Piston_Grasso_6_Installation_and_Maintenance_Manual.pdf

-Page 1-Reciprocating Compressors for industrial refrigeration / Series Grasso 6ca0148_0089238_v002_gbr

Reciprocating Compressors for industrial refrigeration

Series Grasso 6

Installation and Maintenance Manual (IMM)

-Page 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 IMM0312/v002

Copyright

All Rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent 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 held responsible, neither for any errors occurring in this publication nor for their consequences.

This manual must be carefull read and understood prior to installing and servicing the compressor (package)

Safety

This manual is written with great care, but the contractor/installer is held responsible to examine this information and to take care of possible additional and/ or deviated safety measures.

Safety instructions

It is the task of the contractor/installer to inform and explain to his client the operation of the compressor (Package).Do respect all federal, state or local safety regulations/legislations during installing, connecting and operating this compressor (package).

Construction changes

In compliance with the regulations of the Pressure

Equipment Directive it is mandatory that no changes be

made to the construction of pressurised parts such as the

crankcase housing, suction filter housing etc.

Installer oriented information

The compressor (package) is filled with nitrogen to prevent penetration of moisture. Therefore, keep the compressor closed until the compressor (package) is being installed.

The compressor is not filled with oil.

After the successful initial run of the compressor (package) the warranty chart must be filled in and returned to Grasso. A warranty chart is attached to each compressor.

Open compressor series and (semi) hermetic

compressor series;

This manual includes procedures and checks for open compressors and (semi) hermetic compressors. a. Open compressor series are Grasso 12E, Grasso 12,

Grasso 6 and Grasso 10.b. Semi hermetic compressor series are Grasso 7S and

Grasso 8S.

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Table of Contents

Section Title Page

1 INSTALLATION AND PREPARATION FOR USE 7

1.1 INSTALLATION 9

1.1.1 Moving instructions and storage 9

1.1.2 Storage 9

1.1.3 Hoisting and moving instructions 9

1.1.4 Required free space 10

1.1.5 Foundation requirements 10

1.1.5.1 Concrete structure 10

1.1.5.2 Anchoring 11

1.1.5.3 Concrete block mounting instructions 11

1.1.5.3.1 Mounting bare compressor on a concrete block 12

1.1.5.3.2 Mounting the base frame on a concrete block 12

1.1.5.3.3 Levelling the base frame 12

1.1.5.3.4 Finishing with a self-levelling grout 12

1.1.6 Connecting to refrigerating system pipework 12

1.1.7 Connecting the power supply 13

1.1.8 Earthing connections 13

1.1.9 Separately delivered components 13

1.2 PREPARATIONS FOR USE 15

1.2.1 Leak test of compressor and system 15

1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 15

1.2.3 Initial oil charge 15

1.2.3.1 Initial oil charge 15

1.2.4 Initial refrigerant charge 15

1.2.5 Adjustment of instruments and safety devices 16

1.2.5.1 Pressure safeties 16

1.2.5.2 Re-adjustment of oil pressure regulator 16

1.2.6 Checking direction of rotation of motor shaft 16

1.2.7 Installing the drive guards (if present) 16

1.2.8 Initial oil warm up 16

1.2.9 Initial start-up 16

1.2.9.1 Limitations of part load operation and start-up 16

1.2.9.2 Pre-start check list 16

1.2.10 Starting and stopping procedures 17

1.2.10.1 First start 17

1.2.10.2 Restart 17

1.2.10.3 Restart after a short standstill period of time (less than 1 month) 17

1.2.10.4 Restart after a long standstill period of time 17

1.2.10.5 Stopping the compressor 17

2 INSPECTION, MAINTENANCE AND TROUBLE SHOOTING 19

2.1 INSPECTION 21


2.1.1 Periodical inspection 21

2.1.2 Survey of periodical inspections 21

2.1.2.1 CHECK LIST PERIODICAL INSPECTIONS 21

2.2 MAINTENANCE (REFER Chapter 5) 23

2.2.1 Post start-up maintenance 23

2.2.2 First maintenance 23

2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 23

2.4 LUBRICATION DATA 23

2.4.1 Topping up oil with compressor operating 23

2.5 EVACUATION OF THE COMPRESSOR 24

2.6 DRAINING AND CHANGE OF OIL 24

2.7 OIL SUCTION AND DISCHARGE FILTERS 24

2.8 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 24

2.9 COMPRESSOR PURGING 24

2.10 TROUBLESHOOTING TABLE 24

3 PARTS COMPRESSOR 27

4 PARTS ACCESSORIES 57

5 MAINTENANCE 65

5.1 SMS FACTOR 65

5.2 Grasso 6 67

5.3 Checklist 69

6 APPENDIX; Product Information (PI) 71

6.1 TECHNICAL DATA 71

6.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 73

6.3 SHAFT END COMPRESSOR 74

6.4 LIMITS OF OPERATION AND FIELDS OF APPLICATION 75

6.4.1 GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 6 75

6.4.1.1 FIELDS OF APPLICATION 76

6.4.2 PRECISE FIELD OF APPLICATION 77

6.4.3 LIMITATIONS OF PART-LOAD OPERATION 77

6.5 LUBRICATING OILS (choice and recommendations) 79

6.6 CAPACITY CONTROL 80

6.6.1 CYLINDER NUMBERING 81

6.7 PACKAGED BASE FRAME 82

6.7.1 PACKAGED BASE FRAME 82

6.8 CRANKCASE HEATER 83

6.8.1 DETAILS CRANKCASE HEATER 83

7 NOTES 85

7.1 85

Section Title Page

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Main setup data Grasso 6 Table 1 Main setup data

Cylinder numbering of Grasso reciprocating

compressors

Description Value Remark

Start frequency max. 4 starts per hour

Time interval between stopping and re-starting min. 2 minutes

Time interval between starting and re-starting min. 15 minutes

Time interval between loading and unloading min. 3 minutesFor continuous minimum

part-load (i.e. more than 30 minutes) consult Grasso.

Oil level 25-75% crankcase sight glass

Min. oil temperaturewarmer than surroundings and 20 C for NH3 and 30

C for halocarbons

Max. oil temperature Refer to oil selection table/applied type of oilRequired oil viscosity;

10 cSt during operation at location of bearings

Lubricating oil pressure difference Setting approx. 2.2 bar

After a mimimum of 15 minutes running time at an oil temperature of approx. 50 oC

(122 oF)

Max. discharge temperature 155 C

Min. suction pressure 0.3 bar

Pdischarge - Psuction 24.0 bar

Superheat>0 Kfor NH3,

>15K for R507/R404A/R134a

Direction of rotation of compressor drive shaft Initially both directions are allowed

Normally counterclockwise when facing shaft end of the

compressor.

After initial run, never

change the direction of

rotaion anymore.


Fig. 1 Cylinder numbering Grasso reciprocating compressors

Legend

1, 2, 3, ... Cylinder numbers

T Top view of compressor

M Motor/Drive end of compressor

O Oil pump of compressor

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1. INSTALLATION AND PREPARATION

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1. INSTALLATION AND PREPARATION FOR USE

Table of Contents

Section Title Page

1.1 INSTALLATION 9

1.1.1 Moving instructions and storage 9

1.1.2 Storage 9

1.1.3 Hoisting and moving instructions 9

1.1.4 Required free space 10

1.1.5 Foundation requirements 10

1.1.5.1 Concrete structure 10

1.1.5.2 Anchoring 11

1.1.5.3 Concrete block mounting instructions 11

1.1.5.3.1 Mounting bare compressor on a concrete block 12

1.1.5.3.2 Mounting the base frame on a concrete block 12

1.1.5.3.3 Levelling the base frame 12

1.1.5.3.4 Finishing with a self-levelling grout 12

1.1.6 Connecting to refrigerating system pipework 12

1.1.7 Connecting the power supply 13

1.1.8 Earthing connections 13

1.1.9 Separately delivered components 13

1.2 PREPARATIONS FOR USE 15

1.2.1 Leak test of compressor and system 15

1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 15

1.2.3 Initial oil charge 15

1.2.3.1 Initial oil charge 15

1.2.4 Initial refrigerant charge 15

1.2.5 Adjustment of instruments and safety devices 16

1.2.5.1 Pressure safeties 16

1.2.5.2 Re-adjustment of oil pressure regulator 16

1.2.6 Checking direction of rotation of motor shaft 16

1.2.7 Installing the drive guards (if present) 16

1.2.8 Initial oil warm up 16

1.2.9 Initial start-up 16

1.2.9.1 Limitations of part load operation and start-up 16

1.2.9.2 Pre-start check list 16

1.2.10 Starting and stopping procedures 17

1.2.10.1 First start 17

1.2.10.2 Restart 17

1.2.10.3 Restart after a short standstill period of time (less than 1 month) 17

1.2.10.4 Restart after a long standstill period of time 17

1.2.10.5 Stopping the compressor 17

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1.1 INSTALLATION

The compressor is not charged with oil, therefore, DO

NOT start the compressor before it has been installed

and prepared according to Grassos instructions.

