Grasso Mseries

Screw Compressor Packages
GEA Grasso M-Series
Operating Manual (Translation of the original text)

P_261511_1
Downloaded from www.Manualslib.com manuals search engine

Operating Manual | GEA Grasso M-Series
COPYRIGHT
this document may contain or for their consequen-
All Rights reserved. ces.
No part of this documentation may be copied or pub- The manufacturer reserves the right to make techni-
lished by means of printing, photocopying, microfilm cal modifications during the course of further devel-
or otherwise without prior written consent of opment of the equipment covered by these operating
• GEA Refrigeration Germany GmbH instructions.
herein after referred to as the manufacturer. This Illustrations and drawings in these operating instruc-
restriction also applies to the drawings and diagrams tions are simplified representations. As a result of the
contained in the documentation. improvements and changes, it is possible that the
illustrations do not exactly match the unit you are
LEGAL NOTICE operating. The technical data and dimensions are
subject to change. No claims can be made on the
These operating instructions are part of the technical basis of them.
documentation for the scope of delivery. They con-
The manufacturer cannot accept liability for damages
tain important instructions for ensuring safe and
proper transport, installation, start-up, economic • which occur during the warranty period as a
operation, maintenance and repair of the unit. Their result of
observance helps in avoiding dangers, reducing
– improper operating conditions and conditions
repair costs and down-times and increasing the relia-
of use,
bility and durability of the unit.
These operating instructions are intended for the – inadequate maintenance,
users of the equipment and are specifically intended – improper operation,
for the operating company and its operating and
maintenance personnel. – incorrect installation,
It is essential that the operating company and its – incorrect or improper connection of the main
operating and maintenance staff read these operat- electrical drive,
ing instructions prior to transport, installation, start- • or which result from or can be attributed to
up, use, maintenance, repair, disassembly and dis- improper modifications or failure to observe the
posal. This obligation to read also applies to person- instructions;
nel involved in activities in the life phases of the
machine. • through the use of accessories or spare parts
The operating company must supplement these which were not supplied or recommended by the
operating instructions with instructions regarding manufacturer.
health and safety at work and environmental protec-
tion on the basis of existing national regulations for
industrial safety.
In addition to these operating instructions and the
binding accident prevention regulations valid for the
respective country and area where the product is
used, the recognised technical regulations for safe
and professional work must also be observed.
These operating instructions are part of the unit. The
entire documentation comprises these operating
instructions and all additional operating instructions
supplied with the unit. It must be kept readily availa-
ble where the unit is installed. The entire documenta-
tion must also be forwarded if the unit is installed at
another location and if the unit is sold.
These operating instructions have been written in
good faith. However, GEA Refrigeration Germany
GmbH cannot be held responsible for any errors that
2 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

SYMBOLS USED IN THIS MANUAL

Danger!
Stands for an immediate danger which
leads to heavy physical injuries or to
the death.
Warning!
Stands for a possibly dangerous situa-
tion which leads to heavy physical
injuries or to the death.
Caution!
Stands for a possibly dangerous situa-
tion which could lead to light physical
injuries or to damages to property.
Hint!
Stands for an important tip whose
attention is important for the designa-
ted use and function of the device.
GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 3

LAYOUT INFORMATION
Bullet points and numbered list characters

Bullet points are used to separate logical contents within a section:
• Bullet point 1
Types of bullet point 1.
• Bullet point 2
Types of bullet point 2.
Numbered list characters are used to separate enumerations within a descriptive text:
Descriptive text with consecutive numbering:
– Numbered list point 1
– Numbered list point 2
Handling instructions
Handling instructions require you to do something. Several consecutive steps result in a handling sequence that
should be run in the specified order. The handling sequence can be divided into separate steps.
Handling sequence
1. Handling sequence step 1
– step 1,
– step 2,
– step 3.
2. Handling sequence step 2
The subsequent handling sequence is the expected result:
® Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
– Individual work steps

TABLE OF CONTENTS
1 BASICS 11
1.1 Importance of the documentation 11
1.2 Requirements for personnel, obligation to exercise due care 11
1.3 Legal foundations (Germany) 12
1.4 Specified Use 14
1.5 Warning against foreseeable abusive use 14
1.6 CE mark 15
2 MANUFACTURER INFORMATION 16
3 CUSTOMER SERVICE 17
3.1 Technical customer service department 17
3.2 Spare parts 17
3.3 Training courses 17
3.4 Service contracts 17
4 SAFETY 18
4.1 General information for safety 18
4.2 Behaviour in the case of emergency 18
4.3 Possible residual hazards 18
4.4 Installation in explosive atmospheres, installation zones 1 and 2 19
5 TRANSPORT, STORAGE 21
5.1 General instructions 21
5.2 Delivery 21
5.3 Transport (crane transport) 21
5.4 Bearings 23
5.5 Storage (several years) 24
6 INSTALLATION 26
6.1 Basic information for installation 26
6.2 Rigid installation 26
6.3 Anti-vibration mounting 26
6.4 Electrical connection 26
6.4.1 Use in explosive atmospheres, installation zones 1 und 2 27
6.5 Sound insulation, weather protection 27
6.6 Information regarding noise emissions 27
7 DESCRIPTION OF DESIGN AND FUNCTION 29
7.1 Installation in explosive atmospheres, installation zones 1 und 2 29
7.2 Product code of screw compressor packages - Grasso SP1, SP2, SPduo and M Series 30
7.3 Technical specifications 32
7.4 Location of the product identification (name plate) 33
7.5 Information and safety labels on the product 34
7.5.1 Labelling of the pressure and temperature sensors, heater 34
7.5.2 Label of the safety valve 34
7.5.3 Labels of the screwed connections with DiNova ring 34
7.5.4 Labels of the pipelines 35
7.5.5 Marking the direction of rotation of the compressor drive motor 35
7.5.6 Marking the direction of rotation of the oil pump motor 35
7.5.7 Labels of the pressure gauge 36
7.5.8 Labeling of the control / control cabinet 36
7.5.9 Designation of the earth connection 37
7.6 Process flow diagram 37
7.7 Main components 38
7.7.1 Screw compressor 39
7.7.2 Compressor drive motor 39
7.7.3 Compressor with coupling housing 40
7.7.4 Oil separator 40
7.7.5 OMC block with oil filter system 41
7.7.6 Oil cooler 41
7.7.7 Oil pump (optional) 41
7.7.8 Suction filter - check valve combination 42
7.7.9 Controller 43
7.7.10 Fittings 43
7.7.11 Safety devices 44

7.7.12 Monitoring devices 45

7.7.13 Components installed by the client 45
7.8 General functional description 45
7.9 Refrigerant circuit 45
7.10 Oil System 46
7.10.1 Oil separation 46
7.10.2 Oil heater 46
7.10.3 Oil cooling 46
7.10.4 Oil filter 46
7.10.5 Oil pump 46
7.10.6 Oil injection 47
7.10.7 Oil circuit, OMC block 47
7.11 Capacity control 47
7.12 Technical specifications 47
7.12.1 Designed for use in explosive atmospheres! 47
7.12.2 Basic terms 48
7.12.3 Operating media 48
7.12.3.1 Refrigerant 48
7.12.3.2 Refrigeration machine oils 48
7.12.3.3 Secondary refrigerant 48
7.12.4 Operating limits 48
7.12.5 Water quality requirements, parameters 50
8 START-UP 53
8.1 Important information for start-up 53
8.2 Basics 54
8.3 Connecting the screw compressor package 54
8.3.1 Connecting the pipes 54
8.3.2 Electrical connection 55
8.4 Paint and insulation 55
8.5 Start-up procedure 55
8.5.1 Checking the electrical connection 55
8.5.2 Leak test 55
8.5.3 Drying, vacuum 56
8.5.4 Operating position of valves 57
8.5.5 Oil charge 60
8.5.5.1 Pressure compensation with the cooling system 60
8.5.5.2 Checking the direction of rotation of the oil pump motor 60
8.5.6 Checking the fault monitoring 61
8.5.7 Checking of the safety pressure limiter 61
8.5.8 Checking of the emergency-OFF button. 61
8.5.9 Adjustment of oil pressure 62
8.5.10 Checking the direction of rotation of the drive motor 62
8.5.11 Mounting the coupling 62
8.5.12 Checking the water circuits 63
8.5.13 Initial start-up 63
8.5.14 Checking the adjustment of the control slide 63
8.5.15 Checking the control slide adjustment times 63
8.5.16 Checking the oil cooler 63
8.5.17 Adjusting the amount of injection oil and the oil temperature 63
8.5.17.1 Screw compressor packages without refrigerant injection 64
8.5.17.2 Compressor units with refrigerant injection 64
8.6 Start-up after long standstill periods 64
8.7 Restarting after approx. 1 year standstill 64
9 USE, OPERATION, CONTROL 65
9.1 Use in explosive atmospheres, installation zones 1 and 2 65
9.2 Important information for the operator 65
9.3 Prerequisite for switching on 65
9.3.1 Overview of the operating modes 67
9.3.2 Setting of setpoint and limiting values as well as safety devices 69
9.4 Operation of the screw compressor package 69
9.5 Instructions regarding failures, their causes and remedies 69
10 CLEANING, MAINTENANCE, REPAIR 72
10.1 Use in explosive atmospheres, installation zones 1 and 2 72

10.2 Important information for service personnel 72

10.3 Cleaning the heat exchanger 72
10.3.1 Mechanical cleaning 73
10.3.2 Chemical cleaning 73
10.4 Maintenance 73
10.4.1 General instructions 73
10.4.2 Repair work 74
10.4.2.1 Repair information 74
10.4.2.2 Repairs of pressure vessels subject to approval inspection 74
10.4.3 Maintenance intervals 74
10.4.4 Maintenance work 74
10.4.4.1 Maintenance of the screw compressor 74
10.4.4.2 Changing the block mounting filter element 75
10.4.4.3 Replacing the oil filter 75
10.4.4.4 Maintenance of the suction filter 76
10.4.4.5 Oil draining, oil filling, oil change 76
10.4.4.6 Oil pump maintenance 78
10.4.4.7 Changing the fine oil separation cartridges 78
10.4.4.8 Tightening screw fastenings 79
10.4.4.9 Coupling maintenance 79
10.4.4.10 Checking the function of check valves 79
10.4.4.11 Searching for leaks on the refrigerant side / leak test 79
10.4.4.12 Venting the refrigerant circuit 80
10.4.4.13 Refrigerant evacuation 80
10.4.4.14 Checking the bearing noise 81
10.4.4.15 Checking the solenoid valves for capacity control 81
10.4.4.16 Checking the oil heater 81
10.4.4.17 Maintenance of the compressor drive motor 81
10.4.4.18 Checking the start regime 81
10.4.4.19 Checking the safety devices 81
10.4.4.20 Checking the operating parameters 81
10.4.4.21 Maintenance of the switching cabinet 82
10.4.4.22 Checking the earth connection 83
10.4.4.23 Insulation 83
10.4.4.24 Check of the tightening torque on the adjusting elements of the fixing base. 83
11 DECOMMISSIONING 84
11.1 Shut-down in the event of dangerous situations 84
11.2 Standstill for a period <48 hours 84
11.3 Standstill for a period >48 hours 84
11.4 Measures during shutdowns 84
11.4.1 Monthly measures during standstill 85
11.4.2 Four weeks before restarting 85
12 DECOMMISSIONING, DISPOSAL 86


TABLE OF FIGURES
fig. 1 CE mark 15
fig. 2 Designation of the lifting points 21
fig. 3 Stopper with shackle 22
fig. 4 Transportation with a wire rope hoist 22
fig. 5 transportation using crossbeam 23
fig. 6 Location of the product identification (type plate) 33
fig. 7 Type plate 33
fig. 8 Safety labels of the pressure and temperature sensors, heater 34
fig. 9 Label of the safety valve 34
fig. 10 Labels of the screwed connections 34
fig. 11 Labels of the pipelines 35
fig. 12 Marking the direction of rotation of the compressor drive motor 35
fig. 13 Marking the direction of rotation of the oil pump motor 35
fig. 14 Labels of the pressure gauge 36
fig. 15 Test verification for the control system 36
fig. 16 Designation of the earth connection 37
fig. 17 Process flow diagram Grasso SP1, M-series 37
fig. 18 Main components of the GEA Grasso M-Series 38
fig. 19 GEA Grasso M-Series, arrangement of the SCP 39
fig. 20 GEA Grasso M-Series, arrangement of the compressor drive motor 39
fig. 21 GEA Grasso M-Series, arrangement of the coupling housing 40
fig. 22 GEA Grasso M-Series, arrangement of the oil separator 40
fig. 23 GEA Grasso M-Series, arrangement of the OMC block with oil filter system 41
fig. 24 GEA Grasso M-Series, arrangement of the oil cooler 41
fig. 25 GEA Grasso M-Series, arrangement of the (optional) oil pump 42
fig. 26 GEA Grasso M-Series, suction filter - check valve combination 42
fig. 27 GEA Grasso M-Series, arrangement of the controller 43
fig. 28 Corrosion resistance in presence of chlorides 51
fig. 29 Vacuum required to remove moisture from refrigerating plants 56
fig. 30 Stop valve open 57
fig. 31 Stop valve closed 57
fig. 32 Check valve 57
fig. 33 Shuttable check valve 57
fig. 34 Control valve 58
fig. 35 Shuttable check valve 58
fig. 36 Solenoid valve 58
fig. 37 Change-over valve 58
fig. 38 Oil pressure control valve 58
fig. 39 Overflow valve, safety valve 59
fig. 40 Pressure controlled check valve 59
fig. 41 Quick acting valve, spring-loaded 59
fig. 42 Charging valve, drain valve 59
fig. 43 Service valve 59
fig. 44 Oil temperature limiter 60
fig. 45 Temperature controlled control valve 60
fig. 46 Motor direction of rotation 62
fig. 47 Arrangement of MIN / MAX sight glasses 78
fig. 48 Operating position of the fine oil separation cartridges 79


Operating Manual | GEA Grasso M-Series Basics
1 BASICS
– applicable international and national standards,
1.1 Importance of the documentation – applicable occupational safety regulations,
These operating instructions are part of the technical – applicable accident prevention regulations,
documentation for the Grasso scope of delivery. It – applicable environmental protection regulations,
contains advice for operating the package/chiller
safely, properly and economically. The observance – the construction and functioning of the unit,
of the operating manual helps in avoiding dangers, – recognised technical regulations for safe work
reducing repair costs and down-times and increasing according to good professional practice.
the reliability and durability of the package/chiller.
The technical personnel must:
This operating manual is directed at the users of the
package/chiller and is specifically intended for the – be able to assess the work assigned to them,
operating company and its operating and mainte- recognise and avoid possible dangers,
nance personnel. This operating manual must be – be authorised by those responsible for the safety
read prior to transport, installation, commissioning, of the system to carry out the requisite work and
maintenance, repair, disassembly/disposal. activities.
All work explained in this operating manual must only
be carried out by technical personnel. Caution!
This operating manual must be supplemented with No arbitrary changes may be made to
instructions based on prevailing national regulations the control or other components
regarding industrial safety, health protection and belonging to the unit. Maintenance
environmental protection. work may only be done by authorised
In addition to this operating manual and the manda- service staff.
tory accident prevention regulations applicable for
the respective place of installation, the accepted Special requirements for the electrical techni-
technical regulations for safe work according to good cians
professional practices must also be observed. Work on electrical components and modules may
The operating manual is a part of the total product. only be carried out by an electrical technician
The entire documentation, consisting of this operat- according to the rules relevant to electrical engineer-
ing manual as well as all supplied additional instruc- ing. Furthermore the operator has to take care that
tions, is to be always kept easily accessible at the the electrical systems, tools and fixtures are oper-
place of installation of the package/chiller. The com- ated according to the rules relevant to electrical engi-
plete set of documentation must also accompany the neering and applicable standards and serviced prop-
package/chiller if it is sold. erly.
– In principle it is prohibited to carry out work on
parts under voltage.
1.2 Requirements for personnel, obliga- – Fuses may only be replaced and not repaired or
tion to exercise due care bypassed.
Qualification – Only the fuses specified in the electrical circuit

diagram may be used.
All work explained in this manual (assembly, electri-
cal connection, commissioning, operation, etc.) may – A two-pole voltage tester must be used to ensure
only be carried out by trained technical personnel that the parts are de-energised.
who observe the relevant technical regulations. – The power supply as well as the unit casing must
Technical personnel are representatives of the unit be sufficiently grounded and tagged with a suita-
manufacturer and persons who, as a result of their ble label.
technical training, experience and personal instruc-
– Deficiencies noticed in the electrical systems/
tion in training measures, have sufficient knowledge
modules/tools and fixtures must be corrected
of:
immediately. If an acute danger exists till then,

Basics Operating Manual | GEA Grasso M-Series
the package/chiller must not be operated in the – Accident Prevention Regulation including
defective condition. implementation regulations (BGR 500, chapter
2.35) on refrigeration plants, heat pumps and
Minimum age cooling equipment (BGV B3) regarding noise
The minimum age for the operation of the package/
– EN 12284 Refrigerant fittings, safety related
chiller and installation is 18 years. All persons
technical definitions, testing and marking
involved in the assembly and installation of the pack-
age/chiller and the system must get themselves – DIN 2405 Pipes in refrigeration plants, marking
trained at regular intervals and/or familiarise them-
– VDMA specifications,in particular VDMA 24
selves with the current technical data of the device.
243 and 24 020
The training and instructions is to be conducted at
least once a year, unless some other interval has – VDI Guidelines
been agreed upon with the manufacturer.
– Instruction sheets for handling ammonia,
Obligation to exercise due care Instruction sheet for halogenated hydrocar-
bons containing fluorine BGI 648
The statutory regulations for meeting the obligation
to exercise due care are to be observed. – Safety data sheet for ammonia and other refrig-
Meeting the obligation to exercise due care accord- erants and refrigeration oils
ing to the current level of technology requires that The list of rules and standards has been taken from
everything that is Status Report No. 5 of the German Refrigeration and
Air Conditioning Engineering Association "Safety and
– technically possible (use of accepted technologi-
environmental protection in ammonia refrigeration
cal rules) and
plants" and also fully applies to other refrigerants.
– economically reasonable
Danger!
be done to prevent damage in a protectively safe
manner.
1.3 Legal foundations (Germany) The additional safety instructions as

defined in "Appendix E" must be
The following standards, regulations, ordinances and observed for packages for the desig-
laws must be strictly observed to ensure the safety nated use in potentially explosive
and functional reliability of the packages and chillers: atmospheres, installation zones 1 and
– EC Machinery Directive 2006/42/EC 2 in accordance with EN 60079-10.
– EC Pressure Equipment Directive The following:
2014/68/EC– AD 2000 Info Sheets
– standards,
– Hazardous Incident Ordinance (12. BlmSchV)
with 1st failure VwV – safety regulations,
– Federal Pollution Control Act (BImSchG), 4th – guidelines and recognised engineering practice,
BimSchV listed in these operating instructions must be
observed at least!
– Water Resources Act (WHG), VawS
Hint!
– Hazardous Substances Ordinance (GefStoffV)
If the package/chiller is used in a
– Recycling and Waste Management Act (KrW-
country other than Germany, the rules
AbfG)
and regulations applicable at the place
– DIN EN 378, Part 1 to Part 4 Safety-related of installation must be observed and
technical requirements and environmental complied with!
requirements
The mandatory accident prevention regulations
applicable for the respective country and area where
the product is used must also be observed.

