Screw Compressor Grasso SC

LT series, Types P, R, S, T, V, W, Y

Installation Instruction

(Translation of the original text)

Refrigeration / Grasso _133511_ea_sc_gbr_1_.doc 1

15.12.2009
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.

2 _510105_um_sc_py_gbr_ 12/04
1 GENERAL SAFETY INSTRUCTIONS 510090(ATEX)gbr

2 OVERALL CONZEPT AI_LT_02_gbr

3 DESCRIPTION OF DESIGN AI_LT_03_gbr

4 CONNECTIONS AI_PY_04_gbr

5 OPERATION AND MAINTENANCE AI_LT_05_gbr

6 LIST OF TOOLS AI_P_06_gbr

AI_RST_06_gbr
AI_VWY_06_gbr

Grasso
Refrigeration Division
SAFETY INSTRUCTIONS
All operations described in these
"Operating Instructions" are only to be
undertaken by trained professional
members of staff.
The following regulations are to be observed strictly:
• For installation of refrigeration machines and
protection of personnel
EN 378-3 and prEN 12693, section 4.1
• For testing the refrigeration machine prior to start-
up EN 378-2, section 9.5
• For renewal tests
EN 378-2, annex C
• For testing for corrosion
EN 378-2, annex D
• For taking a plant record
EN 378-2, section 11.5 and EN 378-4, section 6.6
• For taking measures in case of emergency
EN 378-2, section 11.2.3
• For instruction of the competent operating
personnel EN 378-4, section 4.1
• For maintenance and repair
EN 378-4, section 5
• For recovery, reuse and disposal of refrigerants, oil,
secondary refrigerants and parts of the
refrigeration machine (e.g. filters, driers, heat
insulation)
EN 378-4, section 6
• For draining oil from an ammonia refrigeration
machine
EN 378-4, annex A
• For handling and storage of refrigerants
EN 378-4, annex C
Consider duly Annex E for specified use
of screw compressors in explosion-
endangered areas subject to regulations
of the CE Directive 94/9/CE (ATEX 100a).
HINTS FOR MAINTENANCE AND REPAIR
• Before commencing any repair work the screw
compressor unit must be put out of operation
according to the operating instructions, all
refrigerant removed and the unit depressurized.
• Preparations for maintenance work on the
compressor are to be undertaken in such a manner
that it is only necessary for the machine to be open
for a short period.
03.07.03
GENERAL SAFETY INSTRUCTIONS
SCREW COMPRESSORS
• The sealing and locking devices which have become
accessible must be renewed.
• Utmost cleanliness during assembly is absolutely
essential for continued trouble-free operation.
• After maintenance and repair work has been
carried out, the parts must be cleaned with an
organical degreasing agent and treated with the
refrigerating machinery lube oil of the same brand
used in the plant.
• The compressor must be evacuated when all work
operations have been completed after which a
pressure and vacuum test must be carried out.
• Instructions for prolonged shutdown periods:
When the compressor is shut down for a long
period of time (longer than one week), the
following is recommended:
→ Close the shut-off valves on the suction and the
discharge side of the screw-compressor unit.
→ Turn the coupling of the compressor by one
eighth of a shaft turn every four weeks.
• When the compressor is to be stored separ-ately, it
must be filled with dry nitrogen after it has been
evacuated (0.5 bar excess pressure).
• A description of maintenance and repair work for
all screw compressor subassemblies accessible from
the outside is given in Chapter „Operation and
Maintenance“ of the Manual.
• The screw-compressor can remain connected to the
unit during the maintenance and repair operations
described here since subassemblies are only
partially disassembled. Repair of the compressor
when completely disassembled requires specific
technological prerequisites and is therefore not
described here.
• We recommend the operator of the compressor to
ensure that maintenance and repair work is carried
out according to the time schedules specified. For
criteria of subassembly replacement see specified
chapters.
• The figures in brackets after the individual parts
refer to the numbers of the parts given in the List
of Parts and Drawing Index. See figures of drawing
index too.
• The tools used are denoted with T. and are quoted
in the List of Tools.
• Take a look at defined tightening torques during
assembly.
510090(ATEX)gbr.doc - 1/1
 OVERALL CONCEPT
Grasso
Refrigeration Division

OVERALL CONCEPT
SCREW COMPRESSORS
LT SERIES,
TYPES P, R, S, T, V, W, Y, Z, XA, XB, XC, XD, XE, XF
• Introduction
• Compression
• Oil system
• Capacity control
• Vi-Adjustment

07/2003 AI_LT_02_gbr.doc - 1/5


Grasso
Refrigeration Division
INTRODUCTION
The screw compressors herein described are twin-shaft
rotary piston machines operating on the positive
displacement principle with oil injection operating
with different refrigerants.
Both rotors are machined to a helical lobe asymmetric
profile intermeshing with minimal clearance and
enclosed in a housing.
The male rotor having 5 or 4 lobes and driven by the
motor drives in its turn the female rotor having 6
lobes.
Journal bearings support radial loads, and angular ball
bearings axial loads. A compensating (balance)
unloading piston fittet to the male rotor shaft reduces
axial-loading on the ball bearings. The drive shaft is
fitted with an oil-retaining, unloaded shaft seal.
The compressor's capacity and internal volume ratio Vi
can be set by two adjustable slides, i.e. the primary
Inlet
Shaft seal
Position Hydraulically
sensor system
Figure 1 Schematic Representation of the Compressor
AI_LT_02_gbr.doc - 2/5
OVERALL CONCEPT
and secondary slides (tandem slides, system TS).
Adjustment and setting are by means of pressurised
oil which is supplied to the compressor. An hermetic
machanical-electrical display system indicates the
position of the primary slide (Position sensor).
The compressor has one or two additional suction
openings for feeding in a further volume flow (e.g. for
economizer coupling). Connections to the
compression chamber are provided for injecting liquid
refrigerant to provide additional cooling of the
compression process.
A connection from the oil-separator to the pressure-
casing supplies oil for eliminating gas pulsations in the
lower part load range at high working pressure
conditions. Simplified construction of these
compressors features a fixed internal volume ratio Vi
of 2.6, 3.6, 4.8 or 5.5. In addition, a special model for
operation at low pressure differences (booster) is also
available.
Radial bearing Male rotor Axial bearing
Outlet
Secondary Primary Balance
slide slide piston
07/2003
 OVERALL CONCEPT
Grasso
Refrigeration Division

COMPRESSION Suction side Discharge side

While the rotors are turning, the meshing shifts from
the suction side to the discharge side. A V-shaped
space is formed between 2 male and female teeth in
each case which increases to a maximum size (Suction
process: Figure 2; 1-3, View of the upper side of the
rotors).
As the rotor continues to turn, the V-shaped space is
closed by the new meshing on the suction side. This
space gradually becomes smaller as the meshing
continues (Compression process: Figure 2; 4-5, View of
the lower side of the rotors).
The compression process ends when the tooth space
reaches the control edges which are incorporated in
the casing and control slide or Vi-slide (Figure 2; 6).
The control edges are part of the outlet opening
which has an axial and a radial part.
The position of the conrol edges determines the size
of the compressed volume and thus the level of
compression. As the rotors continue to turn, the
compressed volume is pushed out of the tooth space
which diminishes to zero into the discharge area of
the compressor. The process described above is
repeated for every subsequent tooth space, thus
achieving an almost continuous delivery.