This section contains instructions for the proper installation of a Grasso compressor (package). Before the compressor (package) is ready for the initial start up, the installation instructions in the following paragraphs must be followed:

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

2. All piping should be completed.3. The system and the compressor are to be pressure

tested for leaks (see. Section 1.2.1)4. The system should be evacuated to remove air and

moisture.5. The electric wiring should be completed as per wiring

diagrams. Do not energise the main power control cabinet until oil is added and the direction of rotation1 has been checked.

6. The compressor is to be filled with the correct type and amount of lubricating oil.

7. Open compressors only;1 Open compressors;

The drive system should be installed.2 (Semi) hermitic compressors;

Mark R-S-T-N power supply in the terminal box of the motor.

8. The system should be charged with the correct amount of refrigerant.

9. The oil should be warmed up above minimum start up oil temperature (see "Product Information").

10.The control cabinet should be energised to check the package controls.

Do not forget to charge the oil separator (if present) initially with oil, to the level of the float assembly

1.1.1 MOVING INSTRUCTIONS AND STORAGE

For loose component or compressor package weights, refer either to the relevant component type plate or package lay-out or to the suppliers document. For bare compressor weights, see "Product Information".

Every precaution must be taken while moving the package to its final location. Pushing, pulling or climbing on any package component or piping, can easily create damage.

1.1.2 STORAGE

The compressor (package) is filled with dry nitrogen. Keep the system closed until the package is installed. If the compressor (package) is stored, it should be kept at all times in a dry location to prevent corrosion damage. If the compressor (package) is to be stored for a prolonged period of time, it should be checked weekly to ensure that the holding charge of dry nitrogen remains above atmospheric pressure.

1.1.3 HOISTING AND MOVING INSTRUCTIONS

Fig. 1.1-1 Hoisting a compressor package

Packaged base frame:

The only places that can be used for safe hoisting of the package are the four hoisting eyes on the steel base frame as shown in the above figure. Prior to hoisting a compressor package with a V-belt drive arrangement, the factory mounted drive guard has to be removed. Attach spreader bars to the slings so as to prevent damage to piping and components.

1. The direction of rotation of the compressor cannot be checked for (semi) hermetic compressors. For these compressors the electrical connection should be marked, to be sure that the compressor has always the same direction of rotation!

Legend

C Compressor

M Motor



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DO NOT use the compressor or motor or oil separator

hoisting eyes to move the package! These hoisting eyes

are intended for lifting loose components only and not

for the entire package!

Bare compressor or loose components:

Determine the dead weight of the particular component (see "Product Information (ED)"), prior to moving a bare compressor or loose component. Use the hoisting eyes only, DO NOT sling from other compressor parts (see Fig. 1.1-2).

Fig. 1.1-2 Hoisting angle

Moving by fork-lift truck

The bare compressor or package can be transported with a fork-lift truck with the forks spread as much as possible between the skids. To simplify moving, the 2 wooden transport beams must still be mounted underneath the base frame and stored in this way, until the package is positioned above its approximate location.

1.1.4 REQUIRED FREE SPACE

For easy operating, servicing and maintenance access, the compressor (package) should be installed with sufficient free space around it.

Refer to Product Information for minimum requirements.

1.1.5 FOUNDATION REQUIREMENTS

This paragraph covers measures to be taken for a compressor (package) mounting on a concrete floor.Two foundation arrangements are described: Compressor package with steel base frame mounted

on a concrete block. Bare compressor direct mounted on a concrete block

via grouted machined anchors (see "Product Information (ED)"). The mounting surfaces of these machined anchors must be level without any deviation and projecting at least 10 mm above the concrete base.

COMPRESSOR AND COMPRESSOR PACKAGE TO BE MOUNTED ON A CONCRETE BLOCK. On request, Grasso can calculate the exact dimensions of the concrete block, based on the compressor size and operating conditions.

1.1.5.1 CONCRETE STRUCTURE

Fig. 1.1-3 Concrete block

The concrete block for compressor and motor or compressor package should have a profile as illustrated in Table on Page 10and made according to the following recommendations:

The concrete block should be set on firm footings or on a floor capable of carrying the weight of the concrete block and capable of absorbing the free forces and gas forces of the compressor during operation. The ground under the concrete block should be horizontal and flat.

The top surface of the block should be level and even.

Legend

1 Cork board

2 Concrete base

3 (Concrete) Floor

4 Sand



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There should be sufficient free space around the block to install corkboard (or similar).

The block should be provided with anchor bolt recesses or holes according to the anchor bolt spacing as per package lay out drawing.

Table 1.1-1

It is recommended to consult a concrete specialist/ constructor for the following items: The compound of the concrete with/without

reinforcement. The exact grouting depth (dependent on the soil

conditions). Installing foundation onto an existing floor, with

sealing corkboard or vibration isolators.

1.1.5.2 ANCHORING

After the concrete block has cured the anchors should be installed as shown above and in case of a package in accordance with the package lay out drawing. Templates should be made to locate the anchor bolts or chemical anchors to match the holes in the bottom flange of the base frame.

Grout the mortar according to the supplier instructions. Install chemical anchors as illustrated in Fig. 1.1-4 and according to the instructions of the anchor supplier.

Fig. 1.1-4 Anchoring details

1.1.5.3 CONCRETE BLOCK MOUNTING

INSTRUCTIONS

Legend

A Chemical anchor

B Grouted anchor, grounded to reinforcing steel

Legend

A Drilled chemical anchor (M20)

B Grouted anchor recesses (M20)

1 Installed chemical anchor before placing the base frame

2Installing chemical anchor after placing the base frame

(base frame cannot be removed easily)

3 Drilling angle



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1.1.5.3.1 MOUNTING BARE COMPRESSOR ON A

CONCRETE BLOCK

If no base frame is applied the compressor and motor should be installed as described in the "Product Information (ED)".

1.1.5.3.2 MOUNTING THE BASE FRAME ON A

CONCRETE BLOCK

General

After the space between base frame and concrete base has been filled-up with a filling grout, the package base frame must be secured tightly to the foundation block or floor.

1.1.5.3.3 LEVELLING THE BASE FRAME

Fig. 1.1-5 Grouting details

After the anchor filling mortar has completely cured the frame should be levelled with a space between block and lower frame flange of 3 - 5 mm*. This space is necessary for levelling using the base frame adjusting bolts with metal washers (supplied separately). The base frame should be levelled on each frame side. Adjust the frame on each adjusting place until all frame sides are horizontal.

This space largely depends on the sort of grout or mortar used. Determine this space according to the instructions of the grout or mortar supplier.

1.1.5.3.4 FINISHING WITH A SELF-LEVELLING GROUT

After levelling has been completed the adjusting bolt ends must be greased to avoid bonding to the self-levelling grout. The space between concrete block and frame must be completely filled with the

self-levelling grout to ensure that the complete bottom surface of the base frame will be supported. Therefore, it is not allowed to use shims between concrete base and base frame.

Grouting must be carried out in accordance with the instructions provided by the grouting supplier. After complete de-aeration of the grouted layer, secure the base frame by tightening the anchor bolt nuts and remove all adjusting bolts. At this stage the drive system can be installed. These (accessories) installation instructions can be found in the order manual.

1.1.6 CONNECTING TO REFRIGERATING SYSTEM

PIPEWORK

DO NOT ground through the compressor when arc

welding

After the compressor (package) has been levelled and secured to the foundation, the system piping may be connected. The suction line(s) and discharge line(s) should be installed and supported such that there is no load exerted on the compressor. The size and location of the suction and discharge connections, can be found in the "Product Information" (bare compressor) and in case of a package, the package lay out drawing.

In order to ensure that suction gas strainer can be removed easily, special attention for pipe work is required for (semi) hermetic compressors.

If an oil rectifier system is applied in the refrigeration system, the oil return line must be connected to the oil return connection (see "Product Information").

Never connect the oil rectifier return line to the suction line or to the suction gas filter.

Suspension of system pipework

To eliminate vibration transmission to the system piping, the following is recommended: Install all piping free of tension. Secure the piping by clips or brackets in two

directions. Install (stop) valves, piping and accessories such, that

there is no load exerted on the compressor.

Legend

1 Self-levelling grout

2 Adjusting bolts (4x)

3 Washer

4 Temporary barrier strip around and inside frame

5 Complete cured concrete block

6 Grout layer



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1.1.7 CONNECTING THE POWER SUPPLY

Information about further electrical connections to be made (e.g. crankcase heater, drive motor starting equipment, thermal protection of drive motor, automatic start/ stop and other external electrical devices) can be found in the plant manual (not supplied by Grasso).

1.1.8 EARTHING CONNECTIONS

Grasso compressors and packages are equipped with litz-wires and earth connecting points.To avoid leakage current flowing through the components, disconnect all litz-wires when arc-welding. After all installation functions are completed, reconnect the litz-wires and ground the package to earth.

