Professional Documents
Culture Documents
Series Grasso 6
Installation and Maintenance Manual (IMM)
ca0148_0089238_v002_gbr
-Page 1-
Copyright
All Rights reserved. No part of this publication may be
copied or published by means of printing, photocopying,
microfilm or otherwise without prior written consent of
Grasso.
This restriction also applies to the corresponding
drawings and diagrams.
Legal Notice
This publication has been written in good faith.
However, Grasso cannot be held responsible, neither for
any errors occurring in this publication nor for their
consequences.
Safety
This manual is written with great care, but the
contractor/installer is held responsible to examine this
information and to take care of possible additional and/
or deviated safety measures.
Safety instructions
It is the task of the contractor/installer to inform and
explain to his client the operation of the compressor
(Package).
Do respect all federal, state or local safety
regulations/legislations during installing, connecting and
operating this compressor (package).
Construction changes
-Page 2-
IMM0312/v002
Table of Contents
Section
Title
Page
1.1
INSTALLATION
1.1.1
1.1.2
Storage
1.1.3
1.1.4
10
1.1.5
Foundation requirements
10
1.1.5.1
Concrete structure
10
1.1.5.2
Anchoring
11
1.1.5.3
11
1.1.5.3.1
12
1.1.5.3.2
12
1.1.5.3.3
12
1.1.5.3.4
12
1.1.6
12
1.1.7
13
1.1.8
Earthing connections
13
1.1.9
13
1.2
15
1.2.1
15
1.2.2
15
1.2.3
15
1.2.3.1
15
1.2.4
15
1.2.5
16
1.2.5.1
Pressure safeties
16
1.2.5.2
16
1.2.6
16
1.2.7
16
1.2.8
16
1.2.9
Initial start-up
16
1.2.9.1
16
1.2.9.2
16
1.2.10
17
1.2.10.1
First start
17
1.2.10.2
Restart
17
1.2.10.3
17
1.2.10.4
17
1.2.10.5
17
19
2.1
INSPECTION
21
IMM0312/v002
-Page 3-
Section
Title
Page
2.1.1
Periodical inspection
21
2.1.2
21
2.1.2.1
21
2.2
23
2.2.1
23
2.2.2
First maintenance
23
2.3
23
2.4
LUBRICATION DATA
23
2.4.1
23
2.5
24
2.6
24
2.7
24
2.8
24
2.9
COMPRESSOR PURGING
24
2.10
TROUBLESHOOTING TABLE
24
PARTS COMPRESSOR
27
PARTS ACCESSORIES
57
MAINTENANCE
65
5.1
SMS FACTOR
65
5.2
Grasso 6
67
5.3
Checklist
69
71
6.1
TECHNICAL DATA
71
6.2
73
6.3
74
6.4
75
6.4.1
75
6.4.1.1
FIELDS OF APPLICATION
76
6.4.2
77
6.4.3
77
6.5
79
6.6
CAPACITY CONTROL
80
6.6.1
CYLINDER NUMBERING
81
6.7
82
6.7.1
82
6.8
CRANKCASE HEATER
83
6.8.1
83
NOTES
85
7.1
-Page 4-
85
IMM0312/v002
Description
Value
Start frequency
min. 2 minutes
min. 15 minutes
min. 3 minutes
Oil level
After a mimimum of 15
minutes running time at an oil
temperature of approx. 50 oC
(122 oF)
155 C
0.3 bar
Pdischarge - Psuction
24.0 bar
Superheat
Remark
Normally counterclockwise
when facing shaft end of the
compressor.
IMM0312/v002
-Page 5-
Legend
1, 2, 3, ...
Cylinder numbers
-Page 6-
IMM0312/v002
Title
Page
1.1
INSTALLATION
1.1.1
1.1.2
Storage
1.1.3
1.1.4
10
1.1.5
Foundation requirements
10
1.1.5.1
Concrete structure
10
1.1.5.2
Anchoring
11
1.1.5.3
11
1.1.5.3.1
12
1.1.5.3.2
12
1.1.5.3.3
12
1.1.5.3.4
12
1.1.6
12
1.1.7
13
1.1.8
Earthing connections
13
1.1.9
13
1.2
15
1.2.1
15
1.2.2
15
1.2.3
15
1.2.3.1
15
1.2.4
15
1.2.5
16
1.2.5.1
Pressure safeties
16
1.2.5.2
16
1.2.6
16
1.2.7
16
1.2.8
16
1.2.9
Initial start-up
16
1.2.9.1
16
1.2.9.2
16
1.2.10
17
1.2.10.1
First start
17
1.2.10.2
Restart
17
1.2.10.3
17
1.2.10.4
17
1.2.10.5
17
IMM0312/v002
-Page 7-
-Page 8-
IMM0312/v002
1.1
INSTALLATION
Legend
C
Compressor
Motor
IMM0312/v002
-Page 9-
CONCRETE STRUCTURE
Legend
-Page 10-
Cork board
Concrete base
(Concrete) Floor
Sand
IMM0312/v002
Table 1.1-1
Legend
A
Chemical anchor
Legend
A
Drilling angle
1.1.5.3
IMM0312/v002
-Page 11-
1.1.5.3.1
General
After the space between base frame and concrete base
has been filled-up with a filling grout, the package base
frame must be secured tightly to the foundation block or
floor.