Figure 2 Compression process

07/2003 AI_LT_02_gbr.doc - 3/5


Grasso
Refrigeration Division
OIL SYSTEM
The oil supplied to the compressor serves the
following purposes:
1. Injection of oil into the compression chamber.
2. Sealing and cooling of the oil seals.
3. Lubrication of journal and thrust bearings.
4. Loading of the balance-piston.
5. Actuation of the capacity control and Vi-
adjustment
Oil injected into the compression chamber (item 1
above) serves the following purposes:
− Absorbtion and dissipation of the heat of
compression.
− Lubrication of meshing surfaces between male and
female rotors.
− Sealing of clearances at meshing position between
the rotors and of radial and axial clearances
between rotors and housing.
− Abatement of noise.
All oil supplied to the compressor is conveyed together
with the compressed refrigerant from the compressor
discharge into an oil separator where the oil is
separated from the refrigerant.
AI_LT_02_gbr.doc - 4/5
OVERALL CONCEPT
CAPACITY CONTROL
Capacity control is by means of regulating the suction
volume. This is achieved by shortening the effective
compression stroke. A proportion of the gaseous
refrigerant is fed back to suction through an internal
bypass connection by displacement of primary and
secondary slides (see Figure 3).
The capacity control permits the compressor discharge
rate to be continuously varied from 100 % down to
about 10 %.
In the upper part-load range, capacity control of
compressors with variable Vi is obtained by moving
the secondary slide with the primary slide in fixed
position. In medium and lower part load range the
primary slide realizes the capacity control.
In its minimum setting the primary slide provides
unloaded compressor start-up due to the minimal
absorbed power required (see Figure 3).
The slides are activated hydraulically and by means of
the compressor differential pressure applied to the
primary-slide. The primary slide position is indicated by
an electronic sensor.
Screw compressors with fixed Vi realize the capacity
control with only one control slide. This control slide
has the function as primary slide.
07/2003
 OVERALL CONCEPT
Grasso
Refrigeration Division

Vi-ADJUSTMENT
The internal volume ratio Vi is an intrinsic characte-
ristic of the screw compressor and is defined as the
ratio of the volume of interlobe space at the start to Full load operation
Inlet Optimum Vi
that at the end of the compression process. Termina-
tion of compression and internal volume ratio Vi are
determined by the position of the radial discharge
port formed by the notches machined into the
primary-slide. Various Vi settings are obtained by Rotor
adjusting the primary slide in its full load position to Outlet
various axial displacements thus altering the size of optimum
Full load
the radial discharge port. The internal volume ratio Vi position Vi position
is adjusted to actual external operating conditions
(suction pressure, delivery pressure) so that the
pressure in the interlobe space at the discharge port Secondary slide control Primary slide control
equals the required delivery pressure thus reducing
compression losses and power input to a minimum.
The full load setting of the primary-slide at its
optimum compression ratio is by means of the
Upper part load operation
Secondary slide control
compressor's memory programmed control device Inlet Optimum Vi
operating according to an empirically derived
algorithm. The setting of the primary slide is
determined by an electronic position transmitter. Once
the primary slide is positioned the secondary slide is
brought up behind to butt against it. Both slides are Rotor
actuated hydraulically. Outlet
Part load optimum
position Vi position

Internal By-pass

Lower part load operation

Primary slide control
Inlet

Rotor
Outlet

Part load Part load

position position

Internal By-pass

Figure 3 System of combined Vi part load control

07/2003 AI_LT_02_gbr.doc - 5/5

 DESCRIPTION OF DESIGN
Grasso
Refrigeration Division

DESCRIPTION OF DESIGN
SCREW COMPRESSORS
LT SERIES,
TYPES P, R, S, T, V, W, Y, Z, XA, XB, XC, XD, XE, XF
• Casing
• Rotors
• Bearings
• Shaft Seal
• Capacity control
• Vi-adjustment
• Display of slide position

03/2004 /Rev.1 AI_LT_03_gbr.doc - 1/4


Grasso
Refrigeration Division
Reference should be made to the lists of
parts and drawing index for a better
understanding of the following
descriptions.
CASING
The grey cast iron housing consists of three vertically
split sections namely the suction, rotor and discharge
casings. Suction intake is horizontal and discharge
outlet vertical. O-ring seals are fitted between the
individual casing-sections and are also fitted to the
housing cover and flanges.
Oil drain screw plugs are provided. The suction-side
front wall of the working space features covering
flanges or casing edges with guide surfaces for the
movable secondary slide.
The delivery-opening and guide surfaces for the axially
adjustable primary-slide are located in flanges which
comprise the compression chamber discharge side
end-plate.
ROTORS
The rotors are of material C 45 with tempered
bearing-surfaces. The speed ratio of male to female
rotor is
5:6 or 4:6.
The profile diameters of the male and female rotors
are identical or different.
To achieve optimum performance parameters, the
rotor profiles are finished with maximum accuracy by
hobbing. All rotors are dynamically balanced.
AI_LT_03_gbr.doc - 2/4
DESCRIPTION OF DESIGN
BEARINGS
Bearings absorb the radial and axial loads resulting
from the compression process.
Journal bearings of steel-sleeve and white-metal liner
construction absorb radial loads.
Inclined ball bearings, arranged in pairs, absorb axial
loads and ensure precise axial mounting of the rotors.
Taking into consideration the space conditions
available, several compressor sizes are fitted with
differing angular contact ball bearings on both the
male and female rotor sides.
To accommodate the particular requirements of screw
compressors, the inclined ball bearings are fitted with
heavy duty cages and have radial clearance between
outer-race and housing so as to minimise
radial loads and thus extend service life. To eliminate
rotation the outer-races are axially clamped in tension.
Due to the high axial loading on the male rotor, a
balance piston is fitted on the discharge shaft end of
the male rotor thus unloading the bearings and
extending service life. Lube oil at discharge pressure is
applied to one side of the balance piston thus
producing an axial counter-force. For booster
application (small pressure differences), the
compressor need not be fitted with a balancing
piston. The heat pump compressor-models are
equipped with double thrust bearings on both rotors
in a special arrangement.
SHAFT SEAL
The driven male rotor shaft is sealed on its suction side
by an oil flooded, unloaded slide-ring seal thus
ensuring longest possible service life.
The counter ring arranged in the cover and the sealing
ring with spring assembly rotating with the shaft are
used in different material combinations (special cast
iron, hard carbon, hard metal, SiC). An O-ring provides
additional sealing of the slide ring with the shaft.
Lube oil at slightly less than discharge pressure is
supplied to the seal and thereafter to the suction-side
journal bearings. The seal faces of slide and backing
rings are separated by a thin oil-film and free of
contact with one another thus ensuring minimal
leakage and long service life.
03/2004/ Rev.1
 DESCRIPTION OF DESIGN
Grasso
Refrigeration Division

