Installation Main Ten Ace Manual Grasso 10 PDF

Grasso
Refrigeration Division
Reciprocating Compressors for industrial refrigeration

Series Grasso 10
Installation and Maintenance Manual (IMM)
IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 1

Grasso
Copyright
All Rights reserved. No part of this publication may
be copied or published by means of printing,
photocopying, microfilm or otherwise without prior The compressor is not filled with oil.
written consent of Grasso.
This restriction also applies to the corresponding
drawings and diagrams.
Legal Notice
After the successful initial run of the compressor
This publication has been written in good faith. (package) the warranty chart must be filled in and
However, Grasso cannot be held responsible, returned to Grasso. A warranty chart is attached to
neither for any errors occurring in this publication each compressor.
nor for their consequences.
This manual must be carefull read and understood

prior to installing and servicing the compressor
(package)
Safety
This manual is written with great care, but the
contractor/installer is held responsible to examine
this information and to care of possible additional
and/ or deviated safety measures.
Safety instructions
It is the task of the contractor/installer to inform
and explain his client about the operation of the
compressor (Package).
Do respect all federal, state or local safety
regulations/legislations during installing,
connecting and operating this compressor
(package).
Installer oriented information

The compressor (package) is filled with nitrogen to
prevent penetration of moisture. Therefore, keep
the compressor closed until the compressor
(package) is being installed.
Page 2 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

Grasso
Table of Contents
Section Title Page

1 INSTALLATION AND PREPARATION FOR USE 9
1.1 INSTALLATION 11
1.1.1 Moving instructions and storage 11
1.1.2 Storage 11
1.1.3 Hoisting and moving instructions 11
1.1.4 Required free space 12
1.1.5 Foundation requirements 12
1.1.5.1 Concrete structure 12
1.1.5.2 Anchoring 13
1.1.5.3 Concrete block mounting instructions 13
1.1.5.3.1 Mounting bare compressor on a concrete block 14
1.1.5.3.2 Mounting the base frame on a concrete block 14
1.1.5.3.3 Levelling the base frame 14
1.1.5.3.4 Finishing with a self-levelling grout (See figure 1.1.5) 14
1.1.6 Connecting to refrigerating system pipework 14
1.1.7 Connecting the power supply 15
1.1.8 Earthing connections 15
1.1.9 Separately delivered components 15
1.2 PREPARATIONS FOR USE 17
1.2.1 Leak test of compressor and system 17
1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 17
1.2.3 Initial oil charge 17
1.2.4 Initial refrigerant charge 18
1.2.5 Adjustment of instruments and safety devices 18
1.2.5.1 Monitron CR 18
1.2.5.2 Pressure safety switches 18
1.2.5.3 Re-adjustment of oil pressure regulator (refer to fig. 1.2.1) 18
1.2.6 Checking direction of rotation of motor shaft 19
1.2.7 Installing the drive guards (if present) 19
1.2.8 Initial oil warm up 19
1.2.9 Initial start-up 19
1.2.9.1 Limitations of part load operation and start-up of two-stage compressors 19
1.2.9.2 Pre-start check list 19
1.2.10 Starting and stopping procedures 20
1.2.10.1 Starting for the very first time (between brackets [ ] are Monitron CR units) 20
1.2.10.2 Restart (not within 2 minutes after a stop. If Monitron Cr Controlled, refer to the Monitron CR Instruction manual) 21
1.2.10.3 Starting after a short standstill period of time (less than 1 month) 21
1.2.10.4 Starting after a seasonal standstill (1 till 6 months) or maintenance operations 21
1.2.10.5 Starting after a long standstill period of time (more than 6 months) 21
1.2.10.6 Stopping the compressor 21
2 INSPECTION, MAINTENANCE AND TROUBLE SHOOTING 23

Grasso
Section Title Page

2.1 INSPECTION 25
2.1.1 Periodical inspection 25
2.1.2 Survey of periodical inspections ("check list") 25
2.2 MAINTENANCE (Contractor's level) 27
2.2.1 Post start-up maintenance 27
2.2.2 First maintenance 27
2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 27
2.4 LUBRICATION DATA 27
2.4.1 Topping up oil with compressor operating 27
2.5 EVACUATION OF THE COMPRESSOR 28
2.6 DRAINING AND CHANGE OF OIL 28
2.7 REPLACEMENT OF OIL FILTERS 28
2.7.1 Oil discharge filter 29
2.7.2 Oil suction filter (pos B in Fig. 1.2-1) 29
2.8 REPLACEMENT OF SUCTION GAS FILTER(S) 29
2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 29
2.10 COMPRESSOR PURGING 29
2.11 TROUBLESHOOTING TABLE 31
3 APPENDIX; Parts List 33
3.1 Partslist Grasso 10 33
4 APPENDIX; Engineering Data 35
4.1 GENERAL DATA 37
4.1.1 TECHNICAL DATA 37
4.1.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 38
4.1.3 SHAFT END COMPRESSOR 40
4.2 LIMITS OF OPERATION AND FIELDS OF APPLICATION 41
4.2.1 GENERAL LIMITS AND FIELDS OF OPERATION 41
4.2.2 FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER 42
4.2.3 FIELDS OF APPLICATION TWO STAGE 43
4.2.4 LIMITATIONS OF PART-LOAD OPERATION 45
4.2.5 STARTING UP OF TWO-STAGE COMPRESSORS 47
4.3 LUBRICATING OILS (choice and recommendations) 49
4.4 CAPACITY CONTROL SYSTEMS 50
4.4.1 SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START 50
4.4.2 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) 52
4.4.3 MANUAL CAPACITY CONTROL 54
4.5 PACKAGED BASE FRAME AND FOUNDATION BLOCK 55
4.5.1 PACKAGED BASE FRAME 55
4.5.2 BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK 57
4.6 CRANKCASE HEATER 58

Grasso
Preface 3) Grasso CD-ROM ´Documentation Navigator´
This preface gives a survey of the types of Contents

documentation and software available for this All Grasso documentation including a user friendly
Grasso compressor series. navigation system.
All Grasso documentation and Grasso selection With this CD-rom it is possible to re-use all text,
software is available on CD-Roms (Consult Grasso). graphics, tables, etc. for various purposes
(presentations, reports, ...)
1) Grasso Refrigeration Equipment Catalogue

User group
(REC)
Project engineers, application engineers, sales
Contents managers, product managers for both end-users
This catalogue contains all engineering data and all and contractors.
brochures of the reciprocating compressors, screw Distribution
compressors, air purgers, chillers, packages, etc.
This catalogue also includes the CD-Rom ´Grasso Sales Department of Grasso.
Software´ and the CD-ROM ´Documentation
Navigator´. 4) Engineering Data Sheets (ED)
User group Contents
Project engineers, applications engineers, sales All engineering data for this series compressor and
managers and product managers for both the corresponding recommended accessories. It is
end-users and contractors. meant to be a guide to the selection of these
components.
Distribution
Sales Department of Grasso. User group
Project engineers, application engineers, sales
2) Grasso CD-ROM ´Grasso Software´ managers, product managers for both end-users
and contractors.
Contents
Distribution
COMSEL programme (the Grasso COMpressor
SELection programme), PURGER programme (to Sales Department of Grasso.
calculate energy savings and pay-back time) and
REVALCO software (to select Revalco valves, check 5) Installation and maintenance manual (IMM)
valves, Revalco parts etc.).
Contents
User group
This manual will provide information on how to
Project engineers, application engineers, sales transport, install, start-up and maintain the
managers, product managers for both end-users compressor (package). It also contains a number of
and contractors. "Engineering Data Sheets" and the current "Parts
List"
Distribution
Sales Department of Grasso. User group
To be used in the field by qualified personnel for
both end-user and contractor.
Distribution
Supplied together with the compressor.

Grasso
6) Instructions for Accessories (IFA) User group

To be used in the field by qualified personnel of
Contents refrigeration installers or contractors.
The compressor is supplied with accessories, all the
relevant mounting and installation instructions and Distribution
spare parts information for those accessories. Service and Parts Department of Grasso.
User group
To be used in the field by qualified personnel for 10) Miscellaneous
both end-user and contractor.
Typographic signs:
Distribution Indicates a caution, note or procedure to which you
Supplied together with the compressor. should pay special attention.
READ IT CAREFULLY!
7) Parts list (PL)
Contents
All current parts of the compressor and accessories Indicates a WARNING. READ IT CAREFULLY!
together with the design changes applicable to
previous supplied components ("History").
User group
Service and parts department for both end-sure
and contractor. Indicates an IMPORTANT note or procedure to
which you should pay special attention.
Distribution
Service and Parts Department of Grasso.
8) Service & Maintenance Schedules (SMS) Indicates a HINT.
Contents
Values between []
Complete set of service and maintenance schedules
for 100 operating hours up to 48000 operating Values between [ ] are read-outs of Grasso's
hours (inspection, renewal, measuring, cleaning, ...) electronic control device Monitron CR.
of the bare shaft compressor.
User group
Service and parts department and in the field by
qualified personnel for both end-user and
contractor.
Distribution
Service and Parts Department of Grasso.
9) Service and Maintenance Manual (SIM)
Contents
Description of (re)assembling, inspection, repair
and part or total overhaul of the bare shaft
compressor. This manual should be used together
with the 'Installation and Maintenance Manual'.

