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Reciprocating Compressors for industrial refrigerationGrasso 8S

Installation and Maintenance Manual0089296gbr_3

COPYRIGHT

All Rights reserved. No part of this publication maybe copied or published by means of printing, photo-copying, microfilm or otherwise without prior writtenconsent of Grasso.This restriction also applies to the correspondingdrawings and diagrams.

LEGAL NOTICEThis publication has been written in good faith. How-ever, Grasso cannot be held responsible, neither forany errors occurring in this publication nor for theirconsequences.

Installation and Maintenance Manual | Grasso 8SReciprocating Compressors for industrial refrigeration

2 GEA Refrigeration Netherlands N.V. | 0089296gbr_3 | Created 25.04.2016

SAFETY INSTRUCTIONSHint!

This manual must be carefull read andunderstood prior to installing andservicing the compressor (package)

Safety

This manual is written with great care, but the con-tractor/installer is held responsible to examine thisinformation and to take care of possible additionaland/ or deviated safety measures.

Safety instructions

It is the task of the contractor/installer to inform andexplain to his client the operation of the compressor(Package).Do respect all federal, state or local safety regula-tions/legislations during installing, connecting andoperating this compressor (package).

Construction changes

Warning!

In compliance with the regulations ofthe Pressure Equipment Directive it ismandatory that no changes be madeto the construction of pressurisedparts such as the crankcase housing,suction filter housing etc.

Installer oriented information

The compressor (package) is filled with nitrogen toprevent penetration of moisture. Therefore, keep thecompressor closed until the compressor (package) isbeing installed.

Warning!

The compressor is not filled with oil.

Hint!

After the successful initial run of thecompressor (package) the warrantychart must be filled in and returned toGrasso. A warranty chart is attachedto each compressor.


GEA Refrigeration Netherlands N.V. | 0089296gbr_3 | Created 25.04.2016 3

PREFACE

General

1. All documentation can be downloaded via ourweb site.

2. Grasso’s technical manuals includes “genericparagraphs”; this means that it can occur thatnot all data as described is relevant for the cur-rent compressor series as mentioned in thismanual. (For instance, not all compressor seriesare suitable for all mentioned refrigerants or notall compressor series includes two-stage com-pressors)

Directives

Equipment is based on Pressure Equipment Direc-tive (PED 97/23/EG) regulations and according toMachine 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



GENERALINFO

Description Value Remark

Start frequency max. 6 starts perhour

Time interval between stopping andre-starting min. 2 minutes

Time interval between starting andre-starting min. 10 minutes

Time interval between loading andunloading min. 3 minutes

For continuous minimum part-load (i.e. morethan30 minutes) consult Grasso.

Adjust the steps between up and down loading, insuch a way that the system is running stable.

Oil level 25-75% crankcasesight glass

Min. oil temperature ≥ surroundings AND≥ 20 °C

Max. oil temperatureRefer to oil selectiontable/applied type of

oil

Required oil viscosity;≥ 10 cSt during operation at location of bearings

Lubricating oil pressure difference Setting approx. 2.5bar Oil temperature approx. 60 oC

Max. discharge temperature +155 °C

Min. suction pressure 0.3 bar (a)

Max. suction pressure 8.5 bar (a)

Pdischarge - Psuction ≤ 25.0 bar

Superheat >0 K

Cooling water inlet temperature ≤ Tc - 7 K

Direction of rotation of compressordrive shaft

Initially both direc-tions are allowed

Normally counterclockwise when facing shaft endof the compressor, both directions are possible

Warning!

After initial run, never change thedirection of rotation anymore.



Description Value Remark

Running-in suction gas filter

Hint!

Factory mounted; to be replacedafter max. 100 running hours by

permanent filter

Permanent suction filterSupplied loose; Replacement for factory mounted

running-in filter; To be mounted after max. 100running hours



TABLE OF CONTENTS1 INSTALLATION AND PREPARATION FOR USE 9

1.1 Running-in oil filter has to be installed after an overhaul or big repair 91.2 INSTALLATION 9

1.2.1 Moving instructions and storage 91.2.2 Storage 91.2.3 Hoisting and moving instructions 101.2.4 Required free space 101.2.5 Connecting to refrigerating system pipework 101.2.6 Connecting the power supply 111.2.7 Earthing connections 111.2.8 Separately delivered components 11

1.3 PREPARATIONS FOR USE 121.3.1 Leak test of compressor and system 121.3.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 121.3.3 Initial oil charge 12

1.3.3.1 Initial oil charge Grasso 8S 121.3.4 Initial refrigerant charge 131.3.5 Adjustment of instruments and safety devices 13

1.3.5.1 Pressure safeties 131.3.5.2 Re-adjustment of oil pressure regulator 13

1.3.6 Check power supply 141.3.7 Initial oil warm up 141.3.8 Initial start-up 14

1.3.8.1 Limitations of part load operation and start-up 141.3.8.2 Frequency controlled compressor 141.3.8.3 Pre-start check list 14

1.3.9 Starting and stopping procedures 141.3.9.1 First start 151.3.9.2 Restart 151.3.9.3 Restart after a short standstill period of time (less than 1 month) 151.3.9.4 Restart after a long standstill period of time 151.3.9.5 Stopping the compressor 15