CAPACITY CONTROL Vi-DISPLACEMENT

The primary and secondary slides form part of the The Vi value is determined by position of the primary
lower compression chamber wall. Adjusting the slides slide. At the full load operation applying pressurised
opens a bypass port connected though ducts in the oil to the hydraulic piston displaced the secondary
housing to the suction chamber of the compressor. slide into the primary slide (secondary slide touch the
primary slide). With displacement of the primary slide
The primary slide can be displaced axially from its full
in direction discharge side (Vi-enlargement) or in
load position towards the discharge casing and is
direction suction side (Vi-reduction) always the
coupled on the suction side by a connecting rod to an
secondary slide touch the primary slide.
hydraulic piston which is reciprocally activated by
pressurised oil. The piston moves in a cylinder closed Alternatively the Vi value can be adjusted manually by
at both ends. The cylinder spaces of the hydraulic the compressor control device..
piston are filled and drained via solenoid valves either
The simplified version of these compressors with fixed
directly flanged onto the compressor or still arranged
built-in Vi has stationary secondary slide with the
externally on several sizes.
discharge port of the primary slide corresponding to Vi
At upper part load range capacity control is by = 2.6, 3.6, 4.8, or 5.5. The Vi value must be selected
adjusting the secondary slide alone while the primary during construction of the compressor and depends
slide remains stationary. Spring-loaded pins in the on the expected operating conditions (suction
secondary slide cause the bypass-port to open pressure, condensing pressure).
whereas the hydraulic piston connected to the
secondary slide is used to reduce the bypass-port. Due
to filling and draining the hydraulic space via two
additional solenoid valves, the secondary slide can be
brought into any position.
Capacity control in the medium and lower part load
ranges is by displacing the primary slide which results
in shortening the effective rotor length and
consequently reducing the discharge flow-rate. The
minimum part load position is reached when the
suction side edge of the primary slide closes the Primary slide
passing interlobe space just before the axial discharge
port is reached. The primary slide passes underneath Secondary slide
the discharge casing end-plate flanges whose contour
prevents rotary-tilting of the primary slide. Figure 1 Capacity control / Vi-Adjusting Device
During compressor operation, the discharge/suction
differential pressure is applied to the primary-slide
end-faces. This results in the primary slide moving P0
towards the suction side, i.e. towards full load.
For lower operating pressure differences, the
differential pressure load across the primary slide is
insufficient to produce movement and must be P
increased by means of pressured oil applied to the
rear face of the hydraulic piston. In this condition, the
cylinder chamber at the front face of the piston is MIN
discharged to the suction side.
MAX
To displace the primary slide towards the discharge
casing, i.e. part load operation, the front face of the P P0
hydraulic piston is loaded with pressurised oil and its
rear face is discharged to the suction side.
Primary slide

Secondary slide

Figure 2 Solenoid valve blocks for primary and secondary slides

03/2004 /Rev.1 AI_LT_03_gbr.doc - 3/4

 DESCRIPTION OF DESIGN
Grasso
Refrigeration Division

DISPLAY OF SLIDE POSITION 2. Secondary slide

1. Primary slide/ Control slide
Types P, R, S, T, V, W, Y, Z, XA
The position of the primary slide (Vi variable) or
control slide (fixed Vi) is determined by the HDT
(Hermetic Differential Transformer) indicator-system
mounted on the cover plate of the capacity control
unit.
By means of 2 series connected tension springs of
different lengths the large length of adjustment of the
slide/piston rod/hydraulic piston complex can be
reduced to a small length which corresponds to the
measuring range of the position sensor.
A long pin is attached to the junction of both springs
where a small length of adjustment appears. The end
of the pin slides into a coil of the position sensor thus
generating a measuring signal by altering the
inductivity.
As special design, the compressors can be fitted with
an indicator system for the secondary slide.
The position of the secondary slide is picked up by a
second position sensor on the basis of hermetic
differential transformer (HDT) arranged on the wall of
the rotor casing; for types P through XA on the
female rotor side, for types XB through XF on the
male rotor side. The measuring signal is generated in
the same manner as already described for the primary
slide of types XB through XF.
The position sensor supplies between both end
positions of the secondary slide, i.e. depending on the
depth of HDT pin penetration, a standardized output
signal of 4.0 mA to 8.4 mA.

Types XB, XC, XD, XE, XF

The position of the primary slide/ control slide is
detected by the position sensor indicator system (HDT)
(Hermetized Differential Transformer), which is
located at the wall at the side of the male rotor.
The push rod slides in a longitudinal notch located at
the primary slide with a slight slope, This reduces the
long readjustment path of the slide to a short path,
which is more appropriate to the measuring range of
the sensor. The push rod is connected to a pin, the
opposite end of which immerses into the coil of the
position sensor, generating a measuring signal.
Figure 3 Functional diagram of the position sensor system
for types P, R, S, T, V, W, Y, Z, XA
All types
Depending on the position of the slide, i.e. depth of
the pin immersion, the position sensor supplies an
output signal of between 4 and 20 mA (for screw
compressors with variable Vi).
Setting of the Vi value results in the compressor-
control device simultaneously correcting the output
signal of the indicating system so that the primary
slide full load position is always registered at 100 % on
the indicating device.
The compressor control device computes the optimum
Vi value for setting the position of the primary slide.

Figure 4 Functional diagram of the position sensor system

for types XB, XC, XD, XE, XF

AI_LT_03_gbr.doc - 4/4 03/2004/ Rev.1

 CONNECTIONS
Grasso
Refrigeration Division

CONNECTIONS
SCREW COMPRESSORS
LT SERIES, TYPES P, R, S, T, V, W, Y
• Connections, Threads
• Input Voltage
• External Connections Type P
• External Connections Type R, S, T
• External Connections Type V, Y
• External Connections Type W

03.2004/4 AI_PY_04_gbr.doc - 1/7

 CONNECTIONS
Grasso
Refrigeration Division

CONNECTIONS / THREADS

Item Purpose Nominal width/threads

P R, S, T V, W, Y
S Suction nozzle NB 150 NB 175 NB 250
T Discharge nozzle NB 100 NB 100 NB 150
A shaft seal, suction side bearing M22x1,5 M22x1,5 M22x1,5
B Oil injection M22x1,5 M22x1,5 V: M22x1,5
compression chamber W:M26x1,5
Y: M22x1,5
C discharge side bearing, balance M22x1,5 M22x1,5 M22x1,5
piston
D oil supply balance piston M22x1,5 M22x1,5 M22x1,5
heat pump
D1 Special port axial bearing male rotor M22x1,5 M22x1,5 M22x1,5
Booster applic.
E External oil supply solenoid valve G¼ G¼ G¼
block for capacity control
F Additional oil injection M22x1,5 M22x1,5 M22x1,5
G Oil return M22x1,5 M22x1,5 V: M22x1,5
capacity control W: -
Y: M22x1,5
H1 Refrigerant liquid injection (LP) M22x1,5 M22x1,5 M22x1,5
H2 Refrigerant liquid injection (HP) - M22x1,5 M22x1,5
K Oil supply, - - V: M16x1,5
direction part load W: -
Y: M16x1,5
L Oil supply, - - V: M22x1,5
direction full load W: -
Y: M22x1,5
M Oil supply and return, variable Vi - - V: M16x1,5
W: -
Y: M16x1,5
N Oil return oil separator M16x1,5 M16x1,5 M16x1,5
P Gas pulsation protection M26x1,5 M26x1,5 M33x2
R Economizer port NB 40/ M48x2 NB 40/ M48x2 NB 65
O1 Oil drain plug M14x1,5 M22x1,5 V: M16x1,5
W:M12x1,5
Y: M16x1,5
O2 Oil drain plug M22x1,5 M22x1,5 M22x1,5
O3 Oil drain plug M16x1,5 M16x1,5 -

AI_PY_04_gbr.doc - 2/7 03.2004/4

 CONNECTIONS
Grasso
Refrigeration Division

INPUT VOLTAGE
Item Purpose P, R, S, T, W
Y1/Y4 Solenoid valves capacity control,
direction full load 240 V AC
220 V AC
Y2/Y3 Solenoid valves capacity control, 110 V AC
direction part load 48 V AC
Y5 Solenoid valve 42 V AC
variable Vi 24 V DC
220 V AC
Y6 Solenoid valve expl.-proof
variable Vi
Position sensor for position display
Z
primary slide/ control slide Inlet: 24 V (DC)
Position sensor for position display Output: 4-20 mA
Z1
secondary slide

