RC12-installation Manual

Reciprocating Compressors for industrial refrigeration
Series Grasso 12
Installation and Maintenance Manual (IMM)

0089250
IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 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.
This manual must be carefull read and understood prior

to installing and servicing the compressor (package)
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
In compliance with the regulations of the Pressure

Equipment Directive it is mandatory that no changes be
made to the construction of pressurised parts such as the
crankcase housing, suction filter housing etc.
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.
The compressor is not filled with oil.
After the successful initial run of the compressor

(package) the warranty chart must be filled in and
returned to Grasso. A warranty chart is attached to each
compressor.
- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

Table of Contents
Section Title Page

1 INSTALLATION AND PREPARATION FOR USE 9
1.1 INSTALLATION 9
1.1.1 Moving instructions and storage 9
1.1.2 Storage 9
1.1.3 Hoisting and moving instructions 9
1.1.4 Required free space 10
1.1.5 Foundation requirements 10
1.1.5.1 Concrete structure 10
1.1.5.2 Anchoring 11
1.1.5.3 Mounting the base frame on a concrete block 11
1.1.5.3.1 Levelling the base frame 12
1.1.5.3.2 Finishing with a self-levelling grout 12
1.1.5.4 Mounting bare compressor on a concrete block 12
1.1.6 Connecting to refrigerating system pipework 12
1.1.7 Connecting the power supply 13
1.1.8 Earthing connections 13
1.1.9 Separately delivered components 13
1.2 PREPARATIONS FOR USE 15
1.2.1 Leak test of compressor and system 15
1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 15
1.2.3 Initial oil charge 15
1.2.3.1 Initial oil charge 15
1.2.4 Initial refrigerant charge 15
1.2.5 Adjustment of instruments and safety devices 15
1.2.5.1 CONTROL DEVICES 15
1.2.5.2 Refrigerants R717 and halocarbons 16
1.2.5.3 Re-adjustment of oil pressure regulator 16
1.2.6 Checking direction of rotation of motor shaft 16
1.2.7 Installing the drive guards (if present) 17
1.2.8 Initial oil warm up 17
1.2.9 Initial start-up 17
1.2.9.1 Limitations of part load operation and start-up 17
1.2.9.2 WIRING LOGIC NORMALLY OPEN UNLOADED START SOLENOID 17
1.2.9.3 Frequency controlled compressor 17
1.2.9.4 Pre-start check list 17
1.2.10 Starting and stopping procedures 17
1.2.10.1 First start 17
1.2.10.2 Restart 18
1.2.10.3 Restart after a short standstill period of time (less than 1 month) 18
1.2.10.4 Restart after a long standstill period of time 18
1.2.10.5 Stopping the compressor 18

Section Title Page
2 INSPECTION AND TROUBLE SHOOTING 19
2.1 Periodical inspection 19
2.2 Survey of periodical inspections 19
2.2.1 Check list periodical inspection 20
2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 20
2.4 LUBRICATION DATA 20
2.4.1 Topping up oil with compressor operating 21
2.5 EVACUATION, LEAK TESTING AND START-UP OF THE COMPRESSOR/PACKAGE 21
2.5.1 EVACUATION OF REFRIGERANT BEFORE SERVICING 21
2.5.2 LEAK-TIGHTNESS AFTER SERVICING 21
2.5.3 EVACUATION AFTER SERVICING 21
2.5.4 START-UP AFTER SERVICING 21
2.6 DRAINING AND CHANGE OF OIL 21
2.6.1 DRAINING OIL REVERVOIR FOR MARINE USE (Optional) 22
2.7 REPLACEMENT OF OIL FILTERS 22
2.7.1 Oil discharge filter 22
2.7.2 Oil suction filter (Pos. B) 22
2.8 REPLACEMENT OF SUCTION GAS FILTER(S) 22
2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 22
2.10 COMPRESSOR PURGING 22
2.11 TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS 23
3 MAINTENANCE 27
3.1 Post start-up maintenance 27
3.2 First maintenance 27
3.3 SMS FACTOR 27
3.4 Legend 27
3.4.1 Grasso 12 28
3.4.2 Checklist 30
4 PARTS COMPRESSOR 33
5 SUPPLEMENTARY PARTS 65
6 APPENDIX; Product Information (PI) 73
6.1 GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 12 73
6.2 PART-LOAD POWER CONSUMPTION AND ALLOWED PART LOAD STEPS COMSEL 74
6.3 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) 75
6.3.1 GENERAL DIAGRAM OF ELECTRICALLY OPERATED CAPACITY CONTROL 75
6.3.2 DIAGRAMS 76
6.4 LUBRICATING OILS (choice and recommendations) 81
6.4.1 OIL SELECTION TABLE 81
6.4.1.1 REMARKS 81
6.4.2 STRONGLY RECOMMENDED OIL TYPES 81
6.4.3 ACCEPTED NH3 AND HCFC OIL TYPES 82
6.4.4 ACCEPTED HFC OIL TYPES 82

Preface documentations User group
To be used in the field by qualified personnel of
Typographic signs: contractors.
4) Parts list (PL)

Indicates a WARNING. READ IT CAREFULLY!
Contents
All current parts of the compressor and accessories
Indicates an IMPORTANT note or procedure to which together with the design changes (if applicable) to
you should pay special attention. previous supplied components ("History").
User group
Indicates a HINT. Service and parts departments for both sales
representatives, contractors and end-users.
General
1 All documentation can be downloaded via 5) Service & Maintenance Schedules
grasso-global.com.
2 Grasso’s technical manuals includes “generic Contents
paragraphs”; this means that it can occur that not Service and maintenance schedules up to the date of
all data as described is relevant for the current required overhaul of the bare compressor.
compressor series as mentioned in this manual. (For
instance, not all compressor series are suitable for all User group
mentioned refrigerants or not all compressor series Service and parts departments and in the field by
includes two-stage compressors) qualified personnel for both sales representatives,
contractors and end-users.
1) Product Information (PI)
6) Instructions for accessories
Contents
(Supplied together with the compressor)
All product information (engineering data) for this series
compressor and the corresponding accessories. It is Contents
meant to be a guide to the selection of these
components. All the relevant mounting and installation instructions
and spare parts information for those accessories
User group supplied with the compressor.
Project engineers, application engineers, sales managers, User group
product managers for both sales representatives,
contractors and end-users. To be used in the field by qualified personnel for both
sales representatives, contractors and end-users.
2) Installation and maintenance manual (IMM)

(Supplied together with the compressor) Grasso’s technical manuals includes “generic
paragraphs”; this means that it can occur that not all
Contents data as described is relevant for the current compressor
This manual will provide information on how to series. For instance, not all compressor series are suitable
transport, install, start-up and maintain the compressor for all mentioned refrigerants or not all compressor
(package). It also contains a number of "Product series includes two-stage compressors.
Information Sheets" and the current "Parts List"
User group 7) Directives
To be used in the field by qualified personnel for both Equipment supplied according to PED regulations and
sales representatives, contractors and end-users. Machine Directives EN60204, EN292, EN294, EN378
3) Service Instruction Manual (SIM)
Contents
Description of (re)assembling, inspection, repair and part
or total overhaul of the bare shaft compressor. This
manual should be used together with the 'Installation
and Maintenance Manual'.

Cylinder numbering
Fig. 1 Cylinder numbering Grasso reciprocating compressors
Legend
1, 2, 3, ... Cylinder numbers
T Top view of compressor
M Motor/Drive end of compressor
O Oil pump of compressor

Table 1 MAIN SETUP
NOTES:
Table 2 Main setup data
Description Value Remark

Start frequency max. 6 starts per hour
Time interval between stopping and re-starting min. 2 minutes
Time interval between starting and re-starting min. 10 minutes
For continuous minimum part-load (i.e. more than 30
minutes) consult Grasso.
Time interval between loading and unloading min. 3 minutes
Adjust the steps between up and down loading, in
such a way that the system is running stable.
Oil level 25-75% crankcase sight glass
warmer than surroundings and 20 C
Min. oil temperature
for NH3 and 30 C for halocarbons
Refer to oil selection table/applied type Required oil viscosity;
Max. oil temperature
of oil 10 cSt during operation at location of bearings
Control oil pressure suction pressure + 8 bar
between 1.3 and 4.5 bar Setting approx. After a mimimum of 15 minutes running time at an oil
Lubricating oil pressure difference 2.0 bar temperature of approx. 50 oC (122 oF)
Max. discharge temperature 170 C
Min. suction pressure 0.3 bar
NH3 - 7.0 bar
Max. intermediate pressure R22 - 7.0 bar
Max. suction pressure R134a - 6.2 bar
R404A - 6.0 bar
Pdischarge - Psuction 17.5 bar
>0 Kfor NH3,
Superheat >15K for R507/R404A/R134a
Oil suction filter Blue coloured filter element
Oil discharge - running in - filter Red coloured filter element Factory mounted; to be replaced after max. 100
running hours by permanent oil discharge filter
element
Oil discharge - permanent - filter Grey filter element Supplied loose; replacement for factory
mounted running in filter
Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end

1. INSTALLATION AND PREPARATION
FOR USE
1. INSTALLATION AND PREPARATION FOR USE
1.1 INSTALLATION
Every precaution must be taken while moving the
package to its final location. Pushing, pulling or climbing
The compressor is not charged with oil, therefore, DO on any package component or piping, can easily create
NOT start the compressor before it has been installed damage.
and prepared according to Grasso’s instructions.
This section contains instructions for the proper 1.1.2 STORAGE
installation of a Grasso compressor (package). Before The compressor (package) is filled with dry nitrogen.
the compressor (package) is ready for the initial start up, Keep the system closed until the package is installed. If
the installation instructions in the following paragraphs the compressor (package) is stored, it should be kept at
must be followed: all times in a dry location to prevent corrosion damage.
1. The Compressor (Package) should be levelled and If the compressor (package) is to be stored for a
securely anchored to the foundation. prolonged period of time, it should be checked weekly to
2. All piping should be completed. ensure that the holding charge of dry nitrogen remains
3. The system and the compressor are to be pressure above atmospheric pressure.
tested for leaks (see. Section 1.2.1)
4. The system should be evacuated to remove air and 1.1.3 HOISTING AND MOVING INSTRUCTIONS
moisture.
5. 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
rotation1 has been checked.
6. The compressor is to be filled with the correct type
and amount of lubricating oil and has to be
pre-lubricated before the first start.
7. ‘Open compressors’ only;
1 Open compressors;
The drive system should be installed.
2 (Semi) hermitic compressors;
Mark R-S-T-N power supply in the terminal box of
the motor.
8. The system should be charged with the correct
amount of refrigerant.
9. The oil should be warmed up above minimum start
up oil temperature (see "Product Information").
10.The control cabinet should be energised to check the
package controls. Fig. 1.1-1 Hoisting a compressor package
Do not forget to charge the oil separator (if present) Legend

initially with oil, to the level of the float assembly C Compressor
M Motor
1.1.1 MOVING INSTRUCTIONS AND STORAGE
For loose component or compressor package weights, Packaged base frame:
refer either to the relevant component type plate or The only places that can be used for safe hoisting of the
package lay-out or to the suppliers document. For bare package are the four hoisting eyes on the steel base
compressor weights, see "Product Information". 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.
Attach spreader bars to the slings so as to prevent
damage to piping and components.
1. The direction of rotation of the compressor cannot be checked for (semi)

hermetic compressors. For these compressors the electrical connection should
be marked, to be sure that the compressor has always the same direction of
rotation!

