Related Manuals for GEA Grasso 5
Summary of Contents for GEA Grasso 5
- Page 1 Reciprocating compressors for industrial refrigeration GEA Grasso V Installation and Maintenance instructions (Original text) 0089288_imm_v_english_19...
- Page 2 GEA. This restriction also applies to the corresponding drawings and diagrams. LEGAL NOTICE This publication has been written in good faith. However, GEA cannot be held responsible, neither for any errors occurring in this publication nor for their consequences.
- Page 3 SYMBOLS USED Danger Stands for an immediate danger leading to severe physical injuries or death. ► Description for avoiding the danger. Warning! Stands for a potentially dangerous situation leading to severe physical injuries or death. ► Description for avoiding the dangerous situation. Caution! Stands for a potentially dangerous situation which could lead to minor physical injuries or damage to property.
- Page 4 Installer oriented information The compressor (package) is filled with nitrogen to prevent penetration of moisture. Therefore, keep the compressor closed until the compressor (package) is being installed. Never store the compressor filled with compressed air. Compressed air contains moisture that will corrode the inside and working components of the compressor. To store the compressor, fill it with dry nitrogen after fully evacuating it.
- Page 5 General All documentation can be downloaded via our web site. GEA technical manuals includes “generic paragraphs”; this means that it can occur that not all data as described is relevant for the current compressor series as mentioned in this manual. (For instance, not all compressor series...
- Page 6 0089288_imm_v_english_19 07.04.2021...
- Page 7 CYLINDER NUMBERING, BOOSTER AND SINGLE-STAGE OPERATION Cylinder numbering Fig.1: Example cylinder numbering 6 cylinder compressor Booster or single-stage operation Booster operation applies if condensing temperature < +5 Single-stage operation applies if condensing temperature >= +5 0089288_imm_v_english_19 07.04.2021...
- Page 8 0089288_imm_v_english_19 07.04.2021...
- Page 9 GENERAL INFO Main setup data Value Description Remark Grasso V 300 (T) .. V 600 (T) Grasso V 700 (T) .. V 1800 (T) Caution! General limits of operation Refer to Product Information Section 4.2, Page 51 The NO-solenoid has to be de-energised 20 seconds after starting the compressor Start frequency...
- Page 10 0089288_imm_v_english_19 07.04.2021...
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Page 11: Table Of Contents
TABLE OF CONTENTS INSTALLATION AND PREPARATION FOR USE Running-in oil filter has to be installed after an overhaul or big repair Safety valves INSTALLATION 1.3.1 Moving instructions and storage 1.3.2 Storage 1.3.3 Hoisting and moving instructions 1.3.4 Required free space 1.3.5 Foundation requirements Concrete structure... - Page 12 Spare parts manual Post start-up maintenance First maintenance SERVICE MAINTENANCE SCHEDULE 3.4.1 Description Maintenance A, B and C 3.4.2 EXPLANATION SERVICE ACTIVITIES 3.4.3 Maintenance compressor V (HS, HP) Series Maintenance table V (HS, HP) Series, part 1 of 3 Maintenance table V (HS, HP) Series, part 2 of 3 Maintenance table V (HS, HP) Series, part 3 of 3 Most operated cylinders 3.4.4...
