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<strong>RC</strong>(U)6<br />

<strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong><br />

00.89.238 v004.00.02.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

All rights reserved. No part of this publication may be copied or published by means of printing,<br />

photocopying, microfilm or otherwise without prior written consent of Grasso. This restriction<br />

also applies to the corresponding drawings <strong>and</strong> diagrams.<br />

For extra information as to adjustments, maintenance <strong>and</strong> repair, contact the Technical<br />

Departmentof your supplier.<br />

This publication has been written with great care. However, Grasso cannot be held responsible,<br />

neither for any errors occurring in this publication nor for their consequences.<br />

<strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

1. Document Information<br />

• This ’lnstallation <strong>and</strong> <strong>Maintenance</strong> manual’ will<br />

be supplied together with the compressor.<br />

• This manual is suitable for both end-user <strong>and</strong><br />

contractor <strong>and</strong> will provide information on how<br />

to transport, install, start-up <strong>and</strong> maintain the<br />

compressor (package). It also contains a number<br />

of "Engineering Data Sheets" <strong>and</strong> the current<br />

"Parts List".<br />

2. Additional Documentation<br />

In addition to the above the following is available<br />

for this series compressor:<br />

• Engineering Data Sheets Book;<br />

This book contains all engineering data for this<br />

series compressor <strong>and</strong> the corresponding<br />

recommended accessories. It is meant to be a<br />

guide to the selection of these components.<br />

• Parts book;<br />

This book contains all current parts of the<br />

compressor <strong>and</strong> accessories together with the<br />

design changes applicable to earlier supplied<br />

components ("History").<br />

• Mounting <strong>and</strong> <strong>Installation</strong> Instructions for<br />

Accessories;<br />

If compressor is supplied with accessories, all the<br />

relevant mounting <strong>and</strong> installation instructions<br />

<strong>and</strong> spare parts information for those<br />

accessories will be supplied together with the<br />

compressor.<br />

PREFACE<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 V


<strong>Refrigeration</strong> Division<br />

Grasso<br />

PREFACE<br />

VI <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

This manual must be carefully read <strong>and</strong><br />

understood prior to installing the<br />

compressor (package)<br />

Installer-oriented information<br />

The compressor (package) is filled with nitrogen to<br />

prevent penetration of moisture. Therefore, keep<br />

the compressor closed until the compressor<br />

(package) is being installed. The compressor is not<br />

filled with oil. How to charge the compressor<br />

package with oil is discussed in Section A, §A2.3,<br />

"Initial oil charge".<br />

After the succesful initial run of the compressor<br />

(package) the warranty chart must be filled in <strong>and</strong><br />

returned to Grasso. A warranty chart is attached<br />

to each compressor.<br />

Safety<br />

This manual is written with great care, but the<br />

contractor/installer is held responsible to examine<br />

this information <strong>and</strong> to care of possible additional<br />

<strong>and</strong>/ or deviated safety measures.<br />

Safety instructions<br />

It is the task of the contractor/installer to inform<br />

<strong>and</strong> explain his client about the operation of the<br />

compressor (Package).<br />

Do respect all federal, state or local safety<br />

regulations/legislations during installing,<br />

connecting <strong>and</strong> operating this compressor<br />

(package).<br />

Typographic signs:<br />

Grasso<br />

Indicates a caution, note or procedure to<br />

which you should pay special attention.<br />

Read it carefully!<br />

Values Between [ ]<br />

Values between [ ] are read-outs of Grasso’s<br />

electronic control device Monitron.<br />

GENERAL SAFETY INSTRUCTIONS<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 VII


<strong>Refrigeration</strong> Division<br />

Grasso<br />

GENERAL SAFETY INSTRUCTIONS<br />

VIII <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

General information<br />

Grasso<br />

Operating limits <strong>and</strong> switch settings<br />

(for values between [ ] brackets refer to the Instruction <strong>Manual</strong> of the Monitron)<br />

Timers Time interval refer to chapter:<br />

Switching frequency max. 6 starts per hour A2.10.1<br />

Time interval between stopping <strong>and</strong> re-starting min. 2 minutes A2.10.2<br />

Time interval between starting <strong>and</strong> re-starting min. 10 minutes A2.10.2<br />

Time interval between unloading <strong>and</strong> loading min. 3 minutes B1.2<br />

Oil system limits Value<br />

Oil level 25 - 75% crankcase sight glass B4<br />

Min. oil temperature warmer than surroundings <strong>and</strong> ≥ 20 °C (68 °F)<br />

for NH3 <strong>and</strong> ≥ 30 °C (86 °F) for halocarbons<br />

A2.8<br />

Max. oil temperature [max. Toil] see oil selection table in the appendix section B1.2<br />

Lubricating oil pressure difference [min dOil] between 1.5 <strong>and</strong> 2.5 bar<br />

Setting approx. 1.8 bar<br />

A2.5.2<br />

Temperature <strong>and</strong> pressure limits Value<br />

GENERAL INFORMATION AND SURVEY<br />

OF SETTINGS AND LIMITS<br />

Max. discharge temperature [max Tdis] 155 °C (311 °F) B1.2<br />

Pdischarge - Psuction < 24.0 bar<br />

Superheat [dTo] ≥ 5 K<br />

Cooling water inlet temperature of cylinder<br />

head cooling system<br />

≥Tcond + 10 K<br />

Pressure safety limits A2.5.2<br />

Subject Feature refer to chapter:<br />

Oil viscosity ≥ 10 cSt during operation at location of bearings<br />

Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end A2.6<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 IX


<strong>Refrigeration</strong> Division<br />

Grasso<br />

GENERAL INFORMATION AND SURVEY<br />

OF SETTINGS AND LIMITS<br />

X <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

SUBJECT Page no.:<br />

PREFACE ............................................................................................................................... V<br />

GENERAL SAFETY INSTRUCTIONS ................................................................................................. VII<br />

GENERAL INFORMATION AND SURVEY OF SETTINGS AND LIMITS .......................................... IX<br />

SECTION A: INSTALLATION AND PREPARATIONS FOR USE ....................................................... A1.1<br />

A1 INSTALLATION .......................................................................................................................... A1.1<br />

A1.1 Moving instructions <strong>and</strong> storage ................................................................................. A1.1<br />

A1.1.1 Hoisting <strong>and</strong> moving instructions ...................................................................... A1.1<br />

A1.1.2 Storage ............................................................................................................... A1.2<br />

A1.2 Required free space ....................................................................................................... A1.2<br />

A1.3 Foundation requirements .............................................................................................. A1.2<br />

A1.3.1 Concrete structure ............................................................................................. A1.3<br />

A1.3.2 Anchoring ........................................................................................................... A1.4<br />

A1.4 Concrete block mounting instructions .......................................................................... A1.4<br />

A1.4.1 Mounting bare compressor on a concrete block ............................................. A1.4<br />

A1.4.2 Mounting the base frame on a concrete block ................................................ A1.4<br />

A1.5 Connecting to refrigerating system pipework ............................................................. A1.5<br />

A1.6 Connecting the power supply ....................................................................................... A1.6<br />

A1.7 Earthing connections ..................................................................................................... A1.6<br />

A1.8 Separately delivered components.................................................................................. A1.6<br />

A2 PREPARATIONS FOR USE ......................................................................................................... A2.1<br />

A2.1 Leak test of compressor <strong>and</strong> system ............................................................................. A2.1<br />

A2.2 Evacuation/drying the refrigerating system ................................................................. A2.1<br />

A2.3 Initial oil charge .............................................................................................................. A2.1<br />

A2.4 Initial refrigerant charge ................................................................................................ A2.2<br />

A2.5 Adjustment of instruments <strong>and</strong> safety devices ............................................................ A2.2<br />

A2.5.1 Monitron ............................................................................................................. A2.2<br />

A2.5.2 Pressure safety switches ..................................................................................... A2.2<br />

A2.5.3 Re-adjustment of oil pressure regulator ........................................................... A2.3<br />

A2.6 Checking direction of rotation of motor shaft ............................................................. A2.4<br />

A2.7 Installing the (drive) guards .......................................................................................... A2.4<br />

A2.8 Initial oil warm-up .......................................................................................................... A2.4<br />

A2.9 Initial start-up ................................................................................................................. A2.4<br />

A2.9.1 Limitations part load operation <strong>and</strong> start-up.................................................... A2.4<br />

A2.9.2 Pre-start check list .............................................................................................. A2.4<br />

A2.10 Starting <strong>and</strong> stopping procedures ................................................................................ A2.4<br />

A2.10.1 Starting for the very first time ......................................................................... A2.4<br />

A2.10.2 Restart .............................................................................................................. A2.5<br />

A2.10.3 Starting after a seasonal (1 till 6 months) st<strong>and</strong>still or maintenance operations A2.5<br />

A2.10.4 Starting after a long st<strong>and</strong>still periode of time (more than 6 months) ........ A2.5<br />

A2.10.5 Stopping the compressor ................................................................................. A2.5<br />

SECTION B: INSPECTION, MAINTENANCE AND TROUBLE SHOOTING: .Table of contents ....... B.I<br />

SECTION C: APPENDIX : .......Table of contents ...... C.I<br />

SECTION D: STANDARD ILLUSTRATED SPARE PARTS LIST: ....................Table of contents ....... D.I<br />

For oil selection table refer to "Engineering Data"<br />

TABLE OF CONTENTS<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 III


<strong>Refrigeration</strong> Division<br />

Grasso<br />

TABLE OF CONTENTS<br />

IV <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

The compressor is not charged with oil,<br />

therefore, DO NOT start the compressor<br />

before it has been installed <strong>and</strong> prepared<br />

according to the sections A1 <strong>and</strong> A2.<br />

A1 INSTALLATION<br />

Grasso<br />

This section contains instructions for the proper<br />

installation of a Grasso compressor (package).<br />

Before the compressor (package) is ready for the<br />

initial start up, the installation instructions in the<br />

following paragraphs must be followed:<br />

1. The Compressor (Package) should be levelled <strong>and</strong><br />

securely anchored to the foundation (see §A1.4).<br />

2. All piping should be completed as in §A1.5.<br />

3. The system <strong>and</strong> the compressor are to be pressure<br />

tested for leaks (see §A2.1).<br />

4. The system should be evacuated to remove air <strong>and</strong><br />

moisture (see §A2.2).<br />

5. The electric wiring should be completed as per<br />

wiring diagrams. Do not energize the main power<br />

control cabinet until oil is added <strong>and</strong> the direction<br />

of rotation has been checked.<br />

6. The compressor is to be filled with the correct type<br />

<strong>and</strong> amount of lubricating oil (see §A2.3).<br />

7. The drive coupling or V-belt drive system should be<br />

installed.<br />

8. The system should be charged with the correct<br />

amount of refrigerant.<br />

9. The oil should be warmed up above minimum start<br />

up oil temperature (see "Engineering Data").<br />

10. The control cabinet or Monitron CR should be<br />

energized to check the package control<br />

(see §A2.5).<br />

A: INSTALLATION AND PREPARATION FOR USE<br />

A1.1 Moving instructions <strong>and</strong> storage<br />

For loose component or compressor package<br />

weights, refer either to the relevant component<br />

type plate or package lay-out or to the suppliers<br />

document. For bare compressor weights, see<br />

"Engineering Data".<br />

Every precaution must be taken while<br />

moving the package to its final location.<br />

Pushing, pulling or climbing on any<br />

package component or piping, can easily<br />

create damage.<br />

A1.1.1 Hoisting <strong>and</strong> moving instructions<br />

Fig. A1.1 Hoisting a compressor-package<br />

Packaged base frame:<br />

The only places that can be used for safe hoisting<br />

of the package are the four hoisting eyes on the<br />

steel base frame as shown in the above figure.<br />

Prior to hoisting a compressor package with a<br />

V-belt drive arrangement, the factory mounted<br />

drive guard has to be removed. Attach spreader<br />

bars to the slings so as to prevent damage to<br />

piping <strong>and</strong> components.<br />

DO NOT use the component hoisting<br />

eyes to move the package!<br />

These hoisting eyes are intended for<br />

lifting loose components only <strong>and</strong> not for<br />

the entire package!<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 A1.1


<strong>Refrigeration</strong> Division<br />

Grasso<br />

Bare compressor or loose components:<br />

Determine the dead weight of the particular<br />

component (see "Engineering<br />

Data"), prior to moving a bare compressor<br />

or loose component. Use the hoisting<br />

eyes only to lift so, DO NOT sling<br />

from other compressor parts (see figure<br />

A1.1A).<br />

Fig. A1.1A Hoisting angle bare shaft compressor<br />

Moving by fork-lift truck<br />

The bare compressor or package can be<br />

transported with a fork-lift truck with the forks<br />

spread as much as possible between the skids. To<br />

simplify moving, the 2 wooden transport beams<br />

must still be mounted underneath the base frame<br />

<strong>and</strong> stored in this way, untill the package is<br />

positioned above its approximate location.<br />

A: INSTALLATION AND PREPARATION FOR USE<br />

A1.1.2 Storage<br />

The compressor (package) is filled with dry<br />

nitrogen. Keep the system closed until the<br />

package is<br />

installed. If the compressor (package) is stored, it<br />

should be kept at all times in a dry location to<br />

prevent corrosion damage. If the compressor<br />

(package) is to be stored for a prolonged period<br />

of time, it should be checked weekly to ensure<br />

that the holding charge of dry nitrogen remains<br />

above atmospheric pressure.<br />

A1.2 Required free space<br />

For easy operating, servicing <strong>and</strong> maintenance<br />

access, the compressor (package) should be at<br />

least installed with sufficient free space around it.<br />

A1.3 Foundation requirements<br />

This paragraph covers measures to be taken for a<br />

compressor (package) on a concrete floor.<br />

Two foundation arrangements are described:<br />

• Compressor package with steel base frame<br />

mounted on a concrete block.<br />

• Bare compressor direct mounted on a concrete<br />

block via grouted machined anchors (see<br />

"Engineering Data"). The mounting surfaces of<br />

these machined anchors must be level without<br />

any deviation <strong>and</strong> projecting at least 10 mm<br />

above the concrete base.<br />

COMPRESSOR AND COMPRESSOR<br />

PACKAGE TO BE MOUNTED ON A<br />

CONCRETE BLOCK<br />

On request, Grasso can calculate the<br />

exact dimensions of the concrete block,<br />

based on the compressor size <strong>and</strong><br />

operating conditions.<br />

A1.2 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

A1.3.1 Concrete structure<br />

The concrete block for compressor <strong>and</strong> motor or<br />

compressor package should have a profile as<br />

illustrated in fig. A1.2 <strong>and</strong> made according to the<br />

following recommendations:<br />

Fig. A1.2<br />

Grasso<br />

1 Corkboard<br />

2 Concrete base<br />

3 Basement floor<br />

• The concrete block should be set on firm<br />

footings or on a floor capable of carrying the<br />

weight of the concrete block <strong>and</strong> capable to<br />

absorb the free forces <strong>and</strong> gas forces of the<br />

compressor during operation. The ground under<br />

the concrete block should be horizontal <strong>and</strong> flat<br />

(refer to fig. A1.2).<br />

• The top surface of the block should be level <strong>and</strong><br />

even.<br />

• There should be sufficient free space around the<br />

block to install corkboard (or similar).<br />

• The block should be provided with anchor bolt<br />

recesses or holes (fig A1.3.) according to the<br />

anchor bolt spacing as per package lay out<br />

drawing.<br />

A: INSTALLATION AND PREPARATION FOR USE<br />

A Chemical anchor<br />

B Grouted anchor, grounded to reinforcing steel<br />

Fig. A1.3<br />

It is recommended to consult a concrete specialist/<br />

constructor for the following items:<br />

• The compounding of the concrete with/without<br />

reinforcement.<br />

• The exact grouting depth (dependent on the<br />

soil conditions).<br />

• Installing foundation onto an existing floor, with<br />

sealing corkboard or vibration isolators.<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 A1.3


