Screw Compressor Packages Grasso SP1 Large Series

Screw Compressor Packages
Grasso SP1
Large Series
Operating Manual (Translation of the original text)
P_241511_6
Operating Manual | Large Series
Grasso SP1
COPYRIGHT
this document may contain or for their consequen-
All Rights reserved. ces.
No part of this documentation may be copied or pub- The manufacturer reserves the right to make techni-
lished by means of printing, photocopying, microfilm cal modifications during the course of further devel-
or otherwise without prior written consent of opment of the equipment covered by these operating
• GEA Refrigeration Germany GmbH instructions.
herein after referred to as the manufacturer. This Illustrations and drawings in these operating instruc-
restriction also applies to the drawings and diagrams tions are simplified representations. As a result of the
contained in the documentation. improvements and changes, it is possible that the
illustrations do not exactly match the unit you are
LEGAL NOTICE operating. The technical data and dimensions are
subject to change. No claims can be made on the
These operating instructions are part of the technical basis of them.
documentation for the scope of delivery. They con-
The manufacturer cannot accept liability for damages
tain important instructions for ensuring safe and
proper transport, installation, start-up, economic • which occur during the warranty period as a
operation, maintenance and repair of the unit. Their result of
observance helps in avoiding dangers, reducing
– improper operating conditions and conditions
repair costs and down-times and increasing the relia-
of use,
bility and durability of the unit.
These operating instructions are intended for the – inadequate maintenance,
users of the equipment and are specifically intended – improper operation,
for the operating company and its operating and
maintenance personnel. – incorrect installation,
It is essential that the operating company and its – incorrect or improper connection of the main
operating and maintenance staff read these operat- electrical drive,
ing instructions prior to transport, installation, start- • or which result from or can be attributed to
up, use, maintenance, repair, disassembly and dis- improper modifications or failure to observe the
posal. This obligation to read also applies to person- instructions;
nel involved in activities in the life phases of the
machine. • through the use of accessories or spare parts
The operating company must supplement these which were not supplied or recommended by the
operating instructions with instructions regarding manufacturer.
health and safety at work and environmental protec-
tion on the basis of existing national regulations for
industrial safety.
In addition to these operating instructions and the
binding accident prevention regulations valid for the
respective country and area where the product is
used, the recognised technical regulations for safe
and professional work must also be observed.
These operating instructions are part of the unit. The
entire documentation comprises these operating
instructions and all additional operating instructions
supplied with the unit. It must be kept readily availa-
ble where the unit is installed. The entire documenta-
tion must also be forwarded if the unit is installed at
another location and if the unit is sold.
These operating instructions have been written in
good faith. However, GEA Refrigeration Germany
GmbH cannot be held responsible for any errors that
2 GEA Refrigeration Germany GmbH | P_241511_6 | Generated 01.04.2015

Grasso SP1
SYMBOLS USED IN THIS MANUAL

Danger!
Stands for an immediate danger which
leads to heavy physical injuries or to
the death.
Warning!
Stands for a possibly dangerous situa-
tion which leads to heavy physical
injuries or to the death.
Caution!
Stands for a possibly dangerous situa-
tion which could lead to light physical
injuries or to damages to property.
Hint!
Stands for an important tip whose
attention is important for the designa-
ted use and function of the device.
GEA Refrigeration Germany GmbH | P_241511_6 | Generated 01.04.2015 3

Grasso SP1
LAYOUT INFORMATION
Bullet points and numbered list characters

Bullet points are used to separate logical contents within a section:
• Bullet point 1
Types of bullet point 1.
• Bullet point 2
Types of bullet point 2.
Numbered list characters are used to separate enumerations within a descriptive text:
Descriptive text with consecutive numbering:
– Numbered list point 1
– Numbered list point 2
Handling instructions
Handling instructions require you to do something. Several consecutive steps result in a handling sequence that
should be run in the specified order. The handling sequence can be divided into separate steps.
Handling sequence
1. Handling sequence step 1
– step 1,
– step 2,
– step 3.
2. Handling sequence step 2
The subsequent handling sequence is the expected result:
® Result of the handling sequence.
Individual handling steps
Individual handling steps are marked thus:
– Individual work steps

Grasso SP1
TABLE OF CONTENTS
1 BASICS 11
1.1 Importance of the documentation 11
1.2 Requirements for personnel, obligation to exercise due care 11
1.3 Legal foundations (Germany) 12
1.4 Specified Use 14
1.5 Warning against foreseeable abusive use 14
1.6 CE mark 15
2 MANUFACTURER INFORMATION 16
3 CUSTOMER SERVICE 17
3.1 Technical customer service department 17
3.2 Spare parts 17
3.3 Training courses 17
3.4 Service contracts 17
4 SAFETY 18
4.1 General information for safety 18
4.2 Behaviour in the case of emergency 18
4.3 Installation in explosive atmospheres, installation zones 1 and 2 18
4.4 Possible residual hazards 19
5 TRANSPORT, STORAGE 21
5.1 General instructions 21
5.2 Delivery 21
5.3 Transport (crane transport) 21
5.4 Bearings 22
5.5 Storage (several years) 23
6 INSTALLATION 25
6.1 Basic information for installation 25
6.2 Rigid installation 25
6.3 Anti-vibration mounting 25
6.4 Electrical connection 25
6.5 Sound insulation, weather protection 25
6.6 Information about noise emissions 27
7 DESCRIPTION OF DESIGN AND FUNCTION 32
7.1 Product code of screw compressor packages - Grasso SP1, SP2, SPduo and M Series 32
7.2 Technical specifications 34
7.3 Location of the product identification (type plate) 35
7.4 Information and safety labels on the product 37
7.4.1 Labelling of the pressure and temperature sensors, heater 37
7.4.2 Label of the safety valve 37
7.4.3 Labels of the screwed connections with DiNova ring 37
7.4.4 Labels of the pipelines 38
7.4.5 Marking the direction of rotation of the compressor drive motor 38
7.4.6 Marking the direction of rotation of the oil pump motor 38
7.4.7 Labels of the pressure gauge 39
7.4.8 Labeling of the control / control cabinet 39
7.4.9 Designation of the earth connection 40
7.5 Process flow diagram 41
7.6 Main components 42
7.6.1 Screw compressors 43
7.6.2 Compressor drive motor 44
7.6.3 Coupling 44
7.6.4 Oil separator 44
7.6.5 OMC block with oil filter system 45
7.6.6 Oil cooler 46
7.6.7 Oil pump 46
7.6.8 Suction filter combination SFC 46
7.6.9 Control 47
7.6.10 Fittings 47
7.6.11 Safety devices 48
7.6.12 Monitoring devices 49
7.6.13 Components installed by the client 49

Grasso SP1
7.7 General functional description 49

7.8 Refrigerant circuit 49
7.9 Oil System 50
7.9.1 Oil separation 50
7.9.2 Oil heater 50
7.9.3 Oil cooling 50
7.9.4 Oil filter 50
7.9.5 Oil pump 50
7.9.6 Oil injection 51
7.9.7 Oil circuit, OMC block 51
7.10 Capacity control 51
7.11 Technical specifications 51
7.11.1 Basic terms 51
7.11.2 Operating media 51
7.11.2.1 Refrigerant 51
7.11.2.2 Refrigeration machine oils 52
7.11.2.3 Secondary refrigerant 52
7.11.3 Operation limits 52
7.11.4 Designed for use in explosive atmospheres! 53
7.11.5 Water quality requirements, parameters 54
8 START-UP 56
8.1 Important information for start-up 56
8.2 Basics 57
8.3 Connecting the screw compressor package 57
8.3.1 Connecting the pipes 57
8.3.2 Electrical connection 58
8.4 Paint and insulation 58
8.5 Start-up procedure 58
8.5.1 Checking the electrical connection 58
8.5.2 Leak test 58
8.5.3 Drying, vacuum 59
8.5.4 Operating position of valves 60
8.5.5 Oil charge 63
8.5.5.1 Pressure compensation with the cooling system 63
8.5.5.2 Checking the direction of rotation of the oil pump motor 63
8.5.6 Checking the fault monitoring 64
8.5.7 Adjustment of oil pressure 64
8.5.8 Checking the direction of rotation of the drive motor 65
8.5.9 Mounting the coupling 65
8.5.10 Checking the water circuits 65
8.5.11 Initial start-up 65
8.5.12 Checking the adjustment of the control slide 66
8.5.13 Checking the control slide adjustment times 66
8.5.14 Checking the oil cooler 66
8.5.15 Adjusting the amount of injection oil and the oil temperature 66
8.5.15.1 Screw compressor packages without refrigerant injection 66
8.5.15.2 Compressor units with refrigerant injection 66
8.6 Start-up after long standstill periods 67
8.7 Restarting after approx. 1 year standstill 67
9 USE, OPERATION, CONTROL 68
9.1 Important information for the operator 68
9.2 Prerequisite for switching on 68
9.2.1 Overview of the operating modes 69
9.2.2 Setting of setpoint and limiting values as well as safety devices 71
9.3 Operation of the screw compressor package 71
9.4 Instructions regarding failures, their causes and remedies 71
10 CLEANING, MAINTENANCE, REPAIR 74
10.1 Important information for service personnel 74
10.2 Cleaning the heat exchanger 74
10.2.1 Mechanical cleaning 74
10.2.2 Chemical cleaning 74
10.3 Maintenance 75
10.3.1 General instructions 75

Grasso SP1
10.3.2 Repair work 76

10.3.2.1 Repair information 76
10.3.2.2 Repairs of pressure vessels subject to approval inspection 76
10.3.3 Maintenance intervals 76
10.3.4 Maintenance work 76
10.3.4.1 Maintenance of the screw compressor 76
10.3.4.2 Changing the block mounting filter element 77
10.3.4.3 Maintenance of suction filter combination SFC 77
10.3.4.4 Oil draining, oil filling, oil change 78
10.3.4.5 Oil pump maintenance 80
10.3.4.6 Changing the fine oil separation cartridges 80
10.3.4.7 Tightening screw fastenings 80
10.3.4.8 Coupling maintenance 81
10.3.4.9 Checking the function of check valves 81
10.3.4.10 Searching for leaks on the refrigerant side / leak test 81
10.3.4.11 Venting the refrigerant circuit 82
10.3.4.12 Refrigerant evacuation 82
10.3.4.13 Checking the bearing noise 82
10.3.4.14 Checking the solenoid valves for capacity control 82
10.3.4.15 Checking the oil heater 82
10.3.4.16 Maintenance of the compressor drive motor 82
10.3.4.17 Checking the start regime 82
10.3.4.18 Checking the safety devices 82
10.3.4.19 Checking the operating parameters 83
10.3.4.20 Maintenance of the switching cabinet 84
10.3.4.21 Checking the earth connection 84
10.3.4.22 Insulation 84
10.3.4.23 Check of the tightening torque on the adjusting elements of the fixing base. 84
11 DECOMMISSIONING 85
11.1 Shut-down in the event of dangerous situations 85
11.2 Standstill for a period <48 hours 85
11.3 Standstill for a period >48 hours 85
11.4 Measures during shutdowns 85
11.4.1 Monthly measures during standstill 86
11.4.2 Four weeks before restarting 86
12 DECOMMISSIONING, DISPOSAL 87

