GEA Grasso RC9 Series Instruction Manual
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GEA Grasso RC9 Series Instruction Manual

Refrigeration compressors
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RC9
Instruction Manual For Refrigeration Compressors
00.89.221
v003.99.06.en

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Summary of Contents for GEA Grasso RC9 Series

  • Page 1 Instruction Manual For Refrigeration Compressors 00.89.221 v003.99.06.en...
  • Page 2 Grasso Refrigeration Division All rights reserved. No part of this publication may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of Grasso. This restriction also applies to the corresponding drawings and diagrams. For extra information as to adjustments, maintenance and repair, contact the Technical Department of your supplier.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Grasso Refrigeration Division SUBJECT ..............................See page: 1. INTRODUCTION ..........................1.1 2. FUNCTION OF THE COMPRESSOR IN THE REFRIGERATING PLANT........... 2.1 3. TECHNICAL DATA 3.1 General technical data......................3.1 3.2 Connections and required free space ..................3.2 3.3 Lubrication data........................
  • Page 4 TABLE OF CONTENTS Grasso Refrigeration Division Page II Refrigeration Compressors Series RC9 v002.97.10.en...

  • Page 5: Introduction

    1. INTRODUCTION Grasso Refrigeration Division This instruction manual is intended as a guide for the operating staff in charge of the preventive maintenance of the compressor. In addition to data concerning the construction and operation of the machine, the manual contains operating, inspection and maintenance instructions which should necessarily be followed in order to keep the compressor in the proper state under normal...
  • Page 6 1. INTRODUCTION Grasso Refrigeration Division Page 1.2 Refrigeration Compressors Series RC9 v002.97.10.en...

  • Page 7: Function Of The Compressor In The Refrigerating Plant

    2. FUNCTION OF THE COMPRESSOR IN THE REFRIGERATION PLANT Grasso Refrigeration Division A refrigerating plant is used in cases where a certain room or certain materials are to be brought up to or be maintained at a temperature lower than the ambient temperature.
  • Page 8 2. FUNCTION OF THE COMPRESSOR IN THE REFRIGERATION PLANT Grasso Refrigeration Division Page 2.2 Refrigeration Compressors Series RC9 v002.97.10.en...

  • Page 9: Technical Data

    3. TECHNICAL DATA Grasso Refrigeration Division The range of RC9 refrigeration compressors includes 3-single-stage and 2 two-stage compressor types. All these types are suitable for the usual refrigerants. The single-stage compressors can also used as booster. 3.1 GENERAL TECHNICAL DATA Single-stage compressors Two-stage compressors Compressor type...
  • Page 10 3. TECHNICAL DATA Grasso Refrigeration Division All dimensions in mm All dimensions in mm All dimensions in mm Page 3.2 Refrigeration Compressors Series RC9 v002.97.10.en...
  • Page 11 3. TECHNICAL DATA Grasso Refrigeration Division COMPRESSOR MAIN CONNECTIONS OTHER CONNECTIONS TYPE hole dia. in counter flange in mm for all types 5 Suction pressure 6 Crankcase pressure RC29 ø55 ø43 – – 7 Discharge pressure connection clamp coupling for RC49 ø55 ø62...
  • Page 12 3. TECHNICAL DATA Grasso Refrigeration Division All compressors are provided with an oil pump. The Application of other oils is not permitted without crankcase oil level must reach about the middle of the written consent of Grasso. sight glass. The amount of oil charge is shown in table The choice of the viscosity of the lubricating oils 3.1.

  • Page 13: General Description Of The Compressor

    4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division cylinders liner and jacket serves as suction 4.1 COMPRESSOR HOUSING (see fig. 4.1) chamber. The discharge chamber is formed by the upper part of the cylinder jacket shut-off by the The compressor housing is of a welded steel cylinder head cover.

  • Page 14: Cylinders And Moving Parts

    4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division is at the bottom of the crankcase. To determine gudgeon pin, a bronze bush or, in the case of the oil level, a sight glass is located on the HP-cylinders of two stage compressors, a needle crankcase.

