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Liquid Chillers Grasso Ingenium Compact Plus

Product Information (Translation of the original text)L_121011_3

COPYRIGHTAll Rights reserved.No part of this publication may be copied or pub-lished by means of printing, photocopying, microfilmor otherwise without prior written consent of

• GEA Refrigeration Germany GmbHherein after called manufacturer. This restrictionalso applies to the corresponding drawings and dia-grams.

LEGAL NOTICEThis documentation has been written in all con-science. However, the manufacturer cannot be heldresponsible, neither for any errors occurring in thisdocumentation nor for their consequences.

Product Information |Liquid Chillers Grasso Ingenium Compact Plus

2 GEA Refrigeration Germany GmbH | L_121011_3 | Generated 03.12.2014

SYMBOLS USED IN THIS MANUALDanger!

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Warning!

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

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Hint!

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GEA Refrigeration Germany GmbH | L_121011_3 | Generated 03.12.2014 3

LAYOUT INFORMATION

Bullet points and numbered list charactersBullet points are used to separate logical contents within a section:

• Bullet point 1

Types of bullet point 1.

• Bullet point 2

Types of bullet point 2.Numbered list characters are used to separate enumerations within a descriptive text:Descriptive text with consecutive numbering:

– Numbered list point 1

– Numbered list point 2

Handling instructionsHandling instructions require you to do something. Several consecutive steps result in a handling sequence thatshould be run in the specified order. The handling sequence can be divided into separate steps.Handling sequence

1. Handling sequence step 1

– step 1,

– step 2,

– step 3.

2. Handling sequence step 2The subsequent handling sequence is the expected result:

® Result of the handling sequence.

Individual handling stepsIndividual handling steps are marked thus:

– Individual work steps



TABLE OF CONTENTS1 MAIN MODULES 9

1.1 Technical description and applications 91.1.1 Chiller with reciprocating compressors – Ingenium Compact Plus series 10

1.2 Main components 121.2.1 Reciprocating compressor 131.2.2 Compressor drive motor 131.2.3 Evaporator 141.2.4 Air cooled condenser 141.2.5 Injection control 151.2.6 Oil return system 151.2.7 Fittings in the refrigerant circuit 161.2.8 Switching cabinet / control 16

1.2.8.1 PLC functions 171.2.8.2 Standard design of power section 17

2 MAIN DATA 182.1 Technical data 182.2 Electrical data 252.3 Input/output arrangement of Grasso Ingenium Compact Plus chiller series, including all equipment

versions. 272.4 Operation limits 282.5 Acoustic values 292.6 Process flow diagram 30

2.6.1 List of components 312.7 Main dimensions 33

2.7.1 Comments on the drawings 332.7.2 Connection dimensions Grasso Ingenium Compact Plus 332.7.3 Drawings 34

2.8 Capacity calculation 392.9 Pressure losses 39

3 INSTALLATION 403.1 Installation instructions 40

3.1.1 Delivery 403.1.2 Installation 403.1.3 Cooling agent system 403.1.4 Water treatment 413.1.5 Notes on water piping 413.1.6 Glycol circuit for liquid-cooled cylinder covers 413.1.7 Refrigerant lines 413.1.8 Electrical installation 41

3.2 Foundation plan 423.3 Transport 43

4 TECHNICAL SPECIFICATION 454.1 Technical data 454.2 Components 474.3 Options 514.4 Not included in scope of delivery 51



TABLE OF FIGURESfig. 1 Main components - Grasso Ingenium Compact Plus chiller / Image 1 12fig. 2 Main components - Grasso Ingenium Compact Plus chiller / Image 2 12fig. 3 Main components - Grasso Ingenium Compact Plus chiller / Image 3 12fig. 4 Position of the reciprocating compressor 13fig. 5 Arrangement of the compressor drive motor 13fig. 6 Arrangement of the evaporator 14fig. 7 Position of the condenser 14fig. 8 Injection control 15fig. 9 oil return 15fig. 10 Position of the switching cabinet 16fig. 11 Input/output arrangement of Grasso Ingenium Compact Plus chiller 27fig. 12 Process flow diagram Grasso Ingenium Compact Plus 30fig. 13 Grasso Ingenium Compact Plus - illustration 1 35fig. 14 Grasso Ingenium Compact Plus - illustration 2 37fig. 15 Cooling agent system 41fig. 16 Multiple installation 42fig. 17 Transport by crane 43fig. 18 Designation of the lifting points 44fig. 19 Shackles 44