<strong>Refrigeration</strong> Division<br />

A1.3.2 Anchoring<br />

Grasso<br />

After the concrete block has cured the anchors<br />

should be installed as shown in figs. A1.3 <strong>and</strong>/or<br />

A1.4 <strong>and</strong> in case of a package in accordance with<br />

the package lay out drawing. Templates should be<br />

made to locate the anchor bolts or chemical<br />

anchors to match the holes in the bottom flange<br />

of the base frame.<br />

Grout the mortar as given by the supplier<br />

instructions. Install chemical anchors as illustrated<br />

in figure A1.4 <strong>and</strong> according the instructions of<br />

the anchor supplier.<br />

A Drilled chemical anchor (thread size M16)<br />

B Grouted anchor recesses (thread size M16)<br />

Fig. A1.4 Anchoring details<br />

A1.4 Concrete block mounting instructions<br />

A1.4.1 Mounting bare compressor on a concrete<br />

block<br />

If no base frame is applied the compressor <strong>and</strong><br />

motor should be installed as discussed in §A1.3<br />

<strong>and</strong> "Engineering Data".<br />

A: INSTALLATION AND PREPARATION FOR USE<br />

1 Installed chemical anchor before placing the base frame<br />

2 Installing chemical anchor after placing the base frame (base<br />

frame cannot removed easily)<br />

3 Drilling angle<br />

A1.4.2 Mounting the base frame on a concrete<br />

block<br />

General<br />

After the space between base frame <strong>and</strong> concrete<br />

base is filled-up with a filling grout, the package<br />

base frame must be secured tightly to the<br />

foundation block or floor (refer to fig. A1.3).<br />

A1.4 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

Fig. A1.5 Grouting details<br />

• Levelling the base frame<br />

After the anchor filling mortar is completely cured<br />

the frame should be levelled with a space<br />

between block <strong>and</strong> lower frame flange of 3 - 5<br />

mm. This space largely depends on the sort of<br />

grout or mortar used. Determine this space as<br />

given in the instructions of the grout or mortar<br />

supplier. This space is necessary for levelling using<br />

the base frame adjusting bolts with metal washers<br />

(supplied separately). The base frame should be<br />

levelled on each frame side. Adjust the frame on<br />

each adjusting place until all frame sides are<br />

horizontal.<br />

• Finishing with a self-levelling grout (See figure A1.5)<br />

After levelling is completed the adjusting bolt<br />

ends must be greased to avoid bonding to the<br />

self-levelling grout. The space between concrete<br />

block <strong>and</strong> frame must be completely filled with<br />

the self-levelling grout to ensure that the<br />

complete bottom surface of the base frame will<br />

A: INSTALLATION AND PREPARATION FOR USE<br />

1 Self-levelling grout<br />

2 Adjusting bolt (4x)<br />

3 Washer<br />

4 Temporary barrier strip around <strong>and</strong> inside frame<br />

5 Complete cured concrete block<br />

6 Grout layer<br />

be supported. Therefore, it is not allowed to use<br />

shims between concrete base <strong>and</strong> base frame.<br />

Grouting must be carried out in accordance with<br />

the instructions provided by the grouting supplier.<br />

After complete de-aeration of the grouted layer,<br />

secure the base frame by tightening the anchor<br />

bolt nuts <strong>and</strong> remove all adjusting bolts. At this<br />

stage the drive system can be installed. These<br />

(accessories) installation instructions can be found<br />

in the order manual.<br />

A1.5 Connecting to refrigerating system pipework<br />

After the compressor (package) has been levelled<br />

<strong>and</strong> secured to the foundation, the system piping<br />

may be connected. The suction line(s) <strong>and</strong><br />

discharge line(s) should be installed <strong>and</strong> supported<br />

such that there is no load exerted on the<br />

compressor. The size <strong>and</strong> location of the suction<br />

<strong>and</strong> discharge connections, can be found in the<br />

"Engineering Data" (bare compressor) <strong>and</strong> in case<br />

of a package, the package lay out drawing.<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 A1.5


<strong>Refrigeration</strong> Division<br />

Grasso<br />

If an oil rectifier system is applied in the refrigeration<br />

system, the oil return line<br />

must be connected to the oil return connection.<br />

Never connect the oil rectifier return line to<br />

the suction line or to the suction gas filter.<br />

DO NOT ground through the compressor<br />

when arc welding<br />

Suspension of system pipework<br />

To eliminate vibration transmission to the system<br />

piping, the following is recommended:<br />

• Install all piping free of tension.<br />

• Secure the piping by clips or suspenders in two<br />

directions.<br />

• Install (stop) valves, piping <strong>and</strong> accessories such,<br />

that there is no load exerted on the compressor.<br />

A1.6 Connecting the power supply<br />

Before leaving the factory the compressor<br />

package is completely wired*. The connection to<br />

be made by the installer is between main power<br />

source <strong>and</strong> the Monitron CR (if ordered).<br />

Information about further electrical connections<br />

to be made (e.g. crankcase heater, drive motor<br />

starting equipment, thermal protection of drive<br />

motor, automatic start/ stop, motor current<br />

transducer <strong>and</strong> other external electrical devices)<br />

can be found in the order manual.<br />

* If the st<strong>and</strong>ard recommended Monitron CR is applied.<br />

A: INSTALLATION AND PREPARATION FOR USE<br />

A1.7 Earthing connections<br />

Grasso compressors <strong>and</strong> packages are equipped<br />

with litz-wires <strong>and</strong> earth connecting points.<br />

To avoid leakage current flowing through the<br />

components, disconnect all litz-wires when arcwelding.<br />

After all installation functions are<br />

completed, reconnect the litz-wires <strong>and</strong> ground<br />

the package to earth.<br />

A1.8 Separately delivered components<br />

Mount the separately delivered set-components<br />

e.g. oil charge <strong>and</strong> drain valve, according to the<br />

instruction enclosed in each individual set.<br />

A1.6 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

A2 PREPARATIONS FOR USE<br />

After the Compressor (Package) has been installed<br />

(excl. final connection of drive device), the<br />

following actions should be followed in the order<br />

given:<br />

A2.1 Leak test of compressor <strong>and</strong> system<br />

The compressor (package) has been pressure<br />

tested prior to leaving the factory. In case an<br />

additional leak test is required, this test is should<br />

be carried out with dry nitrogen under pressure<br />

up to a max. of 10 bar(a).<br />

Do NOT add oil to the compressor prior<br />

to pressure testing.<br />

A system leak test should be carried out over 24<br />

hours to ensure that the system is tightly sealed.<br />

Record during the pressure test, the pressure,<br />

ambient temperature <strong>and</strong> outside temperature.<br />

During the initial 6 hours a pressure drop of 2% is<br />

permissable. With respect to temperature<br />

variations, no further pressure loss should be<br />

detected in the remaining 18 hours.<br />

If the test pressure has not decreased by more<br />

than 5% the system can be considered leak free.<br />

A2.2 Evacuation/drying the refrigerating system<br />

For evacuation of compressor only, refer to §B5.<br />

Procedure to evacuate <strong>and</strong> to dry a system:<br />

a) STATUS: System is filled with nitrogen (refer to<br />

§A2.1) <strong>and</strong> no oil into the system (oil prevents any<br />

trapped moisture from boiling off).<br />

b) Verify that all valves in that part of the system to be<br />

evacuated are opened (refer also to the plant<br />

manual).<br />

c) Connect vacuum pump to the evacuation/purging<br />

valve(s) of the compressor (for location of these<br />

valves refer to the "Engineering Data" or to a<br />

connection as mentioned in the plant manual <strong>and</strong><br />

evacuate the system to approx.<br />

5 mm Hg (=6.6 mBar).<br />

A: INSTALLATION AND PREPARATIONS FOR USE<br />

d) Break vacuum by charging dry nitrogen into the<br />

system.<br />

e) Repeat step ’c’.<br />

f) Wait approx. 24 hours.<br />

g) If pressure has been increased (system still contains<br />

moisture), repeat steps ’d’, ’e’ <strong>and</strong> ’f’, otherwise,<br />

continue with the "Initial oil charge" procedure<br />

§A2.3.<br />

A2.3 Initial oil charge<br />

Used or filtered oil should NEVER BE<br />

added to a compressor under any<br />

circumstance.<br />

Use only new oil to be selected from the<br />

oil table (see "Engineering Data").<br />

a) STATUS: System is dried <strong>and</strong> still evacuated (refer to<br />

§A2.2).<br />

b) Close suction <strong>and</strong> discharge stop valves of<br />

compressor <strong>and</strong> oil return line of oil separator<br />

(if present).<br />

c) Fill the compressor crankcase with oil (for oil<br />

quantity see table overleaf) via the oil charge/ drain<br />

valve (for location of this valve refer to the<br />

"Engineering Data").<br />

d) Open evacuation/purging valve(s) of the<br />

compressor (for location of these valves refer to the<br />

"Engineering Data") to bring the compressor to<br />

atmospheric pressure.<br />

e) Fill the following components with oil as given in<br />

the table on the next page with/without prelubrication<br />

valves (explained hereafter) :<br />

- Shaft seal housing via the oil filling opening.<br />

- Oil pump housing via the oil filling opening.<br />

- Oil suction <strong>and</strong> discharge filter housings via the oil<br />

filling openings.<br />

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<strong>Refrigeration</strong> Division<br />

A2.4 Initial refrigerant charge<br />

Refrigerant charging should be done in<br />

accordance to the plant manual by qualified<br />

refrigeration engineers.<br />

Oil charging via the suction line of the<br />

compressor is not allowed.<br />

A2.5 Adjustment of instruments <strong>and</strong> safety<br />

devices<br />

A2.5.1 Monitron<br />

Grasso<br />

For adjustments see table overleaf.<br />

A2.5.2 Pressure safety switches<br />

Refer to the table overleaf. Setting procedures are<br />

described in the Safety Switch supplier instructions.<br />

A: INSTALLATION AND PREPARATIONS FOR USE<br />

QUANTITY OF OIL TO BE FILLED (in dm3)<br />

Compressor series <strong>RC</strong>6 Shaft seal housing Oil filters Oil pump Crankcase<br />

<strong>RC</strong>46<br />

11<br />

<strong>RC</strong>66 ± 0.5 ± 1.0 ± 0.5<br />

12<br />

<strong>RC</strong>86 13<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

Settings of compulsory pressure safeties<br />

Read-out<br />

Monitron 1 )<br />

Description Min. value Max. value (pre)-Setting<br />

Psuc Suction pressure 0.3 bar (4.4 psia) NH3 6.2 bar (90 Psia) 5 °C (9 °F) below design<br />

R22 6.8 bar (99 Psia) evaporating temperature<br />

R134a 6.2 bar (90 Psia)<br />

R404A 6.0 bar (87 Psia)<br />

R507 5.8 bar (84 Psia)<br />

Pdis Discharge pressure > Psuc 26.0 bar (377 Psia) 5 °C (9 °F) above design<br />

condensing temperature<br />

Pdis-Psuc > 0 bar 24.0 bar (348 Psia) < 24.0 bar (348 Psia)<br />

dPoil Lubrication oil 1.5 bar (22 Psia) 2.5 bar (36 Psia) The oil pressure<br />

pressure difference<br />

regulator is adjusted at<br />

the works, but it may<br />

occur that this setting<br />

should be corrected<br />

during the initial run<br />

(see A2.5.3)<br />

1 )In case of Monitron the values are measured via pressure transducers, otherwise protection via switches is compulsory.<br />

A2.5.3 Re-adjustment of oil pressure regulator (refer<br />

to fig. A2.1)<br />

Re-adjustment procedure:<br />

a) Run the compressor for 15 minutes until the<br />

crankcase oil is at its stable operating temperature [Toil].<br />

b) Determine the oil pressure difference (difference<br />

between the pressure gauges of the oil <strong>and</strong> suction<br />

or [dOil]).<br />

c) After approx. 15 minutes of operatinf <strong>and</strong> an oil<br />

temperature of 50 °C, the oil pressure difference<br />

should be approx. 2.0-2.5 bar.<br />

During these first minutes the pressure should be<br />

slightly higher.<br />

Fig. A2.1 Oil pressure regulator<br />

A: INSTALLATION AND PREPARATIONS FOR USE<br />

d) Remove the cap nut (3) with alu ring (2), of the oil<br />

pressure regulator if the pressure needs to be<br />

re-adjusted.<br />

e) Turn the slotted pin (1) with a screwdriver clockwise<br />

or counter clockwise for a higher or lower oil<br />

pressure respectively, until the required oil pressure<br />

differences has been achieved.<br />

f) Replace the cap nut (3) with alu ring (2).<br />

1 slotted pin<br />

2 alu ring<br />

3 cap nut<br />

4 return from oil separator<br />

or oil rectifier<br />

5 oil pressure regulator<br />

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<strong>Refrigeration</strong> Division<br />

A2.6 Checking direction of rotation of motor shaft<br />

Prior to installing the intermediate coupling element<br />

or V-belts, the direction of rotation of the motor<br />

shaft must be checked either by bumping the<br />

electrical drive motor or by measuring the rotation<br />

of the field (direction of rotation normally counter<br />

clockwise when facing compressor shaft end).<br />

A2.7 Installing the (drive) guards (if present)<br />

Only after the compressor is ready for the initial<br />

startup! Refer to the drive guard installing<br />

procedures included in the order documentation.<br />

A2.8 Initial oil warm up<br />

Prior to the initial start-up (refer to §A2.9), the<br />

crankcase heater (if present) must be energized. For<br />

the min. oil temperature (min. [Toil]) refer to page VII.<br />

A2.9 Initial start-up<br />

Grasso<br />

A2.9.1 Limitations of part load operation <strong>and</strong><br />

start-up<br />

The capacity control serves to adapt the compressor<br />

capacity at any moment as closely as possible to the<br />

refrigerating capacity. In order to adapt the capacity,<br />

a number of cylinders can be put in or out of action<br />

either individually or collectively.<br />

Due to start-up limitations <strong>and</strong> to<br />

limitations of part load operation it may<br />

be that not all available part load steps<br />

are allowed under certain conditions.<br />

Use of incorrect control steps can<br />

damage compressor <strong>and</strong>/or components.<br />

In the case of a Monitron Controller, all these<br />

limitations will be checked automatically.<br />

For a detailed description about these start-up<br />

<strong>and</strong> part load limitations refer to the "Engineering<br />

Data".<br />

A2.9.2 Pre-start check list<br />

The following Paragraph covers only the initial<br />

start of the compressor <strong>and</strong> not the complete<br />

refrigeration plant.<br />

A: INSTALLATION AND PREPARATIONS FOR USE<br />

Be sure that all necessary system valves are open<br />

<strong>and</strong> that the refrigeration system is ready for start<br />

up. Use the following check to guarantee that no<br />

items of importance regarding the compressor<br />

(package) have been overlooked.<br />

a) System is charged with refrigerant.<br />

b) Monitron (if present) is properly installed (refer to<br />

the Monitron Instruction <strong>Manual</strong>).<br />

c) Settings of safety limit switches are adjusted properly.<br />

d) Direction of rotation of compressor crankshaft is<br />

correct.<br />

e) Oil level established in sight glass.<br />

f) Stop valves to the pressure gauges are open (if<br />

present).<br />

g) Suction stop valve is closed (in case the evaporating<br />

temperature is much higher than the design<br />

evaporating temperature) <strong>and</strong> the discharge stop<br />

valve is open.<br />

h) Stop valve in the oil return line of the oil separator<br />

(if present) is closed.<br />

When all items a) through h) are verified, the<br />

compressor (package) is ready for the start-up.<br />

A2.10 Starting <strong>and</strong> stopping procedures<br />

When starting the compressor a distinction should<br />

be made between:<br />

A2.10.1 Starting for the very first time (between<br />

brackets [ ] are Monitron units)<br />

a) Notice §A2.9.2 "Pre-start check list", consult also the<br />

plant manual <strong>and</strong> verify the following items:<br />

- Check the oil temperature [Toil] (refer to the<br />

"Engineering Data").<br />

- Check crankcase oil level (refer to §B4.1).<br />

b) Start the compressor <strong>and</strong> check whether the oil<br />

pressure [Poil] increases.<br />

Maximum 6 starts per hour <strong>and</strong> at least 2<br />

minutes between stopping <strong>and</strong> starting<br />

<strong>and</strong> at least 10 minutes between starting<br />

<strong>and</strong> re-starting<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

c) Slowly open suction stop valve <strong>and</strong> watch suction<br />

pressure [Psuc], which may not exceed the max.<br />

value as given for each refrigerant in §A2.5.2.<br />

Refrigerant liquid hammer, will damage<br />

the compressor;<br />

Superheat is always necessary! [dTo]≥5 K<br />

d) More cylinders will be energized.<br />

Watch maximum allowable motor current<br />

[Imot] (refer to motor type plate).<br />

e) Adjust pressure gauge stop valves, in order to avoid<br />

vibration of the pointers (if present).<br />

f) Open the stop valve in the oil return line from the<br />

oil separator (if present).<br />

Retighten the coupling bolts or check or<br />

correct the tension of the V-belts <strong>and</strong><br />

retighten the foundation bolts (with<br />

due respect to the torque settings given<br />

by the supplier of the fasteners!) after<br />

50 hours of operation.<br />

A2.10.2 Restart (not within 2 minutes after a<br />

stop, respectively starting after a short<br />

st<strong>and</strong>still period of time [les than 1<br />

month]). If Monitron Controlled, refer to<br />

the Monitron Instruction manual)<br />

• Proceed to the starting procedure of §A2.10.1<br />

point a), b) <strong>and</strong> d).<br />

A2.10.3 Starting after a seasonal st<strong>and</strong>still (1 till<br />

6 months) or maintenance operations<br />

• Check settings of control <strong>and</strong> safety equipment<br />

(refer to §A2.5).<br />

• Proceed to the complete starting procedure of<br />

§A2.10.1, items a) through f).<br />

A: INSTALLATION AND PREPARATIONS FOR USE<br />

A2.10.4 Starting after a long st<strong>and</strong>still period of<br />

time (more than 6 months)<br />

Consult your supplier. Monitron "st<strong>and</strong>by" status<br />

(ready to operate during this long period of time)<br />

is not allowed! It is recommended to<br />

proceed with the "Initial start-up" procedure of<br />

§A2.10.1.<br />

A2.10.5 Stopping the compressor<br />

The compressor can be stopped at any moment,<br />

however, consult the supplier if further actions are<br />

required.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

A: INSTALLATION AND PREPARATIONS FOR USE<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