Grasso SP1

Grasso SP1
TABLE OF FIGURES
fig. 1 CE mark 15
fig. 2 Designation of the attaching points. 21
fig. 3 Limit stop 22
fig. 4 Location of the product identification (type plate) 35
fig. 5 Type plate 36
fig. 6 Safety labels of the pressure and temperature sensors, heater 37
fig. 7 Label of the safety valve 37
fig. 8 Labels of the screwed connections 37
fig. 9 Labels of the pipelines 38
fig. 10 Marking the direction of rotation of the compressor drive motor 38
fig. 11 Marking the direction of rotation of the oil pump motor 38
fig. 12 Labels of the pressure gauge 39
fig. 13 Test verification for the control system 39
fig. 14 Designation of the earth connection 40
fig. 15 Process flow diagram Grasso SP1, Large 41
fig. 16 Standard Screw Compressor Package of Grasso SP1 LARGE Series 43
fig. 17 Grasso SP1 Large, position of the screw compressor 43
fig. 18 Grasso SP1 Large, position of the compressor drive motor 44
fig. 19 Grasso SP1 Large, position of the coupling 44
fig. 20 Grasso SP1, position of the oil separator 44
fig. 21 Grasso SP1 Large, position of the OMC block with oil filter system 45
fig. 22 Grasso SP1 Large, position of the oil cooler 46
fig. 23 Grasso SP1 Large, position of the oil pump 46
fig. 24 Grasso SP1 Large, position of the suction filter combination SFC 46
fig. 25 Grasso SP1 Large, position of the control 47
fig. 26 Corrosion resistance in presence of chlorides 55
fig. 27 Vacuum required to remove moisture from refrigerating plants 59
fig. 28 Stop valve open 60
fig. 29 Stop valve closed 60
fig. 30 Check valve 60
fig. 31 Shuttable check valve 60
fig. 32 Control valve 61
fig. 33 Shuttable check valve 61
fig. 34 Solenoid valve 61
fig. 35 Change-over valve 61
fig. 36 Oil pressure control valve 61
fig. 37 Overflow valve, safety valve 62
fig. 38 Pressure controlled check valve 62
fig. 39 Quick acting valve, spring-loaded 62
fig. 40 Charging valve, drain valve 62
fig. 41 Service valve 62
fig. 42 Oil temperature limiter 63
fig. 43 Temperature controlled control valve 63
fig. 44 Motor direction of rotation 65
fig. 45 Fine oil separation cartridge 80

Grasso SP1

Operating Manual | Large Series Basics
Grasso SP1
1 BASICS
– applicable international and national standards,
1.1 Importance of the documentation – applicable occupational safety regulations,
These operating instructions are part of the technical – applicable accident prevention regulations,
documentation for the Grasso scope of delivery. It – applicable environmental protection regulations,
contains advice for operating the package/chiller
safely, properly and economically. The observance – the construction and functioning of the unit,
of the operating manual helps in avoiding dangers, – recognised technical regulations for safe work
reducing repair costs and down-times and increasing according to good professional practice.
the reliability and durability of the package/chiller.
The technical personnel must:
This operating manual is directed at the users of the
package/chiller and is specifically intended for the – be able to assess the work assigned to them,
operating company and its operating and mainte- recognise and avoid possible dangers,
nance personnel. This operating manual must be – be authorised by those responsible for the safety
read prior to transport, installation, commissioning, of the system to carry out the requisite work and
maintenance, repair, disassembly/disposal. activities.
All work explained in this operating manual must only
be carried out by technical personnel. Caution!
This operating manual must be supplemented with No arbitrary changes may be made to
instructions based on prevailing national regulations the control or other components
regarding industrial safety, health protection and belonging to the unit. Maintenance
environmental protection. work may only be done by authorised
In addition to this operating manual and the manda- service staff.
tory accident prevention regulations applicable for
the respective place of installation, the accepted Special requirements for the electrical techni-
technical regulations for safe work according to good cians
professional practices must also be observed. Work on electrical components and modules may
The operating manual is a part of the total product. only be carried out by an electrical technician
The entire documentation, consisting of this operat- according to the rules relevant to electrical engineer-
ing manual as well as all supplied additional instruc- ing. Furthermore the operator has to take care that
tions, is to be always kept easily accessible at the the electrical systems, tools and fixtures are oper-
place of installation of the package/chiller. The com- ated according to the rules relevant to electrical engi-
plete set of documentation must also accompany the neering and applicable standards and serviced prop-
package/chiller if it is sold. erly.
– In principle it is prohibited to carry out work on
parts under voltage.
1.2 Requirements for personnel, obliga- – Fuses may only be replaced and not repaired or
tion to exercise due care bypassed.
Qualification – Only the fuses specified in the electrical circuit

diagram may be used.
All work explained in this manual (assembly, electri-
cal connection, commissioning, operation, etc.) may – A two-pole voltage tester must be used to ensure
only be carried out by trained technical personnel that the parts are de-energised.
who observe the relevant technical regulations. – The power supply as well as the unit casing must
Technical personnel are representatives of the unit be sufficiently grounded and tagged with a suita-
manufacturer and persons who, as a result of their ble label.
technical training, experience and personal instruc-
– Deficiencies noticed in the electrical systems/
tion in training measures, have sufficient knowledge
modules/tools and fixtures must be corrected
of:
immediately. If an acute danger exists till then,

Basics Operating Manual | Large Series
Grasso SP1
the package/chiller must not be operated in the – Accident Prevention Regulation including
defective condition. implementation regulations (BGR 500, chapter
2.35) on refrigeration plants, heat pumps and
Minimum age cooling equipment (BGV B3) regarding noise
The minimum age for the operation of the package/
– EN 12284 Refrigerant fittings, safety related
chiller and installation is 18 years. All persons
technical definitions, testing and marking
involved in the assembly and installation of the pack-
age/chiller and the system must get themselves – DIN 2405 Pipes in refrigeration plants, marking
trained at regular intervals and/or familiarise them-
– VDMA specifications,in particular VDMA 24
selves with the current technical data of the device.
243 and 24 020
The training and instructions is to be conducted at
least once a year, unless some other interval has – VDI Guidelines
been agreed upon with the manufacturer.
– Instruction sheets for handling ammonia,
Obligation to exercise due care Instruction sheet for halogenated hydrocar-
bons containing fluorine BGI 648
The statutory regulations for meeting the obligation
to exercise due care are to be observed. – Safety data sheet for ammonia and other refrig-
Meeting the obligation to exercise due care accord- erants and refrigeration oils
ing to the current level of technology requires that The list of rules and standards has been taken from
everything that is Status Report No. 5 of the German Refrigeration and
Air Conditioning Engineering Association "Safety and
– technically possible (use of accepted technologi-
environmental protection in ammonia refrigeration
cal rules) and
plants" and also fully applies to other refrigerants.
– economically reasonable
Danger!
be done to prevent damage in a protectively safe
manner.
1.3 Legal foundations (Germany) The additional safety instructions as

defined in "Appendix E" must be
The following standards, regulations, ordinances and observed for packages for the desig-
laws must be strictly observed to ensure the safety nated use in potentially explosive
and functional reliability of the packages and chillers: atmospheres, installation zones 1 and
– EC Machinery Directive 2006/42/EC 2 in accordance with EN 60079-10.
– EC Pressure Equipment Directive The following:
2014/68/EC– AD 2000 Info Sheets
– standards,
– Hazardous Incident Ordinance (12. BlmSchV)
with 1st failure VwV – safety regulations,
– Federal Pollution Control Act (BImSchG), 4th – guidelines and recognised engineering practice,
BimSchV listed in these operating instructions must be
observed at least!
– Water Resources Act (WHG), VawS
Hint!
– Hazardous Substances Ordinance (GefStoffV)
If the package/chiller is used in a
– Recycling and Waste Management Act (KrW-
country other than Germany, the rules
AbfG)
and regulations applicable at the place
– DIN EN 378, Part 1 to Part 4 Safety-related of installation must be observed and
technical requirements and environmental complied with!
requirements
The mandatory accident prevention regulations
applicable for the respective country and area where
the product is used must also be observed.

Grasso SP1
Failure to observe the safety instructions can lead to

danger to personnel and the environment as well as
damage to the unit.

Basics Operating Manual | Large Series
Grasso SP1
1.4 Specified Use the manufacturer – is responsible for all personal

injury and damage to property resulting from
Hint! improper use.
Observe the "Specified Use" chapter The pressure equipment is not designed for dynamic
of the installation instructions for the loads. If there is a risk of lightning strikes, the pres-
screw compressor! sure equipment must be earthed. The supplier/instal-
ler must record instructions for regular inspection of
The screw compressor package must only be oper- the pressure equipment in his operating manual and
ated up to a maximum discharge pressure in accord- must specify the procedure to be followed by the end
ance with the type plate. user in the event of damage. In order to prevent
It is imperative that you comply with the applicable burns or frostbite, the pressure receptacle must not
conditions of use with respect to pressure and tem- be touched during operation. This can be prevented
perature for the screw compressor package. by respective safety measures. Appropriate warning
Do not change the setting values of the safety pres- signs must be affixed. Compressor units or systems
sure switch. This would endanger the operating must be equipped with safety valves in accordance
safety of the refrigeration plant. with EN 378. The foundation must provide sufficient
rigidity.
If the switch-off value is set higher than 0.9 x maxi-
mum operating pressure (see EN378-2) of the high The supplier/installer must carefully install the acces-
pressure section of the refrigerating system, this may sories for the pressure equipment. The pressure
result in the the tank within this section of the system equipment must not be damaged during installation
rupturing. and must be painted after installation. The pressure
equipment must only be filled with the refrigerant
The operating regime stipulated by the manufacturer, specified in the contract. The pressure units must be
especially for the starting phase of the screw com- installed in the compressor unit or the system in such
pressor package, must be observed. a way that vibrations or pulses cannot be transferred
Operating parameters must be monitored. Operating to the pressure units. The contacts must be installed
parameters must not deviate from within the defined with the power supply disconnected.
limits.
Specified use includes observance of this manual
The screw compressor package has been designed and all supplied operating manuals as well as com-
and manufactured for a specific application under pliance with the maintenance and service intervals
defined conditions of use. Unauthorised structural and conditions stipulated therein.
modifications are not permitted. We assume no liabil- Warranty claims and authorisation for operation
ity for any resulting damage or injury. In the interest become void if the equipment is not used for its
of further development, GEA Refrigeration Germany specified purpose.
GmbH reserves the right to make technical modifica-
tions. The screw compressor package described
here corresponds to the state of the art at the time 1.5 Warning against foreseeable abu-
this operating manual was published.
sive use
The manufacturer must be consulted in all cases as
to the permissibility of the modification if there is any A package/chiller is said to have been abused, if
change of the application or the conditions of use. – unauthorised refrigerants, fuels and lubricants
Do not make any modifications to the screw com- and secondary refrigerant materials are used.
pressor package and the compressor control system.
Hint!
These may impair the safety and functionality of the
SCP. They will also void the guarantee. Observe specification for the project!
The pressure equipment described here must not be – electrical components are wrongly connected.
used for any purpose other than the purpose speci-
fied here. The units must only be installed by the Hint!
supplier/installer and not by the end user. If the pres-
Watch voltage and frequency!
sure equipment is not used according to the regula-
tions, the safe use of the equipment is not guaran-
– mechanical components are wrongly connected.
teed. The supplier/installer or the operator – and not

Grasso SP1
1.6 CE mark
Hint!
Watch pressure and temperature! By affixing the CE mark, the manufacturer confirms
the conformity of the product with the applicable EC
– the supporting, hanging and storage facilities are Directives and compliance with the principle require-
misused. ments stipulated within them.
– control and regulation units including control sys-

tem software are tampered with.
fig.1: CE mark
– the driving power generated by the motor is used
for purposes other than the operation of the
respective compressors and pumps. The CE mark is affixed to the nameplate.
The CE mark for products from GEA Refrigeration
Germany GmbH is provided as defined in the Pres-
sure Equipment Directive, i.e. pressure equipment is
placed on the market with the required equipment
parts with safety function. This complete assembly is
subject to the Pressure Equipment Directive.