Failure to observe the safety instructions can lead to

danger to personnel and the environment as well as
damage to the unit.

Basics Operating Manual | GEA Grasso M-Series
1.4 Specified Use the manufacturer – is responsible for all personal

injury and damage to property resulting from
Hint! improper use.
Observe the "Specified Use" chapter The pressure equipment is not designed for dynamic
of the installation instructions for the loads. If there is a risk of lightning strikes, the pres-
screw compressor! sure equipment must be earthed. The supplier/instal-
ler must record instructions for regular inspection of
The screw compressor package must only be oper- the pressure equipment in his operating manual and
ated up to a maximum discharge pressure in accord- must specify the procedure to be followed by the end
ance with the type plate. user in the event of damage. In order to prevent
It is imperative that you comply with the applicable burns or frostbite, the pressure receptacle must not
conditions of use with respect to pressure and tem- be touched during operation. This can be prevented
perature for the screw compressor package. by respective safety measures. Appropriate warning
Do not change the setting values of the safety pres- signs must be affixed. Compressor units or systems
sure switch. This would endanger the operating must be equipped with safety valves in accordance
safety of the refrigeration plant. with EN 378. The foundation must provide sufficient
rigidity.
If the switch-off value is set higher than 0.9 x maxi-
mum operating pressure (see EN378-2) of the high The supplier/installer must carefully install the acces-
pressure section of the refrigerating system, this may sories for the pressure equipment. The pressure
result in the the tank within this section of the system equipment must not be damaged during installation
rupturing. and must be painted after installation. The pressure
equipment must only be filled with the refrigerant
The operating regime stipulated by the manufacturer, specified in the contract. The pressure units must be
especially for the starting phase of the screw com- installed in the compressor unit or the system in such
pressor package, must be observed. a way that vibrations or pulses cannot be transferred
Operating parameters must be monitored. Operating to the pressure units. The contacts must be installed
parameters must not deviate from within the defined with the power supply disconnected.
limits.
Specified use includes observance of this manual
The screw compressor package has been designed and all supplied operating manuals as well as com-
and manufactured for a specific application under pliance with the maintenance and service intervals
defined conditions of use. Unauthorised structural and conditions stipulated therein.
modifications are not permitted. We assume no liabil- Warranty claims and authorisation for operation
ity for any resulting damage or injury. In the interest become void if the equipment is not used for its
of further development, GEA Refrigeration Germany specified purpose.
GmbH reserves the right to make technical modifica-
tions. The screw compressor package described
here corresponds to the state of the art at the time 1.5 Warning against foreseeable abu-
this operating manual was published.
sive use
The manufacturer must be consulted in all cases as
to the permissibility of the modification if there is any A package/chiller is said to have been abused, if
change of the application or the conditions of use. – unauthorised refrigerants, fuels and lubricants
Do not make any modifications to the screw com- and secondary refrigerant materials are used.
pressor package and the compressor control system.
Hint!
These may impair the safety and functionality of the
SCP. They will also void the guarantee. Observe specification for the project!
The pressure equipment described here must not be – electrical components are wrongly connected.
used for any purpose other than the purpose speci-
fied here. The units must only be installed by the Hint!
supplier/installer and not by the end user. If the pres-
Watch voltage and frequency!
sure equipment is not used according to the regula-
tions, the safe use of the equipment is not guaran-
– mechanical components are wrongly connected.
teed. The supplier/installer or the operator – and not

1.6 CE mark
Hint!
Watch pressure and temperature! By affixing the CE mark, the manufacturer confirms
the conformity of the product with the applicable EC
– the supporting, hanging and storage facilities are Directives and compliance with the principle require-
misused. ments stipulated within them.
– control and regulation units including control sys-

tem software are tampered with.
fig.1: CE mark
– the driving power generated by the motor is used
for purposes other than the operation of the
respective compressors and pumps. The CE mark is affixed to the nameplate.
The CE mark for products from GEA Refrigeration
Germany GmbH is provided as defined in the Pres-
sure Equipment Directive, i.e. pressure equipment is
placed on the market with the required equipment
parts with safety function. This complete assembly is
subject to the Pressure Equipment Directive.

Manufacturer Information Operating Manual | GEA Grasso M-Series
2 MANUFACTURER INFORMATION
GEA Refrigeration Germany GmbH is a company
within GEA Refrigeration Technologies, the Refriger-
ation Technology Segment of the GEA Group and
provides its customers around the world with high-
quality components and services for refrigeration and
process technology applications.
Locations:
GEA Refrigeration Germany GmbH

Factory Berlin
Holzhauser Str. 165
13509 Berlin, Germany
Tel.: +49 30 43592-600
Fax: +49 30 43592-777
Web: www.gea.com
E-Mail: refrigeration@gea.com
GEA Refrigeration Germany GmbH

Factory Halle
Berliner Straße 130
06258 Schkopau/ OT Döllnitz, Germany
Tel.: +49 345 78 236 - 0
Fax: +49 345 78 236 - 14
Web: www.gea.com
E-Mail: refrigeration@gea.com

Operating Manual | GEA Grasso M-Series Customer service
3 CUSTOMER SERVICE
GEA Refrigeration Germany GmbH supplies prod- In most cases, you will receive your spare parts
ucts of high quality and reliability. In addition, the within 24 hours after placing the order.
manufacturer ensures continuous operation of the You can contact us using the following hotlines:
refrigeration and process technology system and
provides exceptional service for the components • Wireless, out of hours
supplied. +49 (0) 172 30 14 579
• Landline, weekdays from 8 to 17 hour
+49 (30) 43 59 27 50
3.1 Technical customer service depart-
ment • Fax
+49 (30) 43 59 27 58
Do you require support from the technical customer
service department? Specially trained, experienced • Email
service technicians are available on call for you in Grasso-parts@geagroup.com
order to provide assistance in case of technical prob-
lems and to offer support in the framework of our • Order spare parts from our G-Pos. online
after-sales service. shop
24/7 Hotline: (Grasso Parts online shop)
the hotlines can reached around the clock on every gea-refrigeration.de.spareparts@gea.com
day of the week:
• Wireless 3.3 Training courses
+49 (0) 172 39 12 050
Warning!
• Landline, weekdays from 7 to 17 hours
+49 (30) 43 59 27 61 All work on our systems must only be
carried out by technical personnel!
+49 (30) 43 59 27 62 Acquire the technical know-how
• Email: required for this in good time!
Grasso-service@geagroup.com Comprehensive training courses are held regularly
outside of Germany, Austria and Switzerland please for service technicians and mechanics, thus ensuring
contact: the safe and proper use and maintenance of our sys-
• local sales office tems.
www.gearefrigeration.de • Email
technical support for liquid chillers with reciprocating Grasso-service@geagroup.com
compressors in Germany, Austria and Switzerland
• 24/7 Hotline
3.4 Service contracts
+49 (345) 78236 20
The specialists of our Technical Customer Service It is possible to sign a long-term service agreement
department support you in installations, acceptan- (service contract). For further information regarding
ces, maintenance, operating questions, on-site the content, scope and conditions of the possible
inspections and repairs of our products. service options, please contact the Technical Cus-
tomer Service department.
• Email:
3.2 Spare parts Grasso-service@geagroup.com
GEA Refrigeration Germany GmbH has its own prac-
tical and rapidly working spare parts department to
supply the necessary spare parts worldwide. Neces-
sary spare parts are shipped as quickly as possible.

Safety Operating Manual | GEA Grasso M-Series
4 SAFETY
4.3 Possible residual hazards
4.1 General information for safety Warning!
The safety aspects to be observed for operating the Despite careful design of the machine
equipment are shown in the chapter on "Safety". and implementation of all the safety-
relevant regulations, further risks for
The equipment has been developed and manufac-
persons and machine during all life
tured according to the currently applicable state of
phases of the package/chiller cannot
the art and is reliable in operation. It has been tested
be fully ruled out. The additional safety
and left the factory in a technically faultless safe con-
instructions in the individual chapters
dition.
of this manual must therefore be care-
In order to maintain this condition for the operation fully observed!
time, the details of the project documentation and
certificates must be observed and complied with. Residual risks that were ascertained during the risk
When operating the equipment, at least the general assessment carried out for the product according to
safety regulations and the provisions and guidelines safety standard EN ISO 14121 - Safety of Machines
referred to in this documentation must be observed. - are:
Only compliance with all provisions and guidelines – mechanical hazards due to sharp sheet metal
will enable optimum protection of the personnel as edges and projecting parts,
well as dangers to the environment and the safe and
smooth operation of the equipment. – electrical hazards as a result of inadvertently
coming in contact with terminals and cables,
– thermal hazards as a result of inadvertently com-
4.2 Behaviour in the case of emergency ing in contact with heat exchangers and pipes,
Hint! – exposure to noise,
Familiarise yourselves with the local – hazards caused by vibration due to improper
evacuation plan before beginning the installation,
work. – hazards due to working materials and other
Should an emergency situation arise despite adher- materials in case of allergies orthe like,
ing to the safety regulations, the package/chiller – neglect of ergonomic principles,
must be shut down immediately and isolated from
– combinations of various hazards,
the electrical mains.
The mains cable must be blocked in such a way it is – unexpected start-up, unexpected rotation in case
not possible to restart the unit accidentally and of incorrect electrical connections or defects,
marked as such. – shut-down, emergency stop when defects are
The operator of the complete system has to take detected,
care that an isolation device, e.g. a mains switch with
– changes to the rotational speed,
appropriate contact rating and an integrated indica-
tor, is pre-installed in the mains cabling on site. – power failure,
A separate mains cable/feed cable must be laid for – failure of the control circuit or control loop,
the operation of the package/chiller.
– incorrect assembly,
The mains cable/feed cable is to be specially protec-
ted and provided with an emergency stop switch. – fracture during operation,
– operating media or objects getting thrown out,
– loss of stability and
– personnel slipping, tripping or falling.

Operating Manual | GEA Grasso M-Series Safety
Hint! lutely necessary to ensure a minimum oil level

above the heating elements. To this end, a sepa-
There are no radiation hazards rate oil level switch is used in each use case
according to the necessary explosion protection
specification.
4.4 Installation in explosive atmos- Operation
pheres, installation zones 1 and 2 The same regulations apply in regard to the operat-
ing instructions for screw compressor packages in
Danger! potentially explosive atmospheres as described in
The additional instructions for using the applicable operating manual.
screw compressor packages in explo- In addition to this, the following extensions
sive atmospheres, installation zones 1 apply:
and 2, must be complied with!
– In addition, the legal safety regulations apply to
the people responsible for operating the screw
Function and Design
compressor package, and must be complied with
The same functional and design characteristics apply respect to the transport, assembly, operation and
to the maintenance instructions for the use of screw maintenance and if necessary the replacement
compressor packages in potentially explosive atmos- of subassemblies, etc. in potentially explosive
pheres as described in the respective applicable atmospheres.
operating manual.
The owner operators regulations must also
In addition to this, the following extensions always be observed – see also section: Safety
apply: information for compressor, Appendix E, and for
– All components relevant for the use of screw package, Appendix E.
compressor packages in relation to their use in – The electrical engineering regulations for instal-
potentially explosive atmospheres (concerns lations in potentially explosive atmospheres ,
both electrical and non-electrical components) especially EN 60079-10, apply to the installation
are separately designed and documented! The and connection of electrical components. The
extended documentation scope (component relevant prescribed cabling material must be
descriptions, certificates, calculations) is part of used.
the product documentation.
– The whole screw compressor package must be
– Extension to the method of working earthed by the owner operator.
The use of screw compressor packages is exten-
Maintenance
ded to use in potentially explosive atmospheres,
including the compression of process gases The same regulations apply to the maintenance of
(only compression for the purposes of pressure screw compressor packages in potentially explosive
increase). The screw compressor packages are atmospheres as described in the respective applica-
not suitable for pumping potentially explosive ble operating manual.
mixtures. This means that, when the compressor In addition to this, the following extensions
is in intake condition, the pumped liquid must not apply:
contain any oxygen. The intake condition always
– In addition, the legal safety regulations for the
refers to pressure layers in the overpressure
installation of the screw compressor packages
range.
apply to the people responsible for the mainte-
The owner operator and the system builder must nance of the screw compressor package with
use monitoring devices reflecting the respective respect to the maintenance of individual compo-
state of the art standards to positively monitor nents or assemblies or their complete replace-
and ensure this effect. ment in potentially explosive atmospheres.
– Safety equipment extension – The maintenance may only be carried out in
If oil heaters are used in potentially explosive agreement/with the knowledge and release of
atmospheres (see component specification), the owner operator.
additional, separate oil level monitoring is abso-

Safety Operating Manual | GEA Grasso M-Series
– The maintenance and replacement regulations

resulting from the operating manual for the com-
ponents must be conformed with.
– Appropriate special tools approved for the poten-
tially explosive atmosphere must be used.
– Only original spare parts may be used. If original
spares are not used, the guarantee is invalidated
or the owner is liable in the event of damage.
– Each maintenance inspection (see maintenance
book) must also include checking the secure fit
of the threaded connections for the coupling
safety hood.

Operating Manual | GEA Grasso M-Series Transport, Storage
5 TRANSPORT, STORAGE
5.2 Delivery
5.1 General instructions Shipment is made in the type of packing stipulated in
the order. The screw compressor package is gener-
Caution! ally supplied without packing.
Adequate lighting must be ensured The screw compressor package has an inert gas
during loading and unloading as well filler in the refrigerant circuit.
as for storage in order to avoid injuries
Warning!
and damage to property.
There is a danger of impacts and The compressor(s) of the screw com-
stumbling due to protruding parts on pressor package is/are not filled with
the equipment (e.g. valve caps). There oil. The screw compressor package
is also the danger of being cut on must not be started, therefore, before
sharp edges and surfaces. There is a proper assembly and start-up.
danger of crushing parts of the body
during the transport work. Personal
protective equipment (work clothing, 5.3 Transport (crane transport)
work books, gloves) must be worn
during all activities on the equipment. Warning!
Hint! The screw compressor packages are

not intended for transport with a fork
These operating instructions must be lift truck!
read prior to transport, storage and
delivery to the installation site. It is Screw compressor packages are high-quality prod-
imperative to strictly observe the ucts, which must be handled with due care during
instructions and information given! transport. Protect the equipment from impact and set
All work explained in these operating it down carefully.
instructions must only be carried out When transported by crane, the screw compressor
by qualified personnel. package must have the same position as in opera-
tion (frame downwards!). Only use the lifting points
provided. The lifting points are marked!
fig.2: Designation of the lifting points
Caution!
It is forbidden to attach SCPs to fit-
tings or pipes or at the eyebolts / lift-
ing rings of the compressor, the elec-
tric motor, the tank or the switching
cabinet.

Transport, Storage Operating Manual | GEA Grasso M-Series
Take special care not to attach the ropes near to

small nominal diameter pipes or insulation and to
damage them. Use spacers if necessary.
The lifting points are not arranged on one plane. The
ropes must be longer than 3 m. The height differen-
ces between individual lifting points must be com-
pensated by suitable extensions.
Make suitable arrangements (timber or insulating
material) to avoid damage to the surface.
Shackles must be used.
fig.3: Stopper with shackle
fig.4: Transportation with a wire rope hoist

5.4 Bearings
When the screw compressor packages are deliv-
ered, check for possible transport damage and report
any damage to the manufacturer in writing.
The storage area of screw compressor units shall be
roofed, plain and paved and secured against access
of unauthorized persons. Place the screw compres-
sor package onto timber planks and have it protected
from jerks or impacts.
Warning!
Screw compressor packages must be
adequately protected from external
influences (humidity, frost, extreme
heat) during storage. This usually con-
cerns lengthy standing times outdoors
before installation and start-up of the
refrigeration plant. The manufacturer
recommends the use of plastic sheet-
ing to cover the whole product.
The venting slits of the electric motors
must always be covered!
Storage temperature: 5°C ... 40°C

fig.5: transportation using crossbeam The composition of the paint on the screw compres-
sor package is designed for installation in the
Danger! machine room (inside installation). Contact with
water (including water spray) must be avoided.
Make certain there is no one under the
suspended load during transport with Warning!
the crane!
The screw compressor package is fil-
Position the screw compressor package on the led with dry gas (e.g. nitrogen) before
transport vehicle such that it is prevented from tilting delivery which prevents any change of
and falling. Load securing is preferably carried out by the properties of any already filled
lashing to the specified points. The pipes and equip- operating medium (e.h. refrigerating
ment of the screw compressor package must not be machine oil). Check the gas filling
entered. Components must be secured against once a week and recharge to the
vibrations. The competent staff member or the com- specified overpressure if required.
pany itself is responsible for ensuring safety during
Turn the shaft of the compressor at least every four
transport.
weeks (approx. 10 revolutions).
Warning! The transport packing (foil if present), that needs to
Screw compressor packages must be be opened for turning the compressor shaft and for
adequately protected from external checking the gas filling, must be closed again after
influences during transport. carrying out the activities in order to ensure protec-
tion against external influences. The packing (foil if
Transport packaging (optional): foil present) must be replaced as needed and for lengthy
storage times.
The foil may only be removed before erecting the
screw compressor package at the intended installa-
tion location in the machine room. Up until this point
in time, the foil serves to protect the screw compres-
sor package against external influences.