2 INSPECTION AND TROUBLE SHOOTING 162.1 Periodical inspection 162.2 Survey of periodical inspections 16

2.2.1 CHECK LIST PERIODICAL INSPECTIONS 162.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 172.4 LUBRICATION DATA 17

2.4.1 Topping up oil with compressor operating 172.5 EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE 18

2.5.1 EVACUATION OF REFRIGERANT BEFORE SERVICING 182.5.2 LEAK-TIGHTNESS AFTER SERVICING 182.5.3 EVACUATION AFTER SERVICING 182.5.4 START-UP AFTER SERVICING 18

2.6 DRAINING AND CHANGE OF OIL 182.7 OIL SUCTION AND DISCHARGE FILTERS 192.8 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 192.9 COMPRESSOR PURGING 192.10 TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS 20

3 MAINTENANCE 233.1 Post start-up maintenance 233.2 First maintenance 233.3 SMS FACTOR 233.4 Legend 23

3.4.1 Grasso 7S and Grasso 8S 253.4.2 Checklist 27



1 INSTALLATION AND PREPARATION FOR USE

1.1 Running-in oil filter has to be instal-led after an overhaul or big repair

Hint!

This is why and when the running inoil filters are required:

Warning!

A running in oil filter has always to beinstalled after an overhaul or big repairfor the 1st 100 hours of operation!The oil and oil oil filters have to bereplaced by new oil and filters.Due to running-in wear of liners andpiston rings, it's normal that the oilbecomes grey during the 1st 100 oper-ating hours.After 100 operating hours, the oilcould slightly become clear again.

1.2 INSTALLATION

Warning!

The compressor is not charged withoil, therefore, DO NOT start the com-pressor before it has been installedand prepared according to Grasso’sinstructions.

This section contains instructions for the properinstallation of a Grasso compressor (package).Before the compressor (package) is ready for the ini-tial start up, the installation instructions in the follow-ing paragraphs must be followed:

1. The Compressor (Package) should be levelledand securely anchored to the foundation.

2. All piping should be completed.

3. The system and the compressor are to be pres-sure tested for leaks (see. Section 1.3.1,Page 12)

4. The system should be evacuated to remove airand moisture.

5. The electric wiring should be completed as perwiring diagrams. Do not energise the main powercontrol cabinet until oil is added and the directionof rotation has been checked.

6. The compressor is to be filled with the correcttype and amount of lubricating oil and has to bepre-lubricated (Refer ) before the first start.

7. ‘Open compressors’ only;

7.1 Open compressors;The drive system should be installed.

7.2 (Semi) hermitic compressors;Mark R-S-T-N power supply in the terminalbox of the motor.

8. The system should be charged with the correctamount of refrigerant.

9. The oil should be warmed up above minimumstart up oil temperature (see "Product Informa-tion").

10. The control cabinet should be energised tocheck the package controls.

Hint!

Do not forget to charge the oil separa-tor (if present) initially with oil, to thelevel of the float assembly

1.2.1 Moving instructions and storage

For loose component or compressor packageweights, refer either to the relevant component typeplate or package lay-out or to the suppliers docu-ment. For bare compressor weights, see "ProductInformation".

Caution!

Every precaution must be taken whilemoving the package to its final loca-tion. Pushing, pulling or climbing onany package component or piping, caneasily create damage.

1.2.2 Storage



The compressor (package) is filled with dry nitrogen.Keep the system closed until the package is instal-led. If the compressor (package) is stored, it shouldbe kept at all times in a dry location to prevent corro-sion damage. If the compressor (package) is to bestored for a prolonged period of time, it should bechecked weekly to ensure that the holding charge ofdry nitrogen remains above atmospheric pressure.

1.2.3 Hoisting and moving instructions

Warning!

DO NOT use the compressor hoistingeyes to move the complete package!These hoisting eyes are intended forlifting loose compressor only!

Bare compressor or loose components:

Determine the dead weight of the particular compo-nent (see "Product Information"), prior to moving abare compressor or loose component. Use the hoist-ing eyes only, DO NOT sling from other compressorparts (see Figure 1, ).

Fig.1: Hoisting eyes compressor (pos. 1)

Moving by fork-lift truck (Not advised!)

The bare compressor can be transported with a fork-lift truck with the forks spread as much as possiblebetween the skids. To simplify moving, the 2 woodentransport beams must still be mounted underneaththe compressor foots and stored in this way, until thecompressor is positioned above its permanent loca-tion.

1.2.4 Required free space

For easy operating, servicing and maintenanceaccess, the compressor (package) should be instal-led with sufficient free space around it.

Hint!

Refer to “Product Information“ forminimum requirements.

1.2.5 Connecting to refrigerating sys-tem pipework

Warning!

DO NOT ground through the compres-sor when arc welding

After the compressor (package) has been levelledand secured to the foundation, the system pipingmay be connected. The suction line(s) and dischargeline(s) should be installed and supported such thatthere is no load exerted on the compressor. The sizeand location of the suction and discharge connec-tions, can be found in the "Product Information" (barecompressor) and in case of a package, the packagelay out drawing.

Hint!

If an oil rectifier system is applied inthe refrigeration system, the oil returnline must be connected to the oilreturn connection (see "Product Infor-mation").

Suspension of system pipework

To eliminate vibration transmission to the systempiping, the following is recommended:

• Install all piping free of tension.