03.2004/4 AI_PY_04_gbr.doc - 3/7

 CONNECTIONS
Grasso
Refrigeration Division

EXTERNAL CONNECTIONS TYPE P

AI_PY_04_gbr.doc - 4/7 03.2004/4

 CONNECTIONS
Grasso
Refrigeration Division

EXTERNAL CONNECTIONS TYPE R, S, T

03.2004/4 AI_PY_04_gbr.doc - 5/7

 CONNECTIONS
Grasso
Refrigeration Division

EXTERNAL CONNECTIONS TYPE V, Y

AI_PY_04_gbr.doc - 6/7 03.2004/4

 CONNECTIONS
Grasso
Refrigeration Division

EXTERNAL CONNECTIONS TYPE W

03.2004/4 AI_PY_04_gbr.doc - 7/7

 OPERATION AND MAINTENANCE
Grasso
Refrigeration Division

OPERATION AND MAINTENANCE

SCREW COMPRESSORS
LT SERIES,
TYPES P, R, S, T, V, W, Y, Z, XA, XB, XC, XD, XE, XF

1 Important instructions 2

2 Introduction 2

3 Shaft Seal 3

4 Capacity control/ Vi Setting Device 4

4.1 Repair criteria 4
4.2 Dismantling 4
4.3 Replacement the seals 5
4.4 Replacement the tension springs 5
(for types P, R, S, T, V, W, Y, Z, XA only)
4.5 Assembly 5

5 Position Sensor Display System 7

5.1 Connection values of Position Sensor 7
5.2 Calibration of the Display System 7

6 Solenoid valve blocks

(not for types V, Y) 8
6.1 Solenoid valve block for capacity control 8
6.2 Solenoid valve block for Vi-adjustment 9

7 Axial Bearings 10
7.1 Axial Gap Measurement 10
7.2 Dismantling of Axial Bearings 11
7.3 Assembly 12

8 Bearing Bushes 13

9 Pressure test 13

10 Vacuum test 13

11 Maintenance 14

12 Table: Tightening Torques 14

03/2004 — rev.1 AI_LT_05_gbr.doc - 1/14

 OPERATION AND MAINTENANCE
Grasso
Refrigeration Division

1. IMPORTANT INSTRUCTIONS 2. INTRODUCTION

• Apart from technicians authorized by the A description of maintenance and repair work for the
manufacturer, repair work on the screw- screw compressor subassemblies is given in these
compressor may only be undertaken by skilled instructions.
operating personnel or qualified technicians in The screw-compressor can remain connected to the
compliance with these safety instructions. unit during the maintenance and repair operations
• Before commencing any repair work the screw described here since subassemblies are only partially
compressor unit must be put out of operation disassembled. Repair of the compressor when
according to the operating instructions, all completely disassembled requires specific
refrigerant removed and the unit depressurized. technological prerequisites and is therefore not
described here.
• Preparations for maintenance work on the
compressor are to be undertaken in such a We recommend the operator of the compressor to
manner that it is only necessary for the machine ensure that maintenance and repair work is carried
to be open for a short period. out according to the time schedules specified. For
criteria of subassembly replacement see specified
• The sealing and locking devices which have chapters.
become accessible must be renewed.
The figures in brackets after the individual parts refer
• Utmost cleanliness during assembly is absolutely to the numbers of the parts given in the List of Parts
essential for continued trouble-free operation. and Drawing Index (Chapter 7). See figures of
drawing index too.
• After maintenance and repair work has been
carried out, the parts must be cleaned with an The tools used are denoted with T. and are quoted in
organical degreasing agent and treated with the the List of Tools given in Chapter 6.
refrigerating machinery lube oil of the same brand
Take a look at tightening torques defined in the
used in the plant.
table in point 11.
• The compressor must be evacuated when all work
operations have been completed after which a
pressure and vacuum test must be carried out (see
sections 9 and 10).
• Instructions for prolonged shutdown periods:
• When the compressor is shut down for a long
period of time (longer than one week), the
following is recommended:
→ Close the shut-off valves on the suction and
the discharge side of the screw-compressor
unit.
→ Turn the coupling of the compressor by one
eighth of a shaft turn every four weeks.
• When the compressor is to be stored separ-ately,
it must be filled with dry nitrogen after it has
been evacuated (0.5 bar excess pressure).

AI_LT_05_gbr.doc - 2/14 03/2004 — rev.1

 OPERATION AND MAINTENANCE
Grasso
Refrigeration Division

3. SHAFT SEAL
The sealing surfaces of both the sealing and the
counter ring of the shaft seal (72) run separated from
one another by a thin oil film whereby a slight
amount of leakage occurs. On the other side, a long
service life is achieved. The leakage oil leaves via the
oil pipe (177). The leakage oil rate is mainly
influenced by
- the condition of wear of the sealing surfaces,
- the discharge pressure,
- the oil viscosity (oil temperature and oil brand),
- the presence of solved refrigerant in oil,
- the frequency of starts and stops.
Leakage oil rate guaranteed:
− Pull seal slide ring and set of springs either in one
piece or separately (dependingonn construction)
off the male rotor by hand, see Figure 2.
− Press off backing ring from cover (45).
− Should signs of wear on the front end sealing
faces of either the slide or backing rings be
detectable, i.e. heavy abrasion or scoring, the
rings must be replaced either singly, if so available
or as complete seal assembly.
− In exceptional cases refinish lapping is permissible
using a plane surface (lapping plate or glass
panel) and suitable lapping paste. However, such
treated parts must be replaced as soon as possible
by new ones.

The values given for the leakage oil rate refer to the − Additional by types Z, XA, XB, XC, XD, XE, XF:
following operating conditions: Remove of the oil disk (178) and check the ring
seal (624/628/727). Renew the ring seal in case of
Oil pressure: 20 bar wear.
Oil supply
temperature: 45 ... 50°C
Speed: 2950 min-1
Oil quality: refrigerant free refrigeration
oil without additives of
viscosity grade ISO-VG 46...68
Types P, R, S, T: 3,5 ml per operating hour
Types V, W, Y, Z, XA: 9,0 ml per operating hour
Types XB, XC, XD: 10,0 ml per operating hour
Types XE, XF: 12,0 ml per operating hour
Due to differing operating conditions such as
- higher oil pressure on the shaft seal,
- higher entering oil temperature,
Figure 1 Removing shaft seal cover
- use of refrigerant soluble oils,
- higher speed,
- frequent starts and stops,
- presence of liquid refrigerant in oil
the values given may rise by three times without
causing impermissible wear on the shaft seal.

If the leakage oil rate is exceeded due to

- wear on the sealing surfaces
- damage of O-rings
- damage of seat on the rotor shaft,
the seal has to be replaced.