TABLE OF CONTENTS<br />

SUBJECT Page no.:<br />

SECTION B: INSPECTION, MAINTENANCE AND TROUBLE SHOOTING ....................................... B1.1<br />

B1 INSPECTION ................................................................................................................................ B1.1<br />

B1.1 Periodical inspection ......................................................................................................... B1.1<br />

B1.2 Survey of periodical inspections ....................................................................................... B1.1<br />

B2 MAINTENANCE .......................................................................................................................... B1.2<br />

B2.1 Post start-up maintenance ............................................................................................... B1.2<br />

B2.2 First maintenance ............................................................................................................. B1.3<br />

B3 STEPS FOR LONGER SHUT-DOWN PERIODS (more than 6 months) ....................................... B1.4<br />

B4 LUBRICATION DATA .................................................................................................................. B1.4<br />

B4.1 Topping up oil with compressor operating .................................................................... B1.4<br />

B5 EVACUATION OF THE COMPRESSOR ....................................................................................... B1.5<br />

B6 DRAINING AND CHANGE OF OIL ............................................................................................. B1.5<br />

B7 CLEANING OF OIL FILTERS ........................................................................................................ B1.5<br />

B8 CLEANING OF SUCTION GAS FILTER(S) .................................................................................... B1.6<br />

B9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES .. B1.6<br />

B10 COMPRESSOR PURGING ............................................................................................................ B1.7<br />

B11 TROUBLE SHOOTING TABLE ..................................................................................................... B1.7<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

TABLE OF CONTENTS<br />

B.II <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

B1 INSPECTION<br />

B1.1 Periodical inspection<br />

These inspections should be made during the normal<br />

shut-down periods as much as possible, so the<br />

compressor is always ready to operate when required. If,<br />

at that time, the number of running hours slightly differs<br />

from the scheduled period below, the inspection should<br />

nevertheless be carried out.<br />

B1.2 Survey of periodical inspections ("check list")<br />

CHECK POINTS 1) FREQUENCY REMARKS<br />

Oil level in crankcase<br />

Colour of the oil<br />

Grasso<br />

Lubricating oil pressure difference<br />

[dOil]<br />

daily<br />

•<br />

•<br />

weekly<br />

monthly<br />

•<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

In this way it will not be necessary to stop the<br />

compressor at inconvenient times.<br />

The frequency of inspections is dependent on the type<br />

of installation <strong>and</strong> operating conditions. In the case of<br />

automatically controlled plants, the periodical inspection<br />

are particularly important. The table below sums up all<br />

the points on the compressor that have to be inspected<br />

or maintained along with inspection <strong>and</strong> maintenance<br />

frequencies.<br />

Between 25% <strong>and</strong> 75% height of the sight glass. For topping up oil, refer to<br />

§B4.1.<br />

The oil should be transparently clear. A disappearing white colour points to<br />

dissolved refrigerant. Refer to § B2.2 for oil analysis frequency.<br />

The indication of the oil pressure gauge should be 1.5 - 2.5 bar higher than<br />

the value shown by the suction pressure gauge.<br />

Oil temperature max. [Toil] • Refer to the "Engineering Data".<br />

Oil leakage of shaft seal max. • In case of more than 1 cc/hr contact supplier.<br />

Suction pressure [Psuc] • Check against design conditions. Refer to plant manual.<br />

Discharge pressure [Pdis]<br />

•<br />

Refer to plant manual. For the max. allowable discharge pressure refer to the<br />

technical data of compressor.<br />

Suction superheat [dTo]<br />

Intermediate superheat [dTm] •<br />

� 5 K<br />

Discharge temperature max. • 155 °C (311 °F)<br />

Cooling water temperature (if<br />

present) min.<br />

•<br />

Actual condensing temperature + 10 K.<br />

Oil temperature min. [Toil]<br />

•<br />

During compressor st<strong>and</strong>still the lower part of the crankcase must remain<br />

warmer than the surroundings: � 20 °C (NH3) <strong>and</strong>�30 °C (halocarbons).<br />

Condition of V-belts<br />

Check belts for:<br />

1) Wear (fraying, cuts etc.) <strong>and</strong> ensure that they do not touch the groove<br />

•<br />

bottom.<br />

2) Tension. Too low a tension gives rise to excessive flapping or oscillation in<br />

operation. For correct tension consult the instructions given by the V-belt<br />

supplier.<br />

Adjustment <strong>and</strong> operation of<br />

pressure safety switches<br />

•<br />

Refer to §A2.5 <strong>and</strong> to instructions of switch manufacturer.<br />

Capacity control<br />

•<br />

The time lag between the unloading <strong>and</strong> loading of one cylinder or cylinder<br />

group should generally be at least 3 - 5 minutes.<br />

Switching frequency of the compressor<br />

•<br />

The time interval between stopping <strong>and</strong> starting should be at least 2 minutes<br />

<strong>and</strong> between starting <strong>and</strong> restarting 10 minutes (see §A2.10.2).<br />

Number of operating hours<br />

•<br />

Check the number of operating hours in view of any maintenance operations<br />

to be carried out.<br />

Apart from the above check points, the sound produced by the compressor provides an indication or its mechanical condition. If<br />

abnormal sounds are audible, their cause should be traced <strong>and</strong> removed immediately in order to prevent serious breakdowns.<br />

1 ) During the first 50 operating hours the compressor should be checked regularly for all the points mentioned above, at least<br />

twice every 24 hours <strong>and</strong> more frequently in cases where irregularities are found.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

B2 MAINTENANCE (Contractor’s level)<br />

B2.1 Post start-up maintenance<br />

After the compressor has run for the initial 100<br />

operating hours:<br />

a) Drain the oil <strong>and</strong> refill the compressor with the<br />

correct amount of fresh oil.<br />

b) Exchange or clean the oil discharge filter element.<br />

c) Exchange or clean oil suction filter element (pos 24<br />

of fig. 2.1) as given in §B7.<br />

d) Clean suction gas filter.<br />

e) Check the compressor shaft seal for leakage.<br />

If excessive (more than 1 cc/hr) replace the seal.<br />

f) Check drive<br />

f1) Retighten the coupling mounting bolts with the<br />

torque settings as given by the coupling<br />

manufacturer.<br />

f2) Verify <strong>and</strong> if necessary, correct the tension of<br />

the V-belts as given in the V-belt supplier’s<br />

instructions.<br />

g) Verify <strong>and</strong> if necessary, correct the torque settings<br />

of all foundation bolts as given in § 7.2 of the<br />

Compressor Service Instruction <strong>Manual</strong>.<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

B1.2 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

B2.2 First maintenance<br />

The maintenance schedule below indicates after<br />

how many operating hours maintenance<br />

operations have to be carried out. This schedule<br />

can be regarded as a directive, based on the<br />

experience gained with a large number of<br />

compressors.<br />

For most of the maintenance operations the<br />

compressor must be put out of action. In order to<br />

avoid that this should take place at inconvenient<br />

times, the operations should as much as possible<br />

be affected during a st<strong>and</strong>-still period. The<br />

schedule has been drawn up in such a way that<br />

several operations can be carried out<br />

sumultaneously, which results in reduced<br />

maintenance costs.<br />

<strong>Maintenance</strong><br />

Grasso<br />

Number of<br />

operating<br />

hours<br />

Cleaning of oil suction filter <strong>and</strong><br />

renewal of oil discharge filter<br />

(ref. to par. 9.6).<br />

100 1 ) 2500 2 )<br />

MAINTENANCE SCHEDULE<br />

5000<br />

7500 2 )<br />

$ $<br />

10,000 10,100 12,500 2 )<br />

Major inspection to be carried<br />

out by installation engineer<br />

15,000<br />

17,500 2 )<br />

$ $<br />

Cleaning of suction gas strainer<br />

(ref. to par. 9.7). $ $ $ $<br />

Inspection of suction <strong>and</strong> discharge<br />

valves<br />

(ref. to par. 9.8)<br />

Draining <strong>and</strong> change of oil 3)<br />

(ref. to par. 9.5).<br />

$ $<br />

$ $ $ $<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

20,000 etc.<br />

1 ) time dependent on pollution.<br />

2 ) Only for NH3-compressors<br />

3 ) In the case of a possible rapid pollution of the oil, it should be drained <strong>and</strong> renewed sooner than at the times given<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 B1.3<br />

Major inspection to be carried<br />

out by installation engineer


<strong>Refrigeration</strong> Division<br />

Grasso<br />

B3 STEPS FOR LONGER SHUT-DOWN PERIODS<br />

(> 6 months)<br />

To shut down a compressor for long term periods,<br />

proceed as follows:<br />

a) Tightly shut both the suction <strong>and</strong> discharge stop<br />

valves <strong>and</strong> the stop valve of the oil return line (if<br />

present).<br />

b) Disconnect the power source from the compressor<br />

drive motor <strong>and</strong> the electrical control cabinet of the<br />

Monitron CR (if present).<br />

c) Place a moisture absorbing compound (eg a<br />

dessicant such as silica gel) inside the control cabinet.<br />

d) Place warning tags on the electric system <strong>and</strong> all<br />

closed stop valves.<br />

Prior to starting up after a shut down, change the oil<br />

(refer to §B6) <strong>and</strong> clean or exchange the oil filters (refer<br />

to §B7). Determine the starting <strong>and</strong> stopping<br />

procedure from §A2.10 prior to start the compressor.<br />

B4 LUBRICATION DATA<br />

Determine max Toil <strong>and</strong> set this value in the safety<br />

device (Monitron CR, if present).<br />

Change the oil as soon as an oil analysis (refer to<br />

§B2.2 for frequency) indicates contaminated oil.<br />

It is expressly pointed out that it is not<br />

permitted to mix different types of oil. If<br />

another type of oil is used, first remove<br />

all the stale oil in the filters, oil pump,<br />

crankcase, shaft seal, oil separator <strong>and</strong><br />

oil drains of the installation.<br />

B4.1 Topping up oil with compressor operating<br />

Topping up oil is permitted during compressor<br />

operation.<br />

Be sure that this oil is the same as in the plant<br />

(refer to §B4).<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

Without affecting the operation of the compressor,<br />

the oil may be topped up by means of a separate oil<br />

pump. This pump enables the oil to be forced into the<br />

crankcase via the oil charging valve, against suction<br />

pressure. If this oil pump is not available, oil can be<br />

charged by reducing the crankcase pressure to below<br />

atmospheric pressure.<br />

The procedure is as follows:<br />

a) Connect a hose to the oil charging valve after<br />

removing the cap nut.<br />

b) Fill the hose with oil <strong>and</strong> immerse its loose end in a<br />

reservoir containing sufficient oil.<br />

c) Close the suction stop valve so, that the suction<br />

pressure falls below the atmospheric pressure.<br />

d) Keep the oil charge valve open as long as the oil in<br />

the crankcase has attained the required level again.<br />

Take care that no air is being drawn into the<br />

crankcase.<br />

e) Slowly open the suction stop valve to avoid liquid<br />

hammer which may damage the compressor.<br />

f) Remove the hose <strong>and</strong> replace the cap nut with<br />

gasket onto the oil charging valve.<br />

Fig. B1 Oil level in compressor sight glass<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

B5 EVACUATION OF THE COMPRESSOR<br />

To evacuate the refrigeration system refer to §A2.2.<br />

Procedure to evacuate the compressor:<br />

a) Close the suction stop valve <strong>and</strong> the stop valve in<br />

the oil return line of the oil separator.<br />

b) Check that the discharge stop valve is open.<br />

c) Set suction pressure safety switch to 0.3 bar(a).<br />

d) Start the compressor (manual).<br />

e) Wait until the compressor will be cut out of<br />

operation either by the min. suction pressure safety<br />

switch [min Psuc] or the min. oil differential<br />

pressure safety switch [dOil].<br />

Do not start the compressor again, but close the<br />

discharge stop valve as soon as possible.<br />

Be sure the compressor will not start again!<br />

g) Remove the remainder of the refrigerant, via the<br />

evacuation/purging valve(s) as prescribed by local<br />

safety regulations. For the location of these valves<br />

refer to the "Engineering Data".<br />

h) Reset the suction pressure safety switch [Psuc].<br />

B6 DRAINING AND CHANGE OF OIL<br />

To top up oil see § B4.1.<br />

Oil changing procedure:<br />

a) Evacuate the compressor (refer to §B5).<br />

b) Drain the oil via the oil charging/drain valve.<br />

Remove the cover of one or more service openings<br />

on the compressor side.<br />

c) Clean the inside of the crankcase with a non-fibrous<br />

cloth (do not use cotton waste!).<br />

d) Replace the service cover(s) with a new gasket.<br />

e) Charge crankcase with clean or fresh oil in<br />

accordance with the procedure of §A2.3.<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

B7 CLEANING OF OIL FILTERS<br />

In most cases the oil filters have to be cleaned for<br />

the first time after 100 operating hours. Besides<br />

thorough cleaning of the strainer element of the<br />

oil suction filter, the paper filter element of the oil<br />

discharge filter should be renewed. Also after the<br />

installation has been extended or modified, the<br />

filters should be cleaned as if the compressor had<br />

just been put in operation. The time at which the<br />

next cleaning has to be carried out highly depends<br />

on the cleanliness of the installation.<br />

Small impurities in the refrigerant gas that are not<br />

retained by the suction strainer eventually find<br />

their way in the lubricating oil <strong>and</strong> may cause<br />

clogging of the oil suction filter. A strong pollution<br />

of this filter is indicated by a falling oil pressure; in<br />

this case it is necessary to clean the filter. It is<br />

recommended, therefore, regularly to check the<br />

oil pressure during the first 100 operating hours.<br />

When the filters remain practically clean, cleaning<br />

can take place simultaneously with the other<br />

maintenance operations.<br />

The oil filters can be cleaned as follows:<br />

a) Drain the oil via the oil charging valve.<br />

b) Purge the compressor (refer to par. B5)<br />

c) Remove the discharge filter housing <strong>and</strong> the<br />

released paper filter element. Catch up the<br />

remaining oil present in this housing. After draining<br />

the oil out of the crankcase, remove one of the side<br />

covers <strong>and</strong> remove the gauze filter element by<br />

unscrewing it from the internal suction pipe.<br />

d) Clean the gauze filter element of the oil suction<br />

filter in a receptacle containing oil or a solvent.<br />

After cleaning, thoroughly dry the element; if<br />

possible, blow through the filter element with<br />

compressed air against the normal oil flow direction.<br />

e) Clean the discharge filter housing <strong>and</strong> dry it with a<br />

non-fibrous cloth.<br />

f) Refit the gauze filter element <strong>and</strong> place a new filter<br />

element.<br />

g) Fit the discharge filter housing against the<br />

crankcase (do not forget the gasket); also check<br />

that the filter element is perfectly fit.<br />

h) Remove the plug on top of the shaft seal housing;<br />

fill this housing with fresh oil <strong>and</strong> replace the plug.<br />

j) Purge the compressor (refer to par. B10)<br />

k) Check oil level <strong>and</strong> top up oil as per par. B4.1.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