• Secure the piping by clips or brackets in twodirections.

• Install (stop) valves, piping and accessoriessuch, that there is no load exerted on the com-pressor.

1.2.6 Connecting the power supply

Information about further electrical connections to bemade (e.g. crankcase heater, drive motor startingequipment, thermal protection of drive motor, auto-matic start/ stop and other external electrical devi-ces) can be found in the plant manual (not suppliedby Grasso).

1.2.7 Earthing connections

Grasso compressors and packages are equippedwith litz-wires and earth connecting points.To avoid leakage current flowing through the compo-nents, disconnect all litz-wires when arc-welding.After all installation functions are completed, recon-nect the litz-wires and ground the package to earth.

1.2.8 Separately delivered components

Hint!

Check whether the sets/parts/compo-nents belonging to this compressorare supplied loose! (Refer to orderconfirmation)

Mount these separately delivered sets, componentsand/or parts, according to the instructions as sup-plied with this compressor (package).



1.3 PREPARATIONS FOR USE

After the Compressor (Package) has been installed(excluding final connection of drive device), the fol-lowing actions should be followed in the order given:

1.3.1 Leak test of compressor and sys-tem

The compressor (package) has been pressure testedprior to leaving the factory. In case an additional leaktest is required, this test is should be carried out withdry nitrogen.

Hint!

DO NOT add oil to the compressorprior to pressure testing

A system leak test should be carried out over 24hours to ensure that the system is tightly sealed.Record during the pressure test, the pressure, ambi-ent temperature and outside temperature. During theinitial 6 hours a pressure drop of 2% is permissable.With respect to temperature variations, no furtherpressure loss should be detected in the remaining 18hours.

1.3.2 EVACUATION/DRYING THEREFRIGERATING SYSTEM

For evacuation of compressor only, refer to Sec-tion 2.5, Page 18

Procedure to evacuate and to dry a system:

i. STATUS: System is filled with nitrogen and nooil has been added (oil prevents any trappedmoisture from boiling off).

ii. Verify that all valves in that part of the systemto be evacuated are opened (refer also to theplant manual).

iii. Connect vacuum pump to the evacuation/purg-ing valve(s) of the compressor (for location ofthese valves refer to the "Product Information"or to a connection as mentioned in the plantmanual and evacuate the system to approx. 6mBar.

iv. Break vacuum by charging dry nitrogen into thesystem.

v. Repeat step iii, "Connect vacuum pump ...".

vi. Wait approx. 24 hours.

vii. If pressure has increased (system still containsmoisture), repeat steps iv, and vi. Otherwise,continue with the "Initial oil charge" procedure.

1.3.3 Initial oil charge

Warning!

Oil charging via the suction line of thecompressor is not allowed.Used or filtered oil should NEVER BEadded to a compressor under any cir-cumstance.Use only new oil as selected from theGrasso oil table. (Refer )

Procedure:

i. STATUS: System is dried and still evacuated.

ii. Charge the oil separator (if present) initiallywith oil .

iii. Close suction and discharge stop valves ofcompressor and oil return line of oil separator(if present).

iv. Charge the compressor crankcase with oil viathe oil charge valve.

Warning!

Pre-lubrication just before the firststart is obligatory.

Hint!

Filling of the afore mentioned compo-nents is also possible by means of aseparate oil filling pump via the oilcharge valves mounted onto the oilpump housing.

1.3.3.1 Initial oil charge Grasso 8S



QUANTITY OF OIL TO BE FILLED (IN dm3)

Number ofcylinders

Internal cir-cuit of

crankshaft

Oilfil-

ters

Oilpump

Crank-case

50.5 1.5 0.5 17.7

6

1.3.4 Initial refrigerant charge

Refrigerant charging should be done in accordancewith the plant manual by qualified refrigeration engi-neers.

1.3.5 Adjustment of instruments andsafety devices

1.3.5.1 Pressure safeties

Pressure safety limit switches

Suction pres-sure1

Setting5oC below designevaporating temp.

(To - 5 K)

Min. >= 0.3 bar(a)

Dischargepres-

sure

Setting5oC above designcondensing temp.

(Tc + 5 K)

Max. <= 26 bar(a)

Lubricationoil pressuredifference

Min. >= 2.0 bar

1 Settings Pdischarge - Psuction may never exceed 24.0bar!

Oil pressure regulator

Lubricationoil pressuredifference2

Setting2.5 bar

(2.5 bar at 50 oC oiltemp.)

1.3.5.2 Re-adjustment of oil pressureregulator

It is possible that after the compressor has beeninstalled, the lubrication oil pressure regulator needsto be re-adjusted.

This lubricating oil pressure regulator is factory pre-set and installed.

Fig.2: Oil pressure regulator

1 Lubricating oil pressure regulator

Re-adjustment procedure:

i. Run the compressor untill the crankcase oil isat its stable operating temperature:

i.1 The lubricating oil pressure differenceshould be according to .

i.2 After the initial run the oil pressure differ-ence should be slightly higher.

ii. Determine the oil pressure difference (differ-ence between the oil pressure gauge and thesuction pressure gauge).

iii. Remove the cap nut of oil pressure regulator ifthe pressure needs to be re-adjusted.