Grasso
Main setup data Grasso 10 Table 1 Main setup data Grasso 10
Descriptiona Value Remark

Start frequency max. 6 starts per hour
Time interval between stopping and re-starting min. 2 minutes
Time interval between starting and re-starting min. 10 minutes
Time interval between loading and unloading min. 3 minutes
Oil level 25-75% crankcase sight glass
warmer than surroundings and ≥ 20 °C for NH3 and ≥ 30
Min. oil temperature
°C for halocarbons
Required oil viscosity;
Max. oil temperature [max. Toil] Refer to oil selection table/applied type of oil ≥ 10 cSt during operation at
location of bearings
Control oil pressure suction pressure + 7 bar
After a mimimum of 15
minutes running time at an oil
Lubricating oil pressure difference [min dOil] between 1.3 and 3.0 bar Setting approx. 2.0 bar
temperature of approx. 50 oC
(122 oF)
Max. discharge temperature [max. Tdis] 170 °C
Min. suction pressure [min Psuc] 0.3 bar
Max. intermediate pressure [max Pint] 8.5 bar
Max. suction pressure
Pdischarge - Psuction ≤25.0 bar
>0 K for NH3, R22
Superheat [dTo]
>15K for R507/R404A/R134a
Oil suction filter Blue coloured filter element
Oil discharge - running in - filter Red coloured filter element Factory mounted; to be
replaced after max. 100
running hours by
permanent oil discharge
filter element
Oil discharge - permanent - filter Grey filter element

Supplied loose;
replacement for factory
mounted running in filter
Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end
a. For values between [ ] brackets refer to the Instruction Manual of the Monitron CR
Release Notes IMM Grasso 10

Grasso
Table 2 Release Notes IMM Grasso 10

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

compressors
Fig. 1 Cylinder numbering Grasso reciprocating

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

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

1. INSTALLATION AND PREPARATION
Grasso FOR USE
1. INSTALLATION AND PREPARATION FOR USE
Table of Contents
Section Title Page

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

Grasso FOR USE
Section Title Page

1.2.10.6 Stopping the compressor 21

Grasso FOR USE
1.1 INSTALLATION
Every precaution must be taken while moving the

package to its final location. Pushing, pulling or
The compressor is not charged with oil, therefore, climbing on any package component or piping, can
DO NOT start the compressor before it has been easily create damage.
installed and prepared according to Grasso’s
instructions.
1.1.2 Storage
This section contains instructions for the proper The compressor (package) is filled with dry
installation of a Grasso compressor (package). nitrogen. Keep the system closed until the package
Before the compressor (package) is ready for the is installed. If the compressor (package) is stored, it
initial start up, the installation instructions in the should be kept at all times in a dry location to
following paragraphs must be followed: prevent corrosion damage. If the compressor
1. The Compressor (Package) should be levelled (package) is to be stored for a prolonged period of
and securely anchored to the foundation. time, it should be checked weekly to ensure that
2. All piping should be completed. the holding charge of dry nitrogen remains above
3. The system and the compressor are to be atmospheric pressure.
pressure tested for leaks (see. Section 1.2.1)
4. The system should be evacuated to remove air 1.1.3 Hoisting and moving instructions
and moisture.
5. The electric wiring should be completed as per
wiring diagrams. Do not energize the main
power control cabinet until oil is added and the
direction of rotation has been checked.
6. The compressor is to be filled with the correct
type and amount of lubricating oil.
7. The drive coupling or V-belt drive system should
be installed.
8. The system should be charged with the correct
amount of refrigerant.
9. The oil should be warmed up above minimum
start up oil temperature (see "Engineering
Data").
10.The control cabinet or Monitron CR should be
energized to check the package controls.
Fig. 1.1-1 Hoisting a compressor package
Do not forget to fill the oil separator (if present) Legend

initially.
C Compressor
M Motor
1.1.1 Moving instructions and storage
Packaged base frame:
For loose component or compressor package
weights, refer either to the relevant component The only places that can be used for safe hoisting of
type plate or package lay-out or to the suppliers the package are the four hoisting eyes on the steel
document. For bare compressor weights, see base frame as shown in the above figure. Prior to
"Engineering Data". hoisting a compressor package with a V-belt drive
arrangement, the factory mounted drive guard has
to be removed. Attach spreader bars to the slings so
as to prevent damage to piping and components.

Grasso FOR USE
1.1.4 Required free space

For easy operating, servicing and maintenance
access, the compressor (package) should be
DO NOT use the compressor or motor or oil installed with sufficient free space around it.
separator hoisting eyes to move the package!
These hoisting eyes are intended for lifting loose
components only and not for the entire package!
Refer to Engineering Data Sheets for minimum
requirements
Bare compressor or loose components:
Determine the dead weight of the particular 1.1.5 Foundation requirements
component (see "Engineering Data"), prior to
moving a bare compressor or loose component. Use This paragraph covers measures to be taken for a
the hoisting eyes only, DO NOT sling from other compressor (package) mounting on a concrete
compressor parts (see Fig. 1.1-1). floor.
Two foundation arrangements are described:
• Compressor package with steel base frame
mounted on a concrete block.
• Bare compressor direct mounted on a concrete
block via grouted machined anchors (see
"Engineering Data"). The mounting surfaces of
these machined anchors must be level without
any deviation and projecting at least 10 mm
above the concrete base.
COMPRESSOR AND COMPRESSOR PACKAGE TO

BE MOUNTED ON A CONCRETE BLOCK. On
request, Grasso can calculate the exact dimensions
of the concrete block, based on the compressor size
and operating conditions.
1.1.5.1 Concrete structure
Fig. 1.1-2 Hoisting angle
Moving by fork-lift truck Fig. 1.1-3 Concrete block

The bare compressor or package can be
transported with a fork-lift truck with the forks
Legend
spread as much as possible between the skids. To
simplify moving, the 2 wooden transport beams 1 Cork board
must still be mounted underneath the base frame 2 Concrete base
and stored in this way, until the package is 3 Basement floor
positioned above its approximate location.
The concrete block for compressor and motor or
compressor package should have a profile as
illustrated below and made according to the

Grasso FOR USE
following recommendations:
• The concrete block should be set on firm
footings or on a floor capable of carrying the
weight of the concrete block and capable of
absorbing the free forces and gas forces of the
compressor during operation. The ground under
the concrete block should be horizontal and flat.
• The top surface of the block should be level and
even.
• There should be sufficient free space around the
block to install corkboard (or similar).
• The block should be provided with anchor bolt
recesses or holes according to the anchor bolt
spacing as per package lay out drawing.
Table 1.1-1
Legend
A Chemical anchor
B Grouted anchor, grounded to reinforcing steel
It is recommended to consult a concrete specialist/

constructor for the following items:
• The compound of the concrete with/without
reinforcement.
• The exact grouting depth (dependent on the soil
conditions).
• Installing foundation onto an existing floor, with
sealing corkboard or vibration isolators.
1.1.5.2 Anchoring
After the concrete block has cured the anchors Fig. 1.1-4 Anchoring details
should be installed as shown above and in case of a
package in accordance with the package lay out
drawing. Templates should be made to locate the Legend
anchor bolts or chemical anchors to match the holes A Drilled chemical anchor (M20)
in the bottom flange of the base frame. B Grouted anchor recesses (M20)
Grout the mortar according to the supplier 1 Installed chemical anchor before placing the base frame
instructions. Install chemical anchors as illustrated in 2
Installing chemical anchor after placing the base frame
Fig. 1.1-4 and according to the instructions of the (base frame cannot be removed easily)
anchor supplier. 3 Drilling angle
1.1.5.3 Concrete block mounting instructions

Grasso FOR USE
1.1.5.3.1 Mounting bare compressor on a 1.1.5.3.4 Finishing with a self-levelling grout (See
concrete block figure 1.1.5)
If no base frame is applied the compressor and After levelling has been completed the adjusting
motor should be installed as described in the bolt ends must be greased to avoid bonding to the
"Engineering Data". self-levelling grout. The space between concrete
block and frame must be completely filled with the
1.1.5.3.2 Mounting the base frame on a concrete self-levelling grout to ensure that the complete
block bottom surface of the base frame will be
supported. Therefore, it is not allowed to use shims
between concrete base and base frame.
General
After the space between base frame and concrete Grouting must be carried out in accordance with
base has been filled-up with a filling grout, the the instructions provided by the grouting supplier.
package base frame must be secured tightly to the After complete de-aeration of the grouted layer,
foundation block or floor. secure the base frame by tightening the anchor bolt
nuts and remove all adjusting bolts. At this stage
1.1.5.3.3 Levelling the base frame the drive system can be installed. These
(accessories) installation instructions can be found
in the order manual.
1.1.6 Connecting to refrigerating system

pipework
After the compressor (package) has been levelled
and secured to the foundation, the system piping
may be connected. The suction line(s) and
discharge line(s) should be installed and supported
such that there is no load exerted on the
compressor. The size and location of the suction
and discharge connections, can be found in the
"Engineering Data" (bare compressor) and in case
Fig. 1.1-5 Grouting details of a package, the package lay out drawing.
Legend
1 Self-levelling grout
2 Adjusting bolts (4x)
3 Washer
4 Temporary barrier strip around and inside frame
5 Complete cured concrete block
6 Grout layer
After the anchor filling mortar has completely cured

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

Grasso FOR USE
arc-welding. After all installation functions are

completed, reconnect the litz-wires and ground the
package to earth.
If an oil rectifier system is applied in the 1.1.9 Separately delivered components
refrigeration system, the oil return line must be
connected to the oil return connection (see
"Engineering Data").
Check whether the sets/parts/components (e.g. fly

wheel) belonging to this compressor are supplied
loose! (Refer to confirmation of order)
Never connect the oil rectifier return line to the
suction line or to the suction gas filter. Mount these separately delivered sets, components
and/or parts, according to the instruction as
enclosed.
DO NOT ground through the compressor when arc

welding
Suspension of system pipework

To eliminate vibration transmission to the system
piping, the following is recommended:
• Install all piping free of tension.
• Secure the piping by clips or brackets in two
directions.
• Install (stop) valves, piping and accessories such,
that there is no load exerted on the compressor.
1.1.7 Connecting the power supply

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

Grasso compressors and packages are equipped
with litz-wires and earth connecting points.
To avoid leakage current flowing through the
components, disconnect all litz-wires when
1. If the standard recommended Monitron CR is applied.