  • Page 15: Suction And Discharge Valves

    4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division crankshaft by means of three grub screws (7.4) with four sinusoidal springs is placed and a drive pin (3) . The slip ring holder with concentrically. The discharge valve seat and the carbon insert can slide axially over the crankshaft suction valve stroke limitor are one and the same.

  • Page 16: Cylinder Head Cooling

    4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division 1. Lever 2. Piston housing 3. Spring 4. Control piston 5. Suction valve ring 6. Push pin 7. Lifting bush A Control oil pressure FIG. 4.4 VALVE—LIFTING MECHANISM and lift the suction valve ring. Shortly after the refrigerating plant via stop valves.

  • Page 17: Oil Pump, Filters And Control Oil System

    4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division Crankcase pressure = suction pressure for both pump consisting of three gears with the centre gear driven by the crankshaft. single- and two-stage compressors In order to prevent excessive discharge pressures The oil suction and oil discharge filters are fitted in the compressor, one or more overflow safety to the pump.

  • Page 18: Lubrication System

    4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division After starting the compressor, the through-flow of 4.10 LUBRICATION SYSTEM the control oil pressure to the valve lifting mechanisms is interrupted for 30 to 60 seconds by The lubrication of the compressor is effected a hydraulic delay valve provided in the pump.
  • Page 19 4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division end of the crankcase, from where it flows back to the oil sump via an internal line: this oil stream is visible behind the sight glass. In the return line an adjustable lubricating pressure regulator is fitted. This spring-loaded ball valve allows the return oil to pass at a certain pressure only, thus determining the pressure in the lubrication system.
  • Page 20 4. GENERAL DESCRIPTION THE COMPRESSOR Grasso Refrigeration Division Page 4.8 Refrigeration Compressors Series RC9 v002.97.10.en...

  • Page 21: Description And Operation Of Accessories

    5. DISCRIPTION AND OPERATION OF ACCESSORIES Grasso Refrigeration Division The accessories of the compressor include those The gauges indicate the pressure in bars; at a pressure devices and systems with which the efficient lower than the atmospheric, the pressure gauge operation of the compressor in the installation can indicates a negative value.

  • Page 22: Crankcase Heating

    5. DISCRIPTION AND OPERATION OF ACCESSORIES Grasso Refrigeration Division The lubricating oil pressure safety switch protects the or by a push button switch in the control compressor against too low lubricating oil pressure. current circuit for the drive motor. The lubricating oil pressure is the difference between oil pressure and crankase pressure (=suction pressure) 5.3 CRANKCASE HEATING indicated by pressure gauges.

  • Page 23: Capacity Control

    5. DISCRIPTION AND OPERATION OF ACCESSORIES Grasso Refrigeration Division klaxon can be connected via auxiliary contacts (see This control system enables the compressor to be the plant manual). controlled in maximum four steps from minimum up to maximum capacity. After stopping the 5.5 CAPACITY CONTROL compressor it is desirable to set the oil distributor again to position 1 (also refer to chapter 7).
  • Page 24 5. DISCRIPTION AND OPERATION OF ACCESSORIES Grasso Refrigeration Division POSITION OF OIL DISTRIBUTOR starting APPLICATION control up to maximum capacity minImum capacity Each figure between brackets refers to the COMPRESSOR TYPE OPERATING CYLINDERS swept volume expressed as a percentage of the full load swept volume Typical numbering of •...
  • Page 25 5. DISCRIPTION AND OPERATION OF ACCESSORIES Grasso Refrigeration Division VALVE NO. non- energized energized minimum APPLICATION starting control up to maximum capacity capacity Each figure between brackets refers to the swept volume expressed as a COMPRESSOR TYPE OPERATING CYLINDERS percentage of the full load swept volume •...

  • Page 26: Injection Interstage Gas Cooler

    5. DISCRIPTION AND OPERATION OF ACCESSORIES Grasso Refrigeration Division “energized”. However, in this case, the valve can externally against the HP-suction line of the no more be operated electrically in the usual way. compressor (see fig. 5.4, overleaf). At compressor standstill the supply of liquid is cut off by a 5.6 INJECTION INTERSTAGE GAS COOLER (only solenoid valve located upstream the expansion...