1.1.5.3.3
Legend
1
Self-levelling grout
Washer
Grout layer
-Page 12-
IMM0312/v002
1.1.7
CONNECTING THE POWER SUPPLY
Information about further electrical connections to be
made (e.g. crankcase heater, drive motor starting
equipment, thermal protection of drive motor,
automatic start/ stop and other external electrical
devices) can be found in the plant manual (not supplied
by Grasso).
1.1.8
EARTHING CONNECTIONS
Grasso compressors and packages are equipped with
litz-wires and earth connecting points.
To avoid leakage current flowing through the
components, disconnect all litz-wires when arc-welding.
After all installation functions are completed, reconnect
the litz-wires and ground the package to earth.
1.1.9
IMM0312/v002
-Page 13-
-Page 14-
IMM0312/v002
1.2
1.2.3
Procedure:
i) STATUS: System is dried and still evacuated.
ii) Charge the oil separator (if present) initially with oil .
iii) Close suction and discharge stop valves of compressor
and oil return line of oil separator (if present).
iv) Charge the compressor crankcase with oil via the oil
charge valve.
Number of
cylinders
Shaft seal
housing, incl.
Oil
Oil
internal circuit of filters pump
crnkshaft
4
6
Crankcase
11
0.5
1.5
0.5
12
13
1.2.4
INITIAL REFRIGERANT CHARGE
Refrigerant charging should be done in accordance with
the plant manual by qualified refrigeration engineers.
IMM0312/v002
-Page 15-
1.2.5
1.2.5.1
Suction pressurea
Setting
Min.
Discharge pressurea
Lubrication oil
pressure difference
Setting
5 C above design
condensing temp.
(Tc + 5 K)
Max.
<= 26 bar(a)
Min.
Setting
2.0 bar
(2.2 bar at 50 oC oil temp.)
a. The oil pressure regulator is adjusted at the works, but it may occur that this
setting should be corrected during the initial run and also if the value <1.7 or
>2.5 bar. The re-adjustment procedure is given in section Re-adjustment of oil
pressure regulator.
1.2.8
INITIAL OIL WARM UP
Prior to the initial start-up, the crankcase heater (if
present) must be energised. For the min. oil temperature
refer to Product Information (ED).
1.2.5.2
1.2.9
Re-adjustment procedure:
i) Run the compressor untill the crankcase oil is at its
stable operating temperature:
1 The lubricating oil pressure difference should be
according to Section 1.2.5.1.
2 After the initial run the oil pressure difference
should be slightly higher.
-Page 16-
1.2.9.1
Legend
1
INITIAL START-UP
1.2.9.2
PRE-START CHECK LIST
The following Paragraph covers only the initial start of
the compressor and not the complete refrigeration
plant.
Be sure that all necessary system valves are open and
that the refrigeration system is ready for start up. Use
the following check to guarantee that no items of
importance regarding the compressor (package) have
been overlooked.
IMM0312/v002
RESTART
IMM0312/v002
-Page 17-
-Page 18-
IMM0312/v002
Title
Page
2.1
INSPECTION
21
2.1.1
Periodical inspection
21
2.1.2
21
2.1.2.1
21
2.2
23
2.2.1
23
2.2.2
First maintenance
23
2.3
23
2.4
LUBRICATION DATA
23
2.4.1
23
2.5
24
2.6
24
2.7
24
2.8
24
2.9
COMPRESSOR PURGING
24
2.10
TROUBLESHOOTING TABLE
24
IMM0312/v002
-Page 19-
-Page 20-
IMM0312/v002
2.1
INSPECTION
2.1.1
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.
In this way it will not be necessary to stop the
compressor at inconvenient times.
The frequency of inspections is dependent on the type of
installation, operating conditions and local regulations.
In the case of automatically controlled plants, the
periodical inspection are particularly important. The
table below sums up all the points on the compressor
that have to be inspected or maintained along with
inspection and maintenance frequencies.
2.1.2
SURVEY OF PERIODICAL INSPECTIONS
Apart from the check points in the table below, the
sound produced by the compressor also provides an
indication or its mechanical condition. If abnormal
sounds are audible, their cause should be traced and
removed immediately in order to prevent serious
breakdowns.
2.1.2.1
IMM0312/v002
-Page 21-
CHECK
POINTSa
Oil level in
crankcase
Colour of the
oil
Lubricating oil
pressure
difference
REMARKS
monthly
weekly
daily
FREQUENCY
Oil
temperature
max.
Suction
pressure
Discharge
pressure
Suction
superheat
0K
Discharge
temperature
max.
155 C/175 Cb
Oil
temperature
min.
