Liquid Chillers Grasso FX GC PP

Liquid Chillers Grasso FX GC PP
Product Information (Translation of the original text)

L_201011_4
Product Information |
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lished by means of printing, photocopying, microfilm
or otherwise without prior written consent of
• GEA Refrigeration Germany GmbH
herein after called manufacturer. This restriction
also applies to the corresponding drawings and dia-
grams.
LEGAL NOTICE
This documentation has been written in all con-
science. However, the manufacturer cannot be held
responsible, neither for any errors occurring in this
documentation nor for their consequences.
2 GEA Refrigeration Germany GmbH | L_201011_4 | Generated 02.12.2014

SYMBOLS USED IN THIS MANUAL

Danger!
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leads to heavy physical injuries or to
the death.
Warning!
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tion which leads to heavy physical
injuries or to the death.
Caution!
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tion which could lead to light physical
injuries or to damages to property.
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GEA Refrigeration Germany GmbH | L_201011_4 | Generated 02.12.2014 3


TABLE OF CONTENTS
1 MAIN MODULES 9
1.1 General description 9
1.1.1 Operating areas and advantages of FX GC PP 9
1.1.2 Technical description FX GC 9
1.1.3 Chiller with reciprocating compressors - series FX GC and MX GC 10
1.1.4 Description of main components 13
1.1.4.1 Reciprocating compressor 13
1.1.4.2 Compressor drive motor 13
1.1.4.3 Evaporator + liquid separator 14
1.1.4.4 Condenser 15
1.1.4.5 Injection control 16
1.1.4.6 Oil return system 16
1.1.4.7 Fittings 16
1.1.4.8 Switching cabinet / control 17
2 MAIN DATA 19
2.1 Technical Data 19
2.1.1 Grasso FX GC PP 260 NH3 to Grasso FX GC PP 1250 NH3 19
2.1.2 Grasso FX GC PP 520 NH3 to Grasso FX GC PP 900 NH3 21
2.1.3 Grasso FX GC PP 1050 duo NH3 to Grasso FX GC PP 1800 duo NH3 23
2.1.4 Operation limits 24
2.1.5 Acoustic values 25
2.2 P+I diagrams 26
2.2.1 P+I diagram FX GC PP 26
2.2.2 Designation for main components and fixtures - Liquid chiller Grasso FX GC PP NH3 27
2.2.3 P+I diagram FX GC PP duo 29
2.2.4 Designation for main components and fixtures - Liquid chiller Grasso FX GC PP NH3 30
2.3 Main dimensions 32
2.3.1 FX GC PP 260 to FX GC PP 1250 32
2.3.2 FX GC PP 520 duo to FX GC PP 1800 duo 34
2.4 Capacity calculation 36
2.5 Pressure losses 36
3 INSTALLATION 37
3.1 Installation 37
3.1.1 Delivery 37
3.1.2 Basic information for installation 37
3.1.2.1 Information regarding installation in machinery room 37
3.1.2.2 Rigid installation 37
3.1.2.3 Installation of the Screw Compressor for Insulation against Structure-borne
Sound 37
3.1.2.4 Electrical connection 37
3.1.2.5 Sound insulation, weather protection 38
3.1.2.6 Air-cooled condenser and evaporation condenser for GG LP and GC VP ser-
ies 38
3.1.3 Cooling agent system 38
3.1.4 Heating agent system 38
3.1.5 Water pipes 38
3.1.6 Refrigerant lines 38
3.1.7 Electrical installation 39
3.1.8 Installation information 40
3.1.8.1 Foundation plan 40
3.2 COOLING AGENT SYSTEMS ON RECIPROCATING CHILLERS 41
3.2.1 Single chiller, single pump systems 41
3.2.2 Single chiller, double-pump systems 43
3.2.3 Multi chiller, double-pump systems 44
3.3 Transport (crane transport) 46
4 MAINTENANCE INSTRUCTIONS 49
4.1 Maintenance schedule for liquid chiller 49
4.2 Regular maintenance 49
4.3 Machine room information 49

4.4 Personal protection 49

5 SPECIFICATION 50
5.1 FX GC PP NH3 50
5.1.1 Technical Data 50
5.1.2 Package 51
5.1.3 Not included in scope of delivery 54
5.2 FX GC PP duo NH3 55
5.2.1 Technical Data 55
5.2.2 Package 57
5.2.3 Not included in scope of delivery 60

TABLE OF FIGURES
fig. 1 Position of the reciprocating compressor 13
fig. 2 Position of the compressor drive motors 13
fig. 3 Arrangement of the evaporator 14
fig. 4 Position of the liquid separator 14
fig. 5 Position of the condenser 15
fig. 6 Heat recovery 15
fig. 7 Injection control 16
fig. 8 Position of the oil return 16
fig. 9 Position of the switching cabinet 17
fig. 10 P+I diagram FX GC PP 26
fig. 11 P+I diagram FX GC PP duo 29
fig. 12 Set drawing FX GC PP 32
fig. 13 Set drawing FX GC PP duo 34
fig. 14 Foundation plan 40
fig. 15 Single chiller, single pump systems 41
fig. 16 Compressor switching frequency 42
fig. 17 Single chiller, double-pump systems 43
fig. 18 Multi chiller, double-pump systems 44
fig. 19 Designation of the lifting points 46
fig. 20 Transport 47
fig. 21 Shackles 47


Product Information | MAIN MODULES
1 MAIN MODULES
1.1 General description • Cylindrical heat exchangers which are easy to

insulate
1.1.1 Operating areas and advantages • All refrigerant-carrying lines are safely mounted
of FX GC PP
• Automatic oil return system for globally available
The FX GC PP series of liquid chillers was devel- mineral oil.
oped as an alternative to the R22 liquid chillers. The
• Bypass line from the pressure line to the suction
function and construction principles enable their
line with bypass line for the compressor.
deployment in many cases formally reserved for the
R22 refrigerant, e.g.: • Stored-program control and monitoring.
• Cold water supply for air conditioners • High COP at full load and part load conditions
• Process cooling • Improved partial load output index
• Heat pumps 1.1.2 Technical description FX GC
• Refrigeration over a range of normal tempera-
FX GC are chillers for interior operation in machine
tures using cooling agent temperatures down to
rooms or similar housings for outdoor installation
-10°C.
which are assembled and tested in the manufactur-
Ammonia (R717) has the following advantages over er's facilities.
refrigerant R134a:
The chillers are automatically-operating single stage
• It is a natural substance (in the nitrogen cycle) chiller units with reciprocating compressors and floo-
ded plate evaporators for cooling water or brine as
• Low TEWI (Total Equivalent Warming Impact),
the cooling agent.
i.e. the direct greenhouse effect of the refrigerant
and the indirect effect of the energy consumption The complete FX GC range comprises 3 series,
by the unit, making it very environmentally com- which can be supplied or complemented with differ-
patible. ent condensers:
• Its GWP (Global Warming Potential) is zero. Liquid chiller with water-cooled con-
GC PP
• Its ODP (Ozone Depletion Potential) is zero. denser and closed refrigerant circuit
• It has a low odour threshold which serves as an