Manufacturer Information Operating Manual | Large Series
Grasso SP1
2 MANUFACTURER INFORMATION
GEA Refrigeration Germany GmbH is a company
within GEA Refrigeration Technologies, the Refriger-
ation Technology Segment of the GEA Group and
provides its customers around the world with high-
quality components and services for refrigeration and
process technology applications.
Locations:
GEA Refrigeration Germany GmbH

Factory Berlin
Holzhauser Str. 165
13509 Berlin, Germany
Tel.: +49 30 43592-600
Fax: +49 30 43592-777
Web: www.gea.com
E-Mail: refrigeration@gea.com

Factory Halle
Berliner Straße 130
06258 Schkopau/ OT Döllnitz, Germany
Tel.: +49 345 78 236 - 0
Fax: +49 345 78 236 - 14
Web: www.gea.com
E-Mail: refrigeration@gea.com

Operating Manual | Large Series Customer service
Grasso SP1
3 CUSTOMER SERVICE
GEA Refrigeration Germany GmbH supplies prod- In most cases, you will receive your spare parts
ucts of high quality and reliability. In addition, the within 24 hours after placing the order.
manufacturer ensures continuous operation of the You can contact us using the following hotlines:
refrigeration and process technology system and
provides exceptional service for the components • Wireless, out of hours
supplied. +49 (0) 172 30 14 579
• Landline, weekdays from 8 to 17 hour
+49 (30) 43 59 27 50
3.1 Technical customer service depart-
ment • Fax
+49 (30) 43 59 27 58
Do you require support from the technical customer
service department? Specially trained, experienced • Email
service technicians are available on call for you in Grasso-parts@geagroup.com
order to provide assistance in case of technical prob-
lems and to offer support in the framework of our • Order spare parts from our G-Pos. online
after-sales service. shop
24/7 Hotline: (Grasso Parts online shop)
the hotlines can reached around the clock on every gea-refrigeration.de.spareparts@gea.com
day of the week:
• Wireless 3.3 Training courses
+49 (0) 172 39 12 050
Warning!
• Landline, weekdays from 7 to 17 hours
+49 (30) 43 59 27 61 All work on our systems must only be
carried out by technical personnel!
+49 (30) 43 59 27 62 Acquire the technical know-how
• Email: required for this in good time!
Grasso-service@geagroup.com Comprehensive training courses are held regularly
outside of Germany, Austria and Switzerland please for service technicians and mechanics, thus ensuring
contact: the safe and proper use and maintenance of our sys-
• local sales office tems.
www.gearefrigeration.de • Email
technical support for liquid chillers with reciprocating Grasso-service@geagroup.com
compressors in Germany, Austria and Switzerland
• 24/7 Hotline
3.4 Service contracts
+49 (345) 78236 20
The specialists of our Technical Customer Service It is possible to sign a long-term service agreement
department support you in installations, acceptan- (service contract). For further information regarding
ces, maintenance, operating questions, on-site the content, scope and conditions of the possible
inspections and repairs of our products. service options, please contact the Technical Cus-
tomer Service department.
• Email:
3.2 Spare parts Grasso-service@geagroup.com
GEA Refrigeration Germany GmbH has its own prac-
tical and rapidly working spare parts department to
supply the necessary spare parts worldwide. Neces-
sary spare parts are shipped as quickly as possible.

Safety Operating Manual | Large Series
Grasso SP1
4 SAFETY
4.3 Installation in explosive atmos-
pheres, installation zones 1 and 2
4.1 General information for safety
Danger!
The safety aspects to be observed for operating the
equipment are shown in the chapter on "Safety". The additional instructions for using
The equipment has been developed and manufac- screw compressor packages in explo-
tured according to the currently applicable state of sive atmospheres, installation zones 1
the art and is reliable in operation. It has been tested and 2, must be complied with!
and left the factory in a technically faultless safe con-
dition. Function and Design
In order to maintain this condition for the operation The same functional and design characteristics apply
time, the details of the project documentation and to the maintenance instructions for the use of screw
certificates must be observed and complied with. compressor packages in potentially explosive atmos-
When operating the equipment, at least the general pheres as described in the respective applicable
safety regulations and the provisions and guidelines operating manual.
referred to in this documentation must be observed. In addition to this, the following extensions
Only compliance with all provisions and guidelines apply:
will enable optimum protection of the personnel as – All components relevant for the use of screw
well as dangers to the environment and the safe and compressor packages in relation to their use in
smooth operation of the equipment. potentially explosive atmospheres (concerns
both electrical and non-electrical components)
are separately designed and documented! The
4.2 Behaviour in the case of emergency extended documentation scope (component
descriptions, certificates, calculations) is part of
Hint! the product documentation.
Familiarise yourselves with the local – Extension to the method of working
evacuation plan before beginning the
The use of screw compressor packages is exten-
work.
ded to use in potentially explosive atmospheres,
Should an emergency situation arise despite adher- including the compression of process gases
ing to the safety regulations, the package/chiller (only compression for the purposes of pressure
must be shut down immediately and isolated from increase). The screw compressor packages are
the electrical mains. not suitable for pumping potentially explosive
mixtures. This means that, when the compressor
The mains cable must be blocked in such a way it is
is in intake condition, the pumped liquid must not
not possible to restart the unit accidentally and
contain any oxygen. The intake condition always
marked as such.
refers to pressure layers in the overpressure
The operator of the complete system has to take range.
care that an isolation device, e.g. a mains switch with
The owner operator and the system builder must
appropriate contact rating and an integrated indica-
use monitoring devices reflecting the respective
tor, is pre-installed in the mains cabling on site.
state of the art standards to positively monitor
A separate mains cable/feed cable must be laid for and ensure this effect.
the operation of the package/chiller.
– Safety equipment extension
The mains cable/feed cable is to be specially protec-
ted and provided with an emergency stop switch. If oil heaters are used in potentially explosive
atmospheres (see component specification),
additional, separate oil level monitoring is abso-
lutely necessary to ensure a minimum oil level
above the heating elements. To this end, a sepa-
rate oil level switch is used in each use case

Operating Manual | Large Series Safety
Grasso SP1
according to the necessary explosion protection – Appropriate special tools approved for the poten-
specification. tially explosive atmosphere must be used.
Operation – Only original spare parts may be used. If original
The same regulations apply in regard to the operat- spares are not used, the guarantee is invalidated
ing instructions for screw compressor packages in or the owner is liable in the event of damage.
potentially explosive atmospheres as described in – Each maintenance inspection (see maintenance
the applicable operating manual. book) must also include checking the secure fit
In addition to this, the following extensions of the threaded connections for the coupling
apply: safety hood.
– In addition, the legal safety regulations apply to
the people responsible for operating the screw
compressor package, and must be complied with 4.4 Possible residual hazards
respect to the transport, assembly, operation and
Warning!
maintenance and if necessary the replacement
of subassemblies, etc. in potentially explosive Despite careful design of the machine
atmospheres. and implementation of all the safety-
The owner operators regulations must also relevant regulations, further risks for
always be observed – see also section: Safety persons and machine during all life
information for compressor, Appendix E, and for phases of the package/chiller cannot
package, Appendix E. be fully ruled out. The additional safety
instructions in the individual chapters
– The electrical engineering regulations for instal- of this manual must therefore be care-
lations in potentially explosive atmospheres , fully observed!
especially EN 60079-10, apply to the installation
and connection of electrical components. The Residual risks that were ascertained during the risk
relevant prescribed cabling material must be assessment carried out for the product according to
used. safety standard EN ISO 14121 - Safety of Machines
- are:
– The whole screw compressor package must be
earthed by the owner operator. – mechanical hazards due to sharp sheet metal
edges and projecting parts,
Maintenance
The same regulations apply to the maintenance of – electrical hazards as a result of inadvertently
screw compressor packages in potentially explosive coming in contact with terminals and cables,
atmospheres as described in the respective applica- – thermal hazards as a result of inadvertently com-
ble operating manual. ing in contact with heat exchangers and pipes,
In addition to this, the following extensions – exposure to noise,
apply:
– hazards caused by vibration due to improper
– In addition, the legal safety regulations for the installation,
installation of the screw compressor packages
apply to the people responsible for the mainte- – hazards due to working materials and other
nance of the screw compressor package with materials in case of allergies orthe like,
respect to the maintenance of individual compo- – neglect of ergonomic principles,
nents or assemblies or their complete replace-
ment in potentially explosive atmospheres. – combinations of various hazards,
– The maintenance may only be carried out in – unexpected start-up, unexpected rotation in case
agreement/with the knowledge and release of of incorrect electrical connections or defects,
the owner operator. – shut-down, emergency stop when defects are
– The maintenance and replacement regulations detected,
resulting from the operating manual for the com- – changes to the rotational speed,
ponents must be conformed with.
– power failure,

Safety Operating Manual | Large Series
Grasso SP1
– failure of the control circuit or control loop,

– incorrect assembly,
– fracture during operation,
– operating media or objects getting thrown out,
– loss of stability and
– personnel slipping, tripping or falling.
Hint!
There are no radiation hazards

Operating Manual | Large Series Transport, Storage
Grasso SP1
5 TRANSPORT, STORAGE
5.2 Delivery
5.1 General instructions Shipment is made in the type of packing stipulated in
the order. The screw compressor package is gener-
Caution! ally supplied without packing.
Adequate lighting must be ensured The screw compressor package has an inert gas
during loading and unloading as well filler in the refrigerant circuit.
as for storage in order to avoid injuries
Warning!
and damage to property.
There is a danger of impacts and The compressor(s) of the screw com-
stumbling due to protruding parts on pressor package is/are not filled with
the equipment (e.g. valve caps). There oil. The screw compressor package
is also the danger of being cut on must not be started, therefore, before
sharp edges and surfaces. There is a proper assembly and start-up.
danger of crushing parts of the body
during the transport work. Personal
protective equipment (work clothing, 5.3 Transport (crane transport)
work books, gloves) must be worn
during all activities on the equipment. Warning!
Hint! The screw compressor packages are

not intended for transport with a fork
These operating instructions must be lift truck!
read prior to transport, storage and
delivery to the installation site. It is Screw compressor units are high-quality products
imperative to strictly observe the which must be handled with due care. Protect the
instructions and information given! equipment from impacts and put it down carefully.
All work explained in these operating When transported by crane, the screw compressor
instructions must only be carried out unit must have the same position (frame downwards)
by qualified personnel. as in operation. Only use the attachment points pro-
vided. The lifting points are marked!
fig.2: Designation of the attaching points.

