirements for personnel, obliga- – Fuses may only be replaced and not repaired or
tion to exercise due care bypassed.
Qualification – Only the fuses specified in the electrical circuit

diagram may be used.
All work explained in this manual (assembly, electri-
cal connection, commissioning, operation, etc.) may – A two-pole voltage tester must be used to ensure
only be carried out by trained technical personnel that the parts are de-energised.
who observe the relevant technical regulations. – The power supply as well as the unit casing must
Technical personnel are representatives of the unit be sufficiently grounded and tagged with a suita-
manufacturer and persons who, as a result of their ble label.
technical training, experience and personal instruc-
– Deficiencies noticed in the electrical systems/
tion in training measures, have sufficient knowledge
modules/tools and fixtures must be corrected
of:
immediately. If an acute danger exists till then,

Basics Operating Manual |
Grasso SSP1
the package/chiller must not be operated in the – EN 12284 Refrigerating systems and heat
defective condition. pumps – Valves – Requirements, testing and
marking
Minimum age
– DIN 2405 Pipes in refrigeration plants, marking
The minimum age for the operation of the package/
chiller and installation is 18 years. All persons – VDMA Directives, particularly VDMA 24 243
involved in the assembly and installation of the pack- and 24 020
age/chiller and the system must get themselves
– VDI Guidelines
trained at regular intervals and/or familiarise them-
selves with the current technical data of the device. – Instruction Sheets for Handling Ammonia,
The training and instructions is to be conducted at Instruction Sheet for halogenated hydrocar-
least once a year, unless some other interval has bons containing fluorine BGI 648
been agreed upon with the manufacturer.
– Safety Data Sheet for ammonia and other refrig-
Obligation to exercise due care erants and refrigeration oils
The statutory regulations for meeting the obligation The list of rules and standards has been taken from
to exercise due care are to be observed. Status Report No. 5 of Deutscher Kälte- und Klima-
technischer Verein "Sicherheit und Umweltschutz bei
Meeting the obligation to exercise due care accord-
Ammoniak-Kälteanlagen (Safety and environmental
ing to the current level of technology requires that
protection in ammonia refrigeration plants)" and fully
everything that is
applies to other refrigerants as well.
– technically possible (use of accepted technologi-
cal rules) and Danger!
– economically reasonable
be done to prevent damage in a protectively safe
manner. The additional safety instructions as
defined in "Appendix E" must be
observed for packages for the desig-
1.3 Legal foundations (Germany) nated use in potentially explosive
atmospheres, installation zones 1 and
Adhere to the following standards, rules, ordinances 2 in accordance with EN 60079-10.
and laws to ensure the safety and functionality of the
compressor units and chillers: The following:
– EC Machinery Directive 2006/42/EC – standards,
– EC Pressure Equipment Directive 97/23/CE - – safety regulations,
AD Instruction Sheets 2000
– guidelines and sound engineering practice,
– Statutory order on hazardous incidents (12. listed in these operating instructions must be
BImSchV) including 1. Breakdown VwV observed at least!
– Federal Emissions Control Act (BImSchG), 4. Hint!
BimSchV
If the package/chiller is used in a
– Water Resources Act (WHG), VawS country other than Germany, the rules
– Hazardous Substances Ordinance (GefStoffV) and regulations applicable at the place
of installation must be observed and
– Closed Substance Cycle Waste Management
complied with!
Act (KrW-AbfG)
– EN 378, Parts 1 to 4 Safety and environmental The mandatory accident prevention regulations
requirements applicable for the respective country and area where
the product is used must also be observed.
– Accident-Prevention Rule including implemen-
Failure to observe the safety instructions can lead to
tation regulations (BGR 500, chapter 2.35)
danger to personnel and the environment as well as
Refrigeration plants, heat pumps and cooling
damage to the equipment.
equipment (BGV B3) Noise

Operating Manual | Basics
Grasso SSP1
1.4 Specified Use the manufacturer is responsible for all injury to per-
sonnel and damage to property which results from
Hint! non-specified use.
Observe the chapter "Specified Use" The pressure units are not designed for dynamic
of the installation instructions for the loads. The pressure units must be earthed if there a
screw compressor! risk of lightning strikes. The supplier/installer must
include regular inspection of the pressure units in his
The screw compressor package must only be oper- operating manual instructions and define the behav-
ated up to a maximum discharge pressure in accord- iour of the end user in the event of damage. To pre-
ance with the type plate. vent burns or frostbite, do not touch the pressure
It is imperative to comply with the applicable condi- vessel while running. This can be prevented by the
tions of use with respect to pressure and tempera- appropriate safety precautions. Corresponding warn-
ture for the screw compressor package. ing signs must be attached. Compressor units or
Do not change the setting values of the safety pres- systems must be equipped with safety valves in
sure switch. This would endanger the operating accordance with EN 378. The oil separator must only
safety of the refrigeration plant. be installed in a vertical position. The foundation
must have adequate rigidity.
If the switch-off value is set higher than 0.9 x maxi-
mum operating pressure (see EN378-2) of the high The supplier/installer must exercise due care when
pressure section of the refrigerating system, this may installing the accessories for the pressure units. The
result in the bursting of the tank of this section of the pressure units must not be damaged during installa-
system. tion and must be painted after installation. The pres-
sure units must only be filled with the refrigerant
The operating regime stipulated by the manufacturer, specified in the contract. The pressure units must be
especially for the starting phase of the screw com- installed in the compressor unit or the system in such
pressor package, must be observed. a way that vibrations or pulses cannot be transferred
Operating parameters must be monitored. Operating to the pressure units. The connection lines must be
parameters must not go outside the defined limits. installed free of stress.
The screw compressor package has been designed Specified use includes observance of this manual
and manufactured for a special application under and all supplied operating manuals as well as com-
defined conditions of use. Unauthorised construc- pliance with the maintenance and service intervals
tional modifications are not permitted. We assume and conditions stipulated therein.
no liability for any resulting damage. GEA Refrigera- Warranty claims and authorization for operation
tion Germany GmbH reserves the right to implement become void if the equipment is not used for its
technical changes in the interest of further develop- proper purpose.
ment. The screw compressor package described
here corresponds to the state of the art at the time
this operating manual was published. 1.5 Warning against foreseeable abu-
The manufacturer must be consulted in all cases as sive use
to the permissibility of the modification if there is any
change of the application or the conditions of use. A package/chiller is said to have been abused, if
Do not make any modifications to the screw com- – unauthorised refrigerants, fuels and lubricants
pressor package and the compressor control system. and secondary refrigerant materials are used.
These may impair the safety and functionality of the Hint!
screw compressor package. They will also invalidate
the guarantee. Observe specification for the project!
The pressure units described here must not be used – electrical components are wrongly connected.
for any purpose other than the purpose specified
here. The units must only be installed by the sup- Hint!
plier/installer and not by the end user. If the pressure
Watch voltage and frequency!
units are not used in accordance with the regula-
tions, safe use of the unit is not guaranteed. The
– mechanical components are wrongly connected.
supplier/installer or the operating company and not

Basics Operating Manual |
Grasso SSP1
1.6 CE mark
Hint!
Watch pressure and temperature! By affixing the CE mark, the manufacturer confirms
the conformity of the product with the applicable EC
– the supporting, hanging and storage facilities are Directives and compliance with the principle require-
misused. ments stipulated within them.
– control and regulation units including control sys-

tem software are tampered with.
fig.1: CE mark
– the driving power generated by the motor is used
for purposes other than the operation of the
respective compressors and pumps. The CE mark is affixed to the nameplate.
The CE mark for products from GEA Refrigeration
Germany GmbH is provided as defined in the Pres-
sure Equipment Directive, i.e. pressure equipment is
placed on the market with the required equipment
parts with safety function. This complete assembly is
subject to the Pressure Equipment Directive.

Operating Manual | Manufacturer information
Grasso SSP1
2 MANUFACTURER INFORMATION
GEA Refrigeration Germany GmbH is a company
within GEA Refrigeration Technologies, the Refriger-
ation Technology Segment of the GEA Group and
provides its customers around the world with high-
quality components and services for refrigeration and
process technology applications.
Locations:
GEA Refrigeration Germany GmbH

Holzhauser Str. 165
13509 Berlin, Germany
Phone: +49 30 43592-600
Fax: +49 30 43592-777
Web: www.gearefrigeration.de
E-Mail: info@grasso.de

Werk Halle
Berliner Straße 130
06258 Schkopau/ OT Döllnitz, Germany
Phone: +49 345 78 236 - 0
Fax: +49 345 78 236 - 14
Web: www.gearefrigeration.de
E-Mail: info@grasso.de

Customer service Operating Manual |
Grasso SSP1
3 CUSTOMER SERVICE
GEA Refrigeration Germany GmbH supplies prod- In most cases, you will receive your spare parts
ucts of high quality and reliability. In addition, the within 24 hours after placing the order.
manufacturer ensures continuous operation of the You can contact us using the following hotlines:
refrigeration and process technology system and
provides exceptional service for the components • Wireless, out of hours
supplied. +49 (0) 172 30 14 579
• Landline, weekdays from 8 to 17 hour
+49 (30) 43 59 27 50
3.1 Technical customer service depart-
ment • Fax
+49 (30) 43 59 27 58
Do you require support from the technical customer
service department? Specially trained, experienced • Email
service technicians are available on call for you in Grasso-parts@geagroup.com
order to provide assistance in case of technical prob-
lems and to offer support in the framework of our • Order spare parts from our G-Pos. online
after-sales service. shop
24/7 Hotline: (Grasso Parts online shop)
the hotlines can reached around the clock on every gea-refrigeration.de.spareparts@gea.com
day of the week:
• Wireless 3.3 Training courses
+49 (0) 172 39 12 050
Warning!
• Landline, weekdays from 7 to 17 hours
+49 (30) 43 59 27 61 All work on our systems must only be
carried out by technical personnel!
+49 (30) 43 59 27 62 Acquire the technical know-how
• Email: required for this in good time!
Grasso-service@geagroup.com Comprehensive training courses are held regularly
outside of Germany, Austria and Switzerland please for service technicians and mechanics, thus ensuring
contact: the safe and proper use and maintenance of our sys-
• local sales office tems.
www.gearefrigeration.de • Email
technical support for liquid chillers with reciprocating Grasso-service@geagroup.com
compressors in Germany, Austria and Switzerland
• 24/7 Hotline
3.4 Service contracts
+49 (345) 78236 20
The specialists of our Technical Customer Service It is possible to sign a long-term service agreement
department support you in installations, acceptan- (service contract). For further information regarding
ces, maintenance, operating questions, on-site the content, scope and conditions of the possible
inspections and repairs of our products. service options, please contact the Technical Cus-
tomer Service department.
• Email:
3.2 Spare parts Grasso-service@geagroup.com
GEA Refrigeration Germany GmbH has its own prac-
tical and rapidly working spare parts department to
supply the necessary spare parts worldwide. Neces-
sary spare parts are shipped as quickly as possible.

Operating Manual | Safety
Grasso SSP1
4 SAFETY
4.3 Possible residual hazards
4.1 General information for safety Warning!
The safety aspects to be observed for operating the Despite careful design of the machine
equipment are shown in the chapter on "Safety". and implementation of all the safety-
relevant regulations, further risks for
The equipment has been developed and manufac-
persons and machine during all life
tured according to the currently applicable state of
phases of the package/chiller cannot
the art and is reliable in operation. It has been tested
be fully ruled out. The additional safety
and left the factory in a technically faultless safe con-
instructions in the individual chapters
dition.
of this manual must therefore be care-
In order to maintain this condition for the operation fully observed!
time, the details of the project documentation and
certificates must be observed and complied with. Residual risks that were ascertained during the risk
When operating the equipment, at least the general assessment carried out for the product according to
safety regulations and the provisions and guidelines safety standard EN ISO 14121 - Safety of Machines
referred to in this documentation must be observed. - are:
Only compliance with all provisions and guidelines – mechanical hazards due to sharp sheet metal
will enable optimum protection of the personnel as edges and projecting parts,
well as dangers to the environment and the safe and
smooth operation of the equipment. – electrical hazards as a result of inadvertently
coming in contact with terminals and cables,
– thermal hazards as a result of inadvertently com-
4.2 Behaviour in the case of emergency ing in contact with heat exchangers and pipes,
Hint! – exposure to noise,
Familiarise yourselves with the local – hazards caused by vibration due to improper
evacuation plan before beginning the installation,
work. – hazards due to working materials and other
Should an emergency situation arise despite adher- materials in case of allergies orthe like,
ing to the safety regulations, the package/chiller – neglect of ergonomic principles,
must be shut down immediately and isolated from
– combinations of various hazards,
the electrical mains.
The mains cable must be blocked in such a way it is – unexpected start-up, unexpected rotation in case
not possible to restart the unit accidentally and of incorrect electrical connections or defects,
marked as such. – shut-down, emergency stop when defects are
The operator of the complete system has to take detected,
care that an isolation device, e.g. a mains switch with
– changes to the rotational speed,
appropriate contact rating and an integrated indica-
tor, is pre-installed in the mains cabling on site. – power failure,
A separate mains cable/feed cable must be laid for – failure of the control circuit or control loop,
the operation of the package/chiller.
– incorrect assembly,
The mains cable/feed cable is to be specially protec-
ted and provided with an emergency stop switch. – fracture during operation,
– operating media or objects getting thrown out,
– loss of stability and
– personnel slipping, tripping or falling.

Safety Operating Manual |
Grasso SSP1
Hint!
There are no radiation hazards

Operating Manual | Transport, Storage
Grasso SSP1
5 TRANSPORT, STORAGE
5.2 Delivery
5.1 General instructions Shipment is made in the type of packing stipulated in
the order. The screw compressor package is gener-
Caution! ally supplied without packing.
Adequate lighting must be ensured The screw compressor package has an inert gas
during loading and unloading as well filler in the refrigerant circuit.
as for storage in order to avoid injuries
Warning!
and damage to property.
There is a danger of impacts and The compressor(s) of the screw com-
stumbling due to protruding parts on pressor package is/are not filled with
the equipment (e.g. valve caps). There oil. The screw compressor package
is also the danger of being cut on must not be started, therefore, before
sharp edges and surfaces. There is a proper assembly and start-up.
danger of crushing parts of the body
during the transport work. Personal
protective equipment (work clothing, 5.3 Transport (crane transport)
work books, gloves) must be worn
during all activities on the equipment. Warning!
Hint! The screw compressor packages are

not intended for transport with a fork
These operating instructions must be lift truck!
read prior to transport, storage and
delivery to the installation site. It is Screw compressor packages are high-quality prod-
imperative to strictly observe the ucts which must be handled with due care during
instructions and information given! transport. Protect the equipment from impacts and
All work explained in these operating put it down carefully.
instructions must only be carried out When transported by crane, the screw compressor
by qualified personnel. package must have the same position as in opera-
tion (frame downwards!). Do not use any other lifting
points than those specially provided for this purpose.
The lifting points are marked!
fig.2: Designation of the lifting points
Caution!
It is prohibited to strap screw com-
pressor packages to any fittings or
pipes or to the eyebolts/lugs on the
compressor, electric motor, container
or switching cabinet.