Evaporator set for connection to a single
effective warning in the event of leaks. GC LP
air cooled condenser.
• It has served as a refrigerant for decades and
has caused no long-term damage. Evaporator set for connection to a single
GC VP
• It provides a greater refrigerating capacity for the air cooled evaporative condenser.
same investment expenditure.
Using the Grasso reciprocating compressor the
• It has a better coefficient of performance FXGC range covers a cooling capacity of 260 to
Hint! 1800 kW for cold water products.
Capacity is automatically adjusted by internal control
The installation must comply with the
facilities which shut down compressors/cylinders
relevant directives for ammonia refrig-
incrementally to suit refrigerating loads. The chillers
eration systems in Germany, e.g. UVV
can be transported assembled.
BGV D4 (formerly VBG 20), DIN 8975
and EN 378. The chillers are produced in accordance with the
valid German regulations (DIN, UVV, VDE) or in
The FX GC range gives safe and dependable opera- accordance with the regulations of the destination
tion with the following features: country and have a CE certification.
• Module-welded plate evaporators
• Module-welded plate condensers

MAIN MODULES Product Information |
1.1.3 Chiller with reciprocating compressors - series FX GC and MX GC
X Chiller series
Y Condenser version
Z Evaporator version
Nominal chiller capacity in kW

9
pertaining to cold-water operations 12°C / 6°C
X1 Chiller type
X2 Refrigerant
X Chiller type
FX GC flooded evaporation
MX GC Special design (flooded evaporation)
Y Condenser version
P Plate heat exchanger (cassette welding)
S Shell and plate condenser (completely welded)
R Tube bundle condenser

L Air cooled condenser (not in the scope of delivery for GEA Refrigeration Germany)
V Vapour condenser (not in the scope of deliver for GEA Refrigeration Germany)
Z Evaporator version
P Plate heat exchanger (cassette welding)
S Plate heat exchanger (completely welded)
O without evaporator (condensing unit)
9 Nominal chiller capacity at 1500 min-1 (V300 ... V600) / 1200 min-1 / (V700 ... V1800) in kW related to cold
water operation 12 °C / 6 °C
with 1 compressors
Compressor type Nominal capacity in kW
V300 260
V450 400
V600 525
V700 600
V1100 900
V1400 1250
V1800 1500
Design with 2 compressors
2x V300 520
V300 / V450 650
2x V450 800
V450 / V600 900
2x V600 1050
2x V700 1200

Design with 2 compressors
V700 / V1100 1500
2x V1100 1800
V1100 / V1400 2200
2x V1400 2500
V1400 / V1800 2750
2x V1800 3000
X1 design of the chiller
(without) Standard version with 1 reciprocating compressor
duo Standard version with 2 reciprocating compressor
X2 refrigerant
NH3 Ammonia
Naming example
FX GC PP 900 Chiller with reciprocating compressor (FX GC)

duo NH3 with plate heat exchanger as condenser (P),
with plate heat exchanger as evaporator (P),
Nominal capacity 900 kW (900),
2 Compressor (duo),
for refrigerant ammonia (NH3)

1.1.4 Description of main components 1.1.4.2 Compressor drive motor

1.1.4.1 Reciprocating compressor
fig.2: Position of the compressor drive motors
fig.1: Position of the reciprocating compressor

The compressors are driven via a coupling by means
of a 4-pole or 6-pole IP23 (option IP55) electric
The FX GC PP chillers use open, single-action, motor with an operating voltage of 400V; 50 Hz run
multi-cylinder reciprocating compressors for the with a clutch.
refrigerant ammonia (R717) in the rated capacity
Optionally, motors can be used in FC operation.
range of 291 to 1274 m3/h per compressor.
The ammonia vapours created in the evaporator are
exhausted and compressed to condensation pres-
sure in one or several compressors.
The pressure and temperature transmitters installed
on the compressor are used to monitor the operating
values of each compressor. With compressors the
individual cylinders can be switched off either by
bypass valves or suction valve 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 monitoring
Safety equipment on the pressure generators is
standard in compliance with EN 378 and accident
prevention regulations BGV D4 by current linkage
valves combined with DBK safety pressure limiters.
To prevent overheating, the compressed gas tem-
perature is monitored for each compressor.

Non-soluble heavier oil is deposited in the oil dome

1.1.4.3 Evaporator + liquid separator and returns automatically controlled from there to the
compressor or compressors. For further details, see
Oil return system section.
In the case of external condensing systems, a maxi-
mum level indicator is installed in the liquid separator
to provide additional protection against overfilling.
The suction pressure and cooling agent outlet tem-
perature are monitored to provide reliable protection
against freezing.
The liquid separator and suction line are supplied
with water vapour diffusion-proof insulation.
The evaporator can be optionally provided with a
detachable insulation box.
fig.3: Arrangement of the evaporator Design, manufacture and acceptance comply with
the requirements of the pressure appliances direc-
In the evaporator heat is absorbed from the cooling tive.
water or brine (which is thereby cooled) by way of There is no evaporator when the chiller is designed
evaporation and superheating of the refrigerant. The as a condensing unit.
evaporator works on the principle of flooded evapo-
ration with external circulation.
The module-welded heat exchanger plates, made
from AISI 304 stainless steel (other materials on
request), are clamped together between the stand
plate and the pressure plate using pulling bolts and
attached to the upper carrying rod and the lower
guide rail. The individual plate modules are sealed
on the coolant side with ring gaskets and on the
coolant/heating agent side with (adhesive-free) elas-
tomer field gaskets.
fig.4: Position of the liquid separator
Liquid drops are effectively separated in the liquid

separator located above the evaporator.
In the operating state, the evaporator is flooded with
ammonia up to the height of the upper sight glass in
the circulation line (item 2555.2).

1.1.4.4 Condenser
fig.5: Position of the condenser
In the condenser the compressed refrigerant vapour

is heated, liquefied and supercooled by dissipating
the energy absorbed in the evaporator and compres-
sor to the heating agent (heating).
The module-welded heat exchanger plates, made
from AISI 316 stainless steel (other materials on
request), are clamped together between the stand
plate and the pressure plate using pulling bolts and
attached to the upper carrying rod and the lower
guiding rod. fig.6: Heat recovery
If the chillers are designed as evaporator units, the 1 Customer-sided
water-cooled condenser is not installed. In this case,
the refrigerant circuit is completed by the customer
with other condenser types.
The heating agent inlet is connected at the bottom,
the outlet connector is located at the top.
Heat recovery (optional)
Depending on the temperature level of the medium
to be heated, the overheated vapour provided by the
compressor or compressors can either be cooled,
cooled and partly condensed, or fully condensed. In
order to achieve the maximum heat exchange sur-
face in the condenser, the condensed ammonia
arriving from the desuperheater (item 2900) should
be discharged. From the specific separator/level
tank, the liquid-free vapour can flow to the condenser
where it is liquefied.