2 The oil pressure regulator is adjusted at the works, but itmay occur that this setting should be corrected during theinitial run and also if the value <2.0 or >3.0 bar. The re-adjustment procedure is given in section “Re-adjustmentof oil pressure regulator.



iv. Turn the slotted pin with a screwdriver clock-wise or counter clockwise for a higher or loweroil pressure respectively, until the requiredlubricating oil pressure difference has beenachieved.

v. Replace cap nut and sealing ring.

1.3.6 Check power supply

Check power supply with type plate of the motor.

1.3.7 Initial oil warm up

Prior to the initial start-up, the crankcase heater (ifpresent) must be energised. For the min. oil temper-ature refer to “Product Information (PI)“.

1.3.8 Initial start-up

1.3.8.1 Limitations of part load opera-tion and start-up

The capacity control serves to adapt the compressorcapacity at any moment as closely as possible to therefrigerating capacity. In order to adjust the capacity,a number of cylinders can be put in or out of actioneither individually or collectively by means of sole-noid valves.

Warning!

Due to start-up limitations and to limi-tations of part load operation it may bethat not all available part load stepsare allowed under certain conditions.Use of incorrect control steps candamage compressor and/or compo-nents.

For a detailed description about start-up and partload limitations refer to the software program “Com-sel”.

1.3.8.2 Frequency controlled com-pressor

Hint!

In case of frequency controlled com-pressors, a separate instruction00.87.041 is required. If you don’t havethis instruction consult Grasso.

1.3.8.3 Pre-start check list

The following Paragraph covers only the initial startof the compressor and not the complete refrigerationplant.

Be sure that all necessary system valves are openand that the refrigeration system is ready for start up.Use the following check to guarantee that no items ofimportance regarding the compressor (package)have been overlooked.

i. System is charged with refrigerant.

ii. Settings of safety limit switches are adjustedproperly.

iii. Direction of rotation of compressor crankshaftis correct.

iv. Check capacity control: Set the electricalcapacity control switch to the position of thelowest part load step.

v. Oil level established in sight glass.

vi. Stop valves to the pressure gauges are open.

vii. Suction stop valve is closed (in case the evap-orating temperature is much higher than thedesign evaporating temperature) and the dis-charge stop valve is open.

viii. Stop valve in the oil return line of the oil sepa-rator (if present) is closed.

When all items are verified, the compressor (pack-age) is ready for the start-up.

1.3.9 Starting and stopping procedures

Hint!

For all limitations refer to "Main setupdata"-overview! The values in the mainsetup data tables, overrules the valuesas mentioned in the text.



When starting the compressor a distinction should bemade between:

1.3.9.1 First start

1. Notice "Pre-start check list", also consult theplant manual and verify the following items:

– Check the oil temperature (refer to the"Product Information").

– Check crankcase oil level (refer to Sec-tion 2.4.1, Page 17).

2. Start the compressor and check whether the oilpressure increases.

Warning!

The time interval between stoppingand starting should be at least 2minutes and between starting and re-starting 10 minutes.

3. Slowly open suction stop valve and watch suc-tion pressure, which may not exceed the max.value.

Warning!

Refrigerant liquid hammer, will dam-age the compressor; Dry gas (super-heat) is always necessary!

4. In case of electrically operated capacity control:One or more cylinders will be energized.

5. Watch maximum allowable motor current (referto motor type plate).

6. Watch discharge temperature and max. allowa-ble motor current (refer to motor type plate).

7. Adjust pressure gauge stop valves, in order toavoid vibration of the pointers. (if present)

8. Open the stop valve in the oil return line from theoil separator (if present).

9. After 50 hours of operation retighten the couplingbolts or check and/or correct the tension of theV-belts and retighten the foundation bolts (withdue respect to the torque settings given by thesupplier of the fasteners!).

1.3.9.2 Restart

Hint!

For the time interval between stoppingand starting refer to "Main setup data"-overview.

Proceed to the complete starting procedure like “Firststart“

1.3.9.3 Restart after a short standstillperiod of time (less than 1month)

• Refer to Section 1.3.9.2, .

1.3.9.4 Restart after a long standstillperiod of time

After a seasonal standstill (1 till 6 months) ormaintenance operations;

Warning!

After a standstill period of time morethan 1 month, pre-lubrication justbefore starting is always obligatory.Refer

• Check settings of control and safety equipment.

• Proceed to the complete starting procedure.

Warning!

Restarting compressor after a stand-still period of time more than 6months, consult your supplier. It isrecommended to proceed with the ini-tial start up procedure.

1.3.9.5 Stopping the compressor

The compressor can be stopped at any moment,however, consult the supplier if further actions arerequired.



2 INSPECTION AND TROUBLE SHOOTING

2.1 Periodical inspection

These inspections should be made during the normalshut-down periods as much as possible, so the com-pressor is always ready to operate when required. If,at that time, the number of running hours slightly dif-fers from the scheduled period below, the inspectionshould nevertheless be carried out.

In this way it will not be necessary to stop the com-pressor at inconvenient times.The frequency of inspections is dependent on thetype of installation, operating conditions and localregulations. In the case of automatically controlledplants, the periodical inspection are particularlyimportant. The table below sums up all the points onthe compressor that have to be inspected or main-tained along with inspection and maintenance fre-quencies.

2.2 Survey of periodical inspections

Apart from the check points in the table below, thesound produced by the compressor also provides anindication of its mechanical condition. If abnormalsounds are audible, their cause should be traced andremoved immediately in order to prevent seriousbreakdowns.

