Related Manuals for GEA Grasso VHS Series
Summary of Contents for GEA Grasso VHS Series
- Page 1 Reciprocating compressors for industrial refrigeration GEA Grasso VHS Installation and Maintenance instructions (Original text) P-NL-094_imm_VHS_English_13...
- 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 P-NL-094_imm_VHS_English_13 26.07.2021...
- 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 P-NL-094_imm_VHS_English_13 26.07.2021...
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- Page 9 GENERAL INFO Main setup data Descriptio Grasso V 700HS .. V 1800HS Remark Caution! General Limits of Operation Refer to Section 4.3, Page 51 The NO-solenoid has to be de-energised 20 seconds after starting the compressor motor Start frequency max. 6 starts per hour to enabel the motor to reach the minimum speed and the...
- Page 10 P-NL-094_imm_VHS_English_13 26.07.2021...
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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 reciprocating compressors 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 58) 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 Vhs
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 50) 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 Oil pressure regulators Setting 2.0 bar Lubrication oil pressure Min. and max. Min.=1.3 bar difference * Max.=4.5 bar at 50 C oil temp. Control oil pressure difference Setting 8.0 bar 1.4.5.3 RE-ADJUSTMENT OF OIL PRESSURE REGULATORS It is possible that after the compressor has been installed, the lubrication oil pressure regulator needs to be adjusted. -
Page 28: Checking Direction Of Rotation Of Motor Shaft
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE 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) 2) The control oil pressure difference (B) After the initial run the oil pressure differences should be slightly higher. -
Page 29: Wiring Logic Normally Open Unloaded Start Solenoid
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: Starting And Stopping Procedures
INSTALLATION AND PREPARATION FOR USE PREPARATIONS FOR USE Stop valves to the pressure gauges are open. vii. Suction stop valve is closed (in case the evaporating temperature is much higher than the design evaporating temperature) and the discharge stop valve is open and in case of two- stage compressors that the stop valves in the intermediate circuit lines are open. -
Page 31: Restart
INSTALLATION AND PREPARATION FOR USE Adjust pressure gauge stop valves, in order to avoid vibration of the pointers. (if present) Open the stop valve in the oil return line from the oil separator (if present). Drive: • Direct drive; After 50 hours of operation re-tighten the coupling bolts •... -
Page 32: 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 33: 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 Oil level in crankcase • glass. For topping up oil, refer to Section 2.4.1, Page 34. -
Page 34: Lubrication Data
INSPECTION AND TROUBLE SHOOTING LUBRICATION DATA iii. Place a moisture absorbing compound (eg a dessicant such as silica gel) inside the control cabinet. Place warning tags on the electric system and all closed stop valves. Prior to starting up after a shut down, change the oil and exchange the oil filters. Determine the starting and stopping procedure from prior to start the compressor. -
Page 35: Leak-Tightness After Servicing
INSPECTION AND TROUBLE SHOOTING EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE Switch off main control panel. Remove main fuses. Close shut-off valves. Relieve refrigerant to atmospheric pressure, via the evacuation/purging valve(s) as prescribed by local safety regulations. For the location of these valves refer to the "Product Information". -
Page 36: Draining And Change Of Oil
INSPECTION AND TROUBLE SHOOTING DRAINING AND CHANGE OF OIL DRAINING AND CHANGE OF OIL To top up oil see Section 2.4.1, Page 34, Oil changing procedure: Evacuate the compressor (refer to Section 2.5, Page 34). Drain the oil via the oil charging/drain valve. Remove the cover of one or more service openings on the compressor side. -
Page 37: Dismantling, Inspection And Re-Assembly Of Suction And Discharge Valves
INSPECTION AND TROUBLE SHOOTING DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES Hint! A high working temperature and rapid temperature variations shorten the life time of the valves, which, for this reason, require regular inspection. - Page 38 INSPECTION AND TROUBLE SHOOTING TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS The troubleshooting table shown overleaf may be helpful to quickly trace and remedy failures that interfere with the proper operation of the compressor. It is emphatically pointed out that the cause of a failure must often be sought in the refrigeration installation itself.