Transport, Storage Operating Manual |
Grasso SSP1
Take special care not to attach the ropes near to

small nominal diameter pipes or insulation and to
damage them. Use spacers if necessary.
The lifting points are not arranged in one plane. The
ropes must be longer than 3 m. The height differen-
ces between individual lifting points must be com-
pensated by suitable extensions.
Make suitable arrangements (timber or insulating
material) to avoid damage to the surface.
Shackles must be used.
fig.5: Transportation with a cross-arm
fig.3: Limit stop Danger!

Make certain there is no one under the
suspended load during transport with
the crane!
Position the screw compressor package on the

transport vehicle such that it is prevented from tilting
and falling. The load securing must preferably be
carried out by lashing to the prescribed points. The
pipes and equipment of the screw compressor pack-
age must not be entered. Components must be
secured against vibration. The competent staff mem-
ber or the company is responsible for ensuring trans-
port safety.
Warning!
Screw compressor packages must be
adequately protected from external
influences during transport.
Transport packaging (optional): Foil

fig.4: Transportation with a wire rope hoist The foil must only be removed before erecting the
screw compressor package at the intended installa-
tion location in the machine room. Up until this point
in time, the foil serves to protect the screw compres-
sor package against external influences.

Operating Manual | Transport, Storage
Grasso SSP1
5.4 Bearings
Warning!
When the screw compressor packages are deliv- Regular ventilation of the screw com-
ered, check for possible transport damage and report pressor package packaging (if
any damage to the manufacturer in writing. present) must be ensured in order to
The storage area of screw compressor units shall be prevent condensation on the surfaces
roofed, plain and paved and secured against access of the machine.
of unauthorized persons. Place the screw compres-
sor package onto timber planks and have it protected Long-term storage
from jerks or impacts.
With a standstill of the compressor of more than 16
Warning! weeks prior to start-up, there is a danger that the
shaft seal may stick on the shaft and therefore be
Screw compressor packages must be
damaged on start-up. Because of this, removal and
adequately protected from external
cleaning of the shaft seal is mandatory in order to
influences (humidity, frost, extreme
ensure that it functions correctly.
heat) during storage. This usually con-
cerns lengthy standing times outdoors 1. Use two pressure screws to remove the cover of
before installation and start-up of the the shaft seal, including the stationary gasket
refrigeration plant. The manufacturer inserted in it.
recommends the use of plastic sheet- 2. Removal of the seal package arranged on the
ing to cover the whole product. shaft with the associated slide ring by hand or, if
The venting slits of the electric motors tightly seated, extraction by means of an appli-
must always be covered! ance. If the seating is loose, the seal package
may adhere to the stationary seal and will be
Storage temperature: 5°C ... 40°C
pulled out when removing the cover.
The composition of the paint on the screw compres-
sor package is designed for installation in the 3. Clean the shaft seat with a lint-free cloth. Grease
machine room (inside installation). Contact with it lightly and push the sealing package back onto
water (including water spray) must be avoided. the shaft again.
4. After pushing onto the shaft, the seal package
Warning!
must be manually compressed against the spring
The screw compressor package is fil- pressure which acts on it. At the same time, it
led with dry gas (e.g. nitrogen) before must be checked whether the gasket springs out
delivery which prevents any change of again.
the properties of any already filled
5. Then re-fit the cover of the shaft seal.
operating medium (e.h. refrigerating
machine oil). Check the gas filling Warning!
once a week and recharge to the
specified overpressure if required. Danger of cuts and crushing injuries.
Turn the shaft of the compressor at least every four 6. If storage is longer than 26 weeks, all O-rings
weeks (approx. 10 revolutions). must be renewed.
The transport packing (foil if present), that needs to
be opened for turning the compressor shaft and for
checking the gas filling, must be closed again after 5.5 Storage (several years)
carrying out the activities in order to ensure protec-
tion against external influences. The packing (foil if Hint!
present) must be replaced as needed and for lengthy The instructions of chapter "Transport,
storage times. storage" must be heeded.
The following storage conditions must be maintained

when storing screw compressor packages which are
equipped with a control.
1. Storage temperature > 10°C

Transport, Storage Operating Manual |
Grasso SSP1
2. Air humidity < 50% Caution!

If storage is intended for the screw compressor pack- Once storage is over and prior to rede-
age, the following preparatory measures must be livery, a general check at the storage
carried out ex-works (especially protection against location by GEA Refrigeration Ger-
internal and external corrosion): many GmbH Technical Customer Serv-
• All process connections on the screw compres- ice is recommended. Please pay atten-
sor package are sealed tight. tion to the information in chapter
"Start-up".
• The screw compressor package is charged with The general check includes changing
dry gas to 1 bar. the O-ring on the compressor shaft
• A suction pressure gauge has been installed. seal as well as replacing the shaft seal
of the oil pump.
• The facing sides of the mounted coupling hubs
have been greased. (Does not apply to sliding
bearing compressor drive motors)
Hint!
When using high voltage motors: The
operating manual of the manufacturer
must be heeded, especially in respect
to any anti-condensation heater
required.
• Free-standing motor and main flow shafts have

been conserved.
• The space on the screw compressor for the shaft
seal has been greased.
• The connections on the oil cooler water side
have been sealed.
The following maintenance work must be carried out
at the storage location during storage:
1. Visual inspection of the general condition of the
screw compressor package.
2. Cyclical rotation of the screw compressor shaft
(about 10 revolutions per month and the com-
pressor drive motor (see operating manual).
Hint!
Does not apply to sliding bearing com-
pressor drive motors.
3. Checking the transport charge on the suction

pressure gauge. If this value is < 1 bar, recharge
with dry gas via valve pos. 85 (see P+I diagram).
All valves are already opened at the factory for a
common pressure range.

Operating Manual | Installation
Grasso SSP1
6 INSTALLATION
misalignment ≤ 0.25 mm) at the coupling is attained
again. Then tighten the foundation bolts.
6.1 Basic information for installation
Caution!
6.3 Anti-vibration mounting
During the installation, make sure that
substances escaping from leaks do The frame of the screw compressor unit must be
not reach into the soil, groundwater or aligned with the levelling bolts until the coarse align-
surface water. The applicable legal ment (radial and angular misalignment (radial and
regulations must be heeded at the angle offset ≤ 0.25 mm) at the coupling is attained
place of installation (e.g.for Germany: again.
German Federal Water Act WHG). Before tightening the foundation bolts of the isola-
tors, check that the isolators over the spring (pre-
All foundation calculations, the selection of materials dominantly made of rubber) are free and do not lie
and the soil analysis are the designer's or owner’s on the foundation.
responsibility.
A plan must be produced for proper and professional
assembly prior to the installation. The electrical and 6.4 Electrical connection
operating media connections must be established. It
must be borne in mind that, in addition to the installa- Danger!
tion area of the screw compressor package, there
Contact with live components is pro-
must be sufficient space available for the pipes as
hibited.
well as for operating during maintenance activities.
Produce the earth connection accord-
Install the screw compressor package on a level sur-
ing to the designation in the general
face. The difference from the horizontal must not be
assembly drawing. See chapter "Des-
more than 0.3 %. Provide enough space for mainte-
ignation of the earth connection".
nance work.
Under normal conditions, the screw compressor Before starting work, make sure that all parts to be
package stands solidly on the installation surface connected are de-energised, e.g. by removing the
due to its own dead weight. We recommend that you main fuse in all phases or installing a jumper wire.
provide ribbed rubber plates for shock absorption The insulation resistance of the electrical tools and
between the support surface and screw compressor fixtures and wiring is to be checked. The connection
package feet or machine base frame. may only be undertaken if this value lies in the allow-
If greater damping is required (installation on a floor able range.
ceiling or on the roof), vibration dampers must be All electrical connections must be established and all
provided. The appropriate type of vibration damper electrical consumers/sensors must be connected
must be determined and realised for this case. Also according to the circuit diagram.
decouple the secondary refrigerant lines using com-
pensators when vibration absorbers are used.
The welding seams must be inspected in accordance
with the Pressure Equipment Directive after welding
work by the customer or operator on pipe line con-
nections and flanges.
6.2 Rigid installation

The frame of the screw compressor unit/ liquid chiller
is placed on foundation bolts on a prepared founda-
tion. The frame must be levelled with suitable shims
such that the coarse alignment (radial and angular

Installation Operating Manual |
Grasso SSP1
6.5 Information about noise emissions

The noise information provides approximate parameters and apply to the installation without any secondary
noise protection measures.
The information has a tolerance of ±3 dB.
The precise data depend closely on the emission values for the motors, which are manufacturer dependent.
Should local conditions require adherence to noise levels, a calculation should be made using the specific motor
data in individual cases.
Noise protection measures such as motor encapsulation or complete assembly encapsulation may generate sig-
nificant noise reduction.
Wearing hearing protection with sufficient noise reduction is recommended in rooms with running screw com-
pressor packages.
Caution!
According to EU Directive 2003/10/EC, the allowable exposure limit value regarding the daily
noise exposure level is 80 db(A). In the event of noise levels above this limit value the system
operator must provide the operator with information on exposure to noise and personal hear-
ing protection and ensure that this is also worn (2003/10/EC Article 6).
Noise level LWA
Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Compressor drive
LWA in dB(A) mains operation 400 V / 50 Hz
motor
at 40°C
C D E G H L M
Output in kW
231 265 321 372 471 544 690
Max 91 91 91
22
Min 84 84 84
Max 92 92 92 92
30
Min 85 85 85 85
Max 93 93 93 93 93
37
Min 86 86 86 86 86
Max 94 94 94 94 94 94
45
Min 87 87 87 87 87 87
Max 95 95 95 95 95 95 95
55
Min 88 88 88 88 88 88 88
Max 96 96 96 96 96 96 96
75
Min 89 89 89 89 89 89 89
Max 97 97 97 97 97 97 97
90
Min 90 90 90 90 90 90 90

Grasso SSP1
Noise level LWA

Compressor drive
motor
at 40°C
C D E G H L M
Output in kW
231 265 321 372 471 544 690
Max 98 98 98 98 98 98
110
Min 91 91 91 91 91 91
Max 98 99 99 99 99
132
Min 92 92 92 92 92
Max 100 100 100

160
Min 93 93 93
Max 101
200
Min 94

Compressor drive
motor
at 40°C
P N R S V
Output in kW T W
805 860 1040 1290 1640
Max 95 95
55
Min 88 88
Max 96 96 96
75
Min 89 89 89
Max 97 97 97 97
90
Min 90 90 90 90
Max 98 98 98 98 98 98
110
Min 91 91 91 91 91 91
Max 99 99 99 99 99 99 99
132
Min 92 92 92 92 92 92 92
Max 100 100 100 100 100 100 100

160
Min 93 93 93 93 93 93 93

Grasso SSP1

Compressor drive
motor
at 40°C
P N R S V
Output in kW T W
805 860 1040 1290 1640
Max 101 101 101 101 101 101 101

200
Min 94 94 94 94 94 94 94
Max 102 102 102 102 102 102 102

250
Min 95 95 95 95 95 95 95
Max 103 103 103 103 103

315
Min 96 96 96 96 96
Max 104 104 104 104 104

400
Min 97 97 97 97 97
Max 104 104 104 104

450
Min 98 98 98 98
Max 105 105 105

500
Min 98 98 98
Max 105 105 105

560
Min 99 99 99
Max 105
630
Min 99
Compressor type/ theoretical swept volume in m³/h at 2940 rpm

Compressor drive
motor
at 40°C
Y Z XA XB XC XD XE XF
Output in kW
2296 2748 3250 4150 4900 5800 7170 8560
Max 99
132
Min 92
Max 100 100

160
Min 93 93
200 Max 101 101 101

Grasso SSP1
Compressor type/ theoretical swept volume in m³/h at 2940 rpm

Compressor drive
motor
at 40°C
Y Z XA XB XC XD XE XF
Output in kW
2296 2748 3250 4150 4900 5800 7170 8560
Min 94 94 94
Max 102 102 102 103

250
Min 95 95 95 100
Max 103 103 103 104 104 105

315
Min 96 96 96 100 100 101
Max 104 104 104 104 104 105 105 105

400
Min 97 97 97 100 100 101 102 102
Max 104 104 104 104 104 105 105 105

450
Min 98 98 98 100 100 101 102 102
Max 105 105 105 105 105 105 105 105

500
Min 98 98 99 100 100 101 102 102
Max 105 105 105 105 105 105 105 105

560
Min 99 99 100 100 100 101 102 102
Max 105 105 105 106 106 106 106 106

630
Min 99 99 99 100 100 101 102 102
Max 105 106 106 106 106 106 106

710
Min 99 99 100 100 101 102 102
Max 106 106 106 106 106 106 106

800
Min 99 99 100 100 101 102 102
Max 107 107 107 107 107

900
Min 100 100 101 102 102
Max 107 107 107 107

1000
Min 100 101 102 102

Grasso SSP1
Hint!
The individual emission data for the motor-compressor combinations can be found in the
tables and added using logarithms for screw compressor packages and chillers (DuoPack ver-
sion) as well as two-stage screw compressor packages.

Operating Manual | Description of Design and Function
Grasso SSP1
7 DESCRIPTION OF DESIGN AND FUNCTION
7.1 Product name
fig.6: Product code Smart ScrewPack SSP1
X = frame size of screw compressor package
Code letter Theoretical volume flow at 2940 min-1 in m³/h
P 805
R 1040
S 1290
T 1460
V 1640
W 1940
Y 2296
Z 2748
XA 3250
Y = design variant of screw compressor package

Description of Design and Function Operating Manual |
Grasso SSP1
Code letter Design type
Horizontal oil separator installed below

A
Refrigerant R717 (ammonia)
9 = design variant of screw compressor
1 Standard refrigerating compressor Vi = 1.8; 2.0; 2.2; 2.6
2 Standard refrigerating compressor Vi = 3.0; 3.6
3 Standard refrigerating compressor Vi = 4.8
4 Standard refrigerating compressor Vi = 5.5
5 Standard refrigerating compressor Vi = variable
6 Booster Vi = fixed
A = Oil cooling
Code letter Oil Cooling
A Water-cooled oil cooler
B Refrigerant cooled oil cooler
C Refrigerant injection
D Water or refrigerant cooled oil cooler
E Water or refrigerant cooled oil cooler and refrigerant injection
F Without oil cooler
Naming example
Grasso Smart ScrewPack SSP1 with screw compressor 1460 m³/h (T)
Refrigerant R717 (ammonia) and horizontal oil separator installed below (A)
TA - 1A
fixed internal volume ratio Vi=1.8; 2.0; 2.2 or 2.6 (1)
with oil separation and water-cooled oil cooler (A)
– list of parameters,
7.2 Technical specifications – general assembly drawing,
Packages / chillers are designed and manufactured – P+I diagram.
for special fields of application. For technical specifi-
cations see the following.
– order specification,

Grasso SSP1
7.3 Location of the product identification (type plate)

The type plate contains the most important technical data of the product. This data and the contractual agree-
ments define the limits of designated use.
As standard, the type plate is fixed to the frame (deviations of the location are possible).
fig.7: Location of the product identification (type plate)
Type plate

Grasso SSP1
fig.8: Type plate
GEA Refrigeration Germany

Contact data of the manufacturer
GmbH:
Type: Type designation of the screw compressor package
Serial no.: Serial number of the screw compressor package
Year of construction: Year of construction of the screw compressor package
Weight without filling: Weight of the screw compressor package without filling
Refrigerant: Information on the refrigerant used
Max operating pressure: Information on the max operating pressure
Volume flow: Information on the volume flow
The standard languages are English and German.