Transport, Storage Operating Manual | Large Series
Grasso SP1
Caution! member or the company is responsible for ensuring

transport safety.
It is prohibited to strap screw com-
pressor packages to any fittings or Warning!
piping or to the eye bolts/lugs on the Screw compressor packages must be
compressor, electric motor, container adequately protected from external
or switching cabinet. influences during transport.
Take special care not to attach the ropes near to
Transport packing (optional): Foil
small diameter tubing or to insulation and not to
damage them. Use spacers if necessary. The foil must be removed just prior to installing the
screw compressor package at the intended location
The lifting points are not arranged in one plane. The
in the machine room. Prior to this, the foil protects
ropes must be longer than 3 m. The height differen-
the screw compressor package against external fac-
ces between the individual lifting points must be
tors.
compensated by appropriate extensions.
Make suitable arrangements (timber or insulating
material) to avoid damage to the surface. 5.4 Bearings
Shackles must be used.
When the screw compressor packages are deliv-
ered, check for possible transport damage and report
any damage to the manufacturer in writing.
The storage area of screw compressor units shall be
roofed, plain and paved and secured against access
of unauthorized persons. Place the screw compres-
sor package onto timber planks and have it protected
from jerks or impacts.
Warning!
Screw compressor packages must be
adequately protected from external
influences (humidity, frost, extreme
heat) during storage. This usually con-
cerns lengthy standing times outdoors
before installation and start-up of the
refrigeration plant. The manufacturer
recommends the use of plastic sheet-
ing to cover the whole product.
The venting slits of the electric motors
must always be covered!
fig.3: Limit stop
Storage temperature: 5°C ... 40°C
The composition of the paint on the screw compres-
Danger! sor package is designed for installation in the
Make certain there is no one under the machine room (inside installation). Contact with
suspended load during transport with water (including water spray) must be avoided.
the crane!
Position the screw compressor unit on the transport

vehicle in such a way that it is prevented from slid-
ing, tilting or falling down. Load securing is preferably
carried out by lashing to the specified points. The
pipes and equipment parts of the screw compressor
package must not be stepped on. Components must
be secured against vibrations. The competent staff

Operating Manual | Large Series Transport, Storage
Grasso SP1
Warning! 5. Then re-fit the cover of the shaft seal.
The screw compressor package is fil- Warning!

led with dry gas (e.g. nitrogen) before
Danger of cuts and crushing injuries.
delivery which prevents any change of
the properties of any already filled
6. If storage is longer than 26 weeks, all O-rings
operating medium (e.h. refrigerating
must be renewed.
machine oil). Check the gas filling
once a week and recharge to the
specified overpressure if required.
5.5 Storage (several years)
Turn the shaft of the compressor at least every four
weeks (approx. 10 revolutions). Hint!
The transport packing (foil if present), that needs to The instructions in the "Transport,
be opened for turning the compressor shaft and for storage" chapter must be heeded.
checking the gas filling, must be closed again after
carrying out the activities in order to ensure protec- The following storage conditions must be maintained
tion against external influences. The packing (foil if when storing screw compressor packages that are
present) must be replaced as needed and for lengthy equipped with a control.
storage times. 1. Storage temperature > 10°C
Warning! 2. Air humidity < 50%
Regular ventilation of the screw com- If the screw compressor package is intended to be
pressor package packaging (if stored, the following preparatory measures must be
present) must be ensured in order to carried out ex-works (especially protection against
prevent condensation on the surfaces internal and external corrosion):
of the machine.
• All process connections on the screw compres-
sor package are sealed tight.
Long-term storage
• The screw compressor package is charged with
With a standstill of the compressor of more than 16
weeks prior to start-up, there is a danger that the dry gas to 1 bar.
shaft seal may stick on the shaft and therefore be • A suction pressure gauge has been installed.
damaged on start-up. Because of this, removal and
• The facing sides of the mounted coupling hubs
cleaning of the shaft seal is mandatory in order to
have been greased. (Does not apply to sliding
ensure that it functions correctly.
bearing compressor drive motors)
1. Use two pressure screws to remove the cover of
the shaft seal, including the stationary gasket Hint!
inserted in it. In case of the use of high-voltage
2. Removal of the seal package arranged on the motors: the operating manual of the
shaft with the associated slide ring by hand or, if manufacturer is to be followed, espe-
tightly seated, extraction by means of an appli- cially regarding any anti-condensation
ance. If the seating is loose, the seal package heater required.
may adhere to the stationary seal and will be • Free-standing motor and main flow shafts have
pulled out when removing the cover.
been conserved.
3. Clean the shaft seat with a lint-free cloth. Grease
• The space on the screw compressor for the shaft
it lightly and push the sealing package back onto
seal has been greased.
the shaft again.
• The connections on the oil cooler water side
4. After pushing onto the shaft, the seal package
have been sealed.
must be manually compressed against the spring
pressure which acts on it. At the same time, it The following maintenance work must be carried out
must be checked whether the gasket springs out at the storage location during storage:
again.

Transport, Storage Operating Manual | Large Series
Grasso SP1
1. Visual inspection of the general condition of the

screw compressor package.
2. Cyclical rotation of the screw compressor shaft
(about 10 revolutions per month and the com-
pressor drive motor (see operating manual).
Hint!
Does not apply to sliding bearing com-
pressor drive motors.
3. Check the transport fill pressure with a pressure

gauge at the connection of item 405 (see P+I
flow chart). If this value < 1 bar, replenish dried
gas via the valve of item 85 (see P+I flow chat).
All valves are already opened at the factory for a
common pressure range.
Caution!
After completion of the storage period
and prior to re-delivery, a general
review in the factory or a general
examination at the storage location,
performed by the technical customer
service technician of GEA Refrigera-
tion Germany GmbH, is recommended.
Please pay attention to the information
in the "Start-up" chapter.
The general check includes changing
the O-ring on the compressor shaft
seal as well as replacing the shaft seal
of the oil pump.

Operating Manual | Large Series Installation
Grasso SP1
6 INSTALLATION
misalignment ≤ 0.25 mm) at the coupling is attained
again. Then tighten the foundation bolts.
6.1 Basic information for installation
Caution!
6.3 Anti-vibration mounting
During the installation, make sure that
substances escaping from leaks do The frame of the screw compressor unit must be
not reach into the soil, groundwater or aligned with the levelling bolts until the coarse align-
surface water. The applicable legal ment (radial and angular misalignment (radial and
regulations must be heeded at the angle offset ≤ 0.25 mm) at the coupling is attained
place of installation (e.g.for Germany: again.
German Federal Water Act WHG). Before tightening the foundation bolts of the isola-
tors, check that the isolators over the spring (pre-
All foundation calculations, the selection of materials dominantly made of rubber) are free and do not lie
and the soil analysis are the designer's or owner’s on the foundation.
responsibility.
A plan must be produced for proper and professional
assembly prior to the installation. The electrical and 6.4 Electrical connection
operating media connections must be established. It
must be borne in mind that, in addition to the installa- Danger!
tion area of the screw compressor package, there
Contact with live components is pro-
must be sufficient space available for the pipes as
hibited.
well as for operating during maintenance activities.
Produce the earth connection accord-
Install the screw compressor package on a level sur-
ing to the designation in the general
face. The difference from the horizontal must not be
assembly drawing. See chapter "Des-
more than 0.3 %. Provide enough space for mainte-
ignation of the earth connection".
nance work.
Under normal conditions, the screw compressor Before starting work, make sure that all parts to be
package stands solidly on the installation surface connected are de-energised, e.g. by removing the
due to its own dead weight. We recommend that you main fuse in all phases or installing a jumper wire.
provide ribbed rubber plates for shock absorption The insulation resistance of the electrical tools and
between the support surface and screw compressor fixtures and wiring is to be checked. The connection
package feet or machine base frame. may only be undertaken if this value lies in the allow-
If greater damping is required (installation on a floor able range.
ceiling or on the roof), vibration dampers must be All electrical connections must be established and all
provided. The appropriate type of vibration damper electrical consumers/sensors must be connected
must be determined and realised for this case. Also according to the circuit diagram.
decouple the secondary refrigerant lines using com-
pensators when vibration absorbers are used.
The welding seams must be inspected in accordance 6.5 Sound insulation, weather protec-
with the Pressure Equipment Directive after welding tion
work by the customer or operator on pipe line con-
nections and flanges. If the screw compressor package is intended for out-
door installation, it must be provided with a suitable
housing for sound insulation and weather protection
6.2 Rigid installation by the customer. The weather protection must pro-
vide the machine with adequate protection against
The frame of the screw compressor unit/ liquid chiller the climatic conditions at the installation location.
is placed on foundation bolts on a prepared founda-
tion. The frame must be levelled with suitable shims
such that the coarse alignment (radial and angular

Installation Operating Manual | Large Series
Grasso SP1
Hint!
The screw compressor package is not
intended for unprotected outdoor
installation. Protection against exter-
nal influences, especially dirt, dust
and moisture (wetness), is essential.
The manufacturer will not accept liability for damage

due to incorrect outdoor installation.

