Rc6 Product Information

Reciprocating Compressors for industrial refrigeration
Series Grasso 6
Product Information (PI)
PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 1-

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.
- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

Table of Contents
Section Title Page

1 DESCRIPTION AND SELECTION OF COMPRESSOR 9
1.1 INTRODUCTION AND SCOPE 9
1.1.1 OUTLINE 9
1.1.2 TYPE DESIGNATION 9
1.1.3 APPLICATION 9
1.1.4 DRIVE SYSTEM 9
1.1.5 SELECTION COMPRESSOR AND ACCESSORIES 9
1.1.6 PRESSURE TESTS 9
1.1.7 ACCEPTANCE TEST 9
1.1.8 STANDARD SCOPE OF SUPPLY 9
1.1.9 OPTIONS 9
1.2 GENERAL DATA 11
1.2.1 TECHNICAL DATA 11
1.2.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 12
1.2.3 SHAFT END COMPRESSOR 13
1.2.4 SOUND RATING 14
1.2.4.1 SOUND DATA 14
1.2.5 PART-LOAD POWER CONSUMPTION 19
1.2.6 STARTING TORQUE 19
1.2.7 FREE FORCES AND MOMENTS 20
1.2.7.1 DETAILS 20
1.2.8 POSITION OF CENTRE OF GRAVITY 21
1.2.8.1 COORDINATES POSITION OF CENTRE GRAVITY 21
1.2.9 TORSIONAL ELASTIC SUBSITUTE SYSTEMS OF CRANKSHAFTS 21
1.3 LIMITS OF OPERATION AND FIELDS OF APPLICATION 25
1.3.1 GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 6 25
1.3.1.1 FIELDS OF APPLICATION 26
1.3.2 PRECISE FIELD OF APPLICATION 27
1.3.3 LIMITATIONS OF PART-LOAD OPERATION 27
1.4 LUBRICATING OILS (choice and recommendations) 29
1.4.1 Oil selection table 29
1.4.1.1 Remarks 29
1.4.2 Strongly recommended oil types for Grasso reciprocating compressors 29
1.4.3 Accepted NH3 and HCFC oil types for Grasso reciprocating compressorss 30
1.4.4 Accepted HCFC oil types for Grasso reciprocating compressors 30
1.5 DESIGN DETAILS OF COMPRESSOR 31
1.5.1 COMPRESSOR HOUSING 31
1.5.1.1 DIAGRAMS Grasso 6(W) 32
1.5.2 CYLINDERS AND MOVING PARTS 33
1.5.3 ROTARY SHAFT SEAL 33
1.5.3.1 DETAILS ROTARY SHAFT SEAL 33

Section Title Page
1.5.4 SUCTION AND DISCHARGE VALVES 33
1.5.4.1 DETAILS SUCTION AND DISCHARGE VALVE ASSEMBLY 33
1.5.5 CAPACITY CONTROL SYSTEMS 34
1.5.5.1 GENERAL 34
1.5.5.2 DESCRIPTION OF CAPACITY CONTROL 34
1.5.5.3 OPERATION OF CAPACITY CONTROL 34
1.5.5.4 PARTIALLY UNLOADED STARTING 34
1.5.5.5 ALTERNATIVES OF CAPACITY CONTROL 35
1.5.5.6 DIAGRAM CAPACITY CONTROL 36
1.5.6 CYLINDER HEAD COVERS 37
1.5.7 WATER COOLED OIL COOLER 37
1.5.8 OVERFLOW SAFETY VALVE AND PRESSURE EQUALISING 37
1.5.8.1 DETAILS PRESSURE RELIEF VALVE 37
1.5.9 DIRECT DRIVE OIL PUMP 38
1.5.9.1 OIL LUBRICATION SYSTEM 39
1.5.9.2 OIL CHANNEL 39
1.5.10 MAIN CONNECTIONS AND SUCTION GAS STRAINER 39
1.5.10.1 DETAILS SUCTION GAS STRAINER 39
2 DESCRIPTION AND SELECTION OF ACCESSORIES 41
2.1 CAPACITY CONTROL 41
2.1.1 CYLINDER NUMBERING 41
2.2 CONTROLS, SAFETIES, GAUGES AND SWITCHES 43
2.2.1 MONITRON CR CONTROL DEVICE 43
2.2.2 PRESSURE GAUGE AND SAFETY SWITCH PANEL 46
2.3 DIRECT AND V-BELT DRIVE 49
2.3.1 SELECTION OF DIRECT DRIVE 49
2.3.2 SELECTION OF V-BELT DRIVE 50
2.3.2.1 DETAILS V-BELT DRIVE 50
2.4 PACKAGED BASE FRAME 51
2.4.1 PACKAGED BASE FRAME 53
2.5 OIL SEPARATOR; OIL RETURN PROTECTION; OIL LEVEL FLOAT SWITCH; OIL EQUALISING AND OIL RETURN 55
2.5.1 OIL SEPARATORS 55
2.5.2 OIL RETURN PROTECTION 58
2.5.3 CRANKCASE OIL LEVEL FLOAT SWITCH 58
2.5.3.1 DETAILS CRANKCASE OIL LEVEL FLOAT SWITCH 59
2.5.4 COMMON OIL RETURN AND OIL EQUALIZING CONNECTION 60
2.6 WATER COOLED CYLINDER HEADS AND COOLING WATER REQUIREMENTS 61
2.7 CRANKCASE HEATER 61
2.7.1 DETAILS CRANKCASE HEATER 62
2.8 SUCTION AND DISCHARGE STOP VALVES AND FLANGES 62
2.8.1 DETAILS STOP VALVE FITTING 62
2.9 SPARE PARTS AND (SPECIAL) TOOLS 63
2.9.1 SPARE PARTS 63

Section Title Page
2.9.2 HAND-OPERATED OIL PUMP 63
3 NOTES 65
3.1 65

Preface 4) Installation and maintenance manual (IMM)
This preface gives a survey of the types of Contents

documentation available for reciprocating Grasso This manual will provide information on how to
compressor series. transport, install, start-up and maintain the compressor
(package). It also contains a number of "Product
Information Sheets" and the current "Parts List"
All documentation and selection software is on-line
available on www.grasso-global.com User group
To be used in the field by qualified personnel for both
end-user and contractor.
1) Product Information (PI)
Distribution
Contents Supplied together with the compressor.
All product information (engineering data) for this series
compressor and the corresponding recommended
accessories. It is meant to be a guide to the selection of 5) Product Descriptions, Instructions for Accessories
these components. (PD)
User group Contents

Project engineers, application engineers, sales managers, All the relevant mounting and installation instructions
product managers for both end-users and contractors. and spare parts information for those accessories
supplied with the compressor.
Distribution
Your Grasso contact only. User group
end-user and contractor.
2) Operating manual (OM)
Distribution
Contents
Supplied together with the compressor.
General operation guide lines; safety instructions,
periodical inspections, fault analysis, periodical
maintenance. 6) Parts list (PL)
User group Contents

To be used in the field by the end-user. All current parts of the compressor and accessories
together with the design changes applicable to previous
Distribution supplied components ("History").
Supplied together with the compressor.
User group
Service and parts department for both end-user and
3) Safety instructions refrigerant ammonia contractor.
Contents Distribution
Strict safety provisions have been defined to protect Your Grasso contact only.
human beings and facilities. Reference is made to the
main guidelines and provisions to be observed
inplanning and operating refrigerating plants. With 7) Service & Maintenance Schedules (SMS)
regard to their operation, the detailed operating
manuals of the plant manufacturers shall be taken into Contents
account as well. Manual will be supplied with all Complete set of service and maintenance schedules for
compressors 100 operating hours up to 48000 operating hours
(inspection, renewal, measuring, cleaning, ...) of the bare
User group shaft compressor.
end-user and contractor. User group
Service and parts department and in the field by
Distribution qualified personnel for both end-user and contractor.
(If applicable supplied together with the compressor)
Distribution
Your Grasso contact only.

8) Service Instruction Manual (SIM)
Contents
Description of (re)assembling, inspection, repair and part
or total overhaul of the bare shaft compressor. This
manual should be used together with the 'Installation
and Maintenance Manual'.
User group
To be used in the field by qualified personnel of
refrigeration installers or contractors.
Distribution
Your Grasso contact only.
9) Typographic signs
Indicates a WARNING. READ IT CAREFULLY!
Indicates an IMPORTANT note or procedure to which

you should pay special attention.
Indicates a HINT.

1. DESCRIPTION AND SELECTION OF
COMPRESSOR
1. DESCRIPTION AND SELECTION OF COMPRESSOR
1.1 INTRODUCTION AND SCOPE Supplied loose:

• Installation and Maintenance Manual(IMM).
1.1.1 OUTLINE
Grasso 6 is the the designation of a series of open, single- Not included:
acting, reciprocating refrigeration compressors with
trunk-type pistons and with 4, 6 and 8 cylinders in resp. • oil charge.
V-, W- and VV-arrangement.
1.1.9 OPTIONS
1.1.2 TYPE DESIGNATION • Lloyds approval (other approvals on request)
The following examples will explain the type REMARK: When the compressor is delivered with a
designation: survey certificate it should be taken into
account that the fields of application are
8 cylinder single-stage compressor type reduced to a certain extent (viz., somewhat
lower discharge pressure = condensing
Grasso 86W:
pressure).
8, Number of cylinders
6, Series indication • Accessories as mentioned in next chapter.
W, Water cooled
1.1.3 APPLICATION
• Industrial operation.
• Evaporating temp. between -68 and +22 °C.
• Refrigerants: amongst others NH3, R134a, R22,
R404A, R507.
• For particular applications (cascade systems, chemical
processes, etc.) consult Grasso.
1.1.4 DRIVE SYSTEM

• Electric motor; direct or V-belt.
• Max. speed 1500 min-1.
• Rotation normally counter-clockwise when facing
shaft end of compressor. (clockwise is permitted)
1.1.5 SELECTION COMPRESSOR AND ACCESSORIES

• Consult Grasso's software program COMSEL
(COMpressor SELection) in combination with
Engineering Data Sheets to select compressor and/or
accessories. The software program COMSEL can be
downloaded from our homepage
"www.grasso-global.com"
1.1.6 PRESSURE TESTS

• Test pressure 34.5 bar(e).
• Design pressure 24.0 bar(a).
• Test run with air.
1.1.7 ACCEPTANCE TEST

• Acceptance test under design conditions, acc. to ISO
917, witnessed by the customer possible on request.
1.1.8 STANDARD SCOPE OF SUPPLY

• Standard bare compressor:
¸ painting hammertone blue
¸ oil and suction filters
¸ Filled with nitrogen
¸ Mating flanges suction and discharge connections
¸ Purge valve on discharge line

COMPRESSOR

COMPRESSOR
1.2 GENERAL DATA

1.2.1 TECHNICAL DATA
Table 1.2-1 Technical Data of Grasso 6 compressors
COMPRESSOR TYPE 46 66 86
Number of cylinders z 4 6 8
Cylinder arrangement 2xV 2xW 2 x VV
Cylinder bore D mm 85
Piston stroke S mm 66
Swept volume at full-load: n = 1450/min Vs m3/h 130.3 195.5 260.7
Standard direction of rotation counter-clockwise when facing shaft end (both

directions permitted)
1450 min-1 n min-1 810- 855- 905- 1015- 1140- 1215- 1285- 1450
Standard compressor speeds (with V-belt drive) at motor (50 Hz)
speed: 1750 min-1 n min-1 800- 875- 980- 1030- 1095- 1225- 1380- 1465
(60 Hz)
Standard steps of capacity control (expressed in percentage % 100-50 100-67-33 100-75-50-25
of full load swept volume)
Mass of bare compressor (without flywheel and other kg 280 345 400
accessories)
Oil charge in crankcase and oil circuit (centre line of sight dm3 9.2 (8.5) 10.0 (9.3) 10.8 (10.1)
glass)a
Friction power at an 55° C oil temperature n= 1450/min Pw kW 1.10 1.58 2.22
Mass moment of inertia of crank mechanism (without
Id kg.m2 0.0361 0.0421 0.0478
flywheel)b
a. The figures between brackets indicate the smaller oil charge for the Grasso 6W compressors due to the presence of an oil cooler.
b. The mass moment of inertia Id expressed in SI units, is required to determine the so-called coefficient of speed fluctuation.

