Screw Compressor Packages

Grasso SPduo
Large Series

Operating manual

01/05 _638332_om_spduo_lrg_gbr_.doc 1
Copyright
All Rights reserved. No part of this publication may be
copied or published by means of printing,
photocopying, microfilm or otherwise without prior
written consent of Grasso. This restriction also applies
to the corresponding drawings and diagrams.
Legal Notice
This publication has been written in good faith.
However, Grasso cannot be held responsible, neither
for any errors occurring in this publication nor for their
consequences.

2 _638332_om_spduo_lrg_gbr_.doc 01/05
 TABLE OF CONTENTS
Grasso OPERATING MANUAL SP DUO LARGE
Refrigeration Division 638332

Title 638332_om_spduo_gbr
Table of contents 638332_inhalt_om_gbr

Description of Design
1 638333gbr
and Function

2 Operating Instructions GSC 510153gbr

3 Operating Instructions 638334gbr

636277gbr
4 Standstill/ Recommissioning 638367gbr

5 Maintenance 638335gbr

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

Process flow diagram

The Grasso Duo Pack LARGE series of screw
compressor packages consists of the following main
assemblies and components:

Figure 1: Process flow diagram: Duo Pack LARGE screw compressor package

010* screw compressor 040 oil pump

015* compressor drive motor 045* suction filter
020 oil separator 060 check valve - discharge side
030 water-cooled oil cooler 075 oil pressure regulating valve
(Design also possible as coolant-cooled oil
170* check valve — compressor discharge side
cooler, Item 200)
280 stop valve — suction side
035 oil filter
* designed for each screw compressor

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

Mode of operation oil Separation

Screw compressor packages Series DUO PACK LARGE The refrigerant-oil mixture is led into the lower part
are refrigeration system components and serve to of the vertical oil separator. There, the first step of oil
compress refrigerants such as ammonia and R22 separation is performed by a combined
(other operating media - as R134a, R404a, R507 - on agglomerator/ demister. The lower part of the oil
request). separator is also used as an oil receiver.
Operation as heat pump is also possible. The fine separation of the aerosol-type oil portion
from the refrigerant is carried out in the upper part
Refrigerant circuit of the oil separator by means of coalescing cartridges.
The oil separated in the fine section of the oil
The screw compressors draw in refrigerant vapour via separator is returned to the compressors suction side
the suction filters and then discharges the compressed via an additional injection orifice.
vapour into the plant via the check valves (on screw
compressors discharge side) and the oil separator.
Oil Cooling
The discharge check valve prevents refrigerant from
Before the oil which has been heated in the
re-condensing in the oil separator.
compressor can be returned to the compressor for re-
use, it must be cooled to a temperature that ensures
The discharge check valve is built into the a sufficient oil viscosity.
oil separator for Screw Compressor
Packages with nominal sizes for the oil filter
discharge side check valve up to NB 150.
After cooling, the oil passes into the oil filter which
The suction filter prevents dirt particles entrained in holds back solid particles from the full oil flow.
the suction flow from entering the compressor. The
filter element features a very large filtering surface The star-folded glass fibre element has, due to its
which is provided by the star-type folding of the large surface area, a large retention capacity and
element. The mesh size is 60 µm. therefore a long service life. The filter has a fineness
of 10 - 15 µm.
Gas oscillations which can arise in the compressor
compression chamber at high pressure ratios during
oil pump
near zero delivery are avoided by a gas oscillation
protection device. This consists of a pressure The oil pump runs for pre- and during compressor
equalisation line between the oil separator and the operation.
compressor working chamber.
It draws the refrigeration compressor oil from the
This pressure equalisation line is only used with receiver space in the oil separator, through the oil
compressors that have an internal volume ratio cooler and oil filter and pumps it to the bearings, the
Vi > 3.6, because only these compressors reach the balance piston, the shaft seal, to the capacity control
critical pressure ratio p ≥ 8 . system and, if fitted, to the compressor's hydraulic Vi
po adjustment system.
The oil pump pumps more oil than the compressor
Oil Circuit uses. This surplus quantity of oil is returned to pump
The screw compressors are run with oil overfeed. suction via the spring loaded oil pressure regulating
Refrigeration compressor oil is fed to the compressors valve. The check valve controls the pressure difference
during the compression process for lubrication, ∆p between the discharge and suction sides of the
sealing, noise reduction and to remove some of the pump.
heat of compression. After the compression process,
the oil is separated from the refrigerant in the oil The set value ∆p is given in the R+I flow
separator. chart
The oil supply for both compressors in the Duo Pack
is realised via an oil pump and an oil coiler in the oil
circuit.

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

Oil injection Oil circuit, miscellaneous

The injection oil is fed without a pump via the oil A multi-function block (MF-block) is flanged on oil
injection regulating valves. filter as an oil distribution system (Standard). The oil
flow is distributed via the bore-holes and drains to
The required compressor discharge temperature is set
different sections of the screw compressor. All for
via the oil injection regulating valves.
controlling the oil circuit necessary fittings and valves
The oil injection regulating valve has a built-in non- are integrated in the MF-block. Thus, a concentrated
return function to prevent refrigerant from being operator unit is available for the screw compressor
drawn into the oil pump. package (see product description).
The oil filter with MF-block is fitted with an oil drain
Function oil and refilling stop valve which may be connected to a
Compressor is fed with function oil from a second separate oil pump or receiver.
compressor port. The functional oil ensures the oil Vent valves are fitted to the suction and oil filters for
supply to the bearings, the compensation piston, and maintenance and repair purposes.
the gland.
Pump pressure supplies the compressor with function
oil.

Solenoid valves oil supply

Solenoid valves are used to supply the screw
compressor with oil. They prevent continued oil feed
if the compressor is shutdown or the MIN end
position of the corresponding compressor’s control
slide is reached.
The solenoid valves are switched via the controls.
Further information is given in the GSC controls
manual.

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

SAFETY DEVICES
Rated current limiter (016) Rated Current limitation is provided by the present compressor control
Safety device of the compressor system. When the rated motor current is exceeded, the compressor
driving motor capacity control slide is driven in the MIN direction until the motor
current reaches an allowable level. The normal capacity control is then
enabled again.

