GEA Grasso RC219, Instruction Manual

Page 1: ...RC9 Instruction Manual For Refrigeration Compressors 00 89 221 v003 99 06 en ...

Page 2: ...is restriction also applies to the corresponding drawings and diagrams For extra information as to adjustments maintenance and repair contact the Technical Department of your supplier This publication has been written with great care However Grasso cannot be held responsible neither for any errors occurring in this publication nor for their consequences Refrigeration Compressors Series RC9 v003 99...

Page 3: ...ity control 5 5 5 6 Injection interstage gas cooler 5 5 6 OPERATION OF THE COMPRESSOR 6 1 Unloaded starting 6 1 6 2 Loaded operation of the compressor 6 1 6 3 Liquid hammer 6 1 7 STARTING STOPPING AND ADJUSTMENT OF COMPRESSOR 7 1 Starting the compressor 7 1 7 2 Stopping the compressor 7 1 7 3 Setting of the oil pressure regulator 7 1 7 4 Setting of pressure safety switches 7 3 8 PERIODICAL INSPECT...

Page 4: ...Refrigeration Division Grasso TABLE OF CONTENTS Page II Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 5: ... the operating staff and for which no specialist knowledge is needed Any parts to be replaced can be ordered on the basis of drawings with parts lists For more specialized repair and overhaul operations the installation engineer should be consulted Faults and defects of the refrigeration compressor should be remedied as soon as possible by qualified personnel in order to reduce down time to a mini...

Page 6: ...Refrigeration Division Grasso 1 INTRODUCTION Page 1 2 Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 7: ...cooled surface This process takes place in the condenser The liquid thus formed is fed from the condenser to the evaporator again in order to evaporate there anew In the line between the two apparatuses a liquid regulator is fitted which ensures that the right amount of refrigerant flows to the evaporator and maintains the pressure difference between condenser and evaporator The correct operation ...

Page 8: ...Refrigeration Division Grasso 2 FUNCTION OF THE COMPRESSOR IN THE REFRIGERATION PLANT Page 2 2 Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 9: ...n of rotation min max min max max max max max mm mm rev min rev min bar e bar e bar e bar C C 110 85 600 1450 0 7 6 0 21 0 17 5 170 70 normally counter clockwise faced against shaft end REMARK bar e means gauge pressure Single stage compressors Two stage compressors Compressor type RC29 RC49 RC69 RC219 RC429 Number of cylinders Weight without flywheel and accessories Oil charge in crankcase LP HP ...

Page 10: ...All dimensions in mm All dimensions in mm All dimensions in mm Refrigeration Division Grasso 3 TECHNICAL DATA Page 3 2 Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 11: ...or 11 Oil temperature 12 Oil charge and drain valve 13 Cooling water supply 14 Crankcase heating 15 Oil leakage drain of rotary shaft seal clamp coupling for 6 x 1 mm steel precision tube 1 2 BSP female plugged off 1 2 BSP male 1 2 BSP female with steel precision tube 12 x 1 5 mm SINGLE STAGE RC29 RC49 RC69 ø55 1 ø55 2 ø91 ø43 ø62 ø77 TWO STAGE RC219 RC429 ø55 1 ø77 ø43 ø62 ø43 ø62 ø43 ø43 1 O D o...

Page 12: ... be chosen when a high oil temperature is expected due to arduous operating conditions such as a high ambient temperature of the compressor high engine room temperature a more than normal superheat of the refrigerant suction vapour prolonged part load operation with a large num ber of cylinders cut out For less arduous operating conditions a lower viscosity may be used For strongly varying conditi...

Page 13: ...red for compressor lubrication FIG 4 1 CONSTRUCTION OF THE COMPRESSOR 1 Crankcase 2 Cylinder jacket 3 Suction manifold 4 Discharge manifold 5 Cylinder liner with valve lifting mechanism 6 Cylinder head cover 7 Cooling water jacket 8 Bearing cover 9 Oil pump 10 Rotary shaft seal 11 Oil sight glass 12 Sleeve for heating element 13 Non return valve 14 Service cover 15 Piston 16 Connecting rod 17 Cran...

Page 14: ...all end The crankshaft is mounted in slide bearings consisting of interchangeable white metal lined steel bushes pressed into the bearing covers The crankshaft furnished with cast on counterweights is dynamically balanced The tapered shaft end with key for taking up flywheel or coupling is carried gastight through the bearing cover see par 4 3 Rotary shaft seal 4 3 ROTARY SHAFT SEAL In order to pa...