COMPRESSOR
1.2.2 MAIN DIMENSIONS AND SPACE

REQUIREMENTS
Table 1.2-2
COMPRESSOR
TYPE 46 46W 66 66W 86 86W
COMPRESSOR
TYPE 46 46W 66 66W 86 86W
MINIMUM REQUIRED FREE SPACE for removal of:
Length A 696 696 721 721 746 746 crankshaft U 661 661 673 673 711 711
Width B 840 893 929 V 260 260 325 325 360 360
piston and
C 316 316 379 379 395 395 cylinder liner W 626 700 748 748 725 725
D 316 316 352 352 363 363 LOCATION OF CENTRE OF GRAVITY
E 189.5 189.5 202 202 202.5 202.5 length Y 225 225 250 250 270 270
F 300 300 248 248 228 228 width Z 72 72 77 77 67 67
Height G 544 544 644 644 619 619 MAIN CONNECTIONS DN (mm) a
H 394 394 432 432 444 444 suction 1 40 40 50 50 50 50

J 60 60 65 65 62 62 discharge 2 32 32 40 40 50 50
K 444 444 482 482 494 494
L 69 69 69
M 155 173 180
N 388 430 446
O 435 328 247
Q 680 660 696

COMPRESSOR
COMPRESSOR
46 46W 66 66W 86 86W
TYPE
AUXILIARY CONNECTIONS
suction
pressure 3
1/4” BSP (plugged off)
discharge
pressure 4
Oil pressure 5 1/8” BSP (plugged off)

Crankcase 6
pressure
Return from oil 1/4” BSP (plugged off)
separator or 7
rectifier
Oil charge and
8
drain valve
1/4” BSP (plugged off)
Oil
9
temperature
Crankcase 1/2” BSP female to suit thread of heating
10
heater element
Oil leakage
clanp coupling provided with dia. 6x1 mm steel
drain of rotary 11 precision pipe
shaft seal
Water
inlet/outlet 12 dia. 19 mm hose connector
(W-types) only
a. Provided with a purging and evacuation stop valve type TAH8 (standard on
discharge connection and optional on suction connection.
1.2.3 SHAFT END COMPRESSOR
Fig. 1.2-1 Shaft end compressor

COMPRESSOR
1.2.4 SOUND RATING

Legend
General H hemisphere
In the following pages the sound characteristics are F floor
stated in: C compressor
SWL (= sound power level) R radius
• Average measured sound power level of the bare
shaft compressor block, without motor. Sound power-frequency characteristics
SPL (= sound pressure level)
The graphs below shows the sound power level (S.W.L.
• The values are based on an average sound pressure in or Lw , expressed in dB, re 10-12W) as a function of the
free field above a reflecting plane at a distance of 1 octave band centre frequency for all compressor types
metre from a fictional frame around an average sized (number of cylinders) at different speeds and at a
unit. (Refer to figure discharge pressure of 12.5 and 25.0 bar(a). The data
• Values are based on compressor + electric motor IP23 represent the sound power emitted by the compressor
+ oil separator (body) only, so excluding the influence of the electric
motor and (V-belt) drive.
Each dB-value2 plotted in the graphs is the direct or
It is possible that the actual measured values are higher derived result of accurate laboratory measurements
as the data stated in the table. (for instance close to the carried out by means of the latest sound intensity
compressor or electric motor). In practice the values analysing system, make “Brüel & Kjaer”, type 3360,
measured in the actual machine room are between the together with a reference sound source of the same
SWL and SPL values and can be calculated provided that make, type 4230.
the acoustic data of the machine room is known.
Both values SWL and SPL are applicable for the following 1.2.4.1 SOUND DATA
conditions of operation:
• All cylinders in operation (full-load)
• All refrigerants
• All suction pressures
• Discharge pressure (Pc) 12.5 bar and 25.0 bar(a)
Conversion to sound pressure level

Provided so-called "free field" conditions may be assumed
(i.e. flat concrete floor and sound reflecting surfaces
sufficiently far away), both the octave band and overall
sound power level Lw can be converted to the
corresponding sound pressure level Lp, appearing at a
distance R from the compressor centre. See Fig. 1.2-2.
The conversion formula reads as follows: Fig. 1.2-3 Fictional frame
Lp = Lw - 8 - 20logR Table 1.2-3 Sound levels SWL
where: - Lp = sound pressure level in dB, re 2x10-5 N/m2 SWL Pdis = 12.5 bar SWL Pdis = 25 bar
Qty speed (min-1)
- Lw = sound power level in dB, re 10-12 W Cylinders
- R = distance (radius) in m (≥1.5 .. 2.51). 800 950 1450 800 950 1450
4 72 76 80 75 78 82
6 75 79 83 78 82 85
8 78 82 86 81 86 88
Table 1.2-4 Sound levels SPL
SPL Pdis = 12.5 bar SPL Pdis = 25 bar

Qty speed (min-1)
Cylinders
800 950 1450 800 950 1450
Fig. 1.2-2 Hemisphere
4 58 62 66 61 64 68
6 61 65 69 64 68 71
1. R is dependent on type of compressor; R must be much larger than the

compressor. 2. Measurement accuracy according to this standard is +/- 3 dB.

COMPRESSOR
SPL Pdis = 12.5 bar SPL Pdis = 25 bar

Qty
speed (min-1)
Cylinders
800 950 1450 800 950 1450
8 64 68 72 67 72 74

COMPRESSOR
Fig. 1.2-4

COMPRESSOR
Fig. 1.2-5

COMPRESSOR
Fig. 1.2-6

COMPRESSOR
1.2.5 PART-LOAD POWER CONSUMPTION — E = compression torque constant according to Table

1.2-5.
— z = total number of cylinders, determined by the
General compressor type. See Table 1.2-5.
To determine the allowed partload steps for the design — zv = standard number of loaded cylinders,determined
conditons and the corresponding partload power by the compressor type. See Table 1.2-5.
consumption refer to software program Comsel. no = final nominal (design) compressor speed in
min-1.
1.2.6 STARTING TORQUE — pe = full-load shaft power consumption in kW at
design speed no and at evaporating temperature to
The electric motor driving the compressor should be and condensing temperature tc, which both occur
checked for proper starting. during starting. Pe can be found by consulting the
For that purpose the "torque - speed characteristic" of software program COMSEL.
the compressor is needed. This torque Ma, the trend of
which is shown in the figure overleaf, is built up of the The total Ma-curve as a function of the speed n is derived
following components: from the components in table below. That means:
Ml = pull-out torque (or break-away torque), required to
initiate the movement of the crankshaft after a period of — For n = 0:Ma = Mc + Mi
compressor standstill. This torque, only occurring at — For 0 < n < synchronous design speed no (min-1) : Ma
compressor speed zero, is a constant for each = Mc + Mw + Mp
compressor type. — The value of Ma for n = 0 drops very quickly with a
smooth transition to the Ma-curve for n > 0.
Mw = friction torque, resulting from the purely
mechanial losses in the crank mechanism. This torque, The Ma-curve, thus obtained, has to be compared with
acting during the entire starting period at a constant the corresponding torque - speed characteristic of the
value, only depends on the compressor type and the oil selected electric motor, as supplied by the motor
temperature according to the formula: manufacturer. Keep in mind however, that in case V-belt
Mw = A - B . toil (N.m) drive is used, the motor characteristic has to be
converted to the compressor shaft by multiplying the
where A and B are compressor constants (see table 4.9) torque curve with the transmission ratio D/d, where D
and toil is the oil temperature during starting, expressed and d are the nominal diameters of the flywheel and
in oC and not lower than 40 oC. motor pulley () . In the normal case of a squirrel cage
motor with star- delta starter, two torque - speed
Mp = pumping torque, pumping torque, due to the flow characteristics Mm (Y) and Mm (D) have to be considered
resistance in the closed loop between the suction as shown in Fig. 1.2-7. The difference between Mm and
chamber and the discharge chambers via the suction Ma at any speed (shaded area) represents the torque
valves, discharge valves and the fully opened by-pass available for accelerating the combination motor -
valves. coupling or flywheel - compressor, the intersection
This torque is zero at zero speed and increases points I and II indicating respectively the theoretical
continuously with speed during the starting period, its switch-over speed from star to delta and the final
magnitude being dependent on the refrigerant, the (partially) unloaded compressor speed.
number of cylinders and the suction pressure according
to the formulas:
Mp = (C . po+ D) zd . n2 . 10-8(N.m)
where:
— C and D are refrigerant constants according to Table
1.2-5.
— po = suction pressure in bar abs. during starting.
— zd = standard number of unloaded cylinders,
determinded by thecompressor type. See Table 1.2-5.
— n =variable compressor speed in min-1, increasing
from zero to the final nominal speed = design speed.
Mc = Compression torque, required to compress the

vapour in the cylinders, which remain loaded during
starting. This torque, which can be considered as a
constant during the entire starting period, is determined
by the compressor type, the percentage of loaded
cylinders, the kind of refrigerant and both the suction
and discharge pressure according to the formula:
Mc = [(9549 pe / no) - E] zv / z (N.m)
where:

COMPRESSOR
masses of the compressor main moving parts

(crankshaft, connecting rods, pistons).
As indicated in the adjacent figure there can be
distinguished horizontal and vertical free forces, called H
and V respectively, both acting in a vertical plane I, which
is perpendicular to the crankshaft centre line at a
distance L from the vertical centre plane of the
compressor foot on drive end.
Likewise, there are horizontal and vertical free moments,
called Mh and Mv and respectively acting in a horizontal
plane II and a vertical plane III, which both pass through
the crankshaft centre line.
Each free force and moment consists of a "primary"
component (see table below for the different
compressor types) with a frequency equal to the
compressor speed and a "secondary" component with a
frequency of double the compressor speed.
Fig. 1.2-7 Compressor torque and electric motor torque - speed

characteristics
Table 1.2-5
COMPRESSOR TYPE 46a 46b 66 86

Total Z 4 6 8
unloaded loaded
Zv 2 1 2 2
During starting
Number of
cylinders
Zd 2 3 4 6 Fig. 1.2-8 Planes
Pull-out torque Mi 12.7 16.8 20.9 Legend
Friction torque A 11.2833 14.6571 18.9892 VPI vertical plane I

constants B 0.0736 0.0838 0.0796 VPIII vertical plane III
R134a
C 93.106 HPII horizontal plane II

D 9.548 F flywheel end of compressor
C 80.079 CF centre line of compressor foot
R22
Refrigerant D 9.761 CL centre line crankshaft

constants of
R404A
pumping torque C 97.403 L distance VPI and centre line compressor foot
D 5.731
1.2.7.1 DETAILS
C 14.553
NH3
D 2.954
Compression torque
constant E 7.2374 10.0497 14.6133
a. Min. capacity control step 50%

b. Min. capacity control step 25%
1.2.7 FREE FORCES AND MOMENTS

Free forces and moments are inertia forces and their
resulting moments, generated by not fully balanced

COMPRESSOR
where: Mc (kg) = mass (weight) of bare compressor

Free force and moments and,
Mv (kg) = mass (weight) of loose flywheel
COMPR. TYPE
Forces H (horizontal) and V (vertical) in

(N); Moments Mh (horizontal) and Mv Distance plain I
(vertical) in (N.m)a and centre line
compressor foot
Secundary L (mm)
Primary b
1475 min-1b 1475 min-1

H 0 321.3
Forces
46 V 0 0
202.5
Mh 0 0
Moments
Mv 0 0
H 0 340.8
Forces
V 0 113.6
66 215.0
Mh 0 0
Moments Fig. 1.2-9 Position of centre of gravity
Mv 0 0
H 0 411.5 1.2.8.1 COORDINATES POSITION OF CENTRE
Forces GRAVITY
V 0 169.5
86 227.5
Mh +4.1 0 Table 1.2-6 Coordinates and weights
Moments
Mv -4.1 0 a b c Mc Mv
Compressor type
a. 1 N = 0.102 kgf = 0.225 lbf; 1 N.m = 0.102 kgf.m = 0.738 lbf.ft. mm kg
b. For different speed n (min-1), all forces and moments have to be multiplied by
(n/1500)2 Grasso 46 225 72 280
Grasso 66 250 77 136 345 54.7
1.2.8 POSITION OF CENTRE OF GRAVITY
Grasso 86 270 67 400
General
1.2.9 TORSIONAL ELASTIC SUBSITUTE SYSTEMS
For the proper design of a concrete compressor OF CRANKSHAFTS
foundation or of the vibration-free mounting of a
complete compressor-unit on a steel base frame, the Reciprocating compressors are being used more and
following data, among other things, are required: more frequently in conjuction with internal combustion
engines (diesel or natural gas) as prime mover,
• Exact position of the centre of gravity of the particularly for heat pump applications.:
combination bare compressor-flywheel. In such cases, and considering direct coupled units, it is
• Free forces and moments, generated by the very important to see to it that the combination engine
compressor. - (flexible) coupling - compressor is checked for torsional
vibration.:
Position of centre of gravity The calculations concerned are normally carried out by
the engine supplier, the packaged unit manufacturer or
In figure Fig. 1.2-9 point Zc represents the centre of any other body specialised in this field. For this purpose
gravity of the bare compressor. It’s spatial position and as far as the compressor is concerned, the following
within the vertical plane through the crankshaft centre data are required:
line is determined by the two indicated distances a and
b, the magnitude of which, in dependance of the • So-called torsional elastic substitute system of the
compressor type. crankshaft as well as the arrangement and
Zv is the centre of gravity of just the flywheel, mounted compression sequence of the cylinders. See Table
on the compressor shaft end. This point is positioned on 1.2-7, Fig. 1.2-10
the crankshaft centre line at a fixed distance of c from • Harmonic analysis (Fourier analysis) of the shaft
the vertical centre-plane of the nearest compressor foot. torque-crank angle characteristic over one complete
The resulting centre of gravity Z of the compressor- revolution under design conditions, both for each
flywheel assembly lies on the line that connects Zc and Zv, individual cylinder and the entire compressor.
whereby its position is determined by the distances x and The resulting harmonic components, determined by
y, as indicated in the figure, which can be calculated as their frequency (order), amplitude and phase angle,
follows: can be provided immediately by Grasso on special
x = (aMc - cMv) / (Mc + Mv) request for each particular case, whereby the
and following information should be stated: compressor
y = bMc / (Mc + Mv) type, kind of refrigerant, rotational speed(s), suction

COMPRESSOR
pressure or evaporating temperature and discharge

pressure or condensing temperature.
Table 1.2-7
Torsional stiffness
Mass moment of
inertia (kg.m2) between masses
Compressor type (N.m/rad)
J2 J2 C1 C2
46 0.0165 0.0165 235,593 1,564.876
66 0.0196 0.0196 229,556 1,111.515
86 0.0224 0.0224 223,819 811,352
REMARK: - J1 = mass moment of inertia of flywheel or

coupling flange. - Diameter of all main
journals and crankpins = 60 mm. - Smallest
diameter of drive end (elastic part C1 = 50
mm. - Crankshaft material: Nodular cast iron
GN60.

COMPRESSOR
* Ι ΙΙ
90o 1 2 3 4 1
3 2 **
1 Ι 4
4 2
ΙΙ
o 2 5 1 2 3 4 5 6 1
60 o
60
4 3
Ι 6 60o 2
1 6 60o
60o 60o
60o 60o
ΙΙ 5 3
6 46o 3 1 2 3 4 5 6 7 8 1
2 7
46
46 o
o 8 2
5 Ι 4 42o 46o
1 8 46o 46o
7
3
46o 46o
ΙΙ 46o 42o
6 4
5
C1 C2
J1 J2 J3
Fig. 1.2-10 Torsional elastic substitute system

COMPRESSOR

COMPRESSOR
1.3 LIMITS OF OPERATION AND FIELDS OF The diagrams overleaf represent the overall fields of
application in which the individual operation limits are
APPLICATION taken into account.
1.3.1 GENERAL LIMITS AND FIELDS OF OPERATION Table 1.3-1 General limits and fields of operation
GRASSO 6
1. In practice, it is not so much the individual operation limits as combinations of
When operating the compressor, none of the limits of them that are decisive for the conditions under which a compressor may
operation as stated in the table below must be operate. To check the various possibilities in this respect, use should be made
exceeded.1 of the "fields of application" ).
REFRIGERANT NH3 R22 R134a R404A R507

min. - 800
Compressor speed n min-1
max. - 1500
min. - 0.3
Suction pressure = evaporating pressure a bar(a) -1
po b >=1140 min 6.0 5.8
=crankcase pressure max. 6.2 6.8 6.2
<1140 min-1 6.8
min. - -55.1 -63.8 -50 -68.1 -68.5
Evaporating temperature = saturation -1
to °C >=1140 min -0.1 -2.0
temperature at suction pressure max. +10.2 +10.0 +22.6
-1
<1140 min +3.8 +3.0
Actual suction temperature c
ta °C min. - -50
Suction superheat ∆t °C min. - 0 15
d
Discharge pressure = condensing pressure pc bar(a) max. - 24.0
Design pressuree bar(a) - 26.5
Condensing temperature = saturation
temperature at discharge pressure tc °C max. - +59.8 +63.2 +79.5 +55.6 +54.4
f
Discharge temperature te °C max. - +155
min. - 1.5
g
Pressure ratio per stage (pc/po) j -
max. - 10 15
Pressure difference (pc-po) h
∆p bar max. - 24
min. - +20 +30
i
Oil temperature in crankcase toil °C
max. - depending on type of oil, refer Section 1.4
a. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.
b. The minimum values of po and to are only of importance for booster applications. In that case the maximum value of to also applies to the saturation intermediate
temperature (tm).For halocarbon refrigerants the maximum values of po and to are based on a density of the suction gas of 30 kg/m3. During start-up and
immediately thereafter, po,max. may be exceeded slightly [up to 11 bar(a) max.] and temporarily, but no longer than about 5 minutes. The maximum static crankcase
pressure during compressor standstill is 21.5 bar(a).
c. Only of importance for booster application.
d. This pressure is also the maximum allowable pre-set value of the HP safety switch.
e. This pressure deviates from the so called max. discharge pressure=condensing pressure (allowed during operation) as stated in the table.
f. This is the actual discharge temperature, measured directly in the gas flow just above the valves.
g. Pressure ratio limits are not absolute but arbitrary values based on practical considerations.
h. The standard built-in overflow safety valve(s) between suction and discharge side has been factory-set to 24.5 (+ 10%) bar to prevent advanced opening during normal
operation at ∆p = (pc - po) ≤24.0 bar.
i. Indicated minimum value is the lowest oil temperature at which compressors are allowed to be started.The maximum oil temperature depends on the operating
conditions of the compressor, the oil type used and (for halocarbon refrigerants only) the solubility of the refrigerant in the oil. A minimum actual oil viscosity of 15
cSt is always required. When using ammonia as refrigerant, the maximum oil temperature will be exceeded only when a combination occurs of high ambient
temperature, high suction superheat and part-load operation. In that case an oil cooler is required. A water-cooled oil cooler always forms part of the standard delivery
of a Grasso 6W-compressor.

COMPRESSOR
1.3.1.1 FIELDS OF APPLICATION
Fig. 1.3-1
Legend
This part of the general field of application is not covered by COMSEL. Consult Grasso to make a selection
A
for this applicaction

COMPRESSOR
1.3.2 PRECISE FIELD OF APPLICATION
The field of application diagrams as shown in this manual

can vary slightly from the actual field of application for
each particular selection.
The actual field of application is dependent on

refrigerant, type of compressor, speed, suction
superheat and partload steps.
Always consult Grasso's software program, COMSEL, to

determine the precise field of application for an actual
compressor selection.
1.3.3 LIMITATIONS OF PART-LOAD OPERATION
General
For continuous minimum part-load (without cylinder

head water cooling) (i.e. more than 30minutes) consult
Grasso.
In the case of an Grasso 6-compressor and NH3,
operating continuously at part-load, the general field of
application is reduced in the sense that for each step of
capacity reduction the limit line for Te = 155 oC moves to
the right as shown in Fig. 1.3-2, by four Vs-indications in
percentage.
In case the of an Grasso 6-compressor and NH3 and
cylinder head water cooling can be applied (optional),
and there are no part-load restrictions. In other words,
the general field of application as shown in Fig. 1.3-2, Fig. 1.3-2 Field of applications for compressor type Grasso 6 with NH3
also remains valid for part-load operation down to and (upper graphic) and Grasso 6 with NH3 and water
including the standard minimum capacity control step of cooled cylinder heads (lower graphic)
Vs = 25%.