1.1.4.5 Injection control 1.1.4.6 Oil return system

In GC PP series units, the pressure drop of the liquid
refrigerant from condensation pressure to evapora-
tion pressure and the optimal utilization of the evapo-
rator capacity are ensured by the ECD (electronic
condenser drain) system. The action of the ECD sys-
tem is based on the variables suction pressure, end
pressure, NH3- level measurement, output power
and the speed of the compressors.
In the case of FX PP, the NH3level measurement
(LC, item 2240.1/2) is made on the high pressure
side. The condensate flows at low speed (< 0.3 m/s)
into the level tank. Injection valve AKVA (Item 2510)
functions according to the pulse to no-current princi-
ple. The cycle time is 3 seconds, i.e. after an open-
ing time of 3s, it is 100% open. The ECD software
will continuously calculate the percentage of opening fig.8: Position of the oil return
required for the injection valve.
The reciprocating compressor requires special refrig-
erating machine oil for lubrication and control.
A small part of the oil is carried off in the circuit dur-
ing the compressing process.
This is returned from the evaporator to the compres-
sor by an automatic, maintenance-free oil return sys-
tem (developed by GEA Refrigeration Germany
GmbH) on the low pressure side of the chiller.
fig.7: Injection control 1.1.4.7 Fittings

1. From the condenser
The term 'fittings' generally designates a control ele-
2. Sight glass ment of the machine. Among other things, the term
3. High-pressure liquid container 'fittings' is also used for valves if they are used for
4. Level sensor high the control and regulation of fluid flows in the pipes.
5. Level sensor low Furthermore, all kinds of installations in pipes, such
6. To the evaporator as sight glasses, measurement apertures, filters and
similar, are also designated as fittings. Therefore, fit-
tings also include all kinds of valves, such as
In evaporator chillers, level measuring is arranged on
the low pressure side and it is provided with an addi- – Stop valves
tional solenoid valve and liquid filter upstream of the – Check valves
injection valve.
– Safety valves
– Throttle valves
Each fitting has its own field of use, according to the
pressure or temperature in the pipe, the size of the
pipe, the sealing requirements for the fitting, the
reduction and direction of the flow of liquid, as well
as the medium itself.
The safety fittings are used to limit the pressure in
systems which are under pressure.

Each fitting is designed for the specific application.

The fittings can be operated manually or by motor,
1.1.4.8 Switching cabinet / control
e.g. by gear motors, or pneumatic or hydraulic cylin-
ders. In reset fittings, the flow of fluid in the pipe cau-
ses automatic closing of the valve.
Depending on the model, different closing elements
(e.g. valve discs, flaps, washers) close the pipe con-
nected to the fitting.
For service and maintenance tasks, manual stop
valves are installed:
– in the compressed gas line between the com-
pressor and condenser,
– in the injection line between the injection valve
and evaporator,
fig.9: Position of the switching cabinet
– before the liquid filter for evaporator units in the
liquid line The chillers are supplied with a switching cabinet as
– in the suction line between evaporator and com- standard.
pressor For transporting the chiller, the switching cabinet is
A suction filter in the compressor protects it from dirt. mounted on beams. These must be removed during
The filter cartridge can be cleaned or replaced. installation on site and the switching cabinet placed
on a level surface.
Hint! Instructions for setting down the switching cabinet on
The documentation of the fittings the on-site foundation can be found in the order-spe-
(acceptance certificates) forms part of cific drawing of the chiller.
the product documentation. The switching cabinet is configured according to the
technical specifications indicated in each order.
The chillers have a type GSC TP control as
standard.
Hint!
All instructions for the controls refer
to the GSC TP (hereinafter referred to
as the GSC).
The GSC consists of the control unit with operator

keypad and display unit, indicator lights for "Run-
ning", "Warning" and "Alarm", the emergency stop
button, the output relays and the casing.
Hint!
It is not permitted to add an external
controller between the GSC and the
power panel; this would extend the
safety chain to be achieved. All control
signals between the GSC and the
power panel must be processed
directly and must not flow indirectly
via an external controller. The manu-
facturer cannot otherwise guarantee
the safe operation of the system.

The GSC performs the following functions as – Profibus DP communication

standard:
The documentation for the GSC is part of the product
• Display of all important physical and technical documentation.
parameters, e.g.
– Pressure
– Temperature
– Capacity
– Number of operating hours
– Operation mode
– Status reports
• Automatic startup and shutdown of the chiller
and capacity control dependent on the following
values:
– 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, motor
current or suction pressure indicate an overload
• Fault memory with date and time
• Wire failure detection for analogue input signals
• Password protection for preventing unauthorised
access to important parameters
• Control of the chiller by a master controller via
potential-free contacts
• Possibility of communication via MPI or Modbus
RTU/TCP with master controller or building man-
agement system
• 10-minute trend display with display of all actual
values which existed just before alarm shutoff
• Remote maintenance via Ethernet connection
(TCP/IP)
The GSC optionally performs the following func-
tions:
– Frequency-controlled compressor drive motor
– Electronic flow switch for cooling agent circuit
– Electronic flow switch for heating agent circuit
– Remote setpoint adjustment (analogue signal)

Product Information | MAIN DATA
2 MAIN DATA
2.1 Technical Data

2.1.1 Grasso FX GC PP 260 NH3 to Grasso FX GC PP 1250 NH3
Type sizes FX GC PP 260 400 525 600 900 1250
Refrigerating capacity 1) Q0 kW 277 415 554 638 957 1276
Power consumption
kW 48.1 71.2 94.3 103.4 153.3 203.6
Compressor 1) Peff
Weight without charging mL kg 4100 4600 5750 6300 8250 11500
Operating weight mB kg 4250 4750 6000 6550 8600 11900
Refrigerant charging quantity NH3 kg 38 42 48 61 83 135
Oil charging quantity VOIL l 11.5 13.5 18.5 21.5 28.5 41.5
Cooling agent volume l 27 40 54 62 91 136
Heating agent volume l 28 40 71 83 132 150
Cooling agent connections 2) DN 100 100 100 100 100 150
Heating agent connections 2) DN 100 100 150 150 150 250
Grasso compressor Typ

V300 V450 V600 V700 V1100 V1400
e
LS power levels 25/37/50

25/37/50
25/50/75 33/50/67 62/75/87 25/50/75 33/50/67
% 62/75/87
100 83/100 75/87/10 100 83/100
100
0
Electrical data of compressor motor -1500 min –-1, 400 V / 3 Ph / 50 Hz3), IP 23, air cooled
Nominal capacity 4) Pn kW 55 90 110 132 200 250
Rated current at 400 V In A 97.5 159 195 251 371 466
Relative start-up current 5) Ia/In 6.5 6.5 7.5 6.8 6.8 6
Switching cabinet for power supply 3 PEN / 400 V, internal control voltage: 230 V / 50 Hz / 24 VDC

MAIN DATA Product Information |
Type sizes FX GC PP 260 400 525 600 900 1250
Supply line cross-section mm2 70 120 185 185 2x120 2x150
Primary fuse A 160 250 315 315 400 500
t K1/K2= 12 / 6 °C; t W1/W2 = 27 / 32 °C

2) Connection flange for cooling and heating agent based on DIN 2633 (corresponds to ISO PN 16)
3) Euro voltage area ±10%, other voltages / frequencies upon demand
4) For water inlet/outlet 12/6°C; if conditions vary, motor output differs
5) For Y - Δ start-up, the starting values are reduced to 30 %
Hint!
Variation in cooling agent and heating agent temperatures can lead to changes in the heat
exchanger and motor classification and therefore to different technical data.

2.1.2 Grasso FX GC PP 520 NH3 to Grasso FX GC PP 900 NH3
Size FX GC PP duo 520 650 800 900
Refrigerating capacity 1) Q0 kW 554 690 830 969
Power consumption
kW 96.2 119.3 142.4 165.5
Compressor 1) Peff
Weight without charging mL kg 5450 7200 8150 9100
Operating weight mB kg 5600 7450 8350 9400
Refrigerant charging quantity NH3 kg 53 73 90 106
Oil charging quantity VOIL l 23 25 27 32
Cooling agent volume l 54 60 70 91
Heating agent volume l 58 65 65 132
Cooling agent connections 2) DN 100 100 100 100
Heating agent connections 2) DN 100 100 100 150

V330+V300 V450+V300 V450+V450 V600+V450
e
LS power levels 16/25/33 / 14/28/43 /

25/38/50 / 20/30/40 /
% 42/50/66 / 50/57/71 /
63/75/ 87/100 50/60 / 80/100
75/83/92 /100 78/86/ 92/100
Nominal capacity 4) Pn kW 55+55 90+55 90+90 110+90
Rated current at 400 V In A 97.5+97.5 159+97.5 159+159 195+159
Relative start-up current 5) Ia/In 6.5/6.5 6.5/6.5 6.5/6.5 7.5/6.5
Supply line cross-section mm2 120 185 2x120 2x120
Primary fuse A 250 315 400 400
t K1/K2= 12 / 6 °C; t W1/W2 = 27 / 32 °C



Hint!