During compressor
standstill the lower part of
the crankcase must remain
warmer than the
surroundings: 20 C
Adjustment
and operation
of pressure
safety switches
Capacity
control (if
provided)
Start/stop
intervals
Number of
operating
hours
Cooling water
temperature
(if present)
-Page 22-
IMM0312/v002
2.2
2.2.1
POST START-UP MAINTENANCE
After the compressor has run for the initial 100
operating hours:
i) Drain the oil and refill the compressor with the
correct amount of fresh oil.
ii) Replace the red marked oil discharge filter element
with the grey marked filter element in accordance
with the filter replacement instructions. Refer also to .
iii) Inspect suction gas filter (refer to the Compressor
Service Instruction Manual).
iv) Exchange or clean oil suction filter element (refer ).
v) Check the compressor shaft seal for leakage. If
excessive (more than 1 cc/hr) replace the seal.
vi) 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 the V-belt supplier's instructions.
vii) Verify and if necessary, correct the torque settings of
all foundation bolts as given in Compressor Service
Instruction Manual.
2.2.2
FIRST MAINTENANCE
For complete service schedules and required service sets
refer to Grasso's Service and Maintenance Schedules
(SMS).
Maintenance
Oil analysis bc
> 100
2.4
LUBRICATION DATA
X
X
2.3
IMM0312/v002
-Page 23-
2.5
2.6
2.7
Schedule
Replace these filters according to the Service
Maintenance Schedules.
The frequency of exchanging these filters depends on
the conditions of the refrigeration system.
2.9
COMPRESSOR PURGING
2.8
-Page 24-
IMM0312/v002
CAUSE
REMEDY
FAULT
CAUSE
E Crankcase
frosted or wet
1. Liquid refrigerant in
crankcase due to:
Provide for crankcase
1a. Room temperature heating or, if provided,
too low
check it for proper
operation
Repair or replace
See A
Stop
compressor
and contact
installation
engineer
7. Discharge valve
defective
Repair or renew
F All cylinders
inactive while
compressor is
operating
1c. Installation
operates too wet
2. Compressor
operates unloaded too Refer to design calculations
frequently
4. Restriction plug at
the bottom of suction
chamber in cylinder
clogged
Clean plug
1. Capacity control
does not operate
Repair
Repair or renew
Repair or renew
D Suction
3. Injection control not
Re-adjust control
pressure too low adjusted correctly
4. Too little refrigerant
Top-up with refrigerant
in installation
5. Suction pressure
gauge defective
Renew
Repair
Open fully
IMM0312/v002
REMEDY
1. Lubricating oil
pressure regulator not
Re-adjust or renew
adjusted properly or
defective
2. Defective oil
pressure and/or
suction pressure gauge Repair or replace
(if present)
-Page 25-
FAULT
CAUSE
REMEDY
Top up oil
3. Lubricating oil
pressure regulator not
Re-adjust or renew
adjusted properly or
defective
4. Liquid refrigerant in
See E
crankcase
5. Defective oil
pressure and/or
Repair or renew
suction pressure gauge
(if present)
6. Worn bearings
K Too low or no
control oil
pressure (For
Grasso 12, Grasso
12E and
Grasso10 only)
Renew bearings
a. During the initial start-up, the oil separator (if present) consumes oil before the
first oil will be returned.
-Page 26-
IMM0312/v002
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR
Table of Contents
Parts List
Page
Figure
28
RC6-01
MAIN BEARINGS
30
RC6-02
CRANKSHAFT
32
RC6-03
34
RC6-04
36
RC6-05
38
RC6-06
OIL PUMP
40
RC6-07
42
RC6-08
44
RC6-09
46
RC6-10
48
RC6-11
50
RC6-12
52
RC6-13
54
RC6-14
IMM0312/v002
-Page 27-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
1.1Aa
RC6-2CR
2336521
1.1Ab
RC6-2CR
2336525
1.1Ba
RC6-1CR
2336510
1.1Bb
RC6-1CR
2336515
1.2
M10x120
0110512
GASKET
190x405x2CR
0907192
on item 1.1A
GASKET
190x405x1CR
0907191
on item 1.1B
1.3A
1.3B
2
2.1a
RC6-OCR
2336500
2.1b
RC6-OCR
2336505
2.2
GASKET
190x405x1.5OCR
0907190
3.a
M10x100
0110510
20
3.b
M10x120
0110512
20
FLAT WASHER
M10
1113501
36
CRANKCASE
RC6
GASKET
175x290x1.5
0907175
7.a
175x290
0530175
7.b
175x290WK
0530178
RC6W (1x)
M10x40
0110540
16
2.62x32.99
0952284
O-RING
10
SIGHT GLASS
29x60
1224029
11
M6x16
0110316
12
EYE BOLT
M16
0118812
26.5G33
1249333
G13S
0136134
240V-200W
1372203
13
14
PLUG
15
CRANKCASE HEATER
16
STOP VALVE
TAH8-12
0607011
17
ORIFICE
G13x3x20
0123139
18
ALU.SEALING RING
21x25x1
0912021
G21
0136216
19.a
19.b
PLUG
G21
0136216
20
21x27x2
0914023
21
13.5x20x1
0912014
22
NIPPLE COUPLING
12G13
0338131
23
NIPPLE COUPLING
12G21
0338211
-Page 28-
PLUG
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 29-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
60x15x11.5
1143600
Remarks
BEARING FLANGE
BEARING ASSY
RC6
2.1
PUMP HOUSING
RC6
---------
2.2
O-RING
3.53x209.14
0952365
2.3
BEARING FLANGE
60x50xM10
1143651
2.4
M10x100
0104510
M10
1113501
16
FLAT WASHER
M10x40
0110540
M10x35
0110535
-Page 30-