COMPRESSOR

COMPRESSOR
1.4 LUBRICATING OILS (CHOICE AND a. to,max is the saturated temperature, corresponding to maximum crankcase
RECOMMENDATIONS) pressure where at the usual oil temperatures the oil/refrigerant mixture has a
viscosity of > 10 cSt.
b. Refer to Section 1.4.1.1.
The choice of oil for a refrigeration compressor should be 1.4.1.1 REMARKS

made by taking into account the entire refrigeration 1. Using ISO VG100 oils to increase viscosity at high
system design and operation as well as the operating expected cranckcase-temperatures makes no sense as
conditions of the compressor. the friction-heat will increase that much, that the
oil-temperature limit related to the minimum viscosity
For lubrication of refrigeration compressors, several of 10 cSt will also be exceeded. Only in case of
brands and types of specially developed lubricating oils expected high refrigerant-concentrations in the
are on the market. The choice of oil depends not only on cranckcase this viscosity-gradeoil is an alternative!
its good lubrication properties (viscosity) and chemical 2. Using ISO VG46 oils to meet low pour point
stability at the operating conditions of the compressor, requirements is only acceptable if coupled to a high
but also on the operating conditions of the refrigerating viscosity-index of at least 100, otherwise the working
plant (solidifying and floc point, solubility). limits are so limited (again concerning the minimum
required oil-viscosity of 10 cSt) that it can be used in
Grasso has tested and approved for use in its medium evaporation-pressures, making no sense to
reciprocating-compressors the brands and types of oil as use them als a low pourpoint alternative!
listed tables below.
The choice of the lubricating oil depends on type of
refrigerant and the operating conditions of the Some of the oil types listed in the tables may be
compressor. marketed under other names and/or designations; these
The oil viscosity should always be more than 10 cSt. oils can also be used, provided their identity can be
A higher ISO-VG number should be chosen when proved beyond any doubt. Application of
refrigerant solubility in crankcase is expected to be high other/alternavive oils is not permitted without the
especially in case of HCFC’s and HFC’s. written consent of Grasso.
OIL SELECTION PROCEDURE:
Use the oil viscosity selection table to select oil viscosity 1.4.2 STRONGLY RECOMMENDED OIL TYPES FOR
required. The following page lists all oils approved by GRASSO RECIPROCATING COMPRESSORS
Grasso for reciprocating compressors.
Table 1.4-2 Strongly recommended oil types for Grasso reciprocating
1.4.1 OIL SELECTION TABLE compressors
Table 1.4-1 Oil selection table Refrigerant

Brand Type designation
used
Max. allowable CPI CP-1009-68

Refrigerant evaporating ISO VG-number, according to
used temperature ISO 3448 PETRO CANADA Reflo 68A
to,max (°C)a NH3 EXXON MOBIL SHC NH68a
46 68 100
NH3 - vb v vb Klüber Summit RHT-68
-50 v TEXACO Capella Premium 68
-30 v v a. Recommended for evaporating temperatures below -37 oC
HCFC’s -20 v
(R22) -10 v v
0 v
+10 v
-50 v v
-30 v v
HFC’s -20 v v
(R134a, R507,
R404A) -10 v v
0 v
+10 v
For all other refrigerants contact Grasso
Legend v Approved by Grasso

COMPRESSOR
1.4.3 ACCEPTED NH3 AND HCFC OIL TYPES FOR 1.4.4 ACCEPTED HCFC OIL TYPES FOR GRASSO
GRASSO RECIPROCATING COMPRESSORSS RECIPROCATING COMPRESSORS
Table 1.4-3 Accepted NH3 and HCFC (e.g. R22) oil types for Grasso Table 1.4-4 Accepted HFC (e.g. R134a, R404A, R407c, R507) oil types
reciprocating compressors for Grasso reciprocating compressors
Brand Type designation ISO VG numbera Brand Type designation ISO VG

numbera
FC 46 44
AVIA Icematic SW 68 67
FC 68 65 CASTROL
Icematic SW 100 100
Energol LPT-F 46 54
BP Solest 68 64
Energol LPT 68b 68 CPI
Solest 120 131
CASTROL Icematic 299 56
ACD 68 M 70
CPI CP-1009-68 69 TOTAL
ACD 100 FY 98
Zerice S46 48
Reniso E 68 68
Zerice S68 68 FUCHS
EXXON MOBIL Reniso E 100 100
Arctic 300 57
Emkarate RL 68H 68
SHC NH68 68 ICI
Emkarate RL 100H 100
Reniso KS 46 47
FUCHS EXXON MOBIL EAL Arctic 68 63
Reniso KC 68 68
Clavus R68 66
KROON OIL Carsinus FC 46/68 46 SHELL
Clavus R100 94
PETRO CANADA Reflo 68Ac 58
Capella HFC 55 52.5
Kuwait Petroleum Q8 Stravinsky C 55
TEXACO Capella HFC 80 80
Clavus 46 46
Capella HFC 120 118
Clavus 68 68
a. Viscosity grade number designation according to ISO Standard 3448.
SHELL Clavus G 46d 46
Clavus G 68d 68
Clavus G 100d 95
Suniso 3.5 GSc 43
Suniso 4 GSc 55
SUN-OIL
Suniso 5 Gc 94
Suniso 4 SAc 57
Capella WF 68 65
TEXACO
Capella Premium 68 67
TOTAL Luneria FR 68 68
Klüber Summit RHT-68 68
a. Viscosity grade number designation according to ISO Standard 3448.
b. Not miscible with R22 at low temperatures
c. NH3 only
d. For NH3 only possible if water and air are not present!

COMPRESSOR
1.5 DESIGN DETAILS OF COMPRESSOR

1.5.1 COMPRESSOR HOUSING
The figure below shows the basic construction of the
compressors Grasso 6. The additional pos nrs. 29 through
34 shows the construction with water cooling (NH3
only). Water-cooled compressors only differ in an
additional (water-cooled) oil cooler incorporated in the
crankcase and different (water-cooled) cylinder head
covers.
This oil cooler and these cylinder head covers are
provided with water in- and outlet connections linked up
with each other in series by means of rubber hoses.
The compressor housing of all compressor types are
made of cast iron and comprise the crankcase, the
cylinder head covers, the inspection side covers, the shaft
seal housing on driving side and the bearing cover with
built-on oil discharge filter housing on oil pump side.
Where the cylinders are located the crankcase has a
double wall; the intermediate space is devided by a
vertical partition into a suction and a discharge chamber
which communicate with the suction and discharge
connection respectively, both situated on oil pump side.
On this side of the crankcase also a sight glass and an oil
charge and drain valve are situated.

COMPRESSOR
1.5.1.1 DIAGRAMS GRASSO 6(W)

Legend
1 Cylinder head cover 9 Oil return check valve
2 Lifting eye 10 Oil sight glass
3 Suction connection 11 Inspection side cover
4 Crankcase heater 30 Cooling water hose
Suction and discharge
5 valve assembly 31 Water inlet connection
6 Cylinder liner 32 Water outlet connection

Piston and connecting
7 rod Cast-in channel for cooling
33
water
8 Discharge connection
Fig. 1.5-1 Design of bare compressor Grasso 6(W)
aaaaaa
aaaaaa
Fig. 1.5-2 Design of bare compressor Grasso 6(W)
Legend
18 Crankshaft 28 Oil charge and drain valve
Legend
19 Shaft seal housing 29 Oil cooler (water cooled)
13 3-way solenoid valve 23 Discharge chamber
20 Oil leakage drain 34 Plug cooling water channel
14 By-pass slide valve 24 Oil discharge filter
21 Oil suction filter Connection for external oil
15 Suction chamber 25 Oil filter housing 35 return line with lubrication oil
22 Crankcase pressure regulator
16 Tube for pressure equalizing 26 Oil pump
17 Rotary shaft seal 27 Bearing cover

COMPRESSOR
1.5.2 CYLINDERS AND MOVING PARTS

The cylinder liners are easily interchangeable and they
are made of special cast iron accurately adapted to the
running properties of the pistons. The upper collar forms
the suction valve seat and is therefore provided with a
ring of cast-in slots. To reduce oil carry-over, the cylinder
liners are sealed with an O-ring in situ of the passage
with the crankcase partition.
Each cylinder liner, together with the suction and
discharge valve assembly, is retained in the head plate by
means of a pressure ring.
The connecting rods are made of cast aluminium alloy
(the same material as that of the main bearings) and
without bearing bushes, thus running direct on both
crankpin and gudgeon pin. The connecting rod shank
has an oil bore.
Specially designed alluminium alloy pistons are provided
with two sealing rings and one oil scraper ring and all
three are located above the hardened steel gudgeon
pin.
The two-throw crankshaft of nodular cast iron with
cast-on counterweights is supported by two main
Fig. 1.5-3
bearings. The cylindrical driving end with key is intended
for the use of clamping sleeve fastening of flywheel or
coupling half. Legend
Both main bearings are (undivided) bushes, made of
special aluminium alloy with outstanding running 1 shaft seal housing 8 driving band
properties. The one on the driving end is bolted direct 2 O-ring 9 supporting ring
into the crankcase, the other one is mounted against the
inside of the bearing cover and also serves to fix the 3 stationary counterslip ring 10 retainer shell
crankshaft axially without play and to take up the axial Oil leakage drain of rotary
load in both directions. For this purpose, this bearing is 4 slip ring 11
shaft seal
retained with both end faces between the crank web
shoulder and a disc fitted to the head face of the shaft 5 flexible elastomer bellows 12 main bearing bush
journal. 6 Spring 13 crankcase
oil supply from internal
1.5.3 ROTARY SHAFT SEAL 7 spring holder 14 lubricating circuit in
For gastight mess between the crankshaft and the crankcase
outside, the compressor is provided with a rotary shaft
seal, the construction of which is shown in Section 1.5.4 SUCTION AND DISCHARGE VALVES
1.5.3.1. The suction valve has one valve ring pressed on to the
Sealing is effected on the lapped sliding surface between valve seat by one sinusoidal spring and located under a
a carbon graphite slip ring rotating with the crankshaft peek (composite material) stroke limitor. They are
and a stationary counter-slip ring, made of special cast mounted in a recess in the cylinder liner.
iron, fitted in the shaft seal housing. The suction stroke limitor also serves as seat of the
The counter-slip ring is secured against rotation and discharge valve.The discharge valve is also of the
sealed against the housing by an O-ring fitted in a groove single-ring type and also loaded with one or two sinoidal
along its outer circumference. springs according to high or low temperature
application.
The slip ring is held in a retainer shell by means of four
notches, which on its turn is carried by a driving band The discharge valve seat and the discharge valve stroke
with flexible elastomer (neoprene) bellows. The whole limitor are assembled via a central bolt so as to form a
assembly can slide axially over the crankshaft and is unit, mounted and pressed on to the cylinder liner by a
pressed onto the counter-slip ring by means of a sturdy pressure ring with a heavy sinusoidal spring in-between,
spring. The bellows also ensures the sealing between slip which also serves as buffer spring to prevent serious
ring and crankshaft. damage to the compressor due to incidental and slight
liquid hammer.
To remove the friction heat developed by the slip rings,
the shaft seal housing is incorporated in the lubricating An O-ring clamped between cylinder liner collar and
oil circuit. Furthermore, the shaft seal housing is discharge valve seat ensures the sealing between suction
provided with an oil leakage drain. and discharge side.
1.5.3.1 DETAILS ROTARY SHAFT SEAL 1.5.4.1 DETAILS SUCTION AND DISCHARGE VALVE
ASSEMBLY