Thermistor motor protection (017) Thermistor which shuts down the compressor drive motor when its
Safety device of the compressor winding temperature limit has been exceeded.
driving motor

Thermistor motor protection (018) Pt100 which shuts down the compressor drive motor when its winding
Safety device of the compressor temperature limit has been exceeded.
driving motor

check valve - discharge side (060) prevents refrigerant re-condensing into the oil separator.

Oil pressure regulating valve (075) regulates the oil differential pressure between the oil pump suction and
discharge sides. The oil pressure regulating valve is integrated into the
multifunction block (Standard). The oil pressure regulating valve is
separately mounted for special operating conditions with external oil
filter.
Set value: see specifications and und R+I flow chart

Discharge pressure transducer (105) The compressor control switch off the drive motor when the discharge
Safety devices to prevent the temperature limit has been exceeded.
discharge pressure from being Limit value p = see Technical Data
exceeded

Oil circuit monitoring When the pressure difference between oil pressure after oil pump and
Safety device to prevent the compressor discharge pressure falls below the specified limit value.
differential pressure between the oil Limit value ∆p = see Specifications
pressure after oil pump (pressure
transducer 110) and the compressor
discharge pressure (pressure
transducer 105) from falling too low

Resistance thermometer (120) The compressor control switch off the drive motor when the discharge
Safety device to prevent the temperature limit has been exceeded.
discharge temperature from being Limit value t = see Specifications
exceeded

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

Resistance thermometer (125) The compressor control switch off the drive motor when the discharge
Safety device to prevent the oil temperature limit has been exceeded.
temperature from being exceeded
Limit value toil (refrigerant ammonia) = see Specifications
Limit value toil (refrigerant R 22) = 45 ± 5 °C
Other refrigerants on request.
The minimum oil viscosity for safe compressor operation is > 7 cSt.
With refrigerant soluble oils, it should be guaranteed that the minimum
oil viscosity is maintained depending on the discharge pressure and
temperature, oil temperature, as well as the type of oil. The oil
temperature for R22 is thus only a standard value.

Pressure relief valve (340) protects the compressor against impermissibly high pressures. The
pressure relief valve must be connected with the suction pipe on site.
Pickup pressure see specifications and R+I flow chart

The pressure relief valve must be connected to the suction

side on installing the package in the refrigeration plant.

Safety valve (345) protects the screw compressor package against impermissibly high
on oil separator pressure.
Blow-off pressure see specifications and R+I flow chart
If the screw compressor package is integrated in refrigeration plant with
an emergency blow-off station, only the connection at the oil separator
is used.
available as an option, depending on the required acceptance

Safety pressure limiter (350) with two separate reset lockout device, of which one can only be reset
using tools (see UVV VBG 20). The safety pressure limiter shuts down the
compressor’s drive motor if the compression discharge pressure exceeds
the set value.
Switching off pressure 1 see Specifications
Switching off pressure 2 see Specifications
If the oil separator cannot be precluded from filling up with liquid by
more than 90% of its volume, the purchaser must provide an additional
safety valve against liquid pressure at the oil separator. The design is in
compliance with DIN 8975-7, 7.5.1.1.

Thermostat (361) Setpoint see Specifications

oil heater

Temperature limiter (362) shuts down the oil heating if a certain surface temperature is exceeded
oil heater at the oil heating.

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

CAPACITY CONTROL
All screw compressors used in the package series are
fitted with a continuous capacity control with a range
of 25 -100 %.
The capacity is adjusted by shortening the compressor
stroke. The defining factor for the compression
process is the effective rotor length; this is altered by
a hydraulically operated control slide.
The position of the control slide is indicated by the
position transducer. The compressor controller
indicates optically by LED means that the MIN or
MAX end position has been reached. The display can
indicate the slide position relative to its full load
position in percent.
The hydraulic slide adjustment is controlled by four
solenoid valves which are contained in one block.
The control slide travel speeds in the MIN and MAX
directions should be approximately the same during
operation to ensure better compressor control.

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

START UP
SV Y1 SV Y2 SV Y3 SV Y4
Screw compressor Type P, R, S, V, Y
capacity
open closed closed open
The solenoid valve block for capacity control is
external located for screw compressors type P, R, S, V capacity  closed open open closed
and Y.
The capacity control slide travel speed in the MIN
During start-up of the screw compressor package, the direction is determined by the fine adjustment of the
oil pump runs for generating the oil pressure required position screw (S6). The capacity control slide travel
for control slide adjustment. speed in the MAX direction is determined by the fine
One of the start-up requirements for the compressor adjustment of the position screw (S5). The position
drive motor is that the control slide of the compressor screw (S7) is opened approximately 2 turns and is
be in its MIN end position. only operated when, despite a fully opened
adjustment screw (S6), the capacity control slide
If the control slide of the compressor is not in its MIN travel speed in the MAX direction is too slow.
end position, the command to reduce capacity is
given and the control slide is driven to its MIN end The pressure limitation valve (DV) guarantees a
position. maximal overpressure ∆p = 6 bar in relation to suction
pressure (for travel speed in the MAX direction). The
The solenoid valve block can be used for all adjusting speed is decreased by throttling screws S5
compressors with fixed Vi at all operating conditions. and S6.
The solenoid valves are pulsed by the control system
and energised in pairs. The adjustment screws S5, S6 and S7 as well as the
pressure limiting valve DV are integrated into the
solenoid valve block for capacity control.
S6 S5

Y2
Y1

L DV1

Y3
Y4

S7

Figure 3: External view of the automatic load regulation’s solenoid

valve block
Figure 2: block with 4 solenoid valves
010 screw compressor
011 control slide position indicator
050 solenoid valve block — capacity control
K K oil supply capacity control,
control direction: part load
L L oil supply capacity control,
control direction: full load
G G oil return capacity control
Oil pressure oil port of oil pump

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 DESCRIPTION OF DESIGN AND OPERATION
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

Screw compressor Type P, R, S, V, Y Setting the adjustment speed

with hydraulic Vi-adjustment
The throttle screws S24 and S25 are used to control
the quantity and are used to set the adjustment
speed. The adjusting speed is decreased by throttling
the valves.