Grasso FOR USE

Grasso FOR USE
1.2 PREPARATIONS FOR USE vii)If pressure has increased (system still contains
moisture), repeat steps iv, vand vi, otherwise,
After the Compressor (Package) has been installed continue with the "Initial oil charge" procedure.
(excluding final connection of drive device), the
following actions should be followed in the order 1.2.3 Initial oil charge
given:
1.2.1 Leak test of compressor and system

The compressor (package) has been pressure tested
prior to leaving the factory. In case an additional Used or filtered oil should NEVER BE added to a
leak test is required, this test is should be carried compressor under any circumstance.
out with dry nitrogen under pressure up to a max.
of 10 bar(a).
Use only new oil as selected from the Grasso oil

table.
DO NOT add oil to the compressor prior to pressure
testing
A system leak test should be carried out over 24

hours to ensure that the system is tightly sealed.
Record during the pressure test, the pressure, Oil charging via the suction line of the compressor
ambient temperature and outside temperature. is not allowed.
During the initial 6 hours a pressure drop of 2% is
permissable. With respect to temperature
variations, no further pressure loss should be
Procedure:
detected in the remaining 18 hours.
If the test pressure has not decreased by more than i) STATUS: System is dried and still evacuated.
5% the system can be considered leak free. ii) Fill the oil separator (if present) initially with oil .
iii) Close suction and discharge stop valves of
1.2.2 EVACUATION/DRYING THE compressor and oil return line of oil separator (if
REFRIGERATING SYSTEM present).
iv) Fill the compressor crankcase with oil via the oil
For evacuation of compressor only, refer to Section charge valve.
2.5
Procedure to evacuate and to dry a system:
i) STATUS: System is filled with nitrogen and no oil
has been added (oil prevents any trapped Pre-lubrication just before the first start is
moisture from boiling off). obligatory.
ii) Verify that all valves in that part of the system to
be evacuated are opened (refer also to the plant v) Open evacuation/purging valve(s) of the
manual). compressor to bring the compressor to
iii) Connect vacuum pump to the atmospheric pressure.
evacuation/purging valve(s) of the compressor
(for location of these valves refer to the
"Engineering Data" or to a connection as
mentioned in the plant manual and evacuate
the system to approx. 5 mm Hg (=6.6 mBar).
iv) Break vacuum by charging dry nitrogen into the
system.
v) Repeat step iii, 'Connect vacuum pump ...'.
vi) Wait approx. 24 hours.

Grasso FOR USE
1.2.5.2 Pressure safety switches

3
QUANTITY OF OIL TO BE FILLED (IN dm )
Shaft seal Pressure safety limit switches
Number of housing incl. Oil Oil
cylinders internal circuit of filters pump Crankcase 5oC below design
Suction pressure Setting
crnkshaft [Psuc] Precondition evaporating temp.
Min. =0.3 bar(a)
2 0.6 6.5
Suction and
3 0.7 9.0 Setting
intermediate Precondition Max.= 8.5 bar(a)
1.5 pressure [Pint]
4 0.7 0.5 6.5
each
5oC above design
6 0.8 9 Discharge pressure Setting condensing temp.
[Pdis] Precondition Max. =26 bar(a)
8 0.9 13.5
Lubrication oil
Setting Min. =1.3 bar
pressure difference
Oil pressure regulators
Filling of the afore mentioned components is also Lubrication oil
Setting
2.0 bar Min. =1.3
possible by means of a separate oil filling pump via pressure difference bar Max. =3.0 bar
Precondition
[dOil] at 50oC oil temp.
the oil charge valves mounted onto the oil pump
Control oil Min. =6.9 bar Max.
housing. pressure difference Setting
=7.1 bar
1.2.5.3 Re-adjustment of oil pressure regulator

1.2.4 Initial refrigerant charge (refer to fig. 1.2.1)
Refrigerant charging should be done in accordance
IT IS POSSIBLE that after the compressor(package)
with the plant manual by qualified refrigeration
has been installed, the lubrication oil pressure
engineers.
regulator (located on the left side of the pump)
needs to be re-adjusted.
1.2.5 Adjustment of instruments and safety
devices Inside the oil pump two regulators are factory
preset and installed; One control oil pressure
1.2.5.1 Monitron CR regulator (right) to control the valve lifting
mechanisms and one lubricating oil pressure
For adjustments as given overleaf (values between regulator for lubrication.
brackets [ ]) refer to the Monitron CR Instruction For settings, refer to Section 1.2.5.2.
Manual.
Fig. 1.2-1 Oil pressure regulator Legend

Oil discharge filter
Legend REMARK: A running in filter is factory mounted; to
B be replaced after max. 100 running
1 Lubricating oil pressure regulator hours by permanent oil discharge filter
2 Control oil pressure regulator element
A Oil suction filter

Grasso FOR USE
Legend startup! Refer to the drive guard installing

procedures included in the order documentation.
Oil charge valve for lubrication circuit.
C REMARK: This connection to be used for
pre-lubrication of the oil circuit
1.2.8 Initial oil warm up
Oil charge plug for oil suction filter (Hand operarated oil Prior to the initial start-up, the crankcase heater (if
D
pump and stop valve are not included) present) must be energized. For the min. oil
E Connection to measure oil control pressure temperature (min. [Toil]) refer to Engineering Data
F Hand operated oil charge pump (optional).
Sheets.
Re-adjustment procedure:
1.2.9 Initial start-up
i) Run the compressor for 15 minutes until the
crankcase oil is at its stable operating 1.2.9.1 Limitations of part load operation and
temperature [Toil] of 50 oC at which: start-up of two-stage compressors
# The lubricating oil pressure difference should
The capacity control serves to adapt the compressor
be 2.0 bar.
capacity at any moment as closely as possible to the
# The control oil pressure difference should be
refrigerating capacity. In order to adapt the
approx. 7.0 bar.
capacity, a number of cylinders can be put in or out
After the initial run the oil pressure differences
of action either individually or collectively. In this
should be slightly higher.
case use is made of the valve lifting mechanism
ii) Determine the lubricating oil pressure difference
fitted on each cylinder which is put in or out of
(difference between the pressure gauges of the
action by oil pump pressure via 3-way solenoid
oil and suction or [dOil]).
valves.
iii) Determine the control oil pressure difference
(difference between the pressure gauges of oil
pump discharge 1 and suction.
iv) Remove the cap nut of both oil pressure
regulators if the pressures need to be
re-adjusted. Due to start-up limitations and to limitations of part
v) Turn the slotted pin with a screwdriver clockwise load operation it may be that not all available part
or counter clockwise for a higher or lower oil load steps are allowed under certain conditions.
pressure respectively, until the required control Use of incorrect control steps can damage
& lubricating oil pressure differences has been compressor and/or components.
achieved 2.
vi) Replace both cap nuts. In the case of a Monitron CR Controller, all these
limitations will be checked automatically.
REMARK: If the valve lifting fails, check the
lubrication oil pressure regulator! For a detailed description about these start-up and
part load limitations refer to the "Engineering
1.2.6 Checking direction of rotation of Data".
motor shaft 1.2.9.2 Pre-start check list
Prior to installing the intermediate coupling The following Paragraph covers only the initial start
element or V-belts, the direction of rotation of the of the compressor and not the complete
motor shaft must be checked either by bumping refrigeration plant.
the electrical drive motor or by measuring the
rotation of the field. The direction of rotation can Be sure that all necessary system valves are open
be determined from the arrow-sticker on the oil and that the refrigeration system is ready for start
pump. up. Use the following check to guarantee that no
items of importance regarding the compressor
1.2.7 Installing the drive guards (if present) (package) have been overlooked.
Only after the compressor is ready for the initial i) System is charged with refrigerant.
ii) Monitron CR (if present) is properly installed
1. To be measured by means of a special control oil pressure gauge to be (refer to the Monitron CR Instruction Manual).
connected at position E on the oil pump.
2. Re-adjusting one regulator will affect the other one, so be sure that both
regulators are properly (re-)adjusted.

Grasso FOR USE
iii) Settings of safety limit switches are adjusted i) Notice "Pre-start check list", also consult the plant
properly. manual and verify the following items:
iv) Direction of rotation of compressor crankshaft is — Check the oil temperature [Toil] (refer to the
correct. "Engineering Data").
— Check crankcase oil level (refer to Section
2.4.1).
ii) Start the compressor and check whether the oil
pressure [Poil] increases.
Different procedure for Manually operated
capacity control and Electrically operated capacity
control:
1. Manually operated capacity control: Set the Maximum 6 starts per hour and at least 2 minutes
electrical capacity control switch to the position between stopping and starting and at least 10
´1´. minutes between starting and re-starting
2. Electrically operated capacity control
Monitron CR Controller: Check whether the i) Slowly open suction stop valve and watch
manual control lever of each solenoid is in its suction pressure [Psuc], which may not exceed
lowest horizontal position. If not, the the max. value as given for each refrigerant in
compressor may be seriously damaged. "Main setup data Grasso 10" on Page 7.
v) Oil level established in sight glass.
vi) Stop valves to the pressure gauges are open.
vii)Suction stop valve is closed (in case the
evaporating temperature is much higher than
the design evaporating temperature) and the Refrigerant liquid hammer, will damage the
discharge stop valve is open and in case of two- compressor; Superheat is always necessary!
stage compressors that the stop valves in the [dTo]≥0-15K. Refer to "Main setup data Grasso 10"
intermediate circuit lines are open. on Page 7.
viii)Stop valve in the oil return line of the oil
separator (if present) is closed. i) In case of electrically operated capacity control
or control by a Monitron CR:
When all items are verified, the compressor — Single-stage compressors: One or more
(package) is ready for the start-up. cylinders will be energized.
— Two-stage compressors: 3 - 5 minutes after
1.2.10 Starting and stopping procedures starting and only when HP-cylinder(s) is (are)
in operation, can the LP cylinders be
When starting the compressor a distinction should energized.
be made between:
• (Section 1.2.10.1) Starting for the very first time.
• (Section 1.2.10.2) Restart (not within 2 minutes
after a stop and, if Monitron CR Controlled, refer
to the Monitron CR Instruction manual)
• (Section 1.2.10.4) Starting after a short standstill
period of time (less than 1 month).
• (Section 1.2.10.5) Starting after a seasonal
standstill (1 till 6 months) or maintenance
operations.
• (Section 1.2.10.6) Starting after a long standstill
period of time (more than 6 months).
• (Section Section 1.2.10.6) Stopping the
compressor.
1.2.10.1 Starting for the very first time (between

brackets [ ] are Monitron CR units)

Grasso FOR USE
Consult your supplier. Monitron CR "standby" status

(ready to operate during this long period of time) is
not allowed! It is recommended to proceed with
the "Initial start-up" procedure of Section 1.2.10.1.
Watch maximum allowable motor current [Imot]
(refer to motor type plate). 1.2.10.6 Stopping the compressor
The compressor can be stopped at any moment,
however, consult the supplier if further actions are
required.
Watch discharge temperatures LP and HP {[Tint]

and [Tdis]}, max. intermediate pressure [Pint]
(Refer Table 1) and max. allowable motor current
(refer to motor type plate).
In the case of decreasing capacity, it is not allowed

to cut out all LP-cylinders.
i) Adjust pressure gauge stop valves, in order to

avoid vibration of the pointers.
ii) Open the stop valve in the oil return line from
the oil separator (if present).
After 50 hours of operation retighten the coupling

bolts or check and/or correct the tension of the
V-belts and retighten the foundation bolts (with
due respect to the torque settings given by the
supplier of the fasteners!).
1.2.10.2 Restart (not within 2 minutes after a

stop. If Monitron Cr Controlled, refer to
the Monitron CR Instruction manual)
• Proceed to the complete starting procedure of
Section 1.2.10.1, items a) through f).
1.2.10.3 Starting after a short standstill period of

time (less than 1 month)
• Refer to Section 1.2.10.2.
1.2.10.4 Starting after a seasonal standstill (1 till