COMPRESSOR
compress gas but just circulate it under suction pressure.
1.5.5.2 DESCRIPTION OF CAPACITY CONTROL

Each controllable cylinder head cover is provided with a
by-pass slide valve, which can move horizontally forward
and backward in a guide bush and is connected via a
push rod to a hot gas operated control piston in a
horizontal control cylinder. Slide valve, push rod and
control piston form one integral steel part.
Via a three-way solenoid valve , which is mounted
outside on top of the cylinder head cover against the
sealing cover of the control cylinder, the control piston
can be communicated either to suction pressure (via lines
c and b, the former connected to the control cylinder
and the latter to the by-pass chamber) or to discharge
pressure (via lines a and c, the former connected to the
permanent discharge chamber in the cylinder head
cover).
Actually, only line a, coming from the solenoid valve, is
an external one; the two others b and c are internal
bores provided in the sealing cover of the control
cylinder and in the walls of the cylinder head cover.
1.5.5.3 OPERATION OF CAPACITY CONTROL

If the solenoid valve is not energized, line a is connected
via line c to the control cylinder, so that hot gas from the
permanent discharge chamber enters this cylinder and,
as the diameter of the control piston is substantially
larger than that of the slide valve, the combination
piston-rod-valve will move to the rightmost position,
Legend causing the slide valve to shut off entirely the permanent
discharge chamber from the space direct above the
suction valve ring with one discharge valves and the latter to be communicated via
1 central bolt 8
sinusoidal spring a ring of circular openings in the guide bush with the
discharge valve ring with one or space between control piston and slide valve (by-pass
2 discharge valve stroke 9 two sinoidal springs accoridng to chamber), which is in permanent communication with
limitor high or low temprature the common suction chamber in the compressor
operation
housing. Both cylinders then operate unloaded as a
3 pressure ring 10 O-ring in crankcase partition result of the by-pass thus effected.
4 sinusoidal buffer spring 11 head plate When the solenoid valve is energised, line b is connected
discharge valve seat, also via line c to the control cylinder, so that there is no
5 12 crankcase partition pressure difference across the control piston and the
suction stroke limitor
combination piston-rod-valve is kept in its loaded
cylinder liner, also suction position by the pressure prevailing in the permanent
6
valve seat 13 Peek stroke limitor discharge chamber and exerted onto the righthand face
7 O-ring of the slide valve. The space direct above the discharge
valves then communicates, via the afore mentioned
1.5.5 CAPACITY CONTROL SYSTEMS circular openings in the guide bush of the slide valve,
with the permanent discharge chamber, so that both
1.5.5.1 GENERAL cylinders operate normally.
The capacity control, i.e. the decrease in capacity at For the standard capacity control part-load steps of the
constant speed and under constant operating various compressor types and the corresponding
conditions, takes place stepwise by successively cutting energising sequence of the solenoid valves, refer to
out cylinders in pairs. Chapter 2.
This is effected by isolating the discharge space direct
above the valves for each individual cylinder head from 1.5.5.4 PARTIALLY UNLOADED STARTING
the common discharge chamber and by putting it into In order to be sure that all controllable cylinder pairs
communication with the common suction chamber, always start fully unloaded when there is no pressure
located in the compressor housing. difference between discharge and suction, a spring is
This socalled “internal recirculation control” is, (apart mounted between each sealing cover and control piston
from the flow resistance in valves and channels,) free to ensure that all control pistons and slide valves are kept
from losses because the cut out cylinders do not in their unloaded position, regardless of whether the

COMPRESSOR
corresponding solenoid valves are energised or not.

On the other hand, to create sufficient discharge
pressure to operate all available capacity control slide
valves when starting the compressor at zero pressure
difference between discharge and suction, one cylinder
head cover of each compressor type is non-controllable,
i.e. it has no built-in slide valve and control piston, but is
provided instead with only a simple vertical partition to
keep the common suction and discharge chambers in the
compressor housing apart from each
other.Consequently, when the discharge pressure is
higher than the suction pressure, only partially unloaded
starting is possible.
Therefore, it is recommended to always check the
electric drive motor in this respect, depending on
compressor design speed and starting conditions.
1.5.5.5 ALTERNATIVES OF CAPACITY CONTROL
Additional capacity control step for 4-cylinder

compressors;
The four-cylinder compressor can also be delivered with
an alternative capacity control, including three part-load
steps (25, 50 and 75%) instead of only one (50%) in the
standard version.
These additional steps are obtained by replacing the
non-controllable cylinder head cover by a partly
controllable one of special design, which means that it
has a partition in the middle of the space direct above
the discharge valves to separate the two adjacent
cylinders entirely from each other.
So, only one cylinder is always in operation, which has
the extra advantage of also reducing the starting load
from 50 to 25%.
Compressors without capacity control

On special order, each standard compressor type can
also be delivered without any capacity control. In that
case not only one but all cylinder head covers are of the
non-controllable type, i.e. not provided with built-in
control piston and by-pass slide valve.
However, the consequence of such a (cheaper) choice is
that either fully loaded compressor starting has to be
accepted, inevitably resulting in a more powerful electric
motor to be installed, or special provisions are to be
made by the installer in the field to overcome this
inconvenience, for instance by applying an external line
with solenoid valve (only open, so energised only during
starting) between the suction and discharge line of the
installation, combined with a non-return valve in the
same discharge line.
Very important installation requirement; To prevent,

during prolonged compressor stand-still, a gradual
pressure equalisation between condenser and
evaporator due to slow leakage of refrigerant gas via the
slide valve, a non-return valve must be mounted in the
external discharge line.

COMPRESSOR
1.5.5.6 DIAGRAM CAPACITY CONTROL
Fig. 1.5-4 A= out of operartion, B= in operation

COMPRESSOR
Table 1.5-1 Legend Fig. 1.5-4 Two of these openings are at the lowest level on either
side of the suction chamber and are provided with a
Legend Fig. 1.5-4
check valve.
1 common suction chamber 9 (by-pass) slide valve The third opening, which is located at the highest level in
the middle of the suction chamber, has no check valve
2 by-pass chamber 10 guide bush
but is provided with a small open-ended tube,
3 push rod 11 space above discharge valves protruding straight downwards into the crankcase.
permanent discharge
4 control cylinder 12 chamber 1.5.8.1 DETAILS PRESSURE RELIEF VALVE
5 control piston 13 common discharge chamber
Cylinders out of operation,
6 sealing cover A solenoid valve not energised
three-way solenoid valve
7 with LED indication Cylinders in operation,
(schematic indication) B solenoid valve energised
8 three-way solenoid valve
1.5.6 CYLINDER HEAD COVERS

For each pair of cylinders viewed lengthwise to the
compressor, a cylinder head cover is provided, which
feeds the discharge gases to the common discharge
chamber in the crankcase via openings in the casting; it
further acts as a pulsation damper.
Moreover, and only if the compressor is equipped with
standard capacity control, all cylinder head covers except
one contain an internal bypass valve, controlled by
discharge pressure via an electrically operated three-way
solenoid valve.
In case of compressor type Grasso 6W each cylinder head
cover is additionally provided with a cast-in cooling
water channel, located inside the upper part of the cover Legend Figure on Page 37
over its entire length and consisting of two equal parallel 1 crankcase
branches, which are connected to each other in series.
2 discharge welding neck flange
1.5.7 WATER COOLED OIL COOLER 3 suction chamber
In case of water cooled compressors, the oil cooling is 4 discharge chamber
effected by means of a water flow through a steel tube
frame, which is fitted onto the inside of one of the 5 pressure relief valve
inspection side covers and immersed into the crankcase
oil sump.
The cooling water inlet and outlet connections of the
coil, both horizontal and on the same level, are located
on the outside of the inspection side cover
concerned.The water flows through this oil cooler first
and then, in series, through all cylinder head covers.
1.5.8 OVERFLOW SAFETY VALVE AND PRESSURE

EQUALISING
In order to protect the compressor against too high a
difference between discharge and suction pressure a
spring-loaded overflow safety valve is located in the
internal partition between the common discharge and
suction chamber.
This safety valve is factory-set at between 24.5 and 27
bar and is accessible after having removed the discharge
welding neck flange and thus the entire discharge stop
valve, if any.In order to equalise the suction and
crankcase pressure and to return the oil entrained with
the suction gas, there are three small openings in the
partition between suction chamber and crankcase.

COMPRESSOR
1.5.9 DIRECT DRIVE OIL PUMP
aaaaaaaa
aaaaaaaa
Table 1.5-2
Legend
1 Oil discharge filter 4 Crankshaft
2 Oil pump element 5 Oil suction filter
3 Oil suction line
The direct-driven oil pump, suitable for both directions of

rotation, is fitted in the bearing cover, which also
comprises the oil suction and discharge chamber.
The oil suction strainer of metal wire mesh (max.
opening 315 microns) is immersed in the crankcase oil
sump and is only accessible after having removed the
inspection side cover.
The oil discharge filter consists of a ring-shaped paper
filter element with a filtration rating of 25 microns,
retaining the fine (metal) particles suspended in the oil.
The direction of the oil flow is from the inside to the
outside through the filter element. The filter is fitted
with a central stud to the oil pump housing and can be
easily replaced from outside by only removing the oil
filter housing.
The lubricating oil circuit, accommodated mainly inside
the compressor housing. From the oil filter housing the
oil flow is forced via a bore in the bearing cover direct
into the crankshaft channel for lubricating the main
bearings, connecting rods and pistons. Sufficient
lubrication of the cylinder walls is ensured by the oil
which is being splashed around in the crankcase. The
connecting rods have an internal oil channel through
which the oil is supplied to the small end bearings.

