Grasso

Refrigeration Division

Liquid ammonia cooling unit’s

series DX LFKA
refrigerating capacity 83 ... 356 kW

Product information

_301011_pi_dxlfka__gbr_.pdf 09/03
 Grasso
Refrigeration Division

 Copyright Grasso GmbH Refrigeration Technology

The contents of this documentation and the enclosed drawings, sketches and diagrams are intended only for plant
user and operating personnel. They may be neither duplicated nor divulged to third parties or firms without written
consent.
The technical data, figures, dimensions and weights presented in the documentation may be more closely defined
or otherwise specified as a result of contractual agreement and are binding only after our confirmation in writing.
The stipulations set forth in the contract have precedence over those in this documentation.
We reserve all rights to introduce technical modification in the course of further development.
 PRODUCT INFORMATION
Grasso
Refrigeration Division CONTENTS
AMMONIA – LIQUID CHILLERS
SERIES DX LFKA

DESCRIPTION OF MAIN COMPONENTS 1

MAIN DATA 2

INSTALLATION 3

SPECIFICATION 4

_301011_pi_dxlfka__gbr_.pdf 09/03
 Grasso
Refrigeration Division
 1
DESCRIPTION OF
MAIN COMPONENTS

General description

Introduction ......................... ......................................................................................................................... Page: 3

Technical description DX LFKA .................................................................................................................... Page: 3
Labelling Schema DX LFKA ......................................................................................................................... Page: 4

Description of main components

Compressor/drive ................ ......................................................................................................................... Page: 4

Condenser ................ ......................................................................................................................... Page: 4
Evaporator ................ ......................................................................................................................... Page: 4
Injection control ................ ......................................................................................................................... Page: 4
Fittings ................ ......................................................................................................................... Page: 5
Switching cabinet ................ ......................................................................................................................... Page: 5

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
DESCRIPTION OF MAIN COMPONENTS
SERIES DX LFKA

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Grasso
Refrigeration Division
INTRODUCTION
With the air-cooled liquid ammonia coolant units (FKS)
of the series DX LFKA proven components are
available as complete refrigerant systems for the
following application cases:
- cold water supply for air conditioners
- process cooling,
- heat pumps,
- low temperature supply in the area of climate
temperature with coolants of +15°C to +3°C
The FKS DX LFKA operates principally with the
natural coolant, ammonia, which can be differentiated
from the synthetic HFKW coolants (e.g. R134a,
R407C) by the following features:
- It is a natural substance (in the nitrogen cycle).
- lower TEWI (Total Equivalent Warming Impact)
- comprises no direct greenhouse effect from the
coolant as well as limiting the indirect greenhouse
effect by the energy consumption of the system)
and is therefore extremely environment-friendly
- Its GWP (Global Warming Potential) is zero.
- Its ODP (Ozone Depletion Potential) is zero.
- It has a low odour threshold which serves as an
effective warning in the event of leaks.
- It has served as a refrigerant for decades and
caused no long-term damage.
- It gives better refrigerating capacity for the same
investment expenditure.
- It has a better coefficient of performance.
The liquid coolant units have been designed for
exterior installation.
For the installation, regulations for
ammonia coolant systems, such as EN 378
in Europe, must be complied with.
The LFKA range gives safe and dependable operation
with the following features:
- Weatherproof frame and housing galvanized
models
- weather protected, vibration damped installation of
the compressor in the housing.
- weather-protected assembly of the switchgear
cabinet in the housing
- elimination of the wearing part - axial face seal -
through use of semi-hermetic compressors
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PRODUCT INFORMATION
AMMONIA - LIQUID CHILLERS
DESCRIPTION OF MAIN COMPONENTS
SERIES DX LFKA
- short seal lengths in the evaporator
- Minimum amount of connection points by
a simple coolant cycle
- All refrigerant-carrying lines are safely mounted.
- oil is led through a closed cycle (dry evaporation)
- bypass line from the pressure line to the suction
line with back pressure independent bypass valve
for the compressor
- low coolant filling amounts per kW of coolant
performance by the evaporation in pipes of small
diameters and simple system switch
- Stored-program control and monitoring.
TECHNICAL DESCRIPTION DX LFKA
The air-cooled liquid chiller units of type LFKA are
completely factory-made and tested automatic single-
step refrigerating systems of compact design with
reciprocating stroke compressor. They are specifically
designed for ammonia (NH3, R 717) refrigerant
service and outdoor installation.
Equipped with the Grasso reciprocating piston series,
the DX LFKA range covers the refrigeration range of
83 to 356 kW for cold water.
Capacity is automatically adjusted by internal control
facilities which shut down compressors/cylinders in
steps to suit refrigerating loads. The packages can be
transported in an assembled state.
The liquid coolant units are produced according to the
valid European pressure device regulation (PED) and
labelled with the CE sign.
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 PRODUCT INFORMATION
Grasso
Air Treatment and
Refrigeration Division AMMONIA - LIQUID CHILLERS
DESCRIPTION OF MAIN COMPONENTS
SERIES DX LFKA