Grasso SP1
6.6 Information about noise emissions

The noise information provides approximate parameters and apply to the installation without any secondary
noise protection measures.
The information has a tolerance of ±3 dB.
The precise data depend closely on the emission values for the motors, which are manufacturer dependent.
Should local conditions require adherence to noise levels, a calculation should be made using the specific motor
data in individual cases.
Noise protection measures such as motor encapsulation or complete assembly encapsulation may generate sig-
nificant noise reduction.
Wearing hearing protection with sufficient noise reduction is recommended in rooms with running screw com-
pressor packages.
Caution!
According to EU Directive 2003/10/EC, the allowable exposure limit value regarding the daily
noise exposure level is 80 db(A). In the event of noise levels above this limit value the system
operator must provide the operator with information on exposure to noise and personal hear-
ing protection and ensure that this is also worn (2003/10/EC Article 6).
Noise level LWA
Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Compressor drive
LWA in dB(A) mains operation 400 V / 50 Hz
motor
at 40°C
C D E G H L M
Output in kW
231 265 321 372 471 544 690
Max 91 91 91
22
Min 84 84 84
Max 92 92 92 92
30
Min 85 85 85 85
Max 93 93 93 93 93
37
Min 86 86 86 86 86
Max 94 94 94 94 94 94
45
Min 87 87 87 87 87 87
Max 95 95 95 95 95 95 95
55
Min 88 88 88 88 88 88 88
Max 96 96 96 96 96 96 96
75
Min 89 89 89 89 89 89 89
Max 97 97 97 97 97 97 97
90
Min 90 90 90 90 90 90 90

Grasso SP1
Noise level LWA

Compressor drive
motor
at 40°C
C D E G H L M
Output in kW
231 265 321 372 471 544 690
Max 98 98 98 98 98 98
110
Min 91 91 91 91 91 91
Max 98 99 99 99 99
132
Min 92 92 92 92 92
Max 100 100 100

160
Min 93 93 93
Max 101
200
Min 94

Compressor drive
motor
at 40°C
P N R S V
Output in kW T W
805 860 1040 1290 1640
Max 95 95
55
Min 88 88
Max 96 96 96
75
Min 89 89 89
Max 97 97 97 97
90
Min 90 90 90 90
Max 98 98 98 98 98 98
110
Min 91 91 91 91 91 91
Max 99 99 99 99 99 99 99
132
Min 92 92 92 92 92 92 92
Max 100 100 100 100 100 100 100

160
Min 93 93 93 93 93 93 93

Grasso SP1

Compressor drive
motor
at 40°C
P N R S V
Output in kW T W
805 860 1040 1290 1640
Max 101 101 101 101 101 101 101

200
Min 94 94 94 94 94 94 94
Max 102 102 102 102 102 102 102

250
Min 95 95 95 95 95 95 95
Max 103 103 103 103 103

315
Min 96 96 96 96 96
Max 104 104 104 104 104

400
Min 97 97 97 97 97
Max 104 104 104 104

450
Min 98 98 98 98
Max 105 105 105

500
Min 98 98 98
Max 105 105 105

560
Min 99 99 99
Max 105
630
Min 99
Compressor type/ theoretical swept volume in m³/h at 2940 rpm

Compressor drive
motor
at 40°C
Y Z XA XB XC XD XE XF
Output in kW
2296 2748 3250 4150 4900 5800 7170 8560
Max 99
132
Min 92
Max 100 100

160
Min 93 93
200 Max 101 101 101

Grasso SP1
Compressor type/ theoretical swept volume in m³/h at 2940 rpm

Compressor drive
motor
at 40°C
Y Z XA XB XC XD XE XF
Output in kW
2296 2748 3250 4150 4900 5800 7170 8560
Min 94 94 94
Max 102 102 102 103

250
Min 95 95 95 100
Max 103 103 103 104 104 105

315
Min 96 96 96 100 100 101
Max 104 104 104 104 104 105 105 105

400
Min 97 97 97 100 100 101 102 102
Max 104 104 104 104 104 105 105 105

450
Min 98 98 98 100 100 101 102 102
Max 105 105 105 105 105 105 105 105

500
Min 98 98 99 100 100 101 102 102
Max 105 105 105 105 105 105 105 105

560
Min 99 99 100 100 100 101 102 102
Max 105 105 105 106 106 106 106 106

630
Min 99 99 99 100 100 101 102 102
Max 105 106 106 106 106 106 106

710
Min 99 99 100 100 101 102 102
Max 106 106 106 106 106 106 106

800
Min 99 99 100 100 101 102 102
Max 107 107 107 107 107

900
Min 100 100 101 102 102
Max 107 107 107 107

1000
Min 100 101 102 102

Grasso SP1
Hint!
The individual emission data for the motor-compressor combinations can be found in the
tables and added using logarithms for screw compressor packages and chillers (DuoPack ver-
sion) as well as two-stage screw compressor packages.

Description of Design and Function Operating Manual | Large Series
Grasso SP1
7 DESCRIPTION OF DESIGN AND FUNCTION
7.1 Product code of screw compressor packages - Grasso SP1, SP2, SPduo and M Ser-
ies
Model size screw compressor package

X The ND screw compressor will be provided for the screw compressor packages in the Grasso
SP2 series (two-stage).
Y Versions of the screw compressor package
9 Screw compressor version variations
A Oil cooling
Screw compressor size HP side

(X1)
Only for screw compressor packages in the Grasso SP2 series (two-stage).
X / (X1) Screw compressor package size
Code letter Theoretical volume flow Code letter Theoretical volume flow
at 2940 min-1 in m³/h at 2940 min-1 in m³/h
C 231 T 1460
D 265 V 1740
E 321 W 1940

Operating Manual | Large Series Description of Design and Function
Grasso SP1
Code letter Theoretical volume flow Code letter Theoretical volume flow
at 2940 min-1 in m³/h at 2940 min-1 in m³/h
G 372 Y 2390
H 471 Z 2748
L 544 XA 3250
M 690 / 708 XB 4150
N 860 / 870 XC 4900
P 805 XD 5800
R 1040 XE 7170
S 1290 XF 8560
* Grasso M Series
Y Screw compressor package version
Refrigerant CO2 and

Design type Refrigerant Refrigerant HFC
R290 and Special
Screw compressor package NH3 R22 Refrigerant
R600a media
Horizontal oil separator installed below A H R F O
Oil separator installed vertically B K S G P
Oil separator horizontally in series C L T
Grasso SPduo/ mechanical suspension D M V Y W
Grasso SP2 (two-phase) E N U
9 Screw compressor versions
1 Standard refrigerating compressor Vi = 1.8; 2.0; 2.2; 2.6; 3.0
2 Standard refrigerating compressor Vi = 3.6
5 Standard refrigerating compressor Vi = variable
6 Booster Vi = fixed

Grasso SP1
7 Heat pump compressor Vi = fixed or variable
8 -- --
9 Speed regulated Vi = variable
A Oil cooling
Code letter Oil cooling
A Water-cooled oil cooler
B Refrigerant cooled oil cooler
C Refrigerant injection
D Water and refrigerant cooled oil cooler
E Water or refrigerant cooled oil cooler and refrigerant injection
F Without oil cooler
Examples of designation
XA B - 6 A Singe stage screw compressor package Grasso SP1 with screw compressor 3250 m³/h
(XA), refrigerant NH3 and vertically installed oil separator (B), booster with fixed internal vol-
ume ratio (6)with oil fine separation and water-cooled oil cooler (A)
TA-2A Singe stage screw compressor package Grasso SP1 or SSP1 with screw compressor 1460
m³/h (T), refrigerant NH3 and horizontally installed oil separator (A), fixed internal volume
ratio Vi = 3.6 (2) with oil fine separation and water-cooled oil cooler (A)
NA-3B Screw compressor package Grasso M with screw compressor 873 m³/h (N), refrigerant NH3
and horizontally installed oil separator (A), fixed internal volume ratio Vi = 4.8 (3)with oil fine
separation and refrigerant-cooled oil cooler (A)
LD - 2 A Screw compressor package Grasso SPduo with 2 of screw compressors 544 m³/h (L),
refrigerant NH3 and DuoPack version or multiple configuration (D), fixed internal volume
ratio Vi = 3.6 (2) with oil fine separation and water-cooled oil cooler (A)
W E - 6 A (L) Two-stage screw compressor package with LP screw compressor 1940 m³/h (W), refriger-
ant NH3 two-stage package (E), LP-compressor as booster (6), with oil fine separation and
water-cooled oil cooler (A), HP-compressor 544 m³/h (L)
– order specification,
7.2 Technical specifications – list of parameters,
Packages / chillers are designed and manufactured – general assembly drawing,
for special fields of application. For technical specifi- – P+I diagram.
cations see the following.

Grasso SP1
7.3 Location of the product identification (type plate)

The type plate contains the most important technical data of the product. This data and the contractual agree-
ments define the limits of designated use.
As standard, the type plate is fixed to the oil separator (deviations of the location are possible).
fig.4: Location of the product identification (type plate)
Type plate

Grasso SP1
fig.5: Type plate
GEA Refrigeration Germany GmbH Contact data of the manufacturer
Type: Type designation of the screw compressor package
Serial no.: Serial number of the screw compressor package
Year of construction: Year of construction of the screw compressor package
Weight without filling: Weight of the screw compressor package without filling
Refrigerant: Information on the refrigerant used
Max operating pressure: Information on the max operating pressure
Volume flow: Information on the volume flow
The standard languages are English and German.

Grasso SP1
7.4 Information and safety labels on the 7.4.2 Label of the safety valve
product
(safety labels)
Danger!
The safety-related labels on the pack-
age/chiller must be followed!
fig.7: Label of the safety valve
7.4.1 Labelling of the pressure and

temperature sensors, heater Importance of the labels
The safety valve must be connected to a blow-off
(safety labels) line.
7.4.3 Labels of the screwed connec-

tions with DiNova ring
(handling instructions)
fig.6: Safety labels of the pressure and temperature sensors,

heater
Importance of the labels:

Before replacing pressure and temperature sensors
without dip tube, it must be ensured that the pipes
into which the sensors are mounted are not pressur-
ised. The pressure-free state can be achieved by fig.8: Labels of the screwed connections
closing the shut-off valves before the sensor to be
replaced.
The informative label for all screwed connections
Before replacing oil heater it must be ensured that with DiNova ring (handling instructions) is attached
the oil separator into which the oil heater is screwed to the electric motor in a clearly visible manner.
in is not pressurised.
Importance of the labels:
Hint! If any leakage occurs at a screwed connection
Not applicable to oil heaters of the (escaping gases or vapours), the screwed connec-
HLP type series. tion must be tightened:
Counter-hold the screwed pipe connection using
a wrench. Tighten the pipe nut about 1/4 to 1/3
rotation beyond the point where the increase in
the force if felt.
® The leakage is remedied.

Grasso SP1
7.4.4 Labels of the pipelines 7.4.5 Marking the direction of rotation

of the compressor drive motor
(information plate)
Pipelines in refrigeration plants must be labelled as (information plate)
follows (DIN 2405):
– Refrigerant
– Direction of flow
– State of phase
fig.9: Labels of the pipelines
1 Arrow head (indication of the direction of flow)

2 Horizontal stripe (indication of the state of fig.10: Marking the direction of rotation of the compressor drive
phase), green = liquid // blue = gaseous cold // motor
red = gaseous hot
3 Information field (label of the refrigerant)
The direction of arrow indicates the direction of rota-
tion of the compressor drive motor
7.4.6 Marking the direction of rotation

of the oil pump motor
(information plate)
fig.11: Marking the direction of rotation of the oil pump motor
The direction of arrow indicates the direction of rota-

tion of the oil pump motor

Grasso SP1
7.4.7 Labels of the pressure gauge 7.4.8 Labeling of the control / control
cabinet
(information plate)
(information plate)
• Label on the rear side of the control unit of the
control system (visible after opening the switch-
ing cabinet):
– Project name
– Make number of the package/chiller
– MPI address
• Label on the inside of the switching cabinet:
– Test verification for the control system
fig.12: Labels of the pressure gauge
1 Description of the pressure gauge measuring

point
The description of the pressure gauge measuring

point is attached directly underneath the pressure
gauge. The gauge board can be arranged horizon-
tally as well as vertically.
fig.13: Test verification for the control system

Grasso SP1
7.4.9 Designation of the earth connec- See general assembly drawing for the position of the
tion earth connections.
Safety labels Hint!