FOR USE
DO NOT use the compressor or motor or oil separator Refer to “Product Information“ for minimum
hoisting eyes to move the package! These hoisting eyes requirements.
are intended for lifting loose components only and not
for the entire package! 1.1.5 FOUNDATION REQUIREMENTS
Bare compressor or loose components: Compressor (package) has to be mounted on a

Determine the dead weight of the particular component concreted block. On request, Grasso can calculate the
(see "Product Information (ED)"), prior to moving a bare exact dimensions of the concrete block, based on the
compressor or loose component. Use the hoisting eyes compressor size and operating conditions.
only, DO NOT sling from other compressor parts (see Fig. This paragraph covers measures to be taken for a
1.1-2). compressor (package) mounting on a concrete block.
Two foundation arrangements are described:
1. Compressor package with steel base frame mounted
on a concrete block.
Following base frames are possible;
a) Frame designed for mounting on concrete block.
For more instalation details refer to; Section
1.1.5.1, Section 1.1.5.2, Section 1.1.5.3, Section
1.1.5.3.1, Section 1.1.5.3.2.
b) Frame designed for mounting on vibration
dampers.
For more details in case mounting base frames on
vibration dampers is applied, refer to separate
instruction sheet and other order documentation
like package drawing, supplied with the
compressor package and consult Grasso if
required.
2. Bare compressor direct mounted on a concrete block
via grouted anchors.
For more installation details refer to; Section 1.1.5.1,
Section 1.1.5.2, Section 1.1.5.4.
1.1.5.1 CONCRETE STRUCTURE
Fig. 1.1-2 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 Fig. 1.1-3 Concrete block
wooden transport beams must still be mounted
underneath the base frame and stored in this way, until
the package is positioned above its approximate Legend
location. 1 Cork board
2 Concrete base
1.1.4 REQUIRED FREE SPACE
For easy operating, servicing and maintenance access, 3 (Concrete) Floor
the compressor (package) should be installed with 4 Sand
sufficient free space around it.
The concrete block for compressor and motor or
compressor package should have a profile as illustrated
in Table on Page 10 and made according to the following
recommendations:

FOR USE
• The concrete block should be set on firm footings or

on a floor capable of carrying the weight of the
concrete block and capable of absorbing the free
forces and gas forces of the compressor during
operation. The ground under the concrete block
should be horizontal and flat.
• The top surface of the block should be level and even.
• There should be sufficient free space around the
block to install corkboard (or similar).
• The block should be provided with anchor bolt
recesses or holes according to the anchor bolt spacing
as per package lay out drawing.
Table 1.1-1
Legend
A Chemical anchor
B 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).
• Installing foundation onto an existing floor, with
sealing corkboard or vibration isolators.
1.1.5.2 ANCHORING
After the concrete block has cured the anchors should be
installed as shown above and in case of a package in
accordance with the package lay out drawing.
Templates should be made to locate the anchor bolts or
chemical anchors to match the holes in the bottom
flange of the base frame.
Grout the mortar according to the supplier instructions. Fig. 1.1-4 Anchoring details
Install chemical anchors as illustrated in Fig. 1.1-4 and
according to the instructions of the anchor supplier.
Legend
A Drilled chemical anchor (M20)
B Grouted anchor recesses (M20)
1 Installed chemical anchor before placing the base frame
Installing chemical anchor after placing the base frame
2 (base frame cannot be removed easily)
3 Drilling angle
1.1.5.3 MOUNTING THE BASE FRAME ON A

CONCRETE BLOCK

FOR USE
General instructions can be found in the order manual.

After the space between base frame and concrete base
has been filled-up with a filling grout, the package base 1.1.5.4 MOUNTING BARE COMPRESSOR ON A
frame must be secured tightly to the foundation block or CONCRETE BLOCK
floor. If base frame is not applied the approximately the same
procedure of levelling the base frame has to be applied
1.1.5.3.1 LEVELLING THE BASE FRAME for the bare shaft compressor (refer Section 1.1.5.3).
The mounting surfaces of the compressor feet must be
level without any deviation and projecting at least 10
mm above the concrete base.
Fig. 1.1-5 Grouting details
Legend
1 Self-levelling grout
2 Adjusting bolts (4x) Fig. 1.1-6 Grouting details of bare compressor on concrete block
3 Washer
4 Temporary barrier strip around and inside frame Legend
5 Complete cured concrete block 1 Self leveling grout
6 Grout layer 2 Foundation anchor

3 Layer of self leveling grout (10 - 15 mm)
After the anchor filling mortar has completely cured the
frame should be levelled with a space between block and 4 Temporary barrier strip aroud each compressor foot
lower frame flange of 3 - 5 mm*. This space is necessary 5 Complete cured concrete block
for levelling using the base frame adjusting bolts with
metal washers (supplied separately). The base frame CF Compressor foot
should be levelled on each frame side. Adjust the frame Width of grout layer
on each adjusting place until all frame sides are WL (WL-WC > 40 mm)
horizontal.
Width of compressor foot
WC
This space largely depends on the sort of grout or mortar (WL-WC > 40 mm)
used. Determine this space according to the instructions
of the grout or mortar supplier. 1.1.6 CONNECTING TO REFRIGERATING SYSTEM
PIPEWORK
1.1.5.3.2 FINISHING WITH A SELF-LEVELLING GROUT
After levelling has been completed the adjusting bolt
ends must be greased to avoid bonding to the DO NOT ground through the compressor when arc
self-levelling grout. The space between concrete block welding
and frame must be completely filled with the
self-levelling grout to ensure that the complete bottom After the compressor (package) has been levelled and
surface of the base frame will be supported. Therefore, secured to the foundation, the system piping may be
it is not allowed to use shims between concrete base and connected. The suction line(s) and discharge line(s)
base frame. should be installed and supported such that there is no
load exerted on the compressor. The size and location of
Grouting must be carried out in accordance with the the suction and discharge connections, can be found in
instructions provided by the grouting supplier. After the "Product Information" (bare compressor) and in case
complete de-aeration of the grouted layer, secure the of a package, the package lay out drawing.
base frame by tightening the anchor bolt nuts and
remove all adjusting bolts. At this stage the drive system
can be installed. These (accessories) installation

FOR USE
In order to ensure that suction gas strainer can be

removed easily, special attention for pipe work is
required for (semi) hermetic compressors.
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").
Never connect the oil rectifier return line to the suction

line or to the suction gas filter.
Suspension of system pipework

To eliminate vibration transmission to the system piping,
the following is recommended:
• Install all piping free of tension.
• Secure the piping by clips or brackets in two
directions.
• Install (stop) valves, piping and accessories such, that
there is no load exerted on the compressor.
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 SEPARATELY DELIVERED COMPONENTS
Check whether the sets/parts/components belonging to

this compressor are supplied loose! (Refer to
confirmation of order)
Mount these separately delivered sets, components
and/or parts, according to the instruction as enclosed.

FOR USE

FOR USE
1.2 PREPARATIONS FOR USE 1.2.3 INITIAL OIL CHARGE

After the Compressor (Package) has been installed
(excluding final connection of drive device), the
following actions should be followed in the order given: Used or filtered oil should NEVER BE added to a
compressor under any circumstance.
1.2.1 LEAK TEST OF COMPRESSOR AND SYSTEM
The compressor (package) has been pressure tested
prior to leaving the factory. In case an additional leak Use only new oil as selected from the Grasso oil
test is required, this test is should be carried out with dry table.(Refer Chapter 6)
nitrogen.
Oil charging via the suction line of the compressor is not

DO NOT add oil to the compressor prior to pressure allowed.
testing
A system leak test should be carried out over 24 hours to Procedure:
ensure that the system is tightly sealed.
Record during the pressure test, the pressure, ambient i) STATUS: System is dried and still evacuated.
temperature and outside temperature. During the initial ii) Charge the oil separator (if present) initially with oil .
6 hours a pressure drop of 2% is permissable. With iii) Close suction and discharge stop valves of compressor
respect to temperature variations, no further pressure and oil return line of oil separator (if present).
loss should be detected in the remaining 18 hours. iv) Charge the compressor crankcase with oil via the oil
charge valve.
1.2.2 EVACUATION/DRYING THE REFRIGERATING
SYSTEM
Pre-lubrication just before the first start is obligatory.
For evacuation of compressor only, refer to Section 2.5
Procedure to evacuate and to dry a system:
i) STATUS: System is filled with nitrogen and no oil has Filling of the afore mentioned components is also
been added (oil prevents any trapped moisture from possible by means of a separate oil filling pump via the
boiling off). oil charge valves mounted onto the oil pump housing.
ii) Verify that all valves in that part of the system to be
evacuated are opened (refer also to the plant 1.2.3.1 INITIAL OIL CHARGE
manual).
iii) Connect vacuum pump to the evacuation/purging
valve(s) of the compressor (for location of these QUANTITY OF OIL TO BE FILLED (IN dm3)
valves refer to the "Product Information" or to a Shaft seal
connection as mentioned in the plant manual and Number of housing incl. Oil Oil
evacuate the system to approx. 5 mm Hg (=6.6 mBar). Crankcase
cylinders internal circuit of filters pump
iv) Break vacuum by charging dry nitrogen into the crankshaft
system. 2 and 3 0.6 7.8
v) Repeat step iii, 'Connect vacuum pump ...'.
vi) Wait approx. 24 hours. 4 0.7 13.6
vii) If pressure has increased (system still contains 6 0.7 1.5 0.5 14.7
moisture), repeat steps iv, vand vi, otherwise, each
continue with the "Initial oil charge" procedure. 9 0.8 21.7
12 0.9 28.7
1.2.4 INITIAL REFRIGERANT CHARGE

Refrigerant charging should be done in accordance with
the plant manual by qualified refrigeration engineers.
1.2.5 ADJUSTMENT OF INSTRUMENTS AND

SAFETY DEVICES
1.2.5.1 CONTROL DEVICES

FOR USE
Legend
Refer to separate user manuals, in case an electrionic
control device is installed. 1 Lubricating oil pressure regulator
2 Control oil pressure regulator
1.2.5.2 REFRIGERANTS R717 AND HALOCARBONS A Oil suction filter
Oil discharge filter
Pressure safety limit switches for R717 and halocarbons REMARK: A running in filter is factory mounted; to
B be replaced after max. 100 running
5oC below design
Setting hours by permanent oil discharge filter
Suction pressure a evaporating temp.
element
Precondition Min. =0.3 bar(a)
Oil charge valve for lubrication circuit.
Max.= depends on C
Suction and
rotational speed, REMARK: This connection to be used for
intermediate Setting pre-lubrication of the oil circuit
refer to Product
pressure
Information (PI)
Oil charge plug for oil suction filter (Hand operarated oil
D
Setting 5oC above design pump and stop valve are not included)
Discharge pressure condensing temp.
E Connection to measure oil control pressure
Precondition Max. =24 bar(a)
F Hand operated oil charge pump (optional).
Lubrication oil
Setting Min. =1.3 bar
pressure difference
Re-adjustment procedure:
a. Settings Pdischarge - Psuction must never exceed max. value as
mentioned in Product Information
REMARK: For settings, refer Table 1.
Oil pressure regulators for R717 and halocarbons
i) Run the compressor for 15 minutes until the
crankcase oil is at its stable operating temperature
Setting 2.0 bar [Toil] of 50 oC at which:
Lubrication oil # The lubricating oil pressure difference should be (A)
pressure
differencea Precondition, Min. =1.3 bar according to Table 1.
at 50 oC oil temp. Max. =4.5 bar # The control oil pressure difference should be
approx. (B) according to Table 1.
Control oil
pressure difference
Setting 8.0 bar After the initial run the oil pressure differences should
be slightly higher.
a. The oil pressure regulator is adjusted at the works, but it may occur ii) Determine the lubricating oil pressure difference
that this setting should be corrected during the initial run and also if
the value <1.5 or >2.5 bar. The re-adjustment procedure is given in
(difference between the pressure gauges of the oil
section “Re-adjustment of oil pressure regulator. and suction or [dOil]).
iii) Determine the control oil pressure difference
1.2.5.3 RE-ADJUSTMENT OF OIL PRESSURE (difference between the pressure gauges of oil pump
REGULATOR discharge 1 and suction.
iv) Remove the cap nut of both oil pressure regulators if
It is possible that after the compressor(package) has the pressures need to be re-adjusted.
been installed, the lubrication oil pressure regulator v) Turn the slotted pin with a screwdriver clockwise or
(located on the left side of the pump) needs to be counter clockwise for a higher or lower oil pressure
re-adjusted. respectively, until the required control & lubricating
Inside the oil pump two regulators are factory preset and oil pressure differences have been achieved 2.
installed; One control oil pressure regulator (right) to vi) Replace both cap nuts.
control the valve lifting mechanisms and one lubricating REMARK: If the valve lifting fails, check the control oil
oil pressure regulator for lubrication. pressure regulator!
1.2.6 CHECKING DIRECTION OF ROTATION OF

MOTOR SHAFT
Prior to installing the intermediate coupling element or
V-belts, the direction of rotation of the motor shaft must
be checked. The direction of rotation can be determined
from the arrow-sticker at the oil pump.
1. To be measured by means of a special control oil pressure gauge to be

Fig. 1.2-1 Oil pressure regulator connected at position E on the oil pump.
2. Re-adjusting one regulator will affect the other one, so be sure that both
regulators are properly (re-)adjusted.

FOR USE
1.2.7 INSTALLING THE DRIVE GUARDS (IF been overlooked.