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Page 13: Installation And Preparation For Use
Safety valves Danger If the package includes an oil separator, be sure that a (dual) safety valve (GEA option) is fitted onto oil separator. Hint! The contractor is responsible for arranging the (dual) safety valve according the Pressure Equipment Directive 2014/68/EU. -
Page 14: Moving Instructions And Storage
INSTALLATION AND PREPARATION FOR USE INSTALLATION The electric wiring should be completed as per wiring diagrams. Do not energise the main power control cabinet until oil is added and the direction of rotation has been checked. The compressor is to be filled with the correct type and amount of lubricating oil and has to be pre-lubricated (Refer Section 4.7, Page 61) before the first start. -
Page 15: Hoisting And Moving Instructions
INSTALLATION AND PREPARATION FOR USE INSTALLATION 1.3.3 Hoisting and moving instructions Fig.2: Hoisting a compressor package Packaged base frame: The only places that can be used for safe hoisting of the package are the four hoisting eyes on the steel base frame as shown in the above figure. Prior to hoisting a compressor package with a V-belt drive arrangement, the factory mounted drive guard has to be removed. -
Page 16: Required Free Space
INSTALLATION AND PREPARATION FOR USE INSTALLATION Fig.3: Hoisting angle Moving by fork-lift truck The bare compressor or package can be transported with a fork-lift truck with the forks spread as much as possible between the skids. To simplify moving, the 2 wooden transport beams must still be mounted underneath the base frame and stored in this way, until the package is positioned above its approximate location. -
Page 17: Concrete Structure
INSTALLATION AND PREPARATION FOR USE INSTALLATION Compressor package with steel base frame mounted on a concrete block. Following base frames are possible; Frame designed for mounting on concrete block. For more instalation details refer to; Section 1.3.5.1, Page 17, Section 1.3.5.2, Page 18, Section 1.3.5.3, Page 19, Section , Page 20, Section , Page 20. -
Page 18: Anchoring
INSTALLATION AND PREPARATION FOR USE INSTALLATION Fig.5 Chemical anchor Grouted anchor, grounded to reinforcing steel It is recommended to consult a concrete specialist/ constructor for the following items: • The compound of the concrete with/without reinforcement. • The exact grouting depth (dependent on the soil conditions). •... -
Page 19: Mounting The Base Frame On A Concrete Block
INSTALLATION AND PREPARATION FOR USE INSTALLATION Fig.6: Anchoring details Drilled chemical anchor (M20) Grouted anchor recesses (M20) Installed chemical anchor before placing the base frame Installing chemical anchor after placing the base frame (base frame cannot be removed easily) Drilling angle 1.3.5.3 Mounting the base frame on a concrete block General After the space between base frame and concrete base has been filled-up with a... - Page 20 INSTALLATION AND PREPARATION FOR USE INSTALLATION Caution! Do not tighten the anchor bolts until grout has fully cured. Levelling the base frame Fig.7: Grouting details Self-levelling grout Adjusting bolts (4x, not included) Washer Temporary barrier strip around and inside frame Complete cured concrete block Grout layer After the anchor filling mortar has completely cured the frame should be levelled...
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Page 21: Mounting Bare Compressor On A Concrete Block
INSTALLATION AND PREPARATION FOR USE INSTALLATION Grouting must be carried out in accordance with the instructions provided by the grouting supplier. After complete de-aeration of the grouted layer, secure the base frame by tightening the anchor bolt nuts and remove all adjusting bolts. At this stage the drive system can be installed. -
Page 22: Torques For Factory Supplied Check Valve / Stop Valve Assembly
INSTALLATION AND PREPARATION FOR USE INSTALLATION be found in the "Product Information" (bare compressor) and in case of a package, the package lay out drawing. Hint! If an oil rectifier system is applied in the refrigeration system, the oil return line must be connected to the oil return connection (see "Product Information"). -
Page 23: Connecting The Power Supply
INSTALLATION AND PREPARATION FOR USE INSTALLATION Fig.10: Stop valve - check valve assembly Nut and stud Stud PN 25 PN 63 (heat pump application) DN 50 4x M16 100 Nm 4x M20 185 Nm DN 65 8x M16 100 Nm 8x M20 185 Nm DN 80... -
Page 24: Preparations For Use
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE PREPARATIONS FOR USE After the Compressor (Package) has been installed (excluding final connection of drive device), the following actions should be followed in the order given: 1.4.1 Leak test of compressor and system The compressor (package) has been pressure tested prior to leaving the factory. -
Page 25: Oil Quantities
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE Warning! Oil charging via the suction line of the compressor is not allowed. Used or filtered oil should NEVER BE added to a compressor under any circumstance. Use only new oil as selected from the Grasso oil table. (Refer Chapter 4, Page 51) Procedure: STATUS: System is dried and still evacuated. -
Page 26: Initial Refrigerant Charge
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE Fig.11: Pre-lubrication valve (P), Oil control pressure regulator (B) Caution! Pre-lubrication just before the first start is obligatory. 1.4.4 Initial refrigerant charge Refrigerant charging should be done in accordance with the plant manual by qualified refrigeration engineers. -