Y6 Y5 DV2

S24 S25

Figure 5: External view of the solenoid valve block of the hydraulic

Figure 4: block with 6 solenoid valves Vi-adjustment

010 screw compressor − capacity increase: actuating S24

capacity decrease: actuating S25
011 control slide position indicator
053 solenoid valve block — capacity control − Adjustment time between the limit positions:
and hydraulic Vi-adjustment 60...(30) sec. Set the throttles so that the
adjustment time is roughly the same in both
K K oil supply capacity control, directions.
control direction: part load
− The adjustment must be carried out while the oil
L L oil supply capacity control,
is at the operating temperature.
control direction: full load
G G oil return capacity control Screw compressor Type W, Z, XA, XB, XC, XD
M M oil supply / oil return at hydraulic Vi- The solenoid valve block is flanged onto the screw
adjustment compressor housing for types W, Z, XA, XB, XC, XD.
Oil pressure oil port of oil pump The connections K, L and M are omitted.
The automatic load regulation and the hydraulic Vi-
The solenoid valves are set as follows for the
adjustment are described in Chapter 4 of the screw
adjustment:
compressor manual.
SV Y1 SV Y2 SV Y3 SV Y4
capacity
open closed closed open
capacity  closed open open closed

SV Y5 SV Y6
capacity
closed open
Full load operation closed open
capacity  open closed

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

Read the ´Operating Instructions´before starting the screw compressor unit/ chiller.
The ´Operating Instructions´ is an extract from the GSC User Manual, containing the most
important information for the operator.
The indexes are identical with those of the GSC User Manual.

For more specific information see GSC User Manual or press the key to obtain more
information about the selected parameter.
The GSC is supplied with text in native language.

CONTENTS

1. DESCRIPTION OF THE GRASSO SYSTEM CONTROL 3

1.1.1. View 3
1.1.2. Lamps/ Push buttons 3

1.2 Operator terminal 3

1.2.1. Key assignment 4
1.2.3 Call up table of contents 5

1.3. Status display 6

4. SYSTEM DESCRIPTION GSC 8

4.1. Explanation of the system LED 8

6. ALARMS 9

6.1.3 View active alarms and warnings 9

6.5 No alarm signal and the compressor will not start 9

7.2 Restart following Alarms 10

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

1. DESCRIPTION OF THE GRASSO SYSTEM CONTROL

1.1.1. View
1.1.2. Lamps/ Push buttons

) White indicator light (Running)

This indicator lamp flashes slowly when the compressor
unit is in the “Ready“ state.

) Yellow indicator light (Warning)

This lamp flashes if an operating condition reaches a
preset value (Warning /Pre-alarm).

) Red indicator light (Alarm)

This lamp flashes if an operating condition exceeds its
permitted value, the machine shuts down on alarm.

) Emergency Stop button

This red button can be used to switch the compressor
unit off at any time in case of an emergency. The
operator terminal controls remain functional.
Figure 1.1: View of outside of switchgear cabinet

1.2 Operator terminal

The operator terminal is the interface between the operator and the control unit.
All switching, operating and control actions are carried out via this operator terminal.
system LED’s function keys soft keys CPU operating mode setting

digital keybord cursor keys system keys system keys LED‘s

Figure 1.3: GSC operator terminal

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

1.2.1. Key assignment

Taste Function

Go to the menu item described in the text display directly above

Back to previous display

Move to next display

Switch on the compressor unit, start enabled

Start 1st compressor (Press key for 5 sec. in operation mode “Manual“)
Increase capacity of 1st compressor (In case of manual capacity control only)

Start 2nd compressor (Press key for 5 sec. in operation mode “Manual“)
Increase capacity of 2nd compressor (In case of manual capacity control only)

No function

Call up display of actual values

Call up alarm signals

Lamp test

Switch off the compressor unit, start disabled

Stop 1st compressor (Press key for 5 sec. in operation mode “Manual“)
Reduce capacity of 1st compressor (In case of manual capacity control only)

Stop 2nd compressor (Press key for 5 sec. in operation mode “Manual“)
Reduce capacity of 2nd compressor (In case of manual capacity control only)

No function

Call up controls — settings

Call up operating mode setting

Call up the menu overview

Return or cancel input

Acknowledge,
reset failure and warning

Confirm input

Display of a help text

Switch over to the 2nd keyboard level

Cursor keys

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

) Special function of the shift key

Change to the “Status display”

+

Change to the “Language selection” or “Contrast menu”

+

Change to the “Digital inputs / outputs display“

+

Change to the “Date, Time“ menu

+

Change between compressor 01 and 02

+ or

1.2.3 Call up table of contents

To get to the table of contents, press the key. A list of the available menus is then displayed.

Number Title Help text

05 Actual values Display of all unit’s actual values

10 Control settings Display and set up of all control parameters
15 Operating modes Selection of operation mode
20 Limit values Set up of alarm, warning and limitation parameters
25 Alarms Display of current and previous alarms
30 Timer settings Set up of timers
35 Unit Options Selection of unit option menus
50 Configuration Enter:
- Refrigerant used
- Compressor type
- With/without economiser
- Scaling of the sensors
— etc
90 Main system menu

To get to these menus, position the cursor on the menu name (using the or key) and confirm with

the key.

) Parameter changes in menu 20, 30, 35, 50 can cause serious damage to the screw compressor unit
or chiller!

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

1.3. Status display

To get to the status display, press the key several times, or press the key and then .
This display shows all of the information shown in the first actual values screen plus the status of the compressor
unit.
PV SP PV: Process Value, display in °C/R (pressure) or °C (temp)
Pos Imot SP: Set Point display in °C / °C/R
Tc Dpoil Pos: Capacity slide position in %
Operating status Imot: Motor current in A
Tc: Discharge pressure in °C/R
dPoil: Differential oil pressure in bar
Operating status: eg Running, Off, Slide to min, Motor in Star etc.

) See menu 05 (actual values) for more detailed information

The operating status provides information about each screw compressor of the DuoPack unit.

Change between compressor 01 and 02

+ or
The following status messages are possible:

Initialisation Initialisation of the controller after swithing on the power supply or after saving the
configuration (save, RAM Æ ROM)

Start to start 01/02 Start delay between two starts is active.

Oil drain 01/02 Oil drain delay is active, the oil pump has run too long by itself.
(Minimum slide position has not been reached during start or stop procedure)

Standby 01/02 Compressor unit ready for switching on, but one or more starting conditions are still
not fulfilled e.g. process variable still below set point

External start 01/02 The controller is waiting for an external signal to enable the start of the unit.

Slide to min 01/02 Starting procedure commenced, slide moving towards minimum position.