2.1.3 Grasso FX GC PP 1050 duo NH3 to Grasso FX GC PP 1800 duo NH3
Size FX GC PP duo 1050 1200 1500 1800
Refrigerating capacity 1) Q0 kW 1108 1276 1595 1914
Power consumption
kW 188.6 206.8 256.7 407.2
Compressor 1) Peff
Weight without charging mL kg 9500 12500 13600 14900
Operating weight mB kg 10000 13000 14100 15500
Refrigerant charging quantity NH3 kg 115 175 222 240
Oil charging quantity VOIL l 37 43 50 57
Cooling agent volume l 105 136 178 234
Heating agent volume l 157 149 190 230
Cooling agent connections 2) DN 100 150 150 150
Heating agent connections 2) DN 150 250 250 250

V600+V600 V700+V700 V1100+V700 V1100+V1100
e
LS power levels 18/25/43 /

16/25/33 /
50/56/ 25/38/50 / 20/30/40 /
% 42/50/66 /
68/75/81 / 63/75/ 87/100 50/60 / 80/100
75/83/92 /100
93/100
Nominal capacity 4) Pn kW 110+110 132+132 200+132 200+200
Rated current at 400 V In A 195+195 251+251 371+251 371+371
Relative start-up current 5) Ia/In 7.5/7.5 6.8/6.8 6.8/6.8 6.8/6.8
Supply line cross-section mm2 2x150 3x120 3x150 3x185
Primary fuse A 500 630 800 800
t K1/K2 = 12 / 6 °C; t W1/W2 = 27 / 32 °C



Hint!
2.1.4 Operation limits Caution!
The ammonia chillers (flooded evaporation) can be During operation of the chiller, the
operated under the most varied operation conditions increase of the cooling agent inlet tem-
within the given limits of application according to the perature must be limited to max. 3 K
requirements involved. The limits of application listed within 2 minutes.
below are based on the operational principle of the If the specified limits are exceeded for a specific
reciprocating compressor, thermodynamic relations, application, the manufacturer must be consulted.
used vessels and safety devices and practical oper-
ating conditions. The appropriate Compressor model In addition to the operating limits stated in the tables,
design should be selected for the particular operating the operating conditions of the respective compres-
conditions. sor type to be complied with must also be taken into
account (e.g. start-up regime, oil pressure, quantity
Caution! of oil, type of oil, etc.).
When considering a specific applica- The data entered pertain to the operating conditions
tion, all the conditions specified in the for a chiller or air conditioner. During shut-down or
table must be taken into account and during start-up, the limits may temporarily be excee-
adhered to. ded or not be met (never permanently).
Suction pres- min 0.7

p0 bar (a)
sure max 7.0
Outlet tempera- min +3

ture of water as tKA °C
cooling agent max +15
Outlet tempera-
ture with frost- min -10
tKA °C
resistant cool- max +15
ing agents
Condensing min 10
pc bar (a)
pressure max 23
Inlet tempera- min +20

ture of heating tWE °C
agent max +45
The specified operation limits apply to operation at

full load.
Partial load operation can lead to limitation of the
operation limits and must be checked in the specific
application.

2.1.5 Acoustic values
Size GC Total Sound Octave sound pressure

P sound power LPOct [dB]
pres-
LWA
sure
1)LP [dB(A)] Average sound frequency fm [Hz]
[dB(A)]
63 125 250 500 1000 2000 4000 8000
260 75 90 81 89 92 90 87 85 83 77
400 78 92 91 89 85 92 91 87 85 79
525 80 96 83 95 94 97 93 84 83 82
600 83 101 87 98 101 97 98 93 88 86
900 83 101 88 99 101 99 98 94 88 86
1250 83 101 88 99 101 99 98 94 88 86
Size GC P duo
520 79 93 84 92 95 93 90 88 86 80
650 81 94 84 92 93 94 92 89 87 81
800 81 95 84 92 88 95 94 90 88 82
900 84 97 85 96 95 98 95 89 87 84
1050 86 99 86 98 97 100 96 87 86 85
1200 87 103 90 100 102 100 101 95 100 88
1500 88 104 90 101 104 100 101 96 91 89
1800 88 104 91 102 104 101 101 97 91 89
1) Measuring point distance 1m; coolant and heating pump range tolerances up to +3 dB

2.2 P+I diagrams
2.2.1 P+I diagram FX GC PP
fig.10: P+I diagram FX GC PP
1 Customer
2 GEA Refrigeration Germany GmbH
3 Temperature probe, delivered separately
4 Flow controller, delivered separately
5 Temperature probe, delivered separately/for installation in line 2 m after evaporator
6 Cooling agent
7 Heating agents
8 Connection made on the liquid separator

2.2.2 Designation for main compo- Item Name

nents and fixtures - Liquid chiller
Grasso FX GC PP NH3 2000 Evaporator
Item Name Resistance thermometer, cooling agent

2040
outlet
10 Reciprocating compressor
Resistance thermometer, cooling agent
2045
15 Motor inlet
16 Motor current converter 2050 Flow switch
17 Motor winding protection 2060 Filling and drain valve
45 Suction filter, compressor 2100 Condenser
Solenoid valve capacity control, compres- 2200 Liquid separator

50
sor
2205 Service valve
90 Service valve, compressor
2230 Safety valve combination
95 Coupling between motor/compressor
2235 Stop valve, injection
100 Pressure transmitter, suction pressure
2255 Service valve
101 Pressure transmitter, crankcase pressure
2280 Heating element
105 Pressure transmitter, discharge pressure
2300 Pulse pump for oil return
110 Pressure transmitter, oil pressure
2305 GPV32D valve
Resistance thermometer Pt1000
115 2310 Solenoid valve, oil return
Suction temperature
Resistance thermometer Pt1000 2315 Stop valve

120
Discharge temperature
2320 Stop valve, oil return

125 2325 Sight glass
Oil temperature
2330 Service valve
260 Pressure stop valve
2340 Nonreturn valve, oil return
280 Suction stop valve
2345 Dirt filter, oil return
340 Overflow valve, compressor
2350 Stop valve
350 Safety pressure limiter
2360 Oil heater, pulse pump
360 Oil heater, compressor

Item Name
2370 Resistance thermometer, pulse pump
2410 Stop valve, overflow valve
2420 Overflow valve
2555 D28 sight glass

2.2.3 P+I diagram FX GC PP duo
fig.11: P+I diagram FX GC PP duo
1 Customer
2 GEA Refrigeration Germany GmbH
3 Temperature probe, delivered separately
4 Flow controller, delivered separately
5 Temperature probe, delivered separately/for installation in line 2 m after evaporator
6 Cooling agent
7 Heating agents
8 Connection made on the liquid separator