driving end
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 31-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
E/K-RC6
Remarks
CRANKSHAFT
1A.a
CRANKSHAFT
E-RC6
2236400
4-cylinder compressor
1A.b
CRANKSHAFT
K-RC6
2236410
4-cylinder compressor
1B.a
CRANKSHAFT
E-RC6
2236600
6-cylinder compressor
1B.b
CRANKSHAFT
K-RC6
2236610
6-cylinder compressor
1C.a
CRANKSHAFT
E-RC6
2236800
8-cylinder compressor
1C.b
CRANKSHAFT
K-RC6
2236810
8-cylinder compressor
14x9x70
1102570
60x5A
1125106
M10x25
0104525
KEY
CARRIER DISC
-Page 32-
from 95.08.1648
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 33-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
85RC6
2436010
Remarks
PISTON ASSY
1.1
PISTON
1.2
GUDGEON PIN
1.3
SAFETY RING
1.4
85RC6H
26x16x68R6
2436260
85RC6
0974084
CONNECTING ROD
60x170xRC6
2436500
2.1
CONNECTING ROD
170RC6
2.2
MF8
0111401
2.3
M8
1139400
2.4
HEXAGON NUT
MF8x1
0147405
-Page 34-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 35-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
DIN 540
Fig. RC6-05 SUCTION AND DISCHARGE VALVE (from mach. nr. 99061345)
1
M10x40
0110540
2
3
FLAT WASHER
M10
1113501
PRESSURE RING
RC6
2736410
SINUSOIDAL SPRING
87x125x4
1133087
5.H
RC6
2736103
5.L
RC6
2736113
5.1
LOCKING NUT
M8
0145400
5.2
FLAT WASHER
M8
1113401
5.3
RC6
5.4a
SINUSOIDAL SPRING
64x76x0.5
5.4b
SINUSOIDAL SPRING
64x76x0.5
5.5
5.6
5.7
FITTED BOLT
64x76x1
RC6
M8x35
5.8H
R
(halocarbons)
1134105
5.8L
NH3
(ammonia)
1134110
108x87x4
DAMPER RING
SINUSOIDAL SPRING
88x103x0.7
88x103x0.7
O-RING
3.53x117.07
0952362
10
CYLINDER LINER
85RC6
2336120
11
O-RING
3.53x91.67
0952361
12
RC6/GR7
1134115
-Page 36-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 37-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6
2636100
Remarks
2A
PLUG
G13S
0136134
2B
PLUG
NPT13X1.5
0365513
6N10
0338810
NIPPLE COUPLING
O-RING
6
7
-Page 38-
3.53x158.34
0952364
M10x35
0110535
FLAT WASHER
M10
1113501
RC6
0962900
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 39-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6
2636700
Remarks
PUMP COVER
BEARING
5
6
7
PUMP HOUSING
-Page 40-
RC6A
2636601
RC6x13.5
2636710
M6x16
0110316
O-RING
3.53x209.14
0952365
O-RING
3.53x136.12
0952363
RC6E
2636503
from 95.08.1647
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 41-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6C
2736702
Remarks
FLANGE
PRESSURE SPRING
FLAT WASHER
GASKET
10
11.1A
VALVE BODY
11.1B
VALVE BODY
M4x10
0168210
RC6
2736600
1.25x10x11.5
x51
1131132
56x51.3x2
0970056
M10
1113501
M10x40
0110540
87x94x1.5
0907087
RC6
2736500
40x36.6x2
0970040
11.2A
VALVE COIL
110-120/5060
11.2B
VALVE COIL
220-240/5060
1316311
1316322
11A
SOLENOID VALVE
110/120V
11B
SOLENOID VALVE
220FA
0680111
NH3
12.a
CONNECTOR
DIN
1316610
without LED
for valves 11A/11B, without LED
12.b
CONNECTOR
220/240 V AC,
DIN incl. LED
1316611
12.c
CONNECTOR
24/48 V
AC/DC, DIN
incl. LED
1316615
6G10
0337106
13
SOCKET COUPLING
14
SET SCREW
M5x10
0123010
15
PLUG
M8x1
0365708
16
O-RING
9.3
0951093
-Page 42-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 43-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
RC6
0711900
3.53x136.12
0952363
480x15
M6
0145300
M6x20
0151320
130
0702130
M10x75
0110575
M10
1113501
Remarks
FILTER SET
1.1
O-RING
1.2
FILTER CARTRIDGE
LOCKING NUT
STUD
FILTER HOUSING
FLAT WASHER
-Page 44-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 45-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
SHOULDER FLANGE
RC46
0539045
1B
SHOULDER FLANGE
RC66
0539051
1C
SHOULDER FLANGE
RC86
0539063
M16x40
0110840
67x81x1.5
0903067
26.5G33
1249333
GASKET
-Page 46-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 47-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
SHOULDER FLANGE
RC46
0539048
Remarks
SHOULDER FLANGE
RC66/RC86
0539060
GASKET
67x81x1.5
0903067
STRAINER ELEMENT
544x100
0716544
-Page 48-
IMM0312/v002
3. PARTS COMPRESSOR
a a a a a a a a a
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a a a a a a a a a
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a aaaaaaaaaaaaaaa
IMM0312/v002
-Page 49-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
STRAINER ELEMENT
149x16
0716164
SWIVEL COUPLING
16G21
0339216
-Page 50-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 51-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
SAM RC6
1241140
1.1
K12x1.5
1241012
1.2
21.5x27x1
0912022
1.3
BEAMING BALL
W16
1119010
1.4
PRESSURE SPRING
1.25x14x9x35
.5
1131134
1.5
THRUST BOLT
G21x60S
0135218
1.6
O-RING
1.78x8.73
0952184
1.7
NIPPLE
G21CxG21
0304921
1.8
10x18x1
0912010
1.9
CAP NUT
GK21R
0117021
NIPPLE COUPLING
12G13
0338131
NIPPLE COUPLING
12G21
0338211
-Page 52-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 53-
3. PARTS COMPRESSOR
Item
Description
Dims.