The cross-section of the ground wire
must be at least 10 mm². Alternatively,
two separately installed and separately
connected ground wire must be used,
ensuring the minimum cross-section
in the sum.
fig.14: Designation of the earth connection
Importance of the labels

Ensure that the product is properly grounded before
start-up. Connect the earth connection. The neces-
sary mounting hardware and cables are not included
in scope of supply.

Grasso SP1
7.5 Process flow diagram
fig.15: Process flow diagram Grasso SP1, Large
10 Screw compressors
15 Compressor drive motor
20 Oil separator
25 Oil filter
30/200 Oil cooler (water cooled/ refrigerant cooled)
40 Oil pump
45 Suction filter
55 Check valve – suction side
60 Check valve – pressure side
260 Stop valve – pressure side
280 Stop valve – suction side

Grasso SP1
7.6 Main components

Screw compressor packages of the Grasso SP1 LARGE series consist of the following main assemblies and
components:
010 Screw compressors See installation instructions for the screw compressor
015 Compressor drive motor See operating manual of the compressor drive motor
020 Oil separator See component documentation
025 OMC block (can be arranged as separate oil filter for greater See component documentation
amounts of oil)
030 Oil cooler (not shown in the picture) See component documentation
040 Oil pump (can be arranged as an external oil pump for See component documentation
greater amounts of oil)
045 Suction filter See component documentation
055 Check valve - suction side
060 Check valve – pressure side

(up to NB 150 integrated into the oil separator or into the
pressure line after the oil cooler, depending on operating con-
ditions and refrigerant)
095 Coupling See component documentation
180 Controller See control documentation
360 Oil heater See component documentation
Safety devices
Common base frame for all components

Grasso SP1
fig.16: Standard Screw Compressor Package of Grasso SP1 LARGE Series

* not shown in the picture
The documentation of the main components are integral parts of the product documentation (see product
description or operating manual from the supplier, e.g. for the compressor drive motor).
The screw compressors are characterised by a com-
pact design, high reliability, high-quality components
7.6.1 Screw compressors and ease of maintenance.
Screw compressors are oil-injected dual-rotor posi-
tive displacement machines.
The screw compressors are operated with refrigerant
(standard: ammonia NH3, other refrigerants on
request). The refrigerating machine oil for the refrig-
erant must be selected in accordance with the infor-
mation about lubricating oils for screw compressors.
Various series and sizes of screw compressors are
available for different fields of application.
The screw compressors are driven directly by the
compressor drive motor via a flexible coupling.
fig.17: Grasso SP1 Large, position of the screw compressor

Grasso SP1
7.6.3 Coupling
Hint!
The documentation of the screw com-
pressor (installation instructions, part
lists, drawings) is part of the product
documentation.
7.6.2 Compressor drive motor
fig.19: Grasso SP1 Large, position of the coupling
The coupling helps in the transmission of torque

between the compressor and compressor drive
motor. The elastic design of the coupling brings
about the neutralisation of otherwise disturbing influ-
ences such as axial or radial forces, vibrations or off-
set.
fig.18: Grasso SP1 Large, position of the compressor drive Speed fluctuations and speed shocks are damped
motor and cushioned, torsional vibrations are reduced.
Hint!
Standard: The compressors are driven via a cou-
pling by means of an air-cooled 2-pole IP23 electric The documentation of the coupling
motor with an operating voltage of 400 V; 50 Hz. (operating manual) is part of the prod-
Optional: Other protection classes, operating vol- uct documentation.
tages and frequencies as well as speed-controlled
motors are available on request.
Hint! 7.6.4 Oil separator

The documentation of the electric
motor (operating manual) is part of the
product documentation.
fig.20: Grasso SP1, position of the oil separator
The design of the oil separators is standardised and

features less oil carry-over and low oil consumption.

Grasso SP1
The oil separator is installed vertically. 7.6.5 OMC block with oil filter system
Hint!
The documentation of the oil separator
(operating and maintenance instruc-
tions, acceptance certificate) is part of
the product documentation.
Oil heater
Electric oil heaters are installed in the oil separator in
order to heat the oil-refrigerant mixture in the oil sep-
arator while the screw compressor package is at a
standstill. Oil heating prevents condensation of the
refrigerant in the oil and hence any foaming of the oil
during start-up.
Oil heaters are equipped with: fig.21: Grasso SP1 Large, position of the OMC block with oil fil-
ter system
– Temperature controller to maintain a constant
oil temperature in the oil separator
The OMC block includes the oil distribution system of
(adjustable from 20°C to 150°C, preset to 60°C) the oil circuit. Necessary control and shut-off fittings
– Temperature limiter in case of faults, e.g.dry- are integrated in the OMC block. Connections for
running protection temperature and pressure sensors as well as service
(permanently set to 150°C) ports are present. The OMC block is combined with
a standardised filter system and oil pump units and
The oil heating is switched on when the screw com- forms the central control and operating unit in the oil
pressor package is at a standstill and switched off circuit.
automatically when starting up. Manual disconnec-
tion is recommended for prolonged standstill periods. Optionally, the OMC block can be equipped with a 3-
way valve element (for ensuring a minimum oil tem-
Hint! perature when starting the compressor).
The documentation of the oil heater Hint!
(operating and maintenance instruc-
tions, acceptance certificate) is part of The documentation of the OMC block
the product documentation. (operating manual, acceptance certifi-
cate) is part of the product documenta-
tion.

Grasso SP1
7.6.6 Oil cooler

Hint!
The documentation of the oil pump
(operating manual, acceptance certifi-
cate) is part of the product documenta-
tion.
7.6.8 Suction filter combination SFC
fig.22: Grasso SP1 Large, position of the oil cooler
The oil cooler is used for cooling the oil heated in the
compressor in order to ensure sufficient oil viscosity
for supplying to the compressor.
Hint!
The documentation of the oil cooler
(operating manual, acceptance certifi- fig.24: Grasso SP1 Large, position of the suction filter combi-
cate) is part of the product documenta- nation SFC
tion.
The suction filter combination SFC contributes sub-
stantially to the high working reliability of the compo-
7.6.7 Oil pump nents and the overall product.
The suction filter combination prevents dirt particles
carried by the suction flow from entering the com-
pressor. The flow through the suction filter element is
from the inside to the outside. It is designed so that
monitoring is not required. The filter element can be
cleaned.
Hint!
The documentation of the suction filter
combination SFC (operating manual,
acceptance certificate) is part of the
fig.23: Grasso SP1 Large, position of the oil pump
The oil pump is an important component of the oil

circuit. It is used for pumping and distributing refrig-
erating machine oil.
The oil pump ensures that the oil is distributed to the
individual lubrication points (e.g.slide bearing, bal-
ance piston and gland of the compressor).

Grasso SP1
7.6.9 Control • Possibility of communication with master control-

ler via MPI
(optionally via Profibus DP, Modbus RTU or
Modbus TCP)
Hint!
The documentation of the controller
(operating manual, circuit diagram,
parameter list, communication guide-
line, Quick Reference Card) is part of
the product documentation.
7.6.10 Fittings
fig.25: Grasso SP1 Large, position of the control The term fitting generally designates a control ele-
ment of the machine. Among other things, the term
The screw compressor package is equipped with a fitting is also used for valves if these are used for the
GSC TP type control as standard. control and regulation of fluid flows in the piping.
The GSC TP consists of the control unit with opera- Furthermore, all kinds of installations in piping, such
tor keypad and display unit, indicator lights for "Run- as sight glasses, measurement apertures, filters and
ning", "Warning" and "Alarm", the emergency stop similar are also designated as fittings. Therefore, fit-
button, the output relays and the housing. tings also include all kinds of valves, such as:
The GSC TP will be mounted directly on the com- – Stop valves
pressor package unit (standard). As an option, the
– Check valves
GSC TP can be arranged in a control centre.
– Safety valves
The GSC TP performs the following functions as
standard: – Throttle valves
• Display of all important physical and technical Each fitting has its own field of use, according to the
parameters, e.g.pressure, temperature, motor pressure or temperature in the pipe, the size of the
current, capacity, number of operating hours, pipe, the sealing requirements for the fitting, the
operating mode and status signals reduction and direction of the flow of liquid as well as
the medium itself.
• Automatic start-up and shut-down of the screw
The safety fittings are used to limit the pressure in
compressor package and capacity control
systems which are under pressure.
depending on the suction pressure or an external
temperature Each fitting is designed for the specific application.
The fittings can be operated manually or by motor,by
• Monitoring of all operating parameters gear motors, or pneumatic or hydraulic cylinders, for
• Compressor capacity limitation, in case the example. In reset fittings, the flow of fluid in the pipe
measured discharge pressure, suction pressure, causes automatic closing of the valve.
secondary refrigerant temperature or motor cur- Depending on the model, different closing elements
rent indicate overload (e.g.valve discs, flaps, pushers) close the pipe con-
nected to the fitting.
• Fault memory with date and time
• Wire failure detection for all analogue input sig- Hint!
nals The documentation of the fittings
• Password protection for preventing unauthorised (acceptance certificates) forms part of
access to important parameters the product documentation.
• Non-volatile saving of program

Grasso SP1
7.6.11 Safety devices Safety device to prevent the discharge tempera-

ture from being exceeded (resistance thermome-
The following safety devices are fitted:
ter 120)
Drive motor safety devices The compressor control system switches off the
Rated current limitation (016) screw compressor package when the specified limit
The rated current limitation is realised by the respec- value has been exceeded.
tive compressor control system. When the rated Limiting value = see parameter list
motor current is exceeded, the compressor capacity
Safety device to prevent the oil temperature from
control slide is driven in the MIN direction until the
being exceeded (resistance thermometer 125)
motor current reaches an allowable level. The nor-
mal capacity control then comes back into force. The compressor control system switches off the
screw compressor package when the specified limit
Thermistor (017)
value has been exceeded.
Thermistor which shuts down the compressor drive
Limiting value = see parameter list
motor when its winding temperature limit has been
exceeded. The minimum oil viscosity for safe compressor oper-
ation is ≥ 7 cSt. In case of oils soluble in the refriger-
Check valve - suction side (055) ant, the minimum oil viscosity must be ensured
The check valve on the suction side protects the depending on the discharge pressure and tempera-
screw compressor package from a sudden pressure ture, oil temperature and type of oil.
equalisation with the suction line after shutdown.
Overflow valve (340)
Check valve - pressure side (060) The overflow valve protects the compressor against
The check valve on the pressure side prevents impermissibly high pressure. The overflow valve
refrigerant from recondensing in the oil separator. must be connected with the suction pipe on site.
Oil pressure regulating valve (075) Triggering pressure = See parameter list and P+I
diagram
The oil pressure control valve regulates the differen-
tial pressure between the oil pump discharge side The overflow valve is designed in accordance with
and the package pressure. In the standard package, DIN EN 13136 "Refrigerating systems and heat
the oil pressure regulating valve is integrated in the pumps - pressure relief devices and associated pip-
oil management centre (OMC block). The oil pres- ing - methods for calculation".
sure regulating valve is separately mounted for spe- Warning!
cial operating conditions with external oil filter.
If not fitted on delivery, the overflow
Safety device to prevent the discharge pressure valve must be connected to the suc-
from being exceeded tion side when installing the screw
(pressure transducer 105) compressor package in the refrigera-
The compressor control system switches off the tion plant!
screw compressor package when the specified limit
value has been exceeded. Safety valve (345) at oil separator
Limiting value = see parameter list The safety valve protects the screw compressor
package against impermissibly high pressure.
Safety device to prevent the differential pressure
between the oil pressure after the oil pump (pres- Triggering pressure = See parameter list and P+I
sure transducer 110) and the discharge pressure diagram
(pressure transducer 105) oil circuit monitoring If the screw compressor package is installed in a
from falling too low refrigeration system comprising an emergency blow-
The compressor control device switches off the drive off station, only the oil separator connection is used.
motor when the pressure difference between the oil The valve is available as an option, depending on
pressure after the oil pump and compressor dis- the required acceptance.
charge pressure falls below the specified limit value.
Safety pressure limiter (350)
Limiting value = see parameter list
Safety pressure limiter with two separate reset locks,
one of which can only be reset using a tool. The
safety pressure limiter switches the compressor drive