Starting 01/02 Compressor motor has been started, and the running feedback signal from the
starter panel has not yet been received.

Running 01/02 Running feedback signal from the starter panel has been received. Unit in operation.

Limit suct press 01/02 A capacity limitation is active (suction pressure too low),
capacity control solenoid to reduce capacity is opened.

Limit disch press 01/02 A capacity limitation is active (discharge pressure too high),
capacity control solenoid to reduce capacity is opened.

Limit mot current 01/02 A capacity limitation is active (motor current too high),
capacity control solenoid to reduce capacity is opened.

Limit ext temp 01/02 A capacity limitation is active (external temperature too low),
capacity control solenoid to reduce capacity is opened.

Limit oil temp 01/02 A temperature limitation is active (oil temperature too high),
refrigerant injection is enabled (optional).

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

Stopping 01/02 The compressor unit has received a shutdown command,

the capacity slide is moved towards its minimum position

Compressor off 01/02 The compressor is switched off

Stop to start 01/02 Start delay between stop and next start is active

Failure01/02 A failure has occurred, which is still active.

italic writing Text display flashes

Normal writing Text display is static

The overall status of the Grasso SPduo is displayed with the LEDs in and .

Key Colour Status Explanation

The Grasso SPduo has received a start request.

Green Flashing
One compressor may start.

Green Continuous light One compressor is running.

The Grasso SPduo is switched off, there is an alarm

None OFF
+ active. The alarm light on the cabinet is active.

Red Continuous light The Grasso SPduo is switched off.

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

4. SYSTEM DESCRIPTION GSC

The system LEDs are located on the front of the GSC. These system LEDs provide information about the status of
the controller.

4.1. Explanation of the system LED

The position of the system LED is given in Chapter 1.2, Fig.1.3.
Meaning of the status and error displays

Display Meaning Explanation

SF (red) C7-CPU-centralised Lights up for:
fault - Hardware errors
- Firmware errors
- Programming errors
- Parameterising errors
- Computational errors
- Time errors
- Faulty internal memory storage
- Battery failure or if standby supply missing for MAINS ON
- Peripheral error in the internal peripheral functions
Further information about the malfunction that has occured can be read
out of the diagnosis memory using the PG.
BATF (red) Battery error Lights up, if battery
- does not have enough voltage,
- is defective,
- is missing.
DC5V Voltage supply
lights up, if the internal DC 5V supply is OK.
(green) for C7
RUN Operating state lights up, if the C7 CPU application program is running.
(green) RUN of the C7-CPU
flashes (2Hz) during the C7 CPU start up (the STOP lamps also lights up;
after the STOP lights go off, the outputs are released).
STOP Operating state lights up, if the C7 is not processing a CPU-application program.
(yellow) STOP of the C7 CPU
flashes at 1-second intervals, if C7 CPU general reset(MRES) is required.
SF-IM (red) Switching module - lights up, if the connection between C7 and the extension rack is
centralised fault interrupted.

Ì
! (red) Alarm active lights up, if a malfunction has been confirmed, but is still active.
flashes, if a further malfunction has been activated.
Help Help text available
lights up, if a help text is available.
(green)
Shift Switch over
lights up, if the SWITCHOVER function is active.
(green) function active

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

6. ALARMS

6.1.3 View active alarms and warnings

The ´Status mode´is displayed by pressing the key several times. The most important actual values are
shown in the first three rows and in the 4th row the status message is shown.

By scrolling with the cursor keys and all active alarms and warnings are displayed.

6.5 No alarm signal and the compressor will not start

Compressor will not start, although there is no active alarm.

Key „ON“ has been pressed and the LED K1 “ON“ is flashing.

Cause Remedy
No ‘start release’ signal The input ´start release´ is not Close input or install a link.
closed.
‘Auto Start dly’ active The time setting ‘Auto start dly’ in Wait until the delay time has
‘control settings menu’ has not yet expired.
expired.
‘Start to start’ delay active The time setting ‘Start to start’ in Wait until the delay time has
‘Timer settings’ menu has not yet expired.
expired.
PV < (SP + ½ NZ) Check set point and neutral zone
settings in ´Control settings´menu.
PV= Process value
SP = Set point Attention:
NZ= Neutral zone In case of suction pressure control
the set point value is entered in
degrees Celsius.

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 Operating Instructions
Grasso Grasso System Control
Refrigeration Division Grasso SP duo

7.2 Restart following Alarms

After pressing the ‘ACK’ key,

the alarm is acknowledged at
the PLC.

The alarm message is deleted

in the display.
The main menu appears in the
display.

Possibility 1 Possibility 2

LED Ì
! (red) ON LED Ì
! (red) OFF

The cause of the alarm Cause of the alarm has

still exists. already been removed.

Remove cause of the alarm

Restore operation
mode active before
alarm occured by
pressing

) Attention! It is not possible to restart the compressor as long as the cause of the alarm still exists!
Display of the cause(s) of the alarms after deleting the display on view (press the key) or in the case that
several alarms have occurred simultaneously:

Step Procedure

1 Call up the ‘Alarms’ menu by pressing the key.

2 Select the ‘View’ menu item for the alarms by pressing the key. The errors that have
occurred can be viewed here with the date and time at which they occur.

) For more detailed explanations for reading the error messages, see Chapter 1.2.2.2. (GSC User
Manual).

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 OPERATING INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

GENERAL INFORMATION Turn the shaft of the compressor at least every four
weeks (approx. 10 revolutions).
The compressor unit must be operated only by trained
and qualified staff who are familiar with the contents At the same time, check the nitrogen filling and
of the user manual for Grasso screw compressor units. recharge to the specified overpressure of 2 bar, if
required. Dry nitrogen with a residual moisture
The safety regulations for the refrigeration plant must
of ≤ 300 ppm is used for this purpose.
always be observed in order to prevent damage to the
compressor unit and injury to the operating staff. INSTALLATION
TRANSPORT AND STORAGE
Rigid installation
Screw compressor units are high-quality products
which must be handled with due care. Protect the The frame of the screw compressor unit is placed on
equipment from impacts and place it down carefully. foundation bolts on a prepared foundation. The frame
must be levelled with suitable shims such that the
When transported by crane, the screw compressor unit coarse alignment (radial and angular misalignment
must have the same position as in operation. Do not ≤ 0,25 mm) at the coupling is attained again. Then
use attaching points other than those provided for this tighten the foundation bolts.
purpose.
The attaching points are designated by the following Anti-vibration mounting
symbol: The frame of the screw compressor unit shall be
aligned with the levelling bolts until the coarse
alignment (radial and angular misalignment
≤ 0,25 mm) at the coupling is attained again.