  • Page 27: Operation Of The Compressor

    6. OPERATION OF THE COMPRESSOR Grasso Refrigeration Division It is sometimes difficult to find out the sort of 6.1 UNLOADED STARTING liquid hammer. Frosting of the cylinder jacket as well as an abnormally low discharge gas When the compressor is at standstill, the suction temperature may point to the fact that liquid valve rings in all cylinders have been lifted refrigerant is being sucked.
  • Page 28 6. OPERATION OF THE COMPRESSOR Grasso Refrigeration Division Page 6.2 Refrigeration Compressors Series RC9 v002.97.10.en...

  • Page 29: Starting, Stopping And Adjustment Of Compressor

    7. STARTING, STOPPING AND ADJUSTMENT OF COMPRESSOR Grasso Refrigeration Division This chapter deals with the starting and stopping d) Check whether the discharge stop valve, the of the compressor in a plant which, after the test pressure gauge valves and (in the case of run, has been delivered completely ready for two-stage compressors) the stop valves in the operation by the installation engineer.

  • Page 30: Stopping The Compressor

    7. STARTING, STOPPING AND ADJUSTMENT OF COMPRESSOR Grasso Refrigeration Division 7.2 STOPPING THE COMPRESSOR The compressor can be stopped at any moment by switching off the drive motor. However, 7.3 SETTING OF THE OIL PRESSURE REGULATOR consult the plant manual for further action The lubricating oil pressure regulator has been set required, especially in the case of plants with a during the testing of the compressor in the works.

  • Page 31: Setting Of Pressure Safety Switches

    7. STARTING, STOPPING AND ADJUSTMENT OF COMPRESSOR Grasso Refrigeration Division pressure respectively, until the required pressure difference has been achieved. After resetting, replace the cap nut with sealing ring on the pressure regulator. 7.4 SETTING OF PRESSURE SAFETY SWITCHES (see fig. 7.2) The discharge pressure and suction pressure safety switches must be set at the values indicated in the plant manual.
  • Page 32 7. STARTING, STOPPING AND ADJUSTMENT OF COMPRESSOR Grasso Refrigeration Division Page 7.4 Refrigeration Compressors Series RC9 v002.97.10.en...

  • Page 33: Periodical Inspections Of The Operating Compressor

    8. PERIODICAL INSPECTION OF THE OPERATING COMPRESSOR Grasso Refrigeration Division 8.1 SURVEY OF PERIODICAL INSPECTIONS ("CHECK LIST") (Also refer to the explanation overleaf) FREQUENCY CHECK POINTS REMARKS Oil level in crankcase The oil level must be between 1 and 3 quarters •...

  • Page 34: Explanation To The Survey Of Periodical Inspections

    8. PERIODICAL INSPECTION OF THE OPERATING COMPRESSOR Grasso Refrigeration Division 8.2 EXPLANATION TO THE SURVEY OF PERIODICAL INSPECTIONS In order to prevent sudden failures as much as possible, it is recommended to inspect the compressor periodically at a certain number of points.

  • Page 35: Compressor Maintenance

    9. COMPRESSOR MAINTENANCE Grasso Refrigeration Division Besides the inspection during operation described in 9.2 LUBRICATION DATA chapter 8, the compressor requires regular maintenance. This maintenance is limited to topping The types of oil mentioned in table 3.1 on page up or changing the lubricating oil, regular cleaning of 3.3 have the required properties and may oil filters and gas suction strainer and to the therefore be used.

  • Page 36: Evacuation Of Compressor

    9. COMPRESSOR MAINTENANCE Grasso Refrigeration Division of a separate oil pump. This pump enables the oil h) Fix a hose to this connection point and put its to be forced into the crankcase via the oil open end at some safe place in the free air. charging valve, against suction pressure.