2.2.4 Designation for main compo- Item Name

nents and fixtures - Liquid chiller
Grasso FX GC PP NH3 255 Pressure stop valve Compressor 2
Item Name 288 Suction stop valve Compressor 1
10 Reciprocating compressor 1 285 Suction stop valve Compressor 2
15 Motor 1 340 Overflow valve, compressor 1/2
16 Motor current converter 1/2 350 Safety pressure limiter 1/2
17 Motor winding protection 1/2 360 Oil heater, compressor 1/2
20 Reciprocating compressor 2 2000 Evaporator
25 Motor 2 Resistance thermometer, cooling agent

2040
outlet
45 Suction filter, compressor 1/2
Resistance thermometer, cooling agent
2045
solenoid valve capacity control inlet
50
Compressor 1/2
2050 Flow switch
90 Service valve, compressor 1/2
2060 Filling and drain valve
95 Coupling between motor/compressor 1/2
2100 Condenser
Pressure transmitter, suction pressure
100 2200 Liquid separator
1/2
Pressure transmitter, crankcase pres- 2205 Service valve

101
sure 1/2
2230 Safety valve - combination
Pressure transmitter, discharge pres-
105 2235 Stop valve, injection
sure 1/2
110 Pressure transmitter, oil pressure 1/2 2255 Service valve
Resistance thermometer Pt1000 2280 Heating element

115
Suction temperature 1/2
2300 Pulse pump for oil return
120 2305 GPV32D valve
Discharge temperature 1/2
2310 Solenoid valve, oil return
125
Oil temperature 1/2 2315 Stop valve
250 Pressure stop valve Compressor 1 2320 Stop valve, oil return

Item Name
2325 Sight glass
2330 Service valve
2340 Nonreturn valve, oil return
2345 Dirt filter, oil return
2350 Stop valve
2360 Oil heater, pulse pump
2370 Resistance thermometer, pulse pump
2420 Overflow valve
2560 D28 sight glass

2.3 Main dimensions
2.3.1 FX GC PP 260 to FX GC PP 1250
fig.12: Set drawing FX GC PP
I Cooling agent inlet of evaporator

II Cooling agent outlet of evaporator
III Heating agent inlet of condenser
IV Heating agent outlet of condenser
V Blow-off line, safety valve
1) For installation on site, dismantle transport console and set electrical cabinet on foundation
Feeding of power feed and control lines (on the customer side) from below
Type Main dimensions
FX GC PP L1 L2 B H
mm

260 3750 3000 2000 2700
400 4000 3250 2000 2750
525 4300 3600 2000 2850
600 5200 4500 2300 3200
900 5450 4750 2300 3300
1250 5700 5000 2300 3500

2.3.2 FX GC PP 520 duo to FX GC PP 1800 duo
fig.13: Set drawing FX GC PP duo
I Cooling agent inlet of evaporator

II Cooling agent outlet of evaporator
III Heating agent inlet of condenser
IV Heating agent outlet of condenser
V Blow-off line, safety valve
FX GC PP duo L1 L2 B H
mm
520 duo 4100 3000 2000 2350
650 duo 4400 3250 2000 2450
800 duo 4600 3600 2200 2600
900 duo 5100 4500 2200 3150

1050 duo 5500 4750 2200 3150
1200 duo 6200 5400 2300 3300
1500 duo 6700 5900 2300 3700
1800 duo 7100 6400 2300 3800

2.4 Capacity calculation

The selection of the matching chiller is made with the
aid of the GUD design software by entering the
desired operating parameters.
2.5 Pressure losses

Precise calculation of the cooling and heating agent
side pressure losses of the evaporator and con-
denser is carried out using the GUD design software.
Water or brine can be used as cooling and heating
agents after their compatibility with the material com-
binations of the evaporator and the pipeline that is to
be connected has been established.

Product Information | INSTALLATION
3 INSTALLATION
3.1 Installation Hint!

The relevant regulations must be
3.1.1 Delivery
observed when designing the machine
Shipment is made in the type of packing stipulated in room and the safety equipment. For
the order. The chiller is generally supplied without further information on machine room
packing. situation, please consult our brochure
The chiller has an inert gas filling (nitrogen, 0.5 bar "Machine room situation and filling
overpressure) in the refrigerant circuit. volumes for NH3 refrigeration installa-
tions according to accident prevention
The heat exchanger connections are closed. regulations".
Warning!
3.1.2.2 Rigid installation
The compressors of the chiller are not
charged with oil, therefore the chiller After the chiller has been placed on the surface,
must not be started before it is prop- determine the deviations from the parallelity that
erly installed and commissioned. have to be maintained. Deviation from the horizontal
plane should not exceed 1.5 mm/m.
3.1.2 Basic information for installation
3.1.2.3 Installation of the Screw Com-
All foundation calculations, the selection of materials pressor for Insulation against
and the soil analysis are the owner’s responsibility. Structure-borne Sound
Caution!
For installation on intermediate ceilings, matched
Make sure that substances escaping vibration decoupling must be carried out on the ceil-
from leaks do not reach into the soil, ing construction.
groundwater or surface water (Federal The vibration isolators supplied have to be fixed to
Water Act WHG). the foundation bolts during assembly. Please consult
the drawing of the chiller for further information about
The lifting of the chiller for alignment must only be
the layout and position of the holes for attaching the
done on the support profiles or by means of crane. If
vibration isolators (order documentation). Refrigerant
small hoists are used (e.g. hydraulic hoists) for this
and heat carrier lines and their connections have to
purpose, ensure that the chiller is evenly lifted by two
be designed to withstand certain oscillations.
small hoists at a time in the transverse direction.
The orientation of the coupling is to be checked in
Outside influences (vibrations, jolts) must be avoi-
every case before or as part of start-up and to be
ded.
corrected in the event of deviations.
The welding seem must be inspected in accordance
with the Pressure Equipment Directive after welding 3.1.2.4 Electrical connection
work by the customer or operator at connections of
pipe lines and flanges. Danger!
Contact with live components is pro-
3.1.2.1 Information regarding installa-
hibited.
tion in machinery room
Produce the earth connection accord-
The chillers have to be installed in closed machine ing to the designation in the general
rooms and on a level surface. Provide enough space assembly drawing. See chapter "Des-
for maintenance work. ignation of the earth connection".
Unless other order-related limitations have to be
Before beginning the work, it must be ensured that
taken into account, the admissible ambient tempera-
all parts to be connected are voltage free, e.g. by
ture in operation is +5 to +40℃.
removing the main fuse in all phases.