ASSEMBLY

Assembly of the components.

If a split design is used for the screw compressor
package, the various individual parts must be
assembled in accordance with the general layout
drawing and the labelling.
The size and weight of the individual parts are given
on the general layout drawing.

Figure 1: Designation of the attaching points. Connecting the pipes

It is forbidden to utilize fittings or pipes All pipes and electric cables must be
for attaching the screw compressor unit. connected so that no mechanical tension
Due to the size of the Duo Pack LARGE screw occurs.
compressor package type series, a split design is Purge the nitrogen filling of the screw compressor unit
possible for transport. In this case the attachment by opening the vent valves before connecting the
points are not located in one plane. The ropes must be pipes.
longer than 3 m and the difference in height of the
Establish all pipe connections so that the transmission
individual attachment points must be compensated for
of thermal expansion and vibration to the screw
by suitable extensions.
compressor unit is limited as far as possible.
A means of precluding damage to the surface must be
provided (timber or Armaflex supports). Bellow expansion joints made of steel and flexible
metal tubes can be used for refrigerant and oil lines,
Shackles must be used. bellow expansion joints made of rubber for water
Position the screw compressor unit on the transport connections.
vehicle such that it is prevented from sliding and Provide all pipe connections with fixed points arranged
tilting. The competent staff member or the company is immediately at the unit.
responsible for ensuring transport safety.
The storage area of screw compressor units shall be
roofed, plain and paved and secured against access of
unauthorized persons. The unit is to be protected
against knocks and impacts.

20.06.02/ 0 638334gbr.doc - 1/5

 OPERATING INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

The following works must be carried out: Reinstall any removed measuring, control and regula-
• Connecting suction pipe ting devices after completion of the compression test if
leakproofness of the screw compressor unit has been
• Connecting pressure pipe shown.
• Fixing in the overflow valve in the suction pipe (if
not already installed in the factory). 2. Drying, vacuum
if units are equipped with a safety valve After the pressure test has been completed, the system
is evacuated and subjected to a vacuum test for 3
• Connection of the safety valve (various designs hours.
possible) to the blow-off pipe.
The plant is evacuated to remove air and moisture.
if units are equipped with a water cooled oil cooler:
• oil cooler water connection The obtained vacuum may rise by a maximum of 5 torr
within 6 h.
if units are equipped with a refrigerant cooled oil
cooler:
• refrigerant feed line from h.p. receiver (note
geodetic height above oil cooler)
• evaporated refrigerant line to condenser
if an economizer is used, then connect
• economizer suction line to supercharging

Connecting the electric cables

Connect the following:
• compressor drive motor
• control device current supply
• oil heater Figure 1: Vacuum required for removing moisture from
refrigeration plants
FIRST COMMISSIONING Shut the compressors off when the specified vacuum is
attained; record the measured values hourly. Following

The following procedures should be completed in the vacuum value, enter the machinery hall
the sequence in which they are described: temperatures, the outside temperatures in the shade.
After the vacuum test can follow the pressure compen-
1. Pressure test, tightness test sation with the refrigerant.
The necessary safety precautions should be taken
before performing the pressure test. The pressure test Shut the oil pump during evacuation!
is performed with dried, oil-free air, or with dry
nitrogen.
3. Filling oil
To test the parts which have been repaired for tight-
ness, they are subjected to a pressure of any above The vacuum present in the SCU before pressure
atmospheric pressure (but not higher than the allowed compensation may be utilized for oil charging. After
operation pressure of the unit) using dry air or the pressure compensation and for refilling with oil a
nitrogen for a period of 3 hours. separate oil recharging pump is required.

It is permissible for the pressure to fall by 2% during Check the oil grade to be charged.
the 3 hours. Consideration must be given to variations in See contract or project or Grasso
the ambient temperature. recommendation.
Before starting the compression test Link the connection of the oil draining/oil charging
remove or shut off control and regulating stop valves (090)/(275) with the oil charging tank.
devices which could be damaged at the Shift the valves to the operating position before oil
mentioned test pressure. charging (see P&I diagram).
A record should be kept of the pressure test, noting Open shut-off valve (090) until the oil level has
the pressure in the pipes tested, the ambient reached at the top of the oblong sight glass in the oil
temperature and the temperature outside in the shade separator.
at hourly intervals.

638334gbr.doc - 2/5 20.06.02/0

 OPERATING INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

Oil charging of oil separator has to carry out general 8. Checking the failure shutdown when the
via the oil cooler. temperature is exceeded

4. Checking the failure monitoring The failure shutdown when the temperature is
exceeded can be checked in accordance with the
The failure monitoring can be checked in accordance operating instructions for the control device (Grasso
with the operating instructions for the control device System Control GSC — user instruction 637700).
(Grasso System Control GSC — user instruction 637700).
9. Checking the direction of rotation of the driving
5. Checking the direction of rotation of the oil motor
pump motor
The oil pump is started with the driving motor The coupling must not yet connect motor
electrically blocked. The stop valves are in the and compressor!
operating position. Secure the electric switchgear so as to prevent the
The direction of the arrow given for the oil pump must compressor driving motor from being switched on
correspond to the direction of rotation of the electric accidentally.
motor. With the control slide in the MIN or MAX position, it
should be possible to rotate the compressor shaft
Since the slide ring shaft seal of the oil easily and smoothly by hand. When checking the
pump is dependent on the direction of direction of rotation of the compressor driving motor
rotation and can be damaged when this pay attention to the conditions for switching the
direction is wrong, checking must be compressor on.
reduced to a very short running period
(less than 2 seconds).
The adjusted differential pressure between the oil
pump discharge side and the suction side of the oil
pressure control valve is checked with the oil pump
rotating in the correct direction.