Dismantling
− Remove compressor end coupling - half according
to operator's instructions for the coupling.
Figure 2 Removing shaft seal
− Remove shaft seal cover (45) together with seal
backing ring inside using two pushing screws, see
Figure 1.
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Assembly
Only types Z, XA, XB, XC, XD, XE, XF:
− Renew O-ring and if necessary seal ring
(624/628/727) of the oil disk (178).
− Mount oil disk:
• Fitting cone (T19) outside moisten with oil and
push on the shaft of the shaft seal up to stop.
• Oil disk push on the fitting cone up to stop.
• Fitting cone pull out.
All Types:
− Push the set of springs and slide ring with new
O-ring (329/184/181/728) onto rotor shaft so that
the cylindrical dowel pin (481/488/487) on the
shaft locates into the bore-hole or groove
provided in the set of springs.
− Place O-ring (333/186/187/728) and outer O-ring
into the cover (45) and insert backing ring of seal
into the cover with due attention to the cylindrical
dowel pin.
− Push cover over shaft stub, set against housing
and screw it down.
AI_LT_05_gbr.doc - 4/14
OPERATION AND MAINTENANCE
4. CAPACITY CONTROL DEVICE/VI SETTING DEVICE
The Maintenance Time Schedules in para 11. specify
the approximate intervals at which piston seals and
as well as gaskets (149/148/70) of the capacity
control device and Vi setting device should be
changed. However, for operating conditions, such
intervals can be longer or shorter.
4.1 Criteria for Repair
In case of problems with the capacity control device /
Vi adjusting device assembly, first check if the oil
supply system the compressor (solenoid valves,
filters) is operating correctly. If it does, repair will be
necessary if the following criteria apply:
Piston seal (148) of piston flange (147):
− The primary slide does not move towards its
partial load position.
− Under manual setting, the primary slide moves
spontaneously towards its full load position.
Piston seal (148/149) of stop piston (21),
gaskets (70):
− Full load operation with secondary slide is not
possible.
− The primary slide does not move towards its full
load position under low working pressure
conditions.
4.2 Dismantling
Removal of piston seal (148) from piston flange
(147):
a) - Set primary slide to its maximum position.
- Remove pipework to connections K, L and M on
cover (7) and suction casing (347).
Only types V, Y.
- Drain oil from suction casing through screwed
drain plug.
b) - Remove position sensor (452) by loosening the
hexagon socket head attachment screw on the
underside of the rectangular housing and by
withdrawing the position sensor.
- Unscrew the threaded pipe.
- Types P, R, S, T, V, Y, W, Z, XA:
Withdraw the position sensor rod (387) by hand
as far as the hook from cover (7) and remove
inner tension spring (461). The position sensor
rod, tension spring support (463) and tension
spring (460) remain assembled.
- Types XB, XC, XD, XE, XF:
You have to manually withdraw the position
sensor rod with push rod (406) and pressure
spring (93) out of the housing.
- Unlock lock plate (370) and unscrew grooved
nut (172) using tool T1.
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c) - Loosen screws and nuts to remove cover (7)

(by using pushing screws).
- Pull off piston flange (147) using puller T3, see
Figure 3.

Removal of piston seal (148/149) from stop piston

(21), gaskets (70):
d) - Remove cylinder (468) and cylinder stop (469)
using puller T3, see Figure 4.
- Pull the primary slide (200) together with piston
rod (150) by hand towards the suction side up
against the secondary slide (199) until stop
piston (21) slides out of check cylinder (23).
- Using two hooks reach over the piston seal
(148/ 149) behind the stop piston (21) and
together with secondary slide (199) withdraw
the stop piston over the piston rod out of the
suction housing (347). Figure 4 Dismantling cylinder (468)

- Loosen fillister head screws (553/510) and

detach stop piston from primary slide.
4.3 Replacement of Seals
Replacement of piston seal (148):
− Remove old seal, replace O-ring (251/255/254/
256/276/288), heat up new piston seal (148) in a
water bath to about 90°C, fit seal, by drawing it
over the flat chamfer of the piston flange.
Replacement of gaskets (70) and slide bushes (130):
− Insert new O-rings (309/718) into the check piston
and the cylinder stop. Heat up gaskets and slide
bushes in a water bath to about 90°C, compress
them slightly to kidney shape and insert them
into the groove. Then roll them in peripherically
using a piece of smooth round material. Grease
gasket (70) of stop piston (21) and using a flat
disc press it axially under O-ring (309/718).
4.4 Replacement of tension spring
(for types P, R, S, T, V, W, Y, Z and XA only)
− Remove cover (7) in the same way as for
dismantling the piston seal (148). Piston rod (150)
will then be in ist MAXIMUM position.
− Remove snap ring (385) and using hook T5
withdraw tension spring (461) together with
tubular housing (16) and screw plug (428).
− Unscrew threaded plug from spring end and
screw it into new tension spring (461).
− Insert tubular housing (16) together with
mounted tension spring and screw plug into the
piston rod and secure assembly with a new snap
ring (385).
When changing tension spring (461)
remember also to change tension spring
(460) fixed to se cover . The springs must
always be changed in pairs !

4.5 Assembly
a) Screw stop piston (21) to secondary slide (199)
ensuring that the complete assembly of springs
(91/90) and pin (84) is present. Tigthen fillister
head screw (553/510) crosswise.
b) Assembly of Secondary Slide (199):
A cylindrical dowel pin (470) located in the guide
of the secondary slide in rotor housings types P, V
and Y (previous design types) prevents rotation,
see Figure 5. Grease pin before assembly to
improve its adhesion and insert it into the groove.
− Pull primary slide with piston rod to its
MAXIMUM position.
Figure 3 Pull off piston flange (147)

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− Push secondary slide (199) with stop piston
(21) over the piston rod into suction casing
(347) and push check cylinder (23) up against
stop. Align assembly so that the outer shape of
secondary slide can pass under cover plate/
flanges (1/3/4/362). Then, the guide groove of
secondary slide has overriden cylindrical dowel
pin (470) and eliminates rotation.
− By inserting the assembly, the piston rod and
the primary slide will also be displaced towards
the discharge side.
− After fitting, secure the assembly secondary
slide (199) and stop piston (21) and pull back
the piston rod together with the primary slide.
− Cylinder (468) will thus be pressed further into
casing (347).
f) For Types P, R, S, T, V, W, Y, Z, XA:
− Insert assembly hook T5 through centre
aperture of cover plate (7) and using hook
pull out spring (461).
− Suspend hook of position sensor rod (387)
onto the end of spring; spring (460) and
tension spring support (463) are already
mounted on position sensor rod (387).
− Allow complete assembly to move back until
the stop in the cover plate is reached.
− Screw threaded pipe into place with O-ring
(253) underneath.
− Place position sensor (452) over threaded pipe
and secure with hexagon socket screw.
g) For Types XB, XC, XD, XE, XF:
− Insert the push rod (406) with screwed-in
sensor rod (452) and pressure spring (93) into
the lateral aperture of the rotor housing as far
as to the stop and insert the screw-in tube with
the O-ring (253) below it.

Figure 5 cylindrical dowel pin for secondary slide

c) Assembly of cylinder stop (469) and cylinder
(468):
− Insert the cylinder stop using the two screws of
puller T3. Insert O-ring (256/262/271/280/294)
into corner groove of cylinder stop.
− Fit O-ring (256/262/271/280/294) into outer
centre groove of cylinder (468) and introduce
cylinder into suction casing until butting againt
the O-ring.
− Only types P, R, S, T, V, Y:
Insert the remaining part of the cylinder into
the casing when securing the cover-plate (7).
d) − To attach piston flange (147) to piston rod
(150):
− Replace O-ring (284) and lock plate (91/370)
− Tighten grooved nut (172) using tool T1.
e) − Pull piston/piston rod assembly to suction side
end (MAXIMUM) position.
− Insert O-ring (256/262/271/280/294) into
corner groove of cylinder (468) (Types Z and
XA: 0-ring push over cylinder), slip over cover-
plate (7) and secure with screws and nuts.

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5. POSITION SENSOR DISPLAY SYSTEM (HDT)

Remove or assemble the display systems of the
capacity control and Vi-adjusting device according to
sections 4.
5.1 Connection Values of the Position Sensor
The connection values of position sensor (452) can be V 0
seen in Illustration 6.
Adjustment
The position sensor (452) must only be controller Adjustment
controller
operated with 24 V DC (max. 30 V). A
higher voltage level would result in
destruction!