Page 27: Re-Adjustment Of Oil Pressure Regulators
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE Pressure safety limit switches Grasso V 700(T) Grasso V 1100(T) 24 bar(a) Grasso V 1400(T) Grasso V 1800(T) Lubrication oil Setting Min. =1.3 bar pressure difference Oil pressure regulators Setting 2.0 bar Lubrication oil pressure Min. - Page 28 INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE Fig.13: Oil control pressure regulator (B), Pre-lubrication valve (P) Caution! Oil charge valve (P) for lubrication circuit. this connection to be used for pre-lubrication of the oil circuit Re-adjustment procedure: Run the compressor for 15 minutes until the crankcase oil is at its stable operating temperature [Toil] of 50 C and check: 1) The lubricating oil pressure difference (A)
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Page 29: Checking Direction Of Rotation Of Motor Shaft
Use of incorrect control steps can damage compressor and/or components. For a detailed description about start-up and part load limitations refer to GEA Grasso Selection Software. 1.4.9.2 WIRING LOGIC NORMALLY OPEN UNLOADED START SOLENOID If compessor is NOT running then NO-solenoid is not energised. -
Page 30: Frequency Controlled Compressor
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE 1.4.9.3 Frequency controlled compressor Hint! In case of frequency controlled compressors, a separate instruction 00.87.041 is required. If you don’t have this instruction consult Grasso. 1.4.9.4 Pre-start check list The following Paragraph covers only the initial start of the compressor and not the complete refrigeration plant. -
Page 31: Restart
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE Notice "Pre-start check list", also consult the plant manual and verify the following items: – Check the oil temperature (refer to the "Product Information"). – Check crankcase oil level (refer to Section 2.4.1, Page 35). –... -
Page 32: Restart After A Long Standstill Period Of Time
INSTALLATION AND PREPARATION FOR USE • Refer to Section 1.4.10.2, Page 31. 1.4.10.4 Restart after a long standstill period of time After a seasonal standstill (1 to 6 months) or maintenance operations; Warning! After a standstill period of time more than 1 month, pre-lubrication just before starting is always obligatory. -
Page 33: Inspection And Trouble Shooting
INSPECTION AND TROUBLE SHOOTING Periodical inspection INSPECTION AND TROUBLE SHOOTING Periodical inspection These inspections should be made during the normal shut-down periods as much as possible, so the compressor is always ready to operate when required. If, at that time, the number of running hours slightly differs from the scheduled period below, the inspection should nevertheless be carried out. -
Page 34: Check List Periodical Inspection
INSPECTION AND TROUBLE SHOOTING STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 2.2.1 Check list periodical inspection Check list periodical inspection FREQUENCY REMARKS CHECK POINTS * Between 25% and 75% height of the sight glass. For Oil level in crankcase •... -
Page 35: Lubrication Data
INSPECTION AND TROUBLE SHOOTING LUBRICATION DATA To shut down a compressor for long term periods, proceed as follows: Tightly shut both the suction and discharge stop valves and the stop valve of the oil return line (if present). Disconnect the power source from the compressor drive motor and the electrical control cabinet. -
Page 36: Evacuation Of Refrigerant Before Servicing
INSPECTION AND TROUBLE SHOOTING EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE Always use a vacuum pump or pump-down unit to evacuate the refrigerant from the compressor. 2.5.1 EVACUATION OF REFRIGERANT BEFORE SERVICING Procedure to evacuate the compressor: Switch off main control panel. Remove main fuses. -
Page 37: Draining And Change Of Oil
INSPECTION AND TROUBLE SHOOTING DRAINING AND CHANGE OF OIL Check running condition. Hint! The job isn't finished until the paper work is done! Complete the service report, e.g. Grasso report 00.89.062. DRAINING AND CHANGE OF OIL To top up oil see Section 2.4.1, Page 35, Oil changing procedure: Evacuate the compressor (refer to Section 2.5, Page 35). -
Page 38: Dismantling, Inspection And Re-Assembly Of Suction And Discharge Valves
INSPECTION AND TROUBLE SHOOTING DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES Oil discharge filter Hint! Use the special tool for (dis)mounting the oil discharge filter element Evacuate the compressor prior to exchange any filters. DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES Hint! A high working temperature and rapid temperature variations shorten... -
Page 39: Troubleshooting Table Grasso Reciprocating Compressors
INSPECTION AND TROUBLE SHOOTING TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS Slowly open suction stop valve. Open the stop valve in the oil return line of the oil separator (if present). vii. For two stage compressor only; vii.a Two-stage system A/B: open liquid supply to interstage cooler. vii.b Two-stage system C/D: refer to the plant manual. - Page 40 INSPECTION AND TROUBLE SHOOTING TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS Troubleshooting FAULT CAUSE REMEDY 1. Discharge stop valve not fully open Open fully 2. Discharge pressure gauge defective Repair or replace Discharge pressure too high 3. Non-condensables in the system Purge with a Automatic Purger 1.