  • Page 37: Cleaning Of Oil Filters

    9. COMPRESSOR MAINTENANCE Grasso Refrigeration Division g) Proceed according to the points h, i and j of the instructions for cleaning oil filters (refer to par. MIND! The paper filter element (oil discharge 9.6). filter) should be placed on the right-hand side of the pump.
  • Page 38 9. COMPRESSOR MAINTENANCE Grasso Refrigeration Division b) Remove the cylinder head cover. MIND! If it appears that valve parts are broken, CAUTION! also the cylinder liner and piston of the relevant The nuts on the long studs must be cylinder must be checked for damage. unscrewed last, thus enabling the buffer spring fitted under the cover to extend before The valve rings and valve seats must be...

  • Page 39: Compressor Purging

    9. COMPRESSOR MAINTENANCE Grasso Refrigeration Division head. Make sure that the buffer spring is f) Open the discharge valve and watch the centred by the cover. Pull the cover with the discharge and suction pressure gauges, nuts on the long studs so far down that the particularly if maintenance operations have other studs been effected on the valves.
  • Page 40 9. COMPRESSOR MAINTENANCE Grasso Refrigeration Division Page 9.6 Refrigeration Compressors Series RC9 v003.98.11.en...

  • Page 41: Fault Finding Table

    10. FAULT FINDING TABLE Grasso Refrigeration Division The fault-finding table below may be helpful to failure must often be sought in the refrigeration quickly trace and remedy failures that interfere installation itself. Therefore, it is necessary, in with the proper operation of the compressor. It is addition to this fault-finding table, also to consult emphatically pointed out that the cause of a the plant manual.
  • Page 42 10. FAULT FINDING TABLE Grasso Refrigeration Division FAULT CAUSE REMEDY F All cylinders out of 1. Control pressure for valve lifting mechanism 1. See K action while compressor too low is operating G Too high oil 1. Type of oil not according to lubrication oil 1.
  • Page 43 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division The standard illustrated parts list on the following pages is meant for identification and accurate specification of current spare parts. Refer to the Monitron CR instruction manual, Chapter 8, Par. 8.7, if equipped with a Monitron CR-Control. In order to facilitate quick retrieval of the required parts, the list and corresponding figures is divided into the following groups of parts: PARTS LIST...
  • Page 44 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks COMPRESSOR HOUSING WITH CONNECTIONS & OVERFLOW SAFETY FIG. RC9-1 VALVES Hex. nut M20 01.15.110 Qty per cylinder cover Cylinder cover 441x298KA85M 23.15.502 — without temp. sensor plug holes Cylinder cover 441x298KA85G13 23.15.510 —...
  • Page 45 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-1 v003.99.06.en Refrigeration Compressors Series RC9...
  • Page 46 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-2 RC9-3 Refrigeration Compressors Series RC9 v003.99.06.en...

  • Page 47: Bearing Covers

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks BEARING COVERS FIG. RC9-2 Bearing cover assy KA85MSB Oil pump side Bearing cover KA85M 21.14.921 Cylindrical pin 4x12 11.06.412 Bearing sleeve 65x72x65 11.46.766 Stud M12x138 01.51.617 Bearing cover assy KA85M SUB A Drive side Bearing cover B KA85 21.14.931...

  • Page 48: Piston And Connecting Rod

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks PISTON AND CONNECTING ROD FIG. RC9-4 Piston assy S110x40x110FA85 24.06.000 Gudgeon pin 28x40x90RC9 24.20.300 Piston Set of piston rings 110KA85 09.74.114 Snap ring 40 11.04.040 Con rod assy S65x210KA85 24.06.500 in single-stage compr.
  • Page 49 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-4 RC9-5 v003.99.06.en Refrigeration Compressors Series RC9...
  • Page 50 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-6 RC9-7 Refrigeration Compressors Series RC9 v003.99.06.en...

  • Page 51: Suction And Discharge Valve

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks SUCTION AND DISCHARGE VALVE FIG. RC9-6 Spring 18x111x3x118 11.31.183 Discharge valve assy RC9A 27.21.101 for all refrigerants, except R502 2.1a Socket head screw M6x25 01.04.325 2.2a Stroke limitor RC9 27.20.350 2.3a Sinusoidal spring 90x115...