Grasso SSP1
7.4 Information and safety labels on the 7.4.2 Label of the safety valve
product
(safety labels)
Danger!
The safety-related labels on the pack-
age/chiller must be followed!
fig.10: Label of the safety valve
7.4.1 Labels of the pressure and tem-

perature sensors, heater Importance of the labels
The safety valve must be connected to a blow-off
(safety labels) line.
7.4.3 Labels of the screwed connec-

tions with DiNova ring
(handling instructions)
fig.9: Safety labels of the pressure and temperature sensors,

heater
Importance of the labels

Before replacing pressure and temperature sensors
without dip tube it must be ensured that the pipelines
into which the sensors are mounted are not pressur-
ised. The pressure free state can be achieved by fig.11: Labels of the screwed connections
closing the shut-off valves before and after the sen-
sor to be replaced.
The informative label for all screwed connections
Before replacing oil heater it must be ensured that with DiNova ring (handling instructions) is attached
the oil separator into which the oil heater is screwed to the electric motor in a clearly visible manner.
in is not pressurised.
Importance of the labels:
If any leakage occurs at a screwed connection
(escaping gases or vapours), the screwed connec-
tion must be tightened:
Counter-hold the screwed pipe connection using
a wrench. Tighten the pipe nut about 1/4 to 1/3
rotation beyond the point where the increase in
the force if felt.
® The leakage is remedied.

Grasso SSP1
7.4.4 Labels of the pipelines 7.4.5 Marking the direction of rotation

of the compressor drive motor
(information plate)
Pipelines in refrigeration plants must be labelled as (information plate)
follows (DIN 2405):
– Refrigerant
– Direction of flow
– State of phase
fig.12: Labels of the pipelines
1 Arrow head (indication of the direction of flow)

2 Horizontal stripe (indication of the state of fig.13: Marking the direction of rotation of the compressor drive
phase), green = liquid // blue = gaseous cold // motor
red = gaseous hot
3 Information field (label of the refrigerant)
The direction of arrow indicates the direction of rota-
tion of the compressor drive motor
7.4.6 Marking the direction of rotation

of the oil pump motor
(information plate)
fig.14: Marking the direction of rotation of the oil pump motor
The direction of arrow indicates the direction of rota-

tion of the oil pump motor

Grasso SSP1
7.4.7 Labeling of the control / control 7.4.8 Designation of the earth connec-
cabinet tion
(information plate) Safety labels
• Label on the rear side of the control unit of the
control system (visible after opening the switch-
ing cabinet):
– Project name
– Make number of the package/chiller
fig.16: Designation of the earth connection
– MPI address
• Label on the inside of the switching cabinet: Importance of the labels
– Test verification for the control system Ensure that the product is properly grounded before
start-up. Connect the earth connection. The neces-
sary mounting hardware and cables are not included
in scope of supply.
See general assembly drawing for the position of the
earth connections.
Hint!
The cross-section of the ground wire
must be at least 10 mm². Alternatively,
two separately installed and separately
connected ground wire must be used,
ensuring the minimum cross-section
in the sum.
fig.15: Test verification for the control system

Grasso SSP1
7.5 Process flow diagram
fig.17: Process flow diagram Grasso SSP1
10 Screw compressors
15 Compressor drive motor
20 Oil separator
25 Oil filter/OMC block
30/200 Oil cooler
40 Oil pump
45 Suction filter SFC
55 Check valve – suction side
60 Check valve – pressure side
260 Stop valve – pressure side
280 Stop valve – suction side
7.6 Main components

The Smart ScrewPack SSP1 series of screw compressor packages consist of the following main assemblies and
components:

Grasso SSP1
fig.18: Grasso Smart ScrewPack SSP1
010 Screw compressors
015 Compressor drive motor
020 Oil separator
025 OMC block (oil management block) with oil filter system
030 Oil cooler (not shown in the picture)
040 Oil pump
045 Suction filter combination SFC, with check valve function
060 Check valve - discharge side (*not shown in the picture)
095 Coupling
180 Control device "Grasso System Control"
360 Oil heater
Safety devices
7.6.1 Screw compressors

Grasso SSP1
Optional: Other protection classes, operating vol-

tages and frequencies as well as speed-controlled
motors on request.
Hint!
The documentation of the electric
motor (operating manual) is a part of
the product documentation.
fig.19: Grasso SSP1, position of the screw compressor

7.6.3 Coupling
The screw compressors are characterized by a com-
pact design, a high reliability, high quality compo-
nents and the ease of maintenance.
Screw compressors are dual rotor positive displace-
ment machines that run according to the principle
and are operate by oil injection.
The screw compressors are operated with ammonia
(NH3) as the refrigerant. When ammonia is used as
refrigerant the refrigerating machine oil is to be
selected in accordance with the information about fig.21: Grasso SSP1, position of the coupling
lubricating oild for screw compressors.
Various series and sizes of screw compressors are The coupling helps in transmission of torque
available for different fields of application. between compressor and compressor drive motor.
The screw compressors are driven directly by the The elastic design of the coupling brings about the
compressor drive motor via a flexible coupling. neutralisation of the otherwise disturbing influences
such as axial or radial forces, vibrations or offset.
Hint!
Speed fluctuations and speed shocks are damped
The documentation of the screw com- and cushioned, torsional vibrations are reduced.
pressor (installation instructions, part
lists, drawings) is a part of the product Hint!
documentation. The documentation of the coupling
(operating manual) is a part of the
product documentation.
7.6.2 Compressor drive motor
7.6.4 Oil separator
fig.20: Grasso SSP1, position of the compressor drive motor
Standard: The compressors are driven by an air- fig.22: Grasso SSP1, position of the oil separator
cooled 2-pole electric motor IP23 with an operating
voltage of 400 V; 50 Hz using a coupling. The design of the oil separators is standardised and
features less oil carry-over and low oil consumption.

Grasso SSP1
The oil separator is installed horizontally. Hint!

Hint! The documentation of the OMC-block
The documentation of the oil separator (operating manual, acceptance certifi-
(operating and maintenance instruc- cate) is a part of the product documen-
tion, acceptance certificate) is a part of tation.
Oil heater
7.6.6 Oil cooler
Electric oil heaters are built into the oil separator to
heat the oil refrigerant mixture in the oil separator
during the standstill of the screw compressor pack-
age. The oil heater prevents condensation of the
refrigerant into the oil and, thus, any foaming of the
oil during start-up.
To protect against overheating, the heater is equip-
ped with an overheating protection according to its
output with a switching temperature of 110°C. This is
self-resetting after cooling to below approx. 105°C.
fig.24: Grasso SSP1, position of the oil cooler
Hint!
The documentation of the oil heater The oil cooler is used for cooling the oil heated in the
(operating and maintenance instruc- compressor in order to ensure sufficient oil viscosity
tion, acceptance certificate) is a part of for supplying to the compressor.
Hint!
The documentation of the oil cooler
(operating manual, acceptance certifi-
7.6.5 OMC block with oil filter system
cate) is a part of the product documen-
tation.
7.6.7 Oil pump
fig.23: Grasso SSP1, position of the OMC-block with oil filter

system
The OMC-block includes the oil distribution system

of the oil circuit. Necessary control and shutoff fit-
tings are integrated in the OMC-block. Connections fig.25: Grasso SSP1, position of the oil pump
for temperature and pressure sensors as well as
service ports are present. The OMC-block is com-
The oil pump is an important component of the oil
bined with a standardised filter system and oil pump
circuit. It is used for pumping and distributing refrig-
units and forms the central control and operator unit
erating machine oil.
in the oil circuit.
The oil pump ensures that the oil is distributed to the
Optionally the OMC-block can be equipped with a 3-
individual lubrication points (e.g., sliding contact
way valve element (for ensuring a minimum oil tem-
bearings, balancing piston and the stuffing box of the
perature when starting the compressor).
compressor).

Grasso SSP1
Hint! The screw compressor package is equipped with a

GSC TP-type controller as standard.
The documentation of the oil pump The GSC TP consists of the control unit with opera-
(operating manual, acceptance certifi- tor keypad and display unit, indicator lights for "Run-
cate) is a part of the product documen- ning", "Warning" and "Alarm", the emergency stop
tation. button, the output relays and the casing.
The GSC TP will be mounted directly on the com-
pressor package unit as standard. As an option, the
7.6.8 Suction filter combination SFC GSC TP can be arranged in a control centre.
The GSC TP performs the following functions as
standard:
• Display of all important physical and technical
parameters, e.g. pressure, temperature, motor
current, capacity, number of operating hours,
operating mode and status signals
• Automatic start-up and shut-down of the screw
compressor package and capacity control
dependent on the suction pressure or an exter-
fig.26: Grasso SSP1, position of the suction filter combination
SFC
nal temperature
• Monitoring of all operating parameters
The suction filter combination SFC contributes sub- • Compressor capacity limitation, in case the
stantially to the high working reliability of the compo-
measured discharge pressure, suction pressure,
nents and the overall product.
secondary refrigerant temperature or motor
The suction filter combination SFC prevents dirt par- current indicate overload
ticles entrained in the intake stream from entering
the screw compressor unit. The flow through the suc- • Fault memory with date and time
tion filter element is from the inside to the outside. It • Wire failure detection for all analogue input sig-
is designed so that monitoring is not required. The fil- nals
ter element can be cleaned.
• Password protection for preventing unauthorised
Hint! access to important parameters
The documentation of the suction filter • Non-volatile saving of program
combination SFC (operating manual,
• Possibility of communication with master control-
acceptance certificate) is a part of the
ler via MPI
(optionally via Profibus-DP, Modbus RTU or
Modbus TCP)
7.6.9 Control Hint!

The documentation of the controller
(operating manual, circuit diagram,
parameter list, communication guide-
line, Quick Reference Card) is part of
7.6.10 Fittings
The term fitting generally designates a control ele-
fig.27: Grasso SSP1 Large, position of the controller
ment of the machine. Among other things, the term
fitting is also used for valves if these are used for the
control and regulation of fluid flows in the piping.

Grasso SSP1
Furthermore, all kinds of installations in piping, such The check valve function of the suction filter combi-
as sight glasses, measurement apertures, filters and nation SFC prevents a pressure equalisation with the
similar are also designated as fittings. Therefore, fit- LP side of the plant and simultaneously prevents a
tings also include all kinds of valves, such as: reverse rotation of the screw compressor.
– Stop valves Check valve - discharge side (060)
– Check valves The discharge side check valve prevents refrigerant
from re-condensing in the oil separator.
– Safety valves
Oil pressure control valve (075)
– Throttle valves
The oil pressure control valve regulates the differen-
Each fitting has its own field of use, according to the tial pressure between the oil pump discharge side
pressure or temperature in the pipe, the size of the and the discharge pressure of the package. The oil
pipe, the sealing requirements for the fitting, the pressure control valve is integrated into the OMC-
reduction and direction of the flow of liquid as well as block (oil management centre).
the medium itself.
Safety device to prevent the discharge pressure
The safety fittings are used to limit the pressure in
from being exceeded
systems which are under pressure.
(pressure transducer 105)
Each fitting is designed for the specific application.
The compressor control sytem switches off the screw
The fittings can be operated manually or by motor,by
compressor package when the specified limit value
gear motors, or pneumatic or hydraulic cylinders, for
has been exceeded.
example. In reset fittings, the flow of fluid in the pipe
causes automatic closing of the valve. Limit value = see parameter list
Depending on the model, different closing elements Safety device to prevent the differential pressure
(e.g.valve discs, flaps, pushers) close the pipe con- between the oil pressure after oil pump (pressure
nected to the fitting. transducer 110) and the discharge pressure
(pressure transducer 105) oil circuit monitoring
Hint! from falling too low
The documentation of the fittings The compressor control system switches off the
(acceptance certificates) forms part of screw compressor package when the pressure differ-
the product documentation. ence between oil pressure after oil pump and dis-
charge pressure falls below the specified limit value
after a delay period.
7.6.11 Safety devices Limit value = see parameter list
The following safety devices are fitted onto the screw Safety device to prevent the discharge tempera-
compressor package of the series Grasso SSP1 as ture from being exceeded (resistance thermome-
standard or optionally: ter 120)
The compressor control system switches off the
Compressor drive motor safety devices screw compressor package when the specified limit
Rated current limitation (016) value has been exceeded.
The rated current limitation is realised by the com- Limit value = see parameter list
pressor control system: When the rated motor cur-
rent is exceeded, the control slide of the compressor Safety device to prevent the oil temperature from
is driven in the MIN direction until the motor current being exceeded (resistance thermometer 125)
reaches an allowable level. The normal output con- The compressor control system switches off the
trol then comes back into force. screw compressor package when the specified limit
Thermistor (017) value has been exceeded.
The thermistor shuts down the compressor drive Limit value = see parameter list
motor when its winding temperature limit has been The minimum oil viscosity for safe compressor oper-
exceeded. ation is ≥ 7 cSt. In case of oils soluble in the refriger-
ant, the minimum oil viscosity is to be ensured
Suction filter combination SFC with check valve depending on the discharge pressure and tempera-
function (suction side) (045 / 055) ture, oil temperature, as well as the type of oil.

Grasso SSP1
Overflow valve (340) 7.6.12 Components installed by the cli-

The overflow valve protects the compressor against ent
impermissibly high pressures. The overflow valve
must be connected with the suction pipe on site. Warning!
Lifting Pressure = see parameter list and P+I dia- The components and parts the cus-
gram tomer installs in particular the secon-
dary refrigerant and cooling medium
The overflow valve is designed in accordance with
circuits as well as the oil circuit need
DIN EN 13136 "Refrigerating systems and heat
to made from materials suitable for the
pumps - pressure relief devices and associated pip-
fluids flowing through them. Further-
ing - methods for calculation“.
more, in the event of modifications to
Warning! the product by the customer, the
effects on the safety devices are to be
The overflow valve must be connected
checked.
to the suction side when installing the
package in the refrigeration plant! GEA Refrigeration Germany GmbH
does not assume any liability for dam-
Safety valve (345) at oil separator age arising and the violation of the
safety regulations which result from
The safety valve protects the screw compressor
the use of unsuitable materials or
package against unallowably high pressure.
through modification to the product
Lifting Pressure = see parameter list and P+I dia- which is not considered in the original
gram safety concept.
If the screw compressor package is installed into a
refrigeration system comprising an emergency blow-
off station, only the oil separator connection is used.
7.7 General functional description
The valve is available as an option, depending on
the required acceptance. Screw compressor packages are refrigeration sys-
The safety valve is designed in accordance with DIN tem components and serve to compress refrigerants
EN 13136 "Refrigerating systems and heat pumps - such as ammonia (other operating media on
pressure relief devices and associated piping - meth- request).
ods for calculation“. Use as a heat pump is also possible.
Safety pressure limiter (350)
Safety pressure limiter with two separate release
7.8 Refrigerant circuit
contacts, one of which can only be reset using tool
(see UVV VBG20). The safety pressure limiter The screw compressor draws in refrigerant vapour
switches off the compressor drive motor if the dis- through the suction filter combination and suction fil-
charge pressure rises above the set point. ter and then discharges the compressed vapour into
Switching off pressure 1 = see parameter list the plant via the oil separator and discharge check
Switching off pressure 2 = see parameter list valve.
If the liquid in the oil separator can reach more than The check valve function of the suction filter combi-
90% of the oil separator’s volume, the client has to nation SFC prevents pressure equalisation with the
install an additional safety valve against liquid pres- LP side of the plant and simultaneously prevents
sure in oil separator. (design in compliance with DIN reverse rotation of the screw compressor.
EN 13136 "Refrigerating systems and heat pumps - The discharge check valve prevents refrigerant from
pressure relief devices and associated piping - meth- re-condensing in the oil separator.
ods for calculation“)
Hint!
The discharge check valve can be inte-
grated in the oil separator for screw
compressor packages with discharge
side nominal diameters up to NB 150.