Page 15: ...der liner by a powerful buffer spring For the function of this buffer spring see Chapter 6 par 6 3 Liquid Hammer Fig 4 3 only shows schematically the construction and operation of the suction and discharge valves For the real construction reference is made to Chapter 9 Compressor Maintenance 4 5 VALVE LIFTING MECHANISM see fig 4 4 In order to enable the compressor to start unloaded all cylinders h...

Page 16: ...op valves The LP suction connection is fitted on the suction strainer housing in which a removable metal strainer element is provided for purifying the intake refrigerant gas Compressor type RC69 is provided with two strainer elements In the case of two stage compressors the LP discharge connection is connected via an interstage cooler to the HP suction connection see also Chapter 5 par 5 6 Inject...

Page 17: ...s provided with a paper filter element retaining the fine metal particles suspended in the oil The oil is drawn from the crankcase via the oil suction filter The pressures dilevered by the gear pump are a lubricating pressure and a control pressure to operate the valvelifting mechanisms capacity control The pressurized lubricating oil is delivered to the discharge filter led back to the pump housi...

Page 18: ... SYSTEM The lubrication of the compressor is effected under pressure the lubricating oil circuit is shown in fig 4 6 overleaf The pump draws the oil from the crankcase via a suction filter and feeds it back under pressure to the oil pump housing via a discharge filter From this housing the oil flows into the crankshaft in which a continuous oil channel is drilled provided with radially drilled oil...

Page 19: ...ure in the lubrication system The connection for the oil pressure gauge and the lubricating oil pressure safety switch is provided upstream the pressure regulator on the shaft seal housing The oil pump supplies besides the lubricating oil pressure also a separate control oil pressure for the valve lifting mechanism for further data refer to chapter 4 9 Oil pump filters and control oil system Refri...

Page 20: ...Refrigeration Division Grasso 4 GENERAL DESCRIPTION THE COMPRESSOR Page 4 8 Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 21: ...atmospheric the pressure gauge indicates a negative value The scale of suction discharge and intermediate pressure gauges is adjusted to the refrigerant in the plant as besides the pressure scale also the saturation temperatures corresponding to te overpressures are given 5 2 PRESSURE SAFETY SWITCHES In order to protect compressor and plant safety switches for discharge pressure suction pressure a...

Page 22: ... auxiliary contact is provided for connecting a pilot lamp or a klaxon The permanently set contact differential is 0 3 bar so that the lubricating oil pressure should be at least 1 3 bar to cause the switch to make circuit again In order to start the compressor and to allow it to build up lubricating oil pressure the contact of the safety switch must have been shunted with the aid of a separate ti...

Page 23: ...eding on the compressor size one or more of the last named ports may be out of use The distributor has five positions In position 1 the control pressure is blocked and the valve lifting mechanisms are connected to the oil return Only the cylinders directconnected to the control pressure are then in operation In the positions 2 3 4 and 5 the control pressure is admitted step by step to the valve li...

Page 24: ...zed energized APPLICATION starting and min capacity control up to maximum capacity COMPRESSOR TYPE OPERATING CYLINDERS Each figure between brackets refers to the swept volume expressed as a percentage of the full load swept volume TABLE 5 2 STANDARD STEPS OF THE ELECTRICALLY OPERATED CAPACITY CONTROL SINGLE STAGE COMPRESSORS ONLY TABLE 5 1 STANDARD STEPS OF THE MANUALLY OPERATED CAPACITY CONTROL S...

Page 25: ...on one side of the valve housing which after being pressed and turned in the upright vertical position keeps the valve VALVE NO m non energized l energized APPLICATION starting minimum capacity control up to maximum capacity COMPRESSOR TYPE OPERATING CYLINDERS Each figure between brackets refers to the swept volume expressed as a percentage of the full load swept volume RC219 Cylinder no 1 omitted...

Page 26: ...he evaporation of this liquids the temperature of the gas to be sucked by the HP cylinders is reduced The amount of liquid is controlled by a thermostatic expansion valve whose temperature bulb must be clamped externally against the HP suction line of the compressor see fig 5 4 overleaf At compressor standstill the supply of liquid is cut off by a solenoid valve located upstream the expansion valv...

Page 27: ...or compressors provided with capacity control a limited minimum allowable number of cylinders is operated direct by the control pressure the other cylinders can if required be cut in or out manually via the oil distributor or electrically via the three way solenoid valves refer also to Chapter 8 Supervision during compressor operation 6 3 LIQUID HAMMER Liquid hammer occurs when together with the r...