Transport, Storage Operating Manual | GEA Grasso M-Series
Warning! 2. Air humidity < 50%
Regular ventilation of the screw com- If the screw compressor package is intended to be
pressor package packaging (if stored, the following preparatory measures must be
present) must be ensured in order to carried out ex-works (especially protection against
prevent condensation on the surfaces internal and external corrosion):
of the machine. • All process connections on the screw compres-
sor package are sealed tight.
Long-term storage
• The screw compressor package is charged with
With a standstill of the compressor of more than 16
dry gas to 1 bar.
weeks prior to start-up, there is a danger that the
shaft seal may stick on the shaft and therefore be • A suction pressure gauge has been installed.
damaged on start-up. Because of this, removal and • The facing sides of the mounted coupling hubs
cleaning of the shaft seal is mandatory in order to have been greased. (Does not apply to sliding
ensure that it functions correctly. bearing compressor drive motors)
1. Use two pressure screws to remove the cover of
Hint!
the shaft seal, including the stationary gasket
inserted in it. In case of the use of high-voltage
motors: the operating manual of the
2. Removal of the seal package arranged on the
manufacturer is to be followed, espe-
shaft with the associated slide ring by hand or, if
cially regarding any anti-condensation
tightly seated, extraction by means of an appli-
heater required.
ance. If the seating is loose, the seal package
may adhere to the stationary seal and will be • Free-standing motor and main flow shafts have
pulled out when removing the cover. been conserved.
3. Clean the shaft seat with a lint-free cloth. Grease • The space on the screw compressor for the shaft
it lightly and push the sealing package back onto seal has been greased.
the shaft again.
• The connections on the oil cooler water side
4. After pushing onto the shaft, the seal package have been sealed.
must be manually compressed against the spring
pressure which acts on it. At the same time, it The following maintenance work must be carried out
must be checked whether the gasket springs out at the storage location during storage:
again. 1. Visual inspection of the general condition of the
5. Then re-fit the cover of the shaft seal. screw compressor package.
2. Cyclical rotation of the screw compressor shaft
Warning!
(about 10 revolutions per month and the com-
Danger of cuts and crushing injuries. pressor drive motor (see operating manual).
6. If storage is longer than 26 weeks, all O-rings Hint!

must be renewed. Does not apply to sliding bearing com-
pressor drive motors.
5.5 Storage (several years) 3. Check the transport fill pressure with a pressure
gauge at the connection of item 405 (see P+I
Hint! flow chart). If this value < 1 bar, replenish dried
gas via the valve of item 85 (see P+I flow chat).
The instructions in the "Transport, All valves are already opened at the factory for a
storage" chapter must be heeded. common pressure range.
The following storage conditions must be maintained
when storing screw compressor packages that are
equipped with a control.
1. Storage temperature > 10°C

Caution!
After completion of the storage period
and prior to re-delivery, a general
review in the factory or a general
examination at the storage location,
performed by the technical customer
service technician of GEA Refrigera-
tion Germany GmbH, is recommended.
Please pay attention to the information
in the "Start-up" chapter.
The general check includes changing
the O-ring on the compressor shaft
seal as well as replacing the shaft seal
of the oil pump.

Installation Operating Manual | GEA Grasso M-Series
6 INSTALLATION
misalignment ≤ 0.25 mm) at the coupling is attained
again. Then tighten the foundation bolts.
6.1 Basic information for installation
Caution!
6.3 Anti-vibration mounting
During the installation, make sure that
substances escaping from leaks do The frame of the screw compressor unit must be
not reach into the soil, groundwater or aligned with the levelling bolts until the coarse align-
surface water. The applicable legal ment (radial and angular misalignment (radial and
regulations must be heeded at the angle offset ≤ 0.25 mm) at the coupling is attained
place of installation (e.g.for Germany: again.
German Federal Water Act WHG). Before tightening the foundation bolts of the isola-
tors, check that the isolators over the spring (pre-
All foundation calculations, the selection of materials dominantly made of rubber) are free and do not lie
and the soil analysis are the designer's or owner’s on the foundation.
responsibility.
A plan must be produced for proper and professional
assembly prior to the installation. The electrical and 6.4 Electrical connection
operating media connections must be established. It
must be borne in mind that, in addition to the installa- Danger!
tion area of the screw compressor package, there
Contact with live components is pro-
must be sufficient space available for the pipes as
hibited.
well as for operating during maintenance activities.
Produce the earth connection accord-
Install the screw compressor package on a level sur-
ing to the designation in the general
face. The difference from the horizontal must not be
assembly drawing. See chapter "Des-
more than 0.3 %. Provide enough space for mainte-
ignation of the earth connection".
nance work.
Under normal conditions, the screw compressor Before starting work, make sure that all parts to be
package stands solidly on the installation surface connected are de-energised, e.g. by removing the
due to its own dead weight. We recommend that you main fuse in all phases or installing a jumper wire.
provide ribbed rubber plates for shock absorption The insulation resistance of the electrical tools and
between the support surface and screw compressor fixtures and wiring is to be checked. The connection
package feet or machine base frame. may only be undertaken if this value lies in the allow-
If greater damping is required (installation on a floor able range.
ceiling or on the roof), vibration dampers must be All electrical connections must be established and all
provided. The appropriate type of vibration damper electrical consumers/sensors must be connected
must be determined and realised for this case. Also according to the circuit diagram.
decouple the secondary refrigerant lines using com-
pensators when vibration absorbers are used.
The welding seams must be inspected in accordance
with the Pressure Equipment Directive after welding
work by the customer or operator on pipe line con-
nections and flanges.
6.2 Rigid installation

The frame of the screw compressor unit/ liquid chiller
is placed on foundation bolts on a prepared founda-
tion. The frame must be levelled with suitable shims
such that the coarse alignment (radial and angular

Operating Manual | GEA Grasso M-Series Installation
6.4.1 Use in explosive atmospheres, The manufacturer will not accept liability for damage
installation zones 1 und 2 due to incorrect outdoor installation.
Danger!
The same regulations apply to the 6.6 Information regarding noise emis-
operating instructions for screw com- sions
pressor packages in potentially explo-
sive atmospheres as described in the The noise information provides approximate parame-
respective applicable operating man- ters and apply to the installation without any secon-
ual. dary noise protection measures.
In addition to this, the following exten- The information has a tolerance of ±3 dB.
sions apply: The precise data depend closely on the emission
values for the motors, which are manufacturer
1. The relevant electrical engineering
dependent.
regulations for installations in
potentially explosive atmos- Should local conditions require adherence to noise
pheres , especially EN 60079-10, levels, a calculation should be made using the spe-
apply to the installation and con- cific motor data in individual cases.
nection of electrical components. Sound insulation measures, such as motor encapsu-
Relevant prescribed cabling mate- lation or complete package encapsulation can ach-
rial must be used. ieve a significant reduction in sound level.
2. The whole screw compressor Wearing hearing protection with sufficient noise
package must be earthed by the reduction is recommended in rooms with running
owner operator. screw compressor packages.
Caution!
According to EU Directive 2003/10/EC,
6.5 Sound insulation, weather protec- the allowable exposure limit value
tion regarding the daily noise exposure
level is 80 db(A). In the event of noise
If the screw compressor package is intended for out- levels above this limit value the sys-
door installation, it must be provided with a suitable tem operator must provide the opera-
housing for sound insulation and weather protection tor with information on exposure to
by the customer. The weather protection must pro- noise and personal hearing protection
vide the machine with adequate protection against and ensure that this is also worn
the climatic conditions at the installation location. (2003/10/EC Article 6).
Hint!
The screw compressor package is not
intended for unprotected outdoor
installation. Protection against exter-
nal influences, especially dirt, dust
and moisture (wetness), is essential.

Installation Operating Manual | GEA Grasso M-Series
Sound power level LWA in dB(A)
Compressor type/theoretical throughput volume in m3/h at 4500 RPM

Compressor drive motor
output in kW H L M N
721 833 1056 1316
Max 103 103 103 103

55
Min 96 96 96 96
Max 104 104 104 104

75
Min 97 97 97 97
Max 105 105 105 105

90
Min 98 98 98 98
Max 106 106 106 106

110
Min 99 99 99 99
Max 107 107 107 107

132
Min 100 100 100 100
Max 108 108 108 108

160
Min 101 101 101 101
Max 109 109 109 109

200
Min 102 102 102 102
Max 110 110

250
Min 103 103
Max 111
315
Min 103

Operating Manual | GEA Grasso M-Series Description of Design and Function
7 DESCRIPTION OF DESIGN AND FUNCTION
7.1 Installation in explosive atmospheres, installation zones 1 und 2

Danger!
The same functional and design characteristics apply to the maintenance instructions for the
use of SCPs in potentially explosive atmospheres as described in the respective applicable
operating manual.
In addition to this, the following extensions apply:
1. All components relevant for the use of SCPs in relation to their use in potentially explosive
atmospheres (concerns both electrical and non-electrical components) are separately
designed and documented – see product description!
2. Extension to the method of working
The use of SCPs is extended to use in potentially explosive atmospheres, including the
compression of process gases (only compression for the purposes of pressure increase).
The SCPs are not suitable for pumping potentially explosive mixtures. This means, when
the compressor is in intake condition, the pumped liquid must not contain any oxygen.
The intake condition always refers to pressure layers in the overpressure range.
The owner operator and the system builder must use monitoring devices reflecting the
respective state of the art standards, to positively monitor and ensure this effect.
3. Safety equipment extension
If oil heaters are used in potentially explosive atmospheres (see also component specifi-
cations in the product description) additional, separate oil level monitoring is absolutely
necessary to ensure a minimum oil level above the heating elements. To this end, a sepa-
rate oil level switch is used in each use case according to the necessary explosion protec-
tion specifications – see also the component specifications in the product description.

Description of Design and Function Operating Manual | GEA Grasso M-Series
7.2 Product code of screw compressor packages - Grasso SP1, SP2, SPduo and M Ser-
ies
Model size screw compressor package

X The ND screw compressor will be provided for the screw compressor packages in the Grasso
SP2 series (two-stage).
Y Versions of the screw compressor package
9 Screw compressor version variations
A Oil cooling
Screw compressor size HP side

(X1)
Only for screw compressor packages in the Grasso SP2 series (two-stage).
X / (X1) Screw compressor package size
Code letter Theoretical volume flow Code letter Theoretical volume flow
at 2940 min-1 in m³/h at 2940 min-1 in m³/h
C 231 T 1460
D 265 V 1740
E 321 W 1940
G 372 Y 2390
H 471 Z 2748

Code letter Theoretical volume flow Code letter Theoretical volume flow
at 2940 min-1 in m³/h at 2940 min-1 in m³/h
L 544 XA 3250
M 690 / 708 XB 4150
N 860 / 870 XC 4900
P 805 XD 5800
R 1040 XE 7170
S 1290 XF 8560
* Grasso M Series
Y Screw compressor package version
Refrigerant CO2 and

Design type Refrigerant Refrigerant HFC
R290 and Special
Screw compressor package NH3 R22 Refrigerant
R600a media
Horizontal oil separator installed below A H R F O
Oil separator installed vertically B K S G P
Oil separator horizontally in series C L T
Grasso SPduo/ mechanical suspension D M V Y W
Grasso SP2 (two-phase) E N U
9 Screw compressor versions
1 Standard refrigerating compressor Vi = 1.8; 2.0; 2.2; 2.6; 3.0
2 Standard refrigerating compressor Vi = 3.6
5 Standard refrigerating compressor Vi = variable
6 Booster Vi = fixed
7 Heat pump compressor Vi = fixed or variable

8 -- --
9 Speed regulated Vi = variable
A Oil cooling
Code letter Oil cooling
A Water-cooled oil cooler
B Refrigerant cooled oil cooler
C Refrigerant injection
D Water and refrigerant cooled oil cooler
E Water or refrigerant cooled oil cooler and refrigerant injection
F Without oil cooler
Examples of designation
XA B - 6 A Singe stage screw compressor package Grasso SP1 with screw compressor 3250 m³/h
(XA), refrigerant NH3 and vertically installed oil separator (B), booster with fixed internal vol-
ume ratio (6)with oil fine separation and water-cooled oil cooler (A)
TA-2A Singe stage screw compressor package Grasso SP1 or SSP1 with screw compressor 1460
m³/h (T), refrigerant NH3 and horizontally installed oil separator (A), fixed internal volume
ratio Vi = 3.6 (2) with oil fine separation and water-cooled oil cooler (A)
NA-3B Screw compressor package Grasso M with screw compressor 873 m³/h (N), refrigerant NH3
and horizontally installed oil separator (A), fixed internal volume ratio Vi = 4.8 (3)with oil fine
separation and refrigerant-cooled oil cooler (A)
LD - 2 A Screw compressor package Grasso SPduo with 2 of screw compressors 544 m³/h (L),
refrigerant NH3 and DuoPack version or multiple configuration (D), fixed internal volume
ratio Vi = 3.6 (2) with oil fine separation and water-cooled oil cooler (A)
W E - 6 A (L) Two-stage screw compressor package with LP screw compressor 1940 m³/h (W), refriger-
ant NH3 two-stage package (E), LP-compressor as booster (6), with oil fine separation and
water-cooled oil cooler (A), HP-compressor 544 m³/h (L)
– list of parameters,
7.3 Technical specifications – general assembly drawing,
Packages / chillers are designed and manufactured – P+I diagram.
for special fields of application. For technical specifi-
cations see the following.
– order specification,

7.4 Location of the product identification

(name plate) Weight without fill- Weight of the screw compres-
ing: sor package when empty
The type plate contains the most important technical
data pertaining to the product. This data and the con- Refrigerant: Information regarding the
tractual agreements define the limits of designated refrigerant used
use.
As standard, the type plate is fixed to the oil separa- Max. operating Information regarding the
tor (deviations of the location are possible). pressure: max. operating pressure
Information regarding the vol-

Volume flow:
ume flow
The default languages are English and German
fig.6: Location of the product identification (type plate)
fig.7: Type plate
GEA Refrigeration Contact data of the manufac-

Germany GmbH turer
Type: Type designation of the screw

compressor package
Serial no.: Serial number of the screw

compressor package
Year of construc- Year of construction of the

tion: screw compressor package

7.5 Information and safety labels on the 7.5.2 Label of the safety valve
product
(safety labels)
Danger!
The safety-related labels on the pack-
age/chiller must be followed!
fig.9: Label of the safety valve
7.5.1 Labelling of the pressure and

temperature sensors, heater Importance of the labels
The safety valve must be connected to a blow-off
(safety labels) line.
7.5.3 Labels of the screwed connec-

tions with DiNova ring
(handling instructions)
fig.8: Safety labels of the pressure and temperature sensors,

heater
Importance of the labels:

Before replacing pressure and temperature sensors
without dip tube, it must be ensured that the pipes
into which the sensors are mounted are not pressur-
ised. The pressure-free state can be achieved by fig.10: Labels of the screwed connections
closing the shut-off valves before the sensor to be
replaced.
The informative label for all screwed connections
Before replacing oil heater it must be ensured that with DiNova ring (handling instructions) is attached
the oil separator into which the oil heater is screwed to the electric motor in a clearly visible manner.
in is not pressurised.
Importance of the labels:
Hint! If any leakage occurs at a screwed connection
Not applicable to oil heaters of the (escaping gases or vapours), the screwed connec-
HLP type series. tion must be tightened:
Counter-hold the screwed pipe connection using
a wrench. Tighten the pipe nut about 1/4 to 1/3
rotation beyond the point where the increase in
the force if felt.
® The leakage is remedied.

7.5.4 Labels of the pipelines 7.5.5 Marking the direction of rotation

of the compressor drive motor
(information plate)
Pipelines in refrigeration plants must be labelled as (information plate)
follows (DIN 2405):
– Refrigerant
– Direction of flow
– State of phase
fig.11: Labels of the pipelines
1 Arrow head (indication of the direction of flow)

2 Horizontal stripe (indication of the state of fig.12: Marking the direction of rotation of the compressor drive
phase), green = liquid // blue = gaseous cold // motor
red = gaseous hot
3 Information field (label of the refrigerant)
The direction of arrow indicates the direction of rota-
tion of the compressor drive motor
7.5.6 Marking the direction of rotation

of the oil pump motor
(information plate)
fig.13: Marking the direction of rotation of the oil pump motor
The direction of arrow indicates the direction of rota-

tion of the oil pump motor

7.5.7 Labels of the pressure gauge 7.5.8 Labeling of the control / control
cabinet
(information plate)
(information plate)
• Label on the rear side of the control unit of the
control system (visible after opening the switch-
ing cabinet):
– Project name
– Make number of the package/chiller
– MPI address
• Label on the inside of the switching cabinet:
– Test verification for the control system
fig.14: Labels of the pressure gauge
1 Description of the pressure gauge measuring

point
The description of the pressure gauge measuring

point is attached directly underneath the pressure
gauge. The gauge board can be arranged horizon-
tally as well as vertically.
fig.15: Test verification for the control system

7.5.9 Designation of the earth connec- See general assembly drawing for the position of the
tion earth connections.
Safety labels Hint!

The cross-section of the ground wire
must be at least 10 mm². Alternatively,
two separately installed and separately
connected ground wire must be used,
ensuring the minimum cross-section
in the sum.
fig.16: Designation of the earth connection
Importance of the labels

Ensure that the product is properly grounded before
start-up. Connect the earth connection. The neces-
sary mounting hardware and cables are not included
in scope of supply.
7.6 Process flow diagram
fig.17: Process flow diagram Grasso SP1, M-series
1 Suction side
2 Compressor
3 Oil separator
4 Pressure side

7.7 Main components

Screw compressor packages within the Grasso M-series series consist of the following main assemblies and
components:
Hint!
The documentation of
the main components is
part of the product docu-
mentation (see product
description or operating
manuals of the supplier,
e.g. for the compressor
drive motor).
fig.18: Main components of the GEA Grasso M-Series
10 Screw compressor See installation instructions for the screw com-

pressor
15 Compressor drive motor See operating manual of the compressor drive

motor
20 Oil separator See component documentation
25 OMC block (possible as separate oil filter for greater amounts of oil) See component documentation
30 * Oil cooler See component documentation
40 * Oil pump (possible as an external oil pump for booster) See component documentation
45 ** Suction filter See component documentation
55 ** Check valve - suction side See component documentation
60 Check valve - pressure side See component documentation
95 Coupling housing See component documentation
180 Controller See control unit documentation
360 * Oil heater See component documentation
Safety devices See component documentation

* not shown in the picture

** integrated into the screw compressor
7.7.2 Compressor drive motor
7.7.1 Screw compressor
fig.20: GEA Grasso M-Series, arrangement of the compressor

drive motor
fig.19: GEA Grasso M-Series, arrangement of the SCP
Standard: The compressors are driven via a cou-
The screw compressors are characterised by a com- pling by means of an air-cooled 2-pole IP23 electric
pact design, high reliability, high quality components motor with an operating voltage of 400 V; 50 Hz.
and ease of maintenance. Option: Other protection classes, operating voltages
Screw compressors are dual rotor positive displace- and frequencies as well as speed-controlled motors
ment machines that run according to the displace- are available on request.
ment principle and operate by oil injection.
Hint!
Screw compressors are operated with refrigerant
(standard: ammonia NH3, other refrigerants upon The documentation of the electric
request). For the refrigerant, refrigerating machine oil motor (operating manual) is an integral
is chosen in accordance with lubricating oil informa- part of the product documentation.
tion for screw compressors.
Various series and sizes of screw compressors are
available for different fields of application.
The screw compressors are driven directly by the
compressor drive motor via a flexible coupling.
Hint!
The documentation of the screw com-
pressor (installation instructions, part
lists, drawings) is an integral product
documentation.