LABELLING SCHEME DX LFKA (exterior installation and ambient motor temperature -

25°C to +55°C).
Example: DX LFKA 250. 2- 11 K 75 The fans are speed-controlled or turned on/off by an
electronic step switching mechanism as a function of
DX series dry evaporation the condenser pressure.
LFKA Air cooled liquid coolant unit for the coolant A super-cooling cycle and a register for the glycol
ammonia recooling has been integrated into the condenser.
250. power rating of the unit in kW
2 compressor semi-hermetic EVAPORATOR
1 No. of compressor per chiller (for a closed water cycle)
1 No. of refrigerating circuit per chiller
K climate temperature range Heat is removed from the cooling water or brine, which
75 is thereby cooled, in the evaporator by way of
nominal motor power in kW
evaporation and superheating of the refrigerant. The
evaporator works on the principle of internal
evaporation with a thermostatically controlled injection
COMPRESSOR/DRIVE
of the refrigerant. This principle permits the use of
small amounts of refrigerant, reliable oil reflux
The compressor draws coolant formed vapour from
throughout the entire temperature and output range as
the evaporator, compresses and transfers it to the
well as simple adjustment of the superheating with the
condenser.
help of incorporated instruments to measure the
Compressors used are semi-hermetic single-action
temperature and pressure.
multi-cylinder piston compressors, cooled by suction
The tube bundle evaporator has a steel tube bundle.
gas, and semi-hermetic motors free from non-ferrous
Plastic baffles ensure high heat transfer efficiency.
metals designed for ammonia.
A manifold uniformly distributes the mixture of liquid
The compressors have the following features:
and gaseous refrigerant to the large number of tubes
after injection.
• starting load-relief
The suction pressure and coolant outlet temperatures
• power controlled by cylinder switch-off
are monitored so that a safe protection against
• differential oil pressure switch
freezing exists during the running of the unit.
• oil sump heating
The evaporators are provided with weather-resistant
• glycol cooled cylinder and housing cover
insulation. If water is used as refrigerating agent,
freezing can occur at sub-zero temperature. The
The pressure creation equipment, which has been
evaporator jacket can be heated on request. Design
tested in terms of safety technology, is in serial form
and production is carried out according to the
as per EN 378, with bypass valves in connection with
European pressure device regulation (PED).
the TÜV tested safety pressure limiters DBK. To
prevent overheating, the compressed gas temperature
INJECTION CONTROL
is monitored for each compressor.
The purpose of the injection control is to reduce the
CONDENSER
pressure of the liquid refrigerant from the condenser
from condenser pressure to evaporator pressure.
In the condenser the compressed refrigerant vapour is
The injection control ensures optimum utilization of
heated, liquefied and super cooled by dissipating the
evaporator capacity. This prevents the compressor
energy absorbed in the evaporator and compressor to
from taking in liquid refrigerant.
the heat carrier (heating).
A solenoid valve and filter are installed upstream from
The air-cooled condensers have a self-supported,
the expansion valve.
galvanized and painted housing with individual fan
shutters.
The heat transfer tubes are galvanized outside and
have aluminium ribs.
The fans are low-noise axial-mounted type.
The ventilators are operated by external rotary motors
of a maintenance free, weather proof construction

