GEA Grasso 7S eration Reciprocating Compressors … Documents/Grasso...1 PARTS COMPRESSOR 1.1...

Reciprocating Compressors for industrial refrig-erationGEA Grasso 7S

Spare parts listpador9116-PL7_4

COPYRIGHT

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

LEGAL NOTICE

This publication has been written in good faith. However, Grasso cannot be heldresponsible, neither for any errors occurring in this publication nor for their conse-quences.

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SAFETY INSTRUCTIONS

Hint!

This manual must be carefully read and understood prior to installingand servicing the compressor (package)

General Safety

All service operations described in this servicemanual are only to be carried outby well-trained/qualified personnel and even then only after this service manualhas been read carefully and is fully understood.

Personal safety

Observe all (inter)national and/or local safety standards, measures and regula-tions during reinstalling, repairing and connecting the compressor (package).

Mechanical safety

If the compressor does not have to be removed from its base, it is advisable toput warning labels on vital parts of the compressor saying that the plant is out-of-operation and must not be started up.If the compressor has to be opened for service,the refrigerant has to be pumpeddown and the electric supply has to be cut off.After having run the initial 100 operating hours,it is essential (in both new andmodified plants) to replace the red running-in discharge oil filter element with thepermanent grey filter element. Also replace the running-in suction gas filter ele-ment.Check the direction of rotation is correct before re-starting the compressor.

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PREFACE

General

1. All documentation can be downloaded via our web site.

2. Grasso’s technical manuals includes “generic paragraphs”; this means that itcan occur that not all data as described is relevant for the current compres-sor series as mentioned in this manual. (For instance, not all compressor ser-ies are suitable for all mentioned refrigerants or not all compressor seriesincludes two-stage compressors)

Directives

Equipment is based on Pressure Equipment Directive (PED 97/23/EG) regula-tions and according to Machine Directive (MD 2006/42/EG) regulations.

The applied standards are:NEN-EN-IEC 60204, NEN-EN-ISO 12100, NEN-EN-ISO 13857, NEN-EN 378

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TABLE OF CONTENTS1 PARTS COMPRESSOR 91.1 Replacement piston rings and cylinder liners 91.2 Running-in oil filter has to be installed after an overhaul or big repair 101.3 ... 101.4 ... 131.5 ... 151.6 ... 171.7 ... 191.8 ... 211.9 ... 231.10 ... 251.11 ... 271.12 ... 291.13 ... 311.14 ... 331.15 ... 351.16 ... 371.17 ... 391.18 ... 411.19 ... 431.20 ... 451.21 ... 47

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TABLE OF FIGURESFig. 1 New honing profile and crosshatching with the right angle 9Fig. 2 Don't use new piston rings on old cylinder liner 10Fig. 3 COMPRESSOR HOUSING WITH CONNECTIONS 12Fig. 4 MAIN BEARING DRIVING END 14Fig. 5 MAIN BEARING OIL PUMP END 16Fig. 6 CRANKSHAFT 18Fig. 7 PISTON AND CONNECTING ROD 20Fig. 8 CYLINDER LINER AND VALVES 22Fig. 9 DISCHARGE VALVE DUMMY 24Fig. 10 OIL PUMP 26Fig. 11 OIL PRESSURE REGULATOR 28Fig. 12 CAPACITY CONTROL MECHANISM 30Fig. 13 OIL DISCHARGE FILTER 32Fig. 14 OIL SUCTION FILTER 34Fig. 15 SUCTION GAS STRAINER 36Fig. 16 DISCHARGE LINE 38Fig. 17 ROTOR 40Fig. 18 STATOR 42Fig. 19 44Fig. 20 Pressure relief valve 46Fig. 21 DISCHARGE LINE 48

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1 PARTS COMPRESSOR

1.1 Replacement piston rings and cylinder liners

Hint!

Recommendation/warning!For major overhauls or every repair where piston rings are beingreplaced it is strongly recommended to replace the cylinder liners aswell. This is very important for the next reasons:

For the best sealing between piston rings and cylinder liners, piston rings have torun in on the cylinder liner’s inner surface. Therefor a new cylinder liner with ahoning profile (crosshatching) in the best condition is absolutely required. Pistonrings cannot run in properly on worn out or partly worn out cylinder liners. Withouta decent honing profile no proper sealing between liners and rings can be ach-ieved which may result in- or contribute to a bad performance of the compressor.Further on, this honing profile with the right crosshatching is demanded for agood lubrication between piston rings and liners and for the right oil distributionon the liner’s inner surface.