PRESENT) i) System is charged with refrigerant.
Only after the compressor is ready for the initial startup! ii) Settings of safety limit switches are adjusted properly.
Refer to the drive guard installing procedures included in iii) Direction of rotation of compressor crankshaft is
the order documentation. correct.
iv) Check capacity control:
1.2.8 INITIAL OIL WARM UP 1. Set the electrical capacity control switch to the
Prior to the initial start-up, the crankcase heater (if position of the lowest part load step.
present) must be energised. For the min. oil temperature 2. Check whether the manual control lever of each
refer to “Product Information (PI)“. solenoid is in its lowest horizontal position.
1.2.9 INITIAL START-UP

If control lever of each solenoid is not in its lowest
1.2.9.1 LIMITATIONS OF PART LOAD OPERATION position, the compressor may be seriously damaged.
AND START-UP v) Oil level established in sight glass.
The capacity control serves to adapt the compressor vi) Stop valves to the pressure gauges are open.
capacity at any moment as closely as possible to the vii) Suction stop valve is closed (in case the evaporating
refrigerating capacity. In order to adjust the capacity, a temperature is much higher than the design
number of cylinders can be put in or out of action either evaporating temperature) and the discharge stop
individually or collectively by means of solenoid valves. valve is open and in case of two- stage compressors
that the stop valves in the intermediate circuit lines
are open.
viii)Stop valve in the oil return line of the oil separator (if
Due to start-up limitations and to limitations of part load present) is closed.
operation it may be that not all available part load steps
are allowed under certain conditions. Use of incorrect When all items are verified, the compressor (package) is
ready for the start-up.
control steps can damage compressor and/or
components. 1.2.10 STARTING AND STOPPING PROCEDURES
For a detailed description about start-up and part load
limitations refer to the software program “Comsel”.
For all limitations refer to Table 1! The values in the main
1.2.9.2 WIRING LOGIC NORMALLY OPEN setup data tables, overrules the values as mentioned in
UNLOADED START SOLENOID the text.
1 If compessor is NOT running then NO-solenoid is not When starting the compressor a distinction should be
energised. made between:
2 Energise the NO-solenoid 10 - 20 seconds before
starting. 1.2.10.1 FIRST START
3 If compressor starts then NO-solenoid is energised i) Notice "Pre-start check list", also consult the plant
and de-energised by means of an auxiliary time relay. manual and verify the following items:
4 Ensure that the NO-solenoid valve is not de-energised — Check the oil temperature (refer to the "Product
until full speed has been achieved and the specified Information").
lubrication oil pressure has been established. — Check crankcase oil level (refer to Section 2.4.1).
5 Energise the NO-solenoid 5 seconds before stopping ii) Start the compressor and check whether the oil
until the compressor is stopped completely. pressure increases.
1.2.9.3 FREQUENCY CONTROLLED COMPRESSOR
The time interval between stopping and starting should
be at least 2 minutes and between starting and
In case of frequency controlled compressors, a separate re-starting 10 minutes.
instruction 00.87.041 is required. If you don’t have this iii) Slowly open suction stop valve and watch suction
instruction consult Grasso. pressure, which may not exceed the max. value.
1.2.9.4 PRE-START CHECK LIST

Refrigerant liquid hammer, will damage the compressor;
The following Paragraph covers only the initial start of Superheat is always necessary! Refer to general limits of
the compressor and not the complete refrigeration operation to determine the mimimum superheat for
plant. current refrigerant!
Be sure that all necessary system valves are open and iv) In case of electrically operated capacity control:
that the refrigeration system is ready for start up. Use a. Single-stage compressors: One or more cylinders
the following check to guarantee that no items of will be energized.
importance regarding the compressor (package) have

FOR USE
b. Two-stage compressors: 3 - 5 minutes after

starting and only when HP-cylinder(s) is (are) in
operation, the LP cylinders can be energised.
In the case of decreasing capacity for two stage

compressors, it is not allowed to cut out all LP-cylinders.
v) Watch maximum allowable motor current (refer to
motor type plate).
vi) Watch discharge temperatures LP and HP, max.
intermediate pressure and max. allowable motor
current (refer to motor type plate).
vii) Adjust pressure gauge stop valves, in order to avoid
vibration of the pointers.
viii)Open the stop valve in the oil return line from the oil
separator (if present).
ix) Open compressors only; After 50 hours of operation
retighten the coupling bolts or check and/or correct
the tension of the V-belts and retighten the
foundation bolts (with due respect to the torque
settings given by the supplier of the fasteners!).
1.2.10.2 RESTART
For the time interval between stopping and starting

refer to Table 1.
Proceed to the complete starting procedure like “First
start“
1.2.10.3 RESTART AFTER A SHORT STANDSTILL

PERIOD OF TIME (LESS THAN 1 MONTH)
• Refer to Section 1.2.10.2.
1.2.10.4 RESTART AFTER A LONG STANDSTILL

PERIOD OF TIME
After a seasonal standstill (1 till 6 months) or

maintenance operations;
After a standstill period of time more than 1 month,

pre-lubrication just before starting is always obligatory.
• Check settings of control and safety equipment.
• Proceed to the complete starting procedure.
Restarting compressor after a standstill period of time

more than 6 months, consult your supplier. It is
recommended to proceed with the initial start up
procedure.
1.2.10.5 STOPPING THE COMPRESSOR

The compressor can be stopped at any moment,
however, consult the supplier if further actions are
required.

2. INSPECTION AND TROUBLE
SHOOTING
2. INSPECTION AND TROUBLE SHOOTING
2.1 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.
2.2 SURVEY OF PERIODICAL INSPECTIONS

Apart from the check points in the table below, the
sound produced by the compressor also provides an
indication of its mechanical condition. If abnormal
sounds are audible, their cause should be traced and
removed immediately in order to prevent serious
breakdowns.

2.2.1 CHECK LIST PERIODICAL INSPECTION CHECK FREQUENCY REMARKS

POINTSa
Table 2.2-1 Check list periodical inspection
monthly
weekly
daily
CHECK
POINTSa FREQUENCY REMARKS
monthly
weekly
Adjustment
daily
and operation Refer also to instructions of

•
of pressure switch manufacturer.
safety switches
Between 25% and 75%
Oil level in height of the sight glass. Capacity
crankcase • For topping up oil, refer to control (if •
Section 2.4.1. provided)
Switching Refer Table 1.
The oil should be
transparently clear. A frequency of
Colour of the the •
• disappearing white colour
oil compressor
points to dissolved
refrigerant. Check the number of
Lubricating oil Number of operating hours in view of
pressure • operating • any maintenance
difference hours operations to be carried
out.
Min. control oil •
pressure a. During the first 50 operating hours the compressor should be checked
regularly for all the points mentioned above, at least twice every 24 hours
Oil and more frequently in cases where irregularities are found.
Refer to the "Product
temperature •
max. Information"
2.3 STEPS FOR LONGER SHUT-DOWN
Oil leakage of • In case of more than 1
shaft seal max. cc/hr contact supplier. PERIODS (> 6 MONTHS)
Check against design To shut down a compressor for long term periods,
Suction
pressure
• conditions. Refer to plant proceed as follows:
manual. i) Tightly shut both the suction and discharge stop
Refer to plant manual. For valves and the stop valve of the oil return line (if
Discharge
the max. allowable present).
• discharge pressure refer to ii) Disconnect the power source from the compressor
pressure the technical data of
compressor. drive motor and the electrical control cabinet.
iii) Place a moisture absorbing compound (eg a dessicant
Suction
15 K required for R404A such as silica gel) inside the control cabinet.
superheat iv) Place warning tags on the electric system and all
• and R507, for other
Intermediate refrigerants 0 K
superheat closed stop valves.
Prior to starting up after a shut down, change the oil
Discharge (refer to ) and exchange the oil filters. Determine the
temperature • 170 C.
max. starting and stopping procedure from prior to start the
compressor.
During compressor
standstill the lower part of
Oil the crankcase must remain 2.4 LUBRICATION DATA
temperature • warmer than the
min. surroundings: 20 C Determine max Toil and set this value in the safety
(NH3) and 30 C device.
(halocarbons). Change the oil as soon as an oil analysis indicates
Cooling water Min. Actual condensing contaminated oil.
temperature • temperature + 10 K
(if present) ( Tc + 10 K)
Check belts for:
1) Wear (fraying, cuts etc.)
and ensure that they do
not touch the groove
bottom.
Condition of 2) Tension. Too low a
•
V-belts tension gives rise to
excessive flapping or
oscillation in operation. For
correct tension consult the
instructions given by the
V-belt supplier.

SHOOTING
which is less than the admissible operating pressure of

the low pressure stage.
It is expressly pointed out that it is not permitted to mix
different types of oil. If another type of oil is used, first 2.5.3 EVACUATION AFTER SERVICING
remove all the stale oil in the filters, oil pump, crankcase, After the pressure test has been completed, the
shaft seal, oil separator and oil drains of the installation. compressor (package) must be evacuated and undergo
a vacuum test. Evacuation is used to remove air and
moisture from the compressor (package)
2.4.1 TOPPING UP OIL WITH COMPRESSOR
OPERATING 2.5.4 START-UP AFTER SERVICING
1 STATUS: Compressor (package) is dried and still
evacuated.
Use Grasso’s hand-operated oil pump, part. no. 2 Charge the oil separator, if present, with oil.
18.13.121 See the appropriate Product Information for the
correct quantity.
Topping up oil is permitted during compressor 3 Charge the compressor crankcase with oil via the oil
operation. charge valve until the minimum level is seen at the
Be sure that this oil is the same as in the plant (refer to sight glass at the level as indicated in IMM.
Section 2.4). It is mandatory to pre-lubricate the oil circuit by
adding the final quantity of oil via the charge valve
Without affecting the operation of the compressor, the mounted onto the oil pump by means of a separate
oil may be topped up by means of a separate oil pump. oil filling pump. The required oil level is indicated in
This pump enables the oil to be forced into the crankcase the IMM.
via the oil charging valve, against suction pressure. 4 Re-install all accessories such as coupling, V-belt guard
etc.
5 Open the shut-off valves.
6 Check the start-stop procedure.
7 Check all safeties and controls.
8 Re-install the main fuses.
9 Start up the compressor.
10 Check running condition.
Note:
Fig. 2.4-1 Oil level in compressor sight glass The job isn't finished until the paper work is done!
Complete the service report, e.g. Grasso report
2.5 EVACUATION, LEAK TESTING AND 00.89.062.
START-UP OF THE
COMPRESSOR/PACKAGE 2.6 DRAINING AND CHANGE OF OIL
To evacuate the refrigeration system refer to Section To top up oil see Section 2.4.1, Oil changing procedure:
1.2.2, i) Evacuate the compressor (refer to Section 2.5).
ii) Drain the oil via the oil charging/drain valve. Remove
Use always a vacuum pump or pump-down unit to the cover of one or more service openings on the
evacuate the refrigerant from the compressor. compressor side.
iii) Clean the inside of the crankcase with a non-fibrous
2.5.1 EVACUATION OF REFRIGERANT BEFORE cloth (do not use cotton waste!).
SERVICING iv) Replace the service cover(s) with a new seal.
Procedure to evacuate the compressor: v) Charge crankcase with clean oil in accordance with
1. Switch off main control panel the procedure.
2. Remove main fuses
3. Close shut-off valves
4. Remove the refrigerant by means of a vacuum pump
or pump-down unit, via the evacuation/purging
valve(s) as prescribed by local safety regulations. For
the location of these valves refer to the "Product
Information".
5. Drain the oil from the compressor and oil separator,
oil return /oil rectifier system if present.
2.5.2 LEAK-TIGHTNESS AFTER SERVICING
The necessary safety precautions should be taken before
carrying out the leak-tightness test. To check
leak-tightness use dry nitrogen at a positive pressure

2.6.1 DRAINING OIL REVERVOIR FOR MARINE USE 2.9 DISMANTLING, INSPECTION AND
(OPTIONAL) RE-ASSEMBLY OF SUCTION AND
DISCHARGE VALVES
In case an oil reservoir for marine use is applied, this oil
reservoir has also to be drained via the oil drain plug of
the oil reservoir. A high working temperature and rapid temperature
variations shorten the life time of the valves, which, for
this reason, require regular inspection.
2.7 REPLACEMENT OF OIL FILTERS The suction and discharge valves of a refrigeration
compressor are parts that are heavily loaded both
mechanically and thermally. Wear and life time of the
Tools; Use the ring spanner for (dis)mounting the oil valves strongly depend on the working conditions of the
filter cups (included in set of special Grasso tools) compressor. It is recommended that valve condition is
regularly checked.For dismantling, inspection and
Evacuate (refer to Section 2.5) the compressor prior to re-assembly of the valves, refer to the relevant
exchange the filter(s). paragraph of the Compressor Service Instruction
Facts: Manual.
Oil suction filter = BLUE coloured
Oil discharge - running-in - filter = RED coloured
Oil discharge - permanent - filter= GREY coloured. In order to reduce the downtime involved in the valve
inspection, it is recommended to have as many complete
2.7.1 OIL DISCHARGE FILTER valve assemblies in stock as there are cylinders on the
compressor.These valves can be exchanged with the
original valves; in this case, these original valves can be
An oil discharge (running-in) filter is factory mounted. inspected and repaired or replaced if necessary later.
This filter must be exchanged after max. 100 running
hours. Oil filters can not be cleaned!
Replace this filter according to the schedule in Section
2.10 COMPRESSOR PURGING
2.2.2 and to the replacement instructions included in the Procedure to purge the compressor(after maintenance
filter set (GREY = permanent) or in case of a modified jobs):
plant (RED = running-in).
2.7.2 OIL SUCTION FILTER (POS. B) STATUS:

The frequency of exchanging this filter depends on the Stop valves of suction, discharge and oil return line are
condition of the refrigeration system. It is recommended still closed (refer to Section 2.5) and compressor is filled
to exchange this filter when the compressor is with oil (refer to Section 2.6).
overhauled or when pressure drop exceeds 1 bar. i) Connect a vacuum pump to the evacuation/purging
valve(s) and evacuate as prescribed by local
2.8 REPLACEMENT OF SUCTION GAS regulations. For the location of these valves refer to
the "Product Information".
FILTER(S) ii) When evacuation is completed open the discharge
stop valve.
iii) Watch suction and discharge pressure.
Running-in suction gas filter(s) is(are) factory mounted.
This(these) filter(s) must be exchanged after max. 100
running hours. Running-in filters can not be cleaned! If suction pressure increases quickly, the discharge valve
assy is leaking.
iv) Start compressor.
Facts: v) Slowly open suction stop valve.
Filter type 2000 = installed in 2-3-4-6 cylinder vi) Open the stop valve in the oil return line of the oil
compressors. separator (if present).
Filter type 3000 = installed in 9 and 12 cylinder vii) For two stage compressor only;
compressors. a. Two-stage system A/B: open liquid supply to
interstage cooler.
b. Two-stage system C/D: refer to the plant manual.
Procedure: viii)If a Self-Limiting Automatic Purger is not installed,
i) Evacuate the compressor. purge the refrigerating system (refer to the plant
ii) Remove and exchange the suction gas filter(s). manual).
iii) Purge the compressor.

SHOOTING
2.11 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. Therefore, it is necessary besides this table also to
consult the plant manual.

Table 2.11-1 Troubleshooting

FAULT CAUSE REMEDY
FAULT CAUSE REMEDY 1. Liquid refrigerant in
crankcase due to:
1. Discharge stop valve
not fully open Open fully E Crankcase
Provide for crankcase
frosted or weta
A Discharge 1a. Room temperature heating or, if provided,
2. Discharge pressure
pressure too high gauge defective Repair or replace too low check it for proper
operation
3. Non-condensables in Purge with a Automatic Stop
1b. Oil return from
the system Purger compressor separator contains Consult plant manual
1. Discharge pressure and contact liquid refrigerant
See A installation
too high
1c. Installation Re-adjust installation and
2. Too many cylinders engineer operates too wet provide for superheat
Cut in more cylinders
cut out
1d. Liquid separator
too small Consult plant manual
3. Suction pressure too
low See D
1. Oil pressure for valve
4. Excessive superheat Eliminate excessive F All cylinders lifting mechanism too
of suction gas superheat inactive while low See J
compressor is (For Grasso V, 12, 12E
5. For two-stage operating and Grasso 10 only)
B Discharge compressors:
temperature too Repair 2. Incorrect wiring of Refer to the "Product
interstage cooling does
high not operate properly capacity control Information”
6. Room temperature Ventilate engine room 1. Type of oil not

too high better according to oil Change oil type
lubrication oil table
7. Discharge valve (too thin oil)
Repair or renew
defective
2. Compressor
8. Pressure relief valve Repair or renew operates unloaded too Refer to design calculations
is leaking frequently
9. Water cooling is not Repair 3. No return from oil Check the operation of
working properly separatorb float valve in oil separator
G Too high oil
1. Capacity control consumption 4. Restriction plug at
does not operate Repair the bottom of suction Clean plug
chamber in cylinder
2. Compressor capacity Refer to plant design clogged
too small
C Suction 5. Worn out oil scraper
ring(s) Replace ring(s)
pressure too high 3. Suction pressure Repair or renew
gauge defective
6. Loss of oil due to
leakage Repair
4. One or more suction Renew suction valve rings
valves defective
7. Leaking shaft seal
5. One or more (max. 1 cc/hr) Repair shaft seal
discharge valves Repair or renew (Not for Grasso 7S and Refer to Section 2.2
defective 8S)()
6. Pressure relief valve 8. Oil level in crankcase Drain/Refill with oil
Repair or renew too high
is leaking
1. Suction stop valve 9. Oil separator is not Refer to section “Initial oil
not fully open Open fully initially filled with oil charge”
2. Suction gas strainer 1. Lubricating oil
Renew H Too high oil pressure regulator not Re-adjust or renew
blocked
pressure during adjusted properly or
D Suction 3. Injection control not normal defective
pressure too low adjusted correctly Re-adjust control
operation at
working 2. Defective oil
4. Too little refrigerant temperature pressure and/or
Top-up with refrigerant Repair or replace
in installation suction pressure gauge
(if present)
5. Suction pressure
gauge defective Renew

SHOOTING
FAULT CAUSE REMEDY

1. Too little oil in
crankcase Top up oil
2. Disturbed oil circuit: Renew the element of oil

Oil suction and/or suction filter and/or oil
discharge filter is dirty discharge filter
J Too low
lubricating oil 3. Lubricating oil
pressure pressure regulator not
adjusted properly or Re-adjust or renew
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 Renew bearings
K Too low or no 1. Failure of control oil
Re-adjust or renew
control oil pressure regulator in
pressure regulator
oil pump
(For Grasso V, 12,
12E and 2. A lack of oil in oil Add oil to the system
Grasso10 only) system
3. Oil pump defect Repair or renew oil pump
a. In case of R744 applications only, crankcase can be frosted or wet, during

normal operating conditions.
b. During the initial start-up, the oil separator (if present) consumes oil before the
first oil will be returned.


3. MAINTENANCE
3. MAINTENANCE
3.1 POST START-UP MAINTENANCE 3.3 SMS FACTOR

After the compressor has run for the initial 100
operating hours: General
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 The running hours mentioned in the SMS tables should
with the filter replacement instructions. only be used as a reference for maintenance intervals.
iii) Inspect suction gas filter (refer to the Compressor
Service Instruction Manual).
iv) Exchange or clean oil suction filter element.
v) Check the compressor shaft seal for leakage. If The running hours mentioned in the tables are based on
excessive (more than 1 cc/hr) replace the seal. a single stage compressor running at -10oC/+35oC, NH3
vi) 1) Retighten the coupling mounting bolts with the at nominal speed. In this case the SMS factor = 1, in all
torque settings as given by the coupling other cases the maintenance intervals have to be
manufacturer. adjusted accordingly.
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 The number of running hours mentioned in the SMS
all foundation bolts as given in Compressor Service tables have to be adjusted accordingly depending on the
Instruction Manual.
operating conditions of the compressor (speed,
evaporating temperature, condensing temperature,
3.2 FIRST MAINTENANCE refrigerant, start frequency, capacity control steps, etc..
This means that the service intervals could be
significantly different.
For complete service schedules and required service sets
refer to Grasso's Service and Maintenance Schedules
(SMS).
3.4 LEGEND
After the refrigerating system has been modified, the These operations cover routine maintenance and are
suction gas filter(s). the oil filters and the oil should be
changed. meant as a guide only. Lack of maintenance, frequency
of stop/starting, extreme operating conditions etc could
lead to accelerated wear.
Maintenance Number of operating hours
100a > 100
Inspect/clean suction gas filter X
General;
refer to Service and
The service and maintenance schedules use the codes as
Renewal oil discharge filter X
Maintenance explained in the table below;
Inspect/clean oil suction filter Schedules (SMS)
X
(strainer) Table 3.4-1 Actions
Oil analysis bc X Legend for service and maintenance schedules (SMS)
a. Time dependent on pollution. Item Code/Actions Description
b. Take an oil sample every 3,000 running hours or once a year and renew if any
sign of discoloration and if the system is contaminated. Inspection / Alternatively renewal - correcting
c. Consult your oil supplier. 1 IC
/ Testing
Inspection Visual / Alternatively electrical
2 IV
testing
3 RE Renewal
4 ME Measure
5 CL Clean

3. MAINTENANCE
3.4.1 GRASSO 12
SERVICE AND MAINTENANCE SCHEDULES Grasso 12

Actions
Running hours * 1000a
3 6 - - -
9 - 12 - -
Item
Description Checkpoint
15 - 18 -
0.1 YEARLY
21 - - 24 - -
27 30 - - -
33 - - - 36
1 CL RE CL RE RE RE RE RE Oil suction filter
2 REb RE RE RE RE RE RE RE Oil discharge filterc
3 Oil - ME ME ME ME ME ME ME Oil analysis
Oil refreshment (If hygroscopical oil is used replace this
4 RE RE - RE RE RE RE RE always after each opening of compressor or
installation)
5 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Housing and element
Oil pump
6 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Control and lubrication oil pressure regulator
7a - - - - - - IC/ME IC/ME Main and intermediate bearing bushes
7b Crankshaft - - - - - - IC/ME IC/ME Running surfaces main and intermediate bearings

crankshaft
8 - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Running surfaces con. rods
9 Shaft seal - IC IC IC IC IC IC IC Oil/refrigerant leakage
10 Conrod - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Big and small end bearings
11 - IC - IC IC IC IC IC Piston
12 Pistons - IC - IC IC IC IC IC Piston rings
13 - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Gudgeon pin
14 Thrust bearing - IV/ME - IV/ME IV/ME IV/ME IV/ME IV/ME Running surfaces/Axial play
15 IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Solenoid valves and coils
16 Capacity control - RE - RE IV IV RE RE Seals of cap. control piston
17 - IC - IC IC IC IC IC Cap. Control mechanism
18 IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Crankcase heater
19 CL CL - CL CL CL CL CL Crankcase
Compressor
20 - - - - IC IC IC IC Non return valves LP/Restrictions HP
housing
21 - IV - IV IV IV IV IV Relief valves
22 REd IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter
23 Discharge valves - IC - RE RE RE RE RE Valves, springs and damper rings
24 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Stroke limitor/Discharge valve seat
25 Suction valves - IC - RE RE RE RE RE Valves, springs and damper rings
26 - IV - IV IV IV IV IV Cap. Control lifting mechanism
Cylinder liners
27 - IV/ME - IV/ME IV/ME IV/ME IV/ME IV/ME Dimension and running profile
28 IC IC IC IC IC IC IC IC Alignment
Drive
29 IC IC IC IC IC IC IC IC V-belts
30 Electric motor Refer to specifications of motor manufacturer

3. MAINTENANCE
SERVICE AND MAINTENANCE SCHEDULES Grasso 12

Actions
Running hours * 1000a
3 6 - - -
9 - 12 - -
Item
Description Checkpoint
15 - 18 -
0.1 YEARLY
21 - - 24 - -
27 30 - - -
33 - - - 36
31 IC IC IC IC IC IC CL/IC CL/IC Oil level switch
32 IC IC IC IC IC IC IC IC Safety switches
33 IC IC IC IC IC IC IC IC Gauges
34 IC IC IC IC IC IC IC IC Thermostats
35 IC IC IC IC IC IC IC IC Thermometers
36 IC IC IC IC IC IC IC IC Electrical control system
37 IC IC IC IC IC IC CL/IC CL/IC Valve oil return protection
38 IV IV IV IV IV IV IV IV Thermistors
39 Optionals IC IC IC IC IC IC IC IC Vibration dampers and bolts
40 IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME Intermediate cooler and injection valve
Oil separator refreshing oil and cleaning/testing of float
41 CL CL - CL CL CL CL CL
valve
42 - IC IC IC IC RE IC IC Heavy duty thrust bearing
43 CL CL CL CL CL CL CL CL Oil cooler, air side
44 RE RE - RE RE RE RE RE Oil cooler, oil side, refrigeration oil
45 Refer to specifications of motor manufacturer Oil cooler, electic motor (fan)
46 ME ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL Cylinder head water cooling system
a. Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to the Service Instruction Manual
(SIM)
b. A running-in oil discharge filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter
is supplied togehter with the compressor.
c. Oil discharge filter change every 3000 hours or check optional pressure drop indicator
d. A running-in suction gas filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter
is supplied together with the compressor
Legend for service and maintenance schedules (SMS)

Item Code/Action Description
1 IC Inspection / Alternatively renewal - correcting / Testing
2 IV Inspection Visual / Alternatively electrical testing
3 RE Renewal
4 ME Measure
5 CL Clean

3. MAINTENANCE
3.4.2 CHECKLIST
SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS

Item
Description 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 Oil control pressure
J General Notes
1 Oil suction filter