COMPRESSOR
1.5.9.1 OIL LUBRICATION SYSTEM with the common discharge chamber in the crankcase.
1.5.10.1 DETAILS SUCTION GAS STRAINER
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a a a a a a
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a a a a a a
Fig. 1.5-5
Legend
Legend
1 Crankcase
1 Oil suction filter
Oil lubrication pressure 2 suction welding neck flange
2 Oil pump 7
regulator 3 suction chamber
3 Oil discharge filter
4 strainer element
4 Thrust bearing 8 Oil sump
5 Crankshaft A Oil lubrication pressure
6 Oil return line B Crankcase pressure
1.5.9.2 OIL CHANNEL

The oil channel in the crankshaft ends in the shaft seal
housing from where excess of oil is fed back to the
crankcase via an external oil return line. In this oil return
line an adjustable lubricating oil pressure regulator is
fitted. This spring-loaded ball valve allows the return oil
to pass at a certain pre-set pressure only, thus
determining the pressure in the lubricating
system.Besides the oil return connection on top of the
shaft seal housing also an connection for the lubricating
oil pressure safety switch is provided.
1.5.10 MAIN CONNECTIONS AND SUCTION GAS

STRAINER
The main connections (suction and discharge) consist of
a welding neck flange and are fitted on the oil pump side
of the compressor housing by means of bolts.
The suction connection communicates with the ample
suction chamber in the crankcase upper part via a built-in
single, cylindrical suction gas strainer of woven mesh
with a filtration rating of 140 microns.
This filter is accessible only after having removed the
suction welding neck flange and thus the entire suction
stop valve, if any. However, to avoid this operation, a
special device (elbow adapter) is available as an
accessory.
The discharge connection is located on the same level as
the suction connection and is in direct communication

COMPRESSOR

ACCESSORIES
2. DESCRIPTION AND SELECTION OF ACCESSORIES
2.1 CAPACITY CONTROL 2.1.1 CYLINDER NUMBERING

For description of the design details of the capacity
control systems, refer to Section 1.5.5
Table 2.1-1 Capacity control steps without water cooling
Qyt Cylinders
Capacity %
Solenoids
Cylinders
50 1+3 -
4
100 1+2+3+4 A
25 3 -
50 1+3 B
4(25%)a
75 2+3+4 A
100 1+2+3+4 A+B
33 1+4 -
6 66 1+2+4+5 B
100 1+2+3+4+5+6 A+B
25 1+5 -
50 1+3+5+7 B
8
75 1+2+3+5+6+7 B+C
100 1 +2 + 3 + 4 + 5 + 6 + 7 + 8 A+B+C
a. Optional (refer to Section 1.5.5.5)
Table 2.1-2 Capacity control steps WATER COOLED

Qyt Cylinders
Capacity %
Solenoids
Cylinders
50 2+4 -
4
100 1+2+3+4 A
25 4 -
50 2+4 B
4(25%)a
75 1+3+4 A
100 1+2+3+4 A+B
33 3+6 -
6 66 2 + 3+ 5+ 6 B
100 1+2+3+4+5+6 A+B Fig. 2.1-1 Cylinder numbering Grasso 6
25 4+8 -
50 2 + 4+ 6+ 8 B Legend/explanation Fig. 2.1-1
8
75 2 + 3+ 4 + 6 + 7 + 8 B+C incl. optional 25%, refer
4W(25%) Grasso 46 Watercooled "Additional capacity control
100 1 +2 + 3 + 4 + 5 + 6 + 7 + 8 A+B+C step for 4-cylinder
a. Optional (refer to Section 1.5.5.5)
compressors;" on Page 35

ACCESSORIES

ACCESSORIES
2.2 CONTROLS, SAFETIES, GAUGES AND 3 Inj; injection solenoid valve (interstage cooling system
(Ecotron) A/B
SWITCHES 4 Oret; oil return protection (optional)
5 Unl; unloaded starting
2.2.1 MONITRON CR CONTROL DEVICE
Additional output signals
General Alarm, Start, Running, Start request.
Grasso can supply a solid state microprocessor-based
control device for monitoring, protecting and controlling
compressors. Standard scope of supply
• Steel cabinet (2) including the electronic control unit.
• Terminal unit (keyboard/display; 1), connected to the
Data cabinet.
• Limitations: • Console (4).
¸ Protection Class IP55. • Pressure transducers and temperature sensors
¸ Ambient temperature between +0 and +55 °C. (mounted and wired).1
¸ Relative humidity between 0 and 95%. • Wiring of three-way solenoid valves of electrical
• Features: capacity control and unloaded start.
¸ Display of all relevant operating parameters. • Discharge pressure safety switch(es) (Refer to table
¸ Automatic start/stop. below)
¸ Sequence control. • All cabling and wiring of components and accessories
¸ Capacity control, based on a pressure or which are built together with the compressor or
temperature signal. The accessory "Electric package.
capacity control" is necessary.
¸ Controlling all individual limits of operation of the
compressor.
¸ Real time clock with battery back-up.
¸ Data storage in EEPROM.
¸ Alarm history file for the last 20 alarms.
¸ Computer communication via MPC (option).
¸ Sensor failure detection.
¸ Emergency stop button (3).
¸ Built-in time relay for unloaded starting.
¸ Password protection.
Main input signals

1 Imot; motor current (optional)
2 Olev; oil level (optional)
3 Pcrk; crankcase pressure
4 Pdis; discharge pressure
5 Pext; external pressure (optional)
6 Pint; LP discharge intermediate pressure
7 Poil; oil pressure
8 Psuc; suction pressure
9 Tcil; cylinder head temperature protection (optional)
10 Text; external temperature (optional)
11 Tdis; discharge temperature
12 Tinh; HP suction intermeditate temperature
13 Tint; LP discharge intermediate temperature
14 Toil; oil temperature in crankcase
15 Tsep; oil temperature in oil separator (optional)
16 Tsuc; suction temperature Fig. 2.2-1 Monitron CR control device
Additional input signals (optional) 1 Terminal unit with keyboard and display
External safety, External start, motor temperature 2 Steel cabinet containing the control unit
protection, start/delta switch.
3 Emergency stop button
Main output signals 4 Console for terminal unit
1 Cap; capacity control 5 Communication cable

2 FPD; fast pull down
1. Grasso can supply compressors with sensors only, without control unit and
display.

ACCESSORIES
Cable entries of e.g. power supply, temperature and pressure • External temperatur sensor incl. signal transducer
6 PT1000/4-20mA) (supplied loose).
signals, etc.
• Pressure safety switch system according to
UVV-VBG20 (mounted on suction filter housing).
Options • Monitron Protocol Converter (MPC; supplied loose).
• Motor current transducer (supplied loose).
• External pressure sensor (supplied loose).
Fig. 2.2-2 Schematic flow diagram

10 three-way solenoid valve
11 hydraulic cylinder of valve lifting mechanism (capacity control)
1 two-stage compressor
12 oil level float switch
2 interstage cooling system A, B, C or D
13 sensor plug of discharge temperature protection
3 oil separator
14 compressor drive motor
4 LP suction header
15 solenoid valve of interstage cooling system A or B
5 LP discharge header
16 solenoid valve of oil return protection
6 HP suction header
three-way solenoid valve for fast pull-down feature for
17 two-stage compressors
7 HP discharge header
8 oil pump 18 three-way solenoid valve for unloaded starting
9 oil pressure regulator 19 mechanical float valve

ACCESSORIES
TU Terminal unit
TC Control unit
AI Additional input signals
AO Additional output signals
T Transducer (temperature or pressure)
A For two-stage compressors only
B To valve lifting mechanism(s)

ACCESSORIES
Table 2.2-1 Pressure safety switches
Applicationb
Description of Standard Range of Range of contact
TÜV Type pressure setting differential Remarksd
pressure safety EN378-2 (bar (e)) c
pressure (bar)
switchesa
Se B TAB TCD Se B TAB TCD
Number of
switches 1 1 1 2 2 2 2 4
pressure limitor switch, locking device,

- X - X RT 30AB 1 to 10 0.4 fixed external reset, protection class IP54
Low stage
discharge [Max.] pressure safety switch , locking defice,
- X RT 30AS 1 to 10 0.4 fixed
internal reset, protection class IP66
pressure limitor switch, locking device
X RT 6AB 10 to 28 1.5 fixed
High stage external reset, protection class IP54
discharge [Max.] pressure safety switch, locking device,
- X RT 6AS 10 to 28 1.5 fixed
internal reset, protection class IP66
a. When mounted on a panel all pressure connections of the safety switches are provided with a clamp coupling for ø6 x 1 mm steel precision tube.
b. S = single-stage; B = booster; T = two-stage; TAB = two-stage system A or B; TCD = two-stage system C or D;
c. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.
d. Protection class of enclosure according to IEC 144 and DIN 40050. Some of the safety switches are provided with a locking device so that, when cut out, the
compressor does not become operative automatically on return of the original pressure. To unlock, an external or internal reset button is used but only after the
reason for cut-out has been investigated.
e. Single stage compressors used as HP compressors in booster systems, are advised to be protected with a maximum suction pressure safety switch with auto reset.
(Not included)
2.2.2 PRESSURE GAUGE AND SAFETY SWITCH compressor delivered can optionally be
PANEL equipped with an oil differential pressure
safety switch, Danfoss MP55, mounted on to
the crankcase and properly connected, but
General not adjusted.
For checking the correct operation and protecting the
compressor and installation, Grasso can supply a
pressure gauge and safety switch cabinet as a standard
accessory, complete with gauges and safety switches to
indicate and control the suction (LP), discharge (HP) and
oil (differential) pressure.
Description of cabinet
The fully enclosed cabinet, made of thin steel sheet,
contains three pressure gauges mounted in the bevelled
upper part of the front panel and two or three (one
additional) pressure switches located inside the cabinet
and easy accessible via the removable vertical part of the
front panel.
This cabinet is suitable for wall mounting by using two
holes in the rear panel as well as for floor mounting by
using the lower extension of the two side panels. Next to
each gauge a text is applied indicating suction, discharge
or oil pressure in five languages, viz. : English, German,
French, Spanish and Dutch.
All internal pressure lines, interconnecting the gauges
and switches, are factory-fitted; mounting of the four
external lines from the bottom plate of the cabinet to
the appropriate pressure connections on the compressor
(refer to dimensioned sketches in fig. Fig. 2.2-3and table
Table 2.2-2), as well as all electric wiring, remain to be
carried out by the installer (on site).
There are two cabinet versions available: one with two
safety switches and one provided with three safety
switches to meet German UVV-VBG20 regulations. Fig. 2.2-3 Pressure gauge and safety switch cabinet
REMARK: In case a pressure gauge and safety switch

cabinet is not ordered as an accessory, the

ACCESSORIES
Description and survey of pressure gauges (see also Table 2.2-2 Survey of pressure gauges
table Table 2.2-2) Temperature range ( OC)
Range (bar
These so-called Bourdon-gauges are glycerine-filled to Description (e))a R22 NH3
reduce the vibration of pointer and internal components
due to pressure fluctuations and/or external mechanical Suction pressure gaugeb -1 to 12 -70 / +34 -60 / +34
vibrations. The stainless steel gauges are of a high Discharge pressure gauge -1 to 25 -70 / +63 -60 / +34
quality, protected against overloading and intended
especially for industrial use. Oil pressure gauge -1 to 12 -
All gauges indicate the pressure in bar(eff.) and all but 5 2
a. 1 bar = 10 N/m = 100 kPa = 1.02 kgf/cm = 14.5 psi. 2
the oil pressure gauge also indicate the corresponding b. According to German UVV-VBG20 regulations the scale of the suction and
saturation temperature in 0C. discharge pressure gauge has to be provided by the contractor with a red line
indicating the maximum operating pressure.
Description and survey of pressure switches (see also Table 2.2-3 Survey of pressure safety switches
table Page 47)
-0.3 to 4.5 6 to 32 -0.9 to 7 Range bar (e)b