B8 CLEANING OF SUCTION GAS FILTER(S)<br />

a) Evacuate the compressor (refer to §B5).<br />

b) Remove the four bolts holding the suction stop valve<br />

<strong>and</strong> remove the valve.<br />

c) Pull the strainer element out of the suction strainer<br />

housing without damaging the gauze. (see also fig.<br />

<strong>RC</strong>6-11 on parts list page 12).<br />

d) Clean element by rinsing it in a solvent. Then<br />

thoroughly dry the element preferably with<br />

compressed air.<br />

e) Check the gauze for damage.<br />

f) Slide the strainer element again into the housing <strong>and</strong> fit<br />

the suction stop valve. Check the oilit gasket for proper<br />

condition.<br />

c) Purge the compressor (refer to §B10).<br />

B9 DISMANTLING, INSPECTION AND RE-ASSEM-<br />

BLY OF SUCTION AND DISCHARGE VALVES<br />

The suction <strong>and</strong> discharge valves of a refrigeration<br />

compressor are parts that are heavily loaded both<br />

mechanically <strong>and</strong> thermally. Wear <strong>and</strong> life time of the<br />

valves strongly depend on the operating conditions<br />

of the compressor. A high working temperature <strong>and</strong><br />

rapid temperature variations shorten the life time of<br />

the valves, which, for this reason, require regular<br />

inspection.<br />

For dismounting, inspection <strong>and</strong> re-assembly of<br />

the valves, proceed as follows:<br />

a) Evacuate the compressor (refer to par. B5).<br />

b) Remove the cylinder head covers.<br />

c) Remove the pressure ring <strong>and</strong> buffer spring.<br />

d) Lift the complete discharge valve out of the cylinder<br />

liner.<br />

e) Remove the suction valve ring <strong>and</strong> sinusoidal springs,<br />

which are loose on the collar of the cylinder liner.<br />

f) Unscrew <strong>and</strong> disassemble the discharge valve.<br />

g) Clean all valve parts <strong>and</strong> check them for break of<br />

damage.<br />

MIND! If it appears that valve parts are broken, also<br />

the cylinder liner <strong>and</strong> piston of the relevant cylinder<br />

must be checked for damage.<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

The valve rings <strong>and</strong> valve seats must be undamaged;<br />

even the slightest damage may easily cause breakage.<br />

Valve ring <strong>and</strong>/or seat should be replaced when, due<br />

to wear, the total score of valve ring <strong>and</strong> seat is over<br />

0.2 mm.<br />

The sinusoidal springs must also be undamaged <strong>and</strong><br />

must have sufficient slack height.<br />

REMARK! All valve parts can be obtained<br />

separately, except the discharge valve<br />

seat, stroke limitor <strong>and</strong> central bolt. If,<br />

for example, the discharge valve seat is<br />

to be renewed, a complete discharge<br />

valve (including stroke limitor, valve<br />

ring <strong>and</strong> sinusoidal springs) should be ordered<br />

(also refer to the parts list).<br />

h) Carefully clean all valve parts <strong>and</strong> slightly oil them with<br />

compressor oil; then re-assemble the discharge valve.<br />

j) After reassembling the discharge valve, check<br />

whether the valve ring <strong>and</strong> springs can be pressed<br />

against the stroke limitor, <strong>and</strong> when released, the<br />

valve ring is properly pressed back on its seat.<br />

k) Place the suction valve ring <strong>and</strong> the corresponding<br />

sinusoidal springs on the collar of the cylinder liner<br />

<strong>and</strong> install the discharge valve, buffer spring <strong>and</strong><br />

pressure ring.<br />

l) Check the gasket of the cylinder head cover <strong>and</strong> lay<br />

the cover onto the cylinder head.<br />

m) Screw all hexagonal bolts <strong>and</strong> firmly tighten them.<br />

n) Purge the compressor (refer to par. B10).<br />

REMARK! In order to reduce the downtime<br />

involved in this valve inspection, it<br />

is recommended to have as many complete<br />

valve assemblies in stock as there<br />

are cylinders on the compressor.<br />

The valves can then be exchanged with<br />

the valves to be checked. The original<br />

valves can then be inspected at leisure<br />

<strong>and</strong>, if necessary, repaired or replaced.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

B10 COMPRESSOR PURGING<br />

Procedure to purge the compressor<br />

(after maintenance jobs):<br />

STATUS:<br />

Stop valves of suction, discharge <strong>and</strong> oil return line<br />

are still closed (refer to §B5) <strong>and</strong> compressor is<br />

filled with oil (refer to §B6).<br />

a) Connect a vacuum pump to the evacuation/<br />

purging valve(s) <strong>and</strong> evacuate as prescribed by local<br />

regulations. For the location of these valves refer to<br />

the "Engineering Data".<br />

b) When evacuation is completed open the discharge<br />

stop valve.<br />

c) Watch suction <strong>and</strong> discharge pressure.<br />

If suction pressure increases quickly, the<br />

discharge valve assy is leaking.<br />

d) Start compressor.<br />

e) Slowly open suction stop valve.<br />

f) Open the stop valve in the oil return line of the oil<br />

separator (if present).<br />

g) If a Self-Limiting Automatic Purger is not installed,<br />

purge the refrigerating system (refer to the plant<br />

manual).<br />

B11 TROUBLESHOOTING TABLE<br />

The troubleshooting table on the next pages may<br />

be helpful to quickly trace <strong>and</strong> remedy failures<br />

that interfere with the proper operation of the<br />

compressor. It is emphatically pointed out that the<br />

cause of a failure must often be sought in the<br />

refrigeration installation itself. Therefore, it is<br />

necessary besides this table also to consult the<br />

plant manual.<br />

For Monitron CR controlled installations refer also<br />

to its own trouble shooting table.<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

FAULT CAUSE REMEDY<br />

A Discharge pressure too high 1. Discharge stop valve not fully open 1. Open fully<br />

2. Discharge pressure gauge defective 2. Renew<br />

3. Non condensables in system 3. Purge system with<br />

Grasso Automatic<br />

Purger<br />

B Discharge temperature too high 1. Discharge pressure too high 1. See A<br />

2. Too many cylinders cut out 2. Cut in more cylinders<br />

3. Suction pressure too low 3. See D<br />

4. Exessive superheat of suction gas 4. Eliminate exessive<br />

superheat<br />

5. Room temperature too high 5. Ventilate engine room<br />

better<br />

6. Discharge valve defective 6. Renew<br />

7. Pressure relief valve leaking 7. Renew<br />

C Suction pressure too high 1. Capacity control does not operate 1. Repair<br />

2. Compressor capacity too small 2. Consult installation<br />

engineer<br />

3. Suction pressure gauge defective 3. Repair or renew<br />

4. One or more suction valves defective 4. Repair or renew<br />

5. One or more discharge valves defective 5. Repair or renew<br />

6. Pressure relief valve is leaking 6. Renew<br />

D Suction pressure too low (suction<br />

pressure safety switch may<br />

possibly become operative)<br />

E Crankcase frosted or wet just after<br />

starting, possibly also during<br />

operation<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

1. Suction stop valve not fully open 1. Open fully<br />

2. Suction gas strainer polluted 2. Clean<br />

3. Too little refrigerant in installation 3. Top-up refrigerant<br />

4. Suction pressure gauge defective 4. Renew<br />

1. Liquid refrigerant in crankcase due to: In the case of big<br />

amount of refrigerant:<br />

stop compressor <strong>and</strong><br />

contact installation<br />

engineer<br />

1a. Room temperature too low 1a. See 1a<br />

1b. Return from oil separator mainly consists 1b. Contact installation<br />

of liquid refrigerant<br />

engineer<br />

1c. <strong>Installation</strong> operates too wet 1c. Re-adjust installation<br />

<strong>and</strong> provide for<br />

superheat<br />

1d. Liquid separator too small 1d. Contact installation<br />

engineer<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

FAULT CAUSE REMEDY<br />

F Cylinders inactive while compressor<br />

is operating<br />

1. Incorrect wiring of capacity control 1. Refer to the "Engineering Data"<br />

G Too high oil consumption 1. Type of oil not according to oil lubrication oil<br />

table (too thin oil)<br />

1. Change oil type<br />

2. Compressor operates unloaded too frequently 2. Refer to design calculations<br />

3. No return from oil separator* 3. Check the operation of float<br />

valve in oil separator<br />

4. Tube of pressure equalizing obstructed 4. Clean tube<br />

5. Worn out oil scraper ring(s) 5. Replace ring(s)<br />

6. Loss of oil due to leakage 6. Repair<br />

7. Leaking shaft seal (max. 1 cc/hr) 7. Repair shaft seal<br />

8. Oil level in crankcase too high 8. Refer to §B2<br />

H Too high oil pressure during<br />

normal operation at working<br />

temperature<br />

1. Lubricating oil pressure regulator not adjusted<br />

properly or defective<br />

2. Defective oil pressure <strong>and</strong>/or suction pressure<br />

gauge (if present)<br />

1. Re-adjust or renew<br />

2. Repair or replace<br />

J Too low lubricating oil pressure 1. Too little oil in crankcase 1. Top up oil<br />

2. Disturbed oil circuit:<br />

Oil suction <strong>and</strong>/or discharge filter is dirty<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

2. Renew the element of oil<br />

suction filter <strong>and</strong>/or oil<br />

discharge filter<br />

3. Re-adjust or renew<br />

3. Lubricating oil pressure regulator not adjusted<br />

properly or defective<br />

4. Liquid refrigerant in crankcase 4. See E<br />

5. Defective oil pressure <strong>and</strong>/or suction pressure 5. Repair or renew<br />

gauge (if present)<br />

6. Worn bearings 6. Renew bearings<br />

*) During the initial start-up, the oil separator (if present) consumes oil before the first oil will be returned.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

B: INSPECTION, MAINTENANCE<br />

AND TROUBLE SHOOTING<br />

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<strong>Refrigeration</strong> Division<br />

SECTION C:<br />

Grasso<br />

TABLE OF CONTENTS<br />

Engineerings<br />

Data Sheet No.<br />

Description Remarks<br />

1 Description <strong>and</strong> operation of capacity control<br />

2 General data<br />

3 Limits of operation <strong>and</strong> fields of applications<br />

4 Drawings (design details)<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

TABLE OF CONTENTS<br />

C.II <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

3.1 GENERAL<br />

Grasso<br />

The capacity control, i.e. the decrease in capacity<br />

at constant speed <strong>and</strong> under constant operating<br />

conditions, takes place stepwise by successively<br />

cutting out cylinders in pairs.<br />

This is effected by isolating the discharge space<br />

direct above the valves for each individual cylinder<br />

head from the common discharge chamber in the<br />

compressor housing <strong>and</strong> by putting it into<br />

communication with the common suction<br />

chamber, also located in the compressor housing.<br />

This socalled “internal recirculation control” is,<br />

apart from the flow resistance in valves <strong>and</strong><br />

channels, free from losses because the cut out<br />

cylinders do not compress gas but just circulate it<br />

under suction pressure.<br />

3.2 DESCRIPTION OF CAPACITY CONTROL<br />

As shown in figure 3.1, each controllable cylinder<br />

head cover is provided with a by-pass slide valve<br />

(item 9), which can move horizontally forward<br />

<strong>and</strong> backward in a guide bush (10) <strong>and</strong> is<br />

connected via a push rod (3) to a hot gas<br />

operated control piston (5) in a horizontal control<br />

cylinder (4). Slide valve, push rod <strong>and</strong> control<br />

piston form one integral steel part.<br />

Via a three-way solenoid valve (7,8), which is<br />

mounted outside on top of the cylinder head<br />

cover against the sealing cover (6) of the control<br />

cylinder, the space to the left of the control piston<br />

can be communicated either to suction pressure<br />

(via lines c <strong>and</strong> b, the former connected to the<br />

control cylinder <strong>and</strong> the latter to the by-pass<br />

chamber 2) or to discharge pressure (via lines a<br />

<strong>and</strong> c, the former connected to the permanent<br />

discharge chamber 12 in the cylinder head cover).<br />

Actually, only line a, coming from the top<br />

connection of the solenoid valve, is an external<br />

one; the two others b <strong>and</strong> c are internal bores<br />

provided in the sealing cover of the control<br />

cylinder <strong>and</strong> in the walls of the cylinder head<br />

cover. These internal bores are not indicated in<br />

the sections of figure 3.1.<br />

3.3 OPERATION OF CAPACITY CONTROL<br />

If the solenoid valve is not energized, line a is<br />

connected via line c to the control cylinder, so that<br />

hot gas from the permanent discharge chamber<br />

enters this cylinder <strong>and</strong>, as the diameter of the<br />

control piston is substantially larger than that of<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

the slide valve, the combination piston-rod-valve<br />

will move to the rightmost position, causing the<br />

slide valve to shut off entirely the permanent<br />

discharge chamber from the space direct above<br />

the discharge valves (11) <strong>and</strong> the latter to be<br />

communicated via a ring of circular openings in<br />

the guide bush with the space between control<br />

piston <strong>and</strong> slide valve (by-pass chamber), which is<br />

in permanent communication with the common<br />

suction chamber (1) in the compressor housing.<br />

Both cylinders then operate unloaded as a result<br />

of the by-pass thus effected. This situation is<br />

shown in the upper part of figure 3.1.<br />

When the solenoid valve is being energized, line b<br />

is connected via line c to the control cylinder, so<br />

that there is no pressure difference across the<br />

control piston <strong>and</strong> the combination<br />

piston-rod-valve is kept in its leftmost position by<br />

the pressure prevailing in the permanent<br />

discharge chamber <strong>and</strong> exerted onto the<br />

righth<strong>and</strong> face of the slide valve. The space direct<br />

above the discharge valves then communicates,<br />

via the afore mentioned circular openings in the<br />

guide bush of the slide valve, with the permanent<br />

discharge chamber, so that both cylinders operate<br />

normally. This situation is shown in the lower part<br />

of figure 3.1.<br />

For the st<strong>and</strong>ard capacity control part-load steps of<br />

the various compressor types <strong>and</strong> the corresponding<br />

energizing sequence of the solenoid valves, refer to<br />

the figures 3.2, 3.4 <strong>and</strong> 3.5 for compressor types<br />

<strong>RC</strong>6 <strong>and</strong> to figures 3.6, 3.8 <strong>and</strong> 3.9 for compressor<br />

type <strong>RC</strong>6W.<br />

3.4 PARTIALLY UNLOADED STARTING<br />

In order to be sure that all controllable cylinder<br />

pairs always operate fully unloaded when there is<br />

no pressure difference between discharge <strong>and</strong><br />

suction, a spring is mounted between each sealing<br />

cover <strong>and</strong> control piston to ensure that in that<br />

case all control pistons <strong>and</strong> slide valves are kept in<br />

their rightmost position, regardless of whether the<br />

corresponding solenoid valves are energized or<br />

not.<br />

On the other h<strong>and</strong>, to create sufficient discharge<br />

pressure to operate all available capacity control<br />

slide valves when starting the compressor at zero<br />

pressure difference between discharge <strong>and</strong><br />

suction, one cylinder head cover of each<br />

compressor type is non-controllable, i.e. it has no<br />

built-in slide valve <strong>and</strong> control piston, but is<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

provided instead with only a simple vertical<br />

partition to keep the common suction <strong>and</strong><br />

discharge chambers in the compressor housing<br />

apart from each other.<br />

Consequently, when the discharge pressure is<br />

higher than the suction pressure, only partially<br />

unloaded starting is possible.<br />

Therefore, it is recommended to always check the<br />

electric drive motor in this respect, depending on<br />

compressor design speed <strong>and</strong> starting conditions,<br />

the procedure of which is set out in paragraph 4.7.<br />

3.5 ALTERNATIVES TO CAPACITY CONTROL<br />

The four-cylinder compressor types <strong>RC</strong>46 can also be<br />

delivered with an alternative capacity control,<br />

including three part-load steps (25, 50 <strong>and</strong> 75%)<br />

instead of only one (50%) in the st<strong>and</strong>ard version.<br />

For the switch sequence of cylinders <strong>and</strong> solenoid<br />

valves of this alternative capacity control, refer to<br />

figure 3.3 <strong>and</strong> figure 3.7 for compressor types<br />

<strong>RC</strong>46 <strong>and</strong> <strong>RC</strong>46W respectively.<br />