7.7.3 Compressor with coupling hous- 7.7.4 Oil separator

ing
fig.22: GEA Grasso M-Series, arrangement of the oil separator

fig.21: GEA Grasso M-Series, arrangement of the coupling
housing The design of the oil separators is standardised and
features reduced oil carry-over and low oil consump-
The coupling housing contains the coupling and is tion.
used for the attachment of the compressor drive The oil separator is installed horizontally.
motor. The elastic design of the coupling brings
about the neutralisation of otherwise disturbing influ- Hint!
ences such as axial or radial forces, vibrations or off-
The documentation of the oil separator
set.
(operating and maintenance instruc-
Speed fluctuations and speed shocks are damped tion, acceptance certificate) is a inte-
and cushioned, torsional vibrations are reduced. gral part of the product documenta-
tion.
Hint!
The documentation of the coupling is Oil heater
a part of the product documentation.
Electric oil heaters are built into the oil separator to
heat the oil refrigerant mixture in the oil separator
during the standstill of the screw compressor pack-
age. The oil heater prevents condensation of the
refrigerant into the oil and, thus, any foaming of the
oil during start-up.
Oil heaters are equipped with:
– Temperature controller for protection against
overheating
(Switching temperature 110°C)
– Temperature limiter in case of faults, e.g. pro-
tection against dry running
(permanently set to 150°C)
The oil heater is switched on when the screw com-
pressor package is stopped and is switched off auto-
matically on starting. A manual switch-off for long
standstill periods is recommended.

7.7.6 Oil cooler

Hint!
The documentation of the oil heater
(operating and maintenance instruc-
tion, acceptance certificate) is a part of
the product documentation.
7.7.5 OMC block with oil filter system
fig.24: GEA Grasso M-Series, arrangement of the oil cooler
The oil cooler is used for cooling the oil heated in the
compressor in order to ensure sufficient oil viscosity
for supplying to the compressor.
Hint!
The documentation of the oil cooler
fig.23: GEA Grasso M-Series, arrangement of the OMC block (operating manual, acceptance certifi-
with oil filter system cate) is an integral part of the product
documentation.
The OMC block contains the oil distributor system in
the oil circuit. Necessary control and shutoff fittings
are integrated in the OMC-block. Connections for
7.7.7 Oil pump (optional)
temperature and pressure sensors as well as service
ports are present. The OMC block is combined with Special design for minor pressure differences
a standardised filter system and oil pump unit and (booster)
forms the central control and regulation unit within
the oil circuit.
Optionally, the OMC-block can be equipped with a 3-
way valve element (for ensuring a minimum oil tem-
perature when starting the compressor).
Hint!
The documentation for the OMC block
(operating manual, acceptance certifi-
cate) is an integral part of the product
documentation.

7.7.8 Suction filter - check valve com-

bination
fig.25: GEA Grasso M-Series, arrangement of the (optional) oil

pump
The oil pump is an important component of the oil

circuit. It is used for pumping and distributing refrig-
erating machine oil.
fig.26: GEA Grasso M-Series, suction filter - check valve com-
The oil pump ensures that the oil is distributed to the bination
individual lubrication points (e.g. journal bearing, bal-
ance piston and packing gland of the compressor).
The suction filter - check valve combination contrib-
Hint! utes substantially to the high working reliability of the
components and the overall product.
The documentation of the oil pump
(operating manual, acceptance certifi- The suction filter - check valve combination prevents
cate) is an integral part of the product dirt particles carried by the suction flow from entering
documentation. into the screw compressor.
Hint!
The documentation of suction filter -
check valve combination is an integral
part of the compressor documenta-
tion.

7.7.9 Controller • Non-volatile saving of program

• Possibility of communication with master control-
ler via MPI
(optionally via Profibus-DP, Modbus RTU or
Modbus TCP)
Hint!
The documentation of the controller
(operating manual, circuit diagram,
parameter list, communication guide-
line) forms part of the product docu-
mentation.
7.7.10 Fittings
The term fitting generally designates a control ele-
fig.27: GEA Grasso M-Series, arrangement of the controller ment of the machine. Among other things, the term
fitting is also used for valves if these are used for the
The screw compressor package is equipped with a control and regulation of fluid flows in the piping.
GEA Omni™-type controller. Furthermore, all kinds of installations in piping, such
The GEA Omni consists of the control unit with oper- as sight glasses, measurement apertures, filters and
ator keypad and display unit, indicator lights for similar are also designated as fittings. Therefore, fit-
"Running", "Warning" and "Alarm", the emergency tings also include all kinds of valves, such as:
stop button, the output relays and the casing. – Stop valves
The GEA Omni is mounted directly on the package
– Check valves
as standard. As an option, the GEA Omni can be
installed in a control centre. – Safety valves
The GEA Omni performs the following functions – Throttle valves
as standard: Each fitting has its own field of use, according to the
• Display of all important physical and technical pressure or temperature in the pipe, the size of the
parameters, e.g. Pressure, temperature, motor pipe, the sealing requirements for the fitting, the
current, capacity, number of operating hours, reduction and direction of the flow of liquid as well as
operating mode and status signals the medium itself.
The safety fittings are used to limit the pressure in
• Automatic start up and shut down of the screw
systems which are under pressure.
compressor package and capacity control
dependent on the suction pressure or an exter- Each fitting is designed for the specific application.
nal temperature, The fittings can be operated manually or by motor,by
gear motors, or pneumatic or hydraulic cylinders, for
• Monitoring of all operating parameters example. In reset fittings, the flow of fluid in the pipe
• Compressor capacity limitation, in case the causes automatic closing of the valve.
measured discharge pressure, suction pressure, Depending on the model, different closing elements
secondary refrigerant temperature or motor cur- (e.g.valve discs, flaps, pushers) close the pipe con-
rent indicate overload nected to the fitting.
• Fault memory with date and time Hint!
• Wire failure detection for all analogue input sig- The documentation of the fittings
nals (acceptance certificates) forms part of
• Password protection for preventing unauthorised the product documentation.
access to important parameters

7.7.11 Safety devices Safety device to prevent the discharge tempera-

ture from being exceeded (resistance thermome-
The following safety devices are fitted onto the SCPs
ter 120)
of the GEA Grasso M-series type series:
The compressor control system switches off the
Drive motor safety devices screw compressor package when the specified limit
Rated current limitation (016) value has been exceeded.
The rated current limitation is realised by the com- Limit value = see parameter list
pressor control system: When the rated motor cur-
Safety device to prevent the oil temperature from
rent is exceeded, the control slide of the compressor
being exceeded (resistance thermometer 125)
is driven in the MIN direction until the motor current
reaches a permissible level. The normal output con- The compressor control system switches off the
trol then comes back into force. screw compressor package when the specified limit
value has been exceeded.
Thermistor (017)
Limit value = see parameter list
The thermistor shuts down the compressor drive
motor when the temperature of the compressor drive The minimum oil viscosity for safe compressor oper-
motor windings exceeds the allowable value. ation is ≥ 7 cSt. In case of oils that are soluble in
refrigerant, the minimum oil viscosity is to be
Pressure-controlled check valve integrated into ensured depending on the discharge pressure and
the compressor (055) temperature, oil temperature, as well as the type of
The check valve function prevents pressure equali- oil.
sation with the LP side of the plant and simultaneous
Overflow valve (340)
prevents a reverse rotation of the screw compressor.
The overflow valve protects the compressor against
Check valve - pressure side (060) impermissible high pressure. The overflow valve
The pressure side check valve prevents refrigerant (provided that delivered unassembled) must be con-
from re-condensing in the oil separator. nected with the suction pipe on site.
Oil pressure regulating valve (075) Triggering pressure = see parameter list and P+I
flow chart
The oil pressure control valve regulates the differen-
tial pressure between the oil pump discharge side The overflow valve is designed in accordance with
and the discharge pressure of the package. The oil DIN EN 13136 "Refrigerating systems and heat
pressure control valve is integrated into the OMC- pumps - pressure relief devices and associated pip-
block (oil management centre). ing - methods for calculation".
Safety device to prevent the discharge pressure Warning!

from being exceeded If not fitted on delivery, the overflow
(pressure transducer 105) valve must be connected to the suc-
The compressor control system switches off the tion side when installing the SCP in
screw compressor package when the specified limit the refrigeration plant!
value has been exceeded.
Limit value = see parameter list Safety valve (345) on the oil separator
The safety valve protects the screw compressor
Safety device to prevent the differential pressure
package against impermissible high pressure.
between the oil pressure after oil pump (pressure
transducer 110) and the discharge pressure Triggering pressure = see parameter list and P+I
(pressure transducer 105) oil circuit monitoring flow chart
from falling too low If the screw compressor package is installed into a
The compressor control system switches off the refrigeration system comprising an emergency blow-
screw compressor package when the pressure differ- off station, only the oil separator connection is used.
ence between oil pressure after oil pump and dis- The valve is available as an option, depending on
charge pressure falls below the specified limit value the required acceptance.
after a delay period.

The safety valve is designed in accordance with DIN – Oil pressure after oil filter - optional -
EN 13136 "Refrigerating systems and heat pumps -
pressure relief devices and associated piping - meth- – Differential pressure of oil pressure after oil filter
ods for calculation". and discharge pressure (oil filter monitoring) -
optional -
Safety pressure limiter (350)
Safety pressure limiter with two separate trigger con-
tacts, one of which can only be reset using a tool. 7.7.13 Components installed by the cli-
The safety pressure limiter switches off the compres- ent
sor drive motor if the discharge pressure rises above
the set point. Warning!
Switching off pressure 1 = see parameter list The components and parts the cus-
Switching off pressure 2 = see parameter list tomer installs in particular the secon-
If it cannot be ruled out that the liquid refrigerant dary refrigerant and cooling medium
might attain more than 90% of the oil separator’s vol- circuits as well as the oil circuit need
ume, then the customer must install an additional to made from materials suitable for the
safety valve to prevent expansion of the liquid in the fluids flowing through them. Further-
oil separator (design in accordance with DIN EN more, in the event of modifications to
13136, arranged according to EN 378-2 Annex F). the product by the customer, the
effects on the safety devices are to be
checked.
7.7.12 Monitoring devices GEA Refrigeration Germany GmbH
does not assume any liability for dam-
The following operating values will be continually age arising and the violation of the
monitored in a standard screw compressor package: safety regulations which result from
– Suction pressure the use of unsuitable materials or
through modification to the product
– Discharge pressure which is not considered in the original
– Oil pressure oil circuit monitoring safety concept.
– Suction temperature
– Discharge temperature
7.8 General functional description
– Oil temperature
Screw compressor packages are refrigeration sys-
– absolute primary slide position tem components and serve to compress refrigerants
– Motor current such as ammonia (or other operating media on
request).
– Suction pressure saturation temperature
Operation as a heat pump is also possible.
– Saturation temperature
of condensing pressure
– Number of running hours 7.9 Refrigerant circuit
– Difference between oil and discharge pressures The screw compressor draws in refrigerant vapour
(oil circuit monitoring) via the suction check valve and suction filter and
then discharges the compressed vapour into the
– Set point of controled value in °C plant via the oil separator and discharge check valve.
– Real point of controled value in °C The suction-side check valve prevents a sudden
– Internal volume ratio pressure equalisation with the low pressure side of
the chiller, while also preventing reverse rotation of
– Used refrigerant the screw compressor.
– Controled value The pressure side check valve prevents refrigerant
from re-condensing in the oil separator.
– Used options

Hint! not regulated. The maximum temperature of the

heating rod is restricted.
The discharge check valve can be inte-
grated into the oil separator for screw
compressor packages with discharge 7.10.3 Oil cooling
side nominal diameters up to NB 150.
Before it is returned to the compressor for use, the
The suction filter prevents dirt particles carried by the oil heated up in the compressor has to be cooled
suction flow from penetrating into the compressor. down to a temperature at which it has sufficient vis-
The filter element is characterized by a very large fil- cosity.
tering area. The filter fineness is 140 μm.
The following oil coolers are available:
Gas vibrations which can arise in the pressure cham-
ber of compressors under high pressure conditions 1. liquid-cooled (non corrosive media)
in the range of zero delivery are prevented by a gas – water (non corrosive)
vibration protection system. This comprises a pres-
sure compensation line between the oil separator – propylene glycol (25%)
and the working chamber of the compressor. – ethylene glycol (35%)
– Other refrigerants on request
7.10 Oil System 2. Thermosiphon
The screw compressors operate oil-flooded. During 3. Refrigerant injection

the compression process, refrigerating machine oil is
supplied to the compressor for lubrication, sealing,
noise reduction, and absorption of part of the com- 7.10.4 Oil filter
pression heat. After the compression process, the oil
After cooling, the oil enters the oil filter which retains
is separated again from the refrigerant in the oil sep-
solid particles from the entire oil flow.
arator.
Due to its large surface, the star-folded glass fibre
element has a high absorbing capacity and thus a
7.10.1 Oil separation long operating lifetime. The filter has a relative filter
fineness of 25 µm.
The refrigerant-oil mixture is led into the first part of
oil separator. The first part of the oil separator con-
sists of two chambers. The first chamber employs 7.10.5 Oil pump
gravity separation. The hot gas passes the demister
while flowing out of the first chamber into the second The oil pump runs for pre- and during compressor
chamber. The oil separated thereby is collected in operation.
the second chamber. Both the chambers of the first It draws the refrigeration compressor oil from the
part of oil separator simultaneously serve as oil receiver space in the oil separator, through the the
receivers. oil cooler and oil filter and pumps it to the bearings,
In the second part of the oil separator, the fine sepa- the balance piston, the shaft seal, to the capacity
ration of the aerosol oil portion from the refrigerant is control system and, if fitted, to the compressor's
performed by means of replaceable fine oil separa- hydraulic Vi adjustment system.
tion cartridges. The oil separated in the fine separa- The oil pump pumps more oil than the compressor
tion part of the oil separator is returned to the com- uses. This surplus quantity of oil is returned to pump
pressor via an additional orifice. suction via the spring loaded oil pressure regulating
valve. The oil pressure regulating valve regulates a
pressure difference between the oil pump discharge
7.10.2 Oil heater side and the unit final pressure (according to the
value in the P+I diagram).
The oil heater on the oil separator is to be started
when the package is shut down in order to ensure a
minimum oil temperature and sufficient oil viscosity
required for restarting the package. The oil heating is

7.10.6 Oil injection 7.12.1 Designed for use in explosive

atmospheres!
The injection oil is fed without a pump via the oil
injection regulating valve. Danger!
The oil injection control valve is used to adjust the
When operating the screw compressor
necessary compression discharge temperature.
package in explosive atmospheres, the
The control valve is provided with a check function to special safety instructions for use in
prevent sucking refrigerant through the oil pump. explosive atmospheres that are men-
tioned in this operating manual must
be heeded.
7.10.7 Oil circuit, OMC block
Hint!
An OMC-block (oil management block) is flanged on
to the oil filter as an oil distributor system. The oil The screw compressor packages can
flow is distributed via the bore-holes and channels to basically be used in explosive atmos-
functional ranges of the screw compressor. All regu- pheres.
lating valves and shut-off valves necessary for the
Some specifics must be heeded when using the
regulation of the oil circuit are integrated into the
screw compressor packages in explosive atmos-
block. As a result, a centralised control unit is availa-
pheres of installation zones 1 and 2.
ble for the screw compressor package.
The basis for use in explosive atmospheres is the
The oil filter with OMC-block (oil management block)
following data of the operator:
is fitted with an oil drain and refilling stop valve which
may be connected to a separate oil pump or – Zone division as per EN 60079-10 (or other
receiver. equivalent international standards),
Vent valves are fitted to oil filters for maintenance – description of the atmosphere (required gas
and repair purposes. groups),
The oil in oil filter may be drained for changing oil fil-
– required temperature class.
ter via a separate stop valve.
This data is stored in the request sheet for project
055 100A. The 055 100A request sheet is part of the
product documentation.
7.11 Capacity control
For using and placing a screw compressor package
The screw compressors are fitted with a continuous into operation within the EU, the package is manu-
capacity control with a range of 10 -100%. factured ATEX-compliant (see component selection,
The capacity is adjusted by shortening the screw protection systems, regulations, etc.)
compressor stroke. The defining factor for the com- The following marginal parameters generally apply:
pression process is the effective rotor length; this is
altered by a hydraulically operated control slide. – The screw compressor packages can be instal-
led in Zones 1 and 2 in accordance with EN
The position of the control slide is recorded by the
60079-10.
position sensor. Upon reaching the MIN or MAX end
position, it is signalled to the control device and the – The max. achievable temperature class is T4.
relative control slide position can be displayed in per- – The screw compressor packages are not suita-
centage on the touch panel. ble for carrying explosive mixtures; the suction
The hydraulic adjustment of the control slide is real- pressure of the package is always in the over-
ised using solenoid valves, which are integrated into pressure range.
a single block.
The control slide travel speeds in the MIN and MAX
directions should, to the extent possible, be the
same during operation to ensure better compressor
control.
7.12 Technical specifications

7.12.2 Basic terms 7.12.3.2 Refrigeration machine oils
Refrigerant Materials circulating in a plant (liq- Caution!

uid or gas), which by means of In order to ensure an adequate load-
their change of state of the pack- bearing capacity of the sleeve bear-
age withdraw heat from another ings and to ensure the service life of
medium (cooling or heating agent) the roller bearings, a minimum viscos-
or can dissipate heat to this ity of 7cSt (=10-6 m²/s) upstream of the
medium. compressor is required. A suitable oil
must be carefully selected in consider-
Secondary Fluids that can absorb the heat of ation of the operating conditions.
refrigerant a system and dissipate it to a
The selection criteria and selection
refrigerant (reversible process)
tables are summarised in the technical
and are used for the cooling of a
information document entitled "Lubri-
system (industrial process)
cant oils for screw compressors". This
technical information forms part of the
Heating Media (liquid or air), which trans- product documentation.
agents port and emit the heat absorbed in
the secondary refrigerant. If water GEA Refrigeration Germany GmbH can
is used as the heat carrier, the provide assistance in the selection of
terms warm water or cooling water a suitable refrigeration machine oil on
are also used. request.
7.12.3.3 Secondary refrigerant

7.12.3 Operating media
• Low corrosion water
• Permitted brine levels: see Grasso Design Pro-
7.12.3.1 Refrigerant gram
The technical order specification defines the refriger- Hint!

ant used. All components of the screw compressor For other secondary refrigerants, com-
package are designed for use with the defined refrig- patibility with the materials used must
erant. be ensured.
Hint!
The safety data sheet for the refriger-
ant used must be observed. The safety 7.12.4 Operating limits
data sheet is part of the product docu- The screw compressors can be operated under the
mentation. most varied operating conditions within the given lim-
its of application according to the requirements
involved. The limits of application listed below for the
screw compressors are based on the operational
principle of the screw compressor and thermody-
namic ratios and are based on practical operating
conditions and design. The tabulated data apply for
single, two-stage and heat pump operation. Depend-
ing on the compressor the manufacturer selected,
the specific operating conditions limitations may
occur within the parameters in the table.