It must not fall below the prescribed set

value (see R+I flow chart). Compressor

While the compressor is not running and the oil has

not yet reached the operating temperature, the
differential pressure can be slightly higher than the
indicated value.
The differential pressure can be changed by rotating Motor
the spindle on the oil pressure control valve. (The
differential pressure is increased by turning it inwards
and vice versa). Figure 3: Rotation direction of the
compressor drive motor
6. Checking the adjustment of the control slide The compressor driving motor is operated in star-delta
connection for a short period in the operating mode
The adjustment of the control slide can be checked in
"MANUAL". After that the compressor driving motor
accordance with the operating instructions for the
has to switch off.
control device (Grasso System Control GSC — user
instruction 637700). If the direction of rotation of the motor is wrong, it
should be corrected while the electric switchgear is
7. Checking the oil circuit monitoring while the oil secured to prevent the motor from being switched on
pump is running accidentally. The motor must then idle for at least 1h.
The circuit monitoring while the oil pump is running The coupling protection must be in place during this
can be checked in accordance with the operating running-in period as required in the labour safety
instructions for the control device (Grasso System regulations.
Control GSC — user instruction 637700). After checking the direction of rotation of the driving
motor the coupling may be connected with the motor.

20.06.02/ 0 638334gbr.doc - 3/5

 OPERATING INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

10. Mounting the coupling COMMISSIONING

The electric switchgear is then again secured to On completion of the above-mentioned work, the
prevent it from being switched on accidentally. Mount compressor unit can be commissioned in accordance
the coupling, observe instructions of separate with the operating instructions for the control device
documentation (see product description). (Grasso System Control CSC — user instruction 637700).
The values for radial and angular deviations given in
the coupling documentation must be checked and if CHECKING THE CONTROL SLIDE ADJUSTMENT TIMES
necessary corrected.
While the SCU is running, determine the adjustment
The real values have to record at data sheet times needed when the control slide is continually
631632gbr (see chapter 5 of product description). moved from the maximum end position to the
Please send back a copy of the filled data sheet to: minimum end position and back. For the automatic
system to run smoothly, the adjustment times in either
Grasso GmbH Refrigeration Technology
direction must be approximately the same.
Holzhauser Straße 165
13509 Berlin Minimum adjustment time 30 sec.
GERMANY Optimum adjustment time 60 sec.
Phone: +49 (0)30 - 43 592 766
The adjustment times are matched by means of
Fax: +49 (0)30 - 43 592 759
throttle screws (DS) mounted on the solenoid valve
plate.
Pay attention to maintenance
instructions: Screwing inwards Adjustment
Regrease the coupling at the prescribed time

intervals!
Screwing outwards Adjustment
time 
OPERATING POSITION OF VALVES
Influencing towards Maximum DS 5
For the positions of the manually controllable fittings
for the operation of the SCP see P&I diagram. Influencing towards Minimum DS 6

The layout and symbols used in the R+I flow charts CHECKING THE OIL COOLER
comply with the specifications of EN 1861, Issue April
1998.
water cooled oil cooler
The valve positions must match the Checking the cooling water circuit and adjusting the
specifications given in the R+I flow chart cooling water control
to ensure trouble free operation! Check whether the cooling water pumps are running
and the hand-operated shut-off fittings in the cooling
• Valve opened during normal operation water circuit are in their operating positions. While the
compressor unit is operating under project conditions,
adjust the cooling water control so that the oil
temperature lies within the permissible range.

• Valve closed during normal operation refrigerant cooled oil cooler

Adjust a stable circuit by means of the valve in the
refrigerant line coming from the receiving tank so as to
achieve that the oil temperature lies within the
permissible range. For guide values see Technical Data.

638334gbr.doc - 4/5 20.06.02/0

 OPERATING INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGE
DUO PACK LARGE

ADJUSTING THE AMOUNT OF INJECTION OIL AND ADJUSTING THE COMPRESSOR CAPACITY
THE OIL TEMPERATURE
The capacity of the compressors can be adjusted
Compressor units without refrigerant injection independently automatically or controlled by hand.
Suction pressure or one extern temperature are
The amount of injection oil and the oil temperature controlling values.
directly influence the discharge temperature of the
compressor. The amount of injection oil is adjusted Reducing the capacity causes an increase in the suction
under project conditions through the injection oil pressure and vice versa. When doing so check the
control valve. ammeter to ensure that the driving motor is not
overloaded. If the current input is too high, the rated
• Standard values for discharge temperature current limiting control comes into operation. This
t tmax means that the overloaded compressor adjusts itself
towards MIN until the current input reaches an
NH3/HP t ≥ toil + 15 K 95°C acceptable level. The capacity can then be adjusted
NH3/LP t ≥ toil 80°C again without restriction.
approx. 45...60°C
Freon/HP ca. 80°C 95°C COMMISSIONING/ SHUTTING DOWN
Freon /LP ca. 45...60°C 80°C Attention must be paid to the information
(see Specifications) given in Chapter 4 for commissioning and
shutting down the machines.
Compressor units with refrigerant injection
The oil temperature is changed by setting the injection
oil control valve. The more the shut-off valve is
throttled, the more the oil temperature decreases. If
the oil temperature becomes too low or it reaches the
lower range,
− the rated value for the discharge temperature
should be set accordingly lower,
− the oil cooling system should be checked.
When the oil circuit is adjusted for the first time, the
injection oil control valve is opened by approx.
1/2 rotation. The discharge temperature is then
regulated to the value indicated in the Technical Data
by means of the thermostatic expansion valve.
• Standard values for discharge temperature
t
NH3/ Freon 50 + 5 °C
(other refrigerants on request)

20.06.02/ 0 638334gbr.doc - 5/5

 STANDSTILL/ RECOMMISSIONING
Grasso OF SCREW COMPRESSOR PACKAGES
Refrigeration Division

SCREW COMPRESSOR PACKAGE STANDSTILL FOR A LONGER PERIOD

H Switch off the compressor. Observe the user instructions of electrical installation.

H Close the stop valves (combined stop/ check valves) on suction and discharge sides.

H Close the stop valves (combined stop/ check valves) in economizer suction line. *)

H Close the refrigerant supply of thermosyphon - oil cooler. *)

H Close the refrigerant injection stop valve. *)

H Switch off the oil heater.

PROCEDURES DURING SCREW COMPRESSOR PACKAGE STANDSTILL

H Check the humidity contant of refrigerant and lubricating oil in case of packages
standstill for a period longer than half a year, even in spite of gauge pressure in the
package.
The humidity contant is not allowed to differ essential from starting value.

MONTHLY

H Check the gauge pressure in the package. Check for leaks using a leakage detector.

H Switch on the oil pump for approx. 5 minutes.