These additional steps are obtained by replacing<br />

the non-controllable cylinder head cover of<br />

cylinders nr. 1 <strong>and</strong> 3 (<strong>RC</strong>46 in fig. 3.3) or cylinders<br />

nr. 2 <strong>and</strong> 4 (<strong>RC</strong>46W in fig. 3.7) by a partly<br />

controllable one of special design, which means<br />

that it has a partition in the middle of the space<br />

direct above the discharge valves to separate the<br />

two adjacent cylinders entirely from each other,<br />

thereby causing the built-in control piston <strong>and</strong><br />

slide valve to be effective for cylinder nr. 1 (<strong>RC</strong>46)<br />

or cylinder nr. 2 (<strong>RC</strong>46W) only <strong>and</strong> the discharge<br />

valve of cylinder nr. 3 (<strong>RC</strong>46) or cylinder nr. 4<br />

(<strong>RC</strong>46W) to be always in communication with the<br />

permanent discharge chamber in the cylinder head<br />

cover <strong>and</strong> the common discharge chamber in the<br />

compressor housing.<br />

So, only this one cylinder nr. 3 (<strong>RC</strong>46) or cylinder nr.<br />

4 (<strong>RC</strong>46W) is always in operation, which has the<br />

extra advantage of also reducing the starting load<br />

from 50 to 25%.<br />

On special order, just by adding the symbol Z after<br />

the type designation, each st<strong>and</strong>ard compressor<br />

type can also be delivered without any capacity<br />

control. In that case not only one but all cylinder<br />

head covers are of the non-controllable type, i.e. not<br />

provided with built-in control piston <strong>and</strong> by-pass<br />

slide valve.<br />

However, the consequence of such a (cheaper)<br />

choice is that either fully loaded compressor<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

starting has to be accepted, inevitably resulting in<br />

a more powerful electric motor to be installed, or<br />

special provisions are to be made by the installer<br />

in the field to overcome this inconvenience, for<br />

instance by applying an external line with solenoid<br />

valve (only open, so energized only during<br />

starting) between the suction <strong>and</strong> discharge line<br />

of the installation, combined with a non-return<br />

valve in the same discharge line.<br />

Important installation requirement!<br />

To prevent, during prolonged compressor<br />

st<strong>and</strong>-still, a gradual pressure equalisation<br />

between condenser <strong>and</strong> evaporator due to<br />

slow leakage of refrigerant gas via the<br />

slide valve, a non-return valve should all<br />

the times be mounted in the external<br />

discharge line.<br />

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<strong>Refrigeration</strong> Division<br />

a<br />

7<br />

a<br />

7<br />

b b<br />

c<br />

6<br />

5<br />

4<br />

3<br />

2<br />

1<br />

b b<br />

c<br />

6<br />

5<br />

4<br />

3<br />

2<br />

1<br />

Grasso<br />

1. common suction chamber<br />

2. by-pass chamber<br />

3. push rod<br />

4. control cylinder<br />

5. control piston<br />

c<br />

c<br />

➙ ➙<br />

8<br />

8<br />

9 10<br />

9 10<br />

a<br />

a<br />

➙ ➙<br />

11 12<br />

11 12<br />

6. sealing cover<br />

7. three-way solenoid valve with LED indication<br />

(schematic indication)<br />

8. three-way solenoid valve (actual location) Grasso<br />

code 06.80.111, suitable for 200-240V <strong>and</strong> 50/60Hz<br />

Fig. 3.1 Principle of capacity control<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

solenoid valve not energized<br />

CYLINDERS OUT OF OPERATION<br />

solenoid valve energized<br />

CYLINDERS IN OPERATION<br />

➙<br />

➙<br />

➙<br />

13<br />

13<br />

9. (by-pass) slide valve<br />

10. guide bush<br />

11. space direct above discharge valves<br />

12. permanent discharge chamber<br />

13. common discharge chamber<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C1.3


<strong>Refrigeration</strong> Division<br />

Grasso<br />

4<br />

4<br />

A<br />

2<br />

A<br />

2<br />

Number of solenoid valves: 1 (A,)<br />

Number of control steps: 2<br />

B<br />

1<br />

1<br />

3<br />

Fig. 3.2 St<strong>and</strong>ard capacity control of compressor <strong>RC</strong>46<br />

Number of solenoid valves: 2 (A,B)<br />

Number of control steps: 4<br />

3<br />

Fig. 3.3 Alternative capacity control of compressor <strong>RC</strong>46<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

solenoid valves energized<br />

- A �<br />

�<br />

Electrical<br />

control<br />

50 100 % Capacity<br />

No. of operating cylinders<br />

1 1<br />

- 2<br />

3 3<br />

- 4<br />

solenoid valves energized<br />

- - A A �<br />

- B - B<br />

�<br />

<strong>RC</strong>46<br />

(st<strong>and</strong>ard)<br />

Electrical<br />

control<br />

25* 50 75* 100 % Capacity<br />

No. of operating cylinders<br />

- 1 - 1<br />

- - 2 2<br />

3 3 3 3<br />

- - 4 4<br />

* Optional (see paragraph 3.5)<br />

<strong>RC</strong>46<br />

(alternative)<br />

page C1.4 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

8<br />

6<br />

A<br />

4<br />

Grasso<br />

3<br />

A<br />

Number of solenoid valves: 2 (A,B)<br />

Number of control steps: 3<br />

Number of solenoid valves: 3 (A,B,C)<br />

Number of control steps: 4<br />

7<br />

B<br />

3<br />

5<br />

2<br />

B<br />

2<br />

C<br />

6<br />

1<br />

4<br />

Fig. 3.4 St<strong>and</strong>ard capacity control of compressor <strong>RC</strong>66<br />

1<br />

5<br />

Fig. 3.5 St<strong>and</strong>ard capacity control of compressor <strong>RC</strong>86<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

solenoid valves energized<br />

- - A �<br />

- B B<br />

�<br />

Electrical<br />

control<br />

33.3 66.6 100 % Capacity<br />

No. of operating cylinders<br />

1 1 1<br />

- 2 2<br />

- - 3<br />

4 4 4<br />

- 5 5<br />

- - 6<br />

solenoid valves energized<br />

- - - A �<br />

- B B B<br />

- - C C<br />

�<br />

�<br />

<strong>RC</strong>66<br />

Electrical<br />

control<br />

25 50 75 100 % Capacity<br />

No. of operating cylinders<br />

1 1 1 1<br />

- - 2 2<br />

- 3 3 3<br />

- - - 4<br />

5 5 5 5<br />

- - 6 6<br />

- 7 7 7<br />

- - - 8<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C1.5<br />

<strong>RC</strong>86


<strong>Refrigeration</strong> Division<br />

Grasso<br />

2<br />

4<br />

4<br />

Number of solenoid valves: 2 (A,B)<br />

B<br />

2<br />

Number of solenoid valves: 1 (A)<br />

Number of control steps: 2<br />

Number of control steps: 4<br />

A<br />

A<br />

1<br />

1<br />

3<br />

Fig. 3.6 St<strong>and</strong>ard capacity control of compressor <strong>RC</strong>46W<br />

3<br />

solenoid valves energized<br />

Fig. 3.7 Alternative capacity control of compressor <strong>RC</strong>46W<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

solenoid valves energized<br />

- A<br />

- B - B �<br />

- - A A<br />

�<br />

Electrical<br />

control<br />

25 50 75 100 % Capacity<br />

No. of operating cylinders<br />

- - 1 1<br />

- 2 - 2<br />

- - 3 3<br />

4 4 4 4<br />

�<br />

�<br />

Electrical<br />

control<br />

50 100 % Capacity<br />

No. of operating cylinders<br />

- 1<br />

2 2<br />

- 3<br />

4 4<br />

<strong>RC</strong>46W<br />

(st<strong>and</strong>ard)<br />

<strong>RC</strong>46W<br />

(alternative)<br />

page C1.6 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

4<br />

8<br />

3<br />

6<br />

Grasso<br />

Number of solenoid valves: 2 (A,B)<br />

Number of control steps: 3<br />

5<br />

B<br />

solenoid valves energized<br />

Fig. 3.8 St<strong>and</strong>ard capacity control of compressor <strong>RC</strong>66W<br />

Number of solenoid valves: 3 (A,B,C)<br />

2<br />

Number of control steps: 4<br />

7<br />

C<br />

3<br />

2<br />

B<br />

6<br />

A<br />

1<br />

A<br />

4<br />

1<br />

5<br />

- - B �<br />

- A A<br />

�<br />

Electrical<br />

control<br />

33.3 66.6 100 % Capacity<br />

No. of operating cylinders<br />

- - 1<br />

- 2 2<br />

3 3 3<br />

- - 4<br />

- 5 5<br />

6 6 6<br />

solenoid valves energized<br />

- - - C<br />

- B B B<br />

- - A A<br />

Fig. 3.9 St<strong>and</strong>ard capacity control of compressor <strong>RC</strong>86W<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

�<br />

�<br />

�<br />

<strong>RC</strong>66W<br />

Electrical<br />

control<br />

25 50 75 100 % Capacity<br />

No. of operating cylinders<br />

- - - 1<br />

- 2 2 2<br />

- - 3 3<br />

4 4 4 4<br />

- - - 5<br />

- 6 6 6<br />

- - 7 7<br />

8 8 8 8<br />

<strong>RC</strong>86W<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C1.7


<strong>Refrigeration</strong> Division<br />

Grasso<br />

3. DESCRIPTION AND OPERATION<br />

OF CAPACITY CONTROL<br />

page C1.8 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

4.1 TECHNICAL DATA<br />

Table 4.1 Technical data<br />

COMPRESSOR TYPE <strong>RC</strong>F46/<strong>RC</strong>A46 <strong>RC</strong>F66/<strong>RC</strong>A66 <strong>RC</strong>F86/<strong>RC</strong>A86<br />

Number of cylinders z 4 6 8<br />

Cylinder arrangement 2 x V 2 x W 2 x VV<br />

Cylinder bore D mm 85<br />

Piston stroke S mm 66<br />

Direction of rotation both directions permitted<br />

Swept volume at full-load <strong>and</strong> n = 1450/min Vs m 3 /h 130.3 195.5 260.7<br />

St<strong>and</strong>ard compressor speeds (with V-belt drive)<br />

motor speed 1450/min (50 Hz)<br />

n min -1<br />

810 - 855 - 905 - 1015 - 1140 - 1215 - 1285 - 1450<br />

motor speed 1750/min (60 Hz) 800 - 875 - 980 - 1030 - 1095 - 1225 - 1380 - 1465<br />

St<strong>and</strong>ard steps of capacity control (expressed in<br />

percentage of full-load swept volume)<br />

1 ) % 100 - 50 100 - 67 - 33 100 - 75 - 50 - 25<br />

Main dimensions, connections <strong>and</strong> required free space Refer to par. 4.2.<br />

Mass of bare compressor (without<br />

flywheel <strong>and</strong> other accessories)<br />

Oil charge in crankcase (centre line of sight glass)<br />

2 ) dm 3<br />

kg 280 345 400<br />

9.2 (8.5) 10.0 (9.3) 10.8 (10.1)<br />

Oil type to be used Refer to par. 4.3.<br />

Starting torque Refer to par. 4.7.<br />

Friction power at n = 1450/min <strong>and</strong> 55 o C oil temperature 3 ) Pw kW 1.10 1.53 2.22<br />

Mass moment of inertia of crank mechanism<br />

(without flywheel)<br />

Centre of gravity <strong>and</strong> free forces <strong>and</strong> moments<br />

Torsional elastic substitute systems of crankshaft<br />

4 ) Id kg.m 2<br />

0.0361 0.0421 0.0478<br />

5 ) Refer to par. 4.4.<br />

6 ) Refer to par. 4.5.<br />

Sound rating Refer to par. 4.8.<br />

1 ) See also Chapter 3.<br />

Grasso<br />

2<br />

) The figures between brackets indicate the smaller oil charge for the<br />

<strong>RC</strong>A6W compressors due to the presence of an oil cooler.<br />

3<br />

) Pw is needed for calculating the condenser capacity Qc.<br />

See also paragraph 4.6.<br />

Pw = (n/1000).(0.02293.z 2 - 0.08207.z + 0.71931).<br />

4. GENERAL DATA<br />

4 ) The mass moment of inertia Id, expressed in SI-units, is required to<br />

determine the so-called coefficient of speed fluctuation.<br />

5<br />

) The centre of gravity <strong>and</strong> free forces <strong>and</strong> moments are of<br />

importance when calculating a vibration-free mounting of the<br />

compressor.<br />

6<br />

) These crankshaft substitute systems are required to carry out<br />

torsional vibration calculations in case the compressor is driven by<br />

an internal combustion engine.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

4.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS (for connections see table 4.2 ) All dimensions in mm.<br />

Fig. 4.1a Dimensioned sketch of compressor <strong>RC</strong>46<br />

Fig. 4.1b Dimensioned sketch of compressor <strong>RC</strong>46W<br />

4. GENERAL DATA<br />

For unobstructed removal of the crankcase inspection side covers,<br />

a block of at least 40 mm height should be placed under each foot<br />

when installing the compressor on a foundation or base frame.<br />

For unobstructed removal of the crankcase inspection side covers,<br />

a block of at least 40 mm height should be placed under each foot<br />

when installing the compressor on a foundation or base frame.<br />

page C2.2 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

Fig. 4.2a Dimensioned sketch of compressor <strong>RC</strong>66<br />

Fig. 4.2b Dimensioned sketch of compressor <strong>RC</strong>66W<br />

4. GENERAL DATA<br />

For unobstructed removal of the crankcase inspection side covers,<br />

a block of at least 40 mm height should be placed under each foot<br />

when installing the compressor on a foundation or base frame.<br />

For unobstructed removal of the crankcase inspection side covers,<br />

a block of at least 40 mm height should be placed under each foot<br />

when installing the compressor on a foundation or base frame.<br />

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<strong>Refrigeration</strong> Division<br />

Grasso<br />

Fig. 4.3a Dimensioned sketch of compressor <strong>RC</strong>86<br />

Fig. 4.3b Dimensioned sketch of compressor <strong>RC</strong>86W<br />

4. GENERAL DATA<br />

For unobstructed removal of the crankcase inspection side covers,<br />

a block of at least 40 mm height should be placed under each foot<br />

when installing the compressor on a foundation or base frame.<br />

For unobstructed removal of the crankcase inspection side covers,<br />

a block of at least 40 mm height should be placed under each foot<br />

when installing the compressor on a foundation or base frame.<br />

page C2.4 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

Table 4.2 Connections of <strong>RC</strong>6 <strong>and</strong> <strong>RC</strong>6W-compressors<br />

COMPRESSOR TYPE <strong>RC</strong>46(W) <strong>RC</strong>66(W) <strong>RC</strong>86(W)<br />

MAIN CONNECTIONS * outer pipe diameter of welding neck in flange<br />

suction 1 DN40 DN50 DN50<br />

discharge<br />

AUXILIARY CONNECTIONS<br />

2 DN32 DN40 DN50<br />

suction pressure 3<br />

1<br />

/4“ BSP<br />

discharge pressure 4<br />

1<br />

/4“ BSP<br />

oil pressure<br />

crankcase pressure<br />

5<br />

6<br />

1<br />

/8“ BSP<br />

1<br />

/4“ BSP<br />

Remark:<br />

return from oil separator or<br />

oil rectifier<br />

7<br />

1<br />

/4“ BSP<br />

connections 3, 4, 5, 6, 7, 9 <strong>and</strong> 10 are plugged off.<br />

oil charge <strong>and</strong> drain valve 8<br />

1<br />

/4“ BSP<br />

oil temperature 9<br />

1<br />

/4“ BSP<br />

crankcase heating 10 1 /2“ BSP female to suit thread of heating element<br />

oil leakage drain of rotary shaft seal 11 clamp coupling provided with Ø6 x 1 mm steel precision tube<br />

water inlet/outlet (<strong>RC</strong>A6W only) 12 Ø19 mm hose connector<br />

* Provided with a purging <strong>and</strong> evacuation stop valve type TAH8 (st<strong>and</strong>ard on discharge connection <strong>and</strong> optional on suction connection).<br />

Fig. 4.4 Dimensions of shaft end<br />

4. GENERAL DATA<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C2.5


<strong>Refrigeration</strong> Division<br />

4.3 LUBRICATING OILS (choice <strong>and</strong> recommendations)<br />

For lubrication of refrigeration compressors, several<br />

br<strong>and</strong>s <strong>and</strong> types of specially developed lubricating oils<br />

are on the market. The choice of oil depends not only<br />

on its good lubrication properties (viscosity) <strong>and</strong><br />

chemical stability at the operating conditions of the<br />

compressor, but also on the operating conditions of the<br />

refrigerating plant (solidifying <strong>and</strong> floc point, solubility).<br />