1 MAIN MODULES

1.1 Technical description and applica-tions

"Grasso Ingenium Compact Plus" chillers are aircooled chillers used for the cooling of water or brine.These compact chillers, fully assembled and testedat the manufacturer, are specially designed for usewith the refrigerant R717 and are intended for out-door installation.The chillers are automatically operating, single stagerefrigerating units with reciprocating compressorsand a closed refrigerant circuit. The step-controlledcylinder switchoff adjusts the power according to theconsumers. The chillers can be transported assem-bled.The liquid chillers are manufactured in compliancewith European Regulations in force (EN 378, EN60204, pressure vessel directive, UVV, VDE) andare marked with the CE symbol.The "Grasso Ingenium Compact Plus" series of chill-ers has been specially designed for providing thecold water supply to air conditioning systems. Thesechillers are, of course, also suitable for use in otherareas, suchas process cooling.The coolant used in these chillers is ammonia(R717), a natural substance which has been welltried for many decades. The refrigerant R717 or chill-ers that use this type of refrigerant has/have the fol-lowing advantages compared to those that use syn-thetic refrigerants:

• As a naturally occurring substance, ammonia iscontained in the natural nitrogen cycle.

• Its GWP (Global Warming Potential) is zero.

• Its ODP (Ozone Depletion Potential) is zero.

• Low TEWI (Total Equivalent Warming Impact),i.e. the direct greenhouse effect of the refrigerantand the indirect effect of the energy consumptionby the unit, making it very environmentally com-patible.

• The low odour threshold serves as an effectivewarning in the event of even the smallest ofleaks.

• It has served as a refrigerant for decades andhas caused no long-term damage.

• It provides a greater refrigerating capacity for thesame investment expenditure.

• High performance figures.

Particular emphasis was placed on the safety andleak tightness of the refrigerant circuit during thedesign of this range of liquid chillers, in addition tofocusing on the reliability of the chiller.


MAIN MODULES


1.1.1 Chiller with reciprocating compressors – Ingenium Compact Plus series

Ingenium Compact Plus Chiller series

9Nominal chiller capacity in kWpertaining to cold-water operations 12°C / 6°C

X1 Chiller type

Ingenium Compact Plus = Chiller series9 Nominal chiller capacity 1500 min-1 kW related to cold water operation 12 °C / 6°C

Compressor type Nominal capacity in kW

Bock F14 / 1166 100

Bock F14 / 1366 120

Bock F16 / 1751 150

Bock F16 / 2051 180

V300 280

V450 400

V600 520

X1 design of the chiller

N Secondary refrigerant outlet < 0°C

C Secondary refrigerant outlet 0 ... 10°C

E Secondary refrigerant outlet > 10°C

MAIN MODULES Product Information |Liquid Chillers Grasso Ingenium Compact Plus


Naming example

Ingenium Compact Plus 280 C Chiller with reciprocating compressor and shell and tube heat exchangeras evaporator and integrated air cooled condenser,(Ingenium Compact Plus)Nominal capacity 280 kW (280),for secondary refrigerant outlet temperatures of 0 ... 10 °C (C)


MAIN MODULES


1.2 Main components

The Grasso chillers of the Grasso Ingenium Com-pact Plus series consist of the following main compo-nents:

fig.1: Main components - Grasso Ingenium Compact Pluschiller / Image 1



1 Common base frame for all components

010 Reciprocating compressor (in the compressor box)

015 Compressor drive motor (behind the compressor box)

180 Switching cabinet, control and direction of control

2500 Evaporator

2510 Electronic injection valve

2700 Air cooled condenser

2705 Glycol cooler with cylinder head cooling (for GrassoIngenium Compact Plus 100 to 180 chillers)



1.2.1 Reciprocating compressor

fig.4: Position of the reciprocating compressor

The Ingenium Compact Plus chillers use open, sin-gle stage, multi-cylinder reciprocating compressorsfor the refrigerant ammonia (R717) in the ratedcapacity range of 101 to 580 m3/h per compressor.The ammonia vapours created in the evaporator areexhausted and compressed to condensation pres-sure in an F14 and F16 or Grasso V series recipro-cating compressor.The pressure and temperature transmitters installedon the compressor are used to monitor the operatingvalues of each compressor. The individual cylindersmay be switched off using suction load relief devices.The compressors have the following equipment fea-tures:

– Start-up load relief

– Capacity control by cylinder switch-off

– Oil differential pressure control

– Oil heater

– Discharge pressure monitoring

– Suction pressure monitoring

– Crankcase pressure monitoring

– Discharge temperature control

– Oil temperature monitoring

– Suction temperature monitoringSafety equipment on the pressure generators isstandard in compliance with EN 378 and accidentprevention regulations BGV D4 by current linkagevalves combined with DBK safety pressure limiters.To prevent overheating, the compressed gas tem-perature is monitored for each compressor.

1.2.2 Compressor drive motor

fig.5: Arrangement of the compressor drive motor

The compressors are driven via a coupling by meansof a 4-pole standard IP55 electric motor with anoperating voltage of 400V; 50 Hz run with a clutch.Optionally, motors can be used in FC operation.