INSTALLATION Product Information |
The insulation resistance of the electrical tools and ing in the supply documentation for the dimensions
fixtures and wiring is to be checked. The connection and position of the water connections to the evapora-
may only be undertaken if this value lies in the allow- tor.
able range.
• The evaporator should be installed on the pres-
All electrical connections must be established and all sure side of the pump.
electrical consumers/sensors must be connected
according to the circuit diagram. • Arrange a dirt collector immediately upstream of
the evaporator (recommended mesh size 0.5
3.1.2.5 Sound insulation, weather pro- mm).
tection • The volume of cooling agent should be kept at a
If the chiller is intended for outside installation, it constant level.
must be equipped with a suitable casing for sound 3.1.4 Heating agent system
and weather protection by the customer. The
weather protection must provide sufficient protection After the chiller has been aligned, it can be connec-
for the machine with regard to the climatic conditions ted on the heating agent side. The piping for the
at the installation location. heating agent connections must be installed on site
by the plant engineer.
Hint!
If the chiller is mounted on vibration isolators, the
The chiller is not intended for unpro- water lines must be connected to the evaporator
tected outside installation. Protection using flexible connections. The size and position of
against outside influences, especially the water connections for the condenser are indica-
dirt, dust and moisture (wetness) is ted in the drawing contained in the order documenta-
essential. tion.
GEA Refrigeration Germany GmbH will not accept • Install the condenser on the pressure side of the
liability for damage due to incorrect outdoor installa- pump.
tion.
• Arrange a dirt trap immediately upstream of the
3.1.2.6 Air-cooled condenser and condenser (recommended mesh size 0.5 mm).
evaporation condenser for GG • Check the water quality.
LP and GC VP series
3.1.5 Water pipes
If an air-cooled condenser or evaporation condenser
is used, certain points must be observed: • All pipes must be installed with flexible connec-
tions, separate from the chiller unit. No additional
The condenser is not integrated in the liquid chiller; it static or dynamic loads must be applied to the
is installed separately. It is usually installed on the chiller connections.
roof of the building.
The connection between the liquid chiller and the • Make sure that vibrations cannot be transmitted.
condenser must be made on site and the necessary • Charging and draining must be possible.
fittings also mounted on site.
• The pipes must be flushed before connecting.
Take summer and winter operating conditions with This is carried out to remove soiling, foreign par-
respect to refrigerant displacements into considera- ticles and welding residue from the system.
tion in line with local circumstances.
Provide for the installation of a refrigerant collector. 3.1.6 Refrigerant lines
3.1.3 Cooling agent system • FX GC PP
Chillers of the FX GC PP series are delivered
After the chiller has been aligned, it can be connec- with complete refrigerant piping, tested and filled
ted on the cooling agent side. The piping system for with nitrogen on the refrigerant side.
the cooling agent connections must be installed on
The blow-off lines for the safety valves are to be
site by the plant engineer.
installed and connected on site (by the client)
If the chiller is mounted on vibration isolators, the
water lines must be connected to the evaporator
using flexible connections. Please refer to the draw-

As the chiller unit is mounted on vibration isola-

tors, blow-off lines for connection to the chiller
should be flexible.
Chiller units with larger cooling capacities are
supplied partly disassembled if they exceed the
permitted transportation dimensions. On-site
assembly is carried out according to the order-
dependent documentation supplied, in particular
the P+I diagram and the unit drawing.
• Evaporators FX GC VP / LP (on request)
The refrigerant side pipes of the evaporator are
factory-tested, sealed and charged with nitrogen.
The pressure line connection between compres-
sor and condenser and the liquid line between
condenser and evaporator injection must be
installed, connected and tested on site (by the
client).
The blow-off lines for the safety valve must be
installed and connected on site (by the client).
All pipes for connection to the chiller should be
flexible.
3.1.7 Electrical installation

The chiller has been designed for plug-in, reliable
automatic operation.
Connections and almost all external connections are
pre-wired at the factory.
In principle, all the connections must be made in
accordance with the electrical diagram supplied.
Danger!
Contact with live components is pro-
hibited.
Before beginning the work, it must be ensured that

all parts to be connected are voltage free, e.g. by
removing the main fuse.
Connections to the chiller must be flexible and free of
loads.
Dimensioning of the inlet pipe cross-sections must
be according to DIN VDE 100 Part 520.
Some external components, such as the second
EMERGENCY STOP switch, the ammonia sensor,
the water pump flow switch, and the fans of the
machine house, must be connected by the system
erector on site.

3.1.8 Installation information
3.1.8.1 Foundation plan
fig.14: Foundation plan
I Cooling agent inlet

II Cooling agent outlet
III Heating agent inlet
IV Heating agent outlet
1) Primary control side Grasso FX GC
Dimensions for W and L, see table chiller main dimensions

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.
Leave a maintenance space of 0.8 m above the chiller.
Provide clearance for suitable lifting gear in order to dismantle subassemblies for repair.

3.2 COOLING AGENT SYSTEMS ON • Cooling capacity per power step

RECIPROCATING CHILLERS • Allowed restart time of compressor drive motor
Capacity control on reciprocating chillers takes place • Temperature control requirements

incrementally so that the cooling agent temperature (See buffer tank size calculation.) The cooling agent
responds in the same manner. supply temperature can only be accurately controlled
When the system charge is large enough, tempera- if a properly sized buffer tank is fitted in the chiller
ture control usually takes place on the return flow. outlet.
The required cooling agent system charge depends
on:
3.2.1 Single chiller, single pump systems
fig.15: Single chiller, single pump systems
1 Consuming devices
2 Mixing/buffer tank
3 incorrect
4 better
5 best
R Return
S Supply
The construction of the buffer tank should ensure optimum mixing of the entering cooled cooling agent with the
existing cooling agent in order to achieve appropriate cooling and warming in the same time frame.
Theoretical calculations for sizing mixing/buffer tanks

To prevent overheating of the compressor motor, switching frequency should be limited to a maximum of 1 per
10 minutes. Installing a mixing/buffer tank guarantees accurate control of the cooling agent outlet temperature.

mbuffer(kg) · Cpcooling agent(kJ/kgK) · 2 · Δt(K) =

Qomin(kW) · reactivation interval) (s)
(kJ)
----------------------------------------------------------------
2
Qomin is the minimum cooling capacity before switching off (kW)
mbuffer = Vbuffer(m³) · ρ cooling agent(kg/m³) (kg)
Qomin ·150
Vbuffer req. = ----------------------------------- (m³)
pcooling agent · Cρ cooling agent · Δt
fig.16: Compressor switching frequency
1 Temperature
2 Time
3 restart (after 10 minutes)
4 Temperature setpoint
5 Switching state of the compressor
6 Δ tcontrol
7 Δ tcontrol
8 OUT
9 IN
10 Buffer
11 Heating
12 Cooling

3.2.2 Single chiller, double-pump systems

The chiller system is independent of the consumer system by means of an equalising/connecting tank.
Hint!
Ensure that the chiller pump flow is always (at least 20 %) greater than the total pump flow of
the consumer system.
fig.17: Single chiller, double-pump systems
1 Chiller group
2 Equalising / Connecting Tank
3 < 5°C switch-off of the chiller group by the controller
4 > 7°C switch-on of the chiller group by the controller
5 Consuming devices
6 Controller
R Return
S Supply

3.2.3 Multi chiller, double-pump systems

The chiller system is independent of the consumer system by means of an equalising/connecting tank.
fig.18: Multi chiller, double-pump systems
1 Main PLC
2 Under PLC
3 Unit n
4 Unit 2
5 Unit 1
6 Equalising / Connecting Tank
7 < 5°C switch-off of the chiller group by the controller
8 > 7°C switch-on of the chiller group by the controller
9 Consuming devices
10 Controller
R Return
S Supply
Hint!
Ensure that the chiller pump flow is always (at least 20 %) greater than the total pump flow of
the consumer system.

Unlike the mixing tank, the equalising tank should guarantee laminary flow to obtain stratification of the warm
and cold cooling agent. The inlets should be executed in such a manner that no impulse will be introduced and
the cooling agent velocity in the tank should be less than:
2300 x J (m²/s)
V< ------------------------ (m/s)
d Tank (m)
J is the kinematic viscosity of the cooling agent.