Grasso has tested <strong>and</strong> approved for use in its<br />

reciprocating-compressors the br<strong>and</strong>s <strong>and</strong> types of oil<br />

as listed in the adjacent table 4.4.<br />

The choice of the viscosity of the lubricating oil<br />

depends on the operating conditions of the<br />

compressor. The oil viscosity should always be more<br />

than 15 cSt (based on bearing construction<br />

requirements of the compressor). For the selection of<br />

the oil viscosity grade number, refer to table 4.3 below.<br />

A higher viscosity should be chosen, when a high oil<br />

temperature is expected, due to arduous operating<br />

condition such as:<br />

• high evaporating temperature;<br />

• large superheat of the refrigerant suction vapour;<br />

• prolonged part-load operation with a large number<br />

of cylinders cut-out;<br />

• a high surrounding temperature;<br />

• large pressure ratio.<br />

Remark<br />

For the oil types mentioned in the table 4.4, applied<br />

with the refrigerants R22, NH3 <strong>and</strong> R134a, the<br />

minimum requirement of the actual oil viscosity of<br />

15 cSt is fulfilled, but only when the maximum oil<br />

temperature as mentioned in the table 4.3 below is<br />

not exceeded.<br />

Refrigerant<br />

used<br />

Max.<br />

allowable<br />

evaporating<br />

temperature<br />

to,max. ( o C)<br />

Grasso<br />

Table 4.3 Oil selection table<br />

Maximum allowable<br />

crankcase oil temperature*<br />

ISO VG-number<br />

46 68 100<br />

NH3 - 60 68 76<br />

-64 59 68 76<br />

-30 56 66 74<br />

R22<br />

-20<br />

-10<br />

54<br />

51<br />

64<br />

62<br />

71<br />

68<br />

0 44 56 64<br />

+10 29 47 56<br />

-50 - 74 83<br />

-30 - 71 80<br />

R134a<br />

-20<br />

-10<br />

-<br />

-<br />

69<br />

67<br />

79<br />

77<br />

0 - 61 74<br />

+10 - 47 67<br />

* Data based on minimum oil viscosity of 15 cSt at the bearing<br />

surfaces, which is derived from the oil type, solubility of the<br />

refrigerant in the oil (halocarbon refrigerants only) <strong>and</strong> operating<br />

conditions. Assumed is that the oil temperature at the bearing<br />

surfaces = 6 K above crankcase oil temperature.<br />

The grey areas show the recommended ISO VG-numbered oils.<br />

Example: R22, to,max. = 0 o C : recommended oil type is ISO VG100<br />

NH3 under normal operating conditions, oil type with<br />

ISO VG68 is recommended.<br />

Refrigerant<br />

used<br />

NH3<br />

<strong>and</strong><br />

R22<br />

Br<strong>and</strong> Type designation<br />

ISO VG<br />

number 1 )<br />

AVIA Avilub FC 46/68<br />

2<br />

)<br />

BP<br />

Energol LPT-F 46<br />

Energol LPT-F 68<br />

46<br />

68<br />

CASTROL Icematic 299<br />

2<br />

)<br />

CPI CP-1009-68<br />

2<br />

) (NH3 only!)<br />

ELF Elfrima FR 68<br />

2<br />

)<br />

Zerice 46<br />

46<br />

ESSO<br />

Zerice 68<br />

Zerice S 46<br />

68<br />

46<br />

Zerice S 68<br />

68<br />

FINA Purfrigol MP 68 68<br />

FUCHS<br />

KC 46<br />

KC 68<br />

46<br />

68<br />

KROON OIL Carsinus FC 46/68<br />

2<br />

)<br />

MOBIL Arctic oil 300<br />

2<br />

)<br />

PETRO<br />

CANADA<br />

Reflo 68A<br />

2<br />

) (NH3 only!)<br />

Q 8<br />

Stravinsky B<br />

Stravinsky C<br />

2<br />

)<br />

2<br />

)<br />

SHELL<br />

SUN-OIL<br />

4. GENERAL DATA<br />

Table 4.4 Approved oil types for Grasso reciprocating<br />

compressors<br />

Clavus 46<br />

Clavus 68<br />

Clavus G 46<br />

Clavus G 68<br />

Clavus G 100<br />

Suniso 3.5 GS<br />

Suniso 4 GS<br />

Suniso 5 GS<br />

Suniso 4 SA<br />

46<br />

68<br />

46<br />

68<br />

100<br />

2 )<br />

2 )<br />

2 )<br />

2 ) (NH3 only!)<br />

TEXACO Capella WF 68 68<br />

2<br />

TOTAL Lunaria S 46/68<br />

)<br />

R134a<br />

<strong>and</strong><br />

R404A 3 CASTROL<br />

Icematic SW 68<br />

68<br />

Icematic SW 100 100<br />

2<br />

CPI<br />

Solest 68<br />

)<br />

2<br />

Solest 120<br />

)<br />

2<br />

Triton SE 55<br />

)<br />

2<br />

DEA Triton SE 80<br />

)<br />

2<br />

Triton SE 120<br />

)<br />

2<br />

ELF<br />

Planetelf ACD 68<br />

)<br />

2<br />

Planetelf ACD 100 )<br />

2<br />

FINA<br />

Purfrigol ST VG 68 )<br />

2<br />

Purfrigol ST VG 100 )<br />

FUCHS<br />

Reniso E 68<br />

68<br />

)<br />

Reniso E 100<br />

100<br />

2<br />

ICI<br />

Emkarte RL 68S<br />

)<br />

2<br />

Emkarte RL 100S<br />

)<br />

2<br />

MOBIL<br />

EAL Arctic 68<br />

)<br />

2<br />

EAL Arctic 100<br />

)<br />

2<br />

SHELL<br />

Clavus R68<br />

)<br />

2<br />

Clavus R100<br />

)<br />

2<br />

SUN-OIL Suniso Excel<br />

)<br />

TEXACO<br />

Capella HFC 68<br />

68<br />

Capella HFC 100 100<br />

Some of the oil types listed in the table may be marketed under other<br />

names <strong>and</strong>/or designations; these oils can also be used, provided<br />

their identity can be proved beyond any doubt. Application of other<br />

oils is not permitted without written consent of Grasso.<br />

1<br />

) Viscosity grade number designation according to ISO St<strong>and</strong>ard<br />

3448.<br />

2<br />

) Consult your oil supplier to determine the maximum allowable oil<br />

temperature at an oil viscosity of 15 cSt, under prevailing operating<br />

conditions <strong>and</strong> refrigerant used.<br />

3<br />

) In case of R404A always consult your oil supplier in advance for<br />

advise.<br />

page C2.6 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

5.1 INDIVIDUAL LIMITS OF OPERATION<br />

With an operating compressor several working<br />

conditions arise which one by one are bound to certain<br />

limits. These so-called “individual operation limits” are<br />

determined by structural limitations of the compressor<br />

itself or they are based on thermodynamic <strong>and</strong><br />

practical considerations. They apply to both single-stage<br />

<strong>and</strong> booster compressors.<br />

When operating the compressor, none of the limits of<br />

operation as stated in the table 5.1 below must be<br />

exceeded.<br />

Table 5.1<br />

Note:<br />

In practice it is not so much the individual limits<br />

of operation, described in this paragraph, as<br />

combinations of them that are decisive for the<br />

conditions under which a compressor may<br />

operate. To check the various possibilities in this<br />

respect, use should be made of the “fields of<br />

application” according to the figures 5.1 to 5.5.<br />

REFRIGERANT NH3 R22 R134a R404A<br />

Compressor speed n min -1 min. 800<br />

max. 1500<br />

Suction pressure<br />

= evaporating pressure<br />

= crankcase pressure<br />

Evaporating temperature<br />

= saturation temperature<br />

at suction pressure<br />

Actual suction temperature<br />

1 ) po bar(a)*<br />

1 ) to<br />

2 ) ta<br />

o C<br />

min. 0.3<br />

max. 6.2 6.8 6.2 6.0<br />

min. -55.1 -63.8 -50 -68.1<br />

max. +10.2 +10.0 +22.6 -0.1<br />

o C min. -50<br />

Suction superheat ∆to K min. 5<br />

Discharge pressure = condensing pressure<br />

3<br />

) pc bar(a)* max. 26<br />

Condensing temperature<br />

= saturation temperature at discharge pressure<br />

Discharge temperature<br />

Pressure ratio (pc/po)<br />

Pressure difference (pc-po)<br />

Grasso<br />

Oil temperature in crankcase<br />

* 1 bar = 10 5 N/m 2 = 100 kPa = 1.02 kgf/cm 2 = 14.5 psi.<br />

tc<br />

4 ) te<br />

o C max. +59.8 +63.2 +79.5 +55.6<br />

o C max. +155<br />

5<br />

) j -<br />

min. 1.5<br />

max. 10 15<br />

6<br />

) ∆p bar* max. 24<br />

7 ) toil<br />

1<br />

) The minimum values of po <strong>and</strong> to are only of importance for<br />

booster applications. In that case the maximum value of to also<br />

applies to the saturation intermediate temperature (tm).<br />

For halocarbon refrigerants the maximum values of po <strong>and</strong> to are<br />

based on a density of the suction gas of 30 kg/m 3 .<br />

During start-up <strong>and</strong> immediately thereafter, po,max. may be<br />

exceeded slightly [up to 11 bar(a) max.] <strong>and</strong> temporarily, but no<br />

longer than about 5 minutes.<br />

The maximum static crankcase pressure during compressor<br />

st<strong>and</strong>still is 21.5 bar(a).<br />

2<br />

) Only of importance for booster application.<br />

3<br />

) This pressure is also the maximum allowable pre-set value of the HP<br />

safety switch.<br />

4<br />

) This is the actual discharge temperature, measured directly in the<br />

gas flow inside the cylinder head covers, just above the discharge<br />

valves.<br />

o C<br />

5. LIMITS OF OPERATION AND<br />

FIELDS OF APPLICATIONS<br />

min. +20 +30<br />

max. refer to pragraph 4.3<br />

5<br />

) Pressure ratio limits are not absolute but arbitrary values based on<br />

practical considerations.<br />

6<br />

) The st<strong>and</strong>ard built-in overflow safety valve between suction <strong>and</strong><br />

discharge chamber in the compressor housing has been factory-set<br />

to 24.5 (+10%) bar to prevent advanced opening during normal<br />

operation at ∆p ≤ 24 bar.<br />

7 ) Indicated minimum value is the lowest oil temperature at which<br />

compressors are allowed to be started.<br />

The maximum oil temperature depends on the operating<br />

conditions of the compressor, the oil type used <strong>and</strong> (for halocarbon<br />

refrigerants only) the solvability of the refrigerant in the oil. A<br />

minimum actual oil viscosity of 15 cSt is always required.<br />

When using ammonia as refrigerant, the maximum oil temperature<br />

will be exceeded only when a combination occurs of high ambient<br />

temperature, high suction superheat <strong>and</strong> part-load operation. In<br />

that case an oil cooler is required. A water-cooled oil cooler always<br />

form part of the st<strong>and</strong>ard delivery of a <strong>RC</strong>6W-compressor.<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C3.1


<strong>Refrigeration</strong> Division<br />

Grasso<br />

5.2 FIELDS OF APPLICATION FOR SINGLE-STAGE<br />

AND BOOSTER OPERATION.<br />

The following 5 diagrams, related to the refrigerants<br />

R134a, R22, R404A <strong>and</strong> NH3 represent the fields of<br />

application at continuous operation with different<br />

conditions at any speed between 800 <strong>and</strong><br />

1500/min. In case of <strong>RC</strong>6 <strong>and</strong> booster application<br />

the compressor manufactuer should be consulted. In<br />

each diagram the area comprising all allowable<br />

combinations of evaporating temperature to <strong>and</strong><br />

condensing temperature tc (general field of<br />

application) is enclosed by a broken bold line, of<br />

which each line section corresponds to one of the<br />

individual operation limits as stated in table 5.1.<br />

Symbols used in diagrams:<br />

to = evaporating temperature<br />

po = evaporating pressure<br />

tc = condensing temperature<br />

pc = condensing pressure<br />

j = pressure ratio = (pc/po)<br />

∆p = pressure difference = (pc-po)<br />

∆to = suction superheat<br />

te = discharge temperature in cylinder head covers<br />

Vs = part-load swept volume (= part-load capacity)<br />

expressed in percentage of full-load (100%)<br />

Fig. 5.1 Field of application for <strong>RC</strong>6 with refrigerant R134a<br />

5. LIMITS OF OPERATION AND<br />

FIELDS OF APPLICATIONS<br />

Fig. 5.2 Field of application for <strong>RC</strong>6 with refrigerant R22<br />

Fig. 5.3 Field of application for <strong>RC</strong>6 with refrigerant R404A<br />

page C3.2 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

5.3 LIMITATIONS OF PART-LOAD OPERATION<br />

Fig. 5.4 Field of application for compressor type <strong>RC</strong>6 with NH3<br />

Fig. 5.5 Field of application for compressor type <strong>RC</strong>6W with NH3<br />

If a <strong>RC</strong>46 or <strong>RC</strong>86 is to be operated continuously<br />

at the minimum part-load step of 25%, the<br />

manufacturer should be consulted first to check<br />

whether this is allowed under the expected design<br />

conditions.<br />

In case of a <strong>RC</strong>6-compressor operating<br />

continuously at part-load, the general field of<br />

application is reduced in the sense that for each<br />

step of capacity reduction the limit line for te =<br />

155 o C moves to the right as shown in fig. 5.4, by<br />

four Vs-indications in percentage.<br />

5. LIMITS OF OPERATION AND<br />

FIELDS OF APPLICATIONS<br />

In case of a <strong>RC</strong>6W-compressor, however, there are<br />

no part-load restrictions. In other words, the<br />

general field of application as shown in fig. 5.5,<br />

also remains valid for part-load operation down to<br />

<strong>and</strong> including the st<strong>and</strong>ard minimum capacity<br />

control step of Vs = 25%.<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C3.3


<strong>Refrigeration</strong> Division<br />

Grasso<br />

5. LIMITS OF OPERATION AND<br />

FIELDS OF APPLICATIONS<br />

page C3.4 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

1<br />

2<br />

3<br />

4<br />

5<br />

Grasso<br />

31<br />

��������������<br />

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��������������<br />

��������������<br />

Fig. 2.1 Construction of st<strong>and</strong>ard bare compressor (<strong>RC</strong>66W)<br />

DESIGN DETAILS OF STANDARD<br />

BARE COMPRESSOR<br />

30<br />

33<br />

6<br />

7<br />

32<br />

8<br />

9<br />

10<br />

11<br />

12<br />

1. cylinder head cover<br />

(water-cooled)<br />

2. lifting eye<br />

3. suction connection<br />

4. oil differential pressure<br />

safety switch (optional)<br />

5. crankcase heater (optional)<br />

6. suction <strong>and</strong> discharge<br />

valve assembly<br />

7. cylinder liner<br />

8. piston <strong>and</strong> connecting rod<br />

9. discharge connection<br />

10. oil return check valve<br />

11. sight glass<br />

12. inspection side cover<br />

13. 3-way solenoid valve<br />

14. by-pass slide valve<br />

15. suction chamber<br />

16. tube for pressure equalizing<br />

17. rotary shaft seal<br />

18. crankshaft<br />

19. shaft seal housing<br />

20. oil leakage drain<br />

21. oil suction filter<br />

22. crankcase<br />

23. discharge chamber<br />

24. oil discharge filter<br />

25. oil filter housing<br />

26. oil pump<br />

27. bearing cover<br />

28. oil charge <strong>and</strong> drain valve<br />

29. oil cooler (water-cooled)<br />

30. cooling water hose<br />

31. water inlet connection<br />

32. water outlet connection<br />

‘ 33. cast-in channel<br />

for cooling water<br />

34. Plug cooling water channel<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C4.1


<strong>Refrigeration</strong> Division<br />

1<br />

2<br />

3<br />

4<br />

5<br />

6<br />

7<br />

8<br />

9<br />

10<br />

11<br />

7<br />

8<br />

9<br />

10<br />

Grasso<br />

11<br />

12<br />

�<br />

DISCHARGE<br />

1 2<br />

➙<br />

12 13<br />

➙<br />

➙<br />

Fig. 2.2 Rotary shaft seal<br />

�<br />

SUCTION<br />

Fig. 2.3 Suction <strong>and</strong> discharge valve assembly<br />

3<br />

4<br />

5<br />

6<br />

DESIGN DETAILS OF STANDARD<br />

BARE COMPRESSOR<br />

14<br />

1. shaft seal housing<br />

2. O-ring<br />

3. counter-slip ring<br />

4. slip ring<br />

5. flexible elastomer bellows<br />

6. spring<br />

7. spring holder<br />

8. driving b<strong>and</strong><br />

9. supporting ring<br />

10. retainer shell<br />

11. oil leakage drain<br />

12. main bearing bush<br />

13. crankcase<br />

14. oil supply from internal<br />

lubricating circuit in crankcase<br />

1. central bolt<br />

2. discharge valve stroke limitor<br />

3. pressure ring<br />

4. sinusoidal buffer spring<br />

5. discharge valve seat, also<br />

suction stroke limitor<br />

6. cylinder liner, also suction<br />

valve seat<br />

7. O-ring<br />

8. suction valve ring with two (<strong>RC</strong>F6) or<br />

one (<strong>RC</strong>A6) sinusoidal spring(s)<br />

9. discharge valve ring with two (<strong>RC</strong>F6)<br />

or one (<strong>RC</strong>A6) sinusoidal spring(s)<br />

10. O-ring in crankcase partition<br />

11. head plate<br />

12. crankcase partition<br />

page C4.2 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

➊<br />

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1. crankcase<br />

2. suction welding<br />

neck flange<br />

Grasso<br />

➌<br />

➍<br />

3. suction chamber<br />

4. strainer element<br />

Fig. 2.4 Suction gas strainer<br />

➋ ➊<br />

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Fig. 2.6 Lubrication system<br />