MAIN MODULES


1.2.3 Evaporator

fig.6: Arrangement of the evaporator

Evaporation of the coolant takes place in the jacketspace of the shell and tube apparatus where thecooling agent (water) flows inside the heatexchanger tubes. The heat exchanger tubes are wel-ded in the form of shell&tube into the two opposingtube plates. The heat exchanger tubes are com-posed of chrome-nickel steel 1.4404, the tube platesfrom chrome-nickel steel 1.4301.The housing is used for mounting the tube bundleand forms the outer pressure chamber. It consists ofend pieces which are welded to the sheathing tubeusing a circular seam.The end pieces can be arranged so that the coolingagent connections are either on one side or on theopposite equipment ends.The connection and deflection covers consist ofGG25. The covers with the tube bundle form thepressure chamber of the refrigerant and are fastenedto the housing using screws.The max operating pressures are 20 bar on therefrigerant side and 10 bar on the cooling agent side.The evaporator has insulation consisting of PURfoam with aluminium jacket.Design, manufacture and acceptance comply withthe requirements of the pressure appliances direc-tive.Non-soluble heavier oil is deposited in the oil domeand returns automatically controlled from there to thecompressor. For further details, see Oil return sys-tem section.The suction pressure and cooling agent outlet tem-perature are monitored so that, if using water as thecooling agent, there is reliable protection againstfreezing during operation.

1.2.4 Air cooled condenser

fig.7: Position of the condenser

The air cooled condensers in the Ingenium CompactPlus series are characterised by their highly com-pact, space-saving construction.The heat exchanger packages have been designedas a rib block construction with corrugated, easy-to-clean aluminium ribs and stainless steel pipes.The low-noise axial cooling fans are maintenancefree. The unit ships with a continuously variablespeed controller included as standard.The housing is constructed from hot-dip galvanisedsteel plate with a powder coating in pebble grey(RAL 7032).



1.2.5 Injection control

fig.8: Injection control

In chillers, the pressure drop of the liquid refrigerantfrom condensation pressure to evaporation pressureand the optimal utilisation of the evaporator capacityare ensured by the ECD (Electronic CondensorDrain) system. The action of the ECD system isbased on the variables suction pressure, dischargepressure, NH3 level measurement, output power andthe speed (rpm) of the compressor.The injection valve (item 2510) operates as a con-stantly regulating expansion device. The ECD soft-ware will continuously calculate the percentage ofopening required for the injection valve.

1.2.6 Oil return system

fig.9: oil return

The reciprocating compressor requires special refrig-erating machine oil for lubrication and control.

A part of the oil is carried off in the circuit during thecompressing process.This is returned from the evaporator to the compres-sor by an automatic, maintenance-free oil return sys-tem (developed by GEA Refrigeration GermanyGmbH) on the low pressure side of the chiller.


MAIN MODULES


1.2.7 Fittings in the refrigerant circuit

In order to guarantee service-friendly maintenancework, the refrigerant circuits are equipped with thefollowing valves:

• Stop valves in: Pressure, liquid and suction lines

• Refrigerant filling valve and drain valve

• Oil filling valve at the compressor

• Other servicing valves on the pressure, suctionand oil lines

• Monitoring sight glass in the liquid line

• Cleanable liquid filterThe safety-related fittings included in the refrigerantcircuit are all provided in accordance with EN378and include an overflow valve along with a safetyvalve on the low pressure side that discharges to thesurrounding air.

1.2.8 Switching cabinet / control

fig.10: Position of the switching cabinet

The liquid chillers are equipped with a switch cabinet(control and power part) as standard.The chillers have a type GSC TP controller asstandard.

Hint!

All instructions for the controls referto the GSC TP (hereinafter referred toas the GSC).

The GSC consists of the control unit with operatorkeypad and display unit, indicator lights for "Run-ning", "Warning" and "Alarm", the emergency stopbutton, the output relays and the casing.

Hint!

It is not permitted to add an externalcontroller between the GSC and thepower panel; this would extend thesafety chain to be achieved. All controlsignals between the GSC and thepower panel must be processeddirectly and must not flow indirectlyvia an external controller. The manu-facturer cannot otherwise guaranteethe safe operation of the system.

The GSC performs the following functions asstandard:

• Display of all important physical and technicalparameters, e.g.



– Pressure

– Temperature

– Capacity

– Number of operating hours

– Operation mode

– Status reports

• Automatic start-up and shut-down of the chillerand capacity control dependent on the followingvalues:

– Suction pressure

– Inlet temperature

– Outlet temperature

– External temperature

• Monitoring of all operating parameters

• Motor current monitoring

• Compressor power limitation if the measured dis-charge pressure, discharge temperature, motorcurrent or suction pressure indicate an overload

• Fault memory with date and time

• Wire failure detection for analogue input signals

• Password protection for preventing unauthorisedaccess to important parameters

• Control of the chiller by a master controller viapotential-free contacts

• Possibility of communication via MPI or ModbusRTU/TCP with master controller or building man-agement system

• 10-minute trend display with display of all actualvalues which existed just before alarm switchedoff

• Remote maintenance via EtherNet connection(TCP/IP)

• Infinitely variable speed control (phase anglecontrol for the condenser cooling fans)

The GSC optionally performs the following func-tions:

– Frequency-controlled compressor drive motor

– Electronic flow switch for cooling agent circuit

– Remote setpoint adjustment (analogue signal)

– Profibus DP communication

The documentation for the GSC is part of the productdocumentation.