Hint! Caution!
For specific operations the selection To avoid "zero flow" in the compres-
and evaluation will take place within sor, which can damage the compres-
the manufacturer's compressor selec- sor, the minimum control slide posi-
tion programme. tion in the manufacturer's compressor
selection programme must be adhered
to.
"Minimal control slide position <value>
% accepted start."
If the value entered is "> 0", then a lim-
itation of the control slide path must
be put in place in coordination with the
manufacturer. The path limitation can
be set created mechanically with a
stop sleeve or by installing virtual con-
trols (virtual stop sleeve) on the com-
pressor.
≤28 bar
Maximum permitted pressure p bar g. max. or
≤52 bar
Pressure ratio p / p0 π - min. > 1.5
Pressure difference (p - p0) Δp bar min. > 0.8
Suction temperature t0 (compressor inlet) t0h °C min. > - 60
Discharge temperature (compressor outlet) te °C max. < 120
M/N *) M/N *)
Compressor frame size H L
28 bar 52 bar
50 Hz 300 300 300 530

max. Drive power (kW)
60 Hz 360 360 360 640
max. Nominal torque **) Nm 960 960 960 1700
max. permissible speed min-1 4500 4500 4500 4500
min. permissible speed min-1 1000 1000 1000 1000
*) For type M/N, the compressor drive shaft ends are different for 28 bar and 52 bar versions.
**) When running the compressor, the maximum torque falls by 25% as opposed to electrical drives.
Hint! 1. Compressors for a discharge pressure up to 52

bar (currently not available) are equipped with
All of the following requirements must
housings made of a material of higher strength
be observed!
and are fitted with special components.

2. Minimum suction overheating in compressor

p Maximum permitted pressure
inlet: "wet" operation is not possible.
p0 Suction pressure
3. For Δ p = p - po ≤ 2.9 bar an external oil pump to
Δp Pressure difference
be taken for compressor sizes H to N.
π Pressure ratio
4. For π ≥ 8 gas vibration protection is required.
t0h Suction temperature (compressor inlet)
5. For CO2 usage the use of a completely electri-
te Discharge temperature (compressor outlet)
fied oil pump for injection and function oil needs
to be checked in all types of compressors tc Condensing temperature
depending on the operating conditions; toil oil inlet temperature into the compressor
6. The discharge temperature te must be 10 K

above the condensing temperature (te ≥ tc + 10 Notes:
K). 1. During tests of a certain application case, all the
7. Due to the solubility of refrigerant in the oil fol- conditions specified in the table must be consid-
lowing applies: ered and adhered to.
• for Ammonia: 2. Should the given limits not be adhered to in indi-

vidual cases, then the manufacturer needs to be
te ≥ toil + 5 K; contacted.
te ≥ toil + 10 K,when using a PAG oil (solubil-
3. In addition to the application limits stated in the
ity of the refrigerant in the oil). tables, the applicable operating conditions of the
• For R22, R134a, R404A, R407C, R410A, compressor type in question must also be con-
R507, CO2, natural gas, carbohydrate mole- sidered (e. g. start-up regime, oil pressure, oil
cules: quantity etc.).
te ≥ toil + 10 K, wherein solubility of the 4. Depending on the refrigeration requirements,
refrigerant in the oil. economiser operation takes place at a control
slide position between 100% and approx. 70%
• To determine the permitted difference
control slide position.
between the discharge temperature (te)
and oil intake temperature (toil) the set 5. When using R134a as a refrigerant and a evap-
viscosity and the solubility diagram for orating temperature > 60 °C consultation with
the refrigerant-oil pair from the lubrica- the manufacturer must be made.
tion supplier need to be adhered to.
8. Ensure that the oil viscosity will be ≥7...70 cSt (=
7.12.5 Water quality requirements,
10-6 m²/s) for the oil supply to bearings. Take
parameters
into account the drop in viscosity due to refriger-
ant dissolved in the oil! All water bearing components from the manufacturer
9. Limits for temperature differences will be consid- deliver an optimum performance and provide maxi-
ered in compressor selection programs. mum protection from corrosion, provided you meet
all of the limiting values recommended in VDI 3803
10. The oil temperature at the compressor inlet must issue 2010-02 (Tab. B3) for non-corrosive water and
be at least 18°C, the oil must be preheated if adequate water conditioning.
necessary.
11. The rate of temperature change at compressor
suction side should not exceed 0,1 K/s.
12. Rotation direction: view of compressor’s driving
shaft clockwise.
13. For individual cases outside the permitted speed
coordination needs to made with the manufac-
turer.

Hint!
Water quality requirements, parameters
If you fail to adhere to the limiting val-
ues stated in VDI 3803, the manufac- Criterion Value Unit
turer cannot provide any warranty for
water carrying parts within its supplied Active biological
components. KBE < 10,000 per ml
components
Clarification as to whether or not it is
possible to adhere to these limiting Thickness factor EZ 2-4
values with the respective water condi-
tions should be agreed on with a spe- The use of carbon steel and cast iron is required in
cialist company during the planning the most of applications water conditioning with cor-
and design phase. rosion inhibitors.
The limiting values as per VDI 3803, as required for The use of stainless steel requires very special moni-
the use of carbon steel components in non corrosive toring of water in apply to Chloride contents (risk of
water systems, are listed below. stress crack and pitting corrosion).
Hint!
Water quality requirements, parameters
Recommend when using plate heat
Criterion Value Unit exchangers in the refrigerant circuit
< 100 ppm Cl while using steel 1.4301
Appearance clear, with- and
out sedi- maximum 40°C wall temperature in the
ment plate heat exchanger
< 200 ppm Cl while using steel 1.4401
Colour colourless and
maximum 100 °C wall temperature in
Odour none the plate heat exchanger
pH level at 20 °C 7.5 - 9.0
Electrical conductiv-
LF < 220 mS/m
ity
Ca2+,
Soil alkali < 0.5 mol/m³
Mg2+
General hardness,
GH < 20 °d
for stabilization
Carbonate hard-
ness without hard- KH <4 °d
ness stabilizer
fig.28: Corrosion resistance in presence of chlorides
X Chloride ion concentration in ppm Cl-

Chloride Cl < 150 g/m³
Y Wall temperature heat exchanger in °C
Sulphur SO4 < 325 g/m³ A AISI 304

B AISI 316
C SMO 254

Hint!
Manufacturer's recommendation: Use
uncontaminated secondary refriger-
ants and cooling media, in particular in
chillers and when using of plate heat
exchangers.
The media quality must be assured by
means of an appropriate filter on the
inlet to the heat exchanger. The mesh
for such a filter must be ≤ 0.9 mm!
Should the chiller be required to
remain in operation during filter clean-
ing, double filters must be used. Pres-
sure loss through the filter must be
taken into consideration on the build-
ing side when configuring the pump.
The manufacturer recommends enlisting the services

of a reputable water conditioning company.

Operating Manual | GEA Grasso M-Series Start-up
8 START-UP
The following points must be observed before
commencing with the start-up:
8.1 Important information for start-up
– Check of the external condition of the screw
Warning! compressor package (check of insulation, trans-
port damage... ).
Contact with live components is pro-
hibited. – The area around the machine in which the start-
up is carried out must be marked and secured
Hint! against the access of unauthorised persons. Suf-
The Customer Service department of ficient lighting of the working area must be
GEA Refrigeration Germany GmbH ensured to prevent personal injury and material
offer comprehensive support for start- damage.
ing up the screw compressor package. – Personal protection gear (work clothing, work
For contact details, please refer to the boots, gloves) must be worn during all work on
chapter entitled "Technical customer the screw compressor package. There is a dan-
service". ger of impact and stumblingfrom protruding parts
on the screw compressor package (e.g. valve
Warning! caps). There is also the danger of cut wounds on
The screw compressor package must sharp edges and rough surfaces. All activities
only be operated by suitably skilled must therefore be carried out with particular
personnel who are familiar with the attention.
contents of the operating manual for – Suitable hearing protection must be worn in
screw compressor packages. order to protect against damage to hearing or
The safety regulations for refrigeration deafness.
plants must always be observed in
– Thermal hazards resulting in injuries due to
order to prevent damage to the screw
compressor package and injury to the burns or freezing may occur on contact with
operating staff. parts of the system which are at a very high or
very low temperature. Personal protective equip-
The screw compressor packages are tested and ment must be worn.
accepted at the works. By the time these screw – Suitable tools or special tools must be used.
compressor packages are delivered to the cus-
tomer, the following work will have been carried – Check that all electrical work has been carried
out: out in accordance with the standards (e.g.protec-
tive earth, insulation, shielding, covers). If neces-
• Complete installation of the cooling system and sary, an earth connection must be provided.
in particular:
– Pipes and pipe sections must be secured to
– cleaning and drying the refrigerant and oil ensure sufficient mechanical strength. The pipes
circuits and equipment of the screw compressor pack-
– Leak test with air age must not be entered.
– Evacuation of the refrigerant circuit and filling – Operating media (nitrogen, oil, refrigerant) can
with protective gas (nitrogen) to a pressure escape. Preventive measures must be taken to
of 0.3 to 0.5 bar (above atmospheric) collect and dispose of them in an environmen-
tally responsible manner (e.g.using an oil pan).
• Electrical wiring and testing of the wiring
Personal breathing protection must be kept
• Factory setting for the parameters on the control ready in the event of a refrigerant leak. The
safety data sheets of the oil and refrigerant used
• Factory setting of the safety and monitoring devi-
must be read prior to commencing start-up work.
ces
Familiarise yourself with the evacuation plan of
• Works trial runs (at the request of the client) the installation location.

Start-up Operating Manual | GEA Grasso M-Series
– Danger! Check that components which have been removed

for transport, separately delivered components and
Solid mounting of the coupling protec- components provided by the customer are firmly
tion must be checked. Start-up must attached.
not be carried out with the coupling Check that all locating bolts are tight.
protection mounted.
– Check the protective gas filling (a positive pres-

sure ≥ 0.2 bar must be present) 8.3.1 Connecting the pipes
Hint! The nitrogen filling of the screw compressor package
must be purged by opening the vent valves before
If defects are found, notify GEA Refrig- the connection of the pipes.
eration Germany GmbH Service and
proceed according to their instruc- Establish all pipe connections so that the transmis-
tions. sion of thermal expansion and vibration to the screw
compressor package is limited as far as possible.
Bellows-type expansion joints made of steel, or flexi-
ble metal hoses can be used for refrigerant and oil
8.2 Basics lines, bellows-type expansion joints made from rub-
ber can be used for water connections.
The compressor must only be switched on if the
screw compressor package has been correctly con- Provide all pipe connections directly at the unit with
nected and filled with operating materials. fixed points.
The activities described in this "Start-up" chapter • Connection of:
must be carried out in the prescribed sequence.
– Suction line
The screw compressor package is operated via the
terminal of the control unit. – Pressure line
After the target values have been entered, both auto- – Oil cooler water connection
matic and manual operation are possible.
• If units are equipped with a safety valve: Con-
The software of the control device and operation via nect safety valve to the blow-off line.
the terminal are described separately in the operat-
ing manual for the control system. • Integrate relief valve in the suction line.
• if units are equipped with a refrigerant cooled oil
cooler:
8.3 Connecting the screw compressor
– Connect the refrigerant feed line from h.p.
package receiver (note geodetic height above oil
Caution! cooler).
All mechanical connections must be – Connect the evaporated refrigerant line to

made according to the R+I diagram the condenser
which is valid for the project. The R+I • If refrigerant injection is used: Connect the refrig-
diagram is part of the product docu- erant feed line from condenser or h.p. receiver
mentation.
• If an economiser is used: Connection the suction
Caution! line of the economiser to the charge connection.
All electrical connections must be

made according to the circuit diagram
which is valid for the project. The cir-
cuit diagram is part of the product
documentation.

Hint! – Compressor control supply
In principle, all the connections must – Oil heater

be made in accordance with the P+I – Oil pump
diagram applying to the respective
Some external components, such as the second
project. Attach the pipes to the screw
EMERGENCY STOP switch, the ammonia sensor
compressor package in such a way
and the fans of the machine room, must be connec-
that no additional static or dynamic
ted by the system erector on site.
loads are imposed.
All the pipes and systems to be con- Hint!
nected must be checked for leaks
Check that terminal screws (in the
when the work is complete.
switching cabinet) are tight.
8.3.2 Electrical connection 8.4 Paint and insulation

Danger! Damage to the paint and insulation during transport
Contact with live components is pro- and installation must be carefully repaired.
hibited.
The screw compressor package has been designed 8.5 Start-up procedure
for plug-in and reliable automatic operation.
All connections must be carried out according to the The following procedures should be completed in the
current installation regulations. sequence in which they are described:
Connections to the screw compressor package must
be flexible and free of loads.
8.5.1 Checking the electrical connec-
Hint! tion
Dimensioning of the inlet pipe cross-
Danger!
sections must be according to DIN
VDE 100 Part 520. Contact with live components is pro-
hibited.
Before starting work, make sure that all parts to be
connected are de-energised, e.g. by removing the Check that all electrical work has been carried out in
main fuse in all phases or installing a jumper wire. accordance with the standards (e.g.protective earth,
The insulation resistance of the electrical tools and insulation, shielding, covers). If necessary, an earth
fixtures and wiring is to be checked. The connection connection must be provided.
may only be undertaken if this value lies in the allow-
able range.
Connections and almost all external connections are 8.5.2 Leak test
pre-wired at the factory.
Hint!
Warning!
See type plate for permissible operat-
Produce the earth connection according pressure.
ing to the designation in the general
assembly drawing. See chapter "Des- The necessary safety precautions should be taken
ignation of the earth connection". before performing the leak test.
An approx. 3-hour pressure drop test with dry nitro-
The electrical consumers and sensor must be con- gen is used for the test. Test pressure: 7 bar
nected according to the circuit diagram. All electrical
A pressure drop of 2% is allowed during the 3 hours.
connections must be made according to the circuit
Fluctuations in the ambient temperature must be
diagram, e.g.
taken into account.
– Compressor drive motor

Caution!
Checking devices which could be
damaged by the specified test pres-
sure must be removed or blocked
before the leak test is performed.
A record should be kept of the pressure test, noting

the pressure in the pipes tested, the ambient temper-
ature and the outside temperature in the shade at
hourly intervals.
The removed measuring and control instruments
should be reinstalled after completion of the leak test
and if there are no leaks in the package/chiller.
Test strategy fig.29: Vacuum required to remove moisture from refrigerating
plants
Dry nitrogen is used as the test medium. After reach-
ing the test pressure, the pressure drop is measured X Room or Wall temperature in °C
via the differential pressure measurement. This may Y Vacuum in mbar
only change by 0.02 bar within an hour. If the display A Vacuum required to remove moisture from
device does not indicate a leakage through foam for- refrigerating plants
mation, the system is sealed.
Testing devices Measured values have to be checked and recorded
hourly after reaching the required vacuum. After the
A pressure gauge with an accuracy of 0.5% over the
vacuum pressure, the temperatures in the machine
entire measuring range, with a digital resolution of
house and the outdoor temperature in shade must
0.01 bar must be used for the measurement.
be entered in the log. After the vacuum test, the
The testing described here is based on pressure pressure compensation must be carried out with
gauges with pressure gauge and LEAK mode from NH3.
Keller.
Warning!
Display devices
A foaming agent must be used as the means to indi- Shut the oil pump during evacuation!
cate leakages. A solution of 50 parts water and 1
part detergent can be used as the foaming agent. See also "Evacuation on refrigerant side" in the
Leaks are detected through formation of foam. A chapter "Maintenance work".
leak detection spray can be used in problem areas.
Carrying out the test
1. Wet all connecting joints (welded seams, flange
connections, screw fastenings, etc.) with foaming
agent. Remedy any leaks detectable from the
noticeable formation of foam.
8.5.3 Drying, vacuum

After the leak tightness test has been completed, the
plant must be evacuated and undergo a vacuum test
for 3 hours. Evacuation is used to remove air and
moisture from the plant.
A vacuum pump must be used for evacuation.
The permissible increase in vacuum is maximum
6.66 mbar over a period of 3 hours.

8.5.4 Operating position of valves

For the positions of the manually controllable fittings for the operation of the package/chiller, see the P+I dia-
gram.
The layout and symbols used in the P+I diagram comply with the specifications of EN 1861, July 1998 Issue.
Caution!
The valves must be in operating position prior to the start-up of the package / chiller. Trouble-
free operation is only possible in this manner!
Stop valve open during normal operation
fig.30: Stop valve open
Stop valve closed during normal operation
fig.31: Stop valve closed
Check valve during normal operation
fig.32: Check valve
Shuttable check valve open during normal operation
fig.33: Shuttable check valve

Control valve adjusted:

– Start-up
– when operating conditions change
fig.34: Control valve
Shuttable check valve with integrated control function open dur-

ing normal operation
fig.35: Shuttable check valve
with integrated control function
Controlled by the controller (e.g. GEA Omni)
fig.36: Solenoid valve
Change-over valve (3-way valve), opened from below in arrow

direction
fig.37: Change-over valve
Operating position: shut

Δp x,x ± x bar control pressure to be set vis-à-vis reference pres-
sure (see P+I diagram)
fig.38: Oil pressure control valve
Caution!
An oil pressure being set too high or too low may result in serious compressor damage or
even the total breakdown of the compressor after just a short period of operation!