Grasso SP1
motor off if the discharge pressure rises above the – Differential pressure of oil pressure after oil filter
set point. and discharge pressure (oil filter monitoring) -
Switch-off pressure 1 = See parameter list optional -
Switch-off pressure 2 = See parameter list
If the liquid refrigerant can reach more than 90% of
the oil separator’s volume, the client has to install an 7.6.13 Components installed by the cli-
additional safety valve against liquid expansion in the ent
oil separator. Design in accordance with EN 13136,
position in accordance with EN 378-2 Appendix F. Warning!
The components and parts the cus-
Thermostat (361) oil heater
tomer installs in particular the secon-
Setting value = See parameter list dary refrigerant and cooling medium
Temperature limiter (362) oil heater circuits as well as the oil circuit need
The temperature limiter shuts down the oil heating if to made from materials suitable for the
a specific surface temperature of the oil heater is fluids flowing through them. Further-
exceeded. more, in the event of modifications to
the product by the customer, the
effects on the safety devices are to be
checked.
7.6.12 Monitoring devices
The following operating values will be continually does not assume any liability for dam-
monitored in a standard screw compressor package: age arising and the violation of the
– safety regulations which result from
Suction pressure
the use of unsuitable materials or
– Discharge pressure through modification to the product
– Oil pressure oil circuit monitoring which is not considered in the original
safety concept.
– Suction temperature
– Discharge temperature
– Oil temperature 7.7 General functional description
– absolute primary slide position Screw compressor packages are refrigeration sys-
tem components and serve to compress refrigerants
– Motor current
such as ammonia (or other operating media on
– Suction pressure saturation temperature request).
– Saturation temperature Operation as a heat pump is also possible.
of condensing pressure
– Number of running hours
7.8 Refrigerant circuit
– Difference between oil and discharge pressures
(oil circuit monitoring) The screw compressor draws in refrigerant vapour
through the suction filter combination and suction fil-
– Set point of controled value in °C ter and then discharges the compressed vapour into
– Real point of controled value in °C the plant via the oil separator and discharge check
valve.
– Internal volume ratio
The check valve function of the suction filter combi-
– Used refrigerant nation SFC prevents pressure equalisation with the
LP side of the plant and simultaneously prevents
– Controled value
reverse rotation of the screw compressor.
– Used options The discharge check valve prevents refrigerant from
– Oil pressure after oil filter - optional - re-condensing in the oil separator.

Grasso SP1
Hint! required for restarting the package. The oil heating is

not regulated. The maximum temperature of the
The discharge check valve can be inte- heating rod is restricted.
grated in the oil separator for screw
compressor packages with discharge
side nominal diameters up to NB 150. 7.9.3 Oil cooling
The suction filter combination prevents dirt particles Before it is returned to the compressor for use, the
carried by the suction flow from entering the com- oil heated up in the compressor has to be cooled
pressor. The filter element is characterised by a very down to a temperature at which it has sufficient vis-
large filtering area. The filter has a fineness of cosity.
140 µm.
The following oil coolers are available:
Gas vibrations which can occur in the compressor
compression chamber at high pressure ratios in the 1. liquid-cooled (non corrosive media)
zero discharge zone are avoided by a gas vibration – water (non corrosive)
protection device. This consists of a pressure equali-
sation line between the oil separator and the com- – propylene glycol (25%)
pressor working chamber. – ethylene glycol (35%)
– Other refrigerants on request
7.9 Oil System 2. Thermosiphon
The screw compressors operate oil-flooded. During 3. Refrigerant injection

the compression process, refrigerating machine oil is
supplied to the compressor for lubrication, sealing,
noise reduction, and absorption of part of the com- 7.9.4 Oil filter
pression heat. After the compression process, the oil
After cooling, the oil enters the oil filter which retains
is separated again from the refrigerant in the oil sep-
solid particles from the entire oil flow.
arator.
Due to its large surface, the star-folded glass fibre
element has a high absorbing capacity and thus a
7.9.1 Oil separation long operating lifetime. The filter has a relative filter
fineness of 25 µm.
The refrigerant-oil mixture is led into the first part of
oil separator. The first part of the oil separator con-
sists of two chambers. The first chamber employs 7.9.5 Oil pump
gravity separation. The hot gas passes the demister
while flowing out of the first chamber into the second The oil pump runs for pre- and during compressor
chamber. The oil separated thereby is collected in operation.
the second chamber. Both the chambers of the first It draws the refrigeration compressor oil from the
part of oil separator simultaneously serve as oil receiver space in the oil separator, through the the
receivers. oil cooler and oil filter and pumps it to the bearings,
In the second part of the oil separator, the fine sepa- the balance piston, the shaft seal, to the capacity
ration of the aerosol oil portion from the refrigerant is control system and, if fitted, to the compressor's
performed by means of replaceable fine oil separa- hydraulic Vi adjustment system.
tion cartridges. The oil separated in the fine separa- The oil pump pumps more oil than the compressor
tion part of the oil separator is returned to the com- uses. This surplus quantity of oil is returned to pump
pressor via an additional orifice. suction via the spring loaded oil pressure regulating
valve. The oil pressure regulating valve regulates a
pressure difference between the oil pump discharge
7.9.2 Oil heater side and the unit final pressure (according to the
value in the P+I diagram).
The oil heater on the oil separator is to be started
when the package is shut down in order to ensure a
minimum oil temperature and sufficient oil viscosity

Grasso SP1
7.9.6 Oil injection 7.11.1 Basic terms

The injection oil is fed without a pump via the oil
Refrigerant Materials circulating in a plant (liq-
injection regulating valve.
uid or gas), which by means of
The oil injection control valve is used to adjust the their change of state of the pack-
necessary compression discharge temperature. age withdraw heat from another
The control valve is provided with a check function to medium (cooling or heating agent)
prevent sucking refrigerant through the oil pump. or can dissipate heat to this
medium.
7.9.7 Oil circuit, OMC block Secondary Fluids that can absorb the heat of
refrigerant a system and dissipate it to a
An OMC-block (oil management block) is flanged on refrigerant (reversible process)
to the oil filter as an oil distributor system. The oil and are used for the cooling of a
flow is distributed via the bore-holes and channels to system (industrial process)
functional ranges of the screw compressor. All regu-
lating valves and shut-off valves necessary for the Heating Media (liquid or air), which trans-
regulation of the oil circuit are integrated into the agents port and emit the heat absorbed in
block. As a result, a centralised control unit is availa- the secondary refrigerant. If water
ble for the screw compressor package. is used as the heat carrier, the
The oil filter with OMC-block (oil management block) terms warm water or cooling water
is fitted with an oil drain and refilling stop valve which are also used.
may be connected to a separate oil pump or
receiver.
Vent valves are fitted to oil filters for maintenance
and repair purposes. 7.11.2 Operating media
The oil in oil filter may be drained for changing oil fil-
ter via a separate stop valve.
7.11.2.1 Refrigerant
7.10 Capacity control The technical order specification defines the refriger-
ant used. All components of the screw compressor
The screw compressors are fitted with a continuous package are designed for use with the defined refrig-
capacity control with a range of 10 -100%. erant.
The capacity is adjusted by shortening the screw
Hint!
compressor stroke. The defining factor for the com-
pression process is the effective rotor length; this is The safety data sheet for the refriger-
altered by a hydraulically operated control slide. ant used must be observed. The safety
The position of the control slide is recorded by the data sheet is part of the product docu-
position sensor. The control device signals the mentation.
attainment of the MIN or MAX end position and the
relative control slide position can be displayed on the
Touch Panel in percent.
The hydraulic adjustment of the control slide is done
using four solenoid valves which are integrated into a
single block.
The control slide travel speeds in the MIN and MAX
directions should be the same as much as possible
during operation to ensure better compressor con-
trol.
7.11 Technical specifications

Grasso SP1
7.11.2.2 Refrigeration machine oils

Caution! 7.11.2.3 Secondary refrigerant
In order to ensure an adequate load- • Low corrosion water
bearing capacity of the sleeve bear-
ings and to ensure the service life of • Permitted brine levels: see Grasso Design Pro-
the roller bearings, a minimum viscos- gram
ity of 7cSt (=10-6 m²/s) upstream of the Hint!
compressor is required. A suitable oil
must be carefully selected in consider- For other secondary refrigerants, com-
ation of the operating conditions. patibility with the materials used must
be ensured.
The selection criteria and selection
tables are summarised in the technical
information document entitled "Lubri-
cant oils for screw compressors". This
technical information forms part of the
GEA Refrigeration Germany GmbH can
provide assistance in the selection of
a suitable refrigeration machine oil on
request.
7.11.3 Operation limits

The screw compressor packages can be operated under the most varied operating conditions within the given
operation limits according to the requirements involved. The operation limits listed below for the screw compres-
sor packages are based on the operational principle of the screw compressor, the thermodynamic relations and
are the result of the practical operating conditions and design. The tabulated data apply for single, two-stage and
heat pump operation. For the concrete application, selection and checking will be carried out in the compressor
selection program. Depending on the concrete operating conditions, restrictions of the limits specified in the table
can occur according to the specification text.
Suction temperature (compressor inlet) t0h °C min > - 60
Maximum allowable operating pressure p bar (a) max < 28
Discharge temperature (compressor

te °C max < 95
outlet)
Pressure ratio p / p0 π - min > 1.5
Pressure difference p - p0 (t0 < 11°C) Δp bar min > 0.8
Pressure difference p - p0 (t0 ≥ 11°C) Δp bar min > 3.5
Temperature difference te - tc Δt °C min >5

Grasso SP1
Temperature difference te - toil Δt °C min >4
Temperature difference toil - tcooling

Δt °C min ≥5
medium
Compressor type P R, S, T V, W, Y
50 Hz 330 530 900

Max. driving power (kW)
60 Hz 400 640 1080
Max. nominal torque Nm 1060 1700 2900
Max. allowable speeds (rpm) min-1 3600 3600 3600
Compressor type Z, XA XB, XC, XD XE, XF
50 Hz 1250 1800 3000

Max. driving power (kW)
60 Hz 1500 2160 3600
Max. nominal torque Nm 4020 5730 9500
Max. allowable speeds (rpm) min-1 3600 3600 3600
Minimal overheating at suction side: "Wet" operation to be avoided.