1.2.8.1 PLC functions

• Control of cooling agent inlet temperature orcooling agent outlet temperature in automaticmode;

• Restart after power failure (but not faults);

• Monitoring of:

– Compressor motor switching frequency

– Temperatures: Pressure gas, suction gas,motor winding

– Pressures: Suction pressure, dischargepressure, oil difference pressure

• Display of the following operating conditions:

– High/suction/oil pressure

– Running hours

– Cooling agent inlet temperature and coolingagent outlet temperature

– Operation mode

– Unit fault as a collective fault signal, individ-ual fault signal to be displayed on keyboardrequest

– Use of chiller capacity

– Start conditions absent

1.2.8.2 Standard design of power sec-tion

Major components:

• Main switch, emergency stop switch;

• Fuses, full motor protection, overcurrent relay;

• Contactor combination for star-delta starting ofcompressor drive motor;

• Power supply for condenser cooling fans

• Power outlets for compressor oil heating

• Power outlets for compressor box heating

• Power outlets for compressor box fans


MAIN MODULES


2 MAIN DATA

2.1 Technical data

Grasso Ingenium Compact Plus 100 N C E

Weight without charging mL kg 2719 2769

Operating weight mB kg 2758 2830

Refrigerant charging quantity NH3 kg 26 29

Compressor oil fill amount 1) l 6.3

Chiller oil fill amount 2) l 10.3

Cooling agent volume l 14.7 18.2

Cooling agent connections DN 2 1/2" SAE

Air volume m³/h 37164

Number of fans 4

Compressor Type F14/1166

LS power levels % 50/100







Cooling agent volume l 16.1 19.6

Cooling agent connections DN 2 1/2" SAE


Number of fans 4

MAIN DATA Product Information |Liquid Chillers Grasso Ingenium Compact Plus




LS power levels % 50/100

1) Compressor oil fill amount at initial start-up2) Oil fill amount of the chiller, total


MAIN DATA








Cooling agent volume l 18.9 21

Cooling agent connections DN DN100PN16 2 1/2" SAE


Number of fans 4


LS power levels % 33/66/100


Weight without charging mL kg 3263

Operating weight mB kg 3339

Refrigerant charging quantity NH3 kg 37



Cooling agent volume l 22.4

Cooling agent connections DN DN100PN16 2 1/2" SAE DN100PN16


Number of fans 4


LS power levels % 33/66/100

1) Compressor oil fill amount at initial commissioning



2) Oil fill amount of the chiller, total


MAIN DATA






Compressor oil fill amount 1) l 10

Chiller oil fill amount 2) l 15


Cooling agent connections DN DN125PN16 DN80PN16 DN125PN16


Number of fans 6

Compressor Type V300

LS power levels % 25/50/75/100








Cooling agent connections DN DN125PN16


Number of fans 8


LS power levels % 33/50/67/83/100

1) Compressor oil fill amount at initial commissioning



2) Oil fill amount of the chiller, total


MAIN DATA









Cooling agent connections DN DN125PN16


Number of fans 10


LS power levels % 25/37/50/62/75/87/100

1) Compressor oil fill amount at initial commissioning2) Oil fill amount of the chiller, total



2.2 Electrical data

Grasso Ingenium Compact Plus 100 120 150 180

N/C/E N/C/E N/C/E N/C/E

Compressor drive motor

Voltage/phases/frequency V/-/F V/Ph/Hz 400 / 3 / 50 1)

Protection class IP 55

DS rated capacity - motor Pn kW 37 45 55 55

Nominal current at 400 V In A 69 84 100 100

rel. starting current Ia/In 6.3 6.9 7.4 7.4

Condenser fan motor



Rated power per fan motor kW 0.76 2.0 2.0 2.0

Power panel

Power supply 2) 3 PEN / 400 V

Control voltage 3) 230 V AC /24 V DC

Supply line cross-section mm² 4G50 4G50 4G70 4G70

Primary fuse A 80 100 125 160

1) Euro voltage area ±10%, other voltages/frequencies on request2) Feed line of power supply from below3) Internal control voltage


MAIN DATA


Grasso Ingenium Compact Plus 280 400 520

N/C/E N/C/E N/C/E

Compressor drive motor



DS rated capacity - motor Pn kW 75 132 160

Nominal current at 400 V In A 138 235 289

rel. starting current Ia/In 8.0 7.9 7.5

Condenser fan motor



Rated power per fan motor kW 2.0 2.0 2.0

Power panel

Power supply 2) 3 PEN / 400 V

Control voltage 3) 230 V AC /24 V DC

Supply line cross-section mm² 4G95 4G120 4120

Primary fuse A 200 250 250

1) Euro voltage area ±10%, other voltages/frequencies on request2) Feed line of power supply from below3) Internal control voltage



2.3 Input/output arrangement of Grasso Ingenium Compact Plus chiller series, includingall equipment versions.

fig.11: Input/output arrangement of Grasso Ingenium Compact Plus chiller


MAIN DATA


2.4 Operation limits

The "Grasso Ingenium Compact Plus" chillers can beoperated within the operation limits that are specifiedin the GUD calculation software. This program takesinto consideration the calculated evaporation andcondensation temperatures for specific operatingpoints. The temperatures and pressures specifiedhere represent the boundaries within which the oper-ating point may be located.