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Grasso
Refrigeration Division
DESCRIPTION OF MAIN COMPONENTS
VALVES AND FITTINGS
To guarantee service and maintenance work:
- in the compressed gas line between the compressor
and condenser,
- between condenser and filter in the liquid line,
- optional in the suction line between the evaporator
and compressor
installed manual stop valves or closable check valves.
A cleanable suction filter accommodated on the
compressor protects the same from impermissible dirt.
SWITCHING CABINET
This is a standard feature in the DX LFKA series and
consists of a control and power section.
Standard version control section
- stored-program control (SPC);
- digital outputs (potential-free contacts) for:
internal
• compressor motor and solenoid valve capacity
control
external
• coolant pump control
• group alarms
• ready status
- digital inputs (potential-free contacts) for
internal
• safety device evaluation
external
• message coolant pump
• remote control
• flow control, can be looped in
- analog inputs for
internal
• temperature and pressure recording
- operating panel with
• function keys for manual/automatic operation,
etc.
• keys for calling fault reports/messages, altering
control parameters, updating dates/times,
programming time-switch clocks, acknowledging
faults when repaired, input/output status
• four-line display for 20 characters/line
- display for ON/OFF, alarm, menu selection
- pressure controller designed for condenser as
rotation controller or electronic step switching
mechanism for the axial ventilators.
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PRODUCT INFORMATION
AMMONIA - LIQUID CHILLERS
SERIES DX LFKA
SPC functions:
- control of coolant inlet temperature
(or –outlet temperature) in automatic mode;
- restart following power failure (but not faults)
- monitoring of
• compressor motor switching frequency
• Temperature: compressed gas/motor winding
• overpressure, low pressure, differential oil
pressure
• coolant outlet temperature
- Display of these operating conditions:
• high/suction/oil pressure
• Operating hours
• coolant outlet (or inlet) temperature
• operating mode
• unit fault as group fault signal, individual fault
signal to be displayed via keyboard
• chiller capacity utilization
• non-fulfilment of starting conditions
Standard version power section
Major components:
- main switch, emergency stop switch
- fuses, full motor protection, over current relay
- protection combination for the star delta start of
the compressor drive motor and ventilator drive;
- Power consumption of pump cylinder head
cooling and compressor oil heating
Optional version control section (on request)
- Remote adjustment of set point
• switchover to 2nd operating point (digital input,
potential free)
• sliding adjustment of set point (analog input, 4
- 20mA or 0-10V)
- load limitation and load shedding by motor
current monitoring
- coolant outlet temperature recording;
- recording of other operating conditions (on
request)
- Serial interface
• Linking control systems of equal type
• Linking with external systems, Profibus
Optional version power section
- Power switch used as main switch
- external emergency stop, can be looped in
- direct starting
- Modem for remote diagnosis
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 PRODUCT INFORMATION
Grasso
Air Treatment and
Refrigeration Division AMMONIA - LIQUID CHILLERS
DESCRIPTION OF MAIN COMPONENTS
SERIES DX LFKA

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 2
MAIN DATA
Table of contents

Main Data

Technical data DX LFKA..... ...................................................................................................................... Page: 3

Part load behaviour during constant air intake and coolant outlet temperature ....................................... Page: 4
Operating limits ................ ...................................................................................................................... Page: 5
Acoustic values ................ ...................................................................................................................... Page: 5

Leading dimensions

Liquid chiller Type DX LFKA ...................................................................................................................... Page: 6

Power definition

Regulations for the selection...................................................................................................................... Page: 6

R + I Scheme

Circuit diagram DX LFKA .... ...................................................................................................................... Page: 7

Identification of the main components and armatures ............................................................................... Page: 8

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

! Variation in coolant and heat carrier temperatures can lead to changes in the heat exchanger and motor
classification and therefore to different technical data.