1.1.9 SEPARATELY DELIVERED COMPONENTS

Check whether the sets/parts/components belonging to this compressor are supplied loose! (Refer to confirmation of order)

Mount these separately delivered sets, components and/or parts, according to the instruction as enclosed.



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1.2 PREPARATIONS FOR USE

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

1.2.1 LEAK TEST OF COMPRESSOR AND SYSTEM

The compressor (package) has been pressure tested prior to leaving the factory. In case an additional leak test is required, this test is should be carried out with dry nitrogen under pressure up to a max. of 10 bar(a).

DO NOT add oil to the compressor prior to pressure testing

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

1.2.2 EVACUATION/DRYING THE REFRIGERATING

SYSTEM

For evacuation of compressor only, refer to Section 2.5

Procedure to evacuate and to dry a system:

i) STATUS: System is filled with nitrogen and no oil has been added (oil prevents any trapped moisture from boiling off).

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

iii) Connect vacuum pump to the evacuation/purging valve(s) of the compressor (for location of these valves refer to the "Product Information" or to a connection as mentioned in the plant manual and evacuate the system to approx. 5 mm Hg (=6.6 mBar).

iv) Break vacuum by charging dry nitrogen into the system.

v) Repeat step iii, 'Connect vacuum pump ...'.vi) Wait approx. 24 hours.vii) If pressure has increased (system still contains

moisture), repeat steps iv, vand vi, otherwise, continue with the "Initial oil charge" procedure.

1.2.3 INITIAL OIL CHARGE

Used or filtered oil should NEVER BE added to a compressor under any circumstance.

Use only new oil as selected from the Grasso oil table.(Section 6.5)

Oil charging via the suction line of the compressor is not allowed.

Procedure:

i) STATUS: System is dried and still evacuated.ii) Charge the oil separator (if present) initially with oil .iii) Close suction and discharge stop valves of compressor

and oil return line of oil separator (if present).iv) Charge the compressor crankcase with oil via the oil

charge valve.

Pre-lubrication just before the first start is obligatory.

Filling of the afore mentioned components is also possible by means of a separate oil filling pump via the oil charge valves mounted onto the oil pump housing.

1.2.3.1 INITIAL OIL CHARGE

1.2.4 INITIAL REFRIGERANT CHARGE

Refrigerant charging should be done in accordance with the plant manual by qualified refrigeration engineers.

QUANTITY OF OIL TO BE FILLED (IN dm3)

Number of cylinders

Shaft seal housing, incl.

internal circuit of crnkshaft

Oil filters

Oil pump

Crankcase

4

0.5 1.5 0.5

11

6 12

8 13



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1.2.5 ADJUSTMENT OF INSTRUMENTS AND

SAFETY DEVICES

1.2.5.1 PRESSURE SAFETIES

1.2.5.2 RE-ADJUSTMENT OF OIL PRESSURE

REGULATOR

It is possible that after the compressor has been installed, the lubrication oil pressure regulator needs to be re-adjusted.

This lubricating oil pressure regulator is factory preset and installed.

Fig. 1.2-1 Oil pressure regulator

Re-adjustment procedure:

i) Run the compressor untill the crankcase oil is at its stable operating temperature:1 The lubricating oil pressure difference should be

according to Section 1.2.5.1.2 After the initial run the oil pressure difference

should be slightly higher.

ii) Determine the oil pressure difference (difference between the oil pressure gauge and the suction pressure gauge).

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

iv) Turn the slotted pin with a screwdriver clockwise or counter clockwise for a higher or lower oil pressure respectively, until the required lubricating oil pressure difference has been achieved.

v) Replace cap nut and sealing ring.

1.2.6 CHECKING DIRECTION OF ROTATION OF

MOTOR SHAFT

Prior to installing the intermediate coupling element or V-belts, the direction of rotation of the motor shaft must be checked. The direction of rotation can be determined from the arrow-sticker on the oil pump.

1.2.7 INSTALLING THE DRIVE GUARDS (IF

PRESENT)

Only after the compressor is ready for the initial startup! Refer to the drive guard installing procedures included in the order documentation.

1.2.8 INITIAL OIL WARM UP

Prior to the initial start-up, the crankcase heater (if present) must be energised. For the min. oil temperature refer to Product Information (ED).

1.2.9 INITIAL START-UP

1.2.9.1 LIMITATIONS OF PART LOAD OPERATION

AND START-UP

The capacity control serves to adapt the compressor capacity at any moment as closely as possible to the refrigerating capacity. In order to adjust the capacity, a number of cylinders can be put in or out of action either individually or collectively by means of solenoid valves.

Due to start-up limitations and to limitations of part load

operation it may be that not all available part load steps

are allowed under certain conditions. Use of incorrect

control steps can damage compressor and/or

components.

For a detailed description about start-up and part load limitations refer to the software program Comsel.

1.2.9.2 PRE-START CHECK LIST

The following Paragraph covers only the initial start of the compressor and not the complete refrigeration plant.

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

Pressure safety limit switches

Suction pressurea

a. Settings Pdischarge - Psuction may never exceed 24.0 bar!

Setting 5oC below design evaporating temp.

(To - 5 K)

Min. >= 0.3 bar(a)

Discharge pressurea Setting

5oC above design condensing temp.

(Tc + 5 K)

Max. = 1.7 bar

Oil pressure regulator

Lubrication oil pressure

differencea

a. The oil pressure regulator is adjusted at the works, but it may occur that this setting should be corrected during the initial run and also if the value 2.5 bar. The re-adjustment procedure is given in section Re-adjustment of oil pressure regulator.

Setting

2.0 bar(2.2 bar at 50 oC oil temp.)

Legend

1 Lubricating oil pressure regulator



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i) System is charged with refrigerant.ii) Settings of safety limit switches are adjusted properly.iii) Direction of rotation of compressor crankshaft is

correct.iv) Check capacity control: Set the electrical capacity

control switch to the position of the lowest 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 evaporating

temperature is much higher than the design evaporating temperature) and the discharge stop valve is open.

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

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

1.2.10 STARTING AND STOPPING PROCEDURES

When starting the compressor a distinction should be made between:

1.2.10.1 FIRST START

i) Notice "Pre-start check list", also consult the plant manual and verify the following items: Check the oil temperature (refer to the "Product

Information"). Check crankcase oil level (refer to Section 2.4.1).

ii) Start the compressor and check whether the oil pressure increases.

Maximum 4 starts per hour and at least 2 minutes between stopping and starting and at least 15 minutes between starting and re-starting

iii) Slowly open suction stop valve and watch suction pressure, which may not exceed the max. value.

Refrigerant liquid hammer, will damage the compressor; Superheat is always necessary! R404A and R507 dTo15K, other refrigerants dTo0K.

iv) In case of electrically operated capacity control:a. Single-stage compressors: One or more cylinders

will be energized.b. Two-stage compressors: 3 - 5 minutes after

starting and only when HP-cylinder(s) is (are) in operation, the LP cylinders can be energised.

In the case of decreasing capacity for two stage compressors, it is not allowed to cut out all LP-cylinders.

v) Watch maximum allowable motor current (refer to motor type plate).

vi) Watch discharge temperatures LP and HP, max. intermediate pressure and max. allowable motor current (refer to motor type plate).

vii)Adjust pressure gauge stop valves, in order to avoid vibration of the pointers.

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

ix) Open compressors only; After 50 hours of operation retighten the coupling bolts or check and/or correct the tension of the V-belts and retighten the foundation bolts (with due respect to the torque settings given by the supplier of the fasteners!).

1.2.10.2 RESTART

Do not restart within 15 minutes after a stop

Proceed to the complete starting procedure of Section 1.2.10.1.

1.2.10.3 RESTART AFTER A SHORT STANDSTILL

PERIOD OF TIME (LESS THAN 1 MONTH)

Refer to Section 1.2.10.2.

1.2.10.4 RESTART AFTER A LONG STANDSTILL

PERIOD OF TIME

After a seasonal standstill (1 till 6 months) or

maintenance operations;

Check settings of control and safety equipment. Proceed to the complete starting procedure.

Restarting compressor after a standstill period of time

more than 6 months, consult your supplier. It is

recommended to proceed with the initial start up

procedure.

1.2.10.5 STOPPING THE COMPRESSOR

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



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2. INSPECTION, MAINTENANCE AND

TROUBLE SHOOTING

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2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Table of Contents

Section Title Page

2.1 INSPECTION 21

2.1.1 Periodical inspection 21

2.1.2 Survey of periodical inspections 21

2.1.2.1 CHECK LIST PERIODICAL INSPECTIONS 21

2.2 MAINTENANCE (REFER Chapter 5) 23

2.2.1 Post start-up maintenance 23

2.2.2 First maintenance 23

2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 23

2.4 LUBRICATION DATA 23

2.4.1 Topping up oil with compressor operating 23

2.5 EVACUATION OF THE COMPRESSOR 24

2.6 DRAINING AND CHANGE OF OIL 24

2.7 OIL SUCTION AND DISCHARGE FILTERS 24

2.8 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 24

2.9 COMPRESSOR PURGING 24

2.10 TROUBLESHOOTING TABLE 24



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2.1 INSPECTION

2.1.1 PERIODICAL INSPECTION

These inspections should be made during the normal shut-down periods as much as possible, so the compressor is always ready to operate when required. If, at that time, the number of running hours slightly differs from the scheduled period below, the inspection should nevertheless be carried out.