Caution!

When considering a specific applica-tion, all the conditions specified in thetable must be taken into account andadhered to.

max. coolingagent or ambi-ent temperaturewhen stopped

°C 48

Suction pres-sure

p0 bar (a)minmax

0.77.0

Outlet tempera-ture of water ascooling agent

tKA °Cminmax

+3+15

Outlet tempera-ture with frost-resistant cool-ing agents

tKA °Cminmax

-10+15

Cooling agentinlet tempera-ture

tKE °C max 27

Air intake tem-perature: tL °C

minmax

-1540

When the unit is running, the compressor operatinglimits are monitored independently by the PLC forthe liquid chiller unit.The specified operation limits apply to operation atfull load.

Caution!

If the specified limits are exceeded fora specific application, the manufac-turer must be consulted.

During operation of the chiller, the increase of thecooling agent inlet temperature must be limited tomax. 3K within 2 minutes.In addition to the operating limits stated in the tables,the operating conditions of the respective compres-sor type to be complied with must also be taken intoaccount (e.g. start-up regime, oil pressure, quantityof oil, type of oil, etc.).During periods of downtime or start-up, the limitingvalues may be exceeded or undercut for brief (neverprolonged) periods of time.



2.5 Acoustic values

The emission sound power values have been deter-mined in accordance with EN ISO 11203.The values are based on a defined envelope surfaceat a distance of 5 m from the machine when it isinstalled under free field conditions on a level foun-dation.The values apply to the standard version of the liquidchiller (compressor drive motor in the star/triangleoperation) under full load and a discharge pressureof approximately 13 bar (a).Liquid chiller with FU operated motors (option) mayhave deviating noise values.

Type

Acoustic outputlevelLWA

dB(A)

Emission acousticpressure level

LPA1)

dB(A)

100 89 62

120 91 64

150 92 65

180 92 65

280 93 65

400 95 67

520 98 69

1)5 m distanceThe values apply for power levels of 100%The tolerance of the sound values is 3 dB.


MAIN DATA


2.6 Process flow diagram

fig.12: Process flow diagram Grasso Ingenium Compact Plus

1) Customer-side connection

2) GEA Refrigeration Germany GmbH scope of delivery

3) Draining and filling of NH3

4) Glycol cooler with cylinder head cooling (for Grasso Ingenium Compact Plus 100 to 180 chillers)

I Cooling agent inlet

II Cooling agent outlet



2.6.1 List of components

Main components

10 Reciprocating compressor

15 Drive motor

17 Thermal winding shield - compressor drive motor

45 Suction filter, compressor

50 Solenoid valves – capacity control

90 Service valve – oil draining and oil charging

100 Pressure transducer - suction pressure

105 Pressure transducer - discharge pressure

110 Pressure transducer - oil pressure

115 Resistance thermometer - suction temperature

120 Resistance thermometer - discharge temperature

175 Service valve – compressor pressure line

260 Stop valve - pressure side

280 Stop valve - suction side

340 Overflow valve (compressor)

350 Safety pressure limiter

360 Oil heater

2040 Resistance thermometer, cooling agent outlet

2045 Resistance thermometer, cooling agent inlet

2230 Change - Safety valve combination evaporator

2235 Stop valve liquid line

2500 Shell and tube evaporator

2505 Refrigerant draw-in valve and refrigerant draining valve


MAIN DATA


Main components

2510 Expansion valve

2560 Sight glass

2700 condenser, air cooled

2705 Glycol cooler for cylinder head cooling

2710 Pump for cylinder head cooling

2830 Refrigerant liquid filter



2.7 Main dimensions

2.7.1 Comments on the drawings

I Cooling agent inlet of evaporator

II Cooling agent outlet of evaporator

2.7.2 Connection dimensions Grasso Ingenium Compact Plus

TypeN / C / E

100 120 150 180 280 400 520

Illustration figure 1 1 1 1 1 2 2

Water channel num-ber

Evaporator2 2 2 2 2 1 1

Sizes in mm

L 3500 3500 3550 3550 3950 6350 7750

L1 2900 2900 2900 2900 3250 5700 7065

L2 311 211 111 11 320 911 1754

B 2250 2250 2250 2250 2250 2250 2250

B1 511 511 511 511 475 545 555

H 2500 2500 2500 2500 2660 2740 2770

H1 430 430 430 430 449 519 559

H2 541 541 541 541 589 519 559


MAIN DATA


2.7.3 Drawings




MAIN DATA


fig.13: Grasso Ingenium Compact Plus - illustration 1(evaporator with 2 water paths)

We reserve the right to alter the design and construction without prior notice.