Fig.1: New honing profile and crosshatching with the right angle

After being in operation for many running hours cylinder liners and piston ringswill wear out and most cylinder liners will become unworn ridges (bumper rims oredges) due to the displacement of the piston rings inside the liner. The upperunworn ridge occurs at the upper death end and upper side of the upper pistonring and the lower ridge occurs at the death end of the lower side of the lower (oilscraper) ring. In many cases intermediate and oil scraper rings cause their ownbumper ridges. (Bumper steps) Also, both upper and lower edge are set by theworn shape of the piston rings. This clearly explains why new piston rings canbreak when used in old/worn cylinder liners due to hitting the unworn bumperridges at high speed. (See also picture below)Therefor: Never install new pistons with new piston rings in old cylinder liners. Itis strongly recommended to replace the cylinder liners too.

PARTS COMPRESSORReplacement piston rings and cylinder liners

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Fig.2: Don't use new piston rings on old cylinder liner

N Shape of new piston ring (sharp)

O Shape of old piston ring (rounded)

1.2 Running-in oil filter has to be installed after an overhaul or big repair

Hint!

This is why and when the running in oil filters are required:

Warning

A running in oil filter has always to be installed after an overhaul orbig repair for the 1st 100 hours of operation!The oil and oil oil filters have to be replaced by new oil and filters.Due to running-in wear of liners and piston rings, it's normal that theoil becomes grey during the 1st 100 operating hours.After 100 operating hours, the oil could slightly become clear again.

1.3 ...

PARTS COMPRESSORRunning-in oil filter has to be installed after an overhaul or big repair

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PARTS COMPRESSOR...

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PARTS COMPRESSOR...

COMPRESSOR HOUSING WITH CONNECTIONS

Fig. 3 COMPRESSOR HOUSING WITH CONNECTIONS

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COMPRESSOR HOUSING WITH CONNECTIONS