6 months) or maintenance operations
• Check settings of control and safety equipment.
• Proceed to the complete starting procedure.
1.2.10.5 Starting after a long standstill period of

time (more than 6 months)

Grasso FOR USE

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

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


2.1 INSPECTION
2.1.1 Periodical inspection
These inspections should be made during the
normal shut-down periods as much as possible, so
the compressor is always ready to operate when
required. If, at that time, the number of running
hours slightly differs from the scheduled period
below, the inspection should nevertheless be
carried out.
In this way it will not be necessary to stop the
compressor at inconvenient times.
The frequency of inspections is dependent on the
type of installation and operating conditions. In the
case of automatically controlled plants, the
periodical inspection are particularly important. The
table below sums up all the points on the
compressor that have to be inspected or
maintained along with inspection and maintenance
frequencies.
2.1.2 Survey of periodical inspections

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

Table 2.1-1 Survey of periodical inspections ("check CHECK FREQUENCY REMARKS

list") POINTSa
monthly
weekly
daily
CHECK FREQUENCY REMARKS
POINTSa
monthly
weekly
daily
Adjustment
and operation Refer to Section 1.2.5 and
• to instructions of switch
of pressure manufacturer.
safety switches
Between 25% and 75%
Oil level in height of the sight glass. The time lag between the
•
crankcase For topping up oil, refer to Capacity unloading and loading of
Section 2.4.1. control (if • one cylinder or cylinder
provided) group should generally be
The oil should be at least 3 - 5 minutes.
transparently clear. A
disappearing white colour The time interval between
Colour of the
• points to dissolved stopping and starting
oil Switching
refrigerant. Refer to should be at least 2
Section 2.2.2 for oil analysis frequency of • minutes and between
frequency. the
starting and restarting 10
compressor minutes (see Section
The indication of the oil 1.2.10.2).
Lubricating oil pressure gauge should be
pressure
difference • 1.3 - 3.0 bar higher than Check the number of
the value shown by the Number of operating hours in view of
[dOil]
suction pressure gauge. operating • any maintenance
hours operations to be carried
Min. control oil out.
• Suction pressure + 7 bar
pressure
a. During the first 50 operating hours the compressor should be checked
Oil regularly for all the points mentioned above, at least twice every 24 hours
temperature • Refer to the "Engineering
Data" and more frequently in cases where irregularities are found.
max. [Toil]
Oil leakage of • In case of more than 1
shaft seal max. cc/hr contact supplier.
Suction Check against design

pressure [Psuc] • conditions. Refer to plant
manual.
Refer to plant manual. For
the max. allowable
Discharge
pressure [Pdis] • discharge pressure refer to
the technical data of
compressor.
Suction
superheat
[dTo]Intermed • ≥0K
iate superheat
[dTm
Discharge
temperature • 170 °C.
max.
During compressor
standstill the lower part of
Oil the crankcase must remain
temperature • warmer than the
min. [Toil] surroundings: ≥ 20 °C
(NH3) and ≥ 30 °C
(halocarbons).
Check belts for:
1) Wear (fraying, cuts etc.)
and ensure that they do
not touch the groove
bottom.
Condition of 2) Tension. Too low a
•
V-belts tension gives rise to
excessive flapping or
oscillation in operation. For
correct tension consult the
instructions given by the
V-belt supplier.

2.2 MAINTENANCE (Contractor's

level)
2.2.1 Post start-up maintenance After the refrigerating plant has been modified, the
suction gas filter(s). the oil filters and the oil should
After the compressor has run for the initial 100
be changed.
operating hours:
i) Drain the oil and refill the compressor with the
correct amount of fresh oil.
ii) Replace the red marked oil discharge filter 2.3 STEPS FOR LONGER SHUT-DOWN
element with the grey marked filter element in PERIODS (> 6 months)
accordance with the filter replacement
instructions. Refer also to Section 2.7. To shut down a compressor for long term periods,
iii) Inspect suction gas filter (refer to the proceed as follows:
Compressor Service Instruction Manual). i) Tightly shut both the suction and discharge stop
iv) Exchange or clean oil suction filter element valves and the stop valve of the oil return line (if
(refer Section 2.7). present).
v) Check the compressor shaft seal for leakage. If ii) Disconnect the power source from the
excessive (more than 1 cc/hr) replace the seal. compressor drive motor and the electrical
vi) 1) Retighten the coupling mounting bolts with control cabinet of the Monitron CR (if present).
the torque settings as given by the coupling iii) Place a moisture absorbing compound (eg a
manufacturer. dessicant such as silica gel) inside the control
2) Verify and if necessary, correct the tension of cabinet.
the V-belts as given in the V-belt supplier's iv) Place warning tags on the electric system and all
instructions. closed stop valves.
vii)Verify and if necessary, correct the torque Prior to starting up after a shut down, change the
settings of all foundation bolts as given in oil (refer to Section 2.6) and exchange the oil filters
Compressor Service Instruction Manual. (refer to Section 2.7). Determine the starting and
stopping procedure from Section 1.2.10 prior to
2.2.2 First maintenance start the compressor.
For complete service schedules and required service
sets refer to Grasso's Service and Maintenance 2.4 LUBRICATION DATA
Schedules (SMS).
Determine max Toil and set this value in the safety
device (Monitron CR, if present).
Maintenance Number of operating hours Change the oil as soon as an oil analysis (refer to
100a > 100
Section 2.2.2 for frequency) indicates contaminated
oil.
Renewal of oil discharge filter X
Renewal of suction gas filter(s) X
Inspection of oil suction filter X refer to Service
and Maintenance
Oil analysis bc X Schedules (SMS)
Inspection leakage shaft seal X It is expressly pointed out that it is not permitted to
mix different types of oil. If another type of oil is
Inspection relief valve(s)d X
used, first remove all the stale oil in the filters, oil
a. Time dependent on pollution. pump, crankcase, shaft seal, oil separator and oil
b. Take an oil sample every 3,000 running hours or twice a year and renew if any
sign of discoloration and if the system is contaminated. drains of the installation.
c. Consult your oil supplier.
d. If temperature of relief valve is close to (LP/HP) discharged temp, consult your
supplier.
2.4.1 Topping up oil with compressor
operating
Topping up oil is permitted during compressor
operation.

Be sure that this oil is the same as in the plant (refer iii) Set suction pressure safety switch to 0.3 bar(a).
to Section 2.4). iv) Start the compressor (manual).
v) Wait until the compressor is cut out of operation
Without affecting the operation of the compressor, either by the min. suction pressure safety switch
the oil may be topped up by means of a separate oil [min Psuc] or the min. oil differential pressure
pump. This pump enables the oil to be forced into safety switch [dOil].
the crankcase via the oil charging valve, against
suction pressure. If this oil pump is not available, oil
can be charged by reducing the crankcase pressure
to below atmospheric pressure.
The procedure is as follows: Do not start the compressor again, but close the
discharge stop valve as soon as possible. Be sure the
i) Connect a hose to the oil charging valve after compressor will not start again!
removing the cap nut.
ii) Fill the hose with oil and immerse its loose end in vi) Remove the remainder of the refrigerant, via the
a reservoir containing sufficient oil. evacuation/purging valve(s) as prescribed by
iii) Close the suction stop valve so, that the suction local safety regulations. For the location of these
pressure falls below the atmospheric pressure. valves refer to the "Engineering Data".
iv) Keep the oil charge valve open as long as the oil vii)Reset the suction pressure safety switch [Psuc].
in the crankcase has attained the required level
again. Take care that no air is being drawn into
the crankcase. 2.6 DRAINING AND CHANGE OF OIL
v) Slowly open the suction stop valve to avoid To top up oil see Section 2.4.1, Oil changing
liquid hammer which may damage the procedure:
compressor.
vi) Remove the hose and replace the cap nut with i) Evacuate the compressor (refer to Section 2.5).
gasket onto the oil charging valve. ii) Drain the oil via the oil charging/drain valve.
Remove the cover of one or more service
openings on the compressor side.
iii) Clean the inside of the crankcase with a
non-fibrous cloth (do not use cotton waste!).
iv) Replace the service cover(s) with a new O-ring.
v) Charge crankcase with clean or fresh oil in
accordance with the procedure of Section 1.2.3.
2.7 REPLACEMENT OF OIL FILTERS
Fig. 2.4-1 Oil level in compressor sight glass

Tools; Use the ring spanner for (dis)mounting the
2.5 EVACUATION OF THE oil filter cups (included in set of special Grasso tools)
COMPRESSOR Evacuate (refer to Section 2.5) the compressor prior
To evacuate the refrigeration system refer to to exchange the filter(s).
Section 1.2.2, Procedure to evacuate the Facts:
compressor: Oil suction filter = BLUE coloured
i) Close the suction stop valve and the stop valve in Oil discharge - running-in - filter = RED coloured
the oil return line of the oil separator. Oil discharge - permanent - filter= grey.
ii) Check that the discharge stop valve is open.
1. Two-stage system A/B: shut off liquid supply
to interstage cooler.
2. Two-stage system C/D: consult the plant
manual.