  • Page 52: Oil Pump

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks OIL PUMP FIG. RC9-8 Gear pump RC9 18.10.150 Pump housing KA85M 26.14.501 Gear wheel 2x17G18 19.37.467 obtainable as set only Gear wheel 2x17D18 19.37.417 Bearing bush 18x24x61 11.46.718 Bearing bush 18x24x44 11.46.418...
  • Page 53 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-8 v003.99.06.en Refrigeration Compressors Series RC9...
  • Page 54 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-9 Refrigeration Compressors Series RC9 v003.99.06.en...

  • Page 55: Oil Filters

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks OIL FILTERS FIG. RC9-9 Oil suction filter assy RC9 07.15.909 on compr. types RC29, RC49 & RC219 Oil suction filter assy RC9 07.15.969 on compr. types RC69 & RC429 Filter upper housing Swivel coupling 16G21 03.39.216...

  • Page 56: Oil Return Line

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks OIL RETURN LINES FIG. RC9-10 Oil return line G21x360 44.05.924 2-cyl. compressor Oil return line G21x400 44.05.945 3- and 4-cyl. compressor Oil return line G21x440 44.05.964 6-cyl. compressor Valve housing H9K —...
  • Page 57 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-10 RC9-11 v003.99.06.en Refrigeration Compressors Series RC9...
  • Page 58 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division 1.15 1.14 1.13 1.12 1.11 1.10 1.16A 1.17 1.16B 1.18 RC9-12 RC9-13 Refrigeration Compressors Series RC9 v003.99.06.en...

  • Page 59: Electrically Operated Capacity Control

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks MANUALLY OPERATED CAPACITY CONTROL FIG. RC9-12 Manually capacity control 6x6G13 12.73.114 Oil distributor housing Plug G13 01.36.136 Alu sealing ring 13.5x20x1 09.12.014 — Spring 0.75x5.2x7.5x18 11.31.083 Steel ball W6 11.19.004 Ball bearing 6004 Distributor spindle 42x106...

  • Page 60: Pressure Gauge Panel

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks PRESSURE GAUGE PANEL FIG. RC9-14 Pressure gauge Discharge pressure NH3-P-100 12.10.113 NH3, single stage and two stage (except booster) R-P/100 12.12.113 R22, single stage and two stage Suction pressure, intermediate NH3-Z-100 12.10.114...
  • Page 61 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-14 RC9-15 v003.99.06.en Refrigeration Compressors Series RC9...
  • Page 62 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-16 RC9-17 Refrigeration Compressors Series RC9 v003.99.06.en...

  • Page 63: Elastic Coupling

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Item Description Ref. No. Remarks ELASTIC COUPLING FIG. RC9-16 Coupling type 42 (complete) 1.1a Coupling element 42 19.18.842 Coupling type 61 (complete) to facilitate mounting, a steel strip is 1.1b Coupling element 61 19.18.861 clamped around the coupling ele- Coupling type 91 (complete)

  • Page 64: Standard Sets Of Parts, Seals And Tools

    STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division STANDARD SETS OF PARTS, SEALS AND TOOLS NO FIGURE Qty for compressor types Item Description Ref. No. RC29 RC219/49 RC429/69 20.20.010 Set of special tools 20.20.021 Basic set of spare parts 20.20.031 —...
  • Page 65 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division RC9-18 v003.99.06.en Refrigeration Compressors Series RC9...
  • Page 66 STANDARD ILLUSTRATED PARTS LIST RC9 Grasso Refrigeration Division Refrigeration Compressors Series RC9 v003.99.06.en...
  • Page 67 Grasso Refrigeration Division v002.97.10.en Refrigeration Compressors Series RC9...
  • Page 68 Please contact your office: P.O. Box 343 • • • • 5201 AH ’s-Hertogenbosch • • • • The Netherlands Grasso Products B.V. Phone: +31 (0)73 - 6203 911 • • • • Fax: +31 (0)73 - 6231 286 • • • • E-Mail: products@grasso.nl Holzhauser Straße 165 •...

This manual is also suitable for:

Grasso rc29Grasso rc49Grasso rc69Grasso rc219Grasso rc429

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