In this way it will not be necessary to stop the compressor at inconvenient times.The frequency of inspections is dependent on the type of installation, operating conditions and local regulations. In the case of automatically controlled plants, the periodical inspection are particularly important. The table below sums up all the points on the compressor that have to be inspected or maintained along with inspection and maintenance frequencies.

2.1.2 SURVEY OF PERIODICAL INSPECTIONS

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

2.1.2.1 CHECK LIST PERIODICAL INSPECTIONS



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CHECK POINTSa

a. During the first 50 operating hours the compressor should be checked regularly for all the points mentioned above, at least twice every 24 hours and more frequently in cases where irregularities are found.

FREQUENCY REMARKS

daily

weekly

mo

nth

ly

Oil level in crankcase

Between 25% and 75% height of the sight glass. For topping up oil, refer to Section 2.4.1.

Colour of the oil

The oil should be transparently clear. A disappearing white colour points to dissolved refrigerant.

Lubricating oil pressure difference

Oil temperature max.

Refer to the "Product Information"

Suction pressure

Check against design conditions. Refer to plant manual.

Discharge pressure

Refer to plant manual. For the max. allowable discharge pressure refer to the technical data of compressor.

Suction superheat

0 K

Discharge temperature max.

155 C/175 Cb

b. Only in combination with water cooling and cylinderhead temperature protection,

Oil temperature min.

During compressor standstill the lower part of the crankcase must remain warmer than the surroundings: 20 C

Adjustment and operation of pressure safety switches

Refer to Section 1.2.5.1 and to instructions of switch manufacturer.

Capacity control (if provided)

The time lag between the unloading and loading of one cylinder or cylinder group should generally be at least 3 - 5 minutes.

Start/stop intervals

The time interval between stopping and starting, starting and re-starting, loading and unloading refer to section Starting and stopping procedures.

Number of operating hours

Check the number of operating hours in view of any maintenance operations to be carried out.

Cooling water temperature (if present)

Min. actual condensing temperature plus 10 K

(> Tc+10)



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2.2 MAINTENANCE (REFER CHAPTER 5)

2.2.1 POST START-UP MAINTENANCE

After the compressor has run for the initial 100 operating hours:i) Drain the oil and refill the compressor with the

correct amount of fresh oil.ii) Replace the red marked oil discharge filter element

with the grey marked filter element in accordance with the filter replacement instructions. Refer also to .

iii) Inspect suction gas filter (refer to the Compressor Service Instruction Manual).

iv) Exchange or clean oil suction filter element (refer ).v) Check the compressor shaft seal for leakage. If

excessive (more than 1 cc/hr) replace the seal.vi) 1) Retighten the coupling mounting bolts with the

torque settings as given by the coupling manufacturer.2) Verify and if necessary, correct the tension of the V-belts as given in the V-belt supplier's instructions.

vii)Verify and if necessary, correct the torque settings of all foundation bolts as given in Compressor Service Instruction Manual.

2.2.2 FIRST MAINTENANCE

For complete service schedules and required service sets refer to Grasso's Service and Maintenance Schedules (SMS).

After the refrigerating plant has been modified, the suction gas filter(s). the oil filters and the oil should be changed.

2.3 STEPS FOR LONGER SHUT-DOWN

PERIODS (> 6 MONTHS)

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

i) Tightly shut both the suction and discharge stop valves and the stop valve of the oil return line (if present).

ii) Disconnect the power source from the compressor drive motor and the electrical control cabinet.

iii) Place a moisture absorbing compound (eg a dessicant such as silica gel) inside the control cabinet.

iv) Place warning tags on the electric system and all closed stop valves.

Prior to starting up after a shut down, change the oil (refer to ) and exchange the oil filters. Determine the starting and stopping procedure from prior to start the compressor.

2.4 LUBRICATION DATA

Determine max Toil and set this value in the safety device.Change the oil as soon as an oil analysis indicates contaminated oil.

It is expressly pointed out that it is not permitted to mix

different types of oil. If another type of oil is used, first

remove all the stale oil in the filters, oil pump, crankcase,

shaft seal, oil separator and oil drains of the installation.

2.4.1 TOPPING UP OIL WITH COMPRESSOR

OPERATING

Use Grassos hand-operated oil pump, part. no. 18.13.121

Topping up oil is permitted during compressor operation.

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

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

Fig. 2.4-1 Oil level in compressor sight glass

Maintenance Number of operating hours

100a

a. Time dependent on pollution.

> 100

Renewal of oil discharge filter X

refer to Service and Maintenance

Schedules (SMS)

Renewal of suction gas filter(s) X

Inspection of oil suction filter X

Oil analysis bc

b. Take an oil sample every 3,000 running hours or twice a year and renew if any sign of discoloration and if the system is contaminated.

c. Consult your oil supplier.

X

Inspection leakage shaft seal X

Inspection relief valve(s)d

d. If temperature of relief valve is close to (LP/HP) discharged temp, consult your supplier.

X



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2.5 EVACUATION OF THE COMPRESSOR

Use always a vacuum pump to evacuate the compressor.

To evacuate the refrigeration system refer to Section 1.2.2, Procedure to evacuate the compressor:

i) Switch off main control panel.ii) Remove main fuses.iii) Remove the refrigerant by means of a vacuum pump,

via the evacuation/purging valve(s) as prescribed by local safety regulations. For the location of these valves refer to the "Product Information".

2.6 DRAINING AND CHANGE OF OIL

To top up oil see Section 2.4.1, Oil changing 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 service openings on the compressor side.

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

iv) Replace the service cover(s) with a new seal.v) Charge crankcase with clean oil in accordance with

the procedure.

2.7 OIL SUCTION AND DISCHARGE FILTERS

Schedule

Replace these filters according to the Service Maintenance Schedules.The frequency of exchanging these filters depends on the conditions of the refrigeration system.

It is recommended to exchange these filters when the compressor is overhauled or when pressure drop exceeds 1.0 bar.

2.8 DISMANTLING, INSPECTION AND

RE-ASSEMBLY OF SUCTION AND

DISCHARGE VALVES

A high working temperature and rapid temperature variations shorten the life time of the valves, which, for this reason, require regular inspection.

The suction and discharge valves of a refrigeration compressor are parts that are heavily loaded both mechanically and thermally. Wear and life time of the

valves strongly depend on the working conditions of the compressor. It is recommended that valve condition is regularly checked.For dismantling, inspection and re-assembly of the valves, refer to the relevant paragraph of the Compressor Service Instruction Manual.

In order to reduce the downtime involved in the valve inspection, it is recommended to have as many complete valve assemblies in stock as there are cylinders on the compressor.These valves can be exchanged with the original valves; in this case, these original valves can be inspected and repaired or replaced if necessary later.

2.9 COMPRESSOR PURGING

Procedure to purge the compressor(after maintenance jobs):

STATUS:

Stop valves of suction, discharge and oil return line are still closed (refer to Section 2.5) and compressor is filled with oil (refer to Section 2.6).

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

ii) When evacuation is completed open the discharge stop valve.

iii) Watch suction and discharge pressure.

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 the oil

separator (if present).vii) For two stage compressor only;

a. Two-stage system A/B: open liquid supply to interstage cooler.

b. Two-stage system C/D: refer to the plant manual.viii)If a Self-Limiting Automatic Purger is not installed,

purge the refrigerating system (refer to the plant manual).

2.10 TROUBLESHOOTING TABLE

The troubleshooting table shown overleaf may be helpful to quickly trace and remedy failures that interfere with the proper operation of the compressor. It is emphatically pointed out that the cause of a failure must often be sought in the refrigeration installation itself. Therefore, it is necessary besides this table also to consult the plant manual.



