GEA Grasso RC9 Series, Instruction Manual

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

Page 2: ...s 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...

Page 3: ...ty 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...

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 operation...

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

Page 7: ...ooled 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 apparatuse...

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: ...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 me...

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: ...separator 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 B...

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...

Page 13: ...ed 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...

Page 14: ...ll 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...

Page 15: ...er 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 disch...

Page 16: ...p 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 pr...

Page 17: ...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 ar...

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...

Page 19: ...re 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...

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

Page 21: ...tmospheric 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...

Page 22: ...ar An 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...

Page 23: ...ding 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...

Page 24: ...ed 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...

Page 25: ...n 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...

Page 26: ...e 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...

Page 27: ...r 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 vi...

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

Page 29: ...ther 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...

Page 30: ...pressor 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 shoul...

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 l...

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: ...ing 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 surrounding...

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 negl...

Page 35: ...mitted 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 th...

Page 36: ...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 t...

Page 37: ...ew 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 filt...

Page 38: ...RK 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 fitt...

Page 39: ...opped 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 lubricatin...

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

Page 41: ...ety 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...

Page 42: ...ture 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 T...

Page 43: ...e 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 wit...

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...

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: ...t 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 a...

Page 48: ...0x1 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...

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: ...21x150 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...

Page 52: ...0x1 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...

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...

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 r...

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 Serie...

Page 59: ...port 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 Suppor...

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 Cyl...

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: ...upling 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...

Page 64: ...ART 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 RC2...

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: ...genbosch The Netherlands Phone 31 0 73 6203 911 Fax 31 0 73 6231 286 E Mail products grasso nl Grasso GmbH Holzhauser Stra e 165 13509 Berlin Germany Refrigeration Technology Phone 49 0 30 43 592 6 Fa...