2.2.1 CHECK LIST PERIODICALINSPECTIONS

3 During the first 50 operating hours the compressor shouldbe checked regularly for all the points mentioned above,at least twice every 24 hours and more frequently incases where irregularities are found.

CHECKPOINTS3

FRE-QUENC

YREMARKS

dailyw

eeklym

onthly

Oil level incrankcase •

Between 25% and 75%height of the sight glass.For topping up oil, refer toSection 2.4.1, Page 17.

Colour ofthe oil •

The oil should be transpar-ently clear. A disappearingwhite colour points to dis-solved refrigerant.

Lubricatingoil pressuredifference

•

Oil temper-ature max. • Refer to the "Product Infor-

mation"

Suctionpressure •

Check against design con-ditions. Refer to plant man-ual.

Dischargepressure •

Refer to plant manual. Forthe max. allowable dis-charge pressure refer tothe technical data of com-pressor.

Suctionsuperheat • ≥ 0 K

Dischargetempera-ture max.

• 155 °C

Oil temper-ature min. •

During compressor stand-still the lower part of thecrankcase must remainwarmer than the surround-ings: ≥ 20 °C



CHECKPOINTS3

FRE-QUENC

YREMARKS

dailyw

eeklym

onthly

Adjustmentand opera-tion ofpressuresafetyswitches

•

Refer to Section 1.3.5.1,Page 13 and to instruc-tions of switch manufac-turer.

Capacitycontrol (ifprovided)

•

The time lag between theunloading and loading ofone cylinder or cylindergroup should generally beat least 3 - 5 minutes.

Start/stopintervals •

The time interval betweenstopping and starting,starting and re-starting,loading and unloadingrefer to section “Startingand stopping procedures”.

Number ofoperatinghours

•

Check the number of oper-ating hours in view of anymaintenance operations tobe carried out.

Coolingwater tem-perature (if

present)

Min. actual condensingtemperature plus 10 K

(> Tc+10)

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

To shut down a compressor for long term periods,proceed as follows:

3 During the first 50 operating hours the compressor shouldbe checked regularly for all the points mentioned above,at least twice every 24 hours and more frequently incases where irregularities are found.

i. Tightly shut both the suction and dischargestop valves and the stop valve of the oil returnline (if present).

ii. Disconnect the power source from the com-pressor drive motor and the electrical controlcabinet.

iii. Place a moisture absorbing compound (eg adessicant such as silica gel) inside the controlcabinet.

iv. Place warning tags on the electric system andall closed stop valves.

Prior to starting up after a shut down, change the oiland exchange the oil filters. Determine the startingand stopping procedure from prior to start the com-pressor.

2.4 LUBRICATION DATA

Determine max Toil and set this value in the safetydevice.Change the oil as soon as an oil analysis indicatescontaminated oil.

Warning!

It is expressly pointed out that it is notpermitted to mix different types of oil.If another type of oil is used, firstremove all the stale oil in the filters, oilpump, crankcase, shaft seal, oil sepa-rator and oil drains of the installation.

2.4.1 Topping up oil with compressoroperating

Hint!

Use Grasso’s hand-operated oil pump,part. no. 18.13.121

Topping up oil is permitted during compressor opera-tion.

Be sure that this oil is the same as in the plant (referto Section 2.4, ).

Without affecting the operation of the compressor,the oil may be topped up by means of a separate oilpump. This pump enables the oil to be forced intothe crankcase via the oil charging valve, against suc-tion pressure.



Fig.3: Oil level in compressor sight glass

2.5 EVACUATION, LEAK TESTINGAND START-UP OF THE COM-PRESSOR/PACKAGE

To evacuate the refrigeration system refer to Sec-tion 1.3.2, Page 12,Always use a vacuum pump or pump-down unit toevacuate the refrigerant from the compressor.

2.5.1 EVACUATION OF REFRIGER-ANT BEFORE SERVICING

Procedure to evacuate the compressor:

1. Switch off main control panel

2. Remove main fuses

3. Close shut-off valves

4. Remove the refrigerant by means of a vacuumpump or pump-down unit, via the evacuation/purging valve(s) as prescribed by local safetyregulations. For the location of these valves referto the "Product Information".

5. Drain the oil from the compressor and oil separa-tor, oil return /oil rectifier system if present.

2.5.2 LEAK-TIGHTNESS AFTERSERVICING

The necessary safety precautions should be takenbefore carrying out the leak-tightness test. To checkleak-tightness use dry nitrogen at a positive pressurewhich is less than the admissible operating pressureof the low pressure stage.

2.5.3 EVACUATION AFTER SERVIC-ING

After the pressure test has been completed, thecompressor (package) must be evacuated andundergo a vacuum test. Evacuation is used toremove air and moisture from the compressor (pack-age)

2.5.4 START-UP AFTER SERVICING

1. STATUS: Compressor (package) is dried andstill evacuated.

2. Charge the oil separator, if present, with oil.See the appropriate Product Information for thecorrect quantity.

3. Charge the compressor crankcase with oil viathe oil charge valve until the minimum level isseen at the sight glass at the level as indicated inIMM.It is mandatory to pre-lubricate the oil circuit byadding the final quantity of oil via the chargevalve mounted onto the oil pump by means of aseparate oil filling pump. The required oil level isindicated in the IMM.