- Page 41 INSPECTION AND TROUBLE SHOOTING Troubleshooting FAULT CAUSE REMEDY 4. Restriction plug at the bottom of suction Clean plug chamber in cylinder clogged 5. Worn out oil scraper ring(s) Replace ring(s) 6. Loss of oil due to leakage Repair Repair shaft seal 7.
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Page 42: Maintenance
1) Retighten the coupling mounting bolts with the torque settings as given by the coupling manufacturer. 2) Verify and if necessary, correct the tension of the V-belts as given in GEA instruction 0087528. vii. Verify and if necessary, correct the torque settings of all foundation bolts as given in Compressor Service Instruction Manual. -
Page 43: Service Maintenance Schedule
Maintenance A, B and C, service intervals are determined on measured values of GMM/GEA Omni™. Maintenance B can vary between 7.500 and 18.000 running hours where 15.000 running hours is the standard for B- maintenance for compressors running at To -10°C / Tc +35°C and 1200 min Maintenance to execute shown by the Omni or GMM GMM/GEA Omni™... - Page 44 MAINTENANCE SERVICE MAINTENANCE SCHEDULE Without GMM or Omni™: B-and C-Maintenance to be carried out as shown in the Maintenance schedule. Hint! For compressors running at 1500 min fixed speed without GMM or Omni™ the standard of 12000 hrs becomes 10000 running hours. (B- maintenance) Description maintenance A;...
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Page 45: Explanation Service Activities
Clean Clean Remarks The indicated activities to be performed as specified in other GEA Grasso documentation: Parts List (PL), Product Information (PI), Installation and Maintenance Manual (IMM), Service Instruction Manual (SIM) Unless otherwise stated: All checkpoints have to be visually assessed for irregularities like leakages, fractures, overheating, discolourations, dents, bursts, presence of sludge, debris and solid particles etc. - Page 46 MAINTENANCE SERVICE MAINTENANCE SCHEDULE Visual inspections: The visual inspections during maintenance are of importance; measurements should be carried out at the moment that visually abnormalities are detected. The result of the inspection determines whether one or more parts have to be replaced.
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Page 47: Maintenance Table V (Hs, Hp) Series, Part 1 Of
MAINTENANCE SERVICE MAINTENANCE SCHEDULE 3.4.3.1 Maintenance table V (HS, HP) Series, part 1 of 3 GEA Grasso Maintenance intervals, part 1 of 3 Flexible interval: Depending on running conditions and shown by GMM or OMNI - - - - - - - - - -... -
Page 48: Maintenance Table V (Hs, Hp) Series, Part 2 Of
MAINTENANCE SERVICE MAINTENANCE SCHEDULE 3.4.3.2 Maintenance table V (HS, HP) Series, part 2 of 3 GEA Grasso Maintenance intervals, part 2 of 3 Flexible: Depending on running conditions and shown by GMM or OMNI - - - - - - - - - -... -
Page 49: Maintenance Table V (Hs, Hp) Series, Part 3 Of
MAINTENANCE SERVICE MAINTENANCE SCHEDULE 3.4.3.3 Maintenance table V (HS, HP) Series, part 3 of 3 GEA Grasso Maintenance intervals, part 3 of 3 Flexible: Depending on running conditions and shown by GMM or OMNI - - - - - - - - - -... -
Page 50: Package Components
MAINTENANCE Compressor size Most operated cylinders 4 cylinder compressor 6 cylinder compressor 3 or 4 8 cylinder compressor 5 and 6 10 cylinder compressor 5, 7 and 8 3.4.4 Package components Checklist package components Description/checkpoint Drive guard Coupling alignment Oil level float switch on compressor and oil separator Pressure safety switches Pressure gauges Thermostats and thermometers... -
Page 51: Appendix; Product Information (Pi)
APPENDIX; Product Information (PI) GRASSO MAINTENANCE MONITOR APPENDIX; Product Information (PI) GRASSO MAINTENANCE MONITOR Hint! In case the GEA Omni™ is included, the GMM hardware is not required, since the GEA Omni™ includes the GMM software. Fig.16: Grasso Maintenance Monitor GMM connections Ethernet Power input (10 .. - Page 52 APPENDIX; Product Information (PI) GENERAL LIMITS OF OPERATION GRASSO V The diagrams overleaf represent the overall fields of application in which the individual operation limits are taken into account. General limits and fields of operation REFRIGERANT 500 min for direct drive Grasso V 300(T) ..