Grasso SSP1
The suction filter combination prevents dirt particles 7.9.3 Oil cooling
carried by the suction flow from entering the com-
Before it is returned to the compressor for use, the
pressor. The filter element is characterised by a very
oil heated up in the compressor has to be cooled
large filtering area. The filter has a fineness of
down to a temperature at which it has sufficient vis-
140 µm.
cosity.
Gas vibrations which can occur in the compressor
The following oil coolers are available:
compression chamber at high pressure ratios in the
zero discharge zone are avoided by a gas vibration 1. liquid-cooled (non corrosive media)
protection device. This consists of a pressure equali-
– water (non corrosive)
sation line between the oil separator and the com-
pressor working chamber. – propylene glycol (25%)
– ethylene glycol (35%)
7.9 Oil System – Other refrigerants on request
The screw compressors operate oil-flooded. During 2. Thermosiphon

the compression process, refrigerating machine oil is 3. Refrigerant injection
supplied to the compressor for lubrication, sealing,
noise reduction, and absorption of part of the com-
pression heat. After the compression process, the oil 7.9.4 Oil filter
is separated again from the refrigerant in the oil sep-
arator. After cooling, the oil enters the oil filter which retains
solid particles from the entire oil flow.
Due to its large surface, the star-folded glass fibre
7.9.1 Oil separation element has a high absorbing capacity and thus a
long operating lifetime. The filter has a relative filter
The refrigerant-oil mixture is led into the first part of fineness of 25 µm.
oil separator. The first part of the oil separator con-
sists of two chambers. The first chamber employs
gravity separation. The hot gas passes the demister
7.9.5 Oil pump
while flowing out of the first chamber into the second
chamber. The oil separated thereby is collected in The oil pump runs for pre- and during compressor
the second chamber. Both the chambers of the first operation.
part of oil separator simultaneously serve as oil It draws the refrigeration compressor oil from the
receivers. receiver space in the oil separator, through the the
In the second part of the oil separator, the fine sepa- oil cooler and oil filter and pumps it to the bearings,
ration of the aerosol oil portion from the refrigerant is the balance piston, the shaft seal, to the capacity
performed by means of replaceable fine oil separa- control system and, if fitted, to the compressor's
tion cartridges. The oil separated in the fine separa- hydraulic Vi adjustment system.
tion part of the oil separator is returned to the com- The oil pump pumps more oil than the compressor
pressor via an additional orifice. uses. This surplus quantity of oil is returned to pump
suction via the spring loaded oil pressure regulating
valve. The oil pressure regulating valve regulates a
7.9.2 Oil heater pressure difference between the oil pump discharge
The oil heater on the oil separator is to be started side and the unit final pressure (according to the
when the package is shut down in order to ensure a value in the P+I diagram).
minimum oil temperature and sufficient oil viscosity
required for restarting the package. The oil heating is
not regulated. The maximum temperature of the 7.9.6 Oil injection
heating rod is restricted. The injection oil is fed without a pump via the oil
injection regulating valve.
The oil injection control valve is used to adjust the
necessary compression discharge temperature.

Grasso SSP1
The control valve is provided with a check function to 7.11 Technical data
prevent sucking refrigerant through the oil pump.
7.11.1 Basic terms

7.9.7 Oil circuit, OMC block
An OMC-block (oil management block) is flanged on Refrigerant Materials circulating in a plant (liq-
to the oil filter as an oil distributor system. The oil uid or gas), which by means of
flow is distributed via the bore-holes and channels to their change of state of the pack-
functional ranges of the screw compressor. All regu- age withdraw heat from another
lating valves and shut-off valves necessary for the medium (cooling or heating agent)
regulation of the oil circuit are integrated into the or can dissipate heat to this
block. As a result, a centralised control unit is availa- medium.
ble for the screw compressor package.
The oil filter with OMC-block (oil management block) Secondary Fluids that can absorb the heat of
is fitted with an oil drain and refilling stop valve which refrigerant a system and dissipate it to a
may be connected to a separate oil pump or refrigerant (reversible process)
receiver. and are used for the cooling of a
system (industrial process)
Vent valves are fitted to oil filters for maintenance
and repair purposes. Heating Media (liquid or air), which trans-
The oil in oil filter may be drained for changing oil fil- agents port and emit the heat absorbed in
ter via a separate stop valve. the secondary refrigerant. If water
is used as the heat carrier, the
terms warm water or cooling water
7.10 Capacity control are also used.
The screw compressors are fitted with a continuous

capacity control with a range of 10 -100%.
The capacity is adjusted by shortening the screw 7.11.2 Operating media
compressor stroke. The defining factor for the com-
pression process is the effective rotor length; this is
altered by a hydraulically operated control slide.
7.11.2.1 Refrigerant
The position of the control slide is recorded by the
position sensor. The control device signals the The technical order specification defines the refriger-
attainment of the MIN or MAX end position and the ant used. All components of the screw compressor
relative control slide position can be displayed on the package are designed for use with the defined refrig-
Touch Panel in percent. erant.
The hydraulic adjustment of the control slide is done
Hint!
using four solenoid valves which are integrated into a
single block. The safety data sheet for the refriger-
The control slide travel speeds in the MIN and MAX ant used must be observed. The safety
directions should be the same as much as possible data sheet is part of the product docu-
during operation to ensure better compressor con- mentation.
trol.

Grasso SSP1
7.11.2.2 Refrigeration machine oils 7.11.2.3 Secondary refrigerant

Caution! • Low corrosion water
In order to ensure an adequate load- • Permitted brine levels see Grasso installation
bearing capacity of the sleeve bear- program.
ings and to ensure the service life of
Hint!
the roller bearings a minimum viscos-
ity of 7cSt upstream of the compressor Compatible with the materials used
is required. A suitable oil must be must be ensured for other secondary
carefully selected in consideration of refrigerants.
the operating conditions.
The selection criteria and selection
tables are summarised in the technical
information "Lubricant oils for screw
compressors". This technical informa-
tion forms part of the product docu-
mentation.
GEA Refrigeration Germany GmbH can
provide assistance for the selection of
a suitable refrigeration machine oil on
request.

Grasso SSP1
7.11.3 Operating limits

The screw compressor packages can be operated under the most varied operating conditions within the given
limits of application according to the requirements involved. The operation limits listed below for the screw com-
pressor packages are based on the operational principle of the screw compressor, the thermodynamic relations
and are the result of the practical operating conditions and design. The tabulated data apply for single, two-stage
and heat pump operation. For the concrete application, selection and checking will be carried out in the com-
pressor selection program. Depending on the concrete operating conditions, restrictions of the limits specified in
the table can occur according to the specification text.
Suction temperature (compressor

t0h °C min > - 45
inlet)
Maximum allowable operating pres-

p bar (a) max ≤ 28
sure
Discharge temperature (compres-

te °C max < 95
sor outlet)
Pressure ratio p / p0 π - min > 1.5
Pressure difference p - p0 (t0 <

Δp bar min > 0.8
11°C)
Pressure difference p - p0 (t0 ≥

Δp bar min > 3.5
11°C)
Temperature difference te - tc Δt °C min >5
Temperature difference te - toil Δt °C min >4
Temperature difference toil - tcooling

Δt °C min ≥5
medium
Compressor type P R, S, T
50 Hz 330 530
Max. driving power (kW)
60 Hz 400 640
Max. nominal torque Nm 1060 1700
Max. allowable speeds (rpm) min-1 3600 3600
Compressor type V, W, Y Z, XA
50 Hz 900 1250
Max. driving power (kW)
60 Hz 1080 1500

Grasso SSP1
Max. nominal torque Nm 2900 4020
Max. allowable speeds (rpm) min-1 3600 3600
Minimal overheating at suction side: "Wet" operation to be avoided.

The minimum discharge temperature te must sufficiently exceed the value of the oil temperature for supplying the
bearing.
Limits for temperature differences will be considered in the specification.
Gas vibration protection necessary for π ≥ 8.
For pressure differences of 0.8 bar < Δ p ≤ 4 bar, an external oil pump must be provided.
Direction of rotation: view of compressor’s driving shaft: clockwise.
For individual cases outside the permitted speed coordination needs to made with the manufacturer.
Notes
1. During tests of a certain application case, all the
conditions specified in the table must be consid-
ered and adhered to.
2. If the specified limits are exceeded for a specific
application, GEA Refrigeration Germany GmbH
must be consulted.
3. In addition to the operation limits given in the
tables, consider the operating conditions which
must be observed for the compressor (e.g. start-
up regime, oil pressure, oil quantity, etc.).
4. The oil temperature at the compressor inlet must
be at least 18°C, the oil must be preheated if
necessary.
5. An oil viscosity of ≥ 7 ... 70 cSt at n ≥ 2.950 min-1
must be guaranteed for the bearing oil supply.
Take into account the drop in viscosity due to
refrigerant dissolved in the oil!
6. Depending on the requirements of refrigeration
economizer operation proceeds between the
100% and approx. 85% control slide positions.

Grasso SSP1
7.11.4 Water quality requirements,

parameters Water quality requirements, parameters
All water bearing components from the manufacturer Criterion Value Unit
give an optimum performance and maximum protec-
tion from corrosion, if you meet all recommended Chloride Cl < 150 g/m³
limiting values of VDI 3803 issue 2010-02 (Tab. B3)
for non-corrosive water and adequate water condi-
Sulphur SO4 < 325 g/m³
tioning.
Hint! Active biological

KBE < 10,000 per ml
If you don´t meet following rules for components
limiting values of non-corrosive water
the manufacturer can not give war- Thickness factor EZ 2-4
ranty for water contacted components.
All components are designed for use The use of carbon steel and cast iron required in the
with non-corrosive water. Water and most of applications water conditioning with corro-
glycol brine analysis is essential in sion inhibitors.
protecting system components. Analy- The use of stainless steel requires very special moni-
ses prior to start up will prevent corro- toring of water in apply to Chloride contents (risk of
sion. stress crack and pitting corrosion).
Following are shown required limiting values of VDI Hint!

3803, for use of carbon steel components in non cor- Recommend for use of plate heat
rosive water systems. exchangers in refrigerant circuit
< 100 ppm Cl while using steel 1.4301
Water quality requirements, parameters
and
Criterion Value Unit maximum 40 °C wall temperature in
the plate heat exchanger
Appearance clear, with- < 200 ppm Cl while using steel 1.4401
out sedi- and
ments maximum 100 °C wall temperature in
the plate heat exchanger
Colour colourless
Odour without
pH-level at 20 °C 7.5 - 9.0
Electrical conductiv-
LF < 220 mS/m
ity
Ca2+,
Soil alkali < 0.5 mol/m³
Mg2+
General hardness,
GH < 20 °d
for stabilization
Carbonate hard-
ness without hard- KH <4 °d
ness stabilizer

Grasso SSP1
fig.28: Corrosion resistance in presence of chlorides
X Chloride ion concentration in ppm Cl-

Y Wall temperature heat exchanger in °C
A AISI 304
B AISI 316
C SMO 254
Hint!
Manufacturer recommendation: Use
uncontaminated secondary refriger-
ants and cooling media, in particular in
chillers and the use of plate heat
exchangers.
The media quality needs to be assured
through an appropriate filter on the
inlet to the heat exchanger. The mesh
for such a filter needs to be ≤ 0.9 mm!
Should the chiller need to remain in
operation during filter cleaning, double
filters need to be used. Pressure loss
through the filter need to be taken into
consideration on the building side
when configuring the pump.
The manufacturer recommends enlisting the services

of a reputable water conditioning company.

Start-up Operating Manual |
Grasso SSP1
8 START-UP
The following points must be observed before
commencing with the start-up:
8.1 Important information for start-up
– Check of the external condition of the screw
Warning! compressor package (check of insulation, trans-
port damage... ).
hibited. – The area around the machine in which the start-
up is carried out must be marked and secured
Hint! against the access of unauthorised persons. Suf-
The Customer Service department of ficient lighting of the working area must be
GEA Refrigeration Germany GmbH ensured to prevent personal injury and material
offer comprehensive support for start- damage.
ing up the screw compressor package. – Personal protection gear (work clothing, work
For contact details, please refer to the boots, gloves) must be worn during all work on
chapter entitled "Technical customer the screw compressor package. There is a dan-
service". ger of impact and stumblingfrom protruding parts
on the screw compressor package (e.g. valve
Warning! caps). There is also the danger of cut wounds on
The screw compressor package must sharp edges and rough surfaces. All activities
only be operated by suitably skilled must therefore be carried out with particular
personnel who are familiar with the attention.
contents of the operating manual for – Suitable hearing protection must be worn in
screw compressor packages. order to protect against damage to hearing or
The safety regulations for refrigeration deafness.
plants must always be observed in
– Thermal hazards resulting in injuries due to
order to prevent damage to the screw
compressor package and injury to the burns or freezing may occur on contact with
operating staff. parts of the system which are at a very high or
very low temperature. Personal protective equip-
The screw compressor packages are tested and ment must be worn.
accepted at the works. By the time these screw – Suitable tools or special tools must be used.
compressor packages are delivered to the cus-
tomer, the following work will have been carried – Check that all electrical work has been carried
out: out in accordance with the standards (e.g.protec-
tive earth, insulation, shielding, covers). If neces-
• Complete installation of the cooling system and sary, an earth connection must be provided.
in particular:
– Pipes and pipe sections must be secured to
– cleaning and drying the refrigerant and oil ensure sufficient mechanical strength. The pipes
circuits and equipment of the screw compressor pack-
– Leak test with air age must not be entered.
– Evacuation of the refrigerant circuit and filling – Operating media (nitrogen, oil, refrigerant) can
with protective gas (nitrogen) to a pressure escape. Preventive measures must be taken to
of 0.3 to 0.5 bar (above atmospheric) collect and dispose of them in an environmen-
tally responsible manner (e.g.using an oil pan).
• Electrical wiring and testing of the wiring
Personal breathing protection must be kept
• Factory setting for the parameters on the control ready in the event of a refrigerant leak. The
safety data sheets of the oil and refrigerant used
• Factory setting of the safety and monitoring devi-
must be read prior to commencing start-up work.
ces
Familiarise yourself with the evacuation plan of
• Works trial runs (at the request of the client) the installation location.