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

TECHNICAL DATA
DX LFKA
AIR CONDITIONER MODEL

Type
100.2-11 120.2-11 150.2-11 180.2-11 210.2-11 250.2-11 350.2-11 400.2-11
DX LFKA
Refrigerating
1) kW 78 104 127 152 175 201 284 356
capacity Q0
Power
consumption kW 22.5 29 36 44.5 51 58.5 70.7 85.2
1)
Compressor Pkl
Empty weight
kg 2596 2752 3029 3204 3403 3665 4099 4606
mL
Operating
kg 2665 2826 3103 3290 3490 3774 4224 4753
weight mB
Refrigerant
filling amount kg 18 23 23 27 27 34 34 41
NH3
Oil filling
l 11 11 11.5 11.5 12.2 12.2 32 32
amount VOIL
Coolant content
l 33 33 33 40 40 52 52 62
max. volume
m³/h 39 39 39 39 39 56 67 122
current Coo.VKmax
Coolant
2) DN 80 80 80 80 80 100 100 100
Connections
Ventilator
condenser pcs. 2 2 2 2 4 4 4 6
amount
Air throughput
m³/h 32500 40300 51100 54800 69800 76700 105200 140600
Condenser
Nominal rating
kW 0.67 1.2 2.2 2.2 2 2 3.6 3.6
per fan motors
Ventilator speed
1Min 380 520 650 650 880 880 890 890
Continuous
yes yes Yes yes no no no no
speed regulation
Electrical step
no no No no yes yes yes yes
switch board
Grasso Grasso Grasso Grasso Grasso Grasso Grasso Grasso Grasso
Type
compressor 37 47 57 67 77 87 58 68
Power steps 100-80- 100-67- 100-86- 100-75- 100-80- 100-83-
% 100-66 100-50
LS 40 33 57-28 50-25 40 67-50-33
Electrical data –1
Compr. motor 1500 min , 400 V / 3 Ph / 50 Hz3), IP 54, suction gas cooled
Nominal
kW 30 30 45 45 55 55 75 75
performance Pn
Nominal current
A 59 59 88 88 107 107 146 146
by 400 V In
Relative starting
5.1 5.1 5.4 5.4 4.9 4.9 5.4 5.4
current 4) Ia/In
Part load data can you take from the software WinChillcalc.

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

Type
100.2-11 120.2-11 150.2-11 180.2-11 210.2-11 250.2-11 350.2-11 400.2-11
DX LFKA
Switching
cabinet 3 PEN / 400 V, internal control voltage: 230 V / 50 Hz / 24 VDC
power input
Input profile 2
mm 50 50 95 95 95 95 150 150
Primary fuse
A 125 125 200 200 200 200 250 250

1) t K1/K2 = 12 / 6 °C; t (air) infiltration= 32 °C

2) Connection flange for coolant according to DIN 2633 (corresponds to ISO PN 16)
3) Euro voltage area ±10%, other voltages / frequencies upon demand
4) for Y - ∆ − start, the starting values are reduced to 1/3

PART LOAD BEHAVIOR FOR CONSTANT AIR INTAKE AND COOLANT OUTLET TEMPERATURE

DX LFKA
for tK2 = 6°C and tLe = 32°C; VK, = const. Accordingly full load value for tK = 12/6°C; LS = power step

DX LFKA
Stage 100.2-11 120.2-11 150.2-11 180.2-11 210.2-11 250.2-11 350.2-11 400.2-11
proportions in %
LS 100 100 100 100 100 100 100 100
1 Q0 100 100 100 100 100 100 100 100
PKl 100 100 100 100 100 100 100 100
LS 67 75 80 67 86 75 66 86
2 Q0 72 79 84 73 89 79.9 72.3 88
PKl 69 76.3 80.8 69 86.6 76.2 68.8 86
LS 50 40 33 57 50 33 57
3 Q0 56 46 40 64.6 56.9 39 62.7
PKl 53.7 44.8 39 68.2 53.6 38 59.8
LS 28 25 28
4 Q0 35.5 30.5 33
PKl 36 32.3 35

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

OPERATING LIMITS ACOUSTIC VALUES

The liquid ammonia cooling unit of the series DX Type sizes Total acoustic Acoustic level
1)
LFKA for dry evaporation can be operated within the DX LFKA pressure level
application limits according to the respective
specifications under diverse work conditions. The LP [dB(A)] LWA[dB(A)]
displayed application limits are based on the working 100.2-11 55.6 80.0
principle of the reciprocating compressor, the 120.2-11 59.0 85.2
thermodynamic relationships, and the applied 150.2-11 62.7 88.7
containers and safety facilities as well as the 180.2-11 62.7 88.7
practical application conditions. 210.2-11 64.4 90.0
250.2-11 64.4 90.0
function of 350.2-11 68.5 96.0
suction pressure p0 bar (a) 1)
pC
400.2-11 69.5 97.7
exhaust
temperature min 3 1)
Measurement distance 5m;
coolant water o. tK2 °C
air conditioner area in open space conditions
freeze resistant max 15
coolant
Max. volume see table
VKmax m³/h
current coolant techn. data
condensation function of
pc bar (a) 1)
pressure p0
inlet temperature min -10
tWE °C
ambient air max 35