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Table 2.10-1 Troubleshooting

FAULT CAUSE REMEDY

A Discharge pressure too high

1. Discharge stop valve not fully open

Open fully

2. Discharge pressure gauge defective

Repair or replace

3. Non-condensables in the system

Purge with a Automatic Purger

B Discharge temperature too high

1. Discharge pressure too high

See A

2. Too many cylinders cut out

Cut in more cylinders

3. Suction pressure too low

See D

4. Excessive superheat of suction gas

Eliminate excessive superheat

5. For two-stage compressors: interstage cooling does not operate properly

Repair

6. Room temperature too high

Ventilate engine room better

7. Discharge valve defective

Repair or renew

8. Pressure relief valve is leaking

Repair or renew

9. Water cooling is not working properly

Repair

C Suction pressure too high

1. Capacity control does not operate

Repair

2. Compressor capacity too small

Refer to plant design

3. Suction pressure gauge defective

Repair or renew

4. One or more suction valves defective

Renew suction valve rings

5. One or more discharge valves defective

Repair or renew

6. Pressure relief valve is leaking

Repair or renew

D Suction pressure too low

1. Suction stop valve not fully open

Open fully

2. Suction gas strainer blocked

Renew

3. Injection control not adjusted correctly

Re-adjust control

4. Too little refrigerant in installation

Top-up with refrigerant

5. Suction pressure gauge defective

Renew

E Crankcase frosted or wet

Stop compressor and contact installation engineer

1. Liquid refrigerant in crankcase due to:

1a. Room temperature too low

Provide for crankcase heating or, if provided, check it for proper operation

1b. Oil return from separator contains liquid refrigerant

Consult plant manual

1c. Installation operates too wet

Re-adjust installation and provide for superheat

1d. Liquid separator too small

Consult plant manual

F All cylinders inactive while compressor is operating

1. Oil pressure for valve lifting mechanism too low (For Grasso 12, Grasso 12E and Grasso10 only)

See J

2. Incorrect wiring of capacity control

Refer to the "Product Information

G Too high oil consumption

1. Type of oil not according to oil lubrication oil table (too thin oil)

Change oil type

2. Compressor operates unloaded too frequently

Refer to design calculations

3. No return from oil separatora

Check the operation of float valve in oil separator

4. Restriction plug at the bottom of suction chamber in cylinder clogged

Clean plug

5. Worn out oil scraper ring(s)

Replace ring(s)

6. Loss of oil due to leakage

Repair

7. Leaking shaft seal (max. 1 cc/hr) (For Grasso 12, Grasso 12E and Grasso10 and Grasso 6 only)()

Repair shaft sealRefer to Section 2.2

8. Oil level in crankcase too high

Drain/Refill with oil

9. Oil separator is not initially filled with oil

Refer to section Initial oil charge

H Too high oil pressure during normal operation at working temperature

1. Lubricating oil pressure regulator not adjusted properly or defective

Re-adjust or renew

2. Defective oil pressure and/or suction pressure gauge (if present)

Repair or replace

FAULT CAUSE REMEDY



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J Too low lubricating oil pressure

1. Too little oil in crankcase

Top up oil

2. Disturbed oil circuit: Oil suction and/or discharge filter is dirty

Renew the element of oil suction filter and/or oil discharge filter

3. Lubricating oil pressure regulator not adjusted properly or defective

Re-adjust or renew

4. Liquid refrigerant in crankcase

See E

5. Defective oil pressure and/or suction pressure gauge (if present)

Repair or renew

6. Worn bearings Renew bearings

K Too low or no control oil pressure (For Grasso 12, Grasso 12E and Grasso10 only)

1. Failure of control oil pressure regulator in oil pump

Re-adjust or renew regulator

2. A lack of oil in oil system

Add oil to the system

3. Oil pump defect Repair or renew oil pump

a. During the initial start-up, the oil separator (if present) consumes oil before the first oil will be returned.

FAULT CAUSE REMEDY


3. PARTS COMPRESSOR

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3. PARTS COMPRESSOR

Table of Contents

The RC6, RC12 and RC12E have been rebranded and each type number is now prefixed with the name Grasso (ie Grasso 6, Grasso 12, Grasso 12E) However, for this chapter, both the old and the new designations are interchangeable and can be considered valid.

Parts List Page Figure

COMPRESSOR HOUSING WITH CONNECTIONS 28 RC6-01

MAIN BEARINGS 30 RC6-02

CRANKSHAFT 32 RC6-03

PISTON AND CONNECTING ROD 34 RC6-04

SUCTION AND DISCHARGE VALVE (from mach. nr. 99061345) 36 RC6-05

ROTARY SHAFT SEAL 38 RC6-06

OIL PUMP 40 RC6-07

CAPACITY CONTROL MECHANISM 42 RC6-08

OIL DISCHARGE FILTER 44 RC6-09

FLANGED MAIN CONNECTIONS 46 RC6-10

SUCTION GAS STRAINER 48 RC6-11

OIL SUCTION FILTER 50 RC6-12

OIL PRESSURE REGULATOR 52 RC6-13

STANDARD SETS OF PARTS, SEALS AND TOOLS 54 RC6-14


3. PARTS COMPRESSOR

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Item Description Dims. Ref. No. Qty Remarks

Fig. RC6-01 COMPRESSOR HOUSING WITH CONNECTIONS

1 CYLINDER HEAD COVER ASSY * - with capacity control

1.1Aa CYLINDER HEAD COVER RC6-2CR 2336521 - with capacity control for 2 cyl.

1.1Ab CYLINDER HEAD COVER RC6-2CR 2336525 - RC6W: with capacity control for 2 cyl.

1.1Ba CYLINDER HEAD COVER RC6-1CR 2336510 - with capacity control for 1 cyl.

1.1Bb CYLINDER HEAD COVER RC6-1CR 2336515 - RC6W: with capacity control for 1 cyl.

1.2 HEXAGON HEAD BOLT M10x120 0110512 2

1.3A GASKET 190x405x2CR 0907192 - on item 1.1A

1.3B GASKET 190x405x1CR 0907191 - on item 1.1B

2 CYLINDER HEAD COVER ASSY * - without capacity control

2.1a CYLINDER HEAD COVER RC6-OCR 2336500 -

2.1b CYLINDER HEAD COVER RC6-OCR 2336505 - on type RC6W only

2.2 GASKET190x405x1.5-

OCR0907190 -

3.a HEXAGON HEAD BOLT M10x100 0110510 20 18 on item 1 (for RC6 types only)

3.b HEXAGON HEAD BOLT M10x120 0110512 20 18 on item 1 (for RC6W types only)

4 FLAT WASHER M10 1113501 36

5 CRANKCASE RC6 * 1

6 GASKET 175x290x1.5 0907175 1

7.a INSPECTION SIDE COVER 175x290 0530175 2 RC6 (2x), RC6W (1x)

7.b INSPECTION SIDE COVER 175x290WK 0530178 2 RC6W (1x)

8 HEXAGON HEAD BOLT M10x40 0110540 16

9 O-RING 2.62x32.99 0952284 1

10 SIGHT GLASS 29x60 1224029 1


12 EYE BOLT M16 0118812 2

13 SPRING LOADED SAFETY 26.5G33 1249333 1

14 PLUG G13S 0136134 5 if connection not in use

15 CRANKCASE HEATER 240V-200W 1372203 1

16 STOP VALVE TAH8-12 0607011 1

17 ORIFICE G13x3x20 0123139 2

18 ALU.SEALING RING 21x25x1 0912021 2 in RC46(W) compressor only

19.a PLUG G21 0136216 3 in RC46(W) compressor only

19.b PLUG G21 0136216 1 in types RC66(W) & RC86(W)

20 ALU SEALING RING 21x27x2 0914023 1

21 ALU SEALING RING 13.5x20x1 0912014 5

22 NIPPLE COUPLING 12G13 0338131 1

23 NIPPLE COUPLING 12G21 0338211 1


3. PARTS COMPRESSOR

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Fig. 3-1 RC6-01


3. PARTS COMPRESSOR

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Fig. RC6-02 MAIN BEARINGS

1 BEARING FLANGE 60x15x11.5 1143600 1 driving end

2 BEARING ASSY RC6 * 1

2.1 PUMP HOUSING RC6 * --------- refer to parts list FIG. RC6-7

2.2 O-RING 3.53x209.14 0952365 1

2.3 BEARING FLANGE 60x50xM10 1143651 1 oil pump end (from 95.08.1648)

2.4 SOCKET HEAD SCREW M10x100 0104510 4

3 FLAT WASHER M10 1113501 16




3. PARTS COMPRESSOR

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Fig. 3-2 RC6-02


3. PARTS COMPRESSOR

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Fig. RC6-03 CRANKSHAFT

1.1 CRANKSHAFT E/K-RC6 * 1

1A.a CRANKSHAFT E-RC6 2236400 1 4-cylinder compressor

1A.b CRANKSHAFT K-RC6 2236410 1 4-cylinder compressor

1B.a CRANKSHAFT E-RC6 2236600 1 6-cylinder compressor

1B.b CRANKSHAFT K-RC6 2236610 1 6-cylinder compressor

1C.a CRANKSHAFT E-RC6 2236800 1 8-cylinder compressor

1C.b CRANKSHAFT K-RC6 2236810 1 8-cylinder compressor

2 KEY 14x9x70 1102570 1

3 CARRIER DISC 60x5A 1125106 1 from 95.08.1648

4 SOCKET HEAD SCREW M10x25 0104525 2


3. PARTS COMPRESSOR

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Fig. 3-3 RC6-03


3. PARTS COMPRESSOR

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Fig. RC6-04 PISTON AND CONNECTING ROD