2.7.1 Oil discharge filter mechanically and thermally. Wear and life time of
the valves strongly depend on the working
conditions of the compressor. It is recommended
that valve condition is regularly checked.For
dismantling, inspection and re-assembly of the
An oil discharge (running-in) filter is factory valves, refer to the relevant paragraph of the
mounted. This filter must be exchanged after max. Compressor Service Instruction Manual.
100 running hours. Oil filters can not be cleaned!
Replace this filter according to the schedule in

Section 2.2.2 and to the replacement instructions In order to reduce the downtime involved in the
included in the filter set (GREY = permanent) or in valve inspection, it is recommended to have as
case of a modified plant (RED = running-in). many complete valve assemblies in stock as there
are cylinders on the compressor.These valves can be
2.7.2 Oil suction filter (pos B in Fig. 1.2-1) exchanged with the original valves; in this case,
The frequency of exchanging this filter depends on these original valves can be inspected and repaired
the condition of the refrigeration system. It is or replaced if necessary later on.
recommended to exchange this filter when the
compressor is overhauled or when pressure drop
exceeds 1 bar. 2.10 COMPRESSOR PURGING
Procedure to purge the compressor(after
2.8 REPLACEMENT OF SUCTION GAS maintenance jobs):
FILTER(S)
STATUS:
Stop valves of suction, discharge and oil return line
are still closed (refer to Section 2.5) and compressor
is filled with oil (refer to Section 2.6).
Running-in suction gas filter(s) is(are) factory
mounted. This(these) filter(s) must be exchanged i) Connect a vacuum pump to the
after max. 100 running hours. Running-in filters can evacuation/purging valve(s) and evacuate as
not be cleaned! prescribed by local regulations. For the location
of these valves refer to the "Engineering Data".
ii) When evacuation is completed open the
Facts: discharge stop valve.
iii) Watch suction and discharge pressure.
Filter type 1000 = installed in 2-3 cylinder
compressors.
Filter type 2000K = installed in 4-6-8 cylinder
compressors.
If suction pressure increases quickly, the discharge
Procedure: valve assy is leaking.
i) Evacuate the compressor. iv) Start compressor.
ii) Remove and exchange the suction gas filter(s). v) Slowly open suction stop valve.
iii) Purge the compressor. vi) Open the stop valve in the oil return line of the
oil separator (if present).
2.9 DISMANTLING, INSPECTION AND 1. Two-stage system A/B: open liquid supply to
interstage cooler.
RE-ASSEMBLY OF SUCTION AND 2. Two-stage system C/D: refer to the plant
DISCHARGE VALVES manual.
vii)If a Self-Limiting Automatic Purger is not
The suction and discharge valves of a refrigeration installed, purge the refrigerating system (refer
compressor are parts that are heavily loaded both to the plant manual).


2.11 TROUBLESHOOTING TABLE

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

Table 2.11-1 Troubleshooting FAULT CAUSE REMEDY
FAULT CAUSE REMEDY 1. Type of oil not

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

F All cylinders
lifting mechanism too 1. See J
inactive while
low 2. Refer to the
compressor is 2. Incorrect wiring of "Engineering Data
operating
capacity control

3. APPENDIX; Parts List
Grasso
Table of Contents
Section Title Page

3.1 Partslist Grasso 10 33
3.1 Partslist Grasso 10

Data not yet released.
Partslist Grasso 10 is under construction

Grasso

4. APPENDIX; Engineering Data
Grasso
Table of Contents
Section Title Page

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

Grasso

Grasso
4.1 GENERAL DATA

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

compressors
Single-stage Two-stage
COMPRESSOR TYPE Grasso
210 310 410 610 810 2110 3110 4210 6210
zL 2 3 4 6
Number of cylinders 2 3 4 6 8
zH 1 1 2 2
Cylinder arrangement 1xL 1xL 2xV 2xV 4xV 1xL 2xV 2xV 4xV
Cylinder bore D mm 110
Piston stroke S mm 85
Swept volume at n=1500 min-1 Vs m3/h 145 217 290 435 580 145 217 290 435
full-load and:
Standard direction of rotation counter-clockwise when facing shaft end
Standard 1475 min-1 (50
compressor n min-1 1475-1328-1180-1047-929-826-738-661-625
Hz)
speeds (with
V-belt drive) at 1775 min-1 (60
n min-1 1416-1257-1115-991-885-793-750-708-637
motor speed: Hz)
100-87-
manual and 100-67- 100-75- 100-83- 100-83-
100-50 67-50 75-62- 100 100-67 100-75- 67-50-
Standard steps of electric control: 33 50 50-37- 50
-33 33
capacity control 25
(expressed in % % 100- 100-83-
of full-load swept 75(1.5)- 67-
volume): incl. Fast Pull 100-67 75(3.0)- 50(1.5)-
- 100-50
Down(FPD)a 33 50(1.0)- 50(3.0)-
50(2.0)- 33(1.0)-
25 33(2.0)
Mass of bare compressor (without
kg 510 585 610 725 990 590 615 730 998
flywheel and other accessories)
Shipping mass (approx.) kg 560 635 660 775 1040 640 665 780 1048
3
Shipping volume m 0.3 0.4 0.7 0.8 1.1 0.4 0.7 0.8 1.1
Oil charge in crankcase and oil
dm3 9.5 12 9.5 12 16.5 12 9.5 12 16.5
circuit (centre line of sight glass)
Mass moment of inertia of crank kg.m2
Id 0.0776 0.1491 0.0776 0.1491 0.1673 0.1491 0.0776 0.1491 0.1673
mechanism (without flywheel)
a. Volume ratio between brackets

Grasso
4.1.2 MAIN DIMENSIONS AND SPACE

REQUIREMENTS
Fig. 4.1-1 Main dimensions, space requirements Table 4.1-2 Main dimensions and space
requirements
COMPRESSOR TYPE Grasso 210 310 410 610 810 2110 3110 4210 6210
Length A 925 1105 925 1105 1455 1105 925 1105 1455
Width B 536 536 888 888 888 536 888 888 888
High C 765 765 815 815 815 765 815 815 815
D 579 579 782 777 782 577 782 782 777
E - - - - - 685 709 722 722
F - - - - - 513 595 600 600
G - - 787 824 824 709 709 709 709
H - 516 - - - 516 315 345 735
J 343 402 301 372 821 519 315 481 845
K - - - - - 152 152 134 134
L - - - - - 30 38 68 68
M 152 134 0 0 0 152 152 152 152
N 68 68 77 100 98 70 77 77 98

Grasso
COMPRESSOR TYPE Grasso 210 310 410 610 810 2110 3110 4210 6210
O 555 735 555 735 1085 735 555 735 1085
R 240 240 240 240 240 240 240 240 240
S 211 211 0 0 0 210 0 0 0
MINIMUM REQUIRED FREE SPACE for removal of:
T - - - - - 519 326 470 860
a
flywheel U 335 355 335 335 335 335 335 335 335
crankshafta V 750 925 750 925 1270 925 750 925 1270
a
piston and cylinder liner W 1000 1000 790 790 790 1000 790 790 790
X 300 300 530 530 530 300 530 530 530
LOCATION OF CENTRE OF GRAVITY
length Y
on request
width Z
MAIN CONNECTIONS DN (mm)b
(LP) suction 1 50 65 65 80 100 50 65 65 80
LP dicharge/HP suction 2/3 - 32 32 50 50
(HP) discharge 4 32 50 50 65 80 32 32 32 32
AUXILIARY CONNECTIONS
Temperature 5
LP discharge pressure/
temperature 6
HP suction pressure/
7
temperature
HP dicharge pressure/ 1/4” BSP
temperature 8
Crankcase 9
Oil lubrication pressure 10
Oil temperature 11
Oil drain 12
Oil return oil separator 13 1/2’ BSP
Crankcase heater 14
Oil leakage drain of rotary
15 clamp coupling provided width Ø6 x 1.5 mm steel precision tube
shaft seal
Oil control pressure 16 1/2” BSP
Crankcase pressure
17 1/4” BSP
equalizing
Oil charge valve 18 1/2’ bsp (TAH 8)
a. Minimum required free space
b. connection 45 degr. for Grasso 210, 2110 and 310, refer to

Grasso
4.1.3 SHAFT END COMPRESSOR

Grasso
4.2 LIMITS OF OPERATION AND The diagrams overleaf represent the overall fields
of application in which the individual operation
FIELDS OF APPLICATION limits are taken into account.
4.2.1 GENERAL LIMITS AND FIELDS OF Table 4.2-1 General limits and fields of operation
OPERATION
When operating the compressor, none of the limits 1. In practice, it is not so much the individual operation limits as combinations of
them that are decisive for the conditions under which a compressor may
of operation as stated in the table below must be operate. To check the various possibilities in this respect, use should be made
exceeded.1 of the "fields of application" ).
REFRIGERANT NH3 R22 R134a R404A R507

min. 600
Compressor speed n min-1
max. 1500
Suction pressure = evaporating pressure =crankcase min. 0.3

a
po bar(a)
pressure max. 8.5
min. 0.3
Intermediate pressure pm bar(a)
max. 8.5
Evaporating temperature = saturation temperature min. -55 -63 -50 -68 -68
at suction pressure to °C
max. 19 17 33 10 10
Actual suction temperature ta °C min. -50
Discharge pressure = condensing pressure b pc bar(a) max. 26.0
Condensing temperature = saturation temperature
at discharge pressure tc °C max. 60 63 110 55 54
c
Discharge temperature te °C max. +170
min. 1.5
d
Pressure ratio per stage (pc/po or pc/pm or pm/po) j -
max. 10
e
Pressure difference ∆p bar max. 25.0
min. +20 +30
f
Oil temperature in crankcase toil °C depending on type of oil (Required oil viscosity >
max. 10 cSt)
a. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.
b. This pressure is also the maximum allowable pre-set value of the HP safety switch. CAUTION!: When adjusting the HP and/or LP safety switch, care
should be taken that the pressure difference ∆p=(PC-po) never exceeds 25.0 bar.
c. This is the actual discharge temperature, measured directly in the gas flow just before the discharge connection. The given value also applies to the LP
stage of two-stage compressors.
d. Pressure ratio limits are not absolute but arbitrary values based on practical considerations.
e. The standard built-in overflow safety valve(s) between suction and discharge side has been factory-set to 26.0 ≤ 1.5 bar to prevent advanced opening
during normal operation at ∆p = (pc - po) ≤25.0 bar.
f. Indicated minimum value is the lowest oil temperature at which the compressor is allowed to be started. The maximum oil temperature depends on
the operating conditions of the compressor, the oil type used and (for halocarbon refrigerants only) the solubility of the refrigerant in the oil. A
minimum actual oil viscosity of 10 cSt is always required.

Grasso
4.2.2 FIELDS OF APPLICATION

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

to = evaporating temperature
po = evaporating pressure
tc = condensing temperature
pc = condensing pressure
∆to = suction superheat
j = pressure ratio = (pc / po)
∆p = pressure difference = (pc - po)
te,max = maximum discharge temperature
↓ = Line shift downwards for ∆to > 0 K and/or
part-load operation
Procedure and data

• Diagrams in Section 4.2.2 are based on Fig. 4.2-1 Field of application NH3
continuous full-load operaton, suction superheat
= 0K.
• For continuous minimum part-load (i.e. more
than 30 minutes) consult Grasso.