4. Re-install all accessories such as coupling, V-belt guard etc.

5. Open the shut-off valves.

6. Check the start-stop procedure.

7. Check all safeties and controls.

8. Re-install the main fuses.

9. Start up the compressor.

10. Check running condition.

Note:The job isn't finished until the paper work is done!Complete the service report, e.g. Grasso report00.89.062.

2.6 DRAINING AND CHANGE OF OIL

To top up oil see Section 2.4.1, Page 17, Oil chang-ing procedure:

i. Evacuate the compressor (refer to Section 2.5,).



ii. Drain the oil via the oil charging/drain valve.Remove the cover of one or more serviceopenings on the compressor side.

iii. Clean the inside of the crankcase with a non-fibrous cloth (do not use cotton waste!).

iv. Replace the service cover(s) with a new seal.

v. Charge crankcase with clean oil in accordancewith the procedure.

2.7 OIL SUCTION AND DISCHARGEFILTERS

Schedule

Replace these filters according to the Service Main-tenance Schedules.The frequency of exchanging these filters dependson the conditions of the refrigeration system.

Hint!

It is recommended to exchange thesefilters when the compressor is over-hauled or when pressure drop exceeds1.0 bar.

2.8 DISMANTLING, INSPECTION ANDRE-ASSEMBLY OF SUCTION ANDDISCHARGE VALVES

Hint!

A high working temperature and rapidtemperature variations shorten the lifetime of the valves, which, for this rea-son, require regular inspection.

The suction and discharge valves of a refrigerationcompressor are parts that are heavily loaded bothmechanically and thermally. Wear and life time of thevalves strongly depend on the working conditions ofthe compressor. It is recommended that valve condi-tion is regularly checked.For dismantling, inspectionand re-assembly of the valves, refer to the relevantparagraph of the Compressor Service InstructionManual.

Hint!

In order to reduce the downtimeinvolved in the valve inspection, it isrecommended to have as many com-plete valve assemblies in stock asthere are cylinders on the compres-sor.These valves can be exchangedwith the original valves; in this case,these original valves can be inspectedand repaired or replaced if necessarylater.

2.9 COMPRESSOR PURGING

Procedure to purge the compressor (after mainte-nance jobs):

STATUS:

Stop valves of suction, discharge and oil return lineare still closed (refer to Section 2.5, Page 18) andcompressor is filled with oil (refer to Section 2.6,Page 18).

i. Connect a vacuum pump to the evacuation/purging valve(s) and evacuate as prescribedby local regulations. For the location of thesevalves refer to the "Product Information".

ii. When evacuation is completed open the dis-charge stop valve.

iii. Watch suction and discharge pressure.

Hint!

If suction pressure increases quickly,the discharge valve assy is leaking.

iv. Start compressor.

v. Slowly open suction stop valve.

vi. Open the stop valve in the oil return line of theoil separator (if present).

vii. For two stage compressor only;

vii.a Two-stage system A/B: open liquid sup-ply to interstage cooler.

vii.b Two-stage system C/D: refer to the plantmanual.

viii. If a Self-Limiting Automatic Purger is not instal-led, purge the refrigerating system (refer to theplant manual).



2.10 TROUBLESHOOTING TABLEGRASSO RECIPROCATING COM-PRESSORS

The troubleshooting table shown overleaf may behelpful to quickly trace and remedy failures that inter-fere with the proper operation of the compressor. It isemphatically pointed out that the cause of a failuremust often be sought in the refrigeration installationitself. Therefore, it is necessary besides this tablealso to consult the plant manual.



Troubleshooting

FAULT CAUSE REMEDY

ADischargepressure toohigh

1. Discharge stopvalve not fully open Open fully

2. Discharge pres-sure gauge defec-tive

Repair or replace

3. Non-condensa-bles in the system

Purge with a AutomaticPurger

BDischargetemperaturetoo high

1. Discharge pres-sure too high See A

2. Too many cylin-ders cut out Cut in more cylinders

3. Suction pressuretoo low See D

4. Excessive super-heat of suction gas

Eliminate excessivesuperheat

5. For two-stagecompressors: inter-stage cooling doesnot operate properly

Repair

6. Room tempera-ture too high

Ventilate engine roombetter

7. Discharge valvedefective Repair or renew

8. Pressure reliefvalve is leaking Repair or renew

CSuction pres-sure too high

1. Capacity controldoes not operate Repair

2. Compressorcapacity too small Refer to plant design

3. Suction pressuregauge defective Repair or renew

4. One or more suc-tion valves defective

Renew suction valverings

5. One or more dis-charge valvesdefective

Repair or renew

6. Pressure reliefvalve is leaking Repair or renew

Troubleshooting

FAULT CAUSE REMEDY

DSuction pres-sure too low

1. Suction stopvalve not fully open Open fully

2. Suction gasstrainer blocked Renew

3. Injection controlnot adjusted cor-rectly

Re-adjust control

4. Too little refriger-ant in installation Top-up with refrigerant

5. Suction pressuregauge defective Renew

ECrankcasefrosted or wet*4

Warning!