Page 28: ...Refrigeration Division Grasso 6 OPERATION OF THE COMPRESSOR Page 6 2 Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 29: ...ether the discharge stop valve the pressure gauge valves and in the case of two stage compressors the stop valves in the intermediate pressure line are open e In the case of a compressor provided with a manually operated capacity control set the oil distributor to position 1 In the case of a compressor provided with an electrically operated capacity control Check whether the manual control lever o...

Page 30: ...mpressor and wait until it has achieved a constant operating temperature b Determine the difference between the indication of the oil pressure gauge and the suction pressure gauge This difference should be approx 1 5 bar c If the pressure difference is not correct remove the cap nut with sealing ring from the lubrication oil pressure regulator see fig 7 1 Turn the slotted set pin with a screw driv...

Page 31: ... compressor Setting is effected by turning the main spindle with a spanner after the cap on top of the housing has been removed The set value can be read from a graduated scale in the front cover The lubricating oil pressure safety switch must be set at 1 bar which is the minimum allowable difference between oil pressure and crankcase pressure sucton pressure Setting takes place by turning the set...

Page 32: ...Refrigeration Division Grasso 7 STARTING STOPPING AND ADJUSTMENT OF COMPRESSOR Page 7 4 Refrigeration Compressors Series RC9 v002 97 10 en ...

Page 33: ...ling is applied Water temperature must be higher than condensing temperature Crankcase heating if provided During compressor standstill the crankcase bottom side must remain warmer than the surroundings Condition of V belts Check belts for 1 wear fraying cuts etc and ensure that they do not touch the groove bottom 2 Tension Too low a tension gives rise to excessive flapping or oscillation in opera...

Page 34: ... far as the object to be cooled is concerned Particularly in case of fully automatically operating installations for which little or no personnel is available the periodical inspection must not be neglected The table on the back sums up all the points of the compresor that have to be inspected it also contains instructions as to how frequently the various inspections have to be carried out During ...

Page 35: ...rmitted to mix different types of oil If another type of oil is used first remove all stale oil consequently also the oil in the filters oil pump crankcase shaft seal oil separator and oil drains of the installation Oil change must take place as soon as the oil is dirty Dirty oil is dark coloured and hardly transparent In order to find out if it is necessary to change oil a slight quantity of oil ...

Page 36: ...e to this connection point and put its open end at some safe place in the free air j Slowly open the pressure gauge stop valve so that the discharge gas still present in the compressor can escape via the hose k Remove the hose NOTE Connecting the line to the lower side of the discharge pressure safety switch and removing the shunting of the contacts in the suction pressure safety switch should be ...

Page 37: ...new all o rings including the centre seal of both upper filter housing f Place the gauze filter element and a new grey marked paper filter element in their corresponding filter cups MIND The paper filter element oil discharge filter should be placed on the right hand side of the pump g Screw the filter cups do not forget the o ring around the filter cup into their corresponding filter upper housin...

Page 38: ...ARK All valve parts can be obtained separately h Carefully clean all valve parts and slightly oil them with compressor oil then reassemble the discharge valve MIND The sinusoidal springs should be fitted so that the convex side of the springs where the spring profile is flat bears against the stroke limitor The other side of which approx only the outer point of the spring profile bears should ther...

Page 39: ...ropped considerably and wait until the suction pressure ceases to fall or the oil lubricating pressure safety switch becomes operative MIND Immediately stop the compressor as soon as the oil lubricating pressure i e the difference between oil pressure and suction pressure becomes lower than 1 bar d Reconnect the line to the discharge pressure safety switch When the discharge pressure increases the...

Page 40: ...Refrigeration Division Grasso 9 COMPRESSOR MAINTENANCE Page 9 6 Refrigeration Compressors Series RC9 v003 98 11 en ...

Page 41: ...fety valve is leaking 8 Repair or renew C Suction pressure too high 1 Capacity control does not operate 1 Repair 2 Compressor capacity too small 2 Consult installation engineer 3 Suction pressure gauge defective 3 Repair or renew 4 One or more suction valves defective 4 Repair or renew 5 One or more discharge valves defective 5 Repair or renew 6 By pass safety valve is leaking 6 Repair or renew D ...

Page 42: ...ature 1 Lubricating oil pressure regulator not adjusted properly or defective 1 Re adjust or repair 2 Defective oil pressure and or suction pressure gauge 2 Repair or replace J Too low oil pressure 1 Tool little amount of oil in crankcase 1 Top up oil 2 Oil suction and or discharge filter is dirty 2 Clean or renew 3 Lubricating oil pressure regulator not adjusted properly or defective 3 Re adjust ...