- Page 39 INSPECTION AND TROUBLE SHOOTING TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS Troubleshooting FAULT CAUSE REMEDY 1. Discharge stop valve not fully Open fully open 2. Discharge pressure gauge Discharge pressure too Repair or replace defective high 3. Non-condensables in the system Purge with a Automatic Purger 1.
- Page 40 INSPECTION AND TROUBLE SHOOTING Troubleshooting FAULT CAUSE REMEDY 1. Type of oil not according to oil Change oil type lubrication oil table (too thin oil) 2. Compressor operates unloaded Refer to design calculations too frequently Check the operation of float valve in oil 3.
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Page 41: Maintenance
Spare parts manual Hint! A complete spare parts overview is available as a separate manual. Download the parts list manual via GEA website or consult your sales representative. Post start-up maintenance After the compressor has run for the initial 100 operating hours: Drain the oil and refill the compressor with the correct amount of fresh oil. -
Page 42: 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 43 MAINTENANCE SERVICE MAINTENANCE SCHEDULE Description maintenance A; Replace/clean oil discharge filter, clean oil suction filter Visual inspection of cylinders and crankcase Visual inspection of cylinder no. 1 Crankcase inspection on dirt and/or metal particles in case of no oil sampling for analysis Check compressor running conditions Check/test safety equipment Description maintenance B;...
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Page 44: 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 45 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 46: 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 47: 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 48: 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 49: 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 50: 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 51: Technical Data
APPENDIX; Product Information (PI) TECHNICAL DATA TECHNICAL DATA Grasso VHS series COMPRESSOR TYPE 1100 1400 1800 Total number of cylinders Cylinder bore (mm) Piston stroke (mm) speed 1500 min Total swept volume at full-load in (m 1193 1592 1991 clockwise when facing shaft... -
Page 52: Precise Field Of Application
Oil return temperature Toil_ret min. and/or other oil return source) temperature at which the return of oil is allowed When GEA Omni™ controller and oil cooler Capacity control, running time fully max. are applied 10 minutes; otherwise Consult unloaded PRECISE FIELD OF APPLICATION The field of application diagrams as shown in this manual can vary slightly from the actual field of application for each particular selection. - Page 53 APPENDIX; Product Information (PI) PRECISE FIELD OF APPLICATION Fig.17: General field of application Grasso V 700HS – V 1800HS Symbols used in diagram to = evaporating temperature po = evaporating pressure tc = condensing temperature pc = condensing pressure Δto = suction superheat j = pressure ratio = (pc / po) Δp = pressure difference = (pc - po) te,max = maximum discharge temperature...
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Page 54: Diagramsgrams Capacity Control
APPENDIX; Product Information (PI) DIAGRAMSGRAMS CAPACITY CONTROL DIAGRAMSGRAMS CAPACITY CONTROL Solenoid valve/cylinder numbering for electric capacity control Solenoid No. 1 No. 2 No. 3 No. 4 Cylinder number / solenoid valves V 700HS V 1100HS (3+4) (5+6) V 1400HS (5+6) (2+4) (1+3) V 1800HS... - Page 55 APPENDIX; Product Information (PI) DIAGRAMSGRAMS CAPACITY CONTROL Capacity control steps Compressor Capacity % Cylinders Solenoids type (5+7+8) + (3+4) + (9+10) 1 + 2 + 3 + (1+2) (5+7+8) + (9+10) + 1 + 2 + 3 + 4 (1+2)+ (3+4) + 6 Refer to the swept volume expressed as a percentage of the full-load swept volume P-NL-094_imm_VHS_English_13 26.07.2021...
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Page 56: 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 57: 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 58: 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 59 APPENDIX; Product Information (PI) P-NL-094_imm_VHS_English_13 26.07.2021...
- Page 60 • • 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.