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Reciprocating Compressors for industrial refrigeration
Grasso
Operating Manual
0089292gbr_3
Operating Manual | Grasso
Reciprocating Compressors for industrial refrigeration
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.
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Operating Manual | Grasso
Reciprocating Compressors for industrial refrigeration
SYMBOLS USED IN THIS MANUAL
Danger!
Stands for an immediate danger which
leads to heavy physical injuries or to
the death.
Warning!
Stands for a possibly dangerous situation which leads to heavy physical
injuries or to the death.
Caution!
Stands for a possibly dangerous situation which could lead to light physical
injuries or to damages to property.
Hint!
Stands for an important tip whose
attention is important for the designated use and function of the device.
SAFETY INSTRUCTIONS
General
Caution!
This manual must be carefull read and
understood prior to servicing and running the compressor (package). For all
safety instructions refer to Chapter 1,
page 7
This user manual is written with great
care, but the contractor/installer is
held responsible for examining this
information and to take care of possible additional and/ or deviated safety
measures. Please consult your contractor (supplier).
Hint!
Before consulting your contractor
(supplier) for any reason, make note of
the data on the type plate fixed on the
compressor, package and/or other
package components.
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Operating Manual | Grasso
Reciprocating Compressors for industrial refrigeration
PREFACE
This operating manual is meant for the end-users of
Grasso reciprocating compressors and/or packages.
This manual describes all safety instructions, global
product information, required periodical inspections
and a trouble shooting list.
The users of this equipment have to follow all
instructions as given in this manual. In case of any
doubt, the supplier of the refrigeration plant should
be consulted.
For safety instructions refer to Chapter 1, page 7.
Hint!
GEA Grasso herewith declares that the
machines mentioned are intended to
be incorporated into a refrigeration
package (= assembly of refrigeration
components) or to be assembled with
other equipment to constitute machinery covered by Machinery Directive
2006/42/EC and do therefore comply
with the provisions of this directive
that apply to partly completed
machines. Furthermore it is not
allowed to put the machines mentioned into service until the machinery
in which it is to be incorporated, or, of
which it is to be a component, has
been found and declared to be in compliance with the provisions of Machinery Directive 2006/42/EC i.e. as a
whole system including the machinery
referred to in this declaration.
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Operating Manual | Grasso
Reciprocating Compressors for industrial refrigeration
TABLE OF CONTENTS
1
2
3
4
5
SAFETY
1.1 REGULATIONS
1.2 MAINTENANCE AND REPAIRS
1.3 REFRIGERANT
1.4 OIL
1.5 OPERATING INSTRUCTIONS PRESSURE EQUIPMENT
1.5.1
Intended Use
1.5.2
Safety Notes and Warnings
1.5.3
Transport and Storage
1.5.4
Finishing and Installation
INTRODUCTION
2.1 SURVEY COMPRESSOR TYPES
INSPECTION
3.1 DAILY, WEEKLY AND MONTHLY INSPECTIONS
3.2 PERIODICAL INSPECTIONS TO BE CARRIED OUT BY YOUR CONTRACTOR (SUPPLIER)
FAULT ANALYSIS
4.1 GENERAL
MAINTENANCE
5.1 CONSULT YOUR CONTRACTOR (SUPPLIER)
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1.1
SAFETY
Caution!
REGULATIONS
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, oil separator(s),
etc.
Hint!
It is the task of the contractor (supplier) to inform and explain to you as
user, about the operation of the compressor (Package).
Do respect all international, federal,
state and local safety regulations/
legislations during inspection, trouble
shooting and operating this compressor (package).
1.2
After having run the initial 100 operating hours,it is essential (in both new
and modified plants) to replace the
running-in filter element with the permanent filter element supplied. This
operation is only to be carried out by
well-trained and qualified personnel.
Consult your supplier to carry out this
service.
MAINTENANCE AND REPAIRS
Warning!
All maintenance and repairs have to be
carried out only by your contractor
(supplier), except the maintenance as
explicitly mentioned in this manual.
This manual includes a check list for
daily, weekly and monthly inspections.
Temperatures and pressures need to
be checked at several point (eg setting
of all pressure safety switches). In
case this manual does not give these
values then your contractor (supplier)
should instruct you with regard to
their correct setiings. When reference
is made to the plant manual, your contractor (supplier) should take care that
your are instructed in being able to
undertake proper inspections and
trouble shooting.
Do not open the compressor for service.
Hint!
In case of shut downs longer than 1
month, it is advisable to put warning
labels on vital parts of the compressor
saying that the plant is out-of-operation and must not be started up. Consult your contractor (supplier).
1.3
REFRIGERANT
The compressor/package must be filled with
“REFRIGERANT“, to be able to operate.
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The type plates for identification of the pressure
equipment looks like this:
Warning!
For safety instructions in relation to
the refrigerant used in this refrigeration plant, refer to separate information, to be supplied by your contractor
(supplier).
1.4
OIL
The compressor/package must be filled with oil, to
be able to operate.
fig.1:
Example type plate economizer ICH, compressor, package
fig.2:
Example Type plate oil separator
Warning!