Page 43: ...te quick retrieval of the required parts the list and corresponding figures is divided into the following groups of parts GROUP OF PARTS PARTS LIST Page CORRESPONDING FIGURE No o Compressor housing with connections and overflow safety valves 2 RC9 1 o Bearing covers 5 RC9 2 o Crankshaft 5 RC9 3 o Piston and connecting rod 6 RC9 4 o Cylinder and valve lifting mechanism 6 RC9 5 o Suction and dischar...

Page 44: ... Qty per cylinder head Qty per cover on 6 cylinder compressors only for 6 cyl compressors Qty x2 1 per cyl head in single stage compr and on LP side of two stage compr 1 per cyl head on HP side of two stage compressors 21 24 21 22 23 24 Housing of safety valves 12 21 bar Hex head nut M10 Housing top half 18x8 Hex head bolt M10x55 Hex head bolt M10x40 01 15 510 48 13 218 01 10 555 01 10 540 6 1 2 4...

Page 45: ...RC9 1 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 v003 99 06 en Refrigeration Compressors Series RC9 C3 ...

Page 46: ...RC9 2 RC9 3 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 C4 Refrigeration Compressors Series RC9 v003 99 06 en ...

Page 47: ...ft E KA20 with approval K KA20 Crankshaft E KA40 with approval K KA40 Crankshaft E KA60 with approval K KA60 22 15 202 22 15 212 22 15 402 22 15 412 22 15 602 22 15 612 1 1 1 1 1 1 2 cyl compressor 3 and 4 cyl compressor 6 cyl compressor 1 1 1 2 1 3 1 4 1 5 1 5 1 1 5 2 1 5 3 1 6 Crankshaft E K RC9 Cylindrical pin 4x8 Carrier disc 57x9 Locking bolt M6x16 Spacer assy 65x130x36A Fitted bolt M10 Space...

Page 48: ...60x1 5 23 06 000 27 06 600 09 02 150 09 01 150 09 03 150 1 1 1 1 1 1 mm thick 1 25 mm thick 1 5 mm thick 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9a 4 10a 4 11a 4 9b 4 10b 4 11b Valve lifting mechanism Plug G33 O ring 3x33 Piston housing FA55M Spring 3 2x22x9x80 Control piston Lever FA55 O ring 3 53x23 4 O ring 3 5x36 Cover 060G13 Hex head bolt M10x25 Nipple coupling 6G13 Cover KA60x85A Socket head scr...

Page 49: ...RC9 4 RC9 5 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 v003 99 06 en Refrigeration Compressors Series RC9 C7 ...

Page 50: ...RC9 6 RC9 7 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 C8 Refrigeration Compressors Series RC9 v003 99 06 en ...

Page 51: ...121x150 Suction valve ring 121x150x1 Set of discharge valves and springs Set of suction valve and springs 11 34 850 11 34 852 1 1 1 1 one set per cylinder one set per cylinder ROTARY SHAFT SEAL FIG RC9 7 1 2 3 4 Shaft seal housing RC9 Alu sealing ring 17x21x1 Nipple 12G17 Hex nut M12 26 06 211 09 12 016 03 38 171 01 15 610 1 1 1 6 5 5 1 5 1 1 5 2 5 2 1 Shaft seal assy 060 B incl O ring pos 6 Shaft...

Page 52: ...20x1 Nipple coupling 6G13 Tee coupling E6x6x6 Cylindrical pin 6x12 Steel ball W10 Spring 1 25x9 5x9 5x36 Plug Hex head bolt M6x35 Spring seat 18 10 150 26 14 501 19 37 467 19 37 417 11 46 718 11 46 418 09 52 540 26 14 700 26 14 600 26 16 801 26 17 830 11 31 117 09 12 034 09 52 300 01 36 336 09 12 014 03 38 136 03 40 306 11 06 612 11 19 006 11 31 137 01 36 140 01 10 335 11 06 811 1 1 2 1 1 2 2 1 1 ...

Page 53: ...RC9 8 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 v003 99 06 en Refrigeration Compressors Series RC9 C11 ...

Page 54: ...RC9 9 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 C12 Refrigeration Compressors Series RC9 v003 99 06 en ...

Page 55: ... on top Filter cup 25 Spring Ring nut 03 39 216 09 12 010 03 29 921 06 07 013 01 17 021 03 38 212 01 36 216 09 14 023 09 90 030 07 16 695 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 form one welded piece 2 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 2 12 Oil discharge filter assy RC9 Filter upper housing Swivel coupling 16G21 Steel precision pipe 16x2 Nipple coupling 16G21 Plug G21 Alu sealing ring 21x27x2 ...

