grasso compressor manual

Reciprocating compressorsGrasso

Operating Manual0089292gbr_2

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.

Operating Manual | GrassoReciprocating compressors

2 GEA Refrigeration Netherlands N.V. | 0089292gbr_2 | Generated 15.07.2013

SYMBOLS USED IN THIS MANUALDanger!

Stands for an immediate danger whichleads to heavy physical injuries or tothe death.

Warning!

Stands for a possibly dangerous situa-tion which leads to heavy physicalinjuries or to the death.

Caution!

Stands for a possibly dangerous situa-tion which could lead to light physicalinjuries or to damages to property.

Hint!

Stands for an important tip whoseattention is important for the desig-nated use and function of the device.

SAFETY INSTRUCTIONS

General

Caution!

This manual must be carefull read andunderstood prior to servicing and run-ning the compressor (package). For allsafety instructions refer to Chapter 1,page 7This user manual is written with greatcare, but the contractor/installer isheld responsible for examining thisinformation and to take care of possi-ble additional and/ or deviated safetymeasures. Please consult your con-tractor (supplier).

Hint!

Before consulting your contractor(supplier) for any reason, make note ofthe data on the type plate fixed on thecompressor, package and/or otherpackage components.


GEA Refrigeration Netherlands N.V. | 0089292gbr_2 | Generated 15.07.2013 3

PREFACEThis operating manual is meant for the end-users ofGrasso reciprocating compressors and/or packages.This manual describes all safety instructions, globalproduct information, required periodical inspectionsand a trouble shooting list.The users of this equipment have to follow allinstructions as given in this manual. In case of anydoubt, the supplier of the refrigeration plant shouldbe consulted.For safety instructions refer to Chapter 1, page 7.

Hint!

GEA Grasso herewith declares that themachines mentioned are intended tobe incorporated into a refrigerationpackage (= assembly of refrigerationcomponents) or to be assembled withother equipment to constitute machin-ery covered by Machinery Directive2006/42/EC and do therefore complywith the provisions of this directivethat apply to partly completedmachines. Furthermore it is notallowed to put the machines men-tioned into service until the machineryin which it is to be incorporated, or, ofwhich it is to be a component, hasbeen found and declared to be in com-pliance with the provisions of Machin-ery Directive 2006/42/EC i.e. as a wholesystem including the machineryreferred to in this declaration.



TABLE OF CONTENTS1 SAFETY 7

1.1 REGULATIONS 71.2 MAINTENANCE AND REPAIRS 71.3 REFRIGERANT 71.4 OIL 81.5 OPERATING INSTRUCTIONS PRESSURE EQUIPMENT 8

1.5.1 Intended Use 81.5.2 Safety Notes and Warnings 91.5.3 Transport and Storage 91.5.4 Finishing and Installation 9

2 INTRODUCTION 102.1 SURVEY COMPRESSOR TYPES 10

3 INSPECTION 113.1 DAILY, WEEKLY AND MONTHLY INSPECTIONS 113.2 PERIODICAL INSPECTIONS TO BE CARRIED OUT BY YOUR CONTRACTOR (SUPPLIER) 12

4 FAULT ANALYSIS 134.1 GENERAL 13

5 MAINTENANCE 145.1 CONSULT YOUR CONTRACTOR (SUPPLIER) 14



1 SAFETY

1.1 REGULATIONS

Hint!

It is the task of the contractor (sup-plier) to inform and explain to you asuser, about the operation of the com-pressor (Package).Do respect all international, federal,state and local safety regulations/legislations during inspection, troubleshooting and operating this compres-sor (package).

1.2 MAINTENANCE AND REPAIRS

Warning!

All maintenance and repairs have to becarried out only by your contractor(supplier), except the maintenance asexplicitly mentioned in this manual.Do not open the compressor for ser-vice.

Caution!

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, oil separator(s),etc.After having run the initial 100 operat-ing hours,it is essential (in both newand modified plants) to replace therunning-in filter element with the per-manent filter element supplied. Thisoperation is only to be carried out bywell-trained and qualified personnel.Consult your supplier to carry out thisservice.This manual includes a check list fordaily, weekly and monthly inspections.Temperatures and pressures need tobe checked at several point (eg settingof all pressure safety switches). Incase this manual does not give thesevalues then your contractor (supplier)should instruct you with regard totheir correct setiings. When referenceis made to the plant manual, your con-tractor (supplier) should take care thatyour are instructed in being able toundertake proper inspections andtrouble shooting.