For safety instructions in relation to
the oil used in this refrigeration plant,
refer to separate information, to be
supplied by your contractor (supplier).
1.5
OPERATING INSTRUCTIONS
PRESSURE EQUIPMENT
Hint!
For pressure equipment (oil separator
OS, housing suction gas strainer,
Economizer ICH, compressor package)
manufactured by Grasso according to
the European Parliament"s and the
European Council"s Pressure Equipment Directive 97/23/EG of 29 May
1997
General
The following operating instructions according to the
European Pressure Equipment Directive No.
97/23/EG (subsequently referred to as PED)
describe how to handle the pressure equipment for
finishing and installation.
The pressure equipment is intended for installation in
compressor packages or refrigeration plants and can
be equipped with specific accessories during installation by the customer.
If the type plate is covered by finishing/installation,
make sure that the information can be seen by the
end user on another location on the pressure equipment.In case of queries regarding the operating
instructions, please contact Grasso.
1.5.1
Intended Use
The pressure equipment described here may not be
used for any other than the stated purpose. The
equipment may only be installed by the finisher/
installer and not by the end user.
If the pressure equipment is not used according to
these regulations, safe operation of the equipment is
not guaranteed.
The pressure equipment has been manufactured
according to the requirements of the PED. Its design
meets the requirements of the AD2000 regulations.
The finisher/installer or the operator and not the
manufacturer is responsible for all personal injury
and damage to property resulting from unintended
use.
If applicable the finisher/installer (at installation in
compressor package or refrigeration plants and
equipping ready for operation) is obliged to prepare
his own risk analysis and operating manual according to the European Pressure Equipment Directive
97/23/EG.
When not installed by Grasso the finisher/installer
has to properly install accessories for the pressure
equipment. The pressure equipment may not be
damaged during installation and it shall be painted
after installation.
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Operating Manual | Grasso
Reciprocating Compressors for industrial refrigeration
The pressure equipment may only be filled with
refrigerant of refrigerant groups L1 and L2, substance groups 1 and 2. The pressure equipment has
to be installed in the compressor package or plant so
that no vibrations or pulsations can be transmitted to
the equipment.The connecting lines have to be
installed to be tension free. The pressure equipment
is not designed for dynamic loads.Where there is a
risk of lightning strikes, the pressure equipment must
be earthed. The finisher/installer has to include
instructions for regular inspection of the pressure
equipment in his instruction manual and has to
define the end user"s behaviour in case of damage.
To avoid burns or frostbite, the pressure vessel may
not be touched in the operating state. This can be
achieved by means of contact guards. Install appropriate warning signs.
Caution!
Optionally supplied safety valves are
only intended for the protection of the
oil separator against excessive presssure caused by an external heat
source during standstill. This device
may not be used for the protection of
the complete refrigeration system.
(The finisher/installer has to equip the
installation with a safety valve acc. EN
378)
for the new part). For recurring tests please refer to
EN 378 T1 to T4 and local regulations.
1.5.3
Transport and Storage
Transport and store the oil separator in a dry environment. Ensure that the oil separator is not subject
to damage relevant to its further use.
In case of transport damage notify Grasso immediately.
1.5.4
Finishing and Installation
Design details can be seen in drawings at Grasso.
Compare the identification (type plate) with the documentation included in the delivery before finishing,
installing and equipping the oil separator. Mark the
oil separator with the note "Do not use" until the
issue has been resolved with Grasso or an authorised third party (named authority according to the
PED).
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 the
naked eye for corrosion, scoring and similar damage.
Check the equipment for shape consistency of the
connection areas. In particular check and assess the
sealing surfaces for possible damage such as
scratches, scoring or similar.
Keep corrosive substances such as acids away from
the oil separator.
Wall thicknesses may be no more than 1 mm less
than those given in the drawing.
Drain or suck off the medium (refrigerant/oil) prior to
service and repair. These tasks may only be carried
out by trained professionals and in compliance with
the appropriate safety regulations, see standard EN
378.
Carry out a detailed check of the previous operating
history, when an oil separator that has already been
in service is newly finished, installed and equipped.
This includes visual inspection (as described above
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INTRODUCTION
2.1
SURVEY COMPRESSOR TYPES
General
A survey of the full range of Grasso reciprocating
compressors, is given in the table below. Please
refer to the type plate of the compressor to determine the type of compressor you are currently using.
Type *1
Series
Grasso V
Single stage
Two stage
Grasso V 300
Grasso V 300T
Grasso V 450
Grasso V 450T
Grasso V 600
Grasso V 600T
Grasso V 700
Grasso V 700T
Grasso V 1100
Grasso V 1100T
Grasso V 1400
Grasso V 1400T
Grasso V 1800
Grasso V 1800T
Grasso V 300HP
Grasso VHP
Grasso V 450HP
Grasso V 600HP
Grasso V 700 CM
Grasso V 700T CM
Grasso V 1100 CM
Grasso V 1100T
CM
Grasso V 1400 CM
Grasso V 1400T
CM
Grasso V 1800 CM
Grasso V 1800T
CM
Grasso 35HP
-
Grasso 45HP
-
Grasso 55HP
-
Grasso 65HP
-
Grasso VCM
Grasso 5HP
1
10
Type designation can be extended on the type plate of the
compressor with K(Approval), M(Marine application), ...