MAIN DATA


fig.14: Grasso Ingenium Compact Plus - illustration 2(evaporator with 1 water paths)

We reserve the right to alter the design and construction without prior notice.



2.8 Capacity calculation

The selection of the matching chiller is made with theaid of the GUD design software by entering thedesired operating parameters.

2.9 Pressure losses

Precise calculation of the cooling agent side pres-sure losses of the evaporator is carried out using theGUD design software.Water or cooling brines can be used as coolingagents after their compatibility with the material com-binations of the evaporator and the pipeline that is tobe connected has been established.


MAIN DATA


3 INSTALLATION

3.1 Installation instructions

3.1.1 Delivery

The chillers are delivered with an inert gas filling(nitrogen, 0.5 bar overpressure) in the refrigerant cir-cuit.In the chiller version with compressor cooling, thecooling circuit of the cylinder heads is already filledwith a 34% glycol/water mixture.The cooling agent connections are closed. The chill-ers must be checked on arrival for damage in transit.Any damage must be reported to the manufacturer inwriting.

Caution!

Chillers must be protected from dam-age and dirt during prolonged periodsof storage prior to setup or installa-tion. The protective gas fill level mustbe checked monthly during storage.

3.1.2 Installation

Install the chillers on a level surface. The differencefrom the horizontal must not be more than 0.5%.To ensure the necessary air supply and to enablemaintenance work, a free space of at least 1.5 mmust be maintained around the chiller.The chiller must be mounted on the foundation blockor frame with mounting bolts.Where there are increased requirements for a vibra-tion damped installation, suitable spring elements(can be supplied as an option) must be provided formounting.The pipes for the cooling agent must be connectedusing rubber expansion joints in all cases wherevibration dampers are used.If the chiller is installed in a depression, it must beplaced on a plinth in such a way that the fans projectout over the building.Substances leaking in the event of a fault must notget into the ground or surface waters (Water Resour-ces Law WHG).The allowable ambient temperatures can be viewedin the "Operation Limits" table.

3.1.3 Cooling agent system

The chiller is mounted on vibration isolators whichmeans that the connections of the water piping mustbe flexible.All pipes must be secured independently of thechiller. No additional static or dynamic loads must beapplied to the chiller connections.All pipe connections for inlets and outlets should beequipped with stop valves. Vent valves must also beprovided at the highest point for the connection sidesof the heat exchangers.Charging and draining must be possible.The pipes must be flushed before connecting. This iscarried out to remove soiling, foreign particles andwelding residue from the system.After the chiller has been aligned, its cooling agentside can be connected up. The piping system for thecooling agent connections must be installed on siteby the plant engineer. Please refer to the drawing inthe supply documentation for the dimensions andposition of the water connections to the evaporator.The evaporator must be connected to a closed cool-ing agent circuit on the pressure side of the pump.Arrange a dirt collector immediately upstream of theevaporator (recommended mesh size 0.5 mm).The volume flow of cooling agent should be kept at aconstant level.The temperature sensors (item 2040 and item 2045)used to measure the inlet and outlet temperature ofthe cooling agent are supplied separately along withthe welded sleeve and must be installed – like theflow switch (item 2050) – in the pipe system by thesystem erector.The flow switch must be installed in a horizontal pipeor a vertical pipe with a flow running in an upwarddirection. The distance between the elbow orupstream valve in the entry section must be morethan 5 times the pipe diameter.Between the cooling agent outlet from the evaporatorand the thermal sensor (item 2040), at least 2 m ofpipe should be provided and two 90-degree direc-tional changes by pipe elbows or fittings. If the ther-mal sensor (item 2040) is installed directly down-stream of the flow switch (item 2050), a distance ofmore than 5 times the pipe diameter must also bekept here.

INSTALLATION Product Information |Liquid Chillers Grasso Ingenium Compact Plus


fig.15: Cooling agent system

1 Outlet

2 Evaporator

3 Inlet

3.1.4 Water treatment

Industrial water usually contains dissolved or solidmatter that causes corrosion or layers to develop, orencourages algae growth. The water for the evapo-rator circuit should be chemically treated to minimisesuch effects.

Hint!

In order to avoid increasing mainte-nance costs due to additional expendi-ture for the removal of dirt layers orthe replacement of corroded parts, aspecialist water treatment companyshould be used. This can help avoidproblems occurring to a large extent.