Contact
• The combined suction and discharge pressure safety Description of
Type
diff.
pressure safety Function Remarks
switch protects the compressor and plant against too switchesa press.
low a suction pressure and excessive discharge (bar)c
pressure.In case the suction pressure drops to below
the low pressure pre-set value minus the pre-set
Combined 0.7 separate
differential pressure (LP safety switch) or the suction
KP15(Ad)
suction and (fixed) locking device
discharge pressure exceeds the high pressure pre-set discharge and external
value (HP safety switch), the control current circuit is pressure reset for
STANDARD
interrupted and the compressor stops. Standard safety switch 4.0 suction and
discharge (fixed) discharge.
“Danfoss” type KP15(A).
• The oil differential pressure safety switch protects the
locking
MP55(Ad)
compressor against too low a lubricating oil pressure Oil differential device,
and reacts to the difference between oil pressure and pressure - 0.2 external
(fixed)
crankcase pressure (=suction pressure). safety switch reset, internal
The oil pressure switch incorporates an automatic time relay.
time lag relay to bridge the main contacts during
0.9 to 0.7
locking
KP1(Ad)
start-up. The delay of 60 seconds allows the Suction

0.7 device,
pressure - (fixed) external
compressor to built up a sufficient lubricating oil safety switche
pressure. If during operation of the compressor, the reset.
ALTERNATIVE
differential pressure decreases, the control current locking

6 to 32-
discharge
circuit of the motor will be interrupted with a delay combined press. limitor device,
KP7(Ad)BS
of 60 seconds. Standard “Danfoss” type MP55(A). discharge external

switch reset.
• Alternative suction pressure safety switch, “Danfoss” pressure
limitor and 4.0
10 to 32
type KP1(A) and combined discharge pressure safety (fixed)

safety switchf discharge locking
switch, “Danfoss” type KP 7(A)BS, suitable for e.g. press. safety device,
German UVV-VBG20 regulations.1 One part of the switch internal reset
combined discharge pressure safety switch has the a. When mounted in a cabinet all pressure connections of the safety switches are
function of pressure limitor and the other part acts as provided with a flare coupling for Ø6 x 1 mm copper precision tube.
a real safety device. The pressure lines of this switch b. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi. 7
should be connected directly (= without stop valve) c. Protection class of enclosure IP 33 (according to IEC 529 and DIN 40050).
d. A is for NH3
onto the compressor. Both alternative switches are e. Both safety switches together are an alternative for KP15 or KP 15A (e.g.
available on special order only. according to German UVV-VBG20 regulations).
All safety switches mentioned before are provided with f. In case a Monitron CR (optional) is applied, this combined pressure limitor and
a locking device so that, when cut out, the compressor safety switch still remains needed in order to comply with German UVV-VBG20
regulations.
does not become operative automatically on return of
the original pressure. To unlock, an internal or external
reset button is used but only after the reason for cut-out
has been investigated.
A wiring diagram showing the internal electrical
connections is glued to the inside of the front cover of
each pressure safety switch, while a leaflet with further
“Danfoss” instructions is placed behind the front cover.
1. Keep in mind that the setting of the switches should be so that the maximum
pressure difference of 24 bar between the discharge pressure (= condensing
pressure) and the suction pressure (= evaporating pressure = crankcase
pressure) should not be exceeded.

ACCESSORIES

ACCESSORIES
2.3 DIRECT AND V-BELT DRIVE

2.3.1 SELECTION OF DIRECT DRIVE
General
Grasso can supply a complete standard direct drive,
consisting of a specially adapted flexible coupling and
accessories.
Procedure and data

• Selection: Consult COMSEL.
Standard scope of supply

• Flexible coupling including all parts necessary for
mounting and securing.
Options
• Drive guard acc. to CE.
• Tool for removing coupling from shaft.
• Tool for alignment
Fig. 2.3-2 Dimensioned sketch of direct drive
Legend
M Motor
C Compressor
1/2 Coupling half
3 Coupling bolt
4 Coupling element
5 Filling ring
6/7 Clamping bush
Table 2.3-1 Coupling data
Dimensions in mm Mass moment of

Type
D1 DV D2 B C E F inertia Ik (kg/m2)
42 234 -- 170 46 190 18 62 0.098

61 254 -- 186 76 250 15 68 0.142
Fig. 2.3-1 Flexible coupling
91 281 -- 210 76 250 10 78 0.239
61V -- 320 186 76 250 15 68 0.325
Legend
91V -- 320 210 76 250 10 78 0.400
X Distance compressor foot - Motor shaft
Y Distance compressor foot - bolt drive guard
Z Overall length drive guard
M Motor
C Compressor

ACCESSORIES
2.3.2 SELECTION OF V-BELT DRIVE
General
Grasso can supply a complete V-belt drive system.
Procedure and data

• Selection: Consult COMSEL or graphs below.
Options
• Flywheel (supplied loose).
• Motor pulley (mounted for packages, else supplied
loose).
• Set of V-belts (supplied loose).
• Drive guard:
¸ one side protection
¸ two sides protection acc. to CE (mounted for
packages, else supplied loose).
2.3.2.1 DETAILS V-BELT DRIVE
Fig. 2.3-3 Flywheel and drive guard
Table 2.3-2 Flywheel data
Number of grooves 5a
Type of Groove SPB
Mass. approx. kg 54.7
Mass moment of inertiab kg.m2 1.438
D (nom.) 400
a 136
Dimensions b 12.5
(mm) c 76
e 77.5
z 71
a. To determine the required number of V-belts, refer to the graphs.
b. Mass moment of inertia is required to determine the so-called coefficient of
speed fluctuation.

ACCESSORIES
Fig. 2.3-5 Selection graph for V-belt drive applicable to 60 Hz motors

Fig. 2.3-4 Selection graph for V-belt drive applicable to 50 Hz motors
2.4 PACKAGED BASE FRAME
Legend
n Standard compressor speed (min-1) General
Maximum installed motor power (kW) to transmit For mounting on a concrete foundation block, Grasso
P
(installed motor power) can supply a standard welded steel base frame to
#V Number of SPB V-belts
support compressor, motor and accessoiries.
Especially for vibration free operation on floors and on
S Centre distance flywheel - Motor pulley (mm) roof tops, a base frame with vibration dampers can be
L Pitch length of V-belts (mm) delivered (concrete foundation block can be omitted).
d Diameter of motor pulley (mm)
A. BASE FRAME FOR MOUNTING ON CONCRETE BLOCK
(“TRANSPORT BASE FRAME“)
Design Data
• Base frame to be placed on concrete foundation
block. For foundation block dimensions consult
Grasso.
• There should never be a direct rigid connection
whatsoever between the foundation block and the
floor or any other main part of the building.
• The concrete block should be extended down to any
subsoil.
Scope of supply
• Steel base frame, incl mounting of compressor,
electric motor and accessories.

ACCESSORIES
B. BASE FRAME FOR MOUNTING ON VIBRATION

DAMPERS (TORSIONAL STIFF)
Design Data
• Frame to be placed direct on elevated floors and on
roof tops (structural floor should be designed to take
the weight of the packaged unit).
• Concrete foundation block can be omitted.
• The first two pipe supports must be secured to a solid
foundation.
• Horizontal piping must be arranged parallel to the
crankshaft of the compressor.
• Always consult Grasso for installation advice.
Scope of supply
• Steel closed box profile base frame, including
mounting of compressor, electric motor and
accessories.
• Set of vibration dampers.

ACCESSORIES
2.4.1 PACKAGED BASE FRAME
Fig. 2.4-1 Grasso 6 packaged base frame (DD=Direct driven, VD=V-belt

driven)

ACCESSORIES
Dimensions
All dimensions and weights as mentioned are estimated

values. Consult Grasso to determine exact values.
Table 2.4-1 Weights and dimensions, Directdriven
Approx. dimensions and weights

Direct drive
Compressor (kg) L(mm) W(mm) H(mm)
type
46 775
66 890 1850 1025 1530
86 1055
Table 2.4-2 Weights and dimensions, V-belt driven
Approx. dimensions and weights

V-belt drive
Compressor (kg) L(mm) W(mm) H(mm)
type
46 850
66 960 1800 1275 1530
86 1130
Frames on vibration dampers
Packaged base frame for mounting on vibration

dampers can be determined by Grasso on request.

ACCESSORIES
2.5 OIL SEPARATOR; OIL RETURN Design data

PROTECTION; OIL LEVEL FLOAT Table 2.5-1 Oil separator design data
SWITCH; OIL EQUALISING AND OIL
OS3 OS4 OS5 OS6 OS8
RETURN
Weight (kg) 114 190 278 466 618
2.5.1 OIL SEPARATORS Contents (dm3) 70 126 230 379 810
Oil charge (dm3) 6 13 16 22 16
General Design pressure (bar(e)) 26.0
Grasso can supply standard oil separators, designed for Test pressure (bar(e)) 42.9
application in discharge lines (also LP discharge lines for
interstage cooling system C and D). Design temperature -10 ... +170 oC
Procedure and Data Legend (refer Fig. 2.5-2 and Fig. 2.5-3)
• Selection: 1 Inlet connection
— Consult Grasso software program COMSEL.
2 Outlet connection
Standard scope of supply 3 Set of flanges (optional)
• Oil separator according to CE/PED. 4 Stop valve (type TAH8) for oil return to crankcase
• Float valve assembly, for automatic return of oil to 5 Connection for temperature transmitter
crankcase of the compressor and stop valve (not
mounted). 6 Float valve
• Oil drain stop valve (not mounted). 7 Stop valve (type TAH8) for oil drain
• Safety valve connection
8 Base support (optional)
Options 9 Dirt drain
• Other approvals on request. 10 Safety valve connection (1/2” BSP)

• Set of flanges (DIN2635) for in- and outlet
connections.
• Welding mating flanges.
• Base support for mounting on concrete floor.
• Oil return protection.
• Single or double safety valve (1/2” BSP)(refer Fig.
2.5-1)
Fig. 2.5-1 Double safety valve (optional)