Overflow valve, safety valve
fig.39: Overflow valve, safety valve
controlled self-sufficient
fig.40: Pressure controlled check valve
manually operated if necessary
fig.41: Quick acting valve, spring-loaded
– ½” connections
– with cap
fig.42: Charging valve, drain valve
– Connection Rp ¼”
– For pressure gauge and pressure transmitter
fig.43: Service valve

controlled autonomously using control element
fig.44: Oil temperature limiter
Autonomous control via sensor
fig.45: Temperature controlled control valve
When charging with oil for the first time, oil must be
charged via the service valve (135) too. To this end,
8.5.5 Oil charge the stop valve (065) must then be closed.
Caution! While operating the package, the oil level must be
regularly checked (see chapter "Oil level check").
Check the oil grade to be charged! See
contract/project or recommendation of Caution!
GEA Refrigeration Germany GmbH. A
Due to the use of selected compo-
comprehensive overview of the allowa-
nents, the refrigerating machine oils
ble oil types is provided in "Technical
tend to absorb more moisture. There-
information on lubricating oils". This
fore, when charging a compressor the
technical information is part of the
oil should be allowed to come into
product documentation.
contact with air for a short time only.
For severely hygroscopic oils, the oil The contents of an opened drum have
container must be placed under a pro- to be used up within one working day,
tective atmosphere. provided the drum is properly closed
between charging.
The vacuum present in the screw compressor pack-
age before pressure compensation may be utilised
for charging the package with oil. A separate oil
charging pump is required after the pressure com- 8.5.5.1 Pressure compensation with
pensation and for refilling with oil. the cooling system
The connection of the oil draining or oil charging stop
valve (090) must be connected with the oil charging Re-establish the vacuum. Carry out pressure com-
container. pensation via the service stop valve (285).
Before charging with oil, switch the valves to the

operating position.
8.5.5.2 Checking the direction of rota-
The stop valve (090) must be opened until the oil
tion of the oil pump motor
level has reached a value between the upper edge of
the sight glass indicator MIN (N10b, data sheet The oil pump is started with the driving motor electri-
990565) and lower edge of the sight glass indicator cally blocked (service). The stop valves are in the
MAX (N10c, data sheet 990565). operating position.
The oil separator is generally charged with oil via the
oil cooler.

The direction of the arrow given for the oil pump 8. Check the excitation of the solenoid valves of the
must correspond to the direction of rotation of the oil adjusting device for capacity control in the Mini-
pump motor. mum direction.
Caution! 9. Simulate the minimum end position of the control
Since the slide ring shaft seal of the oil slide and check the switching function of main
pump is dependent on the direction of switch and star-delta contactor (for motors with
rotation and can be damaged when star-delta starting).
this direction is wrong, checking must 10. Checking the switching function of the solenoid
be reduced to a very short running valve by forcing the digital outputs.
period (less than 2 seconds).
11. Check the "Oil circuit monitoringfailure". only for
The adjusted differential pressure between the oil external oil pumpAfter 6s, the of the compres-
pump pressure side and the unit final pressure is sor drive motor must be shut off. To do so, the
checked with the oil pump rotating in the correct valve (70) must be throttled in such a manner
direction. It must not fall below the prescribed set that the alarm value for oil difference pressure as
value in the P+I diagram. stated on the parameter list is ot reached.
While the compressor is not running and the oil has 12. Set the motor current limitation acc. to nominal
not yet reached the operating temperature, the differ- motor data. See parameter list!
ential pressure can be slightly higher than the indica-
ted value.
The differential pressure can be changed by rotating 8.5.7 Checking of the safety pressure
the spindle on the oil pressure control valve. (The dif- limiter
ferential pressure is increased by turning it inwards
and vice versa). 1. Setting of the shut-off values as per the panel
data report
2. Switch on the compressor package
8.5.6 Checking the fault monitoring
3. Initiation of the shut-off value
1. Disconnect the incoming feeder of the compres-
4. Check the reaction:
sor drive motor from the mains supply when
checking the safety device (e.g. remove LV/HBC – Compressor must shut off immediately
fuse links).
– Fault report on the display of the control unit
2. Apply voltage to the control device.
3. Check the built-in pressure transducer and
resistance thermometer for correct wiring.
8.5.8 Checking of the emergency-OFF
button.
To do so, loosen the relevant contacts. The mes-
sage "Broken wire <sensor XXX>" appears on Hint!
the display of the control. Check that the display
is correct after the contact has been re-estab- Upon actuation, the emergency-Off
lished. button must immediately shut off the
compressor.
Further information can be found in the con-
troller manual. 1. Actuation of the emergency-OFF button.
4. Check limit values. 2. Check the reaction:
– Compressor must shut off immediately
5. Switch on the screw compressor package/chiller
– Fault report in the display of the control
from the controller.
3. Resetting of the emergency-OFF actuation to
6. "Oil circuit monitoring failure” must be indicated
end the test.
after a starting delay time of 20 sec.
7. Reconnect the oil pump motor to the mains sup-
ply.

8.5.9 Adjustment of oil pressure

Danger!
The oil pressure being set too high or
too low may result in serious compres-
sor damage or even total breakdown
of the compressor after even a short
period of operation!
Before the compressor drive motor and therefore the

unit can be started, the oil pressure must be set cor-
rectly by adjusting the oil pressure regulating valve
fig.46: Motor direction of rotation
(075).
For adjustment solely the oil pump must be started. A Compressor
For units with the control GEA Omni, digital output B Motor
must be forced for this.
The set value of the oil differential pressure should – The compressor drive motor is started directly
be taken from the P+I flow chart of the specific and then switched off again by forcing the digital
project. outputs.
Oil differential pressure = oil pressure item (110)
Hint!
- discharge pressure item (105)
The differential pressure can be changed by rotating Prior to the start-up of the compressor
the spindle on the oil pressure regulating valve (the drive motor, the manufacturer's infor-
differential pressure is increased by turning it mation, e.g. on the lubrication of the
inwards and vice versa). To do so, the seal on the oil motor, must be followed at all costs.
pressure control valve (075) must be removed. – If the direction of rotation of the motor is incor-
In comparison to normal operation conditions, the oil rect, it should be corrected while the electric
differential pressure can be slightly higher if only the switchgear is secured to prevent the motor from
oil pump is operated or if the operating temperature being switched on accidentally. Then the motor
is not reached yet (with the valve open to the same must work for at least 1 hour, unencumbered
degree). and free from errors. This is important in order to
In this case, the oil differential pressure should be dry out residual moisture in the motor (caused
readjusted (according to the value in the P+I flow during transport or storage).
chart) after start of the unit and reaching of the oper- – The coupling protection must be in place during
ation temperature. this start-up period as required by the labour
safety regulations.
8.5.10 Checking the direction of rotation – After checking the direction of rotation of the
drive motor, the coupling may be connected with
of the drive motor
the motor.
Warning!
The coupling must not yet connect the
8.5.11 Mounting the coupling
motor and compressor!
1. The electric switchgear is secured to prevent it
– Secure the electric switchgear so as to prevent from being switched on accidentally.
the compressor drive motor from being switched
on accidentally. 2. Mount the coupling while observing the instruc-
tions of the separate documentation.
– With the control slide in the MIN or MAX position,
it should be possible to rotate the compressor 3. The values for radial and angular deviations
shaft easily and smoothly by hand. When check- given in the coupling documentation must be
ing the direction of rotation of the compressor checked and corrected if necessary. The axis
driving motor pay attention to the conditions for distance between the compressor drive motor
switching the compressor on. and the compressor must be checked.

4. The real values have to record at data sheet of 4. The minimum end position (0%) must be
coupling documentation. Please send back a reached and signalled when the "Decrease
copy of the filled data sheet to: power" button is pressed.
GEA Refrigeration Germany GmbH 5. Vent the adjusting device by moving the control
Holzhauser Straße 165 slide backwards and forwards about ten times.
13509 Berlin
Fax: +49 (0)30 - 43 592 759
8.5.15 Checking the control slide adjust-
Caution! ment times
Observe the maintenance instruction!
Caution!
Regrease the coupling at the prescri-
bed intervals if scheduled in the main- Only adjustment times between 30 and
tenance instruction for the coupling! 60 seconds are permissible.
The throttle valves of the solenoid valves are adjus-

ted in the factory in such a manner that they ensure
8.5.12 Checking the water circuits an optimal adjustment time of the control slide of
between 30 and 60 seconds.
Check whether the cooling and cold water pumps
While running at operating temperature and pressure
are running and the shut-off fittings in the cooling
conditions, determine the adjustment times needed
water circuit are in their operating positions.
when the control slide is continually moved from the
While the unit/ chiller is operating under project con- maximum end position to the minimum end position
ditions, adjust the cooling water control so that the and back. For the automatic system to run smoothly,
condensing and oil temperature lies within the per- the adjustment times in either direction must be
missible range. approximately the same.
The adjustment time can be adjusted with the help of
throttle valves DS5 and DS6.
8.5.13 Initial start-up
Hint!
After carrying out the aforementioned works, the
SCP can be commissioned in accordance with the See the assembly instructions for the
operating manual of the control device. screw compressor.
1. Switch on the control voltage of the control

device.
8.5.16 Checking the oil cooler
2. Remedy and acknowledge existing fault mes-
sages. Guide value for oil temperature = see parameter
list
3. Select manual operating mode.
4. Turn on SCP. Oil cooling with water-cooled oil cooler
The water volume must be regulated so that the
cooling water volume corresponds to the project
8.5.14 Checking the adjustment of the value. The inlet and outlet temperatures must be
control slide checked. The oil temperature adjusts automatically
via the 3-way valve.
1. SCP is running.
Checking the oil cooling with refrigerant-cooled
2. Select manual operating mode. oil cooler
3. The maximum end position (100%) must be No regulating or checking required.
reached and signalled when the "Increase
power" button is pressed.
8.5.17 Adjusting the amount of injection
oil and the oil temperature

8.5.17.1 Screw compressor packages 8.7 Restarting after approx. 1 year

without refrigerant injection standstill
The amount of injection oil and the oil temperature • Change the oil filter inserts (see maintenance
directly influence the discharge temperature of the instruction).
compressor. The amount of injection oil is adjusted
• Switch on the oil heater at least one hour before
under operating conditions through the injection oil
starting the screw compressor package/chiller.
control valve.
• Open the stop valve on the suction side and the
Standard values for discharge temperature pressure side (or check valves which can be
shut off).
t tmax • If fitted: Open the stop valves (or shuttable check
valves) in the suction line of the economiser.
NH3/HP t ≥ toil + 20K 30K 95°C
• If fitted: Open the refrigerant supply to the ther-
mosyphon - oil cooler.
NH3/LP t ≥ toil approx. 45 ... 60°C 80°C
• If fitted: Open the manual stop valve of the refrig-
erant injection.
Freon/HD t ≥ toil + 15K 80°C
• Remove all non-condensable gases by venting.
R22/LP t ≥ 45 ... 60°C 80°C To this end, check the condensing pressure and
temperature (see parameter list).
• Check the oil collection sump and drain if neces-
sary.
8.5.17.2 Compressor units with refriger-
• Switch on the compressor and observe the oper-
ant injection
ating instructions of the electrical switchgear.
The oil temperature is changed by setting the injec- Make a screw compressor package/chiller test
tion oil control valve. The more the shut-off valve is run in order to test the sensor and actor technol-
throttled, the more the oil temperature decreases. If ogies (for operation and indicating precision).
the oil temperature becomes too low or reaches the
lower range, the setpoint for the discharge tempera-
ture should be set higher accordingly. In the first set-
ting of the oil circuit, the control valve for injection oil
is opened approximately half a turn.
The discharge temperature is then regulated to the
value indicated in the parameter list by means of the
thermostatic expansion valve.
Guide value for compressor end temperature: te
= 60 + 10°C (for NH3)
Other refrigerants on request.
8.6 Start-up after long standstill periods

1. Inserting the main fuse
2. Switching on the control unit according to the
operating manual.
3. Checking all parameters on the control unit dis-
play. See parameter list.
4. Checking the settings of all control and safety
devices.

Operating Manual | GEA Grasso M-Series Use, operation, control
9 USE, OPERATION, CONTROL

9.2 Important information for the opera-
tor
9.1 Use in explosive atmospheres,
installation zones 1 and 2 The screw compressor package must be only be
operated by trained and qualified personnel who are
Danger! familiar with the contents of the operating manual for
The same regulations apply to the GEA Refrigeration Germany GmbH screw compres-
operating instructions for screw com- sor packages.
pressor packages in potentially explo- The safety regulations for refrigeration plants must
sive atmospheres as described in the always be observed in order to prevent damage to
respective applicable operating man- the screw compressor package and injury to the
ual. operating staff.
In addition to this, the following exten- Hint!
sions apply:
The screw compressor package is
1. In addition, the legal safety regula- operated via the control panel of the
tions apply for the people respon- control unit. If the control is included
sible for operating the screw com- in the scope of delivery, the operating
pressor package, and must be con- staff must be familiar with the contents
formed with respect to the trans- of the complete documentation of the
port, assembly, operation and control unit. The documentation for
maintenance and if necessary the the control unit is an integral part of
replacement of sub-assemblies, the product documentation.
etc. in potentially explosive atmos-
pheres.
The operator directives must be
complied with in this context – see 9.3 Prerequisite for switching on
also section: Safety instructions The screw compressor package has been designed
for compressor, Appendix E and for automatic operation; the control unit controls the
Screw compressor package, switching on and off of the compressor and its
Appendix E. Both documents are capacity adjustment.
an integral part of the documenta-
Continuous operation and observation of the screw
tion.
compressor package is not necessary in automatic
2. The relevant electrical engineering mode. The necessary steps for switching on the
regulations for installations in screw compressor package can be found in the con-
potentially explosive atmospheres, troller documentation.
especially EN 60079-10, apply to If the screw compressor package is controlled man-
the installation and connection of ually, it must be operated from the refrigerator room.
electrical components. Appropri- In particular, the repair and maintenance instructions
ate, prescribed cabling material must be complied with.
must be used.
The following prerequisites must be fulfilled for
3. The entire screw compressor pack- switching on the screw compressor package:
age must be earthed by the opera-
1. The main power must be available and switched
tor.
on.
2. The screw compressor package must be suffi-
ciently filled with refrigerant and oil.
3. The valves must be in the operating position.
4. The oil level in the oil separator must be within
the permissible range.

Use, operation, control Operating Manual | GEA Grasso M-Series
5. The cooling and cold water pumps must be in

operation.
6. The supply of cooling water or coolant to the oil
cooler must be ensured.
7. The oil heater in the oil separator must have
heated the oil sufficiently.
Hint!
The oil heater in the oil separator can
be switched on while the screw com-
pressor package is not running. It is
then automatically switched off when
the screw compressor package is star-
ted and switched on when it is shut
down. If the ambient temperature is
below 5°C, the oil heater must be
switched on at least one hour before
the screw compressor package is star-
ted.
8. The rated current limitation has been set accord-

ing to the motor rating.
® The screw compressor package can be switched
on as per the controller operating manual.

9.3.1 Overview of the operating modes
Modes Signal for …
Name Remark Start/Stop Capacity +/-
0 Service Oil pump by itself

Compressor motor blocked
1 Manual Manual control via Touch Panel (TP) Manual Manual

+ Manual
2 Manual + Auto Manual Start/Stop via TP and full automatic local Manual Auto
capacity control
3 Auto + Auto Full automatic start/stop and local capacity control Auto Auto
4 Remote Start/stop and capacity demand via digital contacts External External
+ HW (cont) (hardware) from a remote master controller. The GSC continuous
TP derives from the continuous +/- signals the pulses
for capacity (indirect).
5 Remote Start/stop and capacity demand via digital contacts External External
+ HW (pulse) (hardware) from a remote master controller. The mas- pulses
ter also generates the +/- signals as pulses for control-
ling the slide capacity directly.
6 Remote Start/Stop from a remote master controller via digital External Local
+ HW (loc. contacts (hardware). The GSC TP controls the output + setpoint Setpoint
SW) depending on a local setpoint (TP) and from this set- deviation
point also automatically switches the product ON/OFF.
7 Remote Start/Stop from a remote master controller via digital External Remote
+ HW (ext. contacts (hardware). The GSC TP controls the output + setpoint Setpoint
SW) depending on an external setpoint (analog input) and deviation
from this setpoint also automatically switches the
product ON/OFF.
8 Remote Start/stop and capacity demand via network from a Network Network
+ Net (cont) remote master controller. The GSC TP derives from continuous
the continuous +/- signals the pulses for controlling the
capacity (indirect).
9 Remote Start/stop and capacity demand via network from a Network Network
+ Net (pulse) remote master controller. The master also generates pulses
the +/- signals as pulses for controlling the capacity
directly.

Modes Signal for …
10 Remote Start/stop from a central master controller via a bus Network Local
+ Bus (loc. signal. The GSC TP controls the output depending on + setpoint Setpoint
SW) a local setpoint (TP) and from this setpoint also auto- deviation
matically switches the product ON/OFF.
11 Remote Start/stop from a central master controller via a bus Network Network
+ Bus (net. signal. The GSC TP controls the output depending on + setpoint Setpoint
SW) an external setpoint sent externally via the network deviation
and from this setpoint also automatically switches the
product ON/OFF.

9.3.2 Setting of setpoint and limiting GEA Omni performs the following functions as
values as well as safety devices standard:
Caution! – Display of all important physical and technical

parameters, e.g. pressure, temperature, motor
The correct setting of all setpoint and current, capacity, number of operating hours,
limiting values is a prerequisite for the operating mode and status signals
safe operation of the SCP.
– automatic start up and shut down of the com-
For the setting of the setpoint and limiting values, the pressor package and capacity control dependent
on the relevant parameter for the application
1. details (steps) in the control operating manual
(e.g. the suction pressure or an external temper-
and ature),
2. the project-related data are – Monitoring of all operating parameters,
instrumental. The program-based setpoint and limit-
– Compressor capacity limitation if the measured
ing values as well as the setting values of the safety
discharge pressure, suction pressure, secondary
device are stated in the project-based parameter
refrigerant temperature or motor current indicate
list. The parameter list forms part of the documenta-
an overload,
tion for the controller.
– Fault memory with date and time,
– Wire failure detection for all analogue input sig-
9.4 Operation of the screw compressor nals
package
– Password protection for preventing unauthorised
Caution! access to important parameters
Read the control documentation care- – Non-volatile saving of programme,

fully. – MPI communication with a master controller
Contact the GEA Refrigeration Ger- (optionally via Profibus-DP, Modbus RTU or
many GmbH technical customer serv- Modbus TCP).
ice if you require assistance.
The screw compressor package is operated using

9.5 Instructions regarding failures, their
the control (standard: GEA Omni).
causes and remedies
The GEA Omni is mounted directly on the screw
compressor package as standard, but can also be The screw compressor packages/ chillers manufac-
arranged in a control centre. tured by GEA Refrigeration Germany GmbH are
The GEA Omni consists of the control unit with oper- highly advanced, automatic and extremely efficient
ator keypad and display unit (TouchPanel), indicator systems. Nevertheless, faults can occur and may
lights for "Running", "Warning" and "Alarm", the complicate any continuous operation of the plant or
emergency stop button, the output relays and the cause a failure of a part or the entire plant.
casing.
All switching, operating and control actions are car-
ried out via this TouchPanel. The TouchPanel is the
interface between the man and the machine.