Ref. No.
Qty
Remarks
0990046
for RC46
GASKETS (SET)
RC46/GR47
1b
GASKETS (SET)
RC66/GR67
0990066
for RC66
1c
GASKETS (SET)
RC86/GR87
0990086
for RC86
2a
R
(halocarbons)
1134105
2b
NH3
(ammonia)
1134110
RC6/GR7
1134115
RC6/GR7
2036011
5a
TIRE CLAMP
232
1508232
5b
TIRE CLAMP
244
1508244
5c
TIRE CLAMP
280
1508280
-Page 54-
IMM0312/v002
3. PARTS COMPRESSOR
IMM0312/v002
-Page 55-
3. PARTS COMPRESSOR
-Page 56-
IMM0312/v002
4. PARTS ACCESSORIES
4. PARTS ACCESSORIES
Table of Contents
Parts List
Page
Figure
PRESSURE GAUGES AND SAFETY SWITCH CABINET (Use 0337136 if your current pressure gauge connections differs from
fig. RC6-1A
58
RC6-A1
DIRECT DRIVE
60
RC6-A2
62
RC6-A3
IMM0312/v002
-Page 57-
4. PARTS ACCESSORIES
Item
Description
Dims.
Ref. No.
Qty
Remarks
Fig. RC6-A1 PRESSURE GAUGES AND SAFETY SWITCH CABINET (Use 0337136 if your current
pressure gauge connections differs from fig. RC6-1A
1.1a
PRESSURE GAUGE
NH3 - R-P-63
1210065
1.1b
PRESSURE GAUGE
R22 - 63
1212065
1.1c
PRESSURE GAUGE
R134a - 63
1212066
1.1d
R404A
1212067
1.2a
PRESSURE GAUGE
NH3 - R-Z-63
1210066
1.2b
PRESSURE GAUGE
R22 - Z-63-12
1212068
1.2c
R134a Z-63-12
1212069
1.2d
R404A Z-63-12
1212070
1.3
PRESSURE GAUGE
R-O-63
1215065
1.4a
MP55A
1260232
1.4b
MP55
1261232
1.5a
PRESSOSTAT
NH3 KP15A
1260615
1.5b
COMBINED SUCTION/DISCHARGE
PRESSURE SAFETY SWITCH
R KP15
1261615
1.5c
PRESSOSTAT
NH3 KP7ABS
1260618
1.5d
R KP7BS
1261618
1.6a
NH3 KP1A
1260608
1.6b
R KP1
1261608
1a.1
NH3 - std
1208301
1a.2
R22 - std
1208601
1a.3
R134a - std
1208701
1a.4
R404A
1208801
1b.1
NH3 UVV-VB420
1208302
1b.2
NH3 UVV-VB420
1208602
1b.3
NH3 UVV-VB420
1208702
1b.4
NH3 UVV-VB420
1208802
-Page 58-
IMM0312/v002
4. PARTS ACCESSORIES
IMM0312/v002
-Page 59-
4. PARTS ACCESSORIES
Item
Description
Dims.
Ref. No.
Qty
42
1918842
Remarks
COUPLING ELEMENT
1.1b
COUPLING ELEMENT
61
1918861
1.1c
COUPLING ELEMENT
91
1918891
1a
FLEXIBLE COUPLING
type 42
(complete)
1b
FLEXIBILE COUPLING
type 61
(complete)
1c
FLEXIBLE COUPLING
type 91
(complete)
CLAMPING SLEEVE
-Page 60-
IMM0312/v002
4. PARTS ACCESSORIES
IMM0312/v002
-Page 61-
4. PARTS ACCESSORIES
Item
Description
Dims.
Ref. No.