3.1.5 Notes on water piping

All pipes must be secured independently of thechiller. No additional static or dynamic loads must beapplied to the chiller connections.All pipe connections for inlets and outlets should beequipped with stop valves. Vent valves must also beprovided at the highest point for the connection sidesof the heat exchangers.Make sure that vibrations cannot be transmitted.Charging and draining must be possible.The pipes must be flushed before connecting. This iscarried out to remove soiling, foreign particles andwelding residue from the system.

3.1.6 Glycol circuit for liquid-cooled cyl-inder covers

(for Grasso Ingenium Compact Plus 100 to 180chillers)The reciprocating compressor in the F14 and F16series come equipped with a cylinder cover. The cyl-inder covers come connected to the chiller's internalglycol circuit and are filled for operations.The fill level of the circuit must be checked in theexpansion and filler vessel prior to operating the unit.Upon losing the glycol filling the circuit needs to bechecked for leaks, filled and vented using the ventvalve. This procedure needs to be repeated while thecirculation pump is running until all air has beenremoved from the circuit.

3.1.7 Refrigerant lines

The chillers are ready piped on the refrigerant side,tested and filled with nitrogen.

3.1.8 Electrical installation

The chiller has been designed for plug-in, reliableautomatic operation.In principle, all the connections must be made inaccordance with the electrical diagram supplied.All connections must be carried out according to thecurrent installation regulations.Connections to the chiller must be flexible and free ofloads.The connecting cables are fed to the chiller fromunderneath.The lower side of the switch cabinet has removableflange plates, in which the cable screw connectionshave to be fitted. The cable screw connections arenot part of the scope of supply.Dimensioning of the inlet pipe cross-sections mustbe according to DIN VDE 100 Part 520.Connections and almost all external connections arepre-wired at the factory. Certain items of externalapparatus, such as a second emergency stop switch,the ammonia sensor, and the water pump flow moni-tor must be connected on-site by the plant engineer.


INSTALLATION


3.2 Foundation plan

The dimensions required for the installation of the chillers can be found in the order-specific drawing.For single and multiple installations, are to adhere the spacings.If adjacent walls (minimum distance 1.5 m) are higher than 2 m, please consult the manufacturer.

fig.16: Multiple installation



3.3 Transport

Crane transportAmmonia liquid chillers are high-quality products which must be handled with extreme care during transport. Pro-tect the equipment from impacts and put it down carefully.The chiller can be lifted using a crane. If transported by crane, 4 straps/chains must be attached to the transportlugs on the base frame using shackles.The spread of the straps has to be with cross-arm.The touch of the straps to the condensers leads to damaging the ribs and must be avoided

fig.17: Transport by crane

Danger!

Make certain there is no one under the suspended load during transport with the crane!


INSTALLATION


When transported by crane, the chiller must have the same position (frame downwards) as in operation.

Caution!

It is prohibited to strap liquid chillers to any fittings or pipes or to the eyebolts/lugs on thecompressor, electric motor, heat exchanger or switching cabinet.

Use the four carrier eyes on the base frame as lifting points for crane transport. Only use the lifting points provi-ded.The lifting points are marked!

fig.18: Designation of the lifting points

Take special care not to attach the ropes near to small nominal diameter pipes or to insulation and not to dam-age them. To prevent damage, attach cross-arms to the ropes.Make suitable arrangements (timber or Armaflex support) to avoid damage to the surface. Shackles must beused.

fig.19: Shackles

Warning!

Chillers must be adequately protected from external influences during transport.

Position the chiller on the transport vehicle in such a way that it is prevented from sliding, tilting or falling down.Load securing is preferably carried out by lashing to the specified points. The pipes and equipment parts of thechiller must not be stepped on. Components must be secured against vibrations. The competent staff member orthe company is responsible for ensuring transport safety.



4 TECHNICAL SPECIFICATION

1 x chiller type Grasso Ingenium Compact Plus 100 to 520 kW cooling capacity

4.1 Technical data

Rated speed 1480 min -1

Refrigeration capacity acc. to EN 12900 andDIN 8976 kW

Power consumption of the compressor shaftas per EN12900 and DIN 8976 kW

Condenser rating kW

Cooling agent Water with..........% Amount of glycol

Cooling agent inlet temperature °C

Cooling agent outlet temperature °C

Flow rate sec. cooling agent m3/h

Condensing temperature °C

Cooling agent pressure loss kPa

The following dimensions, weights and fill amounts are preliminary. Final binding values accord-ing to the latest valid drawing version only.

Length mm

Width mm

Height mm

Refrigerant NH3 fill amount kg

Reflo 68A oil fill amount l

Shipping weight kg

Operating weight kg


TECHNICAL SPECIFICATION


Chiller type Grasso Ingenium Compact Plus..........

Description

Chiller with open reciprocating compressor, evaporatordesigned as shell&tube heat exchanger, air cooled condenser,single circuit, with low voltage system and control, as compact,factory-mounted, connection-ready unit, for outdoor installation,with factory test run for compressor.