Stop compressor and contactinstallation engineer

1. Liquid refrigerantin crankcase due to:

1a. Room tempera-ture too low

Provide for crankcaseheating or, if provided,check it for proper oper-ation

1b. Oil return fromseparator containsliquid refrigerant

Consult plant manual

1c. Installation oper-ates too wet

Re-adjust installationand provide for super-heat

1d. Liquid separatortoo small Consult plant manual

FAll cylindersinactive whilecompressor isoperating

1. Oil pressure forvalve lifting mecha-nism too low

See J

2. Incorrect wiring ofcapacity control

Refer to the "ProductInformation”

GToo high oilconsumption

1. Type of oil notaccording to oillubrication oil table(too thin oil)

Change oil type

4 In case of R744 applications only, crankcase can be frostedor wet, during normal operating conditions.



Troubleshooting

FAULT CAUSE REMEDY

2. Compressoroperates unloadedtoo frequently

Refer to design calcula-tions

3. No return from oilseparator *5

Check the operation offloat valve in oil separa-tor

4. Restriction plugat the bottom ofsuction chamber incylinder clogged

Clean plug

5. Worn out oil scra-per ring(s) Replace ring(s)

6. Loss of oil due toleakage Repair

7. Leaking shaftseal (max. 1 cc/hr)

Repair shaft sealRefer to Section 2.2

8. Oil level in crank-case too high Drain/Refill with oil

9. Oil separator isnot initially filled withoil

Refer to section “Initialoil charge”

HToo high oilpressure dur-ing normaloperation atworking tem-perature

1. Lubricating oilpressure regulatornot adjusted prop-erly or defective

Re-adjust or renew

2. Defective oilpressure and/orsuction pressuregauge (if present)

Repair or replace

JToo low lubri-cating oil pres-sure

1. Too little oil incrankcase Top up oil

2. Disturbed oil cir-cuit: Oil suctionand/or discharge fil-ter is dirty

Renew the element ofoil suction filter and/oroil discharge filter

3. Lubricating oilpressure regulatornot adjusted prop-erly or defective

Re-adjust or renew

5 During the initial start-up, the oil separator (if present) con-sumes oil before the first oil will be returned.

Troubleshooting

FAULT CAUSE REMEDY

4. Liquid refrigerantin crankcase See E

5. Defective oilpressure and/orsuction pressuregauge (if present)

Repair or renew

6. Worn bearings Renew bearings

KToo low or nocontrol oilpressure(Not or Grasso5HP)

1. Failure of controloil pressure regula-tor in oil pump

Re-adjust or renew reg-ulator

2. A lack of oil in oilsystem Add oil to the system

3. Oil pump defect Repair or renew oilpump



3 MAINTENANCE

3.1 Post start-up maintenance

After the compressor has run for the initial 100 oper-ating hours:

i. Drain the oil and refill the compressor with thecorrect amount of fresh oil.

ii. Inspect the oil discharge and oil suction filters.

iii. Replace the factory mounted running-in suctiongas filter.

iv. Verify and if necessary, correct the torque set-tings of all foundation bolts as given in Com-pressor Service Instruction Manual.

3.2 First maintenance

Hint!

For complete service schedules andrequired service sets refer to Grasso"sService and Maintenance Schedules(SMS).After the refrigerating system hasbeen modified, the suction gas fil-ter(s). the oil filters and the oil shouldbe changed.

Maintenance Number of operating hours

1006 > 100

Inspect/clean suction gas filter X

refer to Service andMaintenance

Schedules (SMS)

Renewal oil discharge filter X

Inspect/clean oil suction filter(strainer) X

Oil analysis 7 8 X

6 Time dependent on pollution.7 Take an oil sample every 3,000 running hours or once a

year and renew if any sign of discoloration and if the systemis contaminated.

8 Consult your oil supplier.

3.3 SMS FACTOR

General

The following maintenance has to be distinguished:

1. Grasso Maintenance Monitor (GMM) is appliedMaintenance A, B and C, service intervals aredetermined on measured values of GMM

2. GMM is not applied:Service intervals according to Service and Main-tenance Schedules (SMS) tables in combinationwith operating conditions

Warning!

GMM is not used: The running hoursmentioned in the SMS tables shouldonly be used as a reference for mainte-nance intervals.The number of running hours men-tioned in the SMS tables have to beadjusted accordingly depending onthe operating conditions of the com-pressor (speed, evaporating tempera-ture, condensing temperature, refriger-ant, start frequency, capacity controlsteps, etc.. This means that the serviceintervals could be significantly differ-ent.The running hours mentioned in thetables are based on a single stagecompressor running at -10oC/+35oC,NH3 at nominal speed. In this case theSMS factor = 1, in all other cases themaintenance intervals have to beadjusted accordingly.

3.4 Legend

Warning!

These operations cover routine main-tenance and are meant as a guideonly. Lack of maintenance, frequencyof stop/starting, extreme operatingconditions etc could lead to acceler-ated wear.