Grasso
Fig. 4.2-2 Field of application R404A/R507
Fig. 4.2-4 Field of application R134a
Table 4.2-2 Fields of Appication

Legend
These parts of the general fields of application are not
A covered by the compressor selection software COMSEL.
Please consult Grasso to make a selection for those
applications
Po Suction pressure (evaporating)
Pc Discharge pressure (condensing)
j Pressure ratio (Pc/Po)
te,max Max. discharge temperature at full-load and superheat 0K
4.2.3 FIELDS OF APPLICATION TWO STAGE
General
The fields of application for two stage compressors
are (besides superheat and part-load operation)
very dependant on ϕ(ratio LP/HP swept volume;
full-load and part-load can have different values).
Because each capacity control step can have a
Fig. 4.2-3 Field of application R22 different ϕ, it is very important to check for every

Grasso
control step (especially during starting up!) that the

compressor will run with-in its limits of operation.
Refer to Starting Up Procedure and Limitations of

Partload Operation
Symbols used in diagrams

to = evaporating temperature
po = evaporating pressure
tc = condensing temperature
pc = condensing pressure
tm = saturation intermediate temperature
j = pressure ratio = (pc / po, pc / pm or pm / po)
∆p = pressure difference = (pc - po)
te,max = maximum discharge temperature Fig. 4.2-5 Dummy diagram
teH,max = maximum discharge temperature HP
ϕ = ratio LP/HP swept volume (full-load and
Table 4.2-3 Dummy Diagram; Explanation two
part-load can have different values)
↓ = Line shift downwards for ∆to > 0 K and/or stage field of application
part-load operation Legend
Area on the right side of this line indicates the
Procedure and Data single stage field of operation (starting up). This
line shifts down in case of continuous part-load
Jmax / te,max
operation and/or (intermediate) superheat.
• Two stage fields of application are not valid for Superheat also results in limited part-load
all types of compressors and/or all part-load operation.
steps. Maximum HP-discharge temperature (not
All compressor types are included within the applicable for halocarbons). This line shifts down
teH,max* / te,max in case of continuous part-load operation and/or
total field of application. (intermediate) superheat. Superheat also results
• Diagrams overleaf are based on LP and HP in limited part-load operation.
suction superheat 0K resp. 10K. Each ϕ (phi) has its own field of appication. The
higher this value, the lower possible evaporating
ϕ
temperature. For each capacity control step field
of application must be verified in relation with ϕ.
Po,min Minimum suction pressure (evaporating)
For continous part-load (i.e. more than 30 minutes) tm,max Maximum intermediate pressure.
consult Grasso.
• The Dummy diagram shows field of application

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

Grasso
Fig. 4.2-6 Field of application two-stage NH3 Fig. 4.2-8 Field of application two-stage R22
4.2.4 LIMITATIONS OF PART-LOAD

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

compressors
In the case of continuous single-stage part-load
operation of Grasso compressors with the
refrigerant NH3, not all standard capacity control
steps can be used under all operating conditions.
Fig. 4.2-7 Field of application two-stage R404A and R507
There is a limitation with respect to minimum
capacity, which, depending on the amount of
suction superheat, is determined by the maximum
discharge temperature of 170 °C. This means that
the full-load field of application as shown in the
NH3- diagram, is reduced at top-left for part-load
operation in a way as indicated by the arrows in the
the relevant diagram.
This part-load restriction cannot be eliminated by
applying a cooling system on the cylinder head.
When, on the contrary, the refrigerants R134a, R22,
R404A and R507 are used for continuous
single-stage part-load operation of all standard
capacity control steps, the same operating
conditions are allowed as for full-load operation
with all cylinders energized. In other words, the
full-load fields of application, also remain valid for

Grasso
part-load operation down to and including the application), or on account of too high a saturation
standard minimum capacity step. intermediate temperature / intermediate pressure
Only under very extreme conditions with respect to (working point to the right of the field of
ambient temperature (e.g. above approx. +40 °C) application). In the case of electrical capacity
and/or suction superheat (e.g. more than approx. control, such disallowed part-load steps can easily
30 K) the situation may occur that during part-load be avoided in actual practice for once and forever
operation the maximum discharge temperature of by adapting accordingly the wiring diagram for
170 °C and/or the maximum oil temperature are/is energizing the three-way solenoid valves.
exeeded, which implies that in these cases it is not
permitted to switch off cylinders down to the
standard minimum capacity.
In such a case the oil temperature is the decisive
factor, the limitation mentioned before can be Should hand-operated capacity control be applied,
avoided by applying an oil cooler. For these special however, the operator in the engine room has to
cases, always consult Grasso.
be well informed about the part-load steps that are
not allowed to be used and consequently about the
positions of the oil distributor handle that must be
avoided. It will be clear that ignorance and/or
negligence in this respect may easily lead to failures
In general the rule is that, irrespective of refrigerant
and/or breakdowns. This is one of the reasons that
and conditions of operation, it is never allowed to
for two-stage compressors hand-operated capacity
run a compressor during a prolonged period of
control is forbidden.
time fully unloaded, i.e. with all cylinders switched
off.
When using a Grasso compressor equipped with a

standard capacity control such a situation is
impossible because then, apart from the starting Apart from the above-mentioned inadmissibility of
period, always one or more cylinders are certain standard part-load control steps, care
permanently connected to the control oil pressure. should always be taken to ensure that the capacity
of two-stage compressors is never reduced to such
Limitations of part-load operation for two-stage an extent that only H.P. cylinders remain operative.
compressors
For then the compressor would operate as a single-
From the diagrams, it appears that for two-stage
stage machine, but under two-stage conditions,
compressors the field of application depends not
which would result, in particular for NH3, in an
only on the kind of refrigerant but also on the ratio
unacceptably high discharge temperature. This
ϕ of L.P. and H.P. swept volume.
restriction means that the three-way solenoid
This involves (since the standard capacity control
valves should be wired so that, when the
steps of the individual two-stage types have not
compressor is running under design conditions, at
always the same ϕ-value) that for the successive
least one solenoid valve remains energized. Here
capacity control steps of a certain compressor type
again the undesirability of hand-operated capacity
different fields of application may be valid. If this is
control becomes evident, for it would mean that, as
the case, the situation may occur that, when
long as the compressor in running, one has to be
cylinders are switched on or off under constant
sure that the handle of the oil distributor is never
(design) conditions of operation, the corresponding
set to (starting) position 1.
working point (= combination of condensing
temperature tc and evaporating temperature to)
lies outside one or more of the relevant fields of
application.
This implies that it is not allowed to use the part
load steps concerned, either on account of too high
a H.P. discharge temperature in case of NH3 only
(working point lies to the left of the field of

Grasso
4.2.5 STARTING UP OF TWO-STAGE single-stage under two-stage conditions,

COMPRESSORS resulting in too high a discharge temperature.
2. The compressor is started at a relatively high
evaporating temperature, that is to say much
General higher than under design conditions and in any
case not suitable for two-stage operation.
Such a situation may occur after a prolonged
period of compressor standstill or when the
The Monitron CR will control automatically all compressor operates on a batch type freezing
full-load and part-load limitations (motor current, tunnel, just loaded with warm products. Under
optimum ϕ etc.) for booster, single- and two-stage these circumstances it is not permitted to switch
compressors. over to two-stage operation with minimum
capacity until the H.P. cylinders already in
operation have lowered (in single-stage) the
Procedure for starting from compressor standstill evaporating temperature to so much that the
corresponding working point at the condensing
In the case of two-stage compressors it is very temperature tc, lies inside the field of application
important that immediately after the period of of the two-stage minimum part-load step
automatic fully unloaded start (ensured by the concerned. Only then, after this step has been
corresponding three-way solenoid valve in the energized, the saturation intermediate
control pressure supply line from the oil pump; only temperature tm will be below its maximum
one or more H.P. cylinders become operative, viz. value. Consequently, the maximum value of to at
only those cylinders of which the suction valve which it is allowed to switch over to two-stage
lifting mechanism is directly and permanently operation, is determined by the intersection of
connected to the control pressure supply of the oil the near-vertical line which represents the right
pump via the starting solenoid valve mentioned. hand limitation of the relevant field of
This means that during starting none of the application and the horizontal line which
three-way solenoid valves for the capacity control represents the condensing temperature tc.
are allowed to be energized. Likewise, during further stepping up to
maximum capacity, the evaporating
Procedure to move on to two-stage operation and temperature has to be pulled down by each
to increase capacity. intermediate part-load step so far that the
corresponding working point at given
Once properly started, as indicated in the previous condensing temperature lies each time just
paragraph, the compressor has to be switched over inside the field of application of the next
to two-stage operation with minimum capacity, part-load step of higher capacity, before that
followed, if and when required, by gradual step is energized.
stepping up to maximum capacity.
The procedure thereby to be applied depends on
the installation operating conditions during starting Fast pull-down part-load control steps
which give rise to two distinct possibilities, viz.: When using the standard capacity control steps of
1. The compressor is started at low evaporating the two-stage compressor types, the pull-down
temperatures, this being approx. the (design) procedure to achieve full-load operation at design
value during normal (full-load) operation. conditions, as described in the previous paragraph,
This situation occurs after the compressor has is rather often very time consuming. This is due to
been stopped for a certain period of time the fact that all compressor types are always started
because of low capacity requirements of the with only one HP cylinder in operation and that the
installation. Under these circumstances it is minimum LP/HP swept volume ratio for any
permitted to switch over to the two-stage part-load step is ϕ = 2.
part-load step of minimum capacity immediately Therefore, for all Grasso two-stage types a fast pull-
after proper starting with H.P. cylinders in down electric capacity control system has been
operation. developed, which allows the compressors to be
In the case of NH3, this is even a necessity, for started with two or more HP cylinders in operation
otherwise the compressor would be running in and which includes one or more part-load steps
with volume ratio ϕ = 1.