1)
Compressor application limits are controlled by SPS.
Power calculations which have been done with
WinChillcalc, also take into account the compression
application limits.

Notes:

1. During tests of a certain application case, all the

conditions specified in the table must be
considered and adhered to.

2. If the specified limits are exceeded for a specific

application case, the producer must be
consulted.

3. In addition to the application limits that are stated

in the table, the operation conditions of the
respective compressor type that must be
adhered to must be considered as well (e.g.
start-up regime, oil pressure, oil quantity, oil type
etc.).

4. The specified data refer to the operating

conditions of a coolant or air condition system.
During the standstill or during the starting state a
short-time (never constant) exceeding or falling
short of the limit values.

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

LEADING DIMENSIONS DX LFKA

Type sizes leading dimensions

length width height
mm
100.2-11 4900 1685 2160
120.2-11 4900 1685 2160
150.2-11 4900 1685 2160
180.2-11 5500 1685 2160
210.2-11 4300 2385 2160
250.2-11 4900 2385 2160
300.2-11 4900 2385 2160
350.2-11 5700 2385 2160

REGULATIONS FOR THE SELECTION Input values: tK1 = tK1 – C1

1. The standard selection is done according to the
performance values in the overview table
"Technical Data“. Operation points can be
calculated with the software WinChillcalc.
2. The power values are based on a dirt factor in the
-4 2
evaporator of sf = 0,5x10 m K/W. For deviating
dirt factor, the input values tK1 and tK2 in
WinChillcalc must be corrected.
tK2 = tK2 – C1
3. The part load behaviour can be calculated with
WinChillcalc, considering the application limits.
4. Water or refrigerants can be used as coolants,
after their compatibility with the material
combinations of the evaporator and the pipe line
that is to be connected has been determined.

Dirt factor in Correction value

-4 2
10 m K/W C1 in K
0,5 0
1 1
2 3

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

CIRCUIT DIAGRAM DX LFKA

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
MAIN DATA
SERIES DX LFKA

IDENTIFICATION OF THE MAIN

COMPONENTS AND ARMATURES IN THE
CIRCUIT DIAGRAM

V1 reciprocating compressor
E1 oil sump heating
F1 suction filter
F2 filter injection pipe
G1 Oil-sight glass compressor
G2 sight glass in liquid line
M1 compressor motor
M2 motor condenser fan
M4 Motor glycol pump
Y1 bypass valve
Y2 safety valve
Y6 safety valve glycol circulation
B2 Pressure balance container glycol cycle
P2 Glycol pump
W1 Liquefier air cooled with glycol after cooling
registry
W2 Evaporator

A4 Evaporator coolant intake

A5 Evaporator coolant outlet
A21 Evaporator discharging
A22 Evaporator ventilation
A26 Evaporator connection

V12 check valve

V13 stop valve - liquid line
V21 service valve discharge line
V24 service valve injection line
V25 service valve liquid line
V41 service valve oil
V47 Stop valve (ventilation glycol cycle)
V48 Stop valve (filling/discharging glycol cycle)
V51 therm. expansion valve with temperature
sensor TC
V61 solenoid valve capacity control
V62 solenoid valve capacity control
V64 solenoid valve
PIC2 Pressure transmitter (P suction)
PIC4 Pressure transmitter (P oil)
PIC15 Pressure transmitter (P end)
PZA12 safety pressure limiter
PC16 Pressure transmitter for speed control or
step switching mechanism liquidiser
ventilators
PI20 Manometer (glycol)
TCA37 resistance thermometer
TIZA34 resistance thermometer
TIZA35 resistance thermometer - oil temperature
(Grasso 7 compressor)
TZA32 Thermal resistor "motor temperature“