General;

The service and maintenance schedules use thecodes as explained in the table below;

Actions

Legend for service and maintenance schedules (SMS)

Item Code/Actions Description

1 IC Inspection / Alternatively renewal - cor-recting / Testing

2 IV Inspection Visual / Alternatively electri-cal testing

3 RE Renewal

4 ME Measure

5 CL Clean



3.4.1 Grasso 7S and Grasso 8S

Service and maintenance schedules Grasso 7S and Grasso 8S

Item Description

Actions

CheckpointRunning hours * 10009

0.1

Year

ly

3 6 -

9 12 -

15 18 -

21 - 24

1

Oil

CL CL CL CL RE Oil suction filter

1a - - - CL CL Oil ejector

2 RE10 RE RE RE RE Oil discharge filter

3 - ME ME ME ME Oil analysis

4 RE - - RE RE Oil refreshment (If hygroscopical oil is used replace this always aftereach opening of compressor or installation)

5Oil pump

- IC/CL - IC/CL IC/CL Housing and element

6 - IC/CL - IC/CL IC/CL Control and lubrication oil pressure regulator

7a

Crankshaft

- IC - IC/CL IC/CL Main and intermediate bearing bushes

7b - - - - IC/CL Main and intermediate bearing surfaces crankshaft

8 - - - IC/CL IC/CL Running surfaces con. rods

10 Conrod - IC - IC/ME

IC/ME Big and small end bearings

11

Pistons

- IC - IC IC/CL Piston

12 - IC - IC IC Piston rings

13 - IC - IC IC Gudgeon pin

14

9 Check after every maintenace job the settings and working of all safety devices, regulators and the running conditions according to theService Instruction Manual (SIM)

10 Supplied together with compressor




Item Description

Actions


0.1

Year

ly

3 6 -

9 12 -

15 18 -

21 - 24

15

Capacity controlIC IC IC/IV IC/CL IC/CL Solenoid valves and coils

16

17 - IC/CL - IC/CL IC/CL Cap. Control mechanism

18

Compressorhousing

IV/CL IV/CL IV IV/CL IV/CL Crankcase heater

19

CL CL - CL CL Crankcase20

21

22 IC/CL IC/CL - IC/CL RE Suction gas filter

23Discharge valves

- - - RE RE Valves, springs and damper rings11

24 - IC/CL - IC/CL IC/CL Stroke limitor/Discharge valve seat

25 Suction valves - - - RE RE Valves, springs and damper rings

27 Cylinder liners - IV/ME - IV/M

EIV/M

E Dimension and running profile

28Drive ME ME ME ME ME Insulation resistance with qualified device

29

31 Optionals IC IC/CL IC IC/CL IC/CL Oil level float switch


11 Dampers rings; not for Grasso 8S




Item Description

Actions


0.1

Year

ly

3 6 -

9 12 -

15 18 -

21 - 24

32 IC IC/CL IC IC/CL IC/CL Valve oil return

33 ME/CL

ME/CL

ME/CL

ME/CL

ME/CL Cylinder head cooling


3.4.2 Checklist

Service and maintenance schedules Grasso RECIPROCATING COMPRESSORS

Item Description Checked/Remarks/Notes Checkpoint/Setting/Value

A Compressor type

B Machine number

C Date

D Running hours

E Refrigerant

E Evaporating temperature/pressure To/Po

F Intermediate temperature/pressure Tm/Pm

G Discharge temperature/pressure Tc/Pc





H Oil lubricating pressure

I Oil control pressure

J GeneralNotes

1

Oil

Oil suction filter

2 Oil discharge filter

3 Oil analysis

4 Oil refreshment (If hygroscopic oil is used replace this always after eachopening of compressor or installation)

5Oil pump

Housing and element

6 Control and lubrication oil pressure regulator

7Crankshaft

Main and intermediate bearing bushes and running surfaces

8 Running surfaces con. rods

9 Shaft seal Oil/refrigerant leakage

10 Conrod Big and small end bearings

11

Pistons

Piston

12 Piston rings

13 Gudgeon pin

14 Thrust bear-ing Running surfaces/Axial play

15 Capacitycontrol

Solenoid valves and coils





16 Seals of cap. control piston

17 Cap. Control mechanism

18

Compressorhousing

Crankcase heater

19 Crankcase

20 Non return valves LP/HP

21 Relief valves

22 Suction gas filter

23Discharge

valves

Valves, springs and damper rings

24 Stroke limitor/Discharge valve seat

25 Suctionvalves Valves, springs and damper rings

26Cylinder lin-

ers

Cap. Control lifting mechanism

27 Dimension and running profile

28Drive

Alignment

29 V-belts

30 Electricmotor Consult motor manufacturer

31

Optionals

Oil level switch

32 Safety switches

33 Gauges

34 Thermostats

35 Thermometers

36 Electrical control system

37 Valve oil return protection

38 Thermistors





39 Vibration dampers and bolts

40 Intermediate cooler and injection valve

41 Oil separator refreshing oil and cleaning/testing of float valve

42 Heavy duty thrust bearing

43 Oil cooler, air side

44 Oil cooler, oil side, refrigeration oil

45 Consult motor manufacturer Oil cooler, electric motor (fan)

46 Cylinder head water cooling system

Settings pressure safeties

Safety Remark Value

1 Suction pressure

2 LP discharge pressure (safety) two stage only

3 LP discharge pressure (limitor) two stage only,TUV

4 High pressure suction (safety) two stage only

5 High pressure (safety)

6 High pressure (limitor) TUV only

7 OIl differential pressure



© G

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GEA Refrigeration Technologies

GEA Refrigeration Netherlands N.V.

Parallelweg 27, 5223 AL ‘s-Hertogenbosch, The NetherlandsPhone: +31 73 [email protected], www.gea.com

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

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