2 Oil discharge filter
3 Oil Oil analysis
Oil refreshment (If hygroscopic oil is used replace this always after each
4
opening of compressor or installation)
5 Housing and element
Oil pump
6 Control and lubrication oil pressure regulator
7 Main and intermediate bearing bushes and running surfaces
Crankshaft
8 Running surfaces con. rods
9 Shaft seal Oil/refrigerant leakage
10 Conrod Big and small end bearings
11 Piston
12 Pistons Piston rings
13 Gudgeon pin
14 Thrust bearing Running surfaces/Axial play
15 Solenoid valves and coils
Capacity
16 control Seals of cap. control piston
17 Cap. Control mechanism

3. MAINTENANCE
SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS

Item
Description Checked/Remarks/Notes Checkpoint/Setting/Value
18 Crankcase heater
19 Crankcase
20 Compressor Non return valves LP/HP
housing
21 Relief valves
22 Suction gas filter
23 Discharge Valves, springs and damper rings
valves
24 Stroke limitor/Discharge valve seat
25 Suction valves Valves, springs and damper rings
26 Cap. Control lifting mechanism
Cylinder liners
27 Dimension and running profile
28 Alignment
Drive
29 V-belts
30 Electric motor Consult motor manufacturer
31 Oil level switch
32 Safety switches
33 Gauges
34 Thermostats
35 Thermometers
36 Electrical control system
37 Valve oil return protection
38 Thermistors
Optionals
39 Vibration dampers and bolts
40 Intermediate cooler and injection valve
41 Oil separator refreshing oil and cleaning/testing of float valve
42 Heavy duty thrust bearing
43 Oil cooler, air side
44 Oil cooler, oil side, refrigeration oil
45 Consult motor manufacturer Oil cooler, electric motor (fan)
46 Cylinder head water cooling system
Table 3.4-2 Settings pressure safeties
Safety Remark Value

1 Suction pressure
2 LP discharge pressure (safety) two stage only
3 LP discharge pressure (limitor) two stage only, TUV
4 High pressure suction (safety) two stage only
5 High pressure (safety)
6 High pressure (limitor) TUV only
7 OIl differential pressure

3. MAINTENANCE

4. PARTS COMPRESSOR
4. PARTS COMPRESSOR

4. PARTS COMPRESSOR
Item Description Dims. Ref. No. Qty Remarks

Fig. RC12-01 COMPRESSOR HOUSING
1 HEXAGON NUT M16 0115810 -
2 FLAT WASHER M16 1113801 -
3A CYLINDER COVER 298.5P 0531997 - Without temp. sensor plug
3B CYLINDER COVER 298.5P-13G 0531999 - With temp. sensor plug
4 GASKET 225X242X1.5 0903226 -
5 STUD M16x60 0151860 -
6 STUD M16x35 0151835 -
7 RESTRICTION NPTF13x0.5 0123020 - HP cylinders (two-stage)
NPTF All cylinders single stage compressors and
8 RESTRICTION PLUG 0123138 -
-18-Lx1.5 LP-cylinders two-stage compressors
9A STUD M16x35 0151835 23
9B STUD M16x55 0151856 3
10 O-RING 3.53x145 0955257 -
11 SERVICE COVER 195X16 0530196 -
12 HEXAGON HEAD BOLT M12x35 0110635 8
13 OIL CONNECTING LINE * - Refer to fig. Grasso12E-10
14 OIL SUCTION LINE * - Refer to fig. Grasso12E-10
15 ALU SEALING RING 21x27x2 0914023 1
16 PLUG G21 0136216 1
17A POCKET 0385333 - For 2 and 3 cylinder compressors
17B POCKET 0385335 - For 4 .. 12 cylinder compressors
19 HEXAGON NUT G33 0148331 1
21 O-RING 2.5X52 0952256 1
22 SIGHT GLASS 46X80 1224046 1
23A SUCTION GAS STRAINER 2000 * - Refer to fig. Grasso 12E-11
23B SUCTION GAS STRAINER 3000 * - Refer to fig. Grasso 12E-11
24 ALU SEALING RING 13.5x20x1 0912014 2
25 PLUG G13S 0136134 2
26 STOP VALVE TAH8-12 0607011 1
27 NIPPLE COUPLING 12G21 0338211 1
28 CONNECTION LINE 12X150 0412120 1
29 NIPPLE COUPLING 12 0336012 1
30 DEMISTER 60x25-22 0705060 1
99 SWIVEL COUPLING 12G21 0339212 1

4. PARTS COMPRESSOR
Fig. 4-1 RC12-01

4. PARTS COMPRESSOR

Fig. RC12-02A BEARING COVER DRIVE SIDE AND INTERMEDIATE BEARINGS
1 BEARING COVER ASSY GRASSO12(E) * 1 Oil groove pointing at 12 O'clock

(DRIVE SIDE)
1.1 BEARING COVER RC12 2138812 1
1.2 BEARING BUSH 90X96X103 1146291 1
1.3 ALU SEALING RING 21x27x2 0914023 1
1.4 PLUG G21-BZK 0365821 1
1.5 O-RING 3.53x21.8 0955212 1
3 NUMBER OF INTERMEDIATE BEARINGS * 1 for 4 and 6 cylinders; 2 for 9 cylinders; 3 for 12

cylinders
3 BEARING BLOCK 90M 1169901 -
3.1 BEARING BLOCK HALVES 90M * 1 4, 6,9 and 12 cylinder compressor
3.2 BEARING SHELL 90x81 1144900 - In two pieces
3.3 HEXAGON HEAD BOLT M16 x 100 0110810 4
3.4 FLAT WASHER M16 1113801 4
3.5 DOWEL PIN 12x26 1106226 2
4 O-RING 5.33X240.67 0955375 2
5 LOCKING RING M20 1139100 2 For each intermediate bearing
7 FLAT WASHER M16 1113801 24
8 HEXAGON NUT M16 0115810 24

4. PARTS COMPRESSOR
Fig. 4-2 RC12-02A

4. PARTS COMPRESSOR

Fig. RC12-02B BEARING COVER OIL PUMP SIDE: BRONZE SLIDE THRUST BEARING
1 BEARING COVER ASSY RC12 BRONZE * 1
1.1 BEARING COVER RC12 BRONZE 2138825 1
1.2 BEARING BUSH 90x96x107A 1146195 1
1.3 THRUST RING RC12 BRONZE 1142013 1 From 03071378
1.4 NIPPLE COUPLING 8G13 0338138 1
1.5 DOWEL PIN 6x12 1106612 1
1.6 STUD M12x110 0151610 7
1.7 DOWEL PIN 4x8 1106408 1
1.8 OIL BAFFLE 1926200 1
1.9 TOOTHED SPRING WASHER M6 1113303 3
1.10 HEXAGON HEAD BOLT M6x16 0110316 3
1.12 PLUG G21-BZK 0365821 3
1.13 DOWEL PIN 6x12 1106612 1
1.14 RESTRICTION M6x10x2 0123311 1
1.15 SETSCREW M12 X 16 X 2 0123617 1
2 O-RING 5.33X240.67 0955375 2
3 HOLD DOWN DISC 149S 1125249 1
3.1 CARRIER DISC 149M10 * 1
3.2 DOWEL PIN 8x28 * 2
3.3 DOWEL PIN 5x20 * 1
4 SOCKET HEAD SCREW M10X40 0104540 4

4. PARTS COMPRESSOR
Fig. 4-3 RC12-02B

4. PARTS COMPRESSOR

Fig. RC12-03 CRANKSHAFT
1A.a CRANKSHAFT E-RC212S 2239200 1
1A.b CRANKSHAFT K-RC211S 2239210 1
1B.a CRANKSHAFT E-RC312S 2239300 1
1B.b CRANKSHAFT K-RC311S 2239310 1
1C.a CRANKSHAFT E-RC412S 2239400 1
1C.b CRANKSHAFT K-RC411S 2239410 1
1D.a CRANKSHAFT E-RC612S 2239600 1
1D.b CRANKSHAFT K-RC611S 2239610 1
1E.a CRANKSHAFT E-RC912S 2239900 1
1E.b CRANKSHAFT E-RC912S 2239910 1
1F.a CRANKSHAFT E-RC1212S 2239000 1
1F.b CRANKSHAFT K-RC1212S 2239010 1
1.1 CRANKSHAFT E/K-RC12 * 1
1.2 COUNTERBALANCE WEIGHT * -
1.3 LOCKING RING SET M16 / 1139800 - in two pieces

13-ST-G.V.
1.4 HEXAGON HEAD BOLT M16x80 0110880 -
1.5 SPACER ASSY 90X116X60S 1112990 1 in 2-cyl. compressor only

M
1.5.1 FITTED BOLT M8X10X10 0124410 2
1.5.2 SPACER 90x116x60E * 1
1.5.3 LOCKING NUT M8 0145400 2
2 KEY 22X14X120 1102012 1
3 HUB FIXING M24X108 1915211 1
4 LOCKING PLATE M24xM12 1114248 1
5 FLAT WASHER M12 1113601 1

4. PARTS COMPRESSOR
Fig. 4-4 RC12-03

4. PARTS COMPRESSOR

Fig. RC12-04 PISTON AND CONNECTING ROD
1 PISTON ASSY S160x50x160 2417011 1

K110M
36x50x148RC
1.1 GUDGEON PIN 2418320 1
11
1.2 PISTON * 1
1.3 LOCKING PLATE M12S 1114642 1
1.4 LOCKING BOLT M12x35 0144635 1
1.5 SET OF PISTON RINGS 0974160 1
only in single-stage compressors and in
2A CONNECTING ROD S275RC11LD 2419510 -
LP-cylinders of two-stage compressors
2A.1a CON ROD (ALUMINIUM ALLOY) * 1
2A.2a BEARING BUSH 50x62x60 1146652 1
2B CONNECTING ROD S275RC11HD 2419520 - only in HP-cylinders of two-stage compressors
2B.1b CON ROD (ALUMINIUM ALLOY) * 1
2B.2b NEEDLE BEARING NK50/25 1163451 2
2B.3b DISTANCE BUSH 52x62x10 1116562 1
2C.4 BEARING SHELL 90x53 1144590 1
2C.5 CONNECTING ROD BOLT MF16 0111810 2
2C.6 LOCKING RING SET M16 / 1139800 2 in two pieces

13-ST-G.V.
2C.7 HEXAGON NUT MF16 0147805 2

4. PARTS COMPRESSOR
Fig. 4-5 RC12-04

4. PARTS COMPRESSOR

Fig. RC12-05 CYLINDER AND VALVE-LIFTING MECHANISM
1 CYLINDER LINER ASSY 160RC12S 2339110 1
1.1 CYLINDER LINER 160RC11 2318010 -
1.2 HEXAGON NUT M6 0115310 4
1.3 PRESSURE RING RC12S 2738515 1
1.4 PRESSURE SPRING 2x10x23x95 1131295 2
1.5 SUPPORTING RING 160K110 2716570 1
1.6 SPRING WIRE 0.75x3.1 1132081 1
1.7 CYLINDER HEAD SCREW M6x133 0168313 2
1.8 SEMI CIRCULAR LEVER K110 2716610 1
1.9 SPLIT PIN 1,5x10 1108010 1
1.10 LOCKING PIN 6x55 1107355 1
1.11 WASHER M6 1113301 1
2.A OILIT SEALING RING 207x216x1 0902206 1 1 mm thick
2.B OILIT SEALING RING 207x216x1.25 0901206 1 1.25 mm thick
2.C OILIT SEALING RING 207x216x1.5 0903206 1 1,50 mm thick
3 CONTROL PISTON SET RC12E 2038134 -
3.1 CYLINDRICAL PIN 14x50 * 1
3.2 O-RING 3.53x59 0952376 1
3.3 O-RING 3.5x44 0952350 1
3.4 CONTROL PISTON * 1
6 PISTON HOUSING RC12 2738650 1
7. NIPPLE COUPLING * 0338106 up to 03091530, 0338108 from

03091531
8 ALU.SEALING RING 27x34x1 0912027 1
9 NIPPLE G27x14 0304514 1

4. PARTS COMPRESSOR
Fig. 4-6 RC12-05

4. PARTS COMPRESSOR

Fig. RC12-06 SUCTION AND DISCHARGE VALVE
1 PRESSURE SPRING 18x88x2.4x11 1131181 1

5
2 PRESSURE RING RC6 2736410 1
3 DISCHARGE VALVE ASSY 160RC11E 2719111 1
3.1 LOCKING NUT M16 0145800 1
3.3 STROKE LIMITOR 160RC11A 2718360 1
3.4 DISCHARGE RING & SPRING SET 2038031 -
3.4.a SINUSOIDAL SPRING 58x69 * 2
3.4.b SINUSOIDAL SPRING 76x87 * 2
3.4.c SINUSOIDAL SPRING 94x105 * 2
3.4.d VALVE RING 58x69x1 * 1
3.4.e VALVE RING 76x87x1 * 1
3.4.f VALVE RING 94x105x1 * 1
3.5 VALVE PLATE 160RC11 2718265 1
3.6 FITTED BOLT M16x62-15 0124863 1
4 SUCTION RING & SPRING SET 2038032 -
4.1 SINUSOIDAL SPRING 171x200 * 2
4.2 VALVE RING 171x200x1 * 1