ACCESSORIES
Fig. 2.5-2 OS series, types OS3, OS4, OS5 and OS6

ACCESSORIES
Fig. 2.5-3 OS series, type OS8

ACCESSORIES
2.5.2 OIL RETURN PROTECTION
General
Grasso can supply an oil return protection system, to
prevent excessive foaming of oil in crankcase, which can
occur when starting the compressor after a long period
of standstill with relatively low oil temperature. (refer
also to accessory 'crankcase heater')
Selection and Data

• The minimum oil return temperature of the
thermostat has to be set at approx. 40 °C.
• Solenoid valve is always closed during compressor
standstill.
• Sensor to be connected to float valve connecton of oil
separator.
Standard scope of supply Fig. 2.5-5 Thermostat with sensor

• Solenoid valve.1
• Thermostat with sensor2 Legend (dimensions in mm)
CL Cable length
Options
For packages with built-on oil separator(s): 2.5.3 CRANKCASE OIL LEVEL FLOAT SWITCH
• Mounting
General
In case two or more compressors operate in parallel on
one common oil reservoir, Grasso can supply an electric
oil level float switch.
Selection and Data

• Mounted in special housing provided with a sight
glass
• Housing to be fitted on crankcase sight glass
connection
• Max peak current = 1 A (auxiliary relay required)
• Wiring: If 'Low oil level' and 'Compressor is running'
then 'solenoid valve open'
Fig. 2.5-4 Oil return protection
• Oil level float switch
Legend oil return protection
C Compressor
OR Oil return linea For exclusions see table below
V1 Solenoid valve
TC Thermostat Options
TT Temperature transmittor • Mounting
OS Oil separator
a. Oil return via the suction line is not allowed!
1. This solenoid valve can also be used in combination with an oil level float
switch (refer Section 2.5.3)
2. When a Monitron CR is applied, a temperature sensor will be supplied, instead
of a thermostat

ACCESSORIES
Fig. 2.5-7 Crankcase oil level float switch
Fig. 2.5-6 Float switch wiring diagram

Legend
Table 2.5-2
A Float switch housing
Legend
B Oil level float switch
a oil from oil separators
C Oil sight glass
b common oil reservoir (not included)
c hand operated stop valve (not included)
d compressor (not included)
e oil level float switch
f oil return from oil separator or liquid rectifier
g solenoid valve (not included)
h auxiliary relay (not included)
N Neutral
L Live
2.5.3.1 DETAILS CRANKCASE OIL LEVEL FLOAT

SWITCH

ACCESSORIES
2.5.4 COMMON OIL RETURN AND OIL EQUALIZING one common oil separator / oil reservoir, the oil return
CONNECTION to the crankcase must be arranged as follows;
General
In case two or more compressor operate in parallel on
Table 2.5-3 Oil level control crankcase
Legend
ORS from oil return system dp Pressure difference
LC Grasso oil level float switch (optional) OS Oil separator
EVRA-3 Solenoid valve RV Regulating non return valve
TAE-7 Stop valve CV Check valve
TC Temperature controller Compr Compressor
TCv Temperature controller vessel OCV Oil collecting vessel
If compressor crankcase level = LCHigh, stop compressor.
Crankcase heater (optional) is recommended
Oil return via suction line of the compressor is not

allowed.

ACCESSORIES
2.6 WATER COOLED CYLINDER HEADS AND in the cylinder heads which may result in liquid hammer
and possible damage to the compressor.
COOLING WATER REQUIREMENTS Furthermore the max. water inlet temperature of 45 oC
and water outlet temperature of 70 oC should not be
General exceeded.
Grasso can supply a cylinder head water cooling Provision should be made to interrupt the waterflow
system(refer to Section 1.5.6) in combination with a when the compressor stops, preferably by means of a
water cooled oil cooler(refer to Section 1.5.7 and Fig. solenoid valve.During long periods of compressor
1.5-2), in order to maintain the field of application in standstill at low ambient temperatures the cooling water
partload for NH3.(refer to Section 1.3.3) should be drained off from the cylinder heads and oil
cooler or an anti-freeze agent should be added to the
cooling water in order to prevent freezing of the cooling
Effect of water cooling water.
In order to avoid the part-load limitations as shown in
the field of application in Fig. 1.3-2(upper), water
cooling should be applied, in which case a much more
favourable field of application is obtained, as shown in 2.7 CRANKCASE HEATER
Fig. 1.3-2(lower).
Water cooling means cylinder head cooling in
combination with oil cooling.Even during full-load
operation the overall compressor housing temperature Recommended for all compressors and all conditions of
will be favourably influenced by applying water cooling, operation.
however, without enlarging the original total field of
application for compressors without water cooling.
General
During standstill of the compressor, refrigerant may
Application requirements dissolve in the oil charge of the crankcase or it may even
The water cooling system, consisting of special cylinder condense, both due to an increase of crankcase pressure,
head covers, a crankcase oil cooler and the a decrease of crankcase temperature and/or possible
interconnecting rubber hoses, as described in chapter 2, temperature differences between crankcase and
has been designed for a maximum water pressure of 6 evaporator.
bar.
Excessive foaming of oil in crankcase, can occur when
Table 2.6-1Table 2.6-1 below gives an approximate starting the compressor after a long period of standstill
indication of the amount of cooling water required at a with relatively low oil temperature which may result in
water inlet temperature of 40 oC. damaging the compressor by a lack of lubrication.
The actual water flow for different values of twi and
depending on the operating conditions to and tc Low oil temperatures may also cause a high oil viscosity,
(evaporating and condensing temp.) should be such, which may result in troublesome starting.
that the crankcase oil temperature does not exceed 80
oC and the discharge gas temperature, measured at the
Selection and Data standard heater
compressor discharge connection, is not higher than tc +
75oC. • Refer to table.
• Engine room temperatures below 20 °C.
Table 2.6-1 • Wiring: If 'compressor NOT running' then 'element is
energised'.
Cooling water required in m3/h at tw = 40 0C
Number of cylinders (approx.)a
min. max.
• Heater element (mounted, not wired).
4 0.18 0.36
6 0.24 0.48
8 0.30 0.60
a. Depending on operating conditions To and Tc
It is recommended to apply a closed water recirculation

system via a separate heat exchanger in order to prevent Fig. 2.7-1 Standard crankcase heater
deposits inside the cooling water channels which could
restrict the free flow of water.The cooling water used
should be non-aggressive (not causing corrosion, e.g. sea Legend
water or brackish water should not be used at all) and CE Cable entry
with an water inlet temperature not lower than 10 oC in
order to prevent premature condensation of refrigerant RC Removable cap to protect connections

ACCESSORIES
2.8.1 DETAILS STOP VALVE FITTING
Mentioned power in Watt; Standard voltages are

110-120 V and 220-240 V.
2.7.1 DETAILS CRANKCASE HEATER
This standard crankcase heater is thermostatically

controlled.
Installed power of heater

element Dimension L (mm)
400 400
2.8 SUCTION AND DISCHARGE STOP

VALVES AND FLANGES Fig. 2.8-1 Compressor with stop valves
Legend
Refer to “Main Dimensions and Space Requirements” to
S Stop valve suction
determine DN connections
E Elbow(adapter for easy removal suction gas strainer), Optional
D Stop valve discharge
General
P Purge valve
Grasso can deliver (straight through) stop valves to suit
suction and discharge connections.
Selection and Data

• For more detailed information refer to Engineering
Data of Revalco B.V.

• Suction and discharge stop valves (not mounted).
Options
• Set of flanges for suction and discharge line (not
mounted).
• Welding stop valves and mating flanges.

ACCESSORIES
2.9 SPARE PARTS AND (SPECIAL) TOOLS

2.9.1 SPARE PARTS
General
Grasso can supply a set of the spare parts kits which may
be required when then compressor has been in
operation up to the recommended overhaul running
hours.
Scope of supply
• Shaft seal assembly,
• Oil discharge filter,
• Discharge valves (rings and springs),
• Suction valves (rings and springs),
• Required gaskets, O-rings, seals.
REMARK: All parts are supplied loose.
2.9.2 HAND-OPERATED OIL PUMP

• hand-operated oil pump
• charging hose
Fig. 2.9-1 Hand-operated oil pump
Legend
a Oil charge valve, located on the oil pump of the compressor
Don’t use the oil drain valve of the compressor.

ACCESSORIES

3. NOTES
3. NOTES
3.1

Rc6 Product Information

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rc6 Product Information

Uploaded by

Copyright:

Available Formats

Reciprocating Compressors for industrial refrigeration

Product Information (PI)

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 1-

- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

Section Title Page

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 3-

- 4- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 5-

This preface gives a survey of the types of Contents

User group Contents

User group Contents

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 7-

Indicates a WARNING. READ IT CAREFULLY!

Indicates an IMPORTANT note or procedure to which

- 8- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

1. DESCRIPTION AND SELECTION OF COMPRESSOR

1.1 INTRODUCTION AND SCOPE Supplied loose:

1.1.4 DRIVE SYSTEM

1.1.5 SELECTION COMPRESSOR AND ACCESSORIES

1.1.6 PRESSURE TESTS

1.1.7 ACCEPTANCE TEST

1.1.8 STANDARD SCOPE OF SUPPLY

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 9-

- 10- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

1.2 GENERAL DATA

Table 1.2-1 Technical Data of Grasso 6 compressors

Standard direction of rotation counter-clockwise when facing shaft end (both

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 11-

1.2.2 MAIN DIMENSIONS AND SPACE

H 394 394 432 432 444 444 suction 1 40 40 50 50 50 50

- 12- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

Oil pressure 5 1/8” BSP (plugged off)

1.2.3 SHAFT END COMPRESSOR

Fig. 1.2-1 Shaft end compressor

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 13-

1.2.4 SOUND RATING

Conversion to sound pressure level

Table 1.2-4 Sound levels SPL

SPL Pdis = 12.5 bar SPL Pdis = 25 bar

1. R is dependent on type of compressor; R must be much larger than the

- 14- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

SPL Pdis = 12.5 bar SPL Pdis = 25 bar

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 15-

- 16- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 17-

- 18- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

1.2.5 PART-LOAD POWER CONSUMPTION — E = compression torque constant according to Table

Mc = Compression torque, required to compress the

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 19-

masses of the compressor main moving parts

Fig. 1.2-7 Compressor torque and electric motor torque - speed

COMPRESSOR TYPE 46a 46b 66 86

Zd 2 3 4 6 Fig. 1.2-8 Planes

Pull-out torque Mi 12.7 16.8 20.9 Legend

Friction torque A 11.2833 14.6571 18.9892 VPI vertical plane I

C 93.106 HPII horizontal plane II

Refrigerant D 9.761 CL centre line crankshaft

a. Min. capacity control step 50%

1.2.7 FREE FORCES AND MOMENTS

- 20- Reciprocating Compressors for industrial refrigeration / Series Grasso 6 PI0503/v004

where: Mc (kg) = mass (weight) of bare compressor

Forces H (horizontal) and V (vertical) in

1475 min-1b 1475 min-1

PI0503/v004 Reciprocating Compressors for industrial refrigeration / Series Grasso 6 - 21-