Operating Manual | Start-up
Grasso SSP1
– Danger! Check that components which have been removed

for transport, separately delivered components and
Solid mounting of the coupling protec- components provided by the customer are firmly
tion must be checked. Start-up must attached.
not be carried out with the coupling Check that all locating bolts are tight.
protection mounted.
– Check the protective gas filling (a positive pres-

sure ≥ 0.2 bar must be present) 8.3.1 Connecting the pipes
Hint! The nitrogen filling of the screw compressor package
must be purged by opening the vent valves before
If defects are found, notify GEA Refrig- the connection of the pipes.
eration Germany GmbH Service and
proceed according to their instruc- Establish all pipe connections so that the transmis-
tions. sion of thermal expansion and vibration to the screw
compressor package is limited as far as possible.
Bellows-type expansion joints made of steel, or flexi-
ble metal hoses can be used for refrigerant and oil
8.2 Basics lines, bellows-type expansion joints made from rub-
ber can be used for water connections.
The compressor must only be switched on if the
screw compressor package has been correctly con- Provide all pipe connections directly at the unit with
nected and filled with operating materials. fixed points.
The activities described in this "Start-up" chapter • Connection of:
must be carried out in the prescribed sequence.
– Suction line
The screw compressor package is operated via the
terminal of the control unit. – Pressure line
After the target values have been entered, both auto- – Oil cooler water connection
matic and manual operation are possible.
• If units are equipped with a safety valve: Con-
The software of the control device and operation via nect safety valve to the blow-off line.
the terminal are described separately in the operat-
ing manual for the control system. • Integrate relief valve in the suction line.
• if units are equipped with a refrigerant cooled oil
cooler:
8.3 Connecting the screw compressor
– Connect the refrigerant feed line from h.p.
package receiver (note geodetic height above oil
Caution! cooler).
All mechanical connections must be – Connect the evaporated refrigerant line to

made according to the R+I diagram the condenser
which is valid for the project. The R+I • If refrigerant injection is used: Connect the refrig-
diagram is part of the product docu- erant feed line from condenser or h.p. receiver
mentation.
• If an economiser is used: Connection the suction
Caution! line of the economiser to the charge connection.
All electrical connections must be

made according to the circuit diagram
which is valid for the project. The cir-
cuit diagram is part of the product
documentation.

Grasso SSP1
Hint! – Compressor control supply
In principle, all the connections must – Oil heater

be made in accordance with the P+I – Oil pump
diagram applying to the respective
Some external components, such as the second
project. Attach the pipes to the screw
EMERGENCY STOP switch, the ammonia sensor
compressor package in such a way
and the fans of the machine room, must be connec-
that no additional static or dynamic
ted by the system erector on site.
loads are imposed.
All the pipes and systems to be con- Hint!
nected must be checked for leaks
Check that terminal screws (in the
when the work is complete.
switching cabinet) are tight.
8.3.2 Electrical connection 8.4 Paint and insulation

Danger! Damage to the paint and insulation during transport
Contact with live components is pro- and installation must be carefully repaired.
hibited.
The screw compressor package has been designed 8.5 Start-up procedure
for plug-in and reliable automatic operation.
All connections must be carried out according to the The following procedures should be completed in the
current installation regulations. sequence in which they are described:
Connections to the screw compressor package must
be flexible and free of loads.
8.5.1 Checking the electrical connec-
Hint! tion
Dimensioning of the inlet pipe cross-
Danger!
sections must be according to DIN
VDE 100 Part 520. Contact with live components is pro-
hibited.
Before starting work, make sure that all parts to be
connected are de-energised, e.g. by removing the Check that all electrical work has been carried out in
main fuse in all phases or installing a jumper wire. accordance with the standards (e.g.protective earth,
The insulation resistance of the electrical tools and insulation, shielding, covers). If necessary, an earth
fixtures and wiring is to be checked. The connection connection must be provided.
may only be undertaken if this value lies in the allow-
able range.
Connections and almost all external connections are 8.5.2 Leak test
pre-wired at the factory.
Hint!
Warning!
See type plate for permissible operat-
Produce the earth connection according pressure.
ing to the designation in the general
assembly drawing. See chapter "Des- The necessary safety precautions should be taken
ignation of the earth connection". before performing the leak test.
An approx. 3-hour pressure drop test with dry nitro-
The electrical consumers and sensor must be con- gen is used for the test. Test pressure: 7 bar
nected according to the circuit diagram. All electrical
A pressure drop of 2% is allowed during the 3 hours.
connections must be made according to the circuit
Fluctuations in the ambient temperature must be
diagram, e.g.
taken into account.
– Compressor drive motor

Grasso SSP1
Caution!
Checking devices which could be
damaged by the specified test pres-
sure must be removed or blocked
before the leak test is performed.
A record should be kept of the pressure test, noting

the pressure in the pipes tested, the ambient temper-
ature and the outside temperature in the shade at
hourly intervals.
The removed measuring and control instruments
should be reinstalled after completion of the leak test
and if there are no leaks in the package/chiller.
Test strategy fig.29: Vacuum required to remove moisture from refrigerating
plants
Dry nitrogen is used as the test medium. After reach-
ing the test pressure, the pressure drop is measured X Room or Wall temperature in °C
via the differential pressure measurement. This may Y Vacuum in mbar
only change by 0.02 bar within an hour. If the display A Vacuum required to remove moisture from
device does not indicate a leakage through foam for- refrigerating plants
mation, the system is sealed.
Testing devices Measured values have to be checked and recorded
hourly after reaching the required vacuum. After the
A pressure gauge with an accuracy of 0.5% over the
vacuum pressure, the temperatures in the machine
entire measuring range, with a digital resolution of
house and the outdoor temperature in shade must
0.01 bar must be used for the measurement.
be entered in the log. After the vacuum test, the
The testing described here is based on pressure pressure compensation must be carried out with
gauges with pressure gauge and LEAK mode from NH3.
Keller.
Warning!
Display devices
A foaming agent must be used as the means to indi- Shut the oil pump during evacuation!
cate leakages. A solution of 50 parts water and 1
part detergent can be used as the foaming agent. See also "Evacuation on refrigerant side" in the
Leaks are detected through formation of foam. A chapter "Maintenance work".
leak detection spray can be used in problem areas.
Carrying out the test
1. Wet all connecting joints (welded seams, flange
connections, screw fastenings, etc.) with foaming
agent. Remedy any leaks detectable from the
noticeable formation of foam.
8.5.3 Drying, vacuum

After the leak tightness test has been completed, the
plant must be evacuated and undergo a vacuum test
for 3 hours. Evacuation is used to remove air and
moisture from the plant.
A vacuum pump must be used for evacuation.
The permissible increase in vacuum is maximum
6.66 mbar over a period of 3 hours.

Grasso SSP1
8.5.4 Operating position of valves

For the positions of the manually controllable fittings for the operation of the package/chiller, see the P+I dia-
gram.
The layout and symbols used in the P+I diagram comply with the specifications of EN 1861, Issue July 1998.
Caution!
Ensure that the valves are in the operating positions before start-up of the package/chiller.
This is the only way to ensure trouble-free operation.
Stop valve open during normal operation
fig.30: Stop valve open
Stop valve closed during normal operation
fig.31: Stop valve closed
Check valve during normal operation
fig.32: Check valve
Shuttable check valve open during normal operation
fig.33: Shuttable check valve

Grasso SSP1
Control valve adjusted:

– Start-up
– when operating conditions change
fig.34: Control valve
Shuttable check valve with integrated control function open dur-

ing normal operation
fig.35: Shuttable check valve
with integrated control function
Controlled by the controller (e.g. GSC TP)
fig.36: Solenoid valve
Change-over valve (3-way valve), open from the bottom in the

direction of the arrow
fig.37: Change-over valve
Operating position: adjusted

Δp x,x ± x bar control pressure to be set vis-à-vis reference pres-
sure (see P+I diagram)
fig.38: Oil pressure control valve
Caution!
Oil pressure which is set too high or too low may result in serious compressor damage or
even total breakdown of the compressor after even a short period of operation!

Grasso SSP1
Overflow valve, safety valve
fig.39: Overflow valve, safety valve
Controlled self-sufficient
fig.40: Pressure controlled check valve
Manually operated if necessary
fig.41: Quick acting valve, spring-loaded
– ½" connections
– with cap
fig.42: Charging valve, draining valve
– Connection Rp ¼“
– For pressure gauges and pressure transducers
fig.43: Service valve

Grasso SSP1
Controlled self-sufficient using control element
fig.44: Oil temperature limiter
Controlled self-sufficient via sensor
fig.45: Temperature controlled valve
When charging with oil for the first time, oil must be
charged via the service valve (135) too. To this end,
8.5.5 Oil charge the stop valve (065) must then be closed.
Caution! While operating the package, the oil level must be
regularly checked (see chapter "Oil level check").
Check the oil grade to be charged! See
contract/project or recommendation of Caution!
GEA Refrigeration Germany GmbH. A
Due to the use of selected compo-
comprehensive overview of the allowa-
nents, the refrigerating machine oils
ble oil types is provided in "Technical
tend to absorb more moisture. There-
information on lubricating oils". This
fore, when charging a compressor the
technical information is part of the
oil should be allowed to come into
contact with air for a short time only.
For severely hygroscopic oils, the oil The contents of an opened drum have
container must be placed under a pro- to be used up within one working day,
tective atmosphere. provided the drum is properly closed
between charging.
The vacuum present in the screw compressor pack-
age before pressure compensation may be utilised
for charging the package with oil. A separate oil
charging pump is required after the pressure com- 8.5.5.1 Pressure compensation with
pensation and for refilling with oil. the cooling system
The connection of the oil draining or oil charging stop
valve (090) must be connected with the oil charging Re-establish the vacuum. Carry out pressure com-
container. pensation via the service stop valve (285).
Before charging with oil, switch the valves to the

operating position.
8.5.5.2 Checking the direction of rota-
The stop valve (090) must be opened until the oil
tion of the oil pump motor
level has reached a value between the upper edge of
the sight glass indicator MIN (N10b, data sheet The oil pump is started with the driving motor electri-
990565) and lower edge of the sight glass indicator cally blocked (service). The stop valves are in the
MAX (N10c, data sheet 990565). operating position.
The oil separator is generally charged with oil via the
oil cooler.

Grasso SSP1
The direction of the arrow given for the oil pump 8. Check the excitation of the solenoid valves of the
must correspond to the direction of rotation of the oil capacity control adjusting device in the mini-
pump motor. mum direction.
Caution! 9. Simulate the minimum end position of the control
Since the slide ring shaft seal of the oil slide and check the switching function of main
pump is dependent on the direction of switch and star-delta contactor (for motors with
rotation and can be damaged when star-delta starting).
this direction is wrong, checking must 10. Check the switching function of the solenoid
be reduced to a very short running valves by actuating the pushbutton switches for
period (less than 2 seconds). capacity increase and capacity decrease:
The adjusted differential pressure between the oil – capacity ↑ - SV1 and SV4 are excited
pump pressure side and the unit final pressure is – capacity ↓ - SV2 and SV3 are excited
checked with the oil pump rotating in the correct
direction. It must not fall below the prescribed set 11. Checking of the oil circuit monitoring failurefor
value in the P+I diagram. external pump only. The compressor driving
motor must be switched off after 6 s. To do this,
While the compressor is not running and the oil has
the valve (70) must be throttled so that the oil dif-
not yet reached the operating temperature, the differ-
ferential pressure is less than the alarm value
ential pressure can be slightly higher than the indica-
from the parameter list.
ted value.
The differential pressure can be changed by rotating 12. Set the motor current limitation for the compres-
the spindle on the oil pressure control valve. (The dif- sor drive motor acc. to nominal motor data. See
ferential pressure is increased by turning it inwards parameter list.
and vice versa).
8.5.7 Adjustment of oil pressure

8.5.6 Checking the fault monitoring
Danger!
1. Disconnect the incoming feeder of the compres-
Oil pressure which is set too high or
sor drive motor from the mains supply when
too low may result in serious compres-
checking the safety device (e.g.remove LV/HBC
sor damage and possibly total break-
fuse links).
down of the compressor after even a
2. Apply voltage to the control device. short period of operation!
3. Check the built-in pressure transducer and Before the compressor drive motor and therefore the
resistance thermometer for correct wiring. unit can be started, the oil pressure must be set cor-
In order to do this, loosen the relevant contacts. rectly by adjusting the oil pressure regulating valve
The status signal "Broken wire <sensor XXX>" (075).
appears on the GSC display. Check the correct For adjustment, only the oil pump must be started.
status signal on the GSC display after recreating For units equipped with a Grasso System Control
the contact. (GSC TP), please select the operating mode "Serv-
Further information can be found in the con- ice mode (0)".
troller manual. The set value of the oil differential pressure should
4. Check limit values. be taken from the P+I diagram of the specific project.
Limit value = see parameter list Oil differential pressure = oil pressure pos. (110)
- discharge pressure pos. (105)
5. Switch on the screw compressor package/chiller
The differential pressure can be changed by rotating
from the controller.
the spindle on the oil pressure regulating valve (the
6. ”Failure Oil circuit monitoring” must be indicated differential pressure is increased by turning it
after a starting delay time of 20 sec. inwards and vice versa). To do this, the seal on the
oil pressure control valve (075) must be removed.
7. Reconnect the oil pump motor to the mains sup-
ply.

Grasso SSP1
In comparison to normal operation conditions, the oil Hint!

differential pressure can be slightly higher (with iden-
tical opening level of the valve) if only the oil pump is It is essential that the manufacturer's
operated ("service mode (0)") or if the operating tem- information e.g. for lubrication of the
perature has not yet been reached. motor is observed before start-up of
the compressor drive motor.
In this case, the oil differential pressure should be
readjusted (according to the value in the P+I dia- – If the direction of rotation of the motor is wrong, it
gram) after the compressor has been started and the should be corrected while the electric switchgear
operating temperature reached. is secured to prevent the motor from being
switched on accidentally. Then the motor must
work at least 1 hour unencumbered and free
8.5.8 Checking the direction of rotation from errors. This is important in order to dry out
of the drive motor residual moisture in the motor (caused during
transport or storage).
Warning!
– The coupling protection must be in place during
The coupling must not yet connect this start-up period as required by the labour
motor and compressor! safety regulations.
– Secure the electric switchgear so as to prevent – After checking the direction of rotation of the
the compressor drive motor from being switched drive motor, the coupling may be connected with
on accidentally. the motor.
– With the control slide in the MIN or MAX position,
it should be possible to rotate the compressor
shaft easily and smoothly by hand. When check- 8.5.9 Mounting the coupling
ing the direction of rotation of the compressor 1. The electric switchgear is secured to prevent it
driving motor pay attention to the conditions for from being switched on accidentally.
switching the compressor on.
2. Mount the coupling while observing the instruc-
tions of the separate documentation.
3. The values for radial and angular deviations
given in the coupling documentation must be
checked and corrected if necessary. The axis
distance between the compressor drive motor
and the compressor must be checked.
4. The real values have to record at data sheet of
coupling documentation. Please send back a
copy of the filled data sheet to:
Holzhauser Straße 165
fig.46: Motor direction of rotation

13509 Berlin
Fax: +49 (0)30 - 43 592 759
A Compressor
B Motor Caution!
Observe the maintenance instruction!
– The compressor drive motor is started directly in Regrease the coupling at the prescri-
mode 1 (manual + manual)" and is then switched bed intervals if scheduled in the main-
off again. tenance instruction for the coupling!

