Reciprocating Compressors for industrial

refrigeration
Grasso

Operating manual
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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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SYMBOLS USED

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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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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TABLE OF CONTENTS
1 SAFETY 7
1.1 REGULATIONS 7
1.2 MAINTENANCE AND REPAIRS 7
1.3 REFRIGERANT 7
1.4 OIL 8
1.5 OPERATING INSTRUCTIONS PRESSURE EQUIPMENT 8
1.5.1 Intended Use 9
1.5.2 Safety Notes and Warnings 10
1.5.3 Transport and Storage 10
1.5.4 Finishing and Installation 10
2 INTRODUCTION 11
2.1 SURVEY COMPRESSOR TYPES 11
3 INSPECTION 12
3.1 DAILY, WEEKLY AND MONTHLY INSPECTIONS 12
3.2 PERIODICAL INSPECTIONS TO BE CARRIED OUT BY YOUR CONTRACTOR (SUPPLIER) 14
4 FAULT ANALYSIS 15
4.1 GENERAL 15
5 MAINTENANCE 16
5.1 CONSULT YOUR CONTRACTOR (SUPPLIER) 16

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 SAFETY
REGULATIONS

1 SAFETY

1.1 REGULATIONS

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 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.
Do not open the compressor for service.

Caution!
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.
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.
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.

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

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SAFETY
OIL

The compressor/package must be filled with “REFRIGERANT“, to be able to

operate.

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.

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.
The pressure equipment has been manufactured according to the requirements
of the PED. Its design meets the requirements of the AD2000 regulations.
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.
The type plates for identification of the pressure equipment looks like this:

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 SAFETY
OPERATING INSTRUCTIONS PRESSURE EQUIPMENT

Fig.1: Example type plate economizer ICH, compressor, package

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 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 finisher/installer or the operator and not the manufacturer is responsible for
all personal injury and damage to property resulting from unintended use.
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.
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

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SAFETY

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)

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 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).

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 INTRODUCTION
SURVEY COMPRESSOR TYPES

2 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
Single stage Two stage
Grasso V 300 Grasso V 300T
Grasso V 450 Grasso V 450T
Grasso V 600 Grasso V 600T
Grasso V 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 VCM
Grasso V 1400 CM Grasso V 1400T CM
Grasso V 1800 CM Grasso V 1800T CM
Grasso 35HP -
Grasso 45HP -
Grasso 5HP
Grasso 55HP -
Grasso 65HP -

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

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INSPECTION
DAILY, WEEKLY AND MONTHLY INSPECTIONS

3 INSPECTION

3.1 DAILY, WEEKLY AND MONTHLY INSPECTIONS

These inspections should be made during the operating periods.
The table below sums up all the points on the compressor that have to be
inspected by the user.

Warning
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).

FREQUENCY

monthly
weekly

CHECK POINTS *2 REMARKS *3

daily

Between 25% and 75% height of the sight glass. For

Oil level in crankcase
Colour of the oil
Lubricating oil pressure
difference
Min. control oil pressure
Oil temperature max.
Oil leakage of shaft seal
Suction pressure
Discharge pressure
Suction superheat
Intermediate superheat
Discharge temperature max.
•
topping up oil, consult your contractor (supplier).
The oil should be transparently clear. A disappearing
•
white colour points to dissolved refrigerant.
Range1.5-3.0 bar
•
Setting 2.5 bar
Consult your contractor (supplier):
•
Min. __________bar
Refer to plant manual, consult your contractor
• (supplier);
Max. __________oC
• Consult your contractor (supplier).
Check against design conditions. Refer to plant
• manual, consult your contractor (supplier);
Min./Max. __________oC
Refer to plant manual, consult your contractor
• (supplier);
Min./Max. __________oC
R404A/R507 ≥ 15 K
• Other refrigerants ≥ 0K
Min. __________oC
• Max. 170 °C

2 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.
3 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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 INSPECTION
DAILY, WEEKLY AND MONTHLY INSPECTIONS

FREQUENCY

monthly
weekly
CHECK POINTS *2 REMARKS *3

daily
During compressor standstill the lower part of the
Oil temperature min. • crankcase must remain warmer than the
surroundings: ≥ 20 °C (NH3)

Cooling water temperature (if Min. Actual condensing temperature + 10 K

•
present) (≥ Tc + 10 K)

2 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.
3 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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INSPECTION
PERIODICAL INSPECTIONS TO BE CARRIED OUT BY YOUR CONTRACTOR (SUPPLIER)

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

FREQUENCY

monthly
CHECK POINTS *4 weekly REMARKS
daily

Wear (fraying, cuts etc.) and ensure that they do not

touch the groove bottom.
Condition of V-belts • Tension. Too low a tension gives rise to excessive
flapping or oscillation in operation. For correct tension
Grasso instruction sheet 0087516 must be used.
Adjustment and operation of
• Refer to instructions of switch manufacturer.
pressure safety switches
The time lag between the unloading and loading of
Capacity control (if provided) • one cylinder or cylinder group should generally be at
least 3 - 5 minutes.
The time interval between stopping and starting
Switching frequency of the
• should be at least 10 minutes and between starting
compressor
and restarting 15 minutes.

4 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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 FAULT ANALYSIS
GENERAL

4 FAULT ANALYSIS

4.1 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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MAINTENANCE
CONSULT YOUR CONTRACTOR (SUPPLIER)

5 MAINTENANCE

5.1 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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 MAINTENANCE

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GEA Refrigeration Technologies

GEA Refrigeration Netherlands N.V.
Parallelweg 27, 5223 AL ‘s-Hertogenbosch, The Netherlands
Phone: +31 73 6203911
info@gea.com, www.gea.com