Hint!

In case of shut downs longer than 1month, it is advisable to put warninglabels on vital parts of the compressorsaying that the plant is out-of-opera-tion and must not be started up. Con-sult your contractor (supplier).

1.3 REFRIGERANT

The compressor/package must be filled withREFRIGERANT, to be able to operate.



Warning!

For safety instructions in relation tothe refrigerant used in this refrigera-tion plant, refer to separate informa-tion, to be supplied by your contractor(supplier).

1.4 OIL

The compressor/package must be filled with oil, tobe able to operate.

Warning!

For safety instructions in relation tothe oil used in this refrigeration plant,refer to separate information, to besupplied by your contractor (supplier).

1.5 OPERATING INSTRUCTIONSPRESSURE EQUIPMENT

Hint!

For pressure equipment (oil separatorOS, housing suction gas strainer,Economizer ICH, compressor package)manufactured by Grasso according tothe European Parliament"s and theEuropean Council"s Pressure Equip-ment Directive 97/23/EG of 29 May1997

General

The following operating instructions according to theEuropean Pressure Equipment Directive No.97/23/EG (subsequently referred to as PED)describe how to handle the pressure equipment forfinishing and installation.The pressure equipment is intended for installation incompressor packages or refrigeration plants and canbe equipped with specific accessories during installa-tion by the customer.The pressure equipment has been manufacturedaccording to the requirements of the PED. Its designmeets the requirements of the AD2000 regulations.If applicable the finisher/installer (at installation incompressor package or refrigeration plants andequipping ready for operation) is obliged to preparehis own risk analysis and operating manual accord-ing to the European Pressure Equipment Directive97/23/EG.

The type plates for identification of the pressureequipment looks like this:

fig.1: Example type plate economizer ICH, compressor, pack-age

fig.2: Example Type plate oil separator

If the type plate is covered by finishing/installation,make sure that the information can be seen by theend user on another location on the pressure equip-ment.In case of queries regarding the operatinginstructions, please contact Grasso.

1.5.1 Intended Use

The pressure equipment described here may not beused for any other than the stated purpose. Theequipment may only be installed by the finisher/installer and not by the end user.If the pressure equipment is not used according tothese regulations, safe operation of the equipment isnot guaranteed.The finisher/installer or the operator and not themanufacturer is responsible for all personal injuryand damage to property resulting from unintendeduse.When not installed by Grasso the finisher/installerhas to properly install accessories for the pressureequipment. The pressure equipment may not bedamaged during installation and it shall be paintedafter installation.



The pressure equipment may only be filled withrefrigerant of refrigerant groups L1 and L2, sub-stance groups 1 and 2. The pressure equipment hasto be installed in the compressor package or plant sothat no vibrations or pulsations can be transmitted tothe equipment.The connecting lines have to beinstalled to be tension free. The pressure equipmentis not designed for dynamic loads.Where there is arisk of lightning strikes, the pressure equipment mustbe earthed. The finisher/installer has to includeinstructions for regular inspection of the pressureequipment in his instruction manual and has todefine the end user"s behaviour in case of damage.To avoid burns or frostbite, the pressure vessel maynot be touched in the operating state. This can beachieved by means of contact guards. Install appro-priate warning signs.

Caution!

Optionally supplied safety valves areonly intended for the protection of theoil separator against excessive press-sure caused by an external heatsource during standstill. This devicemay not be used for the protection ofthe complete refrigeration system.(The finisher/installer has to equip theinstallation with a safety valve acc. EN378)

The oil separator may only be installed vertically.The foundation has to be of sufficient stiffness.