Grasso SSP1
8.5.10 Checking the water circuits The throttle valves of the solenoid valves are adjus-
ted in the factory in such a manner that they ensure
Check whether the cooling and cold water pumps
an optimal adjustment time of the control slide of
are running and the shut-off fittings in the cooling
between 30 and 60 seconds.
water circuit are in their operating positions.
While running at operating temperature and pressure
While the unit/ chiller is operating under project con-
conditions, determine the adjustment times needed
ditions, adjust the cooling water control so that the
when the control slide is continually moved from the
condensing and oil temperature lies within the per-
maximum end position to the minimum end position
missible range.
and back. For the automatic system to run smoothly,
the adjustment times in either direction must be
approximately the same.
8.5.11 Initial start-up
The adjustment time can be adjusted with the help of
On completion of the work described above, the throttle valves DS5 and DS6.
screw compressor package can be started up in
Hint!
accordance with the operating instructions for the
control device (GSC TP). See the assembly instructions for the
screw compressor.
1. Switch on the control voltage of the control
device.
2. Remedy and acknowledge existing fault mes-
sages. 8.5.14 Checking the oil cooler
3. Select the operating mode "Manual + Manual Guide value for oil temperature = see parameter
(1)". list
4. Switch on the screw compressor package. Oil cooling with water-cooled oil cooler
The water volume must be regulated so that the
cooling water volume corresponds to the project
8.5.12 Checking the adjustment of the value. The inlet and outlet temperatures must be
control slide checked. The oil temperature adjusts automatically
via the 3-way valve.
1. The screw compressor package is running.
2. Select the operating mode "Manual + Manual Checking the oil cooling with refrigerant-cooled
oil cooler
(1)".
No regulating or checking required.
3. The maximum end position (100%) must be
reached and signalled when the "Increase com-
pressor capacity" button is pressed.
8.5.15 Adjusting the amount of injection
4. The minimum end position (0%) must be oil and the oil temperature
reached and signalled when the "Decrease com-
pressor capacity" button is pressed.
5. Vent the adjusting device by moving the control 8.5.15.1 Screw compressor packages
slide backwards and forwards around ten times. without refrigerant injection
The amount of injection oil and the oil temperature
8.5.13 Checking the control slide adjust- directly influence the discharge temperature of the
ment times compressor. The amount of injection oil is adjusted
under operating conditions through the injection oil
Caution! control valve.
Only adjustment times between 30 and
60 seconds are permissible.

Grasso SSP1
• Switch on the oil heater at least one hour before

Standard values for discharge temperature
starting the screw compressor package/chiller.
t tmax • Open the stop valve on the suction side and the
pressure side (or check valves which can be
shut off).
NH3/HP t ≥ toil + 20K 30K 95°C
• If fitted: Open the stop valves (or shuttable check
NH3/LP t ≥ toil approx. 45 ... 60°C 80°C valves) in the suction line of the economiser.
• If fitted: Open the refrigerant supply to the ther-
Freon/HD t ≥ toil + 15K 80°C mosyphon - oil cooler.
• If fitted: Open the manual stop valve of the refrig-
R22/LP t ≥ 45 ... 60°C 80°C erant injection.
• Remove all non-condensable gases by venting.
To this end, check the condensing pressure and
8.5.15.2 Compressor units with refriger- temperature (see parameter list).
ant injection • Check the oil collection sump and drain if neces-
sary.
The oil temperature is changed by setting the injec-
tion oil control valve. The more the shut-off valve is • Switch on the compressor and observe the oper-
throttled, the more the oil temperature decreases. If ating instructions of the electrical switchgear.
the oil temperature becomes too low or reaches the Make a screw compressor package/chiller test
lower range, the setpoint for the discharge tempera- run in order to test the sensor and actor technol-
ture should be set accordingly higher. When the oil ogies (for operation and indicating precision).
circuit is adjusted for the first time, the injection oil
control valve is opened by approx. 1/2 rotation.
The discharge temperature is then regulated to the
value indicated in the parameter list by means of the
thermostatic expansion valve.
Guide value for discharge temperature: t = 60 +
10°C (for NH3)
Other refrigerants on request.
8.6 Start-up after long standstill periods

1. Inserting the main fuse
2. Switching on the control unit according to the
operating manual.
3. Checking all parameters on the control unit dis-
play. See parameter list.
4. Checking the settings of all control and safety
devices.
8.7 Restarting after approx. 1 year

standstill
• Change the oil filter inserts (see maintenance
instruction).

Use, operation, control Operating Manual |
Grasso SSP1
9 USE, OPERATION, CONTROL

4. The oil level in the oil separator must be within
the permissible range.
9.1 Important information for the opera-
tor 5. The cooling and cold water pumps must be in
operation.
The screw compressor package must be only be
operated by trained and qualified personnel who are 6. The supply of cooling water or coolant to the oil
familiar with the contents of the operating manual for cooler must be ensured.
GEA Refrigeration Germany GmbH screw compres- 7. The oil heater in the oil separator must have
sor packages. heated the oil sufficiently.
The safety regulations for the refrigeration plant must
Hint!
always be observed in order to prevent damage to
the screw compressor package and injury to the The oil heater in the oil separator can
operating staff. be switched on while the screw com-
pressor package is not running. It is
Hint!
then automatically switched off when
The screw compressor package is the screw compressor package is star-
operated via the control panel of the ted and switched on when it is shut
control unit. If the GSC TP control is down. If the ambient temperature is
included in the scope of delivery, the below 5°C, the oil heater must be
operating staff must be familiar with switched on at least one hour before
the contents of the complete docu- the screw compressor package is star-
mentation of the control. The docu- ted.
mentation for the controller is a part of
the product documentation. 8. The rated current limitation has been set accord-
ing to the motor rating.
® The screw compressor package can be switched
on as per the controller operating manual.
9.2 Prerequisite for switching on
The screw compressor package has been designed
for automatic operation; the control unit controls the
switching on and off of the compressor and its
capacity adjustment.
Continuous operation and observation of the screw
compressor package is not necessary in automatic
mode. The necessary steps for switching on the
screw compressor package can be found in the con-
troller documentation.
If the screw compressor package is controlled man-
ually, it must be operated from the refrigerator room.
In particular, the repair and maintenance instructions
must be complied with.
The following prerequisites must be fulfilled for
switching on the screw compressor package:
1. The main power must be available and switched
on.
2. The screw compressor package must be suffi-
ciently filled with refrigerant and oil.
3. The valves must be in the operating position.

Operating Manual | Use, operation, control
Grasso SSP1
9.2.1 Overview of the operating modes
Modes Signal for …
Name Remark Start/Stop Capacity +/-
0 Service Oil pump by itself

Compressor motor blocked
1 Manual Manual control via Touch Panel (TP) Manual Manual

+ Manual
2 Manual + Auto Manual Start/Stop via TP and full automatic local Manual Auto
capacity control
3 Auto + Auto Full automatic start/stop and local capacity control Auto Auto
4 Remote Start/stop and capacity demand via digital contacts External External
+ HW (cont) (hardware) from a remote master controller. The GSC continuous
TP derives from the continuous +/- signals the pulses
for capacity (indirect).
5 Remote Start/stop and capacity demand via digital contacts External External
+ HW (pulse) (hardware) from a remote master controller. The mas- pulses
ter also generates the +/- signals as pulses for control-
ling the slide capacity directly.
6 Remote Start/Stop from a remote master controller via digital External Local
+ HW (loc. contacts (hardware). The GSC TP controls the output + setpoint Setpoint
SW) depending on a local setpoint (TP) and from this set- deviation
point also automatically switches the product ON/OFF.
7 Remote Start/Stop from a remote master controller via digital External Remote
+ HW (ext. contacts (hardware). The GSC TP controls the output + setpoint Setpoint
SW) depending on an external setpoint (analog input) and deviation
from this setpoint also automatically switches the
product ON/OFF.
8 Remote Start/stop and capacity demand via network from a Network Network
+ Net (cont) remote master controller. The GSC TP derives from continuous
the continuous +/- signals the pulses for controlling the
capacity (indirect).
9 Remote Start/stop and capacity demand via network from a Network Network
+ Net (pulse) remote master controller. The master also generates pulses
the +/- signals as pulses for controlling the capacity
directly.

Grasso SSP1
Modes Signal for …
10 Remote Start/stop from a central master controller via a bus Network Local
+ Bus (loc. signal. The GSC TP controls the output depending on + setpoint Setpoint
SW) a local setpoint (TP) and from this setpoint also auto- deviation
matically switches the product ON/OFF.
11 Remote Start/stop from a central master controller via a bus Network Network
+ Bus (net. signal. The GSC TP controls the output depending on + setpoint Setpoint
SW) an external setpoint sent externally via the network deviation
and from this setpoint also automatically switches the
product ON/OFF.
The GSC TP consists of the control unit with operat-

ing and display unit (Touch Panel), indicator lights
9.2.2 Setting of setpoint and limiting for ”Operation”, ”Warning” and ”Alarm”, the emer-
values as well as safety devices gency stop button, coupling elements, as well as the
housing.
Caution!
All switching, operating and control actions are car-
The correct setting of all setpoint and ried out via this TouchPanel. The TouchPanel is the
limiting values is a prerequisite for the interface between the man and the machine.
safe operation of the screw compres-
sor package. The GSC TP performs the following functions as
standard:
For the setting of the setpoint and limiting values, the – Display of all important physical and technical
1. details (steps) in the control unit operating man- parameters, e.g. pressure, temperature, motor
ual current, capacity, number of operating hours,
and operating mode and status signals,
2. the project-related data are – automatic start up and shut down of the com-
pressor package and capacity control dependent
important. The project-related setpoint and limiting
on the relevant parameter for the application
values as well as the setting values for the safety
(e.g. suction pressure or an external tempera-
devices can be found in the project-related parame-
ture),
ter list. The parameter list is part of the controller
documentation. – Monitoring of all operating parameters,
– Compressor capacity limitation, if the measured
discharge pressure, suction pressure, secondary
9.3 Operation of the screw compressor refrigerant temperature or motor current indicate
package an overload,
Caution! – Fault memory with date and time,
Familiarise yourself with the control – Wire failure detection for all analogue input sig-
unit documentation. nals,
Contact the GEA Refrigeration Ger- – Password protection to prevent unauthorised
many GmbH technical customer serv- access to important parameters,
ice if you require assistance.
– Non-volatile saving of program,
The screw compressor package is operated via the – MPI communication with a master controller
control unit (standard: GSC TP). (optionally via Profibus-DP, Modbus RTU or
The GSC TP will be mounted directly on the com- Modbus TCP).
pressor package unit as standard. As an option, the
GSC TP can be arranged in a control centre.

Operating Manual | Use, operation, control
Grasso SSP1
9.4 Guide to failures, their causes and remedies

The units/chillers manufactured by GEA Refrigeration Germany GmbH are highly advanced, automatic and
extremely efficient systems. However, failures can occur, making it difficult to maintain continuous operation or
causing part or the whole of the system to fail.
Table of malfunctions
Fault Cause Remedy
The suction pressure is too low, Slow loss of refrigerant through Check the entire system for leaks.
performance is reduced and the leaks in the refrigerant circuit. Repair leaks, top up refrigerant if
system overheats. necessary.
Pressure gauge defective. Replace pressure gauge.
Defective capacity control devices Check capacity control devices,

in the compressors connections for solenoid valves.
Suction filters are clogged Clean or replace the filter insert.
The suction pressure increases and The compressors are sucking in Check liquid levels in the system,
the compressors become covered wet steam or liquid when it is star- drain some refrigerant if necessary.
with a thick layer of hair frost or ted up. The safety device to pre- Repair safety device. Check for
makes noises which indicate the vent a too-high liquid level is not superheating.
presence of liquid (refrigerant) in responding.
the compressors.
The condensation pressure is too There is air or other non-condensa- Vent the refrigerant circuit.
high. ble gases in the refrigerant circuit.
The compressor(s) does/do not The electrical circuit is interrupted Switch on the power supply, check
start up after the system is by a unit in the safety chain. the pressure switches and replace
switched on or switch(es) off again. or set properly as appropriate.
No oil pressure is building up in the Replace or clean the oil filters, seal
package/chiller. The oil circuit is the leaks and top up with oil.
disturbed by clogged oil filters or
leaks.
The compressors do not adapt to The capacity control device is mal- Check the oil circuit. The compres-
the required capacity. functioning due to disturbances in sors should only be repaired by
the oil circuit or mechanical influen- experts. Check the position detec-
ces. tor of the compressor control slide.
The compressors are shut off very The condensation pressure is too See above.
often by the maximum pressure high.
governor.
The maximum pressure governor is Remove the maximum pressure
defective or set wrongly. governor, repair it, set it correctly or
replace it.

Grasso SSP1
Fault Cause Remedy
The compressors are shut off very The suction pressure is too low. Open all valves on the suction side
often by the minimum pressure of the compressors.
governor.
The minimum pressure governor is Remove the minimum pressure
defective or set wrongly. governor, repair it, set it correctly or
replace it.
The heat transfer capacity of the Check the evaporator for elevated
evaporator decreases. oil concentration, possibly drain oil
The package/chiller is louder than The compressor(s) or the drive Notify GEA Refrigeration Germany
permitted in operation. motor(s) is/are defective. GmbH Customer Service

Operating Manual | Cleaning, maintenance, repair
Grasso SSP1
10 CLEANING, MAINTENANCE, REPAIR

Hint!
The obligation for signage to prevent unintentional switch-on of the plant during cleaning,
maintenance and repair must be observed.
All maintenance and service tasks have to be carried

out with care to preserve the functionality of the
10.1 Important information for service screw compressor package. Guarantee claims will
personnel not be valid if the customer failed to follow the main-
tenance instructions.
The following chapter is primarily aimed at the main-
tenance and service personnel of the screw com-
pressor package.
Hint!
Heed all safety instructions in this
manual.
Familiarise yourself with the local con-
ditions of the screw compressor pack-
age installation site.
Adhere to all legal and local regula-
tions of health, work and fire protec-
tion as well as the regulations which
must be heeded concerning the gases
to be compressed.
Please read this manual carefully and
completely prior to working on the
Familiarise yourself with the special
features of the screw compressor
package.
Caution!
There is an increased danger of slip-
ping due to contact of operating media
with the floor!
The screw compressor package must be serviced by

appropriately trained operating staff only. For all
maintenance work, the maintenance instructions
must be complied with.
A maintenance checklist is part of the product docu-
mentation. The maintenance certificates in the main-
tenance checklist are completed and signed as part
of the inspection and maintenance by authorised fit-
ters as evidence of the work done.
During the guarantee period, these confirmed main-
tenance certificates are a prerequisite for any claims
under the guarantee.
The responsible certified specialist company must be
informed if any repairs are required.