1 PISTON ASSY 85RC6 2436010 1

1.1 PISTON 85RC6H * 1

1.2 GUDGEON PIN 26x16x68R6 2436260 1

1.3 SAFETY RING * 2

1.4 PISTON RING SET 85RC6 0974084 1

2 CONNECTING ROD 60x170xRC6 2436500 1

2.1 CONNECTING ROD 170RC6 * 1

2.2 CONNECTING ROD BOLT MF8 0111401 2

2.3 LOCKING RING SET M8 1139400 2

2.4 HEXAGON NUT MF8x1 0147405 2


3. PARTS COMPRESSOR

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Fig. 3-4 RC6-04


3. PARTS COMPRESSOR

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Fig. RC6-05 SUCTION AND DISCHARGE VALVE (from mach. nr. 99061345)

1 HEXAGON HEAD BOLT M10x40 0110540 4 DIN 540

2 FLAT WASHER M10 1113501 4

3 PRESSURE RING RC6 2736410 1

4 SINUSOIDAL SPRING 87x125x4 1133087 1

5.H DISCHARGE VALVE ASSY RC6 2736103 1 option "H" (High), refer selection table

5.L DISCHARGE VALVE ASSY RC6 2736113 1 option "L" (Low), refer selection table

5.1 LOCKING NUT M8 0145400 1

5.2 FLAT WASHER M8 1113401 1

5.3 DISCHARGE VALVE STROKE LIMITOR RC6 * 1

5.4a SINUSOIDAL SPRING 64x76x0.5 * 1 option "L" (Low), refer selection table

5.4b SINUSOIDAL SPRING 64x76x0.5 * 2 option "H" (High), refer selection table

5.5 DISCHARGE VALVE RING 64x76x1 * 1

5.6 SUCTION STROKE LIMITOR RC6 * 1

5.7 FITTED BOLT M8x35 * 1

5.8H DISCHARGE VALVE AND SPRINGSR

(halocarbons)1134105 1

5.8L DISCHARGE VALVE AND SPRINGNH3

(ammonia)1134110 1

6 DAMPER RING 108x87x4 * 1

7 SINUSOIDAL SPRING 88x103x0.7 * 1

8 SUCTION VALVE RING 88x103x0.7 * 1

9 O-RING 3.53x117.07 0952362 1

10 CYLINDER LINER 85RC6 2336120 1

11 O-RING 3.53x91.67 0952361 1

12SUCTION VALVE RING, SPRING AND DAMPER RING

RC6/GR7 1134115 1


3. PARTS COMPRESSOR

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Fig. 3-5 RC6-05


3. PARTS COMPRESSOR

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Fig. RC6-06 ROTARY SHAFT SEAL

1 SHAFT SEAL HOUSING RC6 2636100 1

2A PLUG G13S 0136134 1

2B PLUG NPT13X1.5 0365513 1

3 NIPPLE COUPLING 6N10 0338810 1

4 O-RING 3.53x158.34 0952364 1



7 SHAFT SEAL SET RC6 0962900 1


3. PARTS COMPRESSOR

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Fig. 3-6 RC6-06


3. PARTS COMPRESSOR

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Fig. RC6-07 OIL PUMP

1 PUMP COVER RC6 2636700 1

2 OIL PUMP ELEMENT RC6A 2636601 1

3 BEARING RC6x13.5 2636710 1


5 O-RING 3.53x209.14 0952365 3

6 O-RING 3.53x136.12 0952363 1

7 PUMP HOUSING RC6E 2636503 1 from 95.08.1647


3. PARTS COMPRESSOR

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Fig. 3-7 RC6-07


3. PARTS COMPRESSOR

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Fig. RC6-08 CAPACITY CONTROL MECHANISM

1 FLANGE RC6C 2736702 1

2 CYLINDER HEAD SCREW M4x10 0168210 4

3 PISTON CAPACITY CONTROL RC6 2736600 1

4 PRESSURE SPRING1.25x10x11.5

x511131132 1

5 PISTON FITTING RING 56x51.3x2 0970056 1

6 FLAT WASHER M10 1113501 4 per controlled cylinder cover


8 GASKET 87x94x1.5 0907087 4

9 CYLINDER CAPACITY CONTROL RC6 2736500 1

10 PISTON FITTING RING 40x36.6x2 0970040 1

11.1A VALVE BODY * 1

11.1B VALVE BODY * 1

11.2A VALVE COIL110-120/50-

601316311

11.2B VALVE COIL220-240/50-

601316322 1

11A SOLENOID VALVE 110/120V * 1

11B SOLENOID VALVE 220FA 0680111 1 NH3

12.a CONNECTOR DIN 1316610 1without LEDfor valves 11A/11B, without LED

12.b CONNECTOR220/240 V AC, DIN incl. LED

1316611 1with 220V-AC/DC LED`with 220V-AC/DC LED

12.c CONNECTOR24/48 V

AC/DC, DIN incl. LED

1316615 1with 48V-AC/DC LEDwith 48v-AC/DC LED

13 SOCKET COUPLING 6G10 0337106 1

14 SET SCREW M5x10 0123010 1

15 PLUG M8x1 0365708 3

16 O-RING 9.3 0951093 2


3. PARTS COMPRESSOR

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Fig. 3-8 RC6-08


3. PARTS COMPRESSOR

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Fig. RC6-09 OIL DISCHARGE FILTER

1 FILTER SET RC6 0711900 1

1.1 O-RING 3.53x136.12 0952363 1

1.2 FILTER CARTRIDGE 480x15 * 1

2 LOCKING NUT M6 0145300 1

3 STUD M6x20 0151320 1

4 FILTER HOUSING 130 0702130 1




3. PARTS COMPRESSOR

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Fig. 3-9 RC6-09


3. PARTS COMPRESSOR

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Fig. RC6-10 FLANGED MAIN CONNECTIONS

1A SHOULDER FLANGE RC46 0539045 1

1B SHOULDER FLANGE RC66 0539051 1

1C SHOULDER FLANGE RC86 0539063 1

2 HEXAGON HEAD BOLT M16x40 0110840 4 per flanged connection

3 GASKET 67x81x1.5 0903067 1 per flanged connection

4 SPRING LOADED SAFETY 26.5G33 1249333 1


3. PARTS COMPRESSOR

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Fig. 3-10 RC6-10


3. PARTS COMPRESSOR

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Fig. RC6-11 SUCTION GAS STRAINER

1A SHOULDER FLANGE RC46 0539048 1

1B SHOULDER FLANGE RC66/RC86 0539060 1

2 GASKET 67x81x1.5 0903067 2

3 STRAINER ELEMENT 544x100 0716544 1


3. PARTS COMPRESSOR

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Fig. 3-11 RC6-11


3. PARTS COMPRESSOR

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Fig. RC6-12 OIL SUCTION FILTER

1 STRAINER ELEMENT 149x16 0716164 1 from machine nr. 95.08.1648

2 SWIVEL COUPLING 16G21 0339216 1 from machine nr. 95.08.1648


3. PARTS COMPRESSOR

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Fig. 3-12 RC6-12


3. PARTS COMPRESSOR

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Fig. RC6-13 OIL PRESSURE REGULATOR

1 PRESS. REGULATOR SET SAM RC6 1241140 1

lubricating oil pressure regulator included. To replace the internal regulator for an external regulator, conversion kit 12.41.145 should be applied.

1.1STEEL PRECISION PIPE WITH VALVE HOUSING

K12x1.5 1241012 1

1.2 ALU SEALING RING 21.5x27x1 0912022 1

1.3 BEAMING BALL W16 1119010 1

1.4 PRESSURE SPRING1.25x14x9x35

.51131134 1

1.5 THRUST BOLT G21x60S 0135218 1

1.6 O-RING 1.78x8.73 0952184 1

1.7 NIPPLE G21CxG21 0304921 1

1.8 ALU SEALING RING 10x18x1 0912010 1

1.9 CAP NUT GK21R 0117021 1

2 NIPPLE COUPLING 12G13 0338131 1 refer to fig. RC6-6

3 NIPPLE COUPLING 12G21 0338211 1 refer to fig. RC6-1


3. PARTS COMPRESSOR

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Fig. 3-13 RC6-13


3. PARTS COMPRESSOR

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Fig. RC6-14 STANDARD SETS OF PARTS, SEALS AND TOOLS

1a GASKETS (SET) RC46/GR47 0990046 1 for RC46

1b GASKETS (SET) RC66/GR67 0990066 1 for RC66

1c GASKETS (SET) RC86/GR87 0990086 1 for RC86

2a DISCHARGE VALVE AND SPRINGSR

(halocarbons)1134105 1

2b DISCHARGE VALVE AND SPRINGNH3

(ammonia)1134110 1

3SUCTION VALVE RING, SPRING AND DAMPER RING

RC6/GR7 1134115 1 for R ( halocarbons ) and NH3 ( ammonia )

4 SET OF SPARE PARTS RC6/GR7 2036011 1 for all types

5a TIRE CLAMP 232 1508232 1 for coupling element 42

5b TIRE CLAMP 244 1508244 1 for coupling element 61

5c TIRE CLAMP 280 1508280 1 for coupling element 91


3. PARTS COMPRESSOR

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Fig. 3-14 RC6-14


3. PARTS COMPRESSOR

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4. PARTS ACCESSORIES

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Table of Contents

The RC6, RC12 and RC12E have been rebranded and each type number is now prefixed with the name Grasso (ie Grasso 6, Grasso 12, Grasso 12E) However, for this chapter, both the old and the new designations are interchangeable and can be considered valid.