DESIGN DETAILS OF STANDARD<br />

BARE COMPRESSOR<br />

➌ ➍ ➎<br />

1. crankcase<br />

2. discharge welding<br />

neck flange<br />

Fig. 2.5 Pressure relief valve<br />

➋<br />

3. suction chamber<br />

4. discharge chamber<br />

5. overflow safety valve<br />

1. oil discharge filter<br />

2. oil pump<br />

3. oil suction strainer<br />

4. connections for external<br />

oil return line with<br />

lubricating oil pressure<br />

regulator <strong>and</strong> for (optional)<br />

oil pressure safety switch<br />

5. oil leakage drain<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 page C4.3


<strong>Refrigeration</strong> Division<br />

Grasso<br />

DESIGN DETAILS OF STANDARD<br />

BARE COMPRESSOR<br />

page C4.4 <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

TABLE OF CONTENTS<br />

SUBJECT Page no.:<br />

SECTION D: STANDARD ILLUSTRATED PARTS LIST .....................................................................<br />

D1 Spare parts list <strong>RC</strong>6 .................................................................................................................... C1 - C16<br />

....................................................................................................................................... A1 - A8<br />

v001.99.01.en <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 D.I


<strong>Refrigeration</strong> Division<br />

Grasso<br />

TABLE OF CONTENTS<br />

D.II <strong>Installation</strong> <strong>and</strong> <strong>Maintenance</strong> <strong>Manual</strong> <strong>RC</strong>(U)6 v001.99.01.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

The illustrated parts list on the following pages is meant for identification <strong>and</strong> accurate specification of<br />

spare parts. In order to facilitate quick retrieval of the required parts, the list <strong>and</strong> corresponding figures<br />

is divided into the following groups of parts:<br />

GROUP OF PARTS PARTS LIST<br />

Page:<br />

Figures<br />

All parts shown in the figures bear an item number.<br />

Assemblies are indicated by a dotted frame with<br />

separate item number around the parts included in<br />

that particular assembly;<br />

the parts themselves bear the same item number,<br />

followed by a sequence number (e.g. 2.1, 2.3, 2.3, etc.).<br />

Parts lists<br />

The parts are specified by the headings “Item”,<br />

“Description” “Ref. no.” <strong>and</strong> “Qty” (= Quantity).<br />

* If an asterisk is used instead of the Ref. no., this means<br />

that the relevant part cannot be obtained separa-<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

CORRESPONDING FIGURE<br />

No.:<br />

• Compressor housing with connections 2 <strong>RC</strong>6-1<br />

• Main bearings 2 <strong>RC</strong>6-2<br />

• Crankshaft 5 <strong>RC</strong>6-3<br />

• Piston <strong>and</strong> connecting rod 5 <strong>RC</strong>6-4<br />

• Suction <strong>and</strong> discharge valve 6 <strong>RC</strong>6-5<br />

• Rotary shaft seal 9 <strong>RC</strong>6-6<br />

• Oil pump 9 <strong>RC</strong>6-7<br />

• Capacity control mechanism 10 <strong>RC</strong>6-8<br />

• Oil discharge filter 10 <strong>RC</strong>6-9<br />

• Flanged main connections 13 <strong>RC</strong>6-10<br />

• Suction gas strainer 13 <strong>RC</strong>6-11<br />

• Oil suction filter 14 <strong>RC</strong>6-12<br />

• Oil differential pressure safety switch 14 <strong>RC</strong>6-13<br />

• Oil pressure regulator 14 <strong>RC</strong>6-14<br />

• St<strong>and</strong>ard sets of parts <strong>and</strong> seals 16 ---------<br />

tely.<br />

When for some part no quantity has been given, the<br />

quantity required depends on the compressor size.<br />

When determining the required quantity of parts, it<br />

should be considered that the listed quantities relate<br />

to the corresponding figure <strong>and</strong> not to the compressor<br />

as a whole. When ordering, for example, valve<br />

rings for two discharge valves, the quantities stated<br />

in the relevant list must be doubled, because these<br />

apply to one discharge valve only.<br />

<strong>RC</strong>6W<br />

This is a <strong>RC</strong>6 compressor, including water cooled cylinder<br />

heads<br />

How to order!<br />

It is emphatically pointed out that a prompt despatch of the correct spare parts can be<br />

guaranteed only if the following information is given:<br />

1. Type designation of the compressor<br />

shown on the compressor name plate<br />

2. Serial number of the compressor<br />

3. Quantity, Description <strong>and</strong> Ref. No. of the required parts.<br />

0089238-v004.00.02.en <strong>RC</strong>6 C1


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

COMPRESSOR HOUSING WITH CONNECTIONS FIG. <strong>RC</strong>6-1<br />

1 Cylinder head cover assy<br />

* — with capacity control<br />

1.1A Cylinder head cover <strong>RC</strong>6-2CR<br />

23.36.521 — with cap. control for 2 cyl.<br />

Cylinder head cover <strong>RC</strong>6-2CR<br />

23.36.525 — <strong>RC</strong>6W: with cap. control for 2 cyl.<br />

1.1B Cylinder head cover <strong>RC</strong>6-1CR<br />

23.36.510 — with cap. control for 1 cyl.<br />

Cylinder head cover <strong>RC</strong>6-1CR<br />

23.36.515 — <strong>RC</strong>6W: with cap. control for 1 cyl.<br />

1.2 Hex. head bolt M10x120<br />

01.10.512 2<br />

1.3A Oilit gasket 190x405x1.5-2CR<br />

09.07.192 — on item 1.1A<br />

1.3B Oilit gasket 190x405x1.5-1CR<br />

09.07.191 — on item 1.1B<br />

2<br />

2.1<br />

2.2<br />

3<br />

4<br />

5<br />

6<br />

7<br />

8<br />

9<br />

10<br />

11<br />

12<br />

13<br />

14<br />

15<br />

16<br />

17<br />

18<br />

19<br />

20<br />

21<br />

22<br />

23<br />

Cylinder head cover assy<br />

Cylinder head cover <strong>RC</strong>6-0CR<br />

Cylinder head cover <strong>RC</strong>6-0CR<br />

Oilit gasket 190x405x1.5-0CR<br />

Hex. head bolt M10x100<br />

Hex. head bolt M10x120<br />

Washer M10<br />

Crankcase<br />

Oilit gasket 175x290x1.5<br />

Inspection side cover 175x290<br />

Inspection side cover 175x290WK<br />

Hex. head bolt M10x40<br />

O-ring 2.62x32.99<br />

Sight glass 2.9x60<br />

Hex. head bolt M6x16<br />

Eye bolt M16<br />

Safety relief valve 26 5G33<br />

Plug G13S<br />

Crankcase heating element<br />

Stop valve TAH8-12<br />

Oil return orifice<br />

Alu sealing ring 21x25x1<br />

Plug G21<br />

Plug G21<br />

Alu sealing ring 21x27x2<br />

Alu sealing ring 13,5x20x1<br />

Nipple coupling 12G13<br />

Nipple coupling 12G21<br />

*<br />

23.36.500<br />

23.36.505<br />

09.07.190<br />

01.10.510<br />

01.10.512<br />

11.13.501<br />

*<br />

09.07.175<br />

05.30.175<br />

05.30.178<br />

01.10.540<br />

09.52.284<br />

12.24.029<br />

01.10.316<br />

01.18.812<br />

12.49.333<br />

01.36.134<br />

13.72.203<br />

06.07.011<br />

01.23.139<br />

09.12.021<br />

01.36.216<br />

01.36.216<br />

09.14.023<br />

09.12.014<br />

03.38.131<br />

03.38.211<br />

—<br />

—<br />

—<br />

20<br />

20<br />

36<br />

1<br />

1<br />

2<br />

2<br />

16<br />

1<br />

1<br />

3<br />

2<br />

1<br />

5<br />

1<br />

1<br />

2<br />

2<br />

3<br />

1<br />

1<br />

5<br />

1<br />

1<br />

without capacity control<br />

on type <strong>RC</strong>6W only<br />

18 on item 1 (for <strong>RC</strong>6 types only)<br />

18 on item 1 (for <strong>RC</strong>6W types only)<br />

<strong>RC</strong>6 (2x), <strong>RC</strong>6W (1x)<br />

<strong>RC</strong>6W (1x)<br />

if connection not in use<br />

in <strong>RC</strong>46(W) compressor only<br />

in types <strong>RC</strong>66(W) & <strong>RC</strong>86(W)<br />

MAIN BEARINGS FIG. <strong>RC</strong>6-2<br />

1<br />

2<br />

2.1<br />

2.2<br />

2.3<br />

2.4<br />

3<br />

4<br />

5<br />

Grasso<br />

Flange bearing 60x15x11.5<br />

Bearing assy<br />

Pump housing <strong>RC</strong>6<br />

O-ring 3.53x209.14<br />

Flange bearing 60x50xM10<br />

Socket head screw M10x100<br />

Washer M10<br />

Hex. head bolt M10x40<br />

Hex. head bolt M10x35<br />

11.43.600<br />

*<br />

––––-<br />

09.52.365<br />

11.43.651<br />

01.04.510<br />

11.13.501<br />

01.10.540<br />

01.10.535<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

1<br />

1<br />

1<br />

1<br />

1<br />

4<br />

16<br />

8<br />

8<br />

driving end<br />

refer to page 9<br />

oil pump end from 95.08.1648<br />

C2 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

1<br />

3<br />

5<br />

Grasso<br />

2<br />

2.3<br />

2.2<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

2.1<br />

2.4<br />

4<br />

3<br />

<strong>RC</strong>6-1<br />

<strong>RC</strong>6-2<br />

0089238-v004.00.02.en <strong>RC</strong>6 C3


<strong>Refrigeration</strong> Division<br />

Grasso<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

<strong>RC</strong>6-3<br />

<strong>RC</strong>6-4<br />

C4 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

CRANKSHAFT FIG. <strong>RC</strong>6-3<br />

1A<br />

1B<br />

1C<br />

1.1<br />

2<br />

3<br />

4<br />

Crankshaft E-<strong>RC</strong>6<br />

Crankshaft K-<strong>RC</strong>6 (with approval)<br />

Crankshaft E-<strong>RC</strong>6<br />

Crankshaft K-<strong>RC</strong>6 (with approval)<br />

Crankshaft E-<strong>RC</strong>6<br />

Crankshaft K-<strong>RC</strong>6 (with approval)<br />

Crankshaft E/K-<strong>RC</strong>6<br />

Key 14x9x70<br />

Carrier disc 60x5<br />

Socket head screw M10x25<br />

22.36.400<br />

22.36.410<br />

22.36.600<br />

22.36.610<br />

22.36.800<br />

22.36.810<br />

*<br />

11.02.570<br />

11.25.106<br />

01.04.525<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

2<br />

4-cylinder compressor<br />

6-cylinder compressor<br />

8-cylinder compressor<br />

from 95.08.1648<br />

PISTON AND CONNECTING ROD FIG. <strong>RC</strong>6-4<br />

1<br />

1.1<br />

1.2<br />

1.3<br />

1.4<br />

2<br />

2.1<br />

2.2<br />

2.3<br />

2.4<br />

Grasso<br />

Piston assy 85<strong>RC</strong>6<br />

Piston 85<strong>RC</strong>6H<br />

Gudgeon pin 26x18x69<strong>RC</strong>6<br />

Safety ring<br />

Set of piston rings 85<strong>RC</strong>6<br />

Connecting rod assy 60x170x<strong>RC</strong>6<br />

Con rod 170<strong>RC</strong>6<br />

Con rod bolt MF8x1<br />

Locking plate M8<br />

Hex. nut MF8x1<br />

24.36.010<br />

*<br />

24.36.260<br />

*<br />

09.74.084<br />

24.36.500<br />

*<br />

01.11.401<br />

11.39.400<br />

01.47.405<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

0089238-v004.00.02.en <strong>RC</strong>6 C5<br />

1<br />

1<br />

1<br />

2<br />

1<br />

1<br />

1<br />

2<br />

2<br />

2


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

SUCTION AND DISCHARGE VALVE FIG. <strong>RC</strong>6-5<br />

1<br />

2<br />

3<br />

4<br />

5<br />

5.1<br />

5.2<br />

5.3<br />

5.4<br />

5.5<br />

5.6<br />

5.7<br />

6<br />

7<br />

8<br />

9<br />

10<br />

11<br />

12L<br />

12H<br />

13<br />

Grasso<br />

Hex. head bolt M10x40<br />

Washer M10<br />

Pressure ring <strong>RC</strong>6<br />

Sinusoidal buffer spring 87x124x4<br />

Discharge valve assy <strong>RC</strong>6<br />

Locking nut M8<br />

Washer M8<br />

Discharge valve stroke limitor<br />

Sinusoidal spring 64x76x0.5<br />

Discharge valve ring 64x76x1<br />

Suction stroke limitor<br />

Fitted bolt M8x40<br />

Damper ring 108x87x4<br />

Sinusoidal spring 88x108x0.7<br />

Suction valve ring 88x108x0.7<br />

O-ring 3.53x117.07<br />

Cylinder liner 85<strong>RC</strong>6<br />

O-ring 3.53x91.67<br />

Discharge valve ring <strong>and</strong> spring(s) Option L<br />

Discharge valve ring <strong>and</strong> spring(s) Option H<br />

Suction valve ring, spring <strong>and</strong> damper ring<br />

Source of table below; 00.87.315<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

01.10.540<br />

11.13.501<br />

27.36.410<br />

11.33.087<br />

27.36.113<br />

27.36.103<br />

01.45.400<br />

11.13.401<br />

*<br />

*<br />

*<br />

*<br />

*<br />

*<br />

*<br />

*<br />

09.52.362<br />

23.36.120<br />

09.52.361<br />

11.34.110<br />

11.34.105<br />

11.34.115<br />

4<br />

4<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

2<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

Option ’L’(Low)<br />

Option ’H’(High)<br />

Option ’L’ (Low)<br />

Option ’H’(High)<br />

refer<br />

table<br />

below<br />

C6 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

<strong>RC</strong>6-5H <strong>RC</strong>6-5L<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

0089238-v004.00.02.en <strong>RC</strong>6 C7


<strong>Refrigeration</strong> Division<br />

Grasso<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

<strong>RC</strong>6-6<br />

<strong>RC</strong>6-7<br />

C8 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

ROTARY SHAFT SEAL FIG. <strong>RC</strong>6-6<br />

1<br />

2A<br />

2B<br />

3<br />

4<br />

5<br />

6<br />

7<br />

Shaft seal housing <strong>RC</strong>6<br />

Plug G13S<br />

Plug NPT13<br />

Nipple coupling 6N10<br />

O-ring 3.54x158.34<br />

Hex. head bolt M10x35<br />

Washer M10<br />

Shaft seal assy 54<strong>RC</strong>6<br />

26.36.100<br />

01.36.134<br />

03.65.513<br />

03.38.810<br />

09.52.364<br />

01.10.535<br />

11.13.501<br />

09.62.900<br />

OIL PUMP FIG. <strong>RC</strong>6-7<br />

1<br />

2<br />

3<br />

4<br />

5<br />

6<br />

7<br />

Grasso<br />

Pump cover <strong>RC</strong>6<br />

Pump element <strong>RC</strong>6<br />

Bearing<br />

Hex. head bolt M6x16<br />

O-ring 3.53x209.14<br />

O-ring 3.53x136.12<br />

Pump housing <strong>RC</strong>6<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