Pos Description Dims. Item ref. Qty Remarks

1 CYLINDER HEAD COVER ASSY *

1.1a CYLINDER HEAD COVER GR 7-2 2336570

1.1b CYLINDER HEAD COVER GR 7-1 2336560

1.2 HEXAGON HEAD BOLT 10.9 M10x120(10.9)

0187512 2

1.3a GASKET 190x405x2CR

0907192

1.3b GASKET 190x405x1CR

0907191

2 CYLINDER HEAD COVER ASSY *

2.1 CYLINDER HEAD COVER GR 7-0 2336550

2.2 GASKET 190x405x1.5-OCR

0907190

3 HEXAGON HEAD BOLT 10.9 M10x100(10.9)

0187510 20

4 FLAT WASHER M10 1113501

5 CRANKCASE GR 7 * 1

6 GASKET 175x290x1.5

0907175 2

7 INSPECTION SIDE COVER 175x290 0530175 2

8 HEXAGON HEAD BOLT M10x40 0110540 32

9 O-RING 2.62x32.99 0952284 1

10 SIGHT GLASS 29x60 1224029 1


12 EYE BOLT M16 0118812 1

14 PLUG G13S 0136134 4

15 CRANKCASE HEATER 240V-200W

1372203 1 240V-200W

16 STOP VALVE TAH8-12 0607011 1

17 ORIFICE G13x3x20 0123139 2

18 PLUG G21 0136216 1

19 ALU SEALING RING 21x27x2 0914023 1

20 ALU SEALING RING 13.5x20x1 0912014 4

21 NIPPLE COUPLING 12G13 0338131 1

1.4 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

MAIN BEARING DRIVING END

Fig. 4 MAIN BEARING DRIVING END

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MAIN BEARING DRIVING END


1 BEARING COVER GR 7 AZ 2136165 1

2 BEARING BUSH 60x65x55 1146769 2

3 O-RING 3.53x158.34

0952364 1

4 O-RING 101.1x3.53 0952390 1 ex. 09.52.345

5 FLAT WASHER M10 1113501 8


1.5 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

MAIN BEARING OIL PUMP END

Fig. 5 MAIN BEARING OIL PUMP END

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MAIN BEARING OIL PUMP END


2 BEARING ASSY GR 7 * 1

2.1 PUMP HOUSING GR 7 *

2.2 O-RING 3.53x209.14

0952365 1

2.3 BEARING FLANGE 60x40xM10

1143652 1

2.4 SOCKET HEAD SCREW M10x100 0104510 4

3 FLAT WASHER M10 1113501 16

4 SOCKET HEAD SCREW M10X40 0104540 8

5 BEARING BUSH 60x65x22,5K

1146768 2

1.6 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

CRANKSHAFT

Fig. 6 CRANKSHAFT

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CRANKSHAFT


1.1 CRANKSHAFT GR 7 *

1a CRANKSHAFT SE GR 47 2236470 1

1b CRANKSHAFT SE GR 67 2236670 1

1c CRANKSHAFT SE GR 87 2236870 1

3 CARRIER DISC 60x5A 1125106 1

4 SOCKET HEAD SCREW M10x25 0104525 1

1.7 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

PISTON AND CONNECTING ROD

Fig. 7 PISTON AND CONNECTING ROD

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PISTON AND CONNECTING ROD


1 PISTON ASSY 85GR6 2436010 1

1.1 PISTON 85GR6H * 1

1.2 GUDGEON PIN 26x16x68R6

2436260 1

1.3 SAFETY RING * 2

1.4 PISTON RING SET 85GR6 0974084 1

2 CONNECTING ROD 60x170 2436510 1

2.1 CONNECTING ROD 170GR6 * 1

2.2 CONNECTING ROD BOLT MF8 0111401 2

2.3 LOCKING RING SET M8 1139400 2 in two pieces

2.4 HEXAGON NUT MF8x1 0147405 2

2.5 BEARING SHELL 60x65x19 1144360 1

1.8 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

CYLINDER LINER AND VALVES

Fig. 8 CYLINDER LINER AND VALVES

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CYLINDER LINER AND VALVES


1 SOCKET HEAD SCREW M10X40 0104540 4


3 PRESSURE RING GR6 2736410 1

4 SINUSOIDAL SPRING 87x125x4 1133087 1

5 DISCHARGE VALVE ASSY GR7S 2736114 1

5.1 LOCKING NUT M8 0145400 1

5.2 FLAT WASHER M8 1113401 1

5.3 DISCHARGE VALVE STROKE LIM-ITOR

RCA7S 2736270 1

5.4 SINUSOIDAL SPRING 64x76x0.5 * 1

5.5 DEMPERRING 64x76x1 * 1

5.6 DISCHARGE VALVE RING 64x76x1 * 1

5.7 SUCTION STROKE LIMITOR GR6 2736216 1

5.8 FITTED BOLT M8x45 0106445 1

6 DEMPERRING 108x87x4 * 1

7 SINUSOIDAL SPRING 88x108x0,7

* 1

8 VALVE RING 88x108x0,7

* 1

9 O-RING 3.53x117.07

0952362 1 ex. 09.52.385

10 CYLINDER LINER 85GR6 2336120 1

11 O-RING 3.53x91.67 0952361 1

12 DISCHARGE VALVE RINGS ANDSPRINGS

GR7S 1134111 1

13 SUCTION VALVE RING, SPRINGAND DAMPER RING

GR6/GR7 1134115 1

1.9 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

DISCHARGE VALVE DUMMY

Fig. 9 DISCHARGE VALVE DUMMY

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DISCHARGE VALVE DUMMY


1 FITTED BOLT M8x45 0106445 1

2 LOCKING NUT M8 0145400 1

3 DOWEL PIN 4x8 1106408 1


5 SUCTION STROKE LIMITOR DUMMY 2736220 1

6 DISCHARGE VALVE STROKE LIM-ITOR

RCA7S 2736270 1

1.10 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

OIL PUMP

Fig. 10 OIL PUMP

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OIL PUMP


1 PUMP COVER GR6 2636700 1

2 OIL PUMP ELEMENT GR6A 2636601 1

3 BEARING GR6x13.5 2636710 1


5 O-RING 3.53x209.14

0952365 3

6 O-RING 3.53x136.12

0952363 1

7 PUMP HOUSING Grasso 6 2637503 1

1.11 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

OIL PRESSURE REGULATOR

Fig. 11 OIL PRESSURE REGULATOR

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OIL PRESSURE REGULATOR


1 LUBRICATION OIL PRESSUREREGULATOR SET

2038118 1

1.1 ALU SEALING RING 10x18x1 0912010 1

1.2 ALU SEALING RING 33x39x2 0914033 1

1.3 O-RING 3.53x21.8 0955212 1

1.12 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

CAPACITY CONTROL MECHANISM

Fig. 12 CAPACITY CONTROL MECHANISM

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CAPACITY CONTROL MECHANISM


1 FLANGE GR6C 2736702 1 ex. 27.36.701

2 CYLINDER HEAD SCREW M4x10 0168210 4

3 PISTON CAPACITY CONTROL GR6 2736600 1

4 PRESSURE SPRING 1,25x10x11,5x64

1131133 1

5 PISTON FITTING RING 56x51.3x2 0970056 1



8 GASKET 87x94x1.5 0907087 4

9 CYLINDER CAPACITY CONTROL GR6 2736500 1

10 PISTON FITTING RING 40x36.6x2 0970040 1

11.1A VALVE BODY * 1

11.1B VALVE BODY * 1

11.2A VALVE COIL 110-120/50- 60

1316311 1 110-120V

11.2B VALVE COIL 220-240/50- 60

1316322 1 220-240V (ex. 13.16.022-13.16.023)