Table of malfunctions
Fault Cause Remedy
The suction pressure is too low, Slow loss of refrigerant through Check the entire system for leaks.
performance is reduced and the leaks in the refrigerant circuit. Eliminate leakage, replenish refrig-
system overheats. erant if necessary.
Pressure sensor defective. Replace pressure sensor.
Defective capacity control devices Check capacity control devices,

in the compressors especially connections of solenoid
valves
Suction filters are clogged Clean or replace the filter insert.
The suction pressure increases, the The compressor/s are sucking in Check the filling of the system,
compressor(s) frost up to impermis- wet steam or liquid when started drain any refrigerant, repair safety
sibly high level or make noises that up. The safety device to prevent a device. Check for superheating.
suggests fluid (refrigerant) in the too-high liquid level is not respond-
compressor. ing.
The condensation pressure is too There is air or other non-condensa- Vent the refrigerant circuit.
high. ble gases in the refrigerant circuit.
The compressor(s) will not start-up The electrical circuit is interrupted Turn on the power, check safety
after switching on or it shuts down by a unit in the safety chain. devices and replace or correctly
immediately after starting again. adjust if necessary.
No oil pressure is building up in the Exchange or clean oil filter ele-

package/chiller. The oil circuit is ments, eliminate leaks and replen-
disturbed by clogged oil filters or ish oil.
leaks.
The compressors do not adapt to The capacity control device is mal- Check the oil circuit. The compres-
the required capacity. functioning due to disturbances in sors should only be repaired by
the oil circuit or mechanical influen- experts. Check the position detec-
ces. tor of the compressor control slide.
The compressors are shut off very The condensation pressure is too See above.
often by the maximum pressure high.
governor.
The maximum pressure governor is Remove the maximum pressure
defective or set wrongly. governor, repair it, set it correctly or
replace it.
The compressors are shut off very The suction pressure is too low. Open all valves on the suction side
often by the minimum pressure of the compressors.
governor.

Table of malfunctions
Fault Cause Remedy
The pressure governor is defective Remove the minimum pressure

or set wrongly. governor, repair it, set it correctly or
replace it.
The heat transfer capacity of the Check the evaporator for elevated
evaporator decreases. oil concentration, drain oil if neces-
sary.
When operting, the package/chiller The compressor(s) or the drive Inform the GEA Refrigeration Ger-
is louder than permitted. motor(s) is/are defective. many GmbH customer service

Cleaning, maintenance, repair Operating Manual | GEA Grasso M-Series
10 CLEANING, MAINTENANCE, REPAIR

Hint! Hint!
The obligation for signage to prevent Heed all safety instructions in this
the unintentional switch-on of the manual.
plant during cleaning, maintenance Familiarise yourself with the local con-
and repair must be observed. ditions of the screw compressor pack-
age installation site.
Adhere to all legal and local regula-
10.1 Use in explosive atmospheres, tions of health, work and fire protec-
tion as well as the regulations which
installation zones 1 and 2
must be heeded concerning the gases
Danger! to be compressed.
Please read this manual carefully and
The same regulations apply to the
completely prior to working on the
maintenance instructions for SCPs in
screw compressor package.
potentially explosive atmospheres as
described in the respective applicable Familiarise yourself with the special
operating manual. features of the screw compressor
package.
In addition to this, the following extensions
apply: Caution!
1. In addition, for the persons responsible for main- There is an increased danger of slip-
taining the SCP, the legal safety regulations con- ping due to contact of operating media
cerning the installation of the SCP in potentially with the floor!
explosive atmospheres with respect to the main-
The screw compressor package must be serviced by
tenance of the individual components or sub-
appropriately trained operating staff only. For all
assemblies or their complete replacement apply.
maintenance work, the maintenance instructions
2. The maintenance may only be carried out in must be complied with.
agreement / with the knowledge and release of A maintenance checklist is part of the product docu-
the operator. mentation. The maintenance certificates in the main-
3. The maintenance and replacement regulations tenance checklist are completed and signed as part
resulting from the operating manual for the com- of the inspection and maintenance by authorised fit-
ponents are to be complied with. ters as evidence of the work done.
During the guarantee period, these confirmed main-
4. Appropriate special tools approved for the poten-
tenance certificates are a prerequisite for any claims
tially explosive atmosphere must be used.
under the guarantee.
5. Only original spare parts may be used. Other- The responsible certified specialist company must be
wise, any claim of warranty is void or, in case of informed if any repairs are required.
damage, the operator is liable for this.
All maintenance and service tasks have to be carried
6. Each maintenance inspection (see maintenance out with care to preserve the functionality of the
book) must also include the checking of the screw compressor package. Guarantee claims will
secure fit of the threaded connections for the not be valid if the customer failed to follow the main-
coupling safety hood. tenance instructions.
10.2 Important information for service 10.3 Cleaning the heat exchanger
personnel
The following chapter is primarily aimed at the main-
tenance and service personnel of the screw com-
pressor package.

Operating Manual | GEA Grasso M-Series Cleaning, maintenance, repair
10.3.1 Mechanical cleaning During cleaning, repair or maintenance work, the

screw compressor package or its components must
Mechanical cleaning is a maintenance measure in
be protected against the penetration of moisture in
order to ensure the continuous safe operation of the
order to prevent impairment of the function of the
screw compressor package.
components.
Components of the screw compressor packages
The chief principle must be to keep air and moisture
(e.g.suction filter) can be removed for manual
entering the screw compressor package to an abso-
mechanical cleaning. Proceed in accordance with
lute minimum. All foreign substances must kept as
the details in the applicable component documenta-
far away as possible or eliminatedincluding
tion. After completing cleaning work, properly mount
the component and check for leakage. – welding residues,
– sealing remnants,
10.3.2 Chemical cleaning – auxiliary materials such as grease, oil or sol-

vents.
Chemical cleaning of the screw compressor package Welding and soldering work may only be performed
is not recommended by GEA Refrigeration Germany with written permission. The requisite protective
GmbH. measures must be defined. These include:
– personal protective measures when opening the
10.4 Maintenance respective part of the system,
– complete draining of the respective part of equip-
ment,
10.4.1 General instructions – cleaning with the appropriate cleaning agents,
Danger! – concentration measurements,
Contact with live components is pro- – ensuring sufficient ventilation and venting,
hibited. – performance of all welding work with the use of
Maintenance work on the running forming gas.
screw compressor package is not per- If gas filled pipes are opened for maintenance work,
mitted. these pipes must be in a gas-free condition.
Work involving intervention in the refrigerant circuit
must only be carried out by qualified engineers in
accordance with the guarantee conditions.
The screw compressor package must always be
switched off before being dismantled. Before begin-
ning the work, it must be ensured that all parts sub-
ject to maintenance/servicing are de-energised(e.g.
by removing the main fuse or installing a shorting
bridge).
The refrigerant must be removed from the applicable
parts of the system parts. This work must be carried
out with great care, taking into account the safety
regulations, so that the maintenance personnel are
not injured by the refrigerant or by the refrigeration
unit oil present in the system.
Parts of the system under pressure must be com-
pletely vented before opening. While carrying out the
repair, it is must always be ensured that a complete
pressure balance of the affected pressure chambers
with the environment is preserved.

10.4.2 Repair work New inspection and approval is required after pres-
sure vessels that are subject to approval have been
Modifications and repair work may only be carried
repaired or changed. Welding may only be carried
out by qualified persons or persons with suitable
out by approved welders with a valid welder’s card.
training with the manufacturer's consent and must
strictly comply with the rules set out in the mainte-
nance instruction for the components concerned.
10.4.3 Maintenance intervals
Hint!
Caution!
The following maintenance notes must
be observed: The maintenance intervals in accord-
ance with the maintenance schedule
Only spare parts made by the original component must be observed.
manufacturer may be used for repairs and for replac-
ing wearing parts. These are available from the The maintenance schedule is an integral part of the
spare parts department. product documentation. The maintenance schedule
contains all the maintenance instructions and certifi-
cations for the first 15 years of performance of the
10.4.2.1 Repair information screw compressor package. The maintenance certifi-
cates are completed and signed as well as acknowl-
Important features of the technology and production edged on the display of the control as part of the
process must be taken into account when repairing inspection and maintenance by authorised fitters as
the plant: evidence of the work done.
– complete sealing of all devices and pipes. During the warranty period, these validated mainte-
nance certificates also serve as a precondition for
– Dryness and cleanliness of the entire plant. any warranty claim put to GEA Refrigeration Ger-
– Use of welding methods causing only a minimum many GmbH.
amount of dirt to collect in the plant.
– Pipes bent on a pipe-bending machine only
10.4.4 Maintenance work
using refrigerating oil.
– If repairing the piping system from your own Hint!
stocks, we recommend that you use a pipe with The documentation for the main com-
NBK surface quality (annealed and descaled, ponents is a part of the product docu-
mechanically or chemically descaled after mentation. This contains important
annealing). information to be considered before
– When carrying out repairs to piping systems, beginning the maintenance work.
care should be taken to maintain the original pip-
ing routes.
– Only pipes of sufficient material quality, which 10.4.4.1 Maintenance of the screw
are certified according to DIN 10216-2 should be compressor
used.
Maintenance works are to be periodically carried out
on the screw compressor (see maintenance sched-
ule). These include:
10.4.2.2 Repairs of pressure vessels
subject to approval inspection – Measure axial play of bearings,
– Check shaft seal,
Hint!
– Check primary slide movement,
The responsible monitoring body
(e.g.TÜV) must be notified in advance. – Check the adjustment of the position sensor.

Hint! 6. Check that the type designation/manufacturer ID

number on the replacement element matches
The maintenance works on the screw the type designation/ID number on the filter’s rat-
compressor are described in the
ing plate.
installation manual of the compressor.
7. Place the replaced or cleaned filter element back
After 50,000 operating hours or in the 15th operating on the mounting pin by turning it slightly.
year, a general check of the screw compressor is
planned by the manufacturer. Contact Customer 8. Reposition the filter cover and tighten the four
Service in this regard. cover screws. Ensure that installation occurs
without mechanical tension.
9. Vent the housing of the block mounting filter.
10.4.4.2 Changing the block mounting
filter element
10.4.4.3 Replacing the oil filter
Hint!
1. Switch the unit/ chiller off.
When must the filter element be
replaced or cleaned? 2. If the oil filter is very dirty, it may be necessary to
The oil filter element must be replaced replace it outside the normal maintenance
as specified in the maintenance check- schedule.
list for the total product from GEA 3. To change the oil filter insert, close the following
Refrigeration Germany GmbH. valves in accordance with the P+I diagram and
Loss in pressure during operation is the oil filter documentation:
monitored by the internal control – – Stop valve in front of oil filter (item 65)
including a preliminary alarm function
for preventative replacement. – further stop valves in front of oil filter (if avail-
able), e.g. (item 220) if a thermostatic 3-way
The following applies as a guide value
valve (item 215) will be used
for replacement: The filter element
should be replaced after every 5000 see P&I diagram
operating hours or once each year. – Stop valve function oil (item 70) for Grasso
SP1 or (item 190) for Grasso SPduo
Changing the filter element
– Control valve - injection oil with integrated
1. Shut down the screw compressor package/chiller check valve function (item 80)
and depressurise the blocked mounting filter on
Do not forget to note the number of valve
the pressure side.
rotations when you close the valve (item
2. Remove the filter cover by loosening the four 080). When opening the valve it must be
cover screws. returned to its initial position (see point 10).
3. Remove the filter element by slightly turning the This is necessary to ensure the final temper-
mounting pin in the filter head. ature remains unchanged and therefore to
avoid possible vibrations in the oil line.
4. Check the O-ring and support ring in the filter
– Stop valve bypass oil cooler (optional)
bowl for damage and correct positioning.
Replace parts if required. 4. Establish pressure compensation with the
5. Replace glass fibre element, clean or replace atmospheric pressure.
wire mesh. 5. Drain oil.
The efficiency of the cleaning depends on the 6. Remove the cover of the oil filter.
type of dirt and the level of differential pressure
before replacing the filter element. If, after 7. Remove the oil filter element and properly dis-
replacing the filter element, the differential pres- pose of it if it is highly soiled.
sure is more than 50% of the value before 8. Carefully insert a new oil filter element.
replacing the filter element, wire mesh must also
be replaced. 9. Close the cover of the oil filter.

10. Reopen valves in accordance with item 3. The 10.4.4.4.2 Cleaning the filter element
valve (80) must be returned to its initial position. The metal-gauze element used in the filter can be
11. After the pressure has been compensated, vent cleaned and reused several times before it has to be
the oil filter via the vent valve. changed.
Manual cleaning
10.4.4.4 Maintenance of the suction fil- Immerse the soiled metal-gauze element in a clean,
grease-dissolving liquid, then blow it through with
ter
compressed air from the outside inwards. Here it is
important to place a cylindrical part – possibly wrap-
ped in corrugated cardboard – inside the element to
10.4.4.4.1 Changing the filter element catch the dirt particles.
The maintenance interval for changing or cleaning Caution!

the filter element is specified by the manufacturer of Never use wire brushes for cleaning.
the refrigeration system.
The contamination level and mechanical condition of Hint!
the filter element must be inspected at least once a
year. To avoid fatigue failures of the metal
gauze, strainer elements should be
Before opening the filter, always make sure the filter
replaced with new, original filter ele-
housing is not under pressure.
ments after being cleaned 4 – 5 times.
Caution!
Refrigerant may leak out on opening
the filter. The safety data sheets for 10.4.4.5 Oil draining, oil filling, oil
the refrigerants in question must be change
consulted and any prescribed protec-
tive measures observed.
To remove the element, proceed as follows: 10.4.4.5.1 Importance of oil change

1. Unscrew the cover. Aged oil demonstrates an increasing loss of ability to
2. Pull out the cover with the filter element. lubricate. Because of this, all rotating components of
the compressor are endangered. The filter elements
3. Remove the spring wire clamp. become prematurely clogged and must be cleaned
4. Twist the element away from the cover to and replaced at shorter intervals.
release the bayonet catch. The oil in the screw compressor package/chiller must
5. Detach the element from the cover. be changed:
6. Allow the element to drain off into a suitable con- – when the operating time of the oil charge has
tainer. reached the technically specified oil change
interval,
Caution!
Warning!
When carrying out maintenance,
always inspect the sealing ring (O- Oil change intervals
ring) of the cover for mechanical dam- Oil change with ammonia as the refrig-
age and replace it if necessary. erant after every 5,000operating hours
or after 1 year at the latest.
7. Reassemble all parts with the new or cleaned fil- Oil change with freon as the refrig-
ter element following the same procedure in erant after 10,000operating hours or
reverse order. after 2 years at the latest.

– if the oil becomes unacceptably contaminated- sure between the screw compressor package/
due to a major accident (e.g. water penetration chiller and suction line. If screw compressor
into the refrigerant circuit). packages operated in parallel or other separate
The degree to which oil in refrigeration plants has chillers are present, the refrigerant should pref-
aged must be checked by analysis and in compari- erably be drawn off at a pressure which is
son of the data with those of fresh oil. Oil ageing can approx. 1 to3 bar above atmospheric pressure.
also be judged from the darkening of the oil colour Then re-close the stop valves bypass and the
and the deposits found in the oil filters. If the degree suction-side stop valve. Otherwise the pressure
of ageing cannot be assessed reliably by laboratory can be reduced by opening the vent valve on the
analysis and the results of visual examination, it is suction filter and then disposing of the refrigerant
advisable to change the oil at the following intervals as specified by law.
(see maintenance checklist). 4. Then drain the used oil through the oil
The assessment of the condition of the refrigerating draining/oil charging valves and dispose of it
machine oil by means of a general visual inspection (Caution! hazardous waste!). Once this has
(contamination) or laboratory analysis must be car- been done, re-close the valve and if possible
ried out: continue to draw off the refrigerant with a com-
pressor connected in parallel or a disposal
– after 5000 operating hours:
device until atmospheric pressure is almost
or reached.
– at the end of one year's operation 5. Otherwise depressurise the screw compressor
or package/chiller by opening the vent valve on the
suction filter, taking into account the safety rules
– after remedying major damage.
for refrigeration systems.
or
6. Open the drain plugs and valves on the oil
– if the oil is dark coloured or very cloudy. cooler, oil separator and OMC block to drain any
residual oil. Then re-close the drain plugs and
valves.
10.4.4.5.2 Oil change, maintenance
7. Replace the filter element of the oil filter; replace
work
and/or clean the filter element of the suction filter
Take oil samples for analysis and comparison with combination.
the fresh oil data at regular intervals. Check the col- 8. Evacuate the screw compressor package/chiller
ouration of the oil visually and assess the degree of using a vacuum pump.
contamination.
Depending on the results, the user must decide Warning!
whether to approve the postponement of filling the oil Shut off the oil pump!
until the next assessment date or whether to have
the oil changed. 9. Pressurise the screw compressor package/chiller
Inadmissibly damp oil must be removed from the with a slight overpressure via the stop valve
compressor unit/chiller immediately. bypass check valve on the pressure side.
10. Then check all components for leakages. On
successful completion, perform a complete pres-
10.4.4.5.3 Changing the oil sure compensation with the discharge line fol-
1. The screw compressor package/chiller must be lowed by a repeated leakage test of the screw
run for at least half an hour to reach its operating compressor package/chiller. The oil charge oil
temperature before the oil can be changed. and start-up of the screw compressor package/
chiller must be accomplished in accordance with
2. First shut down the screw compressor package/ the operating instructions.
chiller as described in the operating instructions.
3. Open the stop valve in the bypass line around
the check valve on the suction side and the stop
valve on the suction side to equalise the pres-

10.4.4.5.4 Used oil 10.4.4.5.7 Charging with oil, topping

up with oil
Refrigeration machine oil drained from the circuit is
no longer suitable for use in refrigeration plants. It See chapter entitled "Start-up, charging with oil".
has to be stored or transported in appropriately label-
led containers in accordance with the legal provi- Hint!
sions. The operator is responsible for its proper dis- For permissible types of oil, please
posal. refer to the technical information enti-
tled "Lubricating oils".
Oil removed from the compressor
10.4.4.5.5 Draining the oil must not be re-used. Always use fresh
It may be necessary to drain the oil: oil from sealed containers! Do not mix
with other types of oil.
– to inspect or repair the compressor
and
– if there is too much oil in the circuit. 10.4.4.6 Oil pump maintenance
The oil must be drained in accordance with points 1
Assuming correct installation in accordance with the
to 6 of the chapter entitled "Carrying out oil change".
conditions of use and correct fitting, gear pumps
The oil must be drained through the filling hose and
have the design prerequisites for long and fault-free
into a container suitable for waste oil.
operation.
The gear pumps require a minimum of maintenance
10.4.4.5.6 Check the oil level which is, however, indispensable for fault-free opera-
tion since experience has shown that a high percent-
age of the faults and damage which occur are attrib-
utable to the ingress of dirt and inadequate mainte-
nance.
The maintenance intervals have been defined in the
maintenance checklist (part of the product documen-
tation).
An oil leakage of up to one drop/minute is required
for the lubrication of the shaft seal and is permissi-
ble.
The shaft seal is maintenance-free. If the oil leakage
is too great, replace it according to the oil pump doc-
umentation.
Hint!
fig.47: Arrangement of MIN / MAX sight glasses
The regular examination of all operat-
1 Sight glass - MAX (operation)
ing data, such as pressure, tempera-
2 Sight glass - MIN (standstill) ture, power consumption, degree of fil-
ter fouling, etc., helps in the early
The oil level is checked visually via the sight glasses detection of potential failure!
of the oil separator. The oil level should have a value
between 1/2 filling level of sight glass N10c (MAX -
operation) and 1/2 height of sight glass N10b (MIN -
10.4.4.7 Changing the fine oil separa-
standstill).
tion cartridges
If the oil level is too low, i.e. the oil level has a value
less than 1/2 filling level of sight glass N10b (MIN - The fine oil separation cartridges should be replaced
standstill), oil must be replenished. no later than after 25,000 run hours or 5 years.