5.2 Calibrating the Display System of the Capacity

Control
• When the display system is calibrated, the
minimum and maximum output values of the
position sensor (452) are set.
Output values:
MIN - position: 4+0,2 mA (0%...1,5%)
MAX- position: 20+0,5 mA (100%...103%)
• The compressor's position transducer "HDT"
(Hermetic Differential Transducer) has two
adjustment controllers to correlate the slide
position with the output signal (see figure 7).
Adjustment controller "O" moves the midpoints
of the output signal. Adjustment controller "V"
alters both endpoint simultaneously (ca. ±20%)
(see figure 8).
• The display system must be recalibrated when
output signals are defective or when the tension
springs (461 and 460) have been changed.
• Calibration by operating oil pump and blocking
compressor drive.
• Loosen the clamping screw on the position sensor
(452) of the cover (7) of the capacity control.
• Push the position sensor towards the cover until it
reaches the limit stop.
• Then pull the position sensor back approx. 2 mm.
• Tighten the clamping screw on the position sensor
(452) (approx. 3 Nm).
Clamping screw
Output
4-20 mA
1
3
2 3.
Earth
connection
Figure 7 Arrangement of the calibration screws
on the position sensor
Calibrating control slide/ primary slide
1. Bring the control slide (fixed Vi) respectively the
primary slide (variable Vi) to the MIN-position:
Opening the solenoid valves Y2 and Y3 .
With the slide in its MIN-position, use the
adjustment controller "O" to set the value of 4+0,2
mA.
2. Only by variable Vi
Bring the secondary slide (199) to the part load
position: Opening the solenoid valve Y5.
3. Bring the control slide/primary slide to the MAX-
position: Opening the solenoid valves Y1 and Y4.
With the slide in its MAX-positon, use the
adjustment controller "V" to correct the midpoint
between the actual value and the setpoint as
accurately as possible (see Figure 8 ).
4. With the slide in its MAX-position, use the adjust-
ment controller "O" to set the output end value
of 20+0,5 mA.
Adjustment of the output values of the
position sensor in the end positions of the
control slide by means of the adjustment
controllers must be repeated several
times because this setting causes mutual
interference of the output values.
Actual value
"0"
<- > Setpoint
1. "0"
2. "V"
"0"
MIN MAX

Figure 8 Transducer calibration

Input
+24 V DC

Figure 6 Connection values of the position sensor

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Calibrating the secondary slide The relief valve DV1 ensures a maximum excess
pressure of ∆p = 7,0 bar, compared with the suction
1. Move primary slide to MAX-position and
pressure, in space V for control direction MAX.
secondary slide to MIN-position:
For this purpose, open solenoid valves Y1 and
Y4 as well as Y5. When the slides have reached Orifice integrated into valve block Pressure limitation valve 7 bar

their positions, set the adjustment controller ″O“

on the HDT of the secondary slide to the value
of 4+0.2 mA.
Y1 S5 Y3 DV
2. Move primary slide to MIN-position and
secondary slide to MAX-position:
For this purpose, open solenoid valves Y2 and
Y3 as well as Y6. With the secondary slide in its
Y2 S6 Y4 S7
MAX- position, set the adjustment controller ″V“
of the HDT as accurately as possible to the value
p po
of 8.4+0.2 mA. oil
pT pV
to compressor
suction side
Oil pressure
Oil pump
Adjustment of the values of the position
T V
sensor in the end positions of the MAX
MIN
secondary slide by means of the
adjustment controllers must be repeated
several times as the process of Figure 9 Functional diagram of the solenoid valve block
adjustment will cause a mutual influence of the capacity control
of the output values.

6. SOLENOID VALVE BLOCKS S6 S5

(NOT FOR TYPES V, Y)

Technical Data Y2
Power supply: 220 V (AC) Y1
Function: Normally closed (NC)
Design: Seat valve E DV1
Nominal size: 2,5 mm
Y3
6.1 Solenoid Valve Block for the Capacity Control Y4
a) Functioning and Operation
The hydraulic spaces of the adjusting piston (411) of
the capacity control are filled and drained via the
solenoid valve block (147).
There are 4 connection holes on the base of the
block which are congruent with the 4 boreholes of
the casing support surface. These boreholes provide a
connection to the internal oil system (pressure poil), to S7
the suction side of the compressor (suction pressure
p0) and to both hydraulic spaces of capacity control. Figure 10 Outer view of the solenoid valve block
Two solenoid valves are opened, one for each of the capacity control
adjusting direction (MIN, MAX). The valves are
controlled as follows and a description can be seen in b) Setting the Adjustment Speed
figures 9 and 10. The purpose of control valves S5, S6 and S7 is to
control the flow rate. The valves are used to set the
Control direction MAX: Valves Y1 / Y4 open adjustment speed as follows:
Valves Y2 / Y3 closed
• MAX direction: Actuate valve S5
Control direction MIN: Valves Y2 / Y3 open
MIN direction: Actuate valve S6
Valves Y1 / Y4 closed
The adjusting speed can be reduced by throttling
the valves.

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• Adjustment duration between the two end
positions MAX ↔ MIN: 30 ... 60 sec.
(aim to reach 60 seconds).
The adjustment duration should be about the
same in both directions.
• Valve S7 is opened by turning it 2 turns from its
closed state.
This setting is generally maintained. If the
adjusting speed towards MAX is too low even if
valve S5 is fully open, valve S7 can be used for fine
adjustment by opening it further.
• Setting must take place with warm oil.
c) Changing the Parts
The following system malfunctions may occur:
− The valves will not open.
− The valves will not close.
− The adjusting speed cannot be adjusted with the
control valves.
− Pressure in space "V" is too low although the relief
valve DV1 has been adjusted.
The cause of the malfunctions can either be
attributed to an electrical or a mechanical fault. This
can be determined by checking the block.
Some parts can be changed and are available as a
spare parts set, Order No 501298415 (standard) or
501298416 (explosionprotected design). Magnet coils
(158) also are available as a spare part.
If the individual valve seats have deteriorated the
entire block must be renewed together with the
underlying O-rings (257/269).
6.2 Solenoid Valve Block for the Vi-adjustment
a) Functioning and Operation
The solenoid valve block (412) controls the filling and
drainage of the hydraulic spaces of the stop piston (21) at
adjustment of the secondary slide (199). The block has 3
connection holes on its base which correspond to
boreholes on the opposite surface of the compressor
casing. These boreholes provide a connection to the oil
system of the compressor (oil pump pressure poil) and to
the suction side of the compressor (suction pressure p0) as
well as to hydraulic space. The solenoid valves for
adjustment are controlled as follows (see figure 11).
Capacity Valve Y6 open
enlargement: Valve Y5 closed
Capacity Valve Y5 open
reduction: Valve Y6 closed
Full-load operation: Valve Y6 open
Valve Y5 closed
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OPERATION AND MAINTENANCE
The relief valve DV2 ensures a maximum excess pressure
of ∆p = 4,5 bar, compared with the suction pressure, in
the hydraulic space.
b) Setting the adjustment speed
The purpose of control valves 24 and 25 is to control
the flow rate to set the adjustment speed. The
adjustment speed can be reduced by throttling the
valves.
− Capacity - enlargement: Actuate valve S24
Capacity - reduction: Actuate valve S25
− Adjustment duration between Vi-MAX and
Vi-MIN: 60 ... (30) sec.
Set the valves in such a way that the adjustment
duration is about the same for both directions.
− Setting must take place with warm oil.
Y6 Y5 DV2
S24 S25
Figure 11 Functional diagram of the solenoid
valve block of the Vi-adjustment
c) Changing the Parts
Possible malfunctions:
− Valves will not open or close so that capacity
control is not possible.
− Adjustment speed cannot be controlled.
Cause of malfunction:
Electrical or mechanical fault which can be
determined by checking the block.
Some parts can be changed and ordered as a spare
parts set, Order No 501298417 (standard) or
501298418 (explosionprotected design). Magnet coils
(158) are separate spare parts.
If the individual valve seats have deteriorated the
entire block must be renewed together with the
underlying O-rings (257).
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7. AXIAL BEARINGS
7.1 Axial Gap Measurement
In the course of compressor operation, there will be
an increase of the axial gap due to the load acting
on the axial bearings leading to an axial displacement
of the rotors towards the suction side, and hence to
a decrease of the suction-end face gap (face gap:
distance between the face area of the rotor profile
and the casing). When the permissible axial gap is
going to be exceeded, there is the danger that the
rotors will run against the suction casing whereby
considerable damages might occur. In addition, the
discharge-end face gap will increase with growing
axial gap. The compressor capacity will decrease
when the permissible axial gap is exceeded.
Measure the axial gap to check bearings.
During axial gap measurement, the compressor
remains mounted on the package. The time intervals
for measurement are given in section 11, table 1:
Maintenance Schedule.
Recommendation: 1 measurement per year, but at
least after every 5,000 to 8,000 operating hours.
The measurement method described below is easily
feasible and is intended, however, for an
approximate determination of the axial gap only and
is no assessment of the general condition of the
bearings. We recommend to have the measurement
carried out by qualified personnel for finding out the
actual condition of the bearings.
Preparation for Measurement:
- Depressurize the compressor
- Remove the coupling guard
- Remove intermediate piece of coupling
- Loosen the screws / nuts of the cover (45) of the
shaft seal and force the cover out by means of
two forcing-off screws for ab. 7 mm (relieving the
seal)
- Mount dial gauge (T11) with magnetic clamp
(T24) on compressor casing or on package frame
- Set the feeler of the dial gauge at the
compressor-side coupling flange or at the face
end of the male rotor shaft. Care must be taken
to ensure that the gauge feeler is parallel to the
axis of the rotor.
- Remove cover of female rotor (48)
- Screw measuring pin (T20) into face end of
female rotor shaft.
AI_LT_05_gbr.doc - 10/14
OPERATION AND MAINTENANCE
Taking Measurements:
Male rotor
- Force the male rotor towards the discharge side
by means of a suitable lever to be applied to the
compressor-side coupling flange. (force of 100 ...
200 N)
- Remove lever and take a reading on the dial
gauge
- Push the rotor towards the suction side and
remove lever prior to taking a new reading on
the dial gauge.
- The difference between dial readings indicates
the size of the existing axial gap of the male
rotor
Female rotor
- Mount dial gauge with magnetic clamp on
compressor casing or on package frame.
- Set the feeler of the dial gauge at the face of the
measuring pin. Care must also be taken to ensure
that the gauge feeler is parallel to the axis of the
rotor.
- Push the rotor alternately with suitable lever at
the measuring pin both towards the discharge
and suction side as in the case of male rotor.
- Take measurements as in the case of male rotor.
Maximum permissible values of axial gap:
Types P, R, S, T: 0,20 mm
Types V, W, Y: 0,25 mm
Types Z, XA: 0,30 mm
Types XB, XC, XD: 0,35 mm
Types XE, XF: 0,40 mm
For compressors in heat pump design
(versions: .. -7), the thrust bearings are
installed in so-called tandem arrangement.
Hence, the method of measurement
described will not determine the axial gap
but the size of the face gap on the
discharge side of these compressors. Thus,
the increase of the face gap during
operation is identical with the growth of
the axial gap of the thrust bearings. In this
case, the maximum permissible value of the
axial gap is determined by the maximum
permissible value of the discharge-end face
gap.
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Maximum permissible value of the discharge-end