11A SOLENOID VALVE 110/120V * 1

11B SOLENOID VALVE 220FA 0680111 1 ex. 06.80.110/06.80.123

12a CONNECTOR DIN 1316610 1 DINWithout LED

12b CONNECTOR 220/240 VAC/DC,DIN incl.LED

1316611 1 DIN Neon 240V

12c CONNECTOR 24/48 VDC, DINincl. LED

1316615 1 48V

13 SOCKET COUPLING 6G10 0337106 1 Quantities per valve

14 SET SCREW M5x10 0123010 1

15 PLUG M8x1 0365708 5

16 O-RING 1,78x5,6 0952183 2

1.13 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

OIL DISCHARGE FILTER

Fig. 13 OIL DISCHARGE FILTER

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OIL DISCHARGE FILTER


1 FILTER SET GR6 0711900 1

1.1 O-RING 3.53x136.12

0952363 1

1.2 CONNECTING ROD 170GR6 * 1

2 LOCKING NUT M6 0145300 1

3 STUD M6x20 0151320 1

4 FILTER HOUSING 130 0702130 1



1.14 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

OIL SUCTION FILTER

Fig. 14 OIL SUCTION FILTER

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OIL SUCTION FILTER


1 STRAINER ELEMENT 0716164 1 149x16

2 SWIVEL COUPLING 16G21 0339216 1

3 FILTERELEMENT 0716190 1 JP

4 NIPPLE "G1/2""xG1/2"""

0304021 1

5 OIL RETURN LINE GR7S 4405930 1

1.15 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

SUCTION GAS STRAINER

Fig. 15 SUCTION GAS STRAINER

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SUCTION GAS STRAINER



2 GASKET 95x109x2 0904095 1


4 O-RING 5,3x250 0952552 1

5 RING FLANGE 175x133x6 0518176 1

6 SPARE PART KIT BRACKET FIL-TER

2000-B 0234119 1



9 HEXAGON NUT M16 0115810 8

1.16 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

DISCHARGE LINE

Fig. 16 DISCHARGE LINE

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DISCHARGE LINE


1a DISCHARGE LINE GR47S-HOR-R

* 1

1b DISCHARGE LINE GR67S-HOR-R

* 1

1c DISCHARGE LINE GR87S-HOR-R

* 1

2 HEXAGON HEAD BOLT M10x35 0110535

3 GASKET 82x82-PL 0907082

4 HEX. HEAD BOLT M12x50 0110650 4

5 GASKET 67x81x1.5 0903067 1

6 WELDING FLANGE 60B 0501060 1


8 PLUG G13S 0136134 2

9 ALU SEALING RING 13.5x20x1 0912014 2

1.17 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

ROTOR

Fig. 17 ROTOR

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ROTOR



2 LOCKING RING SET 13-ST-G.V.

1139600 3 in two pieces

3 WASHER 3xM12x85 1113685 1

4 ROTOR GR7 * 1

5 CLAMPING BUSH 1003-55-85

1916155 1

6 SEALING RING 60 2636560 1

1.18 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

STATOR

Fig. 18 STATOR

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STATOR


1a STATOR 30 kW * 1

1b STATOR 45 kW * 1

2 O-RING 7x437 0952744 1

3 FLAT WASHER M16 1113801 20


1.19 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

STANDARD SETS OF PARTS

Fig. 19

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STANDARD SETS OF PARTS


1a GASKETS (SET) RC46/GR47

0990046 1

1b GASKETS (SET) GR66/GR67

0990066 1

1c GASKETS (SET) RC86/GR87

0990086 1

2 DISCHARGE VALVE RINGS ANDSPRINGS

GR7S 1134111

3 SUCTION VALVE RING, SPRINGAND DAMPER RING

GR6/GR7 1134115

4 SET OF SPARE PARTS GR6/GR7 2036011 1

1.20 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

Pressure relief valve

Fig. 20 Pressure relief valve

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Pressure relief valve


1 RELIEF VALVE GR7S-25-DO

4827125 1

2 GASKET 50x65x1.5 0903050 1


1.21 ...

PARTS COMPRESSOR...

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PARTS COMPRESSOR...

DISCHARGE LINE

Fig. 21 DISCHARGE LINE

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DISCHARGE LINE


1 DISCHARGE LINE GR 7 * 1


3 GASKET 82x82-PL 0907082


5 GASKET 67x81x1.5 0903067 1


7 ALU.SEALING RING 0914017 2 ex. 09.13.018

8 PLUG G13S 0136134 2

PARTS COMPRESSOR

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GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX® Europe 600 Index.

We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity

GEA RefrigerationGEA Refrigeration Netherlands N.V.Parallelweg 255223 AL ‘s-Hertogenbosch,Netherlands

Phone +31 (0)73 6203 911

[email protected] gea.com

GEA Grasso 7S eration Reciprocating Compressors … Documents/Grasso...1 PARTS COMPRESSOR 1.1...

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Transcript of GEA Grasso 7S eration Reciprocating Compressors … Documents/Grasso...1 PARTS COMPRESSOR 1.1...