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Reciprocating Compressors for industrial refrigeration
INSPECTION
DAILY, WEEKLY AND MONTHLY
INSPECTIONS
CHECK
POINTS *
These inspections should be made during the operating periods.
monthly
FREQUENCY
weekly
3.1
daily
3
REMARKS *
The table below sums up all the points on the compressor that have to be inspected by the user.
Warning!
Oil temperature max.
The compressor can be factory fitted
with gauges and switches and/or with
a micro processor system. In the case
of a micro processor system, refer to
the user manual(s) of the micro processor and/or to the plant manual.
Consult your contractor (supplier).
Refer to plant manual,
consult your contractor
(supplier);
•
Max. __________oC
Oil leakage
of shaft seal
Suction pressure
•
Check against design
conditions. Refer to plant
manual, consult your
contractor (supplier);
•
Min./Max.
__________oC
Oil level in
crankcase
Min. control
oil pressure
2
3
REMARKS *3
Discharge
pressure
•
Suction
superheat
Intermediate
superheat
•
The oil should be transparently clear. A disappearing white colour
points to dissolved refrigerant.
Discharge
temperature
max.
•
Range1.5-3.0 bar
Oil temperature min.
Between 25% and 75%
height of the sight glass.
For topping up oil, consult your contractor (supplier).
•
Colour of the
oil
Lubricating
oil pressure
difference
monthly
weekly
daily
FREQUENCY
CHECK
POINTS *2
•
•
Setting 2.5 bar
•
Consult your contractor
(supplier).
Consult your contractor
(supplier):
Min. __________bar
Cooling
water temperature (if
present)
Refer to plant manual,
consult your contractor
(supplier);
Min./Max.
__________oC
R404A/R507 ≥ 15 K
Other refrigerants ≥ 0K
Min. __________oC
Max. 170 °C
•
•
During compressor
standstill the lower part
of the crankcase must
remain warmer than the
surroundings: ≥ 20 °C
(NH3)
Min. Actual condensing
temperature + 10 K
(≥ Tc + 10 K)
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.
Values of temperatures, pressures etc. as mentioned in this
table, are given by the manufacturer. Actual values for this
refrigeration plant, currently used can differ for the min./max.
values as given in this table. Your supplier has to inform you
about the actual/currently used values for this plant.
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3.2
PERIODICAL INSPECTIONS TO
BE CARRIED OUT BY YOUR
CONTRACTOR (SUPPLIER)
SAFETY
Caution!
For a safe operation of the compressor/package, your contractor (supplier) must carry out the checks as
mentioned in the table below.
Inspections by contractor
monthly
weekly
CHECK
POINTS *4
daily
FREQUENCY
REMARKS
Wear (fraying, cuts etc.)
and ensure that they do
not touch the groove bottom.
Condition of
V-belts
•
Adjustment
and operation of pressure safety
switches
•
Capacity
control (if
provided)
Switching
frequency of
the compressor
4
12
Tension. Too low a tension gives rise to excessive flapping or oscillation in operation. For
correct tension Grasso
instruction sheet
0087516 must be used.
Refer to instructions of
switch manufacturer.
•
The time lag between
the unloading and loading of one cylinder or cylinder group should generally be at least 3 - 5
minutes.
•
The time interval
between stopping and
starting should be at
least 10 minutes and
between starting and
restarting 15 minutes.
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.
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4.1
FAULT ANALYSIS
GENERAL
Warning!
In case you find any problems in the
installation, or one of the issues mentioned in the inspection list are not
OK, (temperatures, oil level, pressures , ...), the compressor must be
switched off. Your contractor (supplier) should inform you how the compressor has to be stopped safely.
Refer also to the plant manual.
Warning!
If crankcase is frosted or wet: stop
compressor immediately.
Instructions in case of any failure;
1. Stop compressor
2. Make note of the information on the type plate of
the 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 working
temperature
8
Too low lubricating oil pressure
9
Too low or no control oil pressure (For Grasso V, Grasso
(12)E and Grasso10 only)
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5
5.1
MAINTENANCE
CONSULT YOUR CONTRACTOR
(SUPPLIER)
All maintenance works are only to be carried out by
the contractor (supplier).
Example of works to be carried out by your contractor;
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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Reciprocating Compressors for industrial refrigeration
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We live our values.
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GEA Refrigeration Technologies
GEA Refrigeration Netherlands N.V.
Parallelweg 27, 5223 AL ‘s-Hertogenbosch, The Netherlands
Phone: +31 73 6203911
[email protected], www.gea.com
© GEA Group AG. All rights reserved. Subject to modification
GEA Group is a global engineering company with ­multi-billion euro sales and ­operations in more than
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