4. PARTS COMPRESSOR
Fig. 4-7 RC12-06

4. PARTS COMPRESSOR

Fig. RC12-07 ROTARY SHAFT SEAL
1 SHAFT SEAL HOUSING RC12 2638012 1
4 ALU SEALING RING 13.5x20x1 0912014 1
5 PLUG G13S 0136134 1
6 SHAFT SEAL SET 085B 2038100 1
6.1 COUNTER-SLIP RING ASSEMBLY * 1
6.1.1 O-RING 101.1x3.53 0952390 1
6.2 SLIP RING ASSEMBLY * 1
6.2.1 O-RING 84.95x4.0 0952340 1
6.3 O-RING 3.53x145 0955257 1
8 BENT STEEL PRECISION TUBE 12x530 4405012 1

4. PARTS COMPRESSOR
Fig. 4-8 RC12-07

4. PARTS COMPRESSOR

Fig. RC12-08 OIL PUMP
Important: In case the direction of rotation of
the oil pump is counter clockwise, when facing
1 OIL PUMP SET RC12 2038116 1 the (mounted] oil pump housing, the
non-standard oil pump assembly 2028117 is
required.
1.1.A. OIL PUMP HOUSING RC12 2638520 1 Standard
For Mark 1 design
1.1.B. OIL PUMP HOUSING Mark 1 2638521 1 For use with heavy duty thrust bearing
1.2 PUMP ELEMENT 2638130 1
1.3 HEXAGON HEAD BOLT M6x20 0110320 8
1.4 WASHER M6 1113301 8
1.5 CARRIER DISC 55x8 1125006 1
1.6 DOWEL PIN 6x18x3 1106617 1
1.7 GASKET 83x115x0.5 0903083 1
CONTROL OIL PRESSURE REGULATOR
2 2038120 1
SET
2.3 O-RING 3.53x21.8 0955212 1
LUBRICATION OIL PRESSURE
3 REGULATOR SET 2038118 1

3.3 O-RING 3.53x21.8 0955212 1
5 PLUG G21-BZK 0365821 5
6 T-COUPLING 6x6x6 0340406 1
8 SOCKET NIPPLE G13xG21 0302213 1
9 MEASURING COUPLING 8 mm 0645608 1
10 O-RING 3.53x21.8 0955212 2
11 O-RING 3.53x145 0955257 1
12 FLAT WASHER M12 1113601 7
13 HEXAGON NUT M12 0115610 7

4. PARTS COMPRESSOR
Fig. 4-9 RC12-08

4. PARTS COMPRESSOR

Fig. RC12-09 OIL FILTERS
1A/B OIL FILTER HOUSING 24 0702625 1
1A SUCTION OIL FILTER ASSY 24 * 1
1B DISCHARGE OIL FILTER ASSY 24 * 1
1.1 FILTER UPPER HOUSING * -
1.2 SET OF SEALS 0990030 1
1.3 FILTER CUP * 1
1.4 RING NUT * 1
SUCTION OIL FILTER SET (BLUE
1.5 MARKED) 24 2038128 1
DISCHARGE OIL FILTER SET (GREY

1.6a MARKED) 24 2038124 1
Check if the length of the oil charge filter is

HIGH CAPACITY OIL FILTER SET (GREY equal to the length of the oil suction filter cup
1.6b 2038125 1 of the compressor involved, if si, a longer oil
MARKED)
discharge filter cup with Ref. Nr. 07.02.675 is
also required!
4 PLUG G21-BZK 0365821 2
6 O-RING 2.65x25 0952281 4
7 SWIVEL COUPLING 12G21 0339212 1
8 STOP VALVE TAH8-12 0607011 1

4. PARTS COMPRESSOR
Fig. 4-10 RC12-09

4. PARTS COMPRESSOR

Fig. RC12-10 LUBRICATING OIL LINES
13.a OIL CONNECTING LINE 22x2x535 0412253 1 For 2 and 4 cylinder compressors
13.b OIL CONNECTING LINE 22x2x865 0412286 1 For 4 cylinder compressor
13.c OIL CONNECTING LINE 22x2x925 0412292 1 For 6 cylinder compressors
13.d OIL CONNECTING LINE 22x2x1315 0412213 1 For 9 cylinder compressors
13.e OIL CONNECTING LINE 22x2x1705 0412217 1 For 12 cylinder compressors
14 OIL INTAKE LINE * 1
14.1 BENDED STEEL PRECISION PIPE 22x2x35x320 0438290 1
14.2 NIPPLE COUPLING 22G22x1 0338273 1
14.3 O-RING 3.53x21.8 0955212 1
14.4 CONNECTION LINE 22x2x32 0412232 1
15 O-RING 3.53x21.8 0955212 1

4. PARTS COMPRESSOR
Fig. 4-11 RC12-10

4. PARTS COMPRESSOR

Fig. RC12-11 SUCTION GAS STRAINER
1A SUCTION GAS FILTER SET RC12-2000 2038130 - 1 piece for RC2112(E) / 4212(E) - 2 for RC212(E)
/ 312(E) / 412(E) / 3112(E) / 5112(E) / 612(E)
1A.1 OILIT SEALING RING 170x230x1.5 0903168 1
1A.2 GAUZE FILTER ELEMENT 2000 * 1
1B SUCTION GAS FILTER SET RC12-3000 2038131 - 1 piece for RC6312(E) / 8412(E) - 2 for RC912(E)
/ 7212(E) / 1212(E) / 9312(E) / 10212(E)
1B.1 OILIT SEALING RING 195x255x1.5 0903195 1
1B.2 GAUZE FILTER ELEMENT 3000 * 1
1.3 O-RING 2.65x13.95 0952269 1
1.4 CIRCLIP RING 14 1103014 1
2A.1 SUCTION HOUSING COVER 236x118 0530240 2 2x for RC312(E) / 612(E) / 5112(E) and 1 for
RC2112(E) / 4212(E)
2A.2 SUCTION HOUSING COVER 236x74.5 0530239 2 For RC212(E) / 412(E) / 3112(E)
2A.3 SUCTION HOUSING COVER 236 0530241 1 For RC211(2)E / 4212(E)
2B.1 SUCTION HOUSING COVER 260x118 0530263 - 1 piece for RC6312(E) / 8412(E) - 2 for RC912(E)
/ 7212(E) / 1212(E) / 9312(E) / 10212(E)
2B.2 SUCTION HOUSING COVER 260 0530262 1
3 SPRING RETAINER 14.5x45 4836015 -
4 PRESSURE SPRING 6x40x2.7x42 1131601 -
5A HEXAGON HEAD BOLT M16x40 0185840 8
5B HEXAGON HEAD BOLT M16x45 0185845 8

4. PARTS COMPRESSOR
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Fig. 4-12 RC12-11

4. PARTS COMPRESSOR

Fig. RC12-12 High / Low PRESSURE RELIEF VALVES
1.1 VALVE GROUP 48 4827048 -
(22 BAR) RELIEF VALVE - PRESSURE For single stage compr./booster compr. RC12(E)
1B DEPENDENT
RC12E-22 * - 212/312/412/612/912/1212
On HP-side of two-stage compr./ single stage
(23.0 BAR) RELIEF VALVE - PRESSURE
2 INDEPENDENT RC12-23 * - compr. and booster compr. acc. to DIN 8975
(whole range)
2.1 RELIEF VALVE HOUSING 48 1249212 1
2.2 O-RING 3.53x66.27 0955231 1
2.3 RELIEF VALVE Grasso 12 - 22 4827424 1
5 HEXAGON HEAD BOLT M12X95 0110696 2
9 O-RING 3.53x59 0952376 2
10 HEX. HEAD BOLT M12X40B 0110641 3
11 BLIND FLANGE 90X102 0504890 2

4. PARTS COMPRESSOR
Fig. 4-13 RC12-12

4. PARTS COMPRESSOR

Fig. RC12-13 MAIN FLANGE SEALING RINGS
1.a GASKET 106x120x2 0904106 1 RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212/ 412
RC12(E) 412/ 4212/ 6312/ 7212/ 8412/ 9312/
1.b GASKET 129x149x2 0904129 1
10212/ 612/ 912/ 1212
1.c GASKET 155x175x2 0904155 1 RC12(E) 612/ 912/ 1212/ 5112
RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/
1.d GASKET 95x109x2 0904095 1
8412/ 9312/ 10212
2.a GASKET 61x75x2 0904061 1 RC12(E) 2112/ 3112
2.b GASKET 95x109x2 0904095 1 RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212
3.a GASKET 73x87x2 0904073 1 RC12(E) 2112/ 3112
3.b GASKET 106x120x2 0904106 1 RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212/ 412
RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/
4.a GASKET 95x109x2 0904095 1
8412/ 9312/ 10212
4.b GASKET 106x120x2 0904106 1 RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212/ 412
4.c GASKET 129x149x2 0904129 1 RC12(E) 412/ 4212/ 6312/ 7212/ 8412/ 9312/
10212/ 612/ 912/ 1212
4.d GASKET 73x87x2 0904073 1 RC12(E) 2112/ 3112

4. PARTS COMPRESSOR
Fig. 4-14 RC12-13

4. PARTS COMPRESSOR

Fig. RC12-14 STANDARD SETS OF PARTS, SEALS AND TOOLS
A BASIC GASKET / O-RING SET 2038017 1
for every two cylinders 1 set / for three cyl.
B ADDITIONAL GASKET / O-RING SET RC12(E) 2038018 - compr. 2 sets, for nine cyl. compr. 5 sets
C SET OF SPARE PARTS 2038021 1 for whole range
D SUCTION RING & SPRING SET 2038032 -
E DISCHARGE RING & SPRING SET 2038031 -
F SHAFT SEAL SET 085B 2038100 1
G SET OF TOOLS GRASSO 12 Grasso 12 2038010 1 GRASSO 12

4. PARTS COMPRESSOR
Fig. 4-15 RC12-14

4. PARTS COMPRESSOR

5. SUPPLEMENTARY PARTS


Fig. RC12-E1 THRUST BEARING MARK1. (from serial no. 03071378)
1 OIL PUMP HOUSING Mark 1 2638521 1 For Mark 1 design

For use with heavy duty thrust bearing
140 x 95 x
2 SPRING RETAINER 2738700 1
23,5 MARK1
RC12(E)
3 DIE SPRING 1135225 6
MARK1
4 BEARING COVER P.Z. RC12(E) 2138824 1

MARK1
152 x 135 x
5 HOUSING RING 0938135 1
37,5 MARK1
RC12(E)
6 THRUST WASHER 1148004 1
MARK1
CYLINDRICAL ROLLER THRUST
7 1148008 1
BEARING
8 SHAFT WASHER 133 x 90 x 76 x 1138090 1

15,5
9 NEEDLE THRUST BEARING 1148002 1
10 HOUSING WASHER 1148006 1
11 CARRIER DISC 100 x 76 x 36 S 1125176 1
90 x 96 x 93
12 BEARING BUSH RC12(E) 1146093 1
MARK1
13 SETSCREW M12 x 16 0123616 1
X SET OF SPARE PARTS THRUST BEARING 2038104 1

MARK1
Y COMPLETE SET THRUST BEARING 2038105 1

MARK1

Fig. 5-1 RC12-E1


Fig. RC12-E2 COMPRESSOR HOUSING MARK1.1.
1 STUD ELBOW 22 x G27 0341322 1
2 STUD ELBOW 22 x G21 0341323 1
3 SERVICE COVER RC12(E) S 0530193 1

MARK1
P.Z. RC12(E)
4 BEARING COVER 2138824 1
MARK1
5 PIPE STEEL 22 x 2 6105022 1

Fig. 5-2 RC12-E2


Fig. RC12-E3 OIL COOLER
1 SOCKET NIPPLE G33 x G27 0302228 2
2 STUD ELBOW 22 x G27 0341322 3
3 STUD ELBOW 22 x G21 0341323 1
RC12(E) S
4 SERVICE COVER 0530193 1
MARK1
5 OIL COOLER VAN LKI 110 230V 0726014 1
6 OIL COOLER LKI 110 0726015 1
7 THERMOSTAT RT 101 1256415 1
8 PIPE STEEL 22 x 2 6105022 2