H Turn the screw compressor shaft manual (min. 10 revolutions).

13.09.99/ 0 636277e.doc - 1/2

 STANDSTILL/ RECOMMISSIONING
Grasso OF SCREW COMPRESSOR PACKAGES
Refrigeration Division

PROCEDURES 4 WEEKS BEFORE PACKAGE RECOMMISSIONING

H Check the humidity contant and ageing phenomena of lubricating oil. Analyse the oil
and compare the values with the parameters of freh oil. Grasso recommends to change
the oil at the latest after 1 year (ammonia) or 2 years (R22) (see Maintenance
Instruction).

H Check the insulation resistance of the compressor drive motors (see electric motor User
Instruction).

H Switch the oil pump on.

H Check the Screw Compressor Package for leaks.

PACKAGE RECOMMISSIONING AFTER 1 YEAR

H Change the oil filter elements (see Maintenance Instruction).

H The heater has to switched on at least one hour before starting the package.

H Open the stop valves (combined stop/ check valves) on suction and discharge sides.

H Open the stop valves (combined stop/ check valves) in economizer suction line. *)

H Open the refrigerant supply of thermosyphon - oil cooler. *)

H Open the refrigerant injection stop valve. *)

H Take care, that not all condensable gases are removed by venting during bringing the
package into operation again. Check condensing pressure and condensing temperature
(see Technical Data).

H Check the oil reservoirs and empty the oil if necessary.

H Switch on the compressor. Observe the user instructions of electrical installation. Make a
Package function checkout for testing the sensor and actor technologies (ready for
operation and indicating precision).

*) if assembled

636277e.doc - 2/2 13.09.99/0

 START-UP
Grasso TEMPORARY SHUT-DOWN
Refrigeration Division

NORMAL START-UP

Move the valves into the operating position.

The oil level in the oil separator must be within the permissible range.

Check the cooling water/refrigerant supply of the oil coolers.

The oil heater in the oil separator can be switched on while the compressor unit is not
running. It is then automatically switched off when the unit is started and switched on
when it is shut down. If the ambient temperature is below 5°C, the oil heater must be
switched on at least one hour before the compressor unit is started. (This applies only
when an oil heater is present).

The motor current limitation has to set according to motor nominal data.

Start the compressor unit in accordance with the operating instructions of the
compressor unit control device.

TEMPORARY SHUT-DOWN

If the compressor unit is shut down temporarily, the valves do not need to be operated;
they remain in their operating positions. If there is a possibility of the temperature in
the evaporator to rise above the cooling water temperature, the cooling water supply
must be interrupted or the shut-off valve on the compressor suction side must be closed.

If it is possible that the temperature in the evaporator rises above the ambient
temperature of the compressor unit, the compressor suction-side shut-off valve must be
closed.

SHUTTING DOWN FOR AN EXTENDED PERIOD

For a longer period of unit stand still see Instructions of Data Sheet 636277gbr!

12.06.02/ 0 638367gbr.doc - 1/1

 MAINTENANCE INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGES
DUO PACK LARGE

GENERAL INFORMATION
The compressor unit must be serviced by authorized staff serve as a precondition for a possible
appropriately trained operating staff only. These guarantee claim put to Grasso.
maintenance instructions shall be adhered to during
If repairs are necessary, contact the service depart-
all maintenance work.
ment of Grasso GmbH Refrigeration Technology.
Moreover, all labour safety and fire prevention
instructions and the technical safety rules for Perform all maintenance work carefully to
refrigeration plants must also be observed. keep the SCU in good working order.
Guarantee claims will be rejected if the
The attached maintenance manual contains all the
customer failed to follow the Maintenance
maintenance instructions and certifications for the
Instructions.
first 10 years of performance of the Screw Compressor
Package. The maintenance certification are given and
signed following the inspection and maintenance by Pay attention to maintenance
authorized fitters. This will prove as an evidence for checklist
the maintenance work done. During the guarantee
period these maintenance certifications confirmed by
all 24—72 hrs

Checking of Remarks
monthly
weekly

Final compression
superheat must not be lower than 25 K,

temperature maximum final compression temperature 100°C

Oil temperature
see Technical Data,

the viscosity shall not be lower than 7 cSt at 3000 rpm

oil pressure
the oil pressure must be at least 1 bar above the final compression
pressure, a faulty oil pressure may be caused by a clogged oil filter

final compression
compare with design value, determine the superheat on the discharge
pressure side by comparison with the final compression temperature

Oil level in oil
check the oil level in the sight glass; if it is below the bottom third of the
separator sight glass, recharge oil

Oil heater
upon standstill of the SCU the heater, if any, must start operating
automatically; if the thermostatic cutout disconnects the heater, this may
be caused lack of oil

Adjustment of
compare setpoints in Technical Data

safety devices

Capacity control
solenoid valves must switch audibly when the capacity is adjusted; check
in operating mode "MANUAL"

Number of
see Maintenance schedule for necessary maintenance work

operating hours

oil reservoir
Empty oil reservoir oil pump

oil pump

oil reservoir rotary
Empty oil reservoir rotary seal

seal

20.06.02/ 1 638335gbr.doc - 1/4

 MAINTENANCE INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGES
DUO PACK LARGE

MAINTENANCE WORK

REPLACEMENT OF SUCTION FILTER OIL CHANGE

1. Close the discharge-side shut-off valve on the
Note:
screw compressor unit.
Aged oil features an increasing loss of lubricity.
2. Open suction-side shut-off valve and shut-off
Because of this all rotating components of the
valve bypassing nonreturn valve - suction side -
compressor are endangered. The filter elements
and thus compensate pressure with the l.p. side.
become prematurely clogged and must be cleaned
3. Close suction-side shut-off valve and bypass valve and replaced at shorter intervals.
- non-return valve.
4. Draw off residual overpressure via vent valve of Maintenance work:
suction filter or release considering the safety Take oil samples for analysis and comparison of the
rules. data with those of fresh oil at regular intervals.
5. Screw off housing cover. Examine the colouration of the oil visually and
evaluate the degree of contamination.
6. Remove suction filter element.
7. Clean suction filter element, wash with Changing the oil:
appropriate fat-dissolving cleaning agent 1. The SCU must be run for at least half an hour to
followed by blowing off with compressed air. reach its operating temperature before the oil
8. Replace O ring on suction filter element and can be changed.
reinsert suction filter element. 2. First shut down the compressor as described in
9. Replace O ring on cover, close cover reliably. the Operating Instructions.