1.5.2 Safety Notes and Warnings

Visually inspect the pressure equipment with thenaked eye for corrosion, scoring and similar damage.Check the equipment for shape consistency of theconnection areas. In particular check and assess thesealing surfaces for possible damage such asscratches, scoring or similar.Keep corrosive substances such as acids away fromthe oil separator.Wall thicknesses may be no more than 1 mm lessthan those given in the drawing.Drain or suck off the medium (refrigerant/oil) prior toservice and repair. These tasks may only be carriedout by trained professionals and in compliance withthe appropriate safety regulations, see standard EN378.Carry out a detailed check of the previous operatinghistory, when an oil separator that has already beenin service is newly finished, installed and equipped.This includes visual inspection (as described above

for the new part). For recurring tests please refer toEN 378 T1 to T4 and local regulations.

1.5.3 Transport and Storage

Transport and store the oil separator in a dry envi-ronment. Ensure that the oil separator is not subjectto damage relevant to its further use.In case of transport damage notify Grasso immedi-ately.

1.5.4 Finishing and Installation

Design details can be seen in drawings at Grasso.Compare the identification (type plate) with the docu-mentation included in the delivery before finishing,installing and equipping the oil separator. Mark theoil separator with the note "Do not use" until theissue has been resolved with Grasso or an autho-rised third party (named authority according to thePED).



2 INTRODUCTION

2.1 SURVEY COMPRESSOR TYPES

General

A survey of the full range of Grasso reciprocatingcompressors, is given in the table below. Pleaserefer to the type plate of the compressor to deter-mine the type of compressor you are currently using.

SeriesType *1

Single stage Two stage

Grasso V

Grasso V 300 Grasso V 300T







Grasso VCM

Grasso V 700 CM Grasso V 700T CM

Grasso V 1100 CM Grasso V 1100TCM



Grasso 5HP

Grasso 35HP -

Grasso 45HP -

Grasso 55HP -

Grasso 65HP -

Grasso 12EGrasso 212E *2 Grasso 2112E *3

Grasso 312E Grasso 3112E

1 Type designation can be extended on the type plate of thecompressor with K(Approval), M(Marine application), ...

2 Grasso 12E compressor, with 2 cylinders.3 Grasso 12E compressor, with 2 low pressure cylinders and

1 high pressure cylinder.

SeriesType *

Single stage Two stage





- Grasso 8412E

- Grasso 9312E

- Grasso 10212E

Grasso 12

Grasso 212 Grasso 2112






- Grasso 8412

- Grasso 9312

- Grasso 10212

Grasso 10

Grasso 210 -







3 INSPECTION

3.1 DAILY, WEEKLY AND MONTHLYINSPECTIONS

These inspections should be made during the oper-ating periods.

The table below sums up all the points on the com-pressor that have to be inspected by the user.

Warning!

The compressor can be factory fittedwith gauges and switches and/or witha micro processor system. In the caseof a micro processor system, refer tothe user manual(s) of the micro pro-cessor and/or to the plant manual.Consult your contractor (supplier).

CHECKPOINTS *4

FREQUENCY

REMARKS *5

daily

wee

kly

mon

thly

Oil level incrankcase

Between 25% and 75%height of the sight glass.For topping up oil, con-sult your contractor (sup-plier).

Colour of theoil

The oil should be trans-parently clear. A disap-pearing white colourpoints to dissolved refrig-erant.

Lubricatingoil pressuredifference

Range1.5-3.0 barSetting 2.5 bar

Min. controloil pressure

Consult your contractor(supplier):Min. __________bar

4 During the first 50 operating hours the compressor shouldbe checked regularly for all the points mentioned above, atleast twice every 24 hours and more frequently in caseswhere irregularities are found.

5 Values of temperatures, pressures etc. as mentioned in thistable, are given by the manufacturer. Actual values for thisrefrigeration plant, currently used can differ for the min./max.values as given in this table. Your supplier has to inform youabout the actual/currently used values for this plant.

CHECKPOINTS *

FREQUENCY

REMARKS *

daily

wee

kly

mon

thly

Oil tempera-ture max.

Refer to plant manual,consult your contractor(supplier);

Max. __________oC

Oil leakageof shaft seal

Consult your contractor(supplier).

Suction pres-sure

Check against designconditions. Refer to plantmanual, consult yourcontractor (supplier);Min./Max.__________oC

Dischargepressure

Refer to plant manual,consult your contractor(supplier);Min./Max.__________oC

Suctionsuperheat

Intermediatesuperheat

R404A/R507 15 KOther refrigerants 0KMin. __________oC

Dischargetemperature

max. Max. 170 C

Oil tempera-ture min.