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Page 53: Starting Up Of Two-Stage Compressors
APPENDIX; Product Information (PI) STARTING UP OF TWO-STAGE COMPRESSORS General limits and fields of operation REFRIGERANT +170 °C This is the actual discharge temperature, measured directly in Discharge temperature Grasso V the gas flow just before the max. discharge connection. The given value also applies to the LP stage of two-stage compressors. - Page 54 APPENDIX; Product Information (PI) STARTING UP OF TWO-STAGE COMPRESSORS Procedure to move on to two-stage operation and to increase capacity. Once properly started, as indicated in the previous paragraph, the compressor has to be switched over to two-stage operation with minimum capacity, followed, if and when required, by gradual stepping up to maximum capacity.
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Page 55: Diagrams Single Stage And Booster
APPENDIX; Product Information (PI) DIAGRAMS SINGLE STAGE AND BOOSTER Therefore, for all Grasso two-stage types a fast pull- down electric capacity control system has been developed, which allows the compressors to be started with two or more HP cylinders in operation and which includes one or more part- load steps with volume ratio ϕ... - Page 56 APPENDIX; Product Information (PI) DIAGRAMS SINGLE STAGE AND BOOSTER Capacity control steps Compressor Capacity % Cylinders Solenoids type (5+6) + (2+4) + (1+3) 3 + 4 (5+6) + 7 + (2+4) + (1+3) 1 + 3 + 4 (5+6) + 7 + 8 + (2+4) + (1+3) 1 + 2 + 3 + 4 (5+6) (5+6) + 8...
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Page 57: Diagrams Two Stage
APPENDIX; Product Information (PI) DIAGRAMS TWO STAGE DIAGRAMS TWO STAGE Solenoid valve/cylinder numbering for electric capacity control Solenoid No. 1 No. 2 No. 3 No. 4 Cylinder number / solenoid valves 300T & 700T 450T & 5, [6 2, 3 1100T 600T &... - Page 58 APPENDIX; Product Information (PI) DIAGRAMS TWO STAGE Capacity control steps Qty HP / Qty LP Compressor Cylinders Solenoids Capacity % Remark type cylinders (1 + 2) + 3 + 1 + 2 (1 + 2) + [6] + Starting only/Fast 1 + 3 (4 + [8]) pull down...
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Page 59: Lubricating Oils (Choice And Recommendations)
LUBRICATING OILS (choice and recommendations) LUBRICATING OILS (choice and recommendations) Hint! In case a Grasso compressor is used inside a GEA Grasso produced chiller, the applicable oils could be limited compared with the oils mentioned in this chapter for use with NH as refrigerant. -
Page 60: Accepted Nh 3 Oil Types
APPENDIX; Product Information (PI) LUBRICATING OILS (choice and recommendations) Strongly recommended oil types for Grasso reciprocating compressors Refrigerant used Brand Type designation Food Grade CP-1009-68 Reflo 68A PETRO CANADA Reflo XL Klüber Summit RHT-68 TEXACO Capella Premium 68 Clavus S-68 SHELL Refrigeration Oil S2 FR-A 68 4.6.2... -
Page 61: Pre-Lubrication Oil System
APPENDIX; Product Information (PI) Pre-lubrication oil system For an add on Heat Pump where an ISO VG 100 oil is mandatory, the oil may also be applied to the refrigeration compressor(s) providing: • An oil cooler is present to ensure the oil temperature stays within normal operating limits (refer to paragraph 2.8 “Air Cooled Oil Cooler”... - Page 62 • • GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.