Cleaning, maintenance, repair Operating Manual |
Grasso SSP1
10.2 Cleaning the heat exchanger
10.2.1 Mechanical cleaning

Mechanical cleaning is a maintenance measure in
order to ensure the continuous safe operation of the
Components of the screw compressor packages
(e.g.suction filter) can be removed for manual
mechanical cleaning. Proceed in accordance with
the details in the applicable component documenta-
tion. After completing cleaning work, properly mount
the component and check for leakage.
10.2.2 Chemical cleaning

Chemical cleaning of the screw compressor package
is not recommended by GEA Refrigeration Germany
GmbH.

Grasso SSP1
10.3 Maintenance
– complete draining of the respective part of equip-

ment,
10.3.1 General instructions
– cleaning with the appropriate cleaning agents,
Danger!
– concentration measurements,
hibited. – ensuring sufficient ventilation and venting,
Maintenance work on the running – performance of all welding work with the use of
screw compressor package is not performing gas.
mitted. If gas filled pipes are opened for maintenance work,
these pipes must be in a gas-free condition.
Work involving intervention in the refrigerant circuit
must only be carried out by qualified engineers in
accordance with the guarantee conditions.
The screw compressor package must always be
switched off before being dismantled. Before begin-
ning the work, it must be ensured that all parts sub-
ject to maintenance/servicing are de-energised(e.g.
by removing the main fuse or installing a shorting
bridge).
The refrigerant must be removed from the applicable
parts of the system parts. This work must be carried
out with great care, taking into account the safety
regulations, so that the maintenance personnel are
not injured by the refrigerant or by the refrigeration
unit oil present in the system.
Parts of the system under pressure must be com-
pletely vented before opening. While carrying out the
repair, it is must always be ensured that a complete
pressure balance of the affected pressure chambers
with the environment is preserved.
During cleaning, repair or maintenance work, the
screw compressor package or its components must
be protected against the penetration of moisture in
order to prevent impairment of the function of the
components.
The chief principle must be to keep air and moisture
entering the screw compressor package to an abso-
lute minimum. All foreign substances must kept as
far away as possible or eliminatedincluding
– welding residues,
– sealing remnants,
– auxiliary materials such as grease, oil or sol-
vents.
Welding and soldering work may only be performed
with written permission. The requisite protective
measures must be defined. These include:
– personal protective measures when opening the
respective part of the system,

Grasso SSP1
10.3.2 Repair work New inspection and approval is required after pres-
sure vessels that are subject to approval have been
Modifications and repair work may only be carried
repaired or changed. Welding may only be carried
out by qualified persons or persons with suitable
out by approved welders with a valid welder’s card.
training with the manufacturer's consent and must
strictly comply with the rules set out in the mainte-
nance instruction for the components concerned.
10.3.3 Maintenance intervals
Hint!
Caution!
The following maintenance notes must
be observed: The maintenance intervals in accord-
ance with maintenance checklist must
Only spare parts made by the original component be observed.
manufacturer may be used for repairs and for replac-
ing wearing parts. These are available from the The maintenance checklist is part of the product doc-
spare parts department. umentation. The attached maintenance checklist
contains all the maintenance instructions and certifi-
cations for the first 10 years of performance of the
10.3.2.1 Repair information screw compressor package. The maintenance certifi-
cates are completed and signed as part of the
Important features of the technology and production inspection and maintenance by authorized fitters as
process must be taken into account when repairing evidence of the work done.
the plant: During the warranty period, these validated mainte-
– complete sealing of all devices and pipes. nance certificates also serve as a precondition for
any warranty claim put to GEA Refrigeration Ger-
– Dryness and cleanliness of the entire plant. many GmbH.
– Use of welding methods causing only a minimum
amount of dirt to collect in the plant.
10.3.4 Maintenance work
– Pipes bent on a pipe-bending machine only
using refrigerating oil. Hint!
– If repairing the piping system from your own The documentation for the main com-
stocks, we recommend that you use a pipe with ponents is a part of the product docu-
NBK surface quality (annealed and descaled, mentation. This contains important
mechanically or chemically descaled after information to be considered before
annealing). beginning the maintenance work.
– When carrying out repairs to piping systems,
care should be taken to maintain the original pip-
ing routes. 10.3.4.1 Maintenance of the screw
– Only pipes of sufficient material quality, which compressor
are certified according to DIN 10216-2 should be
used. The following maintenance work must be performed
on the screw compressor at regular intervals (see
maintenance checklist):
10.3.2.2 Repairs of pressure vessels – Measure axial play of bearings,
subject to approval inspection – Check shaft seal,
Hint! – Check primary slide movement,
The responsible monitoring body – Check the adjustment of the position sensor.
(e.g.TÜV) must be notified in advance. After 50,000running hours or in the 10th running
year, a general check of the screw compressor is
provided by the manufacturer. Contact Customer
Service in this regard.

Grasso SSP1
10.3.4.2 Changing the block mounting 10.3.4.3 Maintenance of suction filter

filter element combination SFC
Hint!
When must the filter element be 10.3.4.3.1 Changing the filter element
replaced or cleaned?
The oil filter element must be replaced The maintenance interval for changing or cleaning
as specified in the maintenance check- the filter element is specified by the manufacturer of
list for the total product from GEA the refrigeration system.
Refrigeration Germany GmbH. The contamination level and mechanical condition of
Loss in pressure during operation is the filter element must be inspected at least once a
monitored by the internal control – year.
including a preliminary alarm function Before opening the filter, always make sure the filter
for preventative replacement. housing is not under pressure.
The following applies as a guide value Caution!
for replacement: The filter element
should be replaced after every 5000 Refrigerant may leak out on opening
operating hours or once each year. the filter. The safety data sheets for
the refrigerants in question must be
Changing the filter element consulted and any prescribed protec-
tive measures observed.
1. Shut down the screw compressor package/chiller
and depressurise the blocked mounting filter on To remove the element, proceed as follows:
the pressure side.
1. Unscrew the cover.
2. Remove the filter cover by loosening the four
2. Pull out the cover with the filter element.
cover screws.
3. Remove the spring wire clamp.
3. Remove the filter element by slightly turning the
mounting pin in the filter head. 4. Twist the element away from the cover to
release the bayonet catch.
4. Check the O-ring and support ring in the filter
bowl for damage and correct positioning. 5. Detach the element from the cover.
Replace parts if required.
6. Allow the element to drain off into a suitable con-
5. Replace glass fibre element, clean or replace tainer.
wire mesh.
Caution!
The efficiency of the cleaning depends on the
type of dirt and the level of differential pressure When carrying out maintenance,
before replacing the filter element. If, after always inspect the sealing ring (O-
replacing the filter element, the differential pres- ring) of the cover for mechanical dam-
sure is more than 50% of the value before age and replace it if necessary.
replacing the filter element, wire mesh must also
7. Reassemble all parts with the new or cleaned fil-
be replaced.
ter element following the same procedure in
6. Check that the type designation/manufacturer ID reverse order.
number on the replacement element matches
the type designation/ID number on the filter’s rat-
ing plate.
7. Place the replaced or cleaned filter element back
on the mounting pin by turning it slightly.
8. Reposition the filter cover and tighten the four
cover screws. Ensure that installation occurs
without mechanical tension.
9. Vent the housing of the block mounting filter.

Grasso SSP1
10.3.4.3.2 Cleaning the filter element – if the oil becomes unacceptably contaminated-
The metal-gauze element used in the filter can be due to a major accident (e.g. water penetration
cleaned and reused several times before it has to be into the refrigerant circuit).
changed. The degree to which oil in refrigeration plants has
aged must be checked by analysis and in compari-
Manual cleaning son of the data with those of fresh oil. Oil ageing can
Immerse the soiled metal-gauze element in a clean, also be judged from the darkening of the oil colour
grease-dissolving liquid, then blow it through with and the deposits found in the oil filters. If the degree
compressed air from the outside inwards. Here it is of ageing cannot be assessed reliably by laboratory
important to place a cylindrical part – possibly wrap- analysis and the results of visual examination, it is
ped in corrugated cardboard – inside the element to advisable to change the oil at the following intervals
catch the dirt particles. (see maintenance checklist).
The assessment of the condition of the refrigerating
Caution!
machine oil by means of a general visual inspection
Never use wire brushes for cleaning. (contamination) or laboratory analysis must be car-
ried out:
Hint! – after 5000 operating hours:
To avoid fatigue failures of the metal or
gauze, strainer elements should be
replaced with new, original filter ele- – at the end of one year's operation
ments after being cleaned 4 – 5 times. or
– after remedying major damage.
or
10.3.4.4 Oil draining, oil filling, oil – if the oil is dark coloured or very cloudy.
change
10.3.4.4.2 Oil change, maintenance

10.3.4.4.1 Importance of oil change work
Aged oil demonstrates an increasing loss of ability to Take oil samples for analysis and comparison with
lubricate. Because of this, all rotating components of the fresh oil data at regular intervals. Check the col-
the compressor are endangered. The filter elements ouration of the oil visually and assess the degree of
become prematurely clogged and must be cleaned contamination.
and replaced at shorter intervals. Depending on the results, the user must decide
The oil in the screw compressor package/chiller must whether to approve the postponement of filling the oil
be changed: until the next assessment date or whether to have
the oil changed.
– when the operating time of the oil charge has
reached the technically specified oil change Inadmissibly damp oil must be removed from the
interval, compressor unit/chiller immediately.
Warning!
Oil change intervals 10.3.4.4.3 Changing the oil
Oil change with ammonia as the refrig- 1. The screw compressor package/chiller must be
erant after every 5,000operating hours run for at least half an hour to reach its operating
or after 1 year at the latest. temperature before the oil can be changed.
Oil change with freons as the refrig-
2. First shut down the screw compressor package/
erant after 10,000operating hours or
chiller as described in the operating instructions.
after 2 years at the latest.

Grasso SSP1
3. Open the stop valve in the bypass line around 10.3.4.4.4 Used oil
the check valve on the suction side and the stop Refrigeration machine oil drained from the circuit is
valve on the suction side to equalise the pres- no longer suitable for use in refrigeration plants. It
sure between the screw compressor package/ has to be stored or transported in appropriately label-
chiller and suction line. If screw compressor led containers in accordance with the legal provi-
packages operated in parallel or other separate sions. The operator is responsible for its proper dis-
chillers are present, the refrigerant should pref- posal.
erably be drawn off at a pressure which is
approx. 1 to3 bar above atmospheric pressure.
Then re-close the stop valves bypass and the
10.3.4.4.5 Draining the oil
suction-side stop valve. Otherwise the pressure
can be reduced by opening the vent valve on the It may be necessary to drain the oil:
suction filter and then disposing of the refrigerant
– to inspect or repair the compressor
as specified by law.
and
4. Then drain the used oil through the oil
draining/oil charging valves and dispose of it – if there is too much oil in the circuit.
(Caution! hazardous waste!). Once this has The oil must be drained in accordance with points 1
been done, re-close the valve and if possible to 6 of the chapter entitled "Carrying out oil change".
continue to draw off the refrigerant with a com- The oil must be drained through the filling hose and
pressor connected in parallel or a disposal into a container suitable for waste oil.
device until atmospheric pressure is almost
reached.
5. Otherwise depressurise the screw compressor 10.3.4.4.6 Check the oil level
package/chiller by opening the vent valve on the
suction filter, taking into account the safety rules
for refrigeration systems.
6. Open the drain plugs and valves on the oil
cooler, oil separator and OMC block to drain any
residual oil. Then re-close the drain plugs and
valves.
7. Replace the filter element of the oil filter; replace
and/or clean the filter element of the suction filter
combination.
8. Evacuate the screw compressor package/chiller
using a vacuum pump.
Warning! fig.47: Arrangement of MIN / MAX sight glasses

Shut off the oil pump! 1 Sight glass - MAX (operation)
2 Sight glass - MIN (standstill)
9. Pressurise the screw compressor package/chiller
with a slight overpressure via the stop valve
bypass check valve on the pressure side. The oil level is checked visually via the sight glasses
of the oil separator. The oil level should have a value
10. Then check all components for leakages. On between 1/2 filling level of sight glass N10c (MAX -
successful completion, perform a complete pres- operation) and 1/2 height of sight glass N10b (MIN -
sure compensation with the discharge line fol- standstill).
lowed by a repeated leakage test of the screw
If the oil level is too low, i.e. the oil level has a value
compressor package/chiller. The oil charge oil
less than 1/2 filling level of sight glass N10b (MIN -
and start-up of the screw compressor package/
standstill), oil must be replenished.
chiller must be accomplished in accordance with
the operating instructions.

Grasso SSP1
10.3.4.4.7 Charging with oil, topping

up with oil
See chapter entitled "Start-up, charging with oil".
Hint!
For permissible types of oil, please
refer to the technical information enti- fig.48: Operating position of the fine oil separation cartridges
tled "Lubricating oils". 1 Cartridge(s)
Oil removed from the compressor 2 Fixing cover with O-ring
must not be re-used. Always use fresh 3 Hexagon-head screw
oil from sealed containers! Do not mix 4 Self-locking hexagon nut
with other types of oil.
1. Close the pressure and suction side shut-off fit-

tings.
10.3.4.5 Oil pump maintenance
2. Drain refrigerant. Evacuate screw compressor
Assuming correct installation in accordance with the package.
conditions of use and correct fitting, gear pumps 3. Check the pressure on the display of the control
have the design prerequisites for long and fault-free
unit or by connection of a test pressure gauge.
operation.
The gear pumps require a minimum of maintenance 4. Dismantle the pipe bend after the oil separator.
which is, however, indispensable for fault-free opera- 5. Dismantle the check valve installed in the oil
tion since experience has shown that a high percent- separator. This step is omitted if a check valve
age of the faults and damage which occur are attrib- which can be shut off is used on the pressure
utable to the ingress of dirt and inadequate mainte- side.
nance.
6. Remove self-locking hexagon nut [4].
The maintenance intervals have been defined in the
maintenance checklist (part of the product documen- 7. Loosen the hexagon-head screw [3] and the fix-
tation). ing cover with O-ring [2] for fixing the fine oil sep-
An oil leakage of up to one drop/minute is required aration cartridges.
for the lubrication of the shaft seal and is permissi- 8. Remove the cartridge(s) [1].
ble.
9. Mount the new cartridge. The cartridge must be
The shaft seal is maintenance-free. If the oil leakage inserted into the oil separator with the O-ring
is too great, replace it according to the oil pump doc- first.
umentation.
Assembly by carrying out steps 1-7 in reverse
Hint! order.
The regular examination of all operat- Warning!
ing data, such as pressure, tempera-
It is essential to apply self-locking hex-
ture, power consumption, degree of fil-
agon nut [4] again and secure it
ter fouling, etc., helps in the early
against turning backwards!
detection of potential failure!
Max. tightening torque = 15 Nm
10.3.4.6 Changing the fine oil separa-

10.3.4.7 Tightening screw fastenings
tion cartridges
Screw fastenings of components can become loose
The fine oil separation cartridges should be replaced
due to vibration or movement. Screw fastenings
at the latest after 20,000 run hours or three years.
must therefore be checked regularly to ensure they
If the oil carry over of the screw compressor package are tight and retightened if necessary.
increases severely (oil recharging at unusually short
intervals), this may be necessary even earlier.