During compressorstandstill the lower partof the crankcase mustremain warmer than thesurroundings: 20 C(NH3)

Coolingwater tem-perature (if

present)

Min. Actual condensingtemperature + 10 K( Tc + 10 K)



3.2 PERIODICAL INSPECTIONS TOBE CARRIED OUT BY YOURCONTRACTOR (SUPPLIER)

SAFETY

Caution!

For a safe operation of the compres-sor/package, your contractor (sup-plier) must carry out the checks asmentioned in the table below.

Inspections by contractor

CHECKPOINTS *6

FREQUENCY

REMARKS

daily

wee

kly

mon

thly

Condition ofV-belts

Wear (fraying, cuts etc.)and ensure that they donot touch the groove bot-tom.

Tension. Too low a ten-sion gives rise to exces-sive flapping or oscilla-tion in operation. Forcorrect tension Grassoinstruction sheet0087516 must be used.

Adjustmentand opera-tion of pres-sure safetyswitches

Refer to instructions ofswitch manufacturer.

Capacitycontrol (ifprovided)

The time lag betweenthe unloading and load-ing of one cylinder orcylinder group shouldgenerally be at least 3 -5 minutes.

Switchingfrequency ofthe compres-

sor

The time intervalbetween stopping andstarting should be atleast 10 minutes andbetween starting andrestarting 15 minutes.

6 During the first 50 operating hours the compressor shouldbe checked regularly for all the points mentioned above, atleast twice every 24 hours and more frequently in caseswhere irregularities are found.



4 FAULT ANALYSIS

4.1 GENERAL

Warning!

In case you find any problems in theinstallation, or one of the issues men-tioned in the inspection list are notOK, (temperatures, oil level, pres-sures , ...), the compressor must beswitched off. Your contractor (sup-plier) should inform you how the com-pressor has to be stopped safely.Refer also to the plant manual.

Warning!

If crankcase is frosted or wet: stopcompressor immediately.

Instructions in case of any failure;

1. Stop compressor

2. Make note of the information on the type plate ofthe compressor

3. Consult your contractor (supplier)

Typical faults, to be solved by your contractor(supplier) are:

Typical faults

FAULTS

1 Discharge pressure too high

2 Discharge temperature too high

3 Suction pressure too high

4 Suction pressure too low

5 All cylinders inactive while compressor is operating

6 Too high oil consumption

7 Too high oil pressure during normal operation at workingtemperature

8 Too low lubricating oil pressure

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



5 MAINTENANCE

5.1 CONSULT YOUR CONTRACTOR(SUPPLIER)

All maintenance works are only to be carried out bythe contractor (supplier).

Example of works to be carried out by your con-tractor;

1. Leak testing

2. Evacuation, drying the refrigeration system

3. Initial oil charging

4. Initial refrigerant charging

5. Adjustment of all safety devices

6. Checking direction of rotation compressor

7. Installing drive guard

8. Initial start of the compressor

9. Preparing the compressor for a shut down period(>6 months)

10. Topping up oil

11. Draining and change of oil

12. Evacuation and purging compressor

13. Replacement of filters

14. Reset GMM (Grasso Maintenance Monitor)

15. Adjustment V-belt tension



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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 50countries. 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

RECIPROCATING COMPRESSORSTABLE OF CONTENTS1 SAFETY1.1 REGULATIONS1.2 MAINTENANCE AND REPAIRS1.3 REFRIGERANT1.4 OIL1.5 OPERATING INSTRUCTIONS PRESSURE EQUIPMENT1.5.1 Intended Use1.5.2 Safety Notes and Warnings1.5.3 Transport and Storage1.5.4 Finishing and Installation

2 INTRODUCTION2.1 SURVEY COMPRESSOR TYPES

3 INSPECTION3.1 DAILY, WEEKLY AND MONTHLY INSPECTIONS3.2 PERIODICAL INSPECTIONS TO BE CARRIED OUT BY YOUR CONTRACTOR (SUPPLIER)

4 FAULT ANALYSIS4.1 GENERAL

5 MAINTENANCE5.1 CONSULT YOUR CONTRACTOR (SUPPLIER)

grasso compressor manual

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table of contents1 safety

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