Fig. 5-3 RC12-E3


6. APPENDIX; Product Information (PI)
6.1 GENERAL LIMITS AND FIELDS OF The diagrams overleaf represent the overall fields of
application in which the individual operation limits are
OPERATION GRASSO 12 taken into account.
When operating the compressor, none of the limits of
operation as stated in the table below must be Table 6.1-1 General limits and fields of operation
exceeded.1 1. In practice, it is not so much the individual operation limits as combinations of
them that are decisive for the conditions under which a compressor may
operate. To check the various possibilities in this respect, use should be made
of the "fields of application" ).
REFRIGERANT NH3 R22 R134a R404A a R507a

min. 500
Compressor speed n min-1
max. 1000
min. 0.3
Suction pressure = evaporating pressure c po bar(a) >=900 6.0 5.8
=crankcase pressureb max. 7.0 6.2
<900 7.0
min. -55.1 -63.8 -50 -68.1 -68.5
Evaporating temperature = saturation to °C >=900 -0.1 -2.0
temperature at suction pressureb max. +13.8 +10.9 +22.6
<900 +4.7 +3.9
Suction superheat/intermediate superheat 't °C min. 0 15
min. 0.3
>=900 6.0 5.8
Intermediate pressure pm bar(a)
max. >800 <900 7.0 6.2 7.0 7.0
<=800 8.2 8.4
min. -68.1 -68.5
>=900 -0.1 -2.0
Intermediate temperature tm °C
max. >800 <900 +13.8 +10.9 +22.6 +4.7 +3.9
<=800 10.1 10.0
Actual suction temperature ta °C min. -50
Discharge pressure = condensing pressure cd pc bar(a) max. 24.0
e
Design pressure bar(a) - 26.5
Condensing temperature = saturation tc °C max. +56.5 +59.5 +75.8 +52.0 +52.8
temperature at discharge pressure
f
Discharge temperature te °C max. +170
min. 1.5
Pressure ratio per stage (pc/po or pc/pm or pm/po) g j -
max. 10 15
Pressure difference ch
'p bar max. 17.5
min. +20 +30
i
Oil temperature in crankcase toil °C
max. depending on type of oil, refer Section 6.4
a. Minimum superheat 15 K. Grasso advises a condensing temperature > +35 oC, to avoid condensation of refrigerant in the compressor
b. For halocarbon refrigerants the maximum values of p0 and t0 are based on a density of the suction gas of 30 kg/m3. In single stage operation during start-up and
immediately thereafter, t0, max may be exceeded slightly and only temporarily. In any case p0 should drop to at least 7 bar(a) within 5 minutes after starting.
c. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.
d. This pressure is also the maximum allowable pre-set value of the HP safety switch. CAUTION!: When adjusting the HP and/or LP safety switch, care should be taken
that the pressure difference 'p=(pC-po) never exceeds 19.0 bar.
e. This pressure deviates from the so called max. discharge pressure=condensing pressure (allowed during operation) as stated in the table.
f. This is the actual discharge temperature, measured directly in the gas flow just before the discharge connection. The given value also applies to the LP stage of
two-stage compressors.
g. Pressure ratio limits are not absolute but arbitrary values based on practical considerations.

h. The standard built-in overflow safety valve(s) between suction and discharge side has been factory-set to 22.0 1.5 bar to prevent opening during normal operation
at 'p = (pc - po) 17.5 bar.
i. Indicated minimum value is the lowest oil temperature at which the compressor is allowed to be started. The maximum oil temperature depends on the operating
conditions of the compressor, the oil type used and (for halocarbon refrigerants only) the solubility of the refrigerant in the oil. A minimum actual oil viscosity of 10
cSt is always required.
6.2 PART-LOAD POWER CONSUMPTION

AND ALLOWED PART LOAD STEPS
COMSEL
To determine the allowed partload steps for the design
conditons and the corresponding partload power
consumption refer to software program Comsel.

6.3 ELECTRIC CAPACITY CONTROL AND 6.3.1 GENERAL DIAGRAM OF ELECTRICALLY

FAST PULL DOWN (FPD) OPERATED CAPACITY CONTROL
General
Electric capacity control is compulsory in the standard
scope of supply for two stage compressors.
Procedure and data

• Refer to diagrams and figures below.
• The possible control steps and the number of
solenoid valves depends on type of compressor
Standard scope of supply

• One NO-solenoid valve (with LED indicator) for
unloaded starting (mounted).
• A number of NC- solenoid valves (each with LED
indicator; mounted).
• Oil pressure lines (mounted).
Options (for two-stage compressors only)

• Fast Pull Down control system
FPD is compulsory for R404A and R507.

The standard starting procedure which is contained in
the standard electrical capacity control, is only
suitable if the compressor is being started at design
evaporating temperature.
In case the compressor has to start frequently with
high evaporating temperatures (batch freezing, etc),
fast pull down capacity control is necessary to avoid
that the compressor runs continuously in part-load.
Legend
A Top view of compressor
B Valve lifting mechanism
C Oil return from valve lifting mechanisms to crankcase
D Oil pump
E Electrical wiring, refer Section 1.2.9.2
H Supply of oil (control pressure)
NO Normally Open; 3-way solenoid valve for unloaded starting
NC Normally Closed; 3-way solenoid valve for capacity control

6.3.2 DIAGRAMS
Table 6.3-1 Solenoid valve/cylinder numbering for electric capacity

control
HP cilinders No.
Solenoid
FPDb UNLd No. 1 No. 2 No. 3 No. 4
Compressor NC c
NOe
NC NC NC NC
typea
Cylinder number / solenoid valves
4 - - 1+2 3 4 - -
6
- - 1+3 6 4 5 2
Single stage
2+3+
6 Booster - - 6 4 1 -
5
9 1+2+ 4+7+
Single stage - - 3 8 5+6 9 -
9 1+3+ 4+7+
Booster - - 5+8 2+6 9 - -
12 1+2+ 4 + 10 6 + 7 +
Single stage - - 3 11 5+8 + 12 9
1+2+
12 7 + 10
Booster - - 3+4+ 5+8 6 + 11 + 12 -
9
31 2 - 2 1+3 4 - -
31 + FPD 2 1 2 3 4 - -
42 3+6 - 3 1+2 5 4+6 -
42 + FPD 3+6 6 3 1+2 5 4 -
51 3 - 3 1+2 6 5 4
51 + FPD 3 1 3 2 6 5 4
3+6 5+8+ 4+7+
63 - 3 1+2 -
+9 9 6
63 + FPD 3+6 6 3 1+2 5+8+ 4+7 -

+9 9
72 3+6 - 3 1+2 7 5+6+

4+9
8
72 + FPD 3+6 6 3 1+2 7 5+8 4+9
3+6
1 + 2 5 +127 + 8 +11
9+ 4+6+
84 +9+ - 3
10
12
3+6
8+9+ 4+6+
84 + FPD +9+ 12 3 1+2 5+7
11 10
12
3+6 1+5+ 2 + 4 + 6 + 11
93 - 3 8
+9 7 9 + 10 + 12
3+6 1+5+ 2+4+ 11 +
93 + FPD +9 6 3 7 8 9 + 10 12
3 + 6 1 +92 +
10 + 7+8+
102 3+6 - 4+5
12 11
102 + FPD 3+6 9 3+6 1+2 4+5 10 + 7+8+

12 11
a. Explanation; 2=Grasso 12(E), 21=Grasso 2112(E)
b. FPD= Fast Pull-Down
c. NC= Normally closed
d. UNL= Unloaded starting
e. NO= Normally open

Table 6.3-2 Capacity control steps
Capacity %a
Solenoids
Capacity %a
Compressor
Solenoids
type Remarks Cylinders Mb
Compressor
type Remarks Cylinders M b
25 - 1+2+3 - -
50 - 1+2 - - 33 - 1 + 2 + 3 + 11 1 -
4
single stage & 75 - 1+2+3 1 - 1+2+3+5
Booster 42 - +8 2 -
100 - 1+2+3+4 1+2 -
1+2+3+5
33 - 1+3 - - 50 - + 8 + 11
1+2 -
50 - 1+3+6 1 - 1+2+3+4
67 - 1+3+4+6 1+2 - 58 - + 10 + 11 + 1+3 -
6 12
single stage 1+3+4+5 1+2+
83 - - 1+2+3+4
+6 3
67 - + 5 + 8 + 10 + 2+3 -
1+2+3+4 1+2+ 12 12
100 - - single stage
+5+6 3+4
1+2+3+5
1+2+
50 - 2+3+5 - - 75 - +6+7+8+ -
9 + 11 4
67 - 2+3+5+6 1 -
1+2+3+4
6 2+3+4+5 83 - + 6 + 7 + 9 + 1 +43 + -
Booster 83 - +6 1+2 - 10 + 11 + 12
1+2+3+4 1+2+ 1+2+3+4 2+3+
100 - - 92 - +6+7+8+ -
+5+6 3 4
9 + 10 + 12
33 - 1+2+3 - -
1+2+3+4
44 - 1+2+3+8 1 - +5+6+7+ 1+2+
100 - -
8 + 9 + 10 + 3 + 4
1+2+3+5 11 + 12
56 - 2 -
+6
42 - 1+2+3+4 - -
1+2+3+5 +9
67 - 1+2 -
+6+8
9 1+2+3+4
single stage 1+2+3+4 58 - 1 -
78 - 1+3 - +5+8+9
+7+8+9
12 1+2+3+4
1+2+3+4 booster 75 - +5+6+8+ 1+2 -
89 - +5+6+7+ 2+3 - 9 + 11
9
1+2+3+4
1+2+3+4 1+2+ +5+6+7+ 1+2+
100 - +5+6+7+ - 100 - 8 + 9 + 10 + 3 -
3
8+9 11 + 12
44 - 1+3+5+8 - - 0 Starting only 2 - 0.0
1+2+3+5 31 67 - 1+2+3 1 2.0
9 67 - 1 -
+6+8
Booster 100 - 1+2+3+4 1+2 3.0
1+2+3+4
100 - +5+6+7+ 1+2 - 0 Starting only 2 - 0.0
8+9
33 Starting only 1+2 FPD 1.0
31 + FPD 1+
67 - 1+2+3 2.0
FPD
1 + 2 + 3 + 4 1 FPD
+2+
100 - 3.0
0 Starting only 3 - 0.0

50 - 1 + 2+ 3 1 2.0
42 75 - 1+2+3+5 1+2 3.0
1+2+3+4 1+2+
100 - +5+6 3 2.0

Capacity %a
Capacity %a
Solenoids
Solenoids
Compressor Remarks Cylinders Mb
Compressor
Remarks Cylinders Mb
type type
0 Starting only 3 - 0.0 0 Starting only 3 - 0.0

0 Starting only 3+6 FPD 0.0 29 - 1+2+3 1 2.0
50 - 1+2+3 1 2.0 43 - 1+2+3+7 1+2 3.0
50 Starting only 1+2+3+6 1+ 1.0 57 -

1+2+3+5
1+3 2.0
FPD +6+8
42 + FPD
75 - 1+2+3+5 1+2 3.0 72 72 -
1+2+3+5 1+2+
2.5
+6+7+8 3
1+2+3+5 1+2+
75 - 1.5
+6 FPD 1+2+3+4
86 - +5+6+8+ 1+3+ 3.0
1+2+ 4
1+2+3+4 9
100 - +5+6 3+ 2.0
FPD 1+2+3+4
1+2+
100 - +5+6+7+ 3.5
0 Starting only 3 - 0.0 3+4
8+9
40 - 1+2+3 1 2.0 0 Starting only 3 - 0.0
60 - 1 + 2 +3 + 6 1+2 3.0 0 Starting only 3+6 FPD 0.0
51
80 - 1+2+3+5 1+2+ 4.0 29 - 1+2+3 1 2.0
+6 3
1+
1+2+3+4 1+2+ 29 Starting only 1+2+3+6 1.0
100 - 5.0 FPD
+5+6 3+4
43 - 1+2+3+7 1+2 3.0
1+2+3+6 1+2+
20 Starting only 1+3 FPD 1.0 43 - 1.5
+7 FPD
1+ 72 + FPD 1+2+3+5 1+3+
40 - 1+2+3 2.0 57 - 2.0
FPD +6+8 FPD
1+2+ 1+2+
60 - 1+2+3+6 FPD 3.0 1+2+3+5
51 + FPD 72 - 3+ 2.5
+6+7+8
FPD
1+2+
1+2+3+5
80 - +6 3+ 4.0 1+2+3+4 1+3+
FPD 86 - +5+6+8+ 4+ 3.0
9 FPD
1+2+3+4 1+2+
100 - 3+4+ 5.0 1+2+3+4 1+2+
+5+6 FPD 100 - +5+6+7+ 3+4+ 3.5
8+9 FPD
33 - 1+2+3 1 2.0
25 - 1+2+3 1 2.0
1+2+3+5
63 67 - +8+9
1+2 2.0
1+2+3+5
50 - 1+2 2.0
+ 7 + 12
1+2+3+4
100 - + 5 + 6 + 7 + 1 +32 + 2.0 84 1+2+3+5 1+2+
8+9 75 - +7+8+9+ 2.0
11 + 12 3
1+2+3+4
0 Starting only 3+6 FPD 0.0 +5+6+7+ 1+2+
100 - 2.0
8 + 9 + 10 + 3 + 4
33 - 1+2+3 1 2.0 11 + 12
33 Starting only 1+2+3+6 1+ 1.0
FPD
63 + FPD 1+2+3+5
67 - 1+2 2.0
+8+9
1+2+3+5 1+2+
67 - 1.3
+6+8+9 FPD
1+2+3+4 1+2+
100 - +5+6+7+ 3+ 2.0
8+9 FPD