26.36.700<br />

26.36.601<br />

26.36.710<br />

01.10.316<br />

09.52.365<br />

09.52.363<br />

26.36.503<br />

1<br />

1<br />

1<br />

1<br />

1<br />

8<br />

8<br />

1<br />

1<br />

1<br />

1<br />

3<br />

1<br />

1<br />

1 from 88.11.2400<br />

0089238-v004.00.02.en <strong>RC</strong>6 C9


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

CAPACITY CONTROL MECHANISM FIG. <strong>RC</strong>6-8<br />

1<br />

2<br />

3<br />

4<br />

5<br />

6<br />

7<br />

8<br />

9<br />

10<br />

11A<br />

11.1A<br />

11.2A<br />

11B<br />

11.1B<br />

11.2B<br />

12<br />

13<br />

14<br />

15<br />

16<br />

Flange capacity control<br />

Cylinder head screw M4x10<br />

Piston<br />

Compression spring 1.25x10x11.5x51<br />

Rectangular ring 56x51.3x2<br />

Washer M10<br />

Hex. head bolt M10x40<br />

Oilit gasket 87x94x1.5<br />

Cylinder<br />

Rectangular ring 40x36.6x2<br />

Solenoid valve 110/120V<br />

Valve body<br />

Coil 110/120V 9W<br />

Solenoid valve 220/240V<br />

Valve body<br />

Coil 220/240V 9W<br />

Connector<br />

Nipple coupling 6G10<br />

Set screw M5x10<br />

Socket head scew M8x1<br />

O-ring<br />

27.36.702<br />

01.68.210<br />

27.36.600<br />

11.31.132<br />

09.70.056<br />

11.13.501<br />

01.10.540<br />

09.07.087<br />

27.36.500<br />

09.70.040<br />

*<br />

*<br />

13.16.311<br />

06.80.111<br />

*<br />

13.16.322<br />

13.16.610<br />

13.16.611<br />

13.16.615<br />

03.37.106<br />

01.23.010<br />

03.65.708<br />

09.51.093<br />

1<br />

4<br />

1<br />

1<br />

1<br />

4<br />

4<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

3<br />

2<br />

per controlled cylinder cover<br />

NH3/R<br />

for valves 11A/11B, without LED<br />

With 220 V-AC/DC LED<br />

With 48 V-AC/DC LED<br />

OIL DISCHARGE FILTER FIG. <strong>RC</strong>6-9<br />

1<br />

1.1<br />

1.2<br />

2<br />

3<br />

4<br />

5<br />

6<br />

Grasso<br />

Filter set<br />

O-ring 3.53x136.12<br />

Filter cartridge 480x15<br />

Hex. nut M6<br />

Stud M6x20<br />

Filter housing 130<br />

Hex. head bolt M10x75<br />

Washer M10<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

07.11.900<br />

09.52.363<br />

*<br />

01.45.300<br />

01.51.320<br />

07.02.130<br />

01.10.575<br />

11.13.501<br />

C10 <strong>RC</strong>6 0089238-v004.00.02.en<br />

1<br />

1<br />

1<br />

1<br />

1<br />

6<br />

6


<strong>Refrigeration</strong> Division<br />

Grasso<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

<strong>RC</strong>6-8<br />

<strong>RC</strong>6-9<br />

0089238-v004.00.02.en <strong>RC</strong>6 C11


<strong>Refrigeration</strong> Division<br />

Grasso<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

� � � � � � � � � � � � � � � � � � � � � � �<br />

�<br />

� � � � � � � � � � � � � � � � � � � � � �<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

�<br />

� � � � � � � � � � � � � � � � � � � � � �<br />

�<br />

� � � � � � � � � � � � � � � � � � � � � �<br />

�<br />

� � � � � � � � � � � � � � � � � � � � � �<br />

�<br />

<strong>RC</strong>6-10<br />

<strong>RC</strong>6-11<br />

C12 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

FLANGED MAIN CONNECTIONS FIG. <strong>RC</strong>6-10<br />

1A<br />

1B<br />

1C<br />

2<br />

3<br />

4<br />

Shoulder flange <strong>RC</strong>46<br />

Shoulder flange <strong>RC</strong>66<br />

Shoulder flange <strong>RC</strong>86<br />

Hex. head bolt M16x40<br />

Oilit ring 67x81x1.5<br />

Relief valve<br />

05.39.045<br />

05.39.051<br />

05.39.063<br />

01.10.840<br />

09.03.067<br />

12.49.333<br />

1<br />

1<br />

1<br />

4<br />

1<br />

per flanged connection<br />

per flanged connection<br />

SUCTION GAS STRAINER FIG. <strong>RC</strong>6-11<br />

1A<br />

1B<br />

2<br />

3<br />

Grasso<br />

Shoulder flange <strong>RC</strong>46<br />

Shoulder flange <strong>RC</strong>66/<strong>RC</strong>86<br />

Oilit ring 67x81x1.5<br />

Wired mesh filter 544x100<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

05.39.048<br />

05.39.060<br />

09.03.067<br />

07.16.544<br />

0089238-v004.00.02.en <strong>RC</strong>6 C13<br />

1<br />

1<br />

2<br />

1


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

OIL SUCTION FILTER FIG. <strong>RC</strong>6-12<br />

1<br />

2<br />

Oil filter 149x16<br />

Swivel coupling 16G21<br />

07.16.164<br />

03.39.216<br />

1<br />

1<br />

from 95.08.1648<br />

OIL DIFFERENTIAL PRESSURE SAFETY SWITCH FIG. <strong>RC</strong>6-13<br />

1<br />

2<br />

3<br />

4<br />

5<br />

6<br />

7<br />

8<br />

Oil pressure safety switch<br />

Bracket 63x115<br />

Angle coupling 6x6x6 (complete)<br />

Socket coupling 6G17 (complete)<br />

Union nut<br />

Steel precision pipe ø6x1 mm<br />

Nipple coupling 6G10<br />

Clamp but sleeve P6<br />

12.60.232<br />

12.61.232<br />

*<br />

03.40.406<br />

03.37.176<br />

03.10.006<br />

*<br />

03.38.106<br />

*<br />

1<br />

1<br />

1<br />

2<br />

2<br />

6<br />

2<br />

1<br />

8<br />

NH3<br />

R<br />

Possibly 6N13 (03.38.813) or 6G13<br />

(03.38.136) are applied<br />

OIL PRESSURE REGULATOR FIG. <strong>RC</strong>6-14<br />

1<br />

1.1<br />

1.2<br />

1.3<br />

1.4<br />

1.5<br />

1.6<br />

1.7<br />

1.8<br />

1.9<br />

2<br />

3<br />

Grasso<br />

Oil return line SAM <strong>RC</strong>6<br />

Steel precision pipe K12x1.5 <strong>and</strong> valve housing<br />

Alu sealing ring 21.5x27x1<br />

Ball W16<br />

Spring 1.25x14x9x35.5<br />

Thrust bolt G21x60S<br />

O-ring 1.78x8.73<br />

Nipple G21CxG21<br />

Alu sealing ring 10x18x1<br />

Cap nut GK21R<br />

Nipple coupling 12G13<br />

Nipple coupling 12G21<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

12.41.140<br />

12.41.012<br />

09.12.022<br />

11.19.010<br />

11.31.134<br />

01.35.218<br />

09.52.184<br />

03.04.921<br />

09.12.010<br />

01.17.021<br />

----------<br />

----------<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

lubricating oil pressure regulator<br />

included<br />

refer to fig. <strong>RC</strong>6-6<br />

refer to fig. <strong>RC</strong>6-1<br />

C14 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

1<br />

Grasso<br />

<strong>RC</strong>6-12<br />

1.1<br />

3<br />

2<br />

1.2<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

1.3 1.4 1.5 1.6 1.7 1.8 1.9<br />

<strong>RC</strong>6-13<br />

<strong>RC</strong>6-14<br />

0089238-v004.00.02.en <strong>RC</strong>6 C15


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

STANDARD SETS OF PARTS, SEALS AND TOOLS FIG. <strong>RC</strong>6- (no figure)<br />

1<br />

2<br />

3<br />

4<br />

Grasso<br />

Set of gaskets <strong>and</strong> seals<br />

Set of spare parts (containing valve rings <strong>and</strong><br />

sinusoidal springs)<br />

Set of basic spare parts<br />

Tire clamp (coupling tool)<br />

STANDARD ILLUSTRATED PARTS LIST <strong>RC</strong>6<br />

09.90.046<br />

09.90.066<br />

09.90.086<br />

*<br />

*<br />

15.08.232<br />

15.08.244<br />

15.08.280<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

for <strong>RC</strong>46<br />

for <strong>RC</strong>66<br />

for <strong>RC</strong>86<br />

for all types<br />

for coupling element 42<br />

for coupling element 61<br />

for coupling element 91<br />

C16 <strong>RC</strong>6 0089238-v004.00.02.en


<strong>Refrigeration</strong> Division<br />

The illustrated parts list of the accessories on the following pages is meant for identification <strong>and</strong><br />

accurate specification of current spare parts. In order to facilitate quick retrieval of the required parts,<br />

the list <strong>and</strong> corresponding figures is divided into the following groups of parts:<br />

GROUP OF PARTS<br />

Grasso<br />

PARTS LIST<br />

Page<br />

CORRESPONDING FIGURE<br />

No.:<br />

o Pressure gauges <strong>and</strong> safety switches 2 <strong>RC</strong>6-A1<br />

o Direct drive 5 <strong>RC</strong>6-A2<br />

o Cooling water device 6 <strong>RC</strong>6-A3<br />

Figures<br />

All parts shown in the figures bear an item number.<br />

Assemblies are indicated by a dotted frame with<br />

separate item number around the parts included in<br />

that particular assembly;<br />

the parts themselves bear the same item number,<br />

followed by a sequence number (e.g. 2.1, 2.3, 2.3, etc.).<br />

Parts lists<br />

The parts are specified by the headings “Item”,<br />

“Description” “Ref. no.” <strong>and</strong> “Qty” (= Quantity).<br />

* If an asterisk is used instead of the Ref. no., this means<br />

that the relevant part cannot be obtained separately.<br />

When for some part no quantity has been given, the<br />

quantity required depends on the compressor size.<br />

When determining the required quantity of parts, it<br />

should be considered that the listed quantities relate<br />

to the corresponding figure <strong>and</strong> not to the compressor<br />

as a whole. When ordering, for example, valve<br />

rings for two discharge valves, the quantities stated<br />

in the relevant list must be doubled, because these<br />

apply to one discharge valve only.<br />

<strong>RC</strong>6W<br />

This is a <strong>RC</strong>6 compressor, including water cooled cylinder<br />

heads<br />

How to order!<br />

It is emphatically pointed out that a prompt despatch of the correct spare parts can be<br />

guaranteed only if the following information is given:<br />

1. Type designation of the compressor<br />

shown on the compressor name plate<br />

2. Serial number of the compressor<br />

3. Quantity, Description <strong>and</strong> Ref. No. of the required parts.<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

v002.99.05.en <strong>RC</strong>6 Accessories 1


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

PRESSURE GAUGES AND SAFETY SWITCHES FIG. <strong>RC</strong>6-1A<br />

1a Pressure gauge <strong>and</strong> safety switch cabinet NH3 - std 12.08.301 1 with two safety switches<br />

R22 - std<br />

12.08.601 1 with an additional safety<br />

R134a - std 12.08.701 1 switch to meet German<br />

R404A - std 12.08.801 1 UVV-VBG20 regulations<br />

1b<br />

1.1<br />

1.2<br />

1.3<br />

1.4<br />

1.5a<br />

1.5b<br />

1.6<br />

Grasso<br />

Pressure gauge <strong>and</strong> safety switch cabinet NH3 - UVV-VB420<br />

Pressure gauge discharge pressure NH3 - R-P-63<br />

R22 - 63<br />

R134a - 63<br />

R404A<br />

Pressure gauge suction pressure NH3 - R-Z-63<br />

R22 - Z-63-12<br />

R134a - Z-63-12<br />

R404A - Z-63-12<br />

Pressure gauge oil pressure R-O-63<br />

Oil pressure safety switch type NH3 MP55A<br />

R MP55<br />

Combined suction <strong>and</strong> discharge pressure safety switch type<br />

NH3 KP15A<br />

R KP15<br />

Combined discharge pressure limitor <strong>and</strong> safety switch type<br />

NH3 kP7ABS<br />

R kP7BS<br />

Suction pressure safety switch type NH3 KP1A<br />

R KP1<br />

12.08.302<br />

12.08.602<br />

12.08.702<br />

12.08.802<br />

12.10.065<br />

12.12.065<br />

12.12.066<br />

12.12.067<br />

12.10.066<br />

12.12.068<br />

12.12.069<br />

12.12.070<br />

12.15.065<br />

12.60.232<br />

12.61.232<br />

12.60.615<br />

12.61.615<br />

12.60.618<br />

12.61.618<br />

12.60.608<br />

12.61.608<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

Accessories 2 <strong>RC</strong>6 v002.99.05.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

<strong>RC</strong>6-1A<br />

v002.99.05.en <strong>RC</strong>6 Accessories 3


<strong>Refrigeration</strong> Division<br />

2<br />

Grasso<br />

1.1<br />

1<br />

electric<br />

motor<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

compressor<br />

<strong>RC</strong>6-2A<br />

Accessories 4 <strong>RC</strong>6 v002.99.05.en


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

DIRECT DRIVE FIG. <strong>RC</strong>6-2A<br />

1a Coupling type 42 (complete)<br />

* 1 to facilitate mounting, a steel strip<br />

1.1a Coupling element 55<br />

19.18.842 1 is clamped around the coupling<br />

1b Coupling type 61 (complete)<br />

* 1 element, which must be removed<br />

1.1b Coupling element 80<br />

19.18.861 1 before putting the compressor into<br />

1c Coupling type 91 (complete)<br />

* 1 operation<br />

1.1c Coupling element 120<br />

19.18.891 1<br />

2<br />

Grasso<br />

Clamping sleeve<br />

*<br />

1<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

v002.99.05.en <strong>RC</strong>6 Accessories 5


<strong>Refrigeration</strong> Division<br />

Item Description Ref. No. Qty Remarks<br />

COOLING WATER DEVICE FIG. <strong>RC</strong>6-3A<br />

1<br />

2<br />

3<br />

4<br />

5<br />

6<br />

6.1<br />

7<br />

8<br />

9<br />

10<br />

Grasso<br />

Hose, rubber 19W<br />

Hose clamp 19-28 mm<br />

Spigot nipple 19xG21<br />

Angle socket coupling G21xG21<br />

Socket nipple G21xG42<br />

Nipple coupling 16G21<br />

Clamping sleeve P16<br />

Coil cooler 16x1.5x64x280<br />

Water cooled cylinder cover without control<br />

Water cooled cylinder cover with control<br />

Side cover for oil cooler coil<br />

15.18.019<br />

15.08.600<br />

15.55.419<br />

03.72.441<br />

03.02.471<br />

03.38.212<br />

03.34.516<br />

04.10.364<br />

23.36.505<br />

23.36.515<br />

05.30.178<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

1<br />

twice per hose<br />

per cyl. head cover connection<br />

per coil connection<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

Accessories 6 <strong>RC</strong>6 v002.99.05.en


<strong>Refrigeration</strong> Division<br />

Grasso<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

<strong>RC</strong>6-3A<br />

v002.99.05.en <strong>RC</strong>6 Accessories 7


<strong>Refrigeration</strong> Division<br />

Grasso<br />

PARTS LIST <strong>RC</strong>6<br />

ACCESSORIES<br />

Accessories 8 <strong>RC</strong>6 v002.99.05.en


<strong>Refrigeration</strong> Division<br />

Grasso


Please contact your office:<br />

Grasso Products B.V. P.O. Box 343 • 5201 AH ’s-Hertogenbosch • The Netherl<strong>and</strong>s<br />

Phone: +31 (0)73 - 6203 911 • Fax: +31 (0)73 - 6231 286 • E-Mail: products@grasso.nl<br />

Grasso GmbHHolzhauser Straße 165 • 13509 Berlin • Germany<br />

<strong>Refrigeration</strong> Technology Phone: +49 (0)30 - 43 592 6 • Fax: +49 (0)30 - 43 592 777

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