Qty
Remarks
19W
1518019
19-28 mm
1508600
19xG21
1555419
HOSE, RUBBER
HOSE CLAMP
SPIGOT NIPPLE
G21xG21
0372441
SOCKET NIPPLE
G21xG42
0302471
NIPPLE COUPLING
16G21
0338212
6.1
CLAMPING SLEEVE
P16
0334516
16x1.5x64x28
0
0410364
COIL COOLER
RC6-OCR
2336505
RC6-1CR
2336515
10
175x290WK
0530178
-Page 62-
IMM0312/v002
4. PARTS ACCESSORIES
IMM0312/v002
-Page 63-
4. PARTS ACCESSORIES
-Page 64-
IMM0312/v002
5. MAINTENANCE
5. MAINTENANCE
Table of Contents
Section
Title
Page
5.1
SMS FACTOR
65
5.2
Grasso 6
67
5.3
Checklist
69
5.1
SMS FACTOR
General
IMM0312/v002
-Page 65-
5. MAINTENANCE
-Page 66-
IMM0312/v002
5. MAINTENANCE
5.2
GRASSO 6
SERVICE AND MAINTENANCE SCHEDULES GRASSO 6
Actions
Description
0.1
YEARLY
Item
12
15
18
21
24
27
30
33
36
Checkpoint
CL
CL
CL
CL
CL
CL
CL
RE
RE
RE
RE
RE
RE
ME
ME
ME
ME
ME
ME
Oil analysis
RE
RE
RE
RE
RE
RE
Oil
4
5
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
7a
IC/ME IC/ME
IC/ME IC/ME
Oil pump
7b
Crankshaft
8
9
Shaft seal
10
Conrod
11
12
Pistons
13
14
Thrust bearing
IC/ME
IC
IC
IC
IC
IC
IC/ME
IC
IC
IC
IC
IC
IC
IC
IC
IC
IC
Piston rings
Gudgeon pin
IV/ME
IC/IV
IC/IV
IC/IV
15
16
IC/IV
IC/IV
IC/IV
IC/IV
Capacity control
17
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
18
IV/CL
IV/CL
IV/CL
IV/CL
IV/CL
IV/CL
IV/CL
Crankcase heater
CL
CL
CL
CL
CL
Crankcase
19
20
Compressor
housing
IC
IC
IC
IC
Throttle valves
21
IV
IV
IV
IV
IV
Relief valves
22
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC
IC
RE
RE
RE
RE
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC/CL
IC
IV
IC
RE
IC
RE
IV
IV
IV
IV
IV
27
IV/ME
28
IC
IC
IC
IC
IC
IC
IC
Alignment
IC
IC
IC
IC
IC
IC
IC
V-belts
23
Discharge valves
24
25
Suction valvesb
26
Cylinder liners
Drive
29
30
Electric motor
IMM0312/v002
-Page 67-
5. MAINTENANCE
Description
0.1
YEARLY
Item
12
15
18
21
24
27
30
Checkpoint
33
36
31
IC
IC
IC
IC
IC
CL/IC
CL/IC
32
IC
IC
IC
IC
IC
IC
IC
Safety switches
33
IC
IC
IC
IC
IC
IC
IC
Gauges
34
IC
IC
IC
IC
IC
IC
IC
Thermostats
IC
IC
IC
IC
IC
IC
IC
Thermometers
36
IC
IC
IC
IC
IC
IC
IC
37
IC
IC
IC
IC
IC
CL/IC
CL/IC
39
IC
IC
IC
IC
IC
IC
IC
41
CL
CL
IC
IC
IC
IC
42
ME
35
Optionals
a. Check after every maintenance job the settings and working of all safety devices, regulators and the running condition according to the service instruction manual
(SIM)
b. Suction valves for compressors < june 1999 (machine number < 9906****) must be changed every 6000 running hours in case not converted to latest standard
Code/Action
Description
IC
IV
RE
Renewal
ME
Measure
CL
Clean
-Page 68-
IMM0312/v002
5. MAINTENANCE
5.3
CHECKLIST
Item
Checked/Remarks/Notes
Checkpoint/Setting/Value
A Compressor type
B Machine number
C Date
D Running hours
E Refrigerant
E Evaporating temperature/pressure To/Po
F Intermediate temperature/pressure Tm/Pm
G Discharge temperature/pressure Tc/Pc
H Oil lubricating pressure
I
J General Notes
2
3
Oil analysis
Oil refreshment (If hygroscopic oil is used replace this always after each
opening of compressor or installation)
4
5
Shaft seal
Oil/refrigerant leakage
10
Conrod
11
12
Piston
Pistons
13
14 Thrust bearing
15
16
Piston rings
Gudgeon pin
Running surfaces/Axial play
Solenoid valves and coils
Capacity
control
17
IMM0312/v002
-Page 69-
5. MAINTENANCE
Item
Checked/Remarks/Notes
18
Crankcase heater
19
20
Crankcase
Compressor
housing
21
Relief valves
22
23
Checkpoint/Setting/Value
24
25 Suction valves
26
27
28
Alignment
Drive
29
V-belts
30 Electric motor
31
32
Safety switches
33
Gauges
34
Thermostats
35
Thermometers
36
37
38
Thermistors
Optionals
39
40
41
42
43
44
45
46
Remark
Suction pressure
-Page 70-
Value
TUV only
IMM0312/v002
Title
Page
6.1
TECHNICAL DATA
71
6.2
73
6.3
74
6.4
75
6.4.1
75
6.4.1.1
FIELDS OF APPLICATION
76
6.4.2
77
6.4.3
77
6.5
79
6.6
CAPACITY CONTROL
80
6.6.1
CYLINDER NUMBERING
81
6.7
82
6.7.1
82
6.8
CRANKCASE HEATER
83
6.8.1
83
6.1
TECHNICAL DATA
Cylinder arrangement
46
66
86
2xV
2xW
2 x VV
Cylinder bore
mm
85
Piston stroke
mm
66
Vs
n = 1450/min
m /h
130.3
195.5
260.7
min-1
1750 min-1
(60 Hz)
min-1
100-50
100-67-33
100-75-50-25
kg
280
345
400
dm3
9.2 (8.5)
10.0 (9.3)
10.8 (10.1)
kW
1.10
1.58
2.22
0.0361
0.0421
0.0478
n= 1450/min
Pw
Id
kg.m
a. The figures between brackets indicate the smaller oil charge for the Grasso 6W compressors due to the presence of an oil cooler.