10. Evacuate the SCP using a vacuum pump. 3. Open the shut-off valves in the line bypassing the
non-return valve -suction side - and the suction-
side shut-off valve for pressure compensation
Shut off oil pump between SCU and suction line. The refrigerant
should preferably be drawn off (by screw
compressor 1 or 2) to attain a pressure which lies
If evacuation is not possible, the SCU is vented in approx. 1 to 3 bar above atmospheric pressure.
the subsequent step through the vent valve Then reclose shut-off valves/bypass and suction
mounted on the suction filter. Collect escaping side shut-off valve. Otherwise the pressure can be
refrigerant and dispose of as required by law. reduced by opening the vent valve on the suction
11. The SCU is pressurized with a slight overpressure filter and then disposing of the refrigerant as
via shut-off valve bypassing non-return valve - specified by law.
discharge side. 4. Drain waste oil through the oil draining/oil
12. Check all components for leakproofness. Then charging valves and dispose (Note: hazardous
perform a complete pressure compensation with waste!). Then close valve and draw off
the discharge line followed by a repeated leakage refrigerant again until about atmospheric
test of the SCU. pressure is reached using a parallel compressor.
5. Otherwise depressurize the SCU by opening the
Since the compressor is not protected vent valve - suction filter, taking into account the
against coarse dirt particles during safety rules for refrigeration plants.
maintenance work on the suction filter,
special care is necessary in addition to the 6. Open the drain plugs and valves on oil cooler, oil
usual cleanliness required while carrying separator and oil filter with multi-function block
such work. to discharge the residual oil. Then reclose the
drain plugs reliably.
7. Replace or clean the filter elements of oil filter
and suction filter. (see oil filter change and
suction filter change)
8. Evacuate the SCP using a vacuum pump.

Shut off oil pump

638335gbr.doc - 2/4 20.06.02/1

 MAINTENANCE INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGES
DUO PACK LARGE

If evacuation is not possible, the SCU is vented in OIL FILTER REPLACEMENT

the subsequent step through the vent valve 1. Switch the unit off.
mounted on the suction filter. Collect escaping
refrigerant and dispose of as required by law. 2. When the oil filter is heavily contaminated it may
be necessary to replace it even if this is not
9. The SCU is pressurized with a slight overpressure provided according to the normal maintenance
via shut-off valve bypassing non-return valve - schedule.
discharge side.
3. Close the valves for changing oil filter as follows
10. Check all components for leakproofness. Then (acc. to P+I diagrams 634049e.doc, page 6 up to
perform a complete pressure compensation with page 8 and documentation oil filter with multi-
the discharge line followed by a repeated leakage function block 634127e.doc, page 4 up to page 6):
test of the SCU. Charge oil and start the SCU as
specified in the Operating Instructions. 065 stop valves before oil filter
070 stop valve - function oil
Notes on oil change intervals 080 control valve - injectio oil with
The degree to which oil in refrigeration plants has integrated check valve function *
aged must be checked by analysis and comparison of 220 stop valve bypassing oil cooler
the data with those of fresh oil. Oil ageing can also be (optional only)
judged from the darkening of the oil colour and the 690 stop valve — oil supply of the solenoid
deposits found in the oil filters. If the degree of valve block
ageing cannot be assessed reliably by laboratory
* Do not forget to note the number of valve revolu-
analysis and the results of visual examination, it is tions when you close the valve (080). You have to
advisable to change the oil at the following intervals make the same number of valve revolutions when you
(see Maintenance schedule). open the valve (080) again. It's important, because the
discharge temperature is dependant on the size of
Change oil in SCUs using freons as valve opening and possible vibrations in the oil line
refrigerant after every 10000 operating should be avoided.
hours or after 2 years at the latest. 4. Compensate pressure with atmospheric pressure.
5. Drain oil.
Change oil in SCUs using ammonia as
refrigerant after every 5000 operating 6. Remove oil filter cover of multifunction block.
hours or after 1 year at the latest. 7. Withdraw oil filter element and dispose in due
manner if it is heavily contaminated.
8. Carefully insert a new oil filter element.
9. Close oil filter cover of multifunction block.
10. Open above-mentioned valves (see point 3). The
valve (080) has to turned the correct number of
revolutions back to starting position
(see point 3).
11. Vent oil filter through the vent valve after
completion of the pressure compensation.

20.06.02/ 1 638335gbr.doc - 3/4

 MAINTENANCE INSTRUCTIONS
Grasso
Refrigeration Division SCREW COMPRESSOR PACKAGES
DUO PACK LARGE

OIL PUMP MAINTENANCE REPLACEMENT OF THE OIL FINE SEPARATION

An amount of leakage oil of up to one drop/minute is CARTRIDGES
required for lubrication of the slide ring seal and thus 1. Close the discharge and suction side shut-off
permissible. fittings.
The slide ring seal is free of maintenance. If the 2. Draw off refrigerant and depressurize the SCP.
amount of leakage oil is too large, replace it according
3. Check the pressure on the display of the
to the Oil Pump Documentation.
compressor control device or connect a test
The axial grooved ball bearing ist not adjustable. The pressure gauge.
axial play is predetermined by the manufacturer and
4. Remove the pipe bend from the oil separator.
cannot be changed.
5. Remove the non-return valve built in the oil
The axial grooved ball bearing should be subjected to
separator. This step is omitted if a non-return valve
a visual examination and replaced according to the oil
is used the discharge side of which can be shut off.
pump documentation, if required.
6. Remove the locking wire [3].
COUPLING MAINTENANCE 7. Loosen the hexagon head screws [2] used to
1. Place the SCU out of operation. attach the oil fine separation cartridges.

2. Secure the electric motor to prevent that is 8. Remove the cartridge [1].
switched on accidentally. 9. Mount the new cartridge in the reverse sequence.
3. Subject the lamination packages to a visual
examination.
Locking wire [3] must be re-attached !
4. Check the tightening torques of the fitting screws.
5. Check the alignment of the electric motor and
correct it according to the Steel Lamination
Coupling Documentation, if required.
6. Regreasing the coupling (if provided for in the
maintenance instructions for the coupling).

Fig. 1

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02/04 Master_Backpage.doc 1