If the oil carry over of the screw compressor package 10.4.4.8 Tightening screw fastenings
increases severely (oil recharging at unusually short
Screw fastenings of components can become loose
intervals), replacement may be necessary even ear-
due to vibration or movement. Screw fastenings
lier.
must therefore be checked regularly to ensure they
are tight and retightened if necessary.
Screw fastenings must only be tightened to the maxi-
mum tightening torques.
Unless otherwise stated by warning signs, the tight-
ening torque is dependent on the size and strength
of the screw fastening.
fig.48: Operating position of the fine oil separation cartridges

10.4.4.9 Coupling maintenance
1 Cartridge(s)
2 Fixing cover with O-ring 1. Switch the screw compressor package/ chiller
3 Hexagon-head screw
off.
4 Self-locking hexagon nut 2. Secure the electric motor against accidentally
being switched on.
1. Close the pressure and suction side shut-off fit- 3. Visually inspect the disk packs.
tings.
4. Check the tightening torques of the fit screws.
2. Drain refrigerant. Evacuate screw compressor
5. Check the alignment of the electric motor and
package.
correct it according to the steel lamination cou-
3. Check the pressure on the display of the control pling documentation, if required.
unit or by connecting a test pressure gauge.
6. Re-grease the coupling (if provided for in the
4. Dismantle the pipe bend after the oil separator. maintenance instructions for the coupling).
5. Dismantle the check valve installed in the oil
separator. This step is omitted if a check valve
which can be shut off is used on the pressure 10.4.4.10 Checking the function of check
side. valves
6. Remove the self-locking hexagon nut [4]. In order for a check valve to be effective, it is impor-
tant to perform function checks at regular intervals.
7. Loosen the hexagon-head screw [3] and the fix-
ing cover with O-ring [2] for fixing the fine oil sep- An inspection is carried out by checking the noise
aration cartridges. behaviour of the valves during operation. After
switching off the screw compressor package, mal-
8. Remove the cartridge(s) [1]. function on the suction side is indicated by prolonged
9. Mount the new cartridge. The cartridge must be turning back of the compressor. Malfunction on the
inserted into the oil separator with the O-ring pressure side leads to an increase of the standstill
first. pressure in the package to the pressure level of the
system pressure side.
Assembly by carrying out steps 1-7 in reverse
order.
Warning! 10.4.4.11 Searching for leaks on the

It is essential to apply self-locking hex- refrigerant side / leak test
agon nut [4] again and secure it
The absence of leaks is a precondition for perfect
against turning backwards!
functioning of the compressor unit/chiller unit. Leak-
max. Tightening torque = 15 Nm ing parts or connecting elements will lead to the loss
of refrigerant and oil as well as the penetration of air
and moisture into the low pressure side. The site of

the leak must therefore be located and remedied if If leaks are determined, these must be sealed imme-
there is: diately. Release the test pressure before beginning
repair! Evacuate the system after repairs are com-
– Loss of the inert gas charge (delivery state),
plete and after rechecking for leaks.
– Loss of the entire refrigerant charge
or
10.4.4.12 Venting the refrigerant circuit
– underfilling.
Lower refrigerant levels in the containers are due to When air penetrates the refrigerant circuit, this
loss of refrigerant as a result of leaks. For this rea- makes itself felt in a fall-off in performance and the
son, all pipes, connections and valve glands should manometer on the discharge side of the compressor
be checked regularly, especially in the initial period indicates a higher pressure compared to the conden-
of assembly. sation temperature. Any leaks must be remedied. In
The most striking feature if there is a leak in the filled extreme cases, air in the circuit may interrupt the
refrigerant circuit is the smell of refrigerant. The flow of refrigerant and cause the oil cooling to fail.
odour threshold of ammonia in the air is approx. 5 There are several ways of venting the system. The
ppm and thus well below the permitted MAK values. air or the NH3-air mixture is vented via the vent
Methods of leak detection: valves of the condenser or the suction filter in water
filled vessels when the package is at a standstill.
– Regular visual inspections.
If air is in the mixture, the venting ammonia is absor-
– Smudges/dirt stains indicate leaking bed from water.
refrigerant/oil mixture.
Hint!
– Leak tests with nitrogen with a max. of 0.5%
ammonia by volume, an elapsed time of more Continuous venting using a Grasso
than 3 hours and application of a foaming agent purger is recommended.
to all the joints with a brush. Oil-filled compres-
sors or circuit sections must only be charged
with nitrogen – not air – to generate pressure. 10.4.4.13 Refrigerant evacuation
– Use of an NH3 leak detector.
Hint!
– Ammonia produces the following colours when
Shut the oil pump during evacuation!
leak tests are performed:
– Red litmus paper turns blue, The purpose of evacuating the system is to remove
air and moisture from the refrigerant circuit.
– Blotting paper impregnated with phenolph-
thalein turns red (moisten). Evacuation is required:
Caution! – after intervention in the refrigerant circuit and

elimination of leaks,
Due to the danger of explosion, oxy-
gen must never be used to build up – before the start-up/restarting.
the pressure! Evacuate the screw compressor package using a
vacuum pump. The screw compressor must not be
Generate a test pressure in the refrigerant circuit that used for evacuation.
meets the intended operating pressure for the leak
During evacuation, all affected parts of the circuit
tightness test to determine leaks on the refrigerant
should be at room temperature at least because cold
side, e.g. in the case of escaped inert gas or refriger-
parts hinder the removal of moisture.
ant. When system parts are individually tested, the
maximum operating pressure indicated on the If there is still any moisture in the screw compressor
respective system part for the corresponding pres- package, this will lead to a rise in pressure. Evacua-
sure chamber must not be exceeded. The use of tion must continue until the pressure no longer
foaming agents gives the best results at test pres- increases. A pressure comparison is based on a
sures < 5 bar. constant ambient temperature.

10.4.4.14 Checking the bearing noise Maintenance of the compressor drive motor includes
the following activities:
The bearings of the drive motor and the compressor
must be checked for unusual running noise, espe- – Lubrication of the motor
cially in comparison to previous maintenance. Recur- Lubrication intervals and quantities according to
rent vibration measurements are recommended. the "Motor documentation" or "Type plate".
– Cleaning of the motor (externally)
10.4.4.15 Checking the solenoid valves Select a suitable cleaning agent according to the
for capacity control "Motor documentation".
See the following sections in the start-up chapter:

• "Checking the control slide adjustment"
10.4.4.18 Checking the start regime
• "Checking the control slide adjustment times" See the operating manual of the compressor control
system.
10.4.4.16 Checking the oil heater

10.4.4.19 Checking the safety devices
Check the electrical function using a clamp-on
ammeter. See section entitled "Checking the fault monitoring"
in the start-up chapter.
Check the outer temperature of the oil separator and
compare with the temperature of the machine room The safety devices are checked by moving to the
(while the screw compressor package is at a stand- switching points (limiting values). For details, see
still). also the operating manual of the compressor control
system.
Limiting value = parameter list
10.4.4.17 Maintenance of the compres- Moving to the switching point is achieved by throt-
sor drive motor tling the pressure-side stop valve.
Hint!
The compressor drive motor must be
maintained in accordance with the
"Motor documentation".
10.4.4.20 Checking the operating parameters

Hint!
The operating parameters are checked via the TouchPanel. The checking intervals recommen-
ded in the table must be observed. The project-related setting values and limits are given in
the parameter list.
Inform the manufacturer contract partner if the parameters are outside the allowable limits.

Parameter to be Every 24
Weekly Monthly Remark
checked to 72hrs
Minimum superheat must not be less than 15 K

for NH3. For other refrigerants, the manufactur-
er's instructions must be noted.
Discharge temperature X Maximum discharge temperature 100°C, in indi-
vidual cases (e.g. heat pump applications) this
may be exceeded in agreement with the manu-
facturer.
See parameter list!

Oil temperature X The viscosity must not be less than 7 cSt at
max. speed (rpm).
The oil pressure must be at least 0.5 bar above

the final discharge pressure. An oil pressure
Oil pressure X fault may be caused by a clogged oil filter. Set-
ting and monitoring of the values in accordance
with the information in the parameter list.
See project value (parameter list). Determine

Discharge pressure X the superheat on the pressure side by compari-
son with the final discharge temperature.
See chapter "Oil level check". An oil level must

Oil level in oil separa- be visible in the sight glasses at all times. If the
X
tor oil level is below the minimum value, the oil
must be recharged.
When compressor is shut down, the heater

Oil heater X must automatically start. Visual check, the
green LED indicates "Voltage ON".
Setting the safety devi-

X See set values in the parameter list.
ces
Solenoid valves must switch audibly when the

Capacity control X capacity is adjusted. Check in operating mode
"1 (manual + manual)“.
See maintenance checklist for maintenance

Number of operating
X work to be carried out according to the number
hours
of operating hours.
10.4.4.21 Maintenance of the switching

cabinet
Terminal screws must be checked for tightness and,
if necessary, tightened at regular intervals (every
5,000 operating hours or at least once per year). The

contacts of the contactors must be checked for loss

of contact material.
10.4.4.22 Checking the earth connection

Check the function of the earth connection frequently
(see the general assembly drawing and the indica-
tions on the product).
Only a specialist company must be commissioned
with inspections.
10.4.4.23 Insulation
Check the insulation (if present) on components,
containers and piping for damage.
Damaged insulation must be replaced. The insula-
tion strength must be selected according to the tem-
perature and humidity at the place of installation.
Details on the insulation can be found in the P+I dia-
gram.
Caution!
No screw connections must be used
under the insulation if the piping is
insulated. The pipes must be welded.
10.4.4.24 Check of the tightening torque

on the adjusting elements of
the fixing base.
The tightening torques vary depending on the
strength and size of the screw used. The values for
tightening torques are to be taken from the applica-
ble DIN, unless otherwise specified.
Hint!
The tightening torques for the adjust-
ing elements should be obtained from
the data sheet. The data sheet forms
part of the product documentation.

Decommissioning Operating Manual | GEA Grasso M-Series
11 DECOMMISSIONING
3. Switch off the main switch of the three-phase
electric system.
11.1 Shut-down in the event of danger-
ous situations 4. If necessary, shut off the secondary refrigerant,
heating agent or the cooling water supply.
The safety equipment of the screw compressor pack-
age complies with EN 378. 5. Ensure that the venting slots of the electric
motors are covered under all circumstances!
By means of automatic monitoring of the individual
operating parameters, the control unit detects haz- ® Shut-down has been carried out
ardous situations in good time and automatically
switches off the screw compressor package.
The cause of the fault is displayed on the control unit 11.3 Standstill for a period >48 hours
and can then be corrected.
Hint!
Among other things, the concept of the screw com-
pressor packages is based onlow maintenance The obligation to label the plant as
refrigerant circuits that are as well sealed as possi- "Plant not in operation" must be
ble. However, residual risks remain, especially due observed!
to possible leaks or escaping refrigerant or rotating
drive parts. If the screw compressor package is shut down for a
period >48 hours, the following activities must be
Hint! performed:
The EMERGENCY STOP switch in the 1. Switch off the compressor in accordance with the
switching cabinet is used to quickly operating instructions for the electrical switch-
switch off the chiller whenever neces- gear.
sary.
2. Switch off all ancillary drives.
Leaking refrigerant can be detected with a gas 3. Switch off the main switch of the three-phase
detector (not included in the scope of delivery). This electric system.
detector can be integrated in the automatic safety
4. Close the stop valve (or combined stop/check
chain.
valves) on the suction side and the pressure
Please consult the safety regulations in this docu- side.
mentation for information about what to do in the
case of leaking refrigerant. 5. Close the stop valves (or shuttable check valves)
in the suction line of the economiser.
6. Shut off the secondary refrigerant, heating agent
11.2 Standstill for a period <48 hours or cooling water.
Hint! 7. Close the manual stop valve of the refrigerant

injection.
The obligation to label the plant as
"Plant not in operation" must be 8. Ensure that the venting slots of the electric
observed! motors are covered under all circumstances!
® Shut-down has been carried out
If the screw compressor package is shut down for a
period <48 hours, the following activities must be
performed:
11.4 Measures during shutdowns
1. Switch off the compressor in accordance with the
operating instructions for the electrical switch- Even though the screw compressor package/ chiller
gear. is under overpressure, check the moisture content of
the refrigerant and lubricating oil in case it is shut-
2. If necessary, shut down all ancillary drives. down for a period longer than half a year. The mois-

Operating Manual | GEA Grasso M-Series Decommissioning
ture content must not differ substantially from the ini-

tial values.
11.4.1 Monthly measures during stand-

still
– Check that the screw compressor package/
chiller is constantly under overpressure. Check
the screw compressor package/chiller for leaks
using a leak detector.
– Start the oil pump for approx. 5 minutes.
– Manually rotate the compressor shaft (min. 10
revolutions).
11.4.2 Four weeks before restarting

– Check the moisture content and ageing condition
of the refrigerating machine oil. Analyse the oil
for this purpose. Compare the results of the anal-
ysis with the values for fresh oil. We recommend
an oil change after 1 year (ammonia as refriger-
ant) (see Maintenance Instructions).
– Check the insulation resistance of the drive
motors (see the operating manual for the electric
motor).
– Switch on the oil pump.
– Check the screw compressor package/chiller for
leakages.

Decommissioning, disposal Operating Manual | GEA Grasso M-Series
12 DECOMMISSIONING, DISPOSAL
Preparatory measures – National regulations (e.g. EN 378-4, Appendix A)
Hint! must be observed for the reclamation and dis-
posal of operating media (oil).
The information in the chapter
"Decommissioning" must be – No unauthorised persons must be within the
observed. installation area of the plant during decommis-
sioning, as they could come into contact with
refrigerant.
Hint!
– All components of the plant which are not to be
Care must be taken during disposal re-used, as well as refrigerant and operating
and devaluation that the various mate- media, must be stored in suitable separate con-
rials are separated and taken for recy- tainers. They must be treated as waste and dis-
cling. Disposal of component remains posed of safely.
and components in the domestic ref-
uge or on refuse tips is not permitted. Hint!
The legal regulations applicable to the Re-use of operating media is not pos-
place of installation regarding the dis- sible!
posal of electrical equipment must be
taken into account.
Dismantled components must be dis-
posed of correctly and according to
legal requirements.
– The dismantling and disposal of the package/

chiller must be carried out in such a way that:
• the plant is free of voltage and is protected
against unintentional reconnection of the
voltage.
• Accidents to persons are prevented,
• material damage is prevented,
• uncontrolled escape of refrigerant or oil is
prevented.
– Disposal and decommissioning work must only
be carried out by personnel who are qualified
according to EN 13313.
– Components may be under elevated pressure
and the pressure must be released before open-
ing them.
– In case of contact with refrigerant or operating
media, their hazardous properties (e.g. toxicity,
inflammability) must be taken into account (see
also the safety data sheet for the refrigerant).
Personal protective equipment compliant with
EN 378-3 must be worn.
– National regulations (e.g. EN 378-4, Section 6)
must be observed for the reclamation and dis-
posal of refrigerants.

Operating Manual | GEA Grasso M-Series Decommissioning, disposal


Grasso Mseries

Uploaded by

Document Information

Original Title

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

Grasso Mseries

Uploaded by

Copyright:

Available Formats

Screw Compressor Packages

GEA Grasso M-Series

Operating Manual (Translation of the original text)

Downloaded from www.Manualslib.com manuals search engine

2 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

SYMBOLS USED IN THIS MANUAL

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 3

Downloaded from www.Manualslib.com manuals search engine

Bullet points and numbered list characters

4 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 5

Downloaded from www.Manualslib.com manuals search engine

7.7.12 Monitoring devices 45

6 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

10.2 Important information for service personnel 72

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 7

Downloaded from www.Manualslib.com manuals search engine

8 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 9

Downloaded from www.Manualslib.com manuals search engine

10 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

Qualification – Only the fuses specified in the electrical circuit

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 11

Downloaded from www.Manualslib.com manuals search engine

1.3 Legal foundations (Germany) The additional safety instructions as

12 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

Failure to observe the safety instructions can lead to

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 13

Downloaded from www.Manualslib.com manuals search engine

1.4 Specified Use the manufacturer – is responsible for all personal

14 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

– control and regulation units including control sys-

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 15

Downloaded from www.Manualslib.com manuals search engine

GEA Refrigeration Germany GmbH

GEA Refrigeration Germany GmbH

16 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 17

Downloaded from www.Manualslib.com manuals search engine

Hint! – exposure to noise,

18 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

Hint! lutely necessary to ensure a minimum oil level

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 19

Downloaded from www.Manualslib.com manuals search engine

– The maintenance and replacement regulations

20 GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015

Downloaded from www.Manualslib.com manuals search engine

Hint! The screw compressor packages are

fig.2: Designation of the lifting points

GEA Refrigeration Germany GmbH | P_261511_1 | Generated 01.04.2015 21

Downloaded from www.Manualslib.com manuals search engine

Take special care not to attach the ropes near to

fig.3: Stopper with shackle

fig.4: Transportation with a wire rope hoist