Compressors typs P, V, W and Y have
face gap for male and female rotors:
identical distance rings on male rotor and
Type P-7, R-7, S-7, T-7: 0,25 mm female rotor! Do not mistake spacer rings
during assembly!
Type V-7, W-7, Y-7: 0,30 mm
Type Z-7, XA-7: 0,35 mm e) For visual inspection of the bearing bushes:
Type XB-7, XC-7, XD-7: 0,40 mm Remove balance piston (19) and balance bush
(20) from male rotor using extractor T10, see
Type XE-7, XF-7: 0,45 mm Figure 15.
Repair Criteria
- Increase of the axial gap is a normal
phenomenon and will not adversely affect the
load-carrying capacity of the bearing
- When the permissible axial gap is exceeded, the
axial bearings are to be dismantled and replaced.
- The use of new bearings will restore the required
value of the discharge-end face gap as is inherent
to a newly designed compressor.

Completion of Measurement
- Remove measuring pin from female rotor shaft
and mount cover of the female rotor (48) Figure 12 mounted clamping device
- Tighten screws/ nuts on cover (45) of the shaft
seal
- Mount intermediate piece of coupling
- Mount coupling guard

7.2 Dismantling of Axial Bearings

a) Dismantle cover-plate (5/6) and plate springs
(407), intermediate rings (464/465).
b) Lock male rotor at its coupling end, using for
example a bar, to prevent it from rotating.
Or:
Dismantle front end coupling section and lock Figure 13 unscrew grooved nuts of rotor using tools T8/T15
rotor using clamping device T7, see Figure 12.
c) Compressor with bearing-fastening by grooved
nuts :
Bend back lock plates, unscrew grooved nuts
using tools T8/T15, see Figure 13.
Compressor with bearing-fastening by clamping
plates:
- Bend back beaded ends of lock plate (792) and
unscrew hexagon-head screws (798)
- Remove clamping plates (783, 784)
d) Remove thrust bearings from rotor shafts:
− Insert puller hooks of extractor T10/T16 into
both slots of the shafts, pass them below the Figure 14 Remove thrust bearings using tools T10/T16
inner bearing races and distance rings
(81)/(82) and rotate by 90 degrees.
− Fasten hooks to the transverse bar and pull off
bearings and spacer rings, see Figure 14.
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Figure 15 Remove balance piston using tool T10

7.3 Assembly Figure 16 Mounting axial bearing using tools T13/T17

a) If in dismantled condition, insert balance piston or

balance ring(19) and balance bushes (20) or
spacer ring (9) and push distance rings (81) and
(82) onto the shafts. If the piston (19) is difficult
to manipulate, fit it when assembling the thrust
bearings, see next item.
b) Mount thrust bearings using screw device T13, see
Figure 16.

Take care when mounting the individual

bearings!
Standard compressor/booster:
The wide face areas of the inner bearing
rings must be directed to one another
(see drawing index chapter 7).
Heat pump compressor:
The wide face areas of both the inner
bearing rings must be directed towards
the shaft end.
c) − Lock male rotor at its coupling end to prevent
it from rotating, (see para dismantling thrust
bearings, item b).
− Compressor with bearing-fastening by grooved
nuts:
- Fit new lock plates.
- Screw down grooved nuts, tighten them
using wrench T8/T15, see Fig 17.
− Compressor with bearing-fastening by
clamping plates:
- Fit clamping plates (783, 784) and use new
lock plates (792)
- Screw down hexagon-head screws (798) and
tighten them
- Torque:
chapter 11, table 2
− Lock grooved nuts and/or screws with lock
plates.
Figure 17 Tighten screw of axial bearing using tools T8/T15
d) − Axial gap measurement according to method
described in section 7.1.
Hint: When using new axial bearings
according to the design specified by the
compressor manufacturer (according to the
List of Parts), the original required value of the
face gap between the face end of the rotor
profile and the casing will be obtained again
similarly to newly designed compressors.
e) − Insert intermediate rings (464/465) into the
housing. For compressor type P, the interme
diate rings (464) are located in cover (5).
− If in dismantled condition, reinsert plate
springs (407) and O-rings (817) into
coverplates (5/6).
Caution: Take care about mounting positions
of plate springs and O-rings, see diagrams in
Drawing Index.
Reinsert lock rings (372) for types V, W, Y.
For compressor type P, press intermediate rings
(464) with O-rings into cover-plates
− Screw on covers.