Grasso

Grasso
4.3 LUBRICATING OILS (choice and Table 4.3-1 Oil selection table
recommendations) Maximum allowable
Max. allowable crankcase oil
For lubrication of refrigeration compressors, several evaporating temperaturea
brands and types of specially developed lubricating temperature ISO VG-number
to,max (°C)
oils are on the market. The choice of oil depends 46 68 100
not only on its good lubrication properties
NH3 - 73 80c 88
(viscosity) and chemical stability at the operating
conditions of the compressor, but also on the -64 72 80c 88
operating conditions of the refrigerating plant -30 69 78 c
86
(solidifying and floc point, solubility). -20 67 76c 84c
R22
Grasso has tested and approved for use in its -10 65 74c 82c
Refrigerant usedb
reciprocating-compressors the brands and types of 0 60 71 78c
oil as listed in Table 4.3-2. +10 52 65 74c
The choice of the viscosity of the lubricating oil
-50 - 88c 94
depends on the operating conditions of the
c
compressor. -30 - 85 92
The oil viscosity should always be more than 10 cSt R134a, R507, -20 - 83 c
91
(based on bearing construction requirements of the R404A -10 - 81c 90c
compressor). For the selection of the oil viscosity
0 - 76 87c
grade number, refer to Table 4.3-1 below.
A higher viscosity should be chosen, when a high oil +10 - 68 84c
temperature is expected, due to arduous operating a. Data based on minimum oil viscosity of 10 cSt at the bearing surfaces,
condition such as: which is derived from the oil type, solubility of the regrigerant in the oil
(halocarbon refrigerants only) and operating conditions. Assumed is that
• high evaporating temperature; the oil temperature at the bearing surfaces = 6 K above crankcase oil
• large superheat of the refrigerant suction temperature.
b. In case of other refrigerants always contact the oil supplier in advance for
vapour; advise
• prolonged part-load operation with a large c. Recommended ISO VG-numbered oil.
number of cylinders cut-out; Example: R22, to,max = 0oC): recommended oil type is ISO VG100. NH3
• a high surrounding temperature; under normal operating conditions, oil type with ISO VG68 is
recommended.
• large pressure ratio.
Table 4.3-2 Recommended oil types for Grasso
Remark reciprocating compressors - NH3
For the oil types mentioned below, applied with the
Refrigerant ISO VG
refrigerants R22, NH3 and R134a, the minimum used
Brand Type designation
numbera
requirement of the actual oil viscosity of 10 cSt is CPI CP-1009-68b 100-68
fulfilled, but only when the maximum oil
NH3
temperature as mentioned in the Table 4.3-1 below Reflo 68ab

PETRO CANADA 68
is not exceeded. Reflo 68Ab
a. Viscosity grade number designation according to ISO Standard 3448.
b. For NH3 only! Strongly recommended for NH3 with discharge temp. > 120 oC
Some of the oil types listed in this table may be marketed under other
names and/or designations; these oils can also be used, provided their
identity can be proved beyond any doubt. Application of other oils is
not permitted without the written consent of Grasso.

Grasso
Table 4.3-3 Accepted oil types for Grasso Refrigerant ISO VG

reciprocating compressors used numbera
Icematic SW 68 68
Refrigerant ISO VG CASTROL
used numbera Icematic SW 100 100
b b
AVIA Avilub FC 46/68 Solest 68
CPI
b
Energol LPT-F 46 46 Solest 120
BP b
Energol LPT-F 68 68 Triton SE 55
b b
CASTROL Icematic 299 DEA Triton SE 80
b
CPI Triton SE 120
CP-1009-68c b
(NH3 only!)
Recommeded! b
Planetelf ACD 68
ELF Elfrima FR 68 b ELF
b
Planetelf ACD 100
R134a/R404A/R507
Zerice 46 46 b
Purfrigol ST VG 68
Zerice 68 68 FINA
Purfrigol ST VG 100 b
ESSO
Zerice 46 46
Reniso E 68 68
Zerice 68 68 FUCHS
Reniso E 100 100
FINA Purfrigol MP 68 68 b
Emkarte RL 685
KC 46 46 ICI
b
FUCHS Emkarte RL 100S
NH3 and R22
KC 68 68 b
EAL Arctic 68
b MOBIL
KROON OIL Carsinus FC 46/68 b
EAL Arctic 100
MOBIL Arctic oil 300 b
b
Clavus R68
PETRO CANADA Reflo 68ab SHELL
b
(NH3 only!) Clavus R100
Recommended! Reflo 68Ab
SUN-OIL Suniso Excel b
StravinksyB b
Q8 Capella HFC 68 68
b TEXACO
Stravinsky C
Capella HFC 100 100
Clavus 46 46
a. Viscosity grade number designation according to ISO Standard 3448.
Clavus 68 68 b. Consult your oil supplier to determine the maximum allowable oil
temperature at an oil viscosity of 10 cSt, under prevailing operating
SHELL Clavus G 46 46 conditions and refrigerant used.
c. For NH3 only! Strongly recommended for NH3 with discharge temp. > 120 oC
Clavus G 68 68 Some of the oil types listed in this table may be marketed under other
Clavus G 100 100 names and/or designations; these oils can also be used, provided their
identity can be proved beyond any doubt. Application of other oils is
Suniso 3.5 GS b not permitted without the written consent of Grasso.
b
Suniso 4 GS
SUN-OIL
Suniso 5 GS b 4.4 CAPACITY CONTROL SYSTEMS
b
Suniso 4 SA (NH3 only!)
TEXACO Capella WF 68 68
4.4.1 SURVEY CAPACITY CONTROL
TOTAL Lunaria S 46/68 b SYSTEMS AND UNLOADED START
General
Capacity control of the compressor will be enabled
by lifting the suction valves, by means of the control
oil pressure from the oil pump. One of the options
mentioned below is compulsory.
One of the options must be applied;

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

Grasso
• 'Fast pull down' (FPD); obligatory for R404A • If compressor is running then solenoid is NOT
and R507 applications; recommended for all energized.
two-stage compressors
• Manual (Not allowed for two-stage
compressors)
In case manual or electric capacity control is

applied, fully unloaded starting of the compressor is
ensured.
Unloaded start
Fully unloaded compressor starting is enabled by
energizing the three-way solenoid valve for
unloaded starting, which is an Normally Open valve
in contrast with the solenoid valves for capacity
control which are Normally Closed.
This NO-solenoid valve has to be energized when
starting the electric motor and has to be
DE-energized by means of the start delta switch of
electric motor when electric motor switches from
star to delta or by means of an auxiliary time relay.
Time relay and/or star-delta switch are not included
(time relay is built-in in Monitron CR).
After fully unloaded compressor starting, this
solenoid valve must be DE-engergized allowing
control oil pressure to the control pistons of these
cylinders and causing these cylinders to become
operative automatically.
In the case of single-stage compressors, they are at
the same time the minimum number of cylinders
that must always remain energized during
continuous operation.
For two-stage compressors only HP cylinders are
involved, which, however, do not at the same time
represent the minimum capacity.
The other cylinders can be energized or
de-energized in one or more steps in a standard
sequence for each type of compressor.
Summary wiring logic NO-unloaded start

solenoid:
• If compessor is NOT running then NO-solenoid is
not energized.
• If compressor starts then NO-solenoid is
energized until start-delta switch switches from
start to delta or by means of an auxiliary time
relay.

Grasso
4.4.2 ELECTRIC CAPACITY CONTROL AND

FAST PULL DOWN (FPD)
General
Electric capacity control is compulsory if Monitron
CR is applied and is included in the standard scope
of supply for two stage compressors.
Procedure and data

• Refer to diagrams and figures below.
• The possible control steps and the number of
three-way solenoid valves depends on type of
compressor
Standard scope of supply

• One three-way NO-solenoid valve (with LED
indicator) for unloaded starting (mounted).
• A number of NC-three-way solenoid valves (each Fig. 4.4-1 General diagram of electrically operated
with LED indicator; mounted). capacity control
• Oil pressure lines (mounted).
Legend
Options (for two-stage compressors only)
A Top view of compressor
• Fast Pull Down control system
B Valve lifting mechanism
C oil return to crankcase
D oil pump
E electrical wiring to start/delta switch of the motor
FPD is compulsory for R404A and R507.
G three-way solenoid valve for unloaded starting (NO)
The standard starting procedure which is H supply of oil pressure
contained in the standard electrical capacity J three-way solenoid valve(s) for capacity control (NC)
control, is only suitable if the compressor is being
NO Normally Open
started at design evaporating temperature.
In case the compressor has to start frequently NC Normally Closed
with high evaporating temperatures (batch
freezing, etc), fast pull down capacity control is Table 4.4-1 Solenoid valve/cylinder numbering for
necessary to avoid that the compressor runs capacity control
continuously in part-load.
HP cilinders No.
Cylinder number
Compr. type
Grasso
Sol. valve
FPDa unloaded Sol valve Sol valve Sol valve
(NC) starting no. 1 no. 2 no. 3
(NC) (NC) (NC)
(NO)
210 - - 1 2 - -
310 - - 1 3 2 -
410 - - 1+2 3 4 -
610 - - 1+2 5 3+4 6
810 - - 1+2 6 3+4 5 + 7 +8
2110 1 - 1 2+3 - -
2110FPD 1 3 1 2 - -

Grasso
HP cilinders No.
Compr. type
Cylinder number
Compr. type
Grasso
Capacity
Grasso
Sol. valve Remarks Cylinders Solenoids ϕb

a Sol valve Sol valve Sol valve %a
FPD unloaded
no. 1 no. 2 no. 3
(NC) starting
(NC) (NC) (NC)
(NO)
starting
0 2 - 0.0
3110 2 - 2 1+3 4 - only
3110
67 - 1+2+3 1 2.0
3110FPD 2 1 2 3 4 -
4210 2-4 - 2 1+3 4+5 6 100 - 1+2+3+4 1+2 3.0
4210FPD 2-4 4 2 1+3 5 6 starting

0 2 - 0.0
only
6210 2-4 - 2 1+6 4+5+7 3 3110+
+8 33 FPD only 1+2 FPD 1.0
FPD
67 - 1+2+3 1+FPD 2.0
6210FPD 2-4 4 2 1+6 5+7+8 3
100 - 1+2+3+4 1+2+FPD 3.0
a. FPD=Fast Pull Down
0 starting 2 - 0.0
only
Table 4.4-2 Capacity control steps
4210 50 - 1+2+3 1 2.0
Compr. type
75 - 1+2+3+6 1+3 3.0