The chiller capacity is controlled by measuring the chilled cooling agent temperature at TT1. Fewer consumers
will cause the consumer flow to decrease, thus the dominant flow of the chilled cooling agent will create an
upflow in the equalising tank.
When the setpoint minus Δ t is reached at minimum capacity, TT3 will switch off one chiller group. When the
consumer flow increases, due to its dominance it will create a downflow in the equalising tank. As soon as the
warm return cooling agent arrives with a temperature of setpoint plus Δ t at TT2, a chiller group switches on.
Summary: TT1 takes care of chiller capacity control and TT2 & TT3 take care of switching on & off the chiller
group. There is a problem when both consumer and chiller flows are equal and supply temperature is too low
(this can occur when the consumer pump control is defective). In this case, temperature in the equalising/
connecting tank stays constant, TT2 & TT3 do not react, and the chiller keeps running at lowest capacity. Only in
this case can TT1 switch off the chiller group. The permission to do so comes from flow monitors 1 and 2, which
must be in "no-flow" position.

3.3 Transport (crane transport)

Warning!
The chiller units are not intended for transport with a fork lift truck!
Ammonia 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.
Danger!
Make certain there is no one under the suspended load during transport with the crane!
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 the
compressor, 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.19: 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.

fig.20: Transport
1 Cross-arm
Make suitable arrangements (timber or Armaflex support) to avoid damage to the surface. Shackles must be
used.
fig.21: 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 the
chiller must not be stepped on. Components must be secured against vibrations. The competent staff member or
the company is responsible for ensuring transport safety.

Product Information | MAINTENANCE INSTRUCTIONS
4 MAINTENANCE INSTRUCTIONS
4.1 Maintenance schedule for liquid • There should be no danger that the equipment
can be damaged by in-plant transport and han-
chiller
dling operations.
The maintenance schedule listed below indicates the • Sufficient space must be available for visual
operating hours at which maintenance activities inspection and maintenance work on the equip-
should be carried out. For most of the maintenance ment.
work, the chiller unit must be disconnected. To avoid
shutting down the system at inconvenient times, • The floor on which the equipment is set up must
such maintenance work should be carried out during be such that ammonia and oil cannot seep in the
regular shut-downs as far as possible. ground.
To reduce maintenance costs, we have set up the The accident prevention directive "Refrigerating sys-
schedule so that various kinds of work can be carried tems, heat pumps and chillers" BGVD4, (see Art. 16)
out at the same time. stipulates additional requirements for the installation
It is advisable to service the chiller unit once a year, of ammonia chillers in order to guarantee that such
irrespective of the number of operating hours. equipment is operated safely.
Chiller unit maintenance must be carried out by the You will find more information on the machine room
plant engineer/client in accordance with the enclosed situation in our brochure "Installing liquid chillers in
schedule. the member states of the European Union - EN 378
requirements".
• After 100 operating hours: Change the lubricat-
ing oil and carry out compressor maintenance 4.4 Personal protection
(see compressor manual)
The company shall provide personal safety equip-
• Replace the disposable suction gas filter on the ment against exposure to refrigerant. This equipment
compressor with the replacement filter provided shall be stored ready-for-use outside the hazardous
after a maximum of 100 hours. Check the tight- areas in an easily accessible manner.
ening torques of the coupling pins. Safety equipment for at least two persons should be
• Every 2,500 hours: Inspection and maintenance available.
of the liquid chiller unit Safety equipment for ammonia:
• Every 10,000 hours: General inspection and – Safety gloves
maintenance of the liquid chiller unit
– Safety goggles
4.2 Regular maintenance – Respiratory equipment with filter
2,500-hour (or annual) maintenance: Safety systems:
1. Inspection and maintenance of the compressor To ensure a high level of safety against leaking
ammonia
2. Check that the chiller unit is level (adjustment of
– Ammonia warning systems and
the vibration insulators if necessary)
3. Inspect water piping flanged connections for – Absorption systems
stress can be ordered.
10,000-hour maintenance:
1. Carry out the 2,500-hour maintenance
2. Carry our general inspection of the compressor
and maintain compressor as described in the
compressor manual.
4.3 Machine room information

When selecting a suitable installation site for the
chiller, take the following aspects into consideration:

Specification Product Information |
5 SPECIFICATION
5.1 FX GC PP NH3
5.1.1 Technical Data
Rated speed min-1
Refrigeration capacity acc. to EN 12900 and DIN 8976 kW
Power consumption kW
Condenser rating kW
Cooling agents
Cooling agent inlet oC
Cooling agent outlet oC
Heating agents
Heating agent inlet oC
Heating agent outlet oC
Condensing temperature oC
Flow rate sec. cooling agent m³/h
Flow rate sec. heating agent m³/h
Main dimensions of chiller unit
Length mm
Width mm
Height mm
Refrigerant charge kg
Oil filling amount l
Shipping weight kg
Operating weight kg

Product Information | Specification
5.1.2 Package
Description Ammonia liquid chiller with reciprocating compressor, evaporator and

condenser in execution as plate heat exchanger, as a compact, complete
factory packaged unit, ready for connection on site.
Compressor configuration Reciprocating compressor Grasso open-type execution with multi-stage

capacity control by cylinder offloading. The compressor is equipped with
integrated gas suction filter, solenoid valves for capacity control, oil
heater, suction and discharge oil filters, back-pressure independent over-
flow valve and partially loaded start. A works certificate for the test run of
the compressor is included.
Compressor type
Liquid separator type horizontal
Valves on suction side Stop valves on suction side
Valves on pressure side Stop valve(s) on discharge side
Wiring
Painting Protective paint system S 2.15 acc. to EN ISO 12944-5 for environmental
conditions C2 acc. to EN ISO 12944-2.
Colour RAL 5014 dove blue
Insulation type Suction pipe and liquid separator insulated with Armaflex
Controller

Controller type Chiller unit control GSC TP (touch panel)

Control on:
• Initial cooling agent temperature
Limit values:
• Suction pressure, condenser pressure, motor current
Modes:
• Control type: central/local, type of start-up: auto/manual, capacity
regulation: auto/manual
The main functions of the PLC are:
• Initial temperature control of the cooling agent
• Electronic aggregate protection and record of operating hours
• Release contacts for secondary refrigerant pump and condenser sys-
tem
• Operating messages and all analogue values are displayed
• Fault messages for operating control, status lamp and text
• Potential-free status reports of the unit for /DDC (unit ready, unit in
operation, multiple fault).
Controller display Display integrated in controller
Controller arrangement Integrated in power panel
Controller communication Standard MPI interface
Display language English
Number of pressure sensors 4
Mounting of pressure sensors in tube
Number of temperature probes 6
Flow switch for cooling agent Mechanical flow switch, delivered separately
Selection of flow switches for cool- without flow switch

ing medium
Drive motor Drive motor
Motor type Low voltage motor IP 23
Design IMB 3
Number of poles
Protection classification IP23

Nominal motor capacity kW
Rated voltage 3 x 400 V ± 5%
Frequency 50
Rated current A
Starting current / rated current (with

DOL starting)
Switch on mode star / delta
Type of power supply Switching cabinet, protection class IP 54, completely wired internally,
main switch gear assembly, fuse disconnect, circuit breaker for drive
motor, protection for auxiliary motor including thermal overcurrent trigger
and fuses, control transformer with double control circuit fuse on primary
and secondary side, 24 V DC power supply,
Cable entry point at the bottom
Evaporator
Operating pressure of evaporator 16 bar
Plate heat exchanger of modular semi-welded design; secondary refrigerant ports are complete with flanges
and counter flanges.
Cassette material of evaporator AISI ...
Pressure drop < 80 kPa
Condenser
Plate heat exchanger of modular semi-welded design; cooling medium ports are complete with flanges and
counter flanges.
Cassette material of condenser AISI ...
Safety devices
Type Double safety valve with change-over valve
Change-over valve 1
Number of overflow valves 1

Approval and documentation
Approval for chiller Work's Certificate, Certificate of Conformity acc. to Machine Directive
98/37/EG. Calculation and manufacture acc. to AD 2000 and EN 378.
Approval pressure equipment Certificate of Conformity acc. to Pressure Equipment Directive (PED)
Non-destructive testing 10 % non-destructive welding test acc. to EN 1435
Documentation consisting of Standard documentation
Language of documentation English
Sets of documentation 2
*** Options (included in price) ***
5.1.3 Not included in scope of delivery
Foundations, pipes on water side, spare parts and special tools, refriger-
Not included in scope of delivery
ant and lubricating oil, performance test and start up.