b. The mass moment of inertia Id expressed in SI units, is required to determine the so-called coefficient of speed fluctuation.
IMM0312/v002
-Page 71-
-Page 72-
IMM0312/v002
6.2
Table 6.2-1
COMPRESSOR
TYPE
Length
Width
IMM0312/v002
46
46W
66
66W
86
86W
696
696
721
721
746
746
840
893
929
46
46W
66
66W
86
86W
661
661
673
673
711
711
piston and
cylinder liner
260
260
325
325
360
360
626
700
748
748
725
725
316
316
379
379
395
395
316
316
352
352
363
363
202
202
202.5
202.5
length
225
225
250
250
270
270
width
72
72
77
77
67
67
Height
COMPRESSOR
TYPE
189.5 189.5
300
300
248
248
228
228
544
544
644
644
619
619
394
394
432
432
444
444
suction
40
40
50
50
50
50
60
60
65
65
62
62
discharge
32
32
40
40
50
50
444
444
482
482
494
494
69
69
69
155
173
180
388
430
446
435
328
247
680
660
696
MAIN CONNECTIONS DN
(mm)a
-Page 73-
COMPRESSOR
TYPE
46
46W
66
66W
86
86W
AUXILIARY CONNECTIONS
suction
pressure
discharge
pressure
Oil pressure
Crankcase
pressure
Oil
temperature
Crankcase
heater
10
Oil leakage
drain of rotary 11 clanp coupling provided with dia. 6x1 mm steel
precision pipe
shaft seal
Water
inlet/outlet
12
(W-types) only
a. Provided with a purging and evacuation stop valve type TAH8 (standard on
discharge connection and optional on suction connection.
6.3
-Page 74-
IMM0312/v002
6.4
6.4.1
speed
Compressor speed
po
min-1
800
max.
1500
min.
Suction superheat
Discharge pressure = condensing pressure
Design
ta
min.
Dt
min.
pc bar(a) max.
pressuree
bar(a)
tc
max.
max.
Discharge temperature
te
Dp
bar
toil
min-1
>=1140 min
<1140
R507
6.0
5.8
-1
max.
R404A
0.3
>=1140 min
max.
<1140
to
R134a
min.
Evaporating temperature = saturation
temperature at suction pressure
R22
min.
bar(a)
b
NH3
6.2
6.8
6.2
-55.1
-63.8
-50
+10.2
+10.0
+22.6
6.8
-68.1
-68.5
-0.1
-2.0
+3.8
+3.0
-1
min-1
-50
15
5
24.0
26.5
min.
max.
max.
min.
max.
+59.8
+63.2
+79.5
+55.6
+54.4
+155
1.5
10
15
24
+20
+30
depending on type of oil, refer Section 6.5
IMM0312/v002
-Page 75-
6.4.1.1
FIELDS OF APPLICATION
Fig. 6.4-1
Legend
A
This part of the general field of application is not covered by COMSEL. Consult Grasso to make a selection
for this applicaction
-Page 76-
IMM0312/v002
6.4.2
General
Fig. 6.4-2 Field of applications for compressor type Grasso 6 with NH3
(upper graphic) and Grasso 6 with NH3 and water
cooled cylinder heads (lower graphic)
IMM0312/v002
-Page 77-
-Page 78-
IMM0312/v002
6.5
Refrigerant
used
NH3
68
100
-50
-30
-20
-10
R22
R134a, R507,
R404A
+10
-50
-30
v
v
-20
-10
+10
v = Approved
NH3
Brand
Type designation
ISO VG
numbera
CPI
CP-1009-68
68
PETRO CANADA
Reflo 68A
68
68
Mobil
SHC-326
Some of the oil types listed in this table may be marketed under other
names and/or designations; these oils can also be used, provided their
identity can be proved beyond any doubt. Application of
other/alternavive oils is not permitted without the written consent of
Grasso.
IMM0312/v002
-Page 79-
Type designation
ISO VG
numbera
AVIA
Avilub FC 46
44
Avilub FC 68
65
Energol LPT-F 46
54
Energol LPT-F 68
68
CASTROL
Icematic 299
56
CPI
CP-1009-68
69
ELF
Elfrima FR 68,
NH3 only!