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 3
INSTALLATION

Table of contents

Installation
Delivery ....................................................................................................................................................... Page: 3
Setup ........................................................................................................................................................... Page: 3
Coolant system ........................................................................................................................................... Page: 3
Water treatment .......................................................................................................................................... Page: 3
Water piping ................................................................................................................................................ Page: 3
Refrigerant piping........................................................................................................................................ Page: 3
Electrical installation.................................................................................................................................... Page: 3

Installation data
Foundation plan .......................................................................................................................................... Page: 4

Transport instructions
Transport instructions ................................................................................................................................. Page: 5

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
INSTALLATION
SERIES DX LFKA

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
INSTALLATION
SERIES DX LFKA

DELIVERY WATER TREATMENT

The liquid chillers are delivered with the protective gas
charge (nitrogen) in the refrigerant circuit.
The heat exchanger connections are closed. Check on
arrival for possible transport damage and report damage
in writing.
Protect chillers from damage, dirt and moisture during
longer periods of storage prior to setup/installation.
(check protective gas charge)
The compressor of the cold water unit has already
been filled with oil and the cycle for the
compression cooling with 34% glycol/water
mixtures.
INSTALLATION
Install the chillers on a level surface. Normally, the
units rest securely on the installation surface because
of their mass. The compressor is flexibly mounted on
a frame in the compressor box and coupled with it in
terms of by means of vibration technology. For higher
demands, vibration dampers can be devised for the
unit, and compensators for the cold water lines.
In order to enable the throughput of the necessary air
volumes and routine maintenance work, it is
necessary to provide free space around the unit. In
case the unit has to be installed in a low area, mount
it on a bracket in such a way that the ventilators are
above the building and a minimum distance of half a
device width is kept to the lateral edges. Material
leaking in the event of a fault must not get into the
ground or surface waters (Water resources law
WHG).
Unless otherwise required by local conditions, the
permissible ambient temperatures for operation are -
18 to +35 °C.
COOLANT SYSTEM
1. The evaporator must be connected to a closed
coolant system on the pressure side of the pump.
2. Arrange a dirt trap immediately upstream of the
evaporator. (recommended mesh size 1.25 mm,
upstream of solenoid/water valves 0.5 mm).
3. The coolant quantity should be constant.
Industrial water mostly contains dissolved or solid
components which cause corrosion or deposit or
encourage algal growth. The water for the evaporator
circuits should be treated chemically to reduce
undesired effects.
In order to avoid additional expense in maintenance
costs arising from the removal of dirt layers or the
exchange of corroding components, the coolant cycle
must be oxygen-free. By consulting a specialist water
treatment company, disadvantageous results can be
avoided to a great degree.
WATER PIPING
1. All pipes must be installed with flexible
connection separate from the unit.
Pipe connections on the unit must not be
exposed to additional static/dynamic loads.
2. Make sure that vibration can not be transmitted.
3. Provide charging/discharging facilities.
4. The pipe lines must be rinsed out before they are
connected. Soiling and welding beads must be
removed from the system.
REFRIGERANT PIPING
1. The units have been connected on the refrigerant
side and tested.
ELECTRICAL INSTALLATION
The liquid chiller has been designed for plug-in and
reliable automatic operation. All the connections inside
the unit have been wired as standard. The system
assemblers must connect only the power connection
and, if necessary, information lines and optional
devices externally. These lines must come from the
bottom and go through the condenser side box rear
wall.
1. All connections must exit according to the current
installation regulations.
2. Connections on the unit should be flexible and
must be free of loads.
3. Feed cross sections should be dimensioned to
DIN VDE 100 part 520.