Capacity %a
Capacity %a
Solenoids
Solenoids
Compressor Remarks Cylinders Mb
Compressor
Remarks Cylinders Mb
type type
0 Starting only 3 - 0.0 0 Starting only 3+6 - 0.0

0 Starting only 3 + 12 FPD 0.0 1+2+3+6
30 - 1 1.5
+9
25 - 1+2+3 1 2.0
50 - 1+2+3+6
1+ 1+2 2.5
25 Starting only 1 + 2 + 3 + 12 1.0 + 9 + 10 + 12
FPD
1+2+3+6
50 - 1+2+3+5 1+2+ 2.0 60 - +7+8+9+ 1+4 3.0
84 + FPD + 7+ 12 FPD 11
1+2+3+5 1+2+ 102 1+2+3+4 1+2+
75 - +7+8+9+ 3+ 2.0 70 - +5+6+9+ 3.5
11 + 12 FPD 3
10 + 12
1+2+3+4 1+2+3+6
1+2+ 1+2+
+5+6+7+ 80 - +7+8+9+ 4.0
100 - 3+4+ 2.0 4
8 + 9 + 10 + FPD 10 + 11 + 12
11 + 12
1+2+3+4
0 Starting only 3 - 0.0 +5+6+7+ 1+2+
100 - 8 + 9 + 10 + 3 + 4 5.0
33 - 1+3+5+7 1 3.0 11 + 12
2+3+4+8 0 Starting only 3+6 - 0.0
45 - + 9 + 10 2+3 2.0
20 Starting only 1+2+3+6 1 1.0
1+3+5+6
56 - + 7 + 11 + 12 1 + 4 2.5
30 - 1+2+3+6 1+ 1.5
+9 FPD
1+2+3+4
93 67 - +5+7+9+ 1+3 3.0 1+2+3+6
10 40 - 1+2 2.0
+ 10 + 12
1+2+3+4 1+2+3+6 1+2+
1+2+ 50 - 2.5
78 - +5+7+8+ 3.5 + 9 + 10 + 12 FPD
9 + 10 3
1+2+3+6
1+2+3+4 1+4+
60 - +7+8+9+ 3.0
+5+6+7+ 1+2+ 11 FPD
100 - 8 + 9 + 10 + 3 + 4
3.0
11 + 12 102 + FPD 1+2+3+4 1+2+
70 - +5+6+9+ 3+ 3.5
0 Starting only 3 - 0.0 10 + 12 FPD
0 Starting only 3+6 FPD 0.0 1+2+3+6 1+2+
80 - +7+8+9+ 4+ 4.0
33 - 1+3+5+7 1 3.0 10 + 11 + 12 FPD
1+3+5+6 1+ 1+2+3+4
33 - 1.5
+7 FPD +5+6+7+ 1+2+
90 - 4.5
8 + 10 + 11 + 3 + 4
2+3+4+8 12
44 - 2+3 2.0
+ 9 + 10
1+2+3+4
+5+6+7+ 1
1+3+5+6 1+4+ +2+
56 - 2.5 100 - 3+4+ 5.0
93 + FPD + 7 + 11 + 12 FPD 8 + 9 + 10 + FPD
1+2+3+4 11 + 12
67 - +5+7+9+ 1+3 3.0
a. Refer to the swept volume expressed as a percentage of the full-load swept
10
volume for single stage compressors, resp. LP full-load swept volume for
1+2+3+4 1+2+ two-stage compressors.
78 - +5+7+8+ 3.5 b. Number of LP/ Number of HP cylinders
3
9 + 10
1+2+3+4
+5+6+7+ 1
+2+
100 - 3+4+ 3.0
8 + 9 + 10 +
11 + 12 FPD


6.4 LUBRICATING OILS (CHOICE AND a. to,max is the saturated temperature, corresponding to maximum crankcase
RECOMMENDATIONS) pressure where at the usual oil temperatures the oil/refrigerant mixture has a
viscosity of > 10 cSt.
b. Refer to Section 6.4.1.1.
The choice of oil for a refrigeration compressor should be 6.4.1.1 REMARKS

made by taking into account the entire refrigeration 1. Using ISO VG100 oils to increase viscosity at high
system design and operation as well as the operating expected cranckcase-temperatures makes no sense as
conditions of the compressor. the friction-heat will increase that much, that the
oil-temperature limit related to the minimum viscosity
For lubrication of refrigeration compressors, several of 10 cSt will also be exceeded. Only in case of
brands and types of specially developed lubricating oils expected high refrigerant-concentrations in the
are on the market. The choice of oil depends not only on cranckcase this viscosity-gradeoil is an alternative!
its good lubrication properties (viscosity) and chemical 2. Using ISO VG46 oils to meet low pour point
stability at the operating conditions of the compressor, requirements is only acceptable if coupled to a high
but also on the operating conditions of the refrigerating viscosity-index of at least 100, otherwise the working
plant (solidifying and floc point, solubility). limits are so limited (again concerning the minimum
required oil-viscosity of 10 cSt) that it can be used in
Grasso has tested and approved for use in its medium evaporation-pressures, making no sense to
reciprocating-compressors the brands and types of oil as use them als a low pourpoint alternative!
listed tables below.
The choice of the lubricating oil depends on type of
refrigerant and the operating conditions of the Some of the oil types listed in the tables may be
compressor. marketed under other names and/or designations; these
The oil viscosity should always be more than 10 cSt. oils can also be used, provided their identity can be
A higher ISO-VG number should be chosen when proved beyond any doubt. Application of
refrigerant solubility in crankcase is expected to be high other/alternavive oils is not permitted without the
especially in case of HCFC’s and HFC’s. written consent of Grasso.
OIL SELECTION PROCEDURE:
Use the oil viscosity selection table to select oil viscosity 6.4.2 STRONGLY RECOMMENDED OIL TYPES
required. The following page lists all oils approved by
Grasso for reciprocating compressors. Table 6.4-2 Strongly recommended oil types for Grasso reciprocating
compressors
6.4.1 OIL SELECTION TABLE
Refrigerant Brand Type designation
used
Table 6.4-1 Oil selection table
CPI CP-1009-68
Max. allowable PETRO CANADA Reflo 68A
Refrigerant evaporating ISO VG-number, according to
used temperature ISO 3448 Klüber Summit RHT-68
NH3
to,max (C)a
46 68 100 TEXACO Capella Premium 68
NH3 - vb v vb SHELL
Clavus S-68 /
Refrigeration Oil S2 FR-Aa
-50 v
a. Old name resp. new name; old name will be phased-out during 2010.
-30 v v
HCFC’s -20 v
(R22) -10 v v
0 v
+10 v
-50 v v
-30 v v
HFC’s -20 v v
(R134a, R507,
R404A) -10 v v
0 v
+10 v
For all other refrigerants contact Grasso
Legend v Approved by Grasso

6.4.3 ACCEPTED NH3 AND HCFC OIL TYPES 6.4.4 ACCEPTED HFC OIL TYPES
Table 6.4-3 Accepted NH3 and HCFC (e.g. R22) oil types for Grasso Table 6.4-4 Accepted HFC (e.g. R134a, R404A, R407c, R507) oil types
reciprocating compressors for Grasso reciprocating compressors
Brand Type designation ISO VG numbera Brand Type designation

ISO VG
numbera
FC 46 44
AVIA Icematic SW 68 67
FC 68 65 CASTROL
Icematic SW 100 100
Energol LPT-F 46 54
BP Solest 68 64
Energol LPT 68b 68 CPI
Solest 120 131
CASTROL Icematic 299 56
ACD 68 M 70
CPI CP-1009-68 69 TOTAL
ACD 100 FY 98
Zerice S46 48
Reniso E 68 68
EXXON MOBIL Zerice S68 68 FUCHS
Reniso E 100 100
Arctic 300 68
Emkarate RL 68H 68
Reniso KS 46 47 ICI
FUCHS Emkarate RL 100H 100
Renisso KC 68 68
EXXON MOBIL EAL Arctic 68 63
KROON OIL Carsinus FC 46/68 46
Clavus R68 /
Refrigeration Oil S4 FR-F 68b 66
PETRO CANADA Reflo 68Ac 58
SHELL
Kuwait Petroleum Q8 Stravinsky C 55 Clavus R100
Refrigeration Oil S4 FR-F 100b 94
1) Clavus 46 46
Capella HFC 55 52.5
1) Clavus 68 68
TEXACO Capella HFC 80 80
1) Clavus G 46d 46
SHELL Capella HFC 120 118
1) Clavus G 68d 68
a. Viscosity grade number designation according to ISO Standard 3448.
Clavus S-68 / b. Old name resp. new name; old name will be phased-out from 2010.
68
Refrigeration Oil S2 FR-Ae
1) Clavus G 100d 95
c
Suniso 3.5 GS 43
c
Suniso 4 GS 55
SUN-OIL
Suniso 5 Gc 94
c
Suniso 4 SA 57
Capella WF 68 65
TEXACO
Capella Premium 68 67
TOTAL Luneria FR 68 68
Klüber Summit RHT-68 68
a. Viscosity grade number designation according to ISO Standard 3448.
b. Not miscible with R22 at low temperatures
c. NH3 only
d. For NH3 only possible if water and air are not present!
e. Old name resp. new name; old name will be phased-out during 2010.
1) These oils cannot be supplied anymore from approx.

January 2011.


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Reciprocating Compressors for industrial refrigeration

Installation and Maintenance Manual (IMM)

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 1-

This manual must be carefull read and understood prior

In compliance with the regulations of the Pressure

Installer oriented information

The compressor is not filled with oil.

After the successful initial run of the compressor

- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

Section Title Page

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 3-

- 4- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

4) Parts list (PL)

2) Installation and maintenance manual (IMM)

3) Service Instruction Manual (SIM)

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 5-

Fig. 1 Cylinder numbering Grasso reciprocating compressors

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 7-

Table 2 Main setup data

Description Value Remark

- 8- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

1. INSTALLATION AND PREPARATION FOR USE

Do not forget to charge the oil separator (if present) Legend

1. The direction of rotation of the compressor cannot be checked for (semi)

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 9-

Bare compressor or loose components: Compressor (package) has to be mounted on a

1.1.5.1 CONCRETE STRUCTURE

Fig. 1.1-2 Hoisting angle

Moving by fork-lift truck

- 10- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

• The concrete block should be set on firm footings or

It is recommended to consult a concrete specialist/

1.1.5.3 MOUNTING THE BASE FRAME ON A

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 11-

General instructions can be found in the order manual.

Fig. 1.1-5 Grouting details

5 Complete cured concrete block 1 Self leveling grout

6 Grout layer 2 Foundation anchor

- 12- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

In order to ensure that suction gas strainer can be

If an oil rectifier system is applied in the refrigeration

Never connect the oil rectifier return line to the suction

Suspension of system pipework

1.1.7 CONNECTING THE POWER SUPPLY

1.1.8 EARTHING CONNECTIONS

1.1.9 SEPARATELY DELIVERED COMPONENTS

Check whether the sets/parts/components belonging to

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 13-

- 14- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

1.2 PREPARATIONS FOR USE 1.2.3 INITIAL OIL CHARGE

Oil charging via the suction line of the compressor is not

1.2.4 INITIAL REFRIGERANT CHARGE

1.2.5 ADJUSTMENT OF INSTRUMENTS AND

1.2.5.1 CONTROL DEVICES

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 15-

1.2.6 CHECKING DIRECTION OF ROTATION OF

1. To be measured by means of a special control oil pressure gauge to be

- 16- Reciprocating Compressors for industrial refrigeration / Series Grasso 12 IMM2010/v007

1.2.7 INSTALLING THE DRIVE GUARDS (IF been overlooked.

1.2.9 INITIAL START-UP

1.2.9.4 PRE-START CHECK LIST

IMM2010/v007 Reciprocating Compressors for industrial refrigeration / Series Grasso 12 - 17-

b. Two-stage compressors: 3 - 5 minutes after