AI_LT_05_gbr.doc - 12/14 03/2004 — rev.1

 OPERATION AND MAINTENANCE
Grasso
Refrigeration Division

8. BEARING BUSHES 9. PRESSURE TEST

We recommend a simple inspection of the conditon The screw compressor must be tested under pressure
of the bearing bushes whenever it becomes necessary using dry nitrogen (humidity content less than
to dismantle the slide ring seals or the thrust 300 mg/kg).
bearings. In this partially dismantled condition the
Seal all refrigerant and oil connections before starting
collar ends of the bearing bushes in the suction and
the pressure test.
discharge casings are visible. Measure the maximum
clearance between the shaft and the bushes with a Seal all refrigrant and oil connections before starting
feeler. the pressure test. Increase pressure slowly up to the
test pressure of 27 bar gauge pressure. Check for
Clearance limits:
leaks by applying a soap solution by brush to all
compressor types P, R, S, T 0,17 mm outside connections.
compressor types V, W, Y 0,20 mm The holding time of the test pressure is at least 30
compressor types Z, XA 0,22 mm minutes. Retain a logged record of the pressure test.
compressor types XB, XC, XD 0,32 mm
compressor types XE, XF 0,36 mm
10. VACUUM TEST
If the clearance exceeds the specified limit or if
Produce a vacuum with a vacuum pump. The screw
bearing metal forced out between the bearing gap
compressor must be evacuated to a vacuum of
and is visible, the compressor must be completely
35 torr. Measure and record the pressure level after
dismantled and the bearing bushes replaced.
4 hours. During this period the pressure may rise to
40 torr.

03/2004 — rev.1 AI_LT_05_gbr.doc - 13/14

 OPERATION AND MAINTENANCE
Grasso
Refrigeration Division

11. MAINTENANCE
The exact time for the activities given in the chart will
be determined in accordance with the special
operational conditions of the compressor. See into the
Maintenance Instruction for these exact times.

12. TIGHTENING TORQUES FOR SCREW AND NUTS

Part component/ subassembly Tightening Torques (Nm)

Type
P R, S, T V, W, Y Z, XA XB, XC, XD XE, XF
Screw Cover for shaft seal 60+20 150+20 150+20 150+20 150+20 250+20
Screw Cover for capacity control 60+20 150+20 150+20 150+20 150+20 250+20
Grooved Piston rod capacity control 100+20 100+20 100+20 100+20 100+20 100+20
nut
Clamping Position sensor 3+1 3+1 3+1 3+1 3+1 3+1
screw
Screw Cover plate (axial bearings) 150+20 150+20 150+20 150+20 150+20 250+20
Grooved Axial bearings male rotor 400+100 500+100 500+100 1000+100 1500+100 1600+100
nut
Grooved Axial bearings female rotor 400+100 400+100 500+100 600+100 1100+100 1200+100
nut

Clamping plate Male rotor 40+10 70+10 70+10 70+10 120+20 120+20
Screw
axial bearings Female rotor 40+10 40+10 70+10 70+10 120+20 120+20

AI_LT_05_gbr.doc - 14/14 03/2004 — rev.1

 LIST OF TOOLS
Grasso SCREW COMPRESSORS
Refrigeration Division LT SERIES, TYPE P

The following is a list of all special tools required for the maintenance and repair work described in this Manual.
The tools may be ordered either individually or as tool sets A, B or C.
Tool set A comprises tools for work on the shaft seal and for axial gap measurement.
In addition to set A, tool set B comprises tools for replacement of thrust bearings on the package.
Tool set C contains all tools given in the table.
Order numbers
Individual tools: acc. to table
Tool set A: 640109 (tools T5, T11, T20, T21, T24)
Tool set B: 640110 (tools T5, T8, T10, T11, T13, T17, T20, T21, T24)
Tool set C: 640092

Item No of parts Designation Order No

T1 1 Grooved nut wrench for piston rod 652600022
T3 1 Puller for capacity control device 652600072
T5 1 Assembly hook 652600064
T7 1 Clamping device for male rotor 652600071
T8 1 Grooved nut wrench for for rotors 652600070
T10 1 Extractor for axial bearings 652600068
T11 1 Dial gauge A60-10 652600002
T13 1 Mounting device for axial bearing male rotor 652600075
T17 1 Mounting device for axial bearing female rotor 652600126
T20 1 Barrel gauge for gate rotor axail play measurement 652600063
T21 1 Extension feeler for dial gauge 652600003
T22 1 Extractor for unloading piston 652600073
T23 1 Washer for piston rod grooved nut wrench 652600062
T24 1 Magnetic measuring stand 652600021

10.2003 AI_P_06_gbr.doc - 1/1

 LIST OF TOOLS
Grasso SCREW COMPRESSORS
Refrigeration Division LT SERIES, TYPES R, S, T

The following is a list of all special tools required for the maintenance and repair work described in this Manual.
The tools may be ordered either individually or as tool sets A, B or C.
Tool set A comprises tools for work on the shaft seal and for axial gap measurement.
In addition to set A, tool set B comprises tools for replacement of thrust bearings on the package.
Tool set C contains all tools given in the table.
Order numbers
Individual tools: acc. to table
Tool set A: 640111 (tools T5, T11, T20, T21, T24)
Tool set B: 640112 (tools T5, T10, T11, T13, T16, T17, T20, T21, T24)
Tool set C: 640093

Item No of parts Designation Order No

T1 1 Grooved nut wrench for piston rod 652600022
T3 1 Puller for capacity control device 652600066
T5 1 Assembly hook 652600064
T7 1 Clamping device for male rotor 652600065
T8 1 Grooved nut wrench for male rotor 652600056
T10 1 Extractor for axial bearing male rotor 652600048
T11 1 Dial gauge A 60-10 652600002
T13 1 Screw-in device for axial bearings male rotor 652600055
T15 1 Grooved nut wrench for female rotor 652600070
T16 1 Extractor for axial bearing female rotor 652600068
T17 1 Screw-in device for axial bearings female rotor 652600126
T20 1 Barrel gauge for gate rotor axail play measurement 652600063
T21 1 Extension feeler for dial gauge 652600003
T22 1 Extractor for unloading piston 652600060
T23 1 Washer for piston rod grooved nut wrench 652600062
T24 1 Magnetic measuring stand 652600021

10.2003 AI_RST_06_gbr.doc - 1/1

 LIST OF TOOLS
Grasso SCREW COMPRESSORS
Refrigeration Division LT SERIES, TYPES V, W, Y

The following is a list of all special tools required for the maintenance and repair work described in this Manual.
The tools may be ordered either individually or as tool sets A, B or C.
Tool set A comprises tools for work on the shaft seal and for axial gap measurement.
In addition to set A, tool set B comprises tools for replacement of thrust bearings on the package.
Tool set C contains all tools given in the table.
Order numbers
Individual tools: acc. to table
Tool set A: 640113 (tools T5, T11, T20, T21, T24)
Tool set B: 640114 (tools T5, T10, T11, T13, T20, T21, T24)
Tool set C: 640094

Item No of parts Designation Order No

T1 1 Grooved nut wrench for piston rod 652600022
T3 1 Puller for capacity control device 652600058
T5 1 Assembly hook 652600064
T7 1 Clamping device for male rotor 652600057
T8 1 Grooved nut wrench for rotors 652600056
T10 1 Extractor for axial bearing 652600048
T11 1 Dial gauge A 60-10 652600002
T13 1 Screw-in device for axial bearings 652600055
T20 1 Barrel gauge for gate rotor axail play measurement 652600063
T21 1 Extension feeler for dial gauge 652600003
T22 1 Extractor for unloading piston 652600060
T23 1 Washer for piston rod grooved nut wrench 652600062
T24 1 Magnetic measuring stand 652600021

10.2003 AI_VWY_06_gbr.doc - 1/1

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