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
INSTALLATION
SERIES DX LFKA

FUNDATION PLAN

Main operator side ( control board side )

Coolant connections for evaporator

Supporting surface of the set main frame

65 mm (frame profile width)

Drilling ∅ 14 mm

Air entrance condenser air exit upwards, the free space above the unit must be a minimum 4m

Air intake compressor box coolant

Air exit compressor box coolant

Free space for the air intake condenser

Free space for maintenance work and air intake of the compressor box coolant
Position of the sheet for throughput of power and information cables at the rear wall of the box
bottom.
Drilling for the power cable screws M63 x 1,5 available

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
INSTALLATION
SERIES DX LFKA

TRANSPORT INSTRUCTIONS

Lifting tackle:
4 sling bands with shackles
Sling bands to suit DIN 61360 and unit weights
Loops should be so arranged as to avoid damage to components when lifting the unit
1 - four strand suspension gear
2 - bracing pipe
3 - container hook for ISO container corner

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
INSTALLATION
SERIES DX LFKA

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 4
SPECIFICATION

Table of contents

Basic version....................... ......................................................................................................................... Page: 3

Technical data..................... ......................................................................................................................... Page: 5
Options ................................ ......................................................................................................................... Page: 6

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA – LIQUID CHILLERS
SPECIFICATION
SERIES DX LFKA

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
SPECIFICATION
SERIES DX LFKA

LIQUID CHILLER WITH SEMI-HERMETIC RECIPROCATING COMPRESSORS

Type: DX LFKA

1 Basic version (standard)

1.1 Scope of supplies

- self-contained factory-tested compact unit with control/power cabinet

- components, features, workmanship to Grasso standards
- suitable for outside installation, operating limits t air = -18 °C to +35 °C;
- fully automatic operation, capacity control in several stages
- equipment as per safety guidelines: EN378, pressure device guidelines, VDE;
- without refrigerant charge, with inert gas charge and oil charge;
- color code for unit: pebble gray RAL 7032;
- documentation: 2 copys (English)

1.2 Description of main components (for 1 DX LFKA)

1.2.1 Housing
- weatherproof, galvanized and painted, access via a door or elements with quick locking mechanism;
- ventilated through accoustic baffles;
- mounted on base frame;

1.2.2 Compressor
- one-step, liquid cooled reciprocating compressor with semi-hermetic, generator gas cooled
built-in motor as well as oil sump heating, suction filter, pressure gas control, oil pressure difference
monitoring;
- vibration-isolated installation, separated by means of vibration technology with flexible pipe connections;
- start load alleviation and power level guidelines by on-demand supply and cut-off to cylinders;
- safety switch gear according to EN 378, with component-tested and back-pressure independent discharge
valve, safety limiter DBK;
- compressor cooling connected internally with air-cooled glycol cooling register;

1.2.3 Motor
- non-ferrous metal free, semi-hermetic built-in motor, 4 pole, with coil protection;
- star-delta starting
- enclosure IP 54

1.2.4 Drying evaporator for closed refrigerant circuit

- pressure tank as per pressure device guidelines, with safety valve;
- with CE label, other certification on request;
- pipe bank structure, heat transfer agent pipes rolled-in in tube sheet;
- heat transfer agent pipes made of steel;
- connection facilities made of durable synthetic material;
- weather-resistant low temperature insulation, sheet metal covering;
- Options (additional price) frost protection heating of the evaporator jacket, thermostatically controlled;
- operating pressure: 17 bar on refrigerant side, 10 bar on coolant side

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA – LIQUID CHILLERS
SPECIFICATION
SERIES DX LFKA

1.2.5 Condenser
- condenser block of self supporting construction with distribution and collection system, casing and feet;
- galvanized steel heat transfer pipes, with aluminium ribs;
- axial ventilator with contact protection grid, low-noise with maintenance-free three-phase A.C. motor,
enclosure: IP 54, with thermal contacts for motor protection;
- control of the condenser pressure by the ventilator switch with electronic stage switching device or
speed regulation (LFKA 100 to 180);
- operating pressure on refrigerant side: 25 bar;

1.2.6 Refrigerant circuit

- pipeline of steel design, production side pressure and tightness tested as well as dehumidified;
- fittings: stop valve - compressors discharge side, stop valve - liquid line, filter and sight glass in
the liquid line, solenoid valve evaporator injection, expansion valve, service valve;
- diffusion tight, single layer flexible low temperature insulation of the main and injection pipe;

1.2.7 Control/power cabinet

- completely wired, protection level IP 54;
- internal control voltage / frequency: 230V/50 Hz
- lead-in for power supply and client’s control lines from below
- cubicle door with pocket for diagrams showing circuitry and terminals