5.2 FX GC PP duo NH3

5.2.1 Technical Data
Rated speed min-1
Refrigeration capacity acc. to EN 12900 and DIN 8976 kW
Power consumption kW
Condenser rating kW
Cooling agents
Cooling agent inlet oC
Cooling agent outlet oC
Heating agents
Heating agent inlet oC
Heating agent outlet oC
Condensing temperature oC
Capacity of compressor 1 max. kW
Capacity of compressor 2 max. kW
Power consumption compressor 1 max. kW
Power consumption compressor 2 max. kW
Flow rate sec. cooling agent m³/h
Flow rate sec. heating agent m³/h
Main dimensions of chiller unit
Length mm
Width mm
Height mm
Refrigerant charge kg
Oil filling amount l

Shipping weight kg
Operating weight kg

5.2.2 Package
Description Ammonia liquid chiller with 2 reciprocating compressors, evaporator and

condenser executed as a plate heat exchanger, as a compact, complete
factory packaged unit, ready for connection on site.
Compressor configuration 2 Reciprocating compressors Grasso …………….., Grasso …………

…..open-type execution with multi-stage capacity control by cylinder off-
loading. The compressor is equipped with integrated gas suction filter,
solenoid valves for capacity control, oil heater, suction and discharge oil
filters, back-pressure independent overflow valve and partially loaded
start. A works certificate for the test run of the compressor is included.
Compressor type Grasso …………../……………
Liquid separator type horizontal
Valves on suction side Stop valves on suction side
Valves on pressure side Stop valve(s) on discharge side
Wiring Wiring
Painting Protective paint system S 2.15 acc. to EN ISO 12944-5 for environmental
conditions C2 acc. to EN ISO 12944-2.
Colour RAL 5014 dove blue
Insulation type Suction pipe and liquid separator insulated with Armaflex
Controller

Controller type Chiller unit control GSC TP (touch panel)

Control on:
• Initial cooling agent temperature
Limit values:
• Suction pressure, condenser pressure, motor current
Modes:
• Control type: central/local, type of start-up: auto/manual, capacity
regulation: auto/manual
The main functions of the PLC are:
• Initial temperature control of the cooling agent
• Electronic aggregate protection and record of operating hours
• Release contacts for secondary refrigerant pump and condenser sys-
tem
• Operating messages and all analogue values are displayed
• Fault messages for operating control, status lamp and text
• Potential-free status reports of the unit for /DDC (unit ready, unit in
operation, multiple fault).
Controller display Display integrated in controller
Controller arrangement Integrated in power panel
Controller communication Standard MPI interface
Display language English
Number of pressure sensors 8
Mounting of pressure sensors in tube
Number of temperature probes 9
Flow switch for cooling agent Mechanical flow switch, delivered separately
Selection of flow switches for cool- without flow switch

ing medium
Drive motor(s)
Motor 1
Design IMB 3
Number of poles

Frequency 50
Rated current A

DOL starting)
Motor 2
Design IMB 3
Number of poles
Frequency 50
Rated current A

DOL starting)
Switch on mode star / delta
Type of power supply Switching cabinet, protection class IP 54, completely wired internally,
main switch gear assembly, fuse disconnect, circuit breaker for drive
motor, protection for auxiliary motor including thermal overcurrent trigger
and fuses, control transformer with double control circuit fuse on primary
and secondary side, 24 V DC power supply,
Cable entry point at the bottom
Evaporator
Plate heat exchanger of modular semi-welded design; secondary refrigerant ports are complete with flanges
and counter flanges.
Cassette material of evaporator AISI ...

Condenser
Plate heat exchanger of modular semi-welded design; cooling medium ports are complete with flanges and
counter flanges.
Cassette material of condenser AISI ...
Safety devices
Type Double safety valve with change-over valve
Change-over valve 1
Number of overflow valves 1
Approval and documentation
Approval for chiller Work's Certificate, Certificate of Conformity acc. to Machine Directive
Approval pressure equipment Certificate of Conformity acc. to Pressure Equipment Directive (PED)
Non-destructive testing 10 % non-destructive welding test acc. to EN 1435
Documentation consisting of Standard documentation
Language of documentation English
Sets of documentation 2
*** Options (included in price) ***
5.2.3 Not included in scope of delivery
Foundations, pipes on water side, spare parts and special tools, refriger-
Not included in scope of delivery
ant and lubricating oil, performance test and start up.


Liquid Chillers Grasso FX GC PP

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Liquid Chillers Grasso FX GC PP

Product Information (Translation of the original text)

2 GEA Refrigeration Germany GmbH | L_201011_4 | Generated 02.12.2014

SYMBOLS USED IN THIS MANUAL

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4.4 Personal protection 49

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1.1 General description • Cylindrical heat exchangers which are easy to

• It has a low odour threshold which serves as an

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1.1.3 Chiller with reciprocating compressors - series FX GC and MX GC

Nominal chiller capacity in kW

MX GC Special design (flooded evaporation)

P Plate heat exchanger (cassette welding)

S Shell and plate condenser (completely welded)

R Tube bundle condenser

10 GEA Refrigeration Germany GmbH | L_201011_4 | Generated 02.12.2014

P Plate heat exchanger (cassette welding)

S Plate heat exchanger (completely welded)

O without evaporator (condensing unit)

Compressor type Nominal capacity in kW

Design with 2 compressors

Compressor type Nominal capacity in kW

V300 / V450 650

V450 / V600 900

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Design with 2 compressors

Compressor type Nominal capacity in kW

V700 / V1100 1500

V1100 / V1400 2200

V1400 / V1800 2750

X1 design of the chiller

(without) Standard version with 1 reciprocating compressor

duo Standard version with 2 reciprocating compressor

FX GC PP 900 Chiller with reciprocating compressor (FX GC)

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1.1.4 Description of main components 1.1.4.2 Compressor drive motor

fig.2: Position of the compressor drive motors

fig.1: Position of the reciprocating compressor

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Non-soluble heavier oil is deposited in the oil dome

fig.4: Position of the liquid separator

Liquid drops are effectively separated in the liquid

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fig.5: Position of the condenser

In the condenser the compressed refrigerant vapour

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1.1.4.5 Injection control 1.1.4.6 Oil return system

fig.7: Injection control 1.1.4.7 Fittings

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Each fitting is designed for the specific application.

The GSC consists of the control unit with operator

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The GSC performs the following functions as – Profibus DP communication

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2.1 Technical Data

Type sizes FX GC PP 260 400 525 600 900 1250

Refrigerating capacity 1) Q0 kW 277 415 554 638 957 1276

Weight without charging mL kg 4100 4600 5750 6300 8250 11500

Operating weight mB kg 4250 4750 6000 6550 8600 11900