Grasso
Capacity
Remarks Cylinders Solenoids ϕb 100 - 1+2+3+4 1+2+3 2.0
%a
starting
0 2 - 0.0
only
50 - 1 - -
210 25 FPD onlyd 2+4 FPD 0.0
100 - 1+2 1 -
50 FPD only 1+2+3+4 1+FPD 1.0
33 - 1 - - 4210+
FPD 50 - 1+2+3 1 2.0
310 67 - 1+2 1 -
75 FPD only 1+2+3+4+5 1+3+FPD 1.5
100 - 1+2+3 1+2 -
75 - 1+2+3+6 1+3 3.0
50 - 1+2 - -
100 - 1+2+3+4+5+6 1+2+3+FPD 2.0
410 75 - 1+2+4 1 -
starting
0 2 - 0.0
100 - 1+2+3+4 1+2 - only
33 - 1+2 - - 33 - 1+2+6 1 2.0
50 - 1+2+5 1 - 6210 50 - 1+2+3+6 1+3 3.0
610 67 - 1+2+3+4 2 - 67 - 2+3+4+5+7+8 2+3 2.0
83 - 1+2+3+4+5 1+2 - 83 - 1+2+4+5+6+7+8 1+2 2.5
100 - 1+2+3+4+5+6 1+2+3 - 100 - 1+2+3+4+5+6+7+8 1+2+3 3.0
25 - 1+2 - - 0
starting
2 - 0.0
only
37 - 1+2+6 1 -
0 FPD only 2+4 FPD 0.0
50 - 1+2+3+4 2 -
33 FPD only 1+2+4+6 1+FPD 1.0
810 62 - 1+2+3+4+6 1+2 -
33 - 1+2+6 1 2.0
75 - 1+2+5+6+7+8 1+3 - 6210+
FPD 50 FPD only 1+2+3+4+6 1+3+FPD 1.5
87 - 1+2+3+4+5+7+8 2+3 -
50 - 1+2+3+6 1+3 3.0
100 - 1+2+3+4+5+6+7+8 1+2+3 -
67 - 2+3+4+5+7+8 2+3+FPD 2.0
starting
0 1 - 0.0
2110 only 83 - 1+2+4+5+6+7+8 1+2+FPD 2.5
100 - 1+2+3 1 2.0 100 - 1+2+3+4+5+6+7+8 1+2+3+FPD 3.0
starting a. Refers to the swept volume expressed as a percentage of the full-load swept
0 1 - 0.0
only volume for single stage compressors, resp. LP full-load swept volume for
2110+ two-stage compressors.
FPDc 50 FPD only 1+3 FPD 1.0 b. Number of LP/ Number of HP cylinders
c. FPD compressor; incl. Fast Pull Down (optional)
100 - 1+2+3 1+FPD 2.0 d. FPD=Fast Pull Down step only;

Grasso
4.4.3 MANUAL CAPACITY CONTROL
General
Instead of the recommended electric capacity
control in combination with the Monitron CR, a
manual operated capacity control system can be
delivered for single stage and booster compressors.
Electrical supply still required for three-way solenoid

valve(s).
Manual capacity control system is equal to standard

electric control system with as extra an electric
capacity control switch.
Capacity control steps are equal to electric capacity Fig. 4.4-2 Diagram of manually operated capacity
control system
control.
Legend
Procedure and data A Top view of compressor
• Monitron CR is not applied. B Valve lifting mechanism
C oil return to crankcase
Standard scope of supply D oil pump
• Standard electric capacity control. E electrical wiring to start/delta switch of the motor
• Electric capacity control switch. G three-way solenoid valve for unloaded starting (NO)
H supply of oil pressure
J three-way solenoid valve(s) for capacity control (NC)
NO Normally Open
NC Normally Closed
ES Electric capacity control switch

Grasso
4.5 PACKAGED BASE FRAME AND • The concrete block should be extend down to
any subsoil.
FOUNDATION BLOCK
4.5.1 PACKAGED BASE FRAME Scope of supply
• Steel base frame, incl mounting of compressor,
electric motor and accessories.
General
For mounting on a concrete foundation block,
B. Base frame for mounting on vibration dampers
Grasso can supply a standard welded steel base
frame to support compressor, motor and
accessoiries. Design Data
Especially for vibration free operation on floors and • Frame to be placed direct on floors and on roof
on roof tops, a base frame with vibration dampers tops (every structural floor should be designed
can be delivered (concrete foundation block can be to take the weight of the packaged unit).
omitted). • Concrete foundation block can be omitted.
• The first two pipe supports must be secured to a
A. Base frame for mounting on concrete block solid foundation.
• Horizontal piping must be arranged parallel to
the crankshaft of the compressor.
Design Data • Consult always Grasso.
• Base frame to be placed on concrete foundation
block. For foundation block dimensions consult
Scope of supply
Grasso.
• There should never be a direct rigid connection • Steel closed box profile base frame, including
whatsoever between the foundation block and mounting of compressor, electric motor and
the floor or any other main part of the building. accessories.
• Set of vibration dampers.
Fig. 4.5-1 Grasso 10 package, direct drive with oil

separator

Grasso
Fig. 4.5-3 Packaged base frame for mounting on

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

Grasso
4.5.2 BARE COMPRESSOR ON CONCRETE

FOUNDATION BLOCK
For direct driven compressors, a packaged base

frame is strongly recommended
Fig. 4.5-4 Foundation top

Grasso
4.6 CRANKCASE HEATER

Legend Dimensions in mm
dg Drive guard
FW Fly wheel
MP Motor pulley Recommended for all types of refrigerant and all
CLC Centre line compressor types of compressors.
CLM Centre line motor
Foundation anchor (number of foudation anchors for
fa compressor = 4) General
fb Foundation block During standstill of the compressor, refrigerant may
fc Filling compound dissolve in the oil charge of the crankcase or it may
even condense, both due to an increase of
cc Concrete
crankcase pressure, a decrease of crankcase
Compressor dimension O temperature and/or possible temperature
Grasso 210/410/3110 555 differences between crankcase and evaporator.
C-O
Grasso 310/610/2110/4210 735
Excessive foaming of oil in crankcase, can occur
Grasso 810/6210 1085 when starting the compressor after a long period of
2.5 x diameter of foundation anchor (= 50 mm for standstill with relatively low oil temperature which
e Grasso10-compressor; only valid when using filling may result in damaging the compressor by a lack of
compound)
lubrication.
h Total height of concrete block (consult Grasso)
Low oil temperatures may also cause a high oil
General viscosity, which may result in troublesome starting.
In case a base frame is not applied, a V-belt driven
compressor can be mounted direct on a concrete
foundation block. Selection and Data
This Data Sheet should not be considered to be a • Refer to table.
guide to the design and lay-out of the foundation • Engine room temperatures between 15 and
block as such. 20 °C.
• Heater fitted into a sleeve so can be exchanged
This matter requires practical experience and a while compressor is in operation.
detailed knowledge of the situation on the spot. • Wiring: If 'compressor NOT running' then
Therefore it is strongly recommended to leave the 'element is energized'.
disign and carrying out of foundations entirely to
qualified firms, which, at the same time, are
Standard scope of supply
prepared to take full responsiblility for the job.
• Heater element (mounted).
Selection and Data
Table 4.6-1 Crankcase heater
• Consult grasso to determine dimensions of
concrete foundation block Number of
Installed power of
compressor Dimension L (mm)
• There should never be a direct rigid connection cylinders
heater element
whatsoever between the foundation block and 2-4 325 380
the floor or any other main part of the building.
3-6-8 525 600
• The concrete block should extend down to any
subsoil.
• Dimensions in the table below are directly
related to the compressor and the drive. Other
dimensions are determined by amongst other
the electric motor.

Grasso
Fig. 4.6-1 Crankcase heater
Legend
CE Cable entry
RC Removable cap to protect connections
M Male
Fig. 4.6-2 Location of crankcase heater sleeve

Grasso
Language of this document Ref. Nr. Grasso IMM10

English 0089286
German 0089386
French 0089486
Spanish 0089586
Italian 0089686
Dutch 0089186
Grasso Products B.V. • P.O. Box 343 • 5201 AH

‘s-Hertogenbosch • The Netherlands
Phone: +31 (0)73 - 6203 911 • Fax: +31 (0)73 - 6231 286
E-Mail: products@grasso.nl • URL: www.grasso.nl
Grasso GmbH Refrigeration Technology • Holzhauser Straße -
165 • 13509 Berlin • Germany
Phone: +49 (0)30 - 43 592 6 • Fax: +49 (0)30 - 43 592 777
E-Mail: info@grasso.de • URL: www.grasso.de
Please contact the technical department of your supplier for

extra information.

Installation Main Ten Ace Manual Grasso 10 PDF

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

Installation Main Ten Ace Manual Grasso 10 PDF

Caricato da

Copyright:

Formati disponibili

Grasso

Reciprocating Compressors for industrial refrigeration

Installation and Maintenance Manual (IMM)

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 1

This manual must be carefull read and understood

Installer oriented information

Page 2 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

Section Title Page

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 3

Section Title Page

Page 4 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

Preface 3) Grasso CD-ROM ´Documentation Navigator´

This preface gives a survey of the types of Contents

1) Grasso Refrigeration Equipment Catalogue

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 5

6) Instructions for Accessories (IFA) User group

7) Parts list (PL)

8) Service & Maintenance Schedules (SMS) Indicates a HINT.

9) Service and Maintenance Manual (SIM)

Page 6 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

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

Descriptiona Value Remark

Oil discharge - permanent - filter Grey filter element

Release Notes IMM Grasso 10

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 7

Table 2 Release Notes IMM Grasso 10

Cylinder numbering of Grasso reciprocating

Fig. 1 Cylinder numbering Grasso reciprocating

Booster or single-stage operation

Page 8 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

1. INSTALLATION AND PREPARATION FOR USE

Section Title Page

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 9

Section Title Page

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

Every precaution must be taken while moving the

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

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 11

1.1.4 Required free space

COMPRESSOR AND COMPRESSOR PACKAGE TO

1.1.5.1 Concrete structure

Fig. 1.1-2 Hoisting angle

Moving by fork-lift truck Fig. 1.1-3 Concrete block

Page 12 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

It is recommended to consult a concrete specialist/

1.1.5.3 Concrete block mounting instructions

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 13

1.1.6 Connecting to refrigerating system

After the anchor filling mortar has completely cured

Page 14 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

arc-welding. After all installation functions are

Check whether the sets/parts/components (e.g. fly

DO NOT ground through the compressor when arc

Suspension of system pipework

1.1.7 Connecting the power supply

1.1.8 Earthing connections

1. If the standard recommended Monitron CR is applied.

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 15

Page 16 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 IMM10/v003

1.2.1 Leak test of compressor and system

Use only new oil as selected from the Grasso oil

A system leak test should be carried out over 24

IMM10/v003 Reciprocating Compressors for industrial refrigeration / Series Grasso 10 Page 17