Page 56: ... 1 1 1 1 1 1 1 1 1 2 3 Coupling 12G21 Weldable coupling 6x11 03 38 212 03 46 028 1 1 SUCTION GAS STRAINER FIG RC9 11 1 2a 3a 4a 5a Suction strainer housing Hex haed bolt M16x60 Blind flange 89B Oilit ring 98x112x1 5 Hex nut M16 01 10 860 05 14 089 09 03 098 01 15 810 1 8 1 2 8 RC29 RC49 and RC219 2b 3b 4b 5b Hex head bolt M20x70 Blind flange 108B Oilit ring 117x131x1 5 Hex nut M20 01 10 170 05 14 ...

Page 57: ...RC9 10 RC9 11 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 v003 99 06 en Refrigeration Compressors Series RC9 C15 ...

Page 58: ... 1 17 4 2 3 1 1 18 1 14 1 12 1 11 1 10 1 9 1 6 1 5 1 4 1 3 1 2 1 3 1 16B 1 16A 1 1 1 6 1 7 1 8 1 13 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 C16 Refrigeration Compressors Series RC9 v003 99 06 en ...

Page 59: ...pport I180x240 01 10 416 11 13 401 02 34 824 4 4 1 except 6 cylinder compressors ELECTRICALLY OPERATED CAPACITY CONTROL FIG RC9 13 1 2 3 4 5 6 6 1 7 8 9 10 11 12 13 14 15 15 1 16 Support I80x240 Support L30x110A Hex head bolt M8x16 Serrated lock washer M8 Hex nut M8 Three way solenoid valve 220HB Valve coil 110 120 50 60 220 240 50 60 Socket coupling 6G10 Angle coupling EV6x6 Tee coupling EV6x6x6 ...

Page 60: ... 2 2 1 2 2 quantities per gauge STANDARD SAFETY SWITCH PANEL FIG RC9 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Panel 5x100 Hex head bolt M10x50 Spacer sleeve 17 1x2 3x34 Hex nut M10 Grommet 2 13 Cylinder head screw M4x50 Hex nut M4 Lock washer M4 Discharge pressure safety switch type RT5 R12 R22 etc type RT5A NH3 Suction pressure safety switch type RT1 R12 R22 etc type RT1A NH3 Oil pressure saf...

Page 61: ...RC9 14 RC9 15 1 2 11 12 13 6 5 3 4 6 7 15 16 8 9 10 14 7 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 v003 99 06 en Refrigeration Compressors Series RC9 C19 ...

Page 62: ...RC9 16 RC9 17 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 C20 Refrigeration Compressors Series RC9 v003 99 06 en ...

Page 63: ...oupling element 61 1 for coupling element 91 1 for coupling element 182 1 4 5 6 7 Hub locking disc M16x82 Locking plate M16xM8 Washer M8 Hex head bolt M8x30 19 15 882 11 14 848 11 13 401 01 10 430 1 1 1 4 to be supplied with flywheel or flexible coupling PARTS FOR CLAMP COUPLINGS FIG RC9 17 1a 2a 1b 2b 3 4 Clamping sleeve P6 Union nut M12x1 5 DIN 2353 Union nut M14x1 5 DIN 2353 Clamping sleeve P16...

Page 64: ...PART NO SIZE PART NO SIZE PART NO SIZE PART NO RC29 SINGLE STAGE 98X112X1 5 09 03 098 48X58X1 5 09 03 048 RC49 98X112X1 5 09 03 098 67X81X1 5 09 03 067 RC69 98X112X1 5 09 03 098 84X98X1 5 09 03 084 RC219 TWO STAGE 98X112X1 5 09 03 098 48X58X1 5 09 03 048 48X58X1 5 09 03 048 48X58X1 5 09 03 048 RC429 84X 98X1 5 09 03 084 48X58X1 5 09 03 048 84X98X1 5 09 03 084 84X98X1 5 09 03 084 FLANGE NO 1 FLANGE...

Page 65: ...RC9 18 Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 v003 99 06 en Refrigeration Compressors Series RC9 C23 ...

Page 66: ...Refrigeration Division Grasso STANDARD ILLUSTRATED PARTS LIST RC9 C24 Refrigeration Compressors Series RC9 v003 99 06 en ...

Page 67: ...Refrigeration Division Grasso v002 97 10 en Refrigeration Compressors Series RC9 ...

Page 68: ...ogenbosch The Netherlands Phone 31 0 73 6203 911 Fax 31 0 73 6231 286 E Mail products grasso nl Grasso GmbH Holzhauser Straße 165 13509 Berlin Germany Refrigeration Technology Phone 49 0 30 43 592 6 Fax 49 0 30 43 592 777 Please contact your office ...