Grasso SSP1
Screw fastenings must only be tightened to the maxi- – underfilling.

mum tightening torques.
Lower refrigerant levels in the containers are due to
Unless otherwise stated by warning signs, the tight- loss of refrigerant as a result of leaks. For this rea-
ening torque is dependent on the size and strength son, all pipes, connections and valve glands should
of the screw fastening. be checked regularly, especially in the initial period
of assembly.
The most striking feature if there is a leak in the filled
10.3.4.8 Coupling maintenance refrigerant circuit is the smell of refrigerant. The
1. Switch the screw compressor package/ chiller odour threshold of ammonia in the air is approx. 5
off. ppm and thus well below the permitted MAK values.
Methods of leak detection:
2. Secure the electric motor against accidentally
being switched on. – Regular visual inspections.
3. Visually inspect the disk packs. – Smudges/dirt stains indicate leaking
refrigerant/oil mixture.
4. Check the tightening torques of the fit screws.
– Leak tests with nitrogen with a max. of 0.5%
5. Check the alignment of the electric motor and
ammonia by volume, an elapsed time of more
correct it according to the steel lamination cou-
than 3 hours and application of a foaming agent
pling documentation, if required.
to all the joints with a brush. Oil-filled compres-
6. Re-grease the coupling (if provided for in the sors or circuit sections must only be charged
maintenance instructions for the coupling). with nitrogen – not air – to generate pressure.
– Use of an NH3 leak detector.
10.3.4.9 Checking the function of check – Ammonia produces the following colours when
valves leak tests are performed:
– Red litmus paper turns blue,
In order for a check valve to be effective, it is impor-
tant to perform function checks at regular intervals. – Blotting paper impregnated with phenolph-
An inspection is carried out by checking the noise thalein turns red (moisten).
behaviour of the valves during operation. After
Caution!
switching off the screw compressor package, mal-
function on the suction side is indicated by prolonged Due to the danger of explosion, oxy-
turning back of the compressor. Malfunction on the gen must never be used to build up
pressure side leads to an increase of the standstill the pressure!
pressure in the package to the pressure level of the
system pressure side. Generate a test pressure in the refrigerant circuit that
meets the intended operating pressure for the leak
tightness test to determine leaks on the refrigerant
side, e.g. in the case of escaped inert gas or refriger-
10.3.4.10 Searching for leaks on the
ant. When system parts are individually tested, the
refrigerant side / leak test maximum operating pressure indicated on the
The absence of leaks is a precondition for perfect respective system part for the corresponding pres-
functioning of the compressor unit/chiller unit. Leak- sure chamber must not be exceeded. The use of
ing parts or connecting elements will lead to the loss foaming agents gives the best results at test pres-
of refrigerant and oil as well as the penetration of air sures < 5 bar.
and moisture into the low pressure side. The site of If leaks are determined, these must be sealed imme-
the leak must therefore be located and remedied if diately. Release the test pressure before beginning
there is: repair! Evacuate the system after repairs are com-
plete and after rechecking for leaks.
– Loss of the inert gas charge (delivery state),
– Loss of the entire refrigerant charge
or

Grasso SSP1
10.3.4.11 Venting the refrigerant circuit 10.3.4.14 Checking the solenoid valves
for capacity control
When air penetrates the refrigerant circuit, this
makes itself felt in a fall-off in performance and the See the following sections in the start-up chapter:
manometer on the discharge side of the compressor
indicates a higher pressure compared to the conden- • "Checking the control slide adjustment"
sation temperature. Any leaks must be remedied. In • "Checking the control slide adjustment times"
extreme cases, air in the circuit may interrupt the
flow of refrigerant and cause the oil cooling to fail.
There are several ways of venting the system. The 10.3.4.15 Checking the oil heater
air or the NH3-air mixture is vented via the vent
Check the electrical function using a clamp-on
valves of the condenser or the suction filter in water
ammeter.
filled vessels when the package is at a standstill.
Check the outer temperature of the oil separator and
If air is in the mixture, the venting ammonia is absor-
compare with the temperature of the machine room
bed from water.
(while the screw compressor package is at a stand-
Hint! still).
Continuous venting using a Grasso
purger is recommended.
10.3.4.16 Maintenance of the compres-
sor drive motor
10.3.4.12 Refrigerant evacuation Hint!
The compressor drive motor must be
Hint!
maintained in accordance with the
Shut the oil pump during evacuation! "Motor documentation".
The purpose of evacuating the system is to remove Maintenance of the compressor drive motor includes
air and moisture from the refrigerant circuit. the following activities:
Evacuation is required: – Lubrication of the motor
– after intervention in the refrigerant circuit and Lubrication intervals and quantities according to
elimination of leaks, the "Motor documentation" or "Type plate".
– before the start-up/restarting. – Cleaning of the motor (externally)

Evacuate the screw compressor package using a Select a suitable cleaning agent according to the
vacuum pump. The screw compressor must not be "Motor documentation".
used for evacuation.
During evacuation, all affected parts of the circuit
should be at room temperature at least because cold 10.3.4.17 Checking the start regime
parts hinder the removal of moisture. See the operating manual of the compressor control
If there is still any moisture in the screw compressor system.
package, this will lead to a rise in pressure. Evacua-
tion must continue until the pressure no longer
increases. A pressure comparison is based on a 10.3.4.18 Checking the safety devices
constant ambient temperature.
See section entitled "Checking the fault monitoring"
in the start-up chapter.
10.3.4.13 Checking the bearing noise The safety devices are checked by moving to the
switching points (limiting values). For details, see
The bearings of the drive motor and the compressor also the operating manual of the compressor control
must be checked for unusual running noise, espe- system.
cially in comparison to previous maintenance. Recur-
Limiting value = parameter list
rent vibration measurements are recommended.

Grasso SSP1
Moving to the switching point is achieved by throt-

tling the pressure-side stop valve.
10.3.4.19 Checking the operating parameters

Hint!
The operating parameters are checked via the TouchPanel. The checking intervals recommen-
ded in the table must be observed. The project-related setting values and limits are given in
the parameter list.
Inform the manufacturer contract partner if the parameters are outside the allowable limits.
Parameter to be Every 24
Weekly Monthly Remark
checked to 72hrs
Minimum superheat must not be less than 15 K

for NH3. For other refrigerants, the manufactur-
er's instructions must be noted.
Discharge temperature X Maximum discharge temperature 100°C, in indi-
vidual cases (e.g. heat pump applications) this
may be exceeded in agreement with the manu-
facturer.
See parameter list!

Oil temperature X The viscosity must not be less than 7 cSt at
max. speed (rpm).
The oil pressure must be at least 0.5 bar above

the final discharge pressure. An oil pressure
Oil pressure X fault may be caused by a clogged oil filter. Set-
ting and monitoring of the values in accordance
with the information in the parameter list.
See project value (parameter list). Determine

Discharge pressure X the superheat on the pressure side by compari-
son with the final discharge temperature.
See chapter "Oil level check". An oil level must

Oil level in oil separa- be visible in the sight glasses at all times. If the
X
tor oil level is below the minimum value, the oil
must be recharged.
When compressor is shut down, the heater

Oil heater X must automatically start. Visual check, the
green LED indicates "Voltage ON".
Setting the safety devi-

X See set values in the parameter list.
ces

Grasso SSP1
Parameter to be Every 24
Weekly Monthly Remark
checked to 72hrs
Solenoid valves must switch audibly when the

Capacity control X capacity is adjusted. Check in operating mode
"1 (manual + manual)“.
See maintenance checklist for maintenance

Number of operating
X work to be carried out according to the number
hours
of operating hours.
10.3.4.23 Checking the tightening torque

on the base fixator
10.3.4.20 Maintenance of the switching
cabinet The tightening torques vary according to the strength
and size of the screw used. Unless specified other-
Terminal screws must be checked for tightness and, wise, the values for tightening torques can be found
if necessary, tightened at regular intervals (every in the applicable DIN.
5,000 operating hours or at least once per year). The
contacts of the contactors must be checked for loss Hint!
of contact material. The tightening torques for the fixators
should be obtained from documenta-
tion data sheet 990290.
10.3.4.21 Checking the earth connection
Check the function of the earth connection frequently
(see the general assembly drawing and the indica-
tions on the product).
Only a specialist company must be commissioned
with inspections.
10.3.4.22 Insulation
Check the insulation (if present) on components,
containers and piping for damage.
Damaged insulation must be replaced. The insula-
tion strength must be selected according to the tem-
perature and humidity at the place of installation.
Details on the insulation can be found in the P+I dia-
gram.
Caution!
No screw connections must be used
under the insulation if the piping is
insulated. The pipes must be welded.

Operating Manual | Decommissioning
Grasso SSP1
11 DECOMMISSIONING
3. Switch off the main switch of the three-phase
electric system.
11.1 Shut-down in the event of danger-
ous situations 4. If necessary, shut off the secondary refrigerant,
heating agent or the cooling water supply.
The safety equipment of the screw compressor pack-
age complies with EN 378. 5. Ensure that the venting slots of the electric
motors are covered under all circumstances!
By means of automatic monitoring of the individual
operating parameters, the control unit detects haz- ® Shut-down has been carried out
ardous situations in good time and automatically
switches off the screw compressor package.
The cause of the fault is displayed on the control unit 11.3 Standstill for a period >48 hours
and can then be corrected.
Hint!
Among other things, the concept of the screw com-
pressor packages is based onlow maintenance The obligation to label the plant as
refrigerant circuits that are as well sealed as possi- "Plant not in operation" must be
ble. However, residual risks remain, especially due observed!
to possible leaks or escaping refrigerant or rotating
drive parts. If the screw compressor package is shut down for a
period >48 hours, the following activities must be
Hint! performed:
The EMERGENCY STOP switch in the 1. Switch off the compressor in accordance with the
switching cabinet is used to quickly operating instructions for the electrical switch-
switch off the chiller whenever neces- gear.
sary.
2. Switch off all ancillary drives.
Leaking refrigerant can be detected with a gas 3. Switch off the main switch of the three-phase
detector (not included in the scope of delivery). This electric system.
detector can be integrated in the automatic safety
4. Close the stop valve (or combined stop/check
chain.
valves) on the suction side and the pressure
Please consult the safety regulations in this docu- side.
mentation for information about what to do in the
case of leaking refrigerant. 5. Close the stop valves (or shuttable check valves)
in the suction line of the economiser.
6. Shut off the secondary refrigerant, heating agent
11.2 Standstill for a period <48 hours or cooling water.
Hint! 7. Close the manual stop valve of the refrigerant

injection.
The obligation to label the plant as
"Plant not in operation" must be 8. Ensure that the venting slots of the electric
observed! motors are covered under all circumstances!
® Shut-down has been carried out
If the screw compressor package is shut down for a
period <48 hours, the following activities must be
performed:
11.4 Measures during shutdowns
1. Switch off the compressor in accordance with the
operating instructions for the electrical switch- Even though the screw compressor package/ chiller
gear. is under overpressure, check the moisture content of
the refrigerant and lubricating oil in case it is shut-
2. If necessary, shut down all ancillary drives. down for a period longer than half a year. The mois-

Decommissioning Operating Manual |
Grasso SSP1
ture content must not differ substantially from the ini-

tial values.
11.4.1 Monthly measures during stand-

still
– Check that the screw compressor package/
chiller is constantly under overpressure. Check
the screw compressor package/chiller for leaks
using a leak detector.
– Start the oil pump for approx. 5 minutes.
– Manually rotate the compressor shaft (min. 10
revolutions).
11.4.2 Four weeks before restarting

– Check the moisture content and ageing condition
of the refrigerating machine oil. Analyse the oil
for this purpose. Compare the results of the anal-
ysis with the values for fresh oil. We recommend
an oil change after 1 year (ammonia as refriger-
ant) (see Maintenance Instructions).
– Check the insulation resistance of the drive
motors (see the operating manual for the electric
motor).
– Switch on the oil pump.
– Check the screw compressor package/chiller for
leakages.

Operating Manual | Decommissioning, disposal
Grasso SSP1
12 DECOMMISSIONING, DISPOSAL
Preparatory measures – National regulations (e.g. EN 378-4, Appendix A)
Hint! must be observed for the reclamation and dis-
posal of operating media (oil).
The information in the chapter
"Decommissioning" must be – No unauthorised persons must be within the
observed. installation area of the plant during decommis-
sioning, as they could come into contact with
refrigerant.
Hint!
– All components of the plant which are not to be
Care must be taken during disposal re-used, as well as refrigerant and operating
and devaluation that the various mate- media, must be stored in suitable separate con-
rials are separated and taken for recy- tainers. They must be treated as waste and dis-
cling. Disposal of component remains posed of safely.
and components in the domestic ref-
uge or on refuse tips is not permitted. Hint!
The legal regulations applicable to the Re-use of operating media is not pos-
place of installation regarding the dis- sible!
posal of electrical equipment must be
taken into account.
Dismantled components must be dis-
posed of correctly and according to
legal requirements.
– The dismantling and disposal of the package/

chiller must be carried out in such a way that:
• the plant is free of voltage and is protected
against unintentional reconnection of the
voltage.
• Accidents to persons are prevented,
• material damage is prevented,
• uncontrolled escape of refrigerant or oil is
prevented.
– Disposal and decommissioning work must only
be carried out by personnel who are qualified
according to EN 13313.
– Components may be under elevated pressure
and the pressure must be released before open-
ing them.
– In case of contact with refrigerant or operating
media, their hazardous properties (e.g. toxicity,
inflammability) must be taken into account (see
also the safety data sheet for the refrigerant).
Personal protective equipment compliant with
EN 378-3 must be worn.
– National regulations (e.g. EN 378-4, Section 6)
must be observed for the reclamation and dis-
posal of refrigerants.

Compressor Manual P 251511 Om Ssp1 GBR 3-A4

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Compressor Manual P 251511 Om Ssp1 GBR 3-A4

Caricato da

Copyright:

Formati disponibili

Screw Compressor Packages

Operating Manual (Translation of the original text)

2 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

SYMBOLS USED IN THIS MANUAL

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 3

Bullet points and numbered list characters

4 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 5

7.9.2 Oil heater 43

6 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

10.3.4.1 Maintenance of the screw compressor 70

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 7

8 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 9

10 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

Qualification – Only the fuses specified in the electrical circuit

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 11

12 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 13

– control and regulation units including control sys-

14 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

GEA Refrigeration Germany GmbH

GEA Refrigeration Germany GmbH

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 15

16 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

Hint! – exposure to noise,

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 17

18 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

Hint! The screw compressor packages are

fig.2: Designation of the lifting points

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 19

Take special care not to attach the ropes near to

fig.5: Transportation with a cross-arm

fig.3: Limit stop Danger!

Position the screw compressor package on the

Transport packaging (optional): Foil

20 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

The following storage conditions must be maintained

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 21

2. Air humidity < 50% Caution!

• Free-standing motor and main flow shafts have

3. Checking the transport charge on the suction

22 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

6.2 Rigid installation

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 23

6.5 Information about noise emissions

Noise level LWA

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

24 GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015

Noise level LWA

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Max 100 100 100

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Max 100 100 100 100 100 100 100

GEA Refrigeration Germany GmbH | P_251511_3 | Generated 12.02.2015 25

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Max 101 101 101 101 101 101 101

Max 102 102 102 102 102 102 102

Max 103 103 103 103 103

Max 104 104 104 104 104

Max 104 104 104 104

Max 105 105 105

Max 105 105 105