Parts List Page Figure

PRESSURE GAUGES AND SAFETY SWITCH CABINET (Use 0337136 if your current pressure gauge connections differs from fig. RC6-1A

58 RC6-A1

DIRECT DRIVE 60 RC6-A2

COOLING WATER DEVICE 62 RC6-A3



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Fig. RC6-A1 PRESSURE GAUGES AND SAFETY SWITCH CABINET (Use 0337136 if your current pressure gauge connections differs from fig. RC6-1A

1.1a PRESSURE GAUGE NH3 - R-P-63 1210065 1

1.1b PRESSURE GAUGE R22 - 63 1212065 1

1.1c PRESSURE GAUGE R134a - 63 1212066 1

1.1dPRESSURE GAUGE DISCHARGE PRESSURE

R404A 1212067 1

1.2a PRESSURE GAUGE NH3 - R-Z-63 1210066 1

1.2b PRESSURE GAUGE R22 - Z-63-12 1212068 1

1.2c PRESSURE GAUGE SUCTION PRESSURER134a - Z-63-12

1212069 1

1.2d PRESSURE GAUGE SUCTION PRESSURER404A - Z-63-12

1212070 1

1.3 PRESSURE GAUGE R-O-63 1215065 1

1.4a PRESSURE SAFETY SWITCH MP55A 1260232 1

1.4b PRESSURE SAFETY SWITCH MP55 1261232 1

1.5a PRESSOSTAT NH3 KP15A 1260615 1

1.5bCOMBINED SUCTION/DISCHARGE PRESSURE SAFETY SWITCH

R KP15 1261615 1

1.5c PRESSOSTAT NH3 KP7ABS 1260618 1

1.5dCOMBINED DISCHARGE PRESSURE LIMITOR AND SAFETY SWITCH

R KP7BS 1261618 1

1.6a SUCTION PRESSURE SAFETY SWITCH NH3 KP1A 1260608 1

1.6b SUCTION PRESSURE SAFETY SWITCH R KP1 1261608 1

1a.1PRESSURE GAUGE AND SAFETY SWITCH CABINET

NH3 - std 1208301 1 with 2 safety switches


R22 - std 1208601 1with an additional safety switch to meet German UVV-VBG20 regulations


R134a - std 1208701 1


R404A 1208801 1

1b.1PRESSURE GAUGE AND SAFETY SWITCH CABINET

NH3 - UVV-VB420

1208302 1


NH3 - UVV-VB420

1208602 1


NH3 - UVV-VB420

1208702 1


NH3 - UVV-VB420

1208802 1



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Fig. 4-1 RC6-A1



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Fig. RC6-A2 DIRECT DRIVE

1.1a COUPLING ELEMENT 42 1918842 1

1.1b COUPLING ELEMENT 61 1918861 1

1.1c COUPLING ELEMENT 91 1918891 1

1a FLEXIBLE COUPLINGtype 42

(complete)* 1

1b FLEXIBILE COUPLINGtype 61

(complete)* 1

1c FLEXIBLE COUPLINGtype 91

(complete)* 1

2 CLAMPING SLEEVE - * 1



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Fig. 4-2 RC6-A2



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Fig. RC6-A3 COOLING WATER DEVICE

1 HOSE, RUBBER 19W 1518019 1 per cylinder head cover connection

2 HOSE CLAMP 19-28 mm 1508600 1twice per hose, per cylinder head cover connection

3 SPIGOT NIPPLE 19xG21 1555419 1 per cyl. head cover connection

4 ANGLE SOCKET NIPPLE G21xG21 0372441 1 per cylinder head cover connection

5 SOCKET NIPPLE G21xG42 0302471 1 per cylinder head cover connection

6 NIPPLE COUPLING 16G21 0338212 1 per coil connection

6.1 CLAMPING SLEEVE P16 0334516 1 per coil connection

7 COIL COOLER16x1.5x64x28

00410364 1

8 CYLINDER HEAD COVER RC6-OCR 2336505 1

9 CYLINDER HEAD COVER RC6-1CR 2336515 1

10 INSPECTION SIDE COVER 175x290WK 0530178 1



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Fig. 4-3 RC6-A3



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5. MAINTENANCE

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5. MAINTENANCE

Table of Contents

5.1 SMS FACTOR

General

The running hours mentioned in the SMS tables should

only be used as a reference for maintenance intervals.

The running hours mentioned in the tables are based on a single stage compressor running at -10oC/+35oC, NH3 at nominal speed. In this case the SMS factor = 1, in all other cases the maintenance intervals have to be adjusted accordingly.

The number of running hours mentioned in the SMS

tables have to be adjusted accordingly depending on the

operating conditions of the compressor (speed,

evaporating temperature, condensing temperature,

refrigerant, start frequency, capacity control steps, etc..

This means that the service intervals could be

significantly different.

Section Title Page

5.1 SMS FACTOR 65

5.2 Grasso 6 67

5.3 Checklist 69


5. MAINTENANCE

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5. MAINTENANCE

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5.2 GRASSO 6

SERVICE AND MAINTENANCE SCHEDULES GRASSO 6

Item

Description

Actions

Checkpoint

Running hours * 1000a

0.1

YEARLY

3 6 - - -

9 - 12 - -

15 - - 18 -

21 - 24 - -

27 30 - - -

33 - - - 36

1

Oil

CL CL CL CL CL CL CL Oil suction filter

2 - RE RE RE RE RE RE Oil discharge filter

3 - ME ME ME ME ME ME Oil analysis

4 RE RE - RE RE RE REOil refreshment (If hygroscopical oil is used replace this always

after each opening of compressor or installation)

5Oil pump

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

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

7a

Crankshaft

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

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

8 - IC/ME - IC/ME IC/ME IC/ME IC/ME Running surfaces con. rods/Axial play

9 Shaft seal - IC IC IC IC IC IC Oil/refrigerant leakage

10 Conrod - IC/ME - IC/ME IC/ME IC/ME IC/ME Big and small end bearings

11

Pistons

- IC - IC IC IC IC Piston

12 - IC - IC IC IC IC Piston rings

13 - - - IC/ME IC/ME IC/ME IC/ME Gudgeon pin

14 Thrust bearing - IV/ME - IV/ME IV/ME IV/ME IV/ME Running surfaces/axial play

15

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

16

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

18

Compressor housing

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

19 - CL - CL CL CL CL Crankcase

20 - - - IC IC IC IC Throttle valves

21 - IV - IV IV IV IV Relief valves

22 IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter

23 Discharge valves - IC IC RE RE RE RE Valves, springs and damper rings

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

25 Suction valvesb - IC IV IC RE IC RE Valves, springs and damper rings

26Cylinder liners

- IV - IV IV IV IV Cap. Control lifting mechanism

27 - IV/ME - IV/ME IV/ME IV/ME IV/ME Dimension and running profile

28Drive

IC IC IC IC IC IC IC Alignment

29 IC IC IC IC IC IC IC V-belts

30 Electric motor Refer to specification of motor supplier


5. MAINTENANCE

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31

Optionals

IC IC IC IC IC CL/IC CL/IC Oil level switch

32 IC IC IC IC IC IC IC Safety switches

33 IC IC IC IC IC IC IC Gauges

34 IC IC IC IC IC IC IC Thermostats

35 IC IC IC IC IC IC IC Thermometers

36 IC IC IC IC IC IC IC Electrical control system

37 IC IC IC IC IC CL/IC CL/IC Valve oil return protection

39 IC IC IC IC IC IC IC Vibration dampers and bolts

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

42 ME ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL Cylinder head water cooling, incl. oil cooler

a. Check after every maintenance job the settings and working of all safety devices, regulators and the running condition according to the service instruction manual (SIM)

b. Suction valves for compressors < june 1999 (machine number < 9906****) must be changed every 6000 running hours in case not converted to latest standard

SERVICE AND MAINTENANCE SCHEDULES GRASSO 6

Item

Description

Actions

Checkpoint

Running hours * 1000a

0.1

YEARLY

3 6 - - -

9 - 12 - -

15 - - 18 -

21 - 24 - -

27 30 - - -

33 - - - 36

Legend for service and maintenance schedules (SMS)

Item Code/Action Description

1 IC Inspection / Alternatively renewal - correcting / Testing

2 IV Inspection Visual / Alternatively electrical testing

3 RE Renewal

4 ME Measure

5 CL Clean


5. MAINTENANCE

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5.3 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 General Notes