TECHNICAL SPECIFICATION Product Information |Liquid Chillers Grasso Ingenium Compact Plus


4.2 Components

Compressor

Compressor configuration Open Bock/Grasso reciprocating compressor with shaft seal.Possible part load stages in %: …......./100.The available part load stages depend on the respective condi-tions of use. The compressor is equipped with gas suction filter,solenoid valves for capacity control, oil heater, overflow valveand start-up load.

Compressor type Bock …....... / Grasso ..........

Valves

Valves on suction side Stop valve (ball valve with electrical actuator)

Valves on pressure side Stop valve and check valve

Paint/Insulation

Painting Coating system S 4.23 acc. to EN ISO 12944-5 for environmen-tal conditions C4 acc. to EN ISO 12944-2.Designed for ambient temperatures between -15 °C and 40 °C.

Colour RAL 7032 (stone grey)

Insulation type Suction line and evaporator are insulated with PUR foam andaluminium jacket for outdoor installationThe insulation is designed for an ambient temperature of 20 °Cand a humidity of 70 %.

Controller

Controller type Grasso System Control chiller controller with Touch Panel (GSCTP), capacity control via cooling agent. Limit values: Suctionpressure, discharge pressure, motor current, 11 different operat-ing modes available such as Auto, Remote, Service, etc.The main functions of the PLC are:

1. Initial temperature control of the cooling agent,

2. Electronic protection of the chiller and storing of the operat-ing hours,

3. Release contacts for refrigerant pump and condenser sys-tem (no condenser pressure control),

4. Operating messages and all analog values are displayed,

5. Fault messages for operating control, status lamp and text,

6. Voltage-free status messages about the liquid chiller forGLT




Controller display Separate display in the control cabinet

Controller arrangement Integrated in power panel

Controller communication Standard MPI interface

Display language …........

Pressure sensors Standard sensor system

Number of pressure sensors 4

Mounting of pressure sensors in the pipe or sensor block on the compressor

Number of temperature sensors 6 Cooling agent inlet and reverse flow temperature sensorenclosed separately for plant side installation according to flowchart and chiller operating manual

Additional temperature sensors None

Flow switch for cooling agent Mechanical flow switch, included separately for plant-side instal-lation

Motor

Motor type Low-voltage DS motorMotor with full protection and temperature sensor in each motorwinding

Number of motors 1

Design IMB 5

Number of poles 4

Protection classification IP55

Efficiency class IE2

Nominal motor capacity .......... kW

Rated voltage 3 x 400 V ± 5% V

Frequency 50 Hz

Switch on mode Star-delta connection. Contactors for drive motor integrated inthe switching cabinet



Type of power supply Switching cabinet, IP 54 protection, completely internally wiredand tested, main switch, fused load-break switch, fuses for aux-iliary drives including thermostatic overcurrent release andsafety fuses, control transformer with primary and secondarydouble control safety fusing, 24 V DC current supply

Cable entry point at the bottom

Evaporator

Type of Construction Tubular heat exchanger, detachable deflection cover, secondaryrefrigerant ports are complete with flange and counterflange

Operating pressure 19 bar coolant side / 10 bar refrigerant side

Heat exchanger tube material Stainless steel (WS 1.4404)

Condenser

Type of Construction Air-cooled condenser in compact, maintenance-free, W-version,heat exchanger packages with heat exchanger tubes and corru-gated, easy-to-clean aluminium ribs.

Operating pressure 25 bar

Heat exchanger tube material Stainless steel (WS 1.4301)

Safety devices

Type Safety valve

Safety valves as per Pressure EquipmentDirective 1

Number of overflow valves (compressor) 1 (integrated in the compressor)

Approval and documentation

Approval for chiller Work's Certificate, Certificate of Conformity acc. to MachineDirective 98/37/EGCalculation and manufacture acc. to AD 2000 and EN 378

Approval pressure equipment Certificate of Conformity acc. to Pressure Equipment Directive(PED) 97/23/EGCalculation and manufacture acc. to AD 2000 and EN 378

Non-destructive testing 10 % non-destructive welding test acc. to EN 1435

Documentation consisting of Paper copy with CD-ROM




Language of documentation …........

Number of documentation sets per chiller 2



4.3 Options

– FC-operated compressor drive motor

– Winter package for water as a cooling agent incl. evaporator auxiliary heating

– Electronic flow switches with welded coupling for cooling agent circuit, loose

– Spring elements for anti-vibration mounting, without synchronization with building

– Manometer kit for suction pressure and compression discharge pressure, mounted,

– Chiller according to CE/PED module H1,

– remote set point adjustment,

– Profibus DP interface,

– Remote diagnostics via VNC viewer

– Rubber expansion joints for cooling agent

– Protection kit in accordance with EN 378

4.4 Not included in scope of delivery

Not included in scope of delivery are: Foundations, pipes on water side, spare parts and special tools,refrigerant.




liquid chillers grasso ingenium compact plus documents/grasso... · also applies to the...

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