54
Refrigerant
used
Brand
Icematic SW 68
67
Icematic SW 100
100
Solest 68
64
CASTROL
CPI
Solest 120
131
Triton SE 55
52.5
Triton SEZ 80
80
Triton SE 120
118
Planetelf ACD 68 M
70
Planetelf ACD
100LT
98
Purfrigol ST VG 68
69
BP
44
Zerice 68
65
Zerice S46
48
Zerice S68
64
Purfrigol MP 68
71
Reniso KC 46
47
Reniso KC 68
68
Carsinus FC 46/68
55
57
SHC 326
65
PETRO CANADA
Reflo 68Ab
58
Kuwait
Petroleum
Q8 StravinksyB
ESSO
FINA
DEA
ELF
Zerice 46
HFC
(e.g. R134a /
R404A /
R407c /
R507)
FINA
KROON OIL
Purfrigol ST VG 100
95
Reniso E 68
68
Reniso E 100
100
FUCHS
FUCHS
Emkarte RL 68S
68
Emkarte RL 100S
100
EAL Arctic 68
63
96
ICI
MOBIL
MOBIL
SHELL
SUN-OIL
Q8 Stravinsky C
68
Clavus 46
46
Clavus 68
68
Clavus G 46
46
Clavus R68
66
Clavus R100
94
SHELL
Suniso Excel
TEXACO
Capella HFC 68
62
Some of the oil types listed in this table may be marketed under other
names and/or designations; these oils can also be used, provided their
identity can be proved beyond any doubt. Application of
other/alternavive oils is not permitted without the written consent of
Grasso.
Clavus G 68
68
Clavus G 100
95
Suniso 3.5 GS
NH3 Only!
43
6.6
Suniso 4 GS
NH3 Only!
55
Suniso 5 G
NH3 Only!
94
Suniso 4 SA
NH3 Only!
57
TEXACO
Capella WF 68
65
TOTAL
Lunaria S 46/68
55
66
Solenoids
Remarks
SUN-OIL
CAPACITY CONTROL
Qyt Cylinders
NH3 and
HCFC
(e.g. R22)
ISO VG
numbera
Type designation
Cylinders
Refrigerant
used
1+3
1+2+3
1+3
1+2+4
1+2+3+4
A+B
3
100
25 a
4
optional
50
75
optional
100
-Page 80-
IMM0312/v002
40
2+5
80
1+2+4+5
100
1+2+3+4+5
A+B
33
2+5
66
1+2+4+5
100
1+2+3+4+5+6
A+B
29
3+7
57
2+3+6+7
1+2+3+5+6+7
B+C
Remarks
Solenoids
6.6.1
Cylinders
Capacity %
Qyt Cylinders
CYLINDER NUMBERING
7
86
100
1+2+3+4+5+6+7 A+B+C
25
3+7
50
2 + 3 + 6+ 7
1 + 2 + 3 + 5+ 6 + 7
B+C
8
75
100
1+3+4+5+6+7+8 A+B+C
a. Optional (refer to )
Legend
W
IMM0312/v002
Water cooled
25%
-Page 81-
6.7
6.7.1
General
For mounting on a concrete foundation block, Grasso
can supply a standard welded steel base frame to
support compressor, motor and accessoiries.
Especially for vibration free operation on floors and on
roof tops, a base frame with vibration dampers can be
delivered (concrete foundation block can be omitted).
A. BASE FRAME FOR MOUNTING ON CONCRETE BLOCK
(TRANSPORT BASE FRAME)
Design Data
Base frame to be placed on concrete foundation
block. For foundation block dimensions consult
Grasso.
There should never be a direct rigid connection
whatsoever between the foundation block and the
floor or any other main part of the building.
The concrete block should be extended down to any
subsoil.
Scope of supply
Steel base frame, incl mounting of compressor,
electric motor and accessories.
B. BASE FRAME FOR MOUNTING ON VIBRATION
DAMPERS (TORSIONAL STIFF)
Design Data
Frame to be placed direct on elevated floors and on
roof tops (structural floor should be designed to take
the weight of the packaged unit).
Concrete foundation block can be omitted.
The first two pipe supports must be secured to a solid
foundation.
Horizontal piping must be arranged parallel to the
crankshaft of the compressor.
Always consult Grasso for installation advice.
Scope of supply
Steel closed box profile base frame, including
mounting of compressor, electric motor and
accessories.
Set of vibration dampers.
-Page 82-
Fig. 6.7-2 Packaged base frame for mounting on concrete block for
V-belt drive
(kg)
L(mm)
W(mm)
H(mm)
46
649
1569
881
804
66
766
1651
906
908
86
860
1664
931
883
IMM0312/v002
Legend
CE
Cable entry
RC
Fig. 6.7-3 Packaged base frame for mounting on vibration dampers for
direct drive (Dimensions B, H and V can be determined
by Grasso on request)
6.8.1
Compressor
type
(kg)
L(mm)
W(mm)
H(mm)
46
574
1527
632
804
66
691
1617
731
908
86
785
1642
758
883
6.8
CRANKCASE HEATER
Installed power of heater
element
Dimension L (mm)
400
400
General
During standstill of the compressor, refrigerant may
dissolve in the oil charge of the crankcase or it may even
IMM0312/v002
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IMM0312/v002
7. NOTES
7. NOTES
Table of Contents
Section
Title
7.1
Page
85
7.1
IMM0312/v002
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