1

Oil

Oil suction filter

2 Oil discharge filter

3 Oil analysis

4Oil refreshment (If hygroscopic oil is used replace this always after each

opening 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 bearing Running surfaces/Axial play

15

Capacity control

Solenoid valves and coils

16 Seals of cap. control piston

17 Cap. Control mechanism


5. MAINTENANCE

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Table 5.3-1 Settings pressure safeties

18

Compressor housing

Crankcase heater

19 Crankcase

20 Non return valves LP/HP

21 Relief valves

22 Suction gas filter

23 Discharge valves

Valves, springs and damper rings

24 Stroke limitor/Discharge valve seat

25 Suction valves Valves, springs and damper rings

26Cylinder liners

Cap. Control lifting mechanism

27 Dimension and running profile

28Drive

Alignment

29 V-belts

30 Electric motor 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

SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS

Item

Description Checked/Remarks/Notes Checkpoint/Setting/Value

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


6. APPENDIX; Product Information (PI)

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Table of Contents

6.1 TECHNICAL DATA

Table 6.1-1 Technical Data of Grasso 6 compressors

Section Title Page

6.1 TECHNICAL DATA 71

6.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 73

6.3 SHAFT END COMPRESSOR 74

6.4 LIMITS OF OPERATION AND FIELDS OF APPLICATION 75

6.4.1 GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 6 75

6.4.1.1 FIELDS OF APPLICATION 76

6.4.2 PRECISE FIELD OF APPLICATION 77

6.4.3 LIMITATIONS OF PART-LOAD OPERATION 77

6.5 LUBRICATING OILS (choice and recommendations) 79

6.6 CAPACITY CONTROL 80

6.6.1 CYLINDER NUMBERING 81

6.7 PACKAGED BASE FRAME 82

6.7.1 PACKAGED BASE FRAME 82

6.8 CRANKCASE HEATER 83

6.8.1 DETAILS CRANKCASE HEATER 83

COMPRESSOR TYPE 46 66 86

Number of cylinders z 4 6 8

Cylinder arrangement 2 x V 2 x W 2 x VV

Cylinder bore D mm 85

Piston stroke S mm 66

Swept volume at full-load: n = 1450/min Vs m3/h 130.3 195.5 260.7

Standard direction of rotationcounter-clockwise when facing shaft end (both

directions permitted)

Standard compressor speeds (with V-belt drive) at motor speed:

1450 min-1

(50 Hz)n min-1 810- 855- 905- 1015- 1140- 1215- 1285- 1450

1750 min-1

(60 Hz)n min-1 800- 875- 980- 1030- 1095- 1225- 1380- 1465

Standard steps of capacity control (expressed in percentage of full load swept volume)

% 100-50 100-67-33 100-75-50-25

Mass of bare compressor (without flywheel and other accessories)

kg 280 345 400

Oil charge in crankcase and oil circuit (centre line of sight glass)a

dm3 9.2 (8.5) 10.0 (9.3) 10.8 (10.1)

Friction power at an 55 C oil temperature n= 1450/min Pw kW 1.10 1.58 2.22

Mass moment of inertia of crank mechanism (without flywheel)b

Id kg.m2 0.0361 0.0421 0.0478

a. The figures between brackets indicate the smaller oil charge for the Grasso 6W compressors due to the presence of an oil cooler.b. The mass moment of inertia Id expressed in SI units, is required to determine the so-called coefficient of speed fluctuation.



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6.2 MAIN DIMENSIONS AND SPACE

REQUIREMENTS

Table 6.2-1

COMPRESSORTYPE

46 46W 66 66W 86 86W

Length A 696 696 721 721 746 746

Width B 840 893 929

C 316 316 379 379 395 395

D 316 316 352 352 363 363

E 189.5 189.5 202 202 202.5 202.5

F 300 300 248 248 228 228

Height G 544 544 644 644 619 619

H 394 394 432 432 444 444

J 60 60 65 65 62 62

K 444 444 482 482 494 494

L 69 69 69

M 155 173 180

N 388 430 446

O 435 328 247

Q 680 660 696

MINIMUM REQUIRED FREE SPACE for removal of:

crankshaft U 661 661 673 673 711 711

piston and cylinder liner

V 260 260 325 325 360 360

W 626 700 748 748 725 725

LOCATION OF CENTRE OF GRAVITY

length Y 225 225 250 250 270 270

width Z 72 72 77 77 67 67

MAIN CONNECTIONS DN (mm)a

suction 1 40 40 50 50 50 50

discharge 2 32 32 40 40 50 50

COMPRESSORTYPE

46 46W 66 66W 86 86W



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6.3 SHAFT END COMPRESSOR

Fig. 6.3-1 Shaft end compressor

AUXILIARY CONNECTIONS

suction pressure

3

1/4 BSP (plugged off)discharge pressure

4

Oil pressure 5 1/8 BSP (plugged off)

Crankcase pressure

6

1/4 BSP (plugged off)Return from oil separator or

rectifier7

Oil charge and drain valve

8

1/4 BSP (plugged off)Oil

temperature9

Crankcase heater

101/2 BSP female to suit thread of heating

element

Oil leakage drain of rotary

shaft seal11

clanp coupling provided with dia. 6x1 mm steel precision pipe

Water inlet/outlet

(W-types) only12 dia. 19 mm hose connector

a. Provided with a purging and evacuation stop valve type TAH8 (standard on discharge connection and optional on suction connection.

COMPRESSORTYPE

46 46W 66 66W 86 86W



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6.4 LIMITS OF OPERATION AND FIELDS OF

APPLICATION

6.4.1 GENERAL LIMITS AND FIELDS OF OPERATION

GRASSO 6

When operating the compressor, none of the limits of operation as stated in the table below must be exceeded.1

The diagrams overleaf represent the overall fields of application in which the individual operation limits are taken into account.

Table 6.4-1 General limits and fields of operation

1. In practice, it is not so much the individual operation limits as combinations of them that are decisive for the conditions under which a compressor may operate. To check the various possibilities in this respect, use should be made of the "fields of application" ).

REFRIGERANT speed NH3 R22 R134a R404A R507

Compressor speed n min-1min. - 800

max. - 1500

Suction pressure = evaporating pressure =crankcase pressure

a pobar(a)

b

min. - 0.3

max.>=1140 min-1

6.2 6.8 6.26.0 5.8

=1140 min-1

+10.2 +10.0 +22.6-0.1 -2.0



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6.4.1.1 FIELDS OF APPLICATION

Fig. 6.4-1

Legend

AThis part of the general field of application is not covered by COMSEL. Consult Grasso to make a selection

for this applicaction



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6.4.2 PRECISE FIELD OF APPLICATION

The field of application diagrams as shown in this manual can vary slightly from the actual field of application for each particular selection.

The actual field of application is dependent on refrigerant, type of compressor, speed, suction superheat and partload steps.

Always consult Grasso's software program, COMSEL, to determine the precise field of application for an actual compressor selection.

6.4.3 LIMITATIONS OF PART-LOAD OPERATION

General

If a compressor operates continuously at the minimum part-load, the manufacturer should be consulted first to check whether this is allowed under the expected design conditions.

In the case of an Grasso 6-compressor and NH3, operating continuously at part-load, the general field of application is reduced in the sense that for each step of capacity reduction the limit line for Te = 155 oC moves to the right as shown in Fig. 6.4-2, by four Vs-indications in percentage.

In case the of an Grasso 6-compressor and NH3 and cylinder head water cooling can be applied (optional), and there are no part-load restrictions. In other words, the general field of application as shown in Fig. 6.4-2, also remains valid for part-load operation down to and including the standard minimum capacity control step of Vs = 25%.

Fig. 6.4-2 Field of applications for compressor type Grasso 6 with NH3 (upper graphic) and Grasso 6 with NH3 and water cooled cylinder heads (lower graphic)



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6.5 LUBRICATING OILS (CHOICE AND

RECOMMENDATIONS)

The choice of oil for a refrigeration compressor should be

made by taking into account the entire refrigeration

system design and operation as well as the operating

conditions of the compressor.

For lubrication of refrigeration compressors, several brands and types of specially developed lubricating oils are on the market. The choice of oil depends not only on its good lubrication properties (viscosity) and chemical stability at the operating conditions of the compressor, but also on the operating conditions of the refrigerating plant (solidifying and floc point, solubility).

Grasso has tested and approved for use in its reciprocating-compressors the brands and types of oil as listed tables below.The choice of the lubricating oil depends on type of refrigerant and the operating conditions of the compressor.The oil viscosity should always be more than 10 cSt.A higher ISO-VG number should be chosen when refrigerant solubility in crankcase is expected to be high especially in case of HCFCs and HFCs.

OIL SELECTION PROCEDURE:Use the oil viscosity selection table to select oil viscosity required. The following page lists all oils approved by Grasso for reciprocating compressors.

Table 6.5-1 Oil selection table

Table 6.5-2 Strongly recommended oil types for Grasso reciprocating

compressors - operati

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