1.2.7.1Control section
- stored-program control (SPC)
- digital outputs (potential-free contacts) for:
• coolant pump
• collective faucollective fault signals
• ready status
- digital inputs (potential-free contacts) for
• coolant pump feedback
• remote control
• flow control, can be looped in
- operating panel with
• function keys for manual/automatic operation, etc.
• keys for calling up fault reports/messages, changing control parameters, updating
date/time, programming time-switch clocks, acknowledging faults after
repair, input/output status
• four-line display for 20 characters/line
- LED display for ON/OFF, alarm, menu selection

SPC functions:
- control of coolant outlet (or inlet) temperature in automatic mode
- automatic restart following power failure (but not faults)
- monitoring of
• compressor motor switching frequency
• motor current
• Temperature: compressed gas, motor windings
• overpressure, low pressure, differential oil pressure
• coolant outlet temperature

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA - LIQUID CHILLERS
SPECIFICATION
SERIES DX LFKA

- Display of these operating conditions:

• high/suction/oil pressure
• Operating hours
• coolant outlet (or inlet) temperature
• operating mode
• set fault as group fault signal, individual fault signal to be displayed via keyboard
• chiller capacity utilization
• non-fulfilment of starting conditions

1.2.7.2 Pressure controller for condenser

- triggering of the axial ventilators,
electronic stage switching device or speed regulation (LFKA 100 to 180);

1.2.7.3 Power section

- main switch, emergency stop button
- contactor combination, safety elements for compressor (star-delta) and ventilator drive;
- full motor protection and over current relays
- compressor oil heating power control
- power control (protective motor switch, contactor) for pump cylinder head cooling;

2 Technical Data (related to 1 DX LFKA) operating point

2.1 Evaporator
No. of evaporators pcs. 1
Unit refrigerating capacity Qo kW
Coolant inlet tK1 °C
Coolant outlet tK2 °C
Coolant volume flow rate VK m³/h
Coolant pressure loss dpK kPa
Cooling agents
connection coolant / flange DNK mm to be connected by client

2.2 Condenser
Condenser capacity QC kW
Air intake temperature tL °C
number of fan z pcs.
Air volume VL m³/h
Power consumption per fan PL kW
voltage / frequency fan motors U/f V/Hz
Ventilator speed nL min-1

2.3 Compressor (technical data per pc.)

Number pcs. 1
Type Grasso
Terminal power for tK2+ tL PKl kW
Load levels LS %
Compressor speed nV min-1

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 PRODUCT INFORMATION
Grasso
Refrigeration Division AMMONIA – LIQUID CHILLERS
SPECIFICATION
SERIES DX LFKA

2.4 compressor motor

Voltage/phases/frequency U/-/f V/Ph/Hz
Terminal power (maximum) PKl max kW
Nominal current IN A
starting current (star-delta) IA A

2.5 Package
No. of circuits pcs. 1
Capacity control TL %
Dimensions:
length L mm
width B mm
height H mm
Weights:
- transport weight mempty kg
- operating weight moper kg
- refrigerant charge mNH3 kg
- oil charge V Öl l
Sound pressure in a distance of 5 m LP dB (A)
in the free field

3 Options (additional price)

Replacement of standard components, if applicable also in the supply contract / extended scope of
supplies.

3.1 Evaporator
3.1.1 Material - heat transfer pipe (standard material: steel St 35.8)
3.1.2 WS 1.4404;

3.2 Refrigerant circuit

3.2.1 Gauge board for high/suction/oil pressure

3.3 Control section

3.3.1 Remote adjustment of set point
3.3.1.1 Sliding adjustment of set point (analog input, 4 – 20 mA or 0 – 10 V)
3.3.2 Serial interface;
3.3.2.1 Linking control systems of equal type
3.3.2.2 Linking with external systems, Profibus
3.3.3 Modem for remote diagnosis

3.4 Power section

3.4.1 Power switch used as main switch
3.4.2 External emergency stop can be looped in
3.4.3 Frost protection of heating evaporator, thermostatically controlled, installed and wired;

3.5 Accessories
3.5.1 Flow rate monitor for refrigerant (supplied loose for connection by client)
3.5.2 vibration dampers (loose supply).
No warranty is given for the adaptation to the building or the magnitude of the structure borne noise
influence. An acoustics expert / structural engineer should be consulted.

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