The minimum discharge temperature te must sufficiently exceed the value of the oil temperature for supplying the
bearing.
An oil viscosity of ≥ 7 ... the 70 cSt needs to provided for the oil solubility. Take into account the drop in viscosity
due to refrigerant dissolved in the oil!
Limits for temperature differences will be considered in the specification.
The oil temperature at the compressor inlet must be at least 18°C, the oil must be preheated if necessary.
A gas vibration protection is necessary for compressors with fixed Vi >= 3.6, or with variable Vi if the value Vi >=
3.6 is exceeded.
Direction of rotation when viewing compressor’s driving shaft: clockwise.
Consultation required with the manufacturer for application cases other than 50 Hz/ 60 Hz.
Notes
1. During tests of a certain application case, all the conditions specified in the table must be considered and
adhered to.
2. If the specified limits are exceeded for a specific application, GEA Refrigeration Germany GmbH must be
consulted.
3. In addition to the operation limits given in the tables, consider the operating conditions which must be
observed for the compressor (e.g. start-up regime, oil pressure, oil quantity, etc.).
4. Depending on the requirements of refrigeration economizer operation proceeds between the 100% and
approx. 70% control slide positions.
7.11.4 Designed for use in explosive
atmospheres!

Grasso SP1
Danger! Hint!
When operating the screw compressor If you fail to adhere to the limiting val-
package in explosive atmospheres, the ues stated in VDI 3803, the manufac-
special safety instructions for use in turer cannot provide any warranty for
explosive atmospheres that are men- water carrying parts within its supplied
tioned in this operating manual must components.
be heeded. Clarification as to whether or not it is
possible to adhere to these limiting
Hint! values with the respective water condi-
The screw compressor packages can tions should be agreed on with a spe-
basically be used in explosive atmos- cialist company during the planning
pheres. and design phase.
Some specifics must be heeded when using the The limiting values as per VDI 3803, as required for
screw compressor packages in explosive atmos- the use of carbon steel components in non corrosive
pheres of installation zones 1 and 2. water systems, are listed below.
The basis for use in explosive atmospheres is the
following data of the operator: Water quality requirements, parameters
– Zone division as per EN 60079-10 (or other Criterion Value Unit

equivalent international standards),
– description of the atmosphere (required gas Appearance clear, with-
groups), out sedi-
ment
– required temperature class.
This data is stored in the request sheet for project
Colour colourless
055 100A. The 055 100A request sheet is part of the
Odour none
For using and placing a screw compressor package
into operation within the EU, the package is manu- pH level at 20 °C 7.5 - 9.0
factured ATEX-compliant (see component selection,
protection systems, regulations, etc.)
Electrical conductiv-
The following marginal parameters generally apply: LF < 220 mS/m
ity
– The screw compressor packages can be instal-
led in Zones 1 and 2 in accordance with EN Ca2+,
Soil alkali < 0.5 mol/m³
60079-10. Mg2+
– The max. achievable temperature class is T4.
General hardness,
– The screw compressor packages are not suita- GH < 20 °d
for stabilization
ble for carrying explosive mixtures; the suction
pressure of the package is always in the over- Carbonate hard-
pressure range. ness without hard- KH <4 °d
ness stabilizer
7.11.5 Water quality requirements, Chloride Cl < 150 g/m³

parameters
All water bearing components from the manufacturer Sulphur SO4 < 325 g/m³
deliver an optimum performance and provide maxi-
mum protection from corrosion, provided you meet
all of the limiting values recommended in VDI 3803
issue 2010-02 (Tab. B3) for non-corrosive water and
adequate water conditioning.

Grasso SP1
Hint!
Water quality requirements, parameters
Manufacturer's recommendation: Use
Criterion Value Unit uncontaminated secondary refriger-
ants and cooling media, in particular in
Active biological chillers and when using of plate heat
KBE < 10,000 per ml exchangers.
components
The media quality must be assured by
Thickness factor EZ 2-4 means of an appropriate filter on the
inlet to the heat exchanger. The mesh
The use of carbon steel and cast iron is required in for such a filter must be ≤ 0.9 mm!
the most of applications water conditioning with cor- Should the chiller be required to
rosion inhibitors. remain in operation during filter clean-
The use of stainless steel requires very special moni- ing, double filters must be used. Pres-
toring of water in apply to Chloride contents (risk of sure loss through the filter must be
stress crack and pitting corrosion). taken into consideration on the build-
ing side when configuring the pump.
Hint!
The manufacturer recommends enlisting the services
Recommend when using plate heat of a reputable water conditioning company.
exchangers in the refrigerant circuit
< 100 ppm Cl while using steel 1.4301
and
maximum 40°C wall temperature in the
plate heat exchanger
< 200 ppm Cl while using steel 1.4401
and
maximum 100 °C wall temperature in
the plate heat exchanger
fig.26: Corrosion resistance in presence of chlorides
X Chloride ion concentration in ppm Cl-

Y Wall temperature heat exchanger in °C
A AISI 304
B AISI 316
C SMO 254

Start-up Operating Manual | Large Series
Grasso SP1
8 START-UP
The following points must be observed before
commencing with the start-up:
8.1 Important information for start-up
– Check of the external condition of the screw
Warning! compressor package (check of insulation, trans-
port damage... ).
hibited. – The area around the machine in which the start-
up is carried out must be marked and secured
Hint! against the access of unauthorised persons. Suf-
The Customer Service department of ficient lighting of the working area must be
GEA Refrigeration Germany GmbH ensured to prevent personal injury and material
offer comprehensive support for start- damage.
ing up the screw compressor package. – Personal protection gear (work clothing, work
For contact details, please refer to the boots, gloves) must be worn during all work on
chapter entitled "Technical customer the screw compressor package. There is a dan-
service". ger of impact and stumblingfrom protruding parts
on the screw compressor package (e.g. valve
Warning! caps). There is also the danger of cut wounds on
The screw compressor package must sharp edges and rough surfaces. All activities
only be operated by suitably skilled must therefore be carried out with particular
personnel who are familiar with the attention.
contents of the operating manual for – Suitable hearing protection must be worn in
screw compressor packages. order to protect against damage to hearing or
The safety regulations for refrigeration deafness.
plants must always be observed in
– Thermal hazards resulting in injuries due to
order to prevent damage to the screw
compressor package and injury to the burns or freezing may occur on contact with
operating staff. parts of the system which are at a very high or
very low temperature. Personal protective equip-
The screw compressor packages are tested and ment must be worn.
accepted at the works. By the time these screw – Suitable tools or special tools must be used.
compressor packages are delivered to the cus-
tomer, the following work will have been carried – Check that all electrical work has been carried
out: out in accordance with the standards (e.g.protec-
tive earth, insulation, shielding, covers). If neces-
• Complete installation of the cooling system and sary, an earth connection must be provided.
in particular:
– Pipes and pipe sections must be secured to
– cleaning and drying the refrigerant and oil ensure sufficient mechanical strength. The pipes
circuits and equipment of the screw compressor pack-
– Leak test with air age must not be entered.
– Evacuation of the refrigerant circuit and filling – Operating media (nitrogen, oil, refrigerant) can
with protective gas (nitrogen) to a pressure escape. Preventive measures must be taken to
of 0.3 to 0.5 bar (above atmospheric) collect and dispose of them in an environmen-
tally responsible manner (e.g.using an oil pan).
• Electrical wiring and testing of the wiring
Personal breathing protection must be kept
• Factory setting for the parameters on the control ready in the event of a refrigerant leak. The
safety data sheets of the oil and refrigerant used
• Factory setting of the safety and monitoring devi-
must be read prior to commencing start-up work.
ces
Familiarise yourself with the evacuation plan of
• Works trial runs (at the request of the client) the installation location.

Operating Manual | Large Series Start-up
Grasso SP1
– Danger! Check that components which have been removed

for transport, separately delivered components and
Solid mounting of the coupling protec- components provided by the customer are firmly
tion must be checked. Start-up must attached.
not be carried out with the coupling Check that all locating bolts are tight.
protection mounted.
– Check the protective gas filling (a positive pres-

sure ≥ 0.2 bar must be present) 8.3.1 Connecting the pipes
Hint! The nitrogen filling of the screw compressor package
must be purged by opening the vent valves before
If defects are found, notify GEA Refrig- the connection of the pipes.
eration Germany GmbH Service and
proceed according to their instruc- Establish all pipe connections so that the transmis-
tions. sion of thermal expansion and vibration to the screw
compressor package is limited as far as possible.
Bellows-type expansion joints made of steel, or flexi-
ble metal hoses can be used for refrigerant and oil
8.2 Basics lines, bellows-type expansion joints made from rub-
ber can be used for water connections.
The compressor must only be switched on if the
screw compressor package has been correctly con- Provide all pipe connections directly at the unit with
nected and filled with operating materials. fixed points.
The activities described in this "Start-up" chapter • Connection of:
must be carried out in the prescribed sequence.
– Suction line
The screw compressor package is operated via the
terminal of the control unit. – Pressure line
After the target values have been entered, both auto- – Oil cooler water connection
matic and manual operation are possible.
• If units are equipped with a safety valve: Con-
The software of the control device and operation via nect safety valve to the blow-off line.
the terminal are described separately in the operat-
ing manual for the control system. • Integrate relief valve in the suction line.
• if units are equipped with a refrigerant cooled oil
cooler:
8.3 Connecting the screw compressor
– Connect the refrigerant feed line from h.p.
package receiver (note geodetic height above oil
Caution! cooler).
All mechanical connections must be – Connect the evaporated refrigerant line to

made according to the R+I diagram the condenser
which is valid for the project. The R+I • If refrigerant injection is used: Connect the refrig-
diagram is part of the product docu- erant feed line from condenser or h.p. receiver
mentation.
• If an economiser is used: Connection the suction
Caution! line of the economiser to the charge connection.
All electrical connections must be

made according to the circuit diagram
which is valid for the project. The cir-
cuit diagram is part of the product
documentation.

Grasso SP1
Hint! – Compressor control supply
In principle, all the connections must – Oil heater

be made in accordance with the P+I – Oil pump
diagram applying to the respective
Some external components, such as the second
project. Attach the pipes to the screw
EMERGENCY STOP switch, the ammonia sensor
compressor package in such a way
and the fans of the machine room, must be connec-
that no additional static or dynamic
ted by the system erector on site.
loads are imposed.
All the pipes and systems to be con- Hint!
nected must be checked for leaks
Check that terminal screws (in the
when the work is complete.
switching cabinet) are tight.
8.3.2 Electrical connection 8.4 Paint and insulation

Danger! Damage to the paint and insulation during transport
Contact with live components is pro- and installation must be carefully repaired.
hibited.
The screw compressor package has been designed 8.5 Start-up procedure
for plug-in and reliable automatic operation.
All connections must be carried out according to the The following procedures should be completed in the
current installation regulations. sequence in which they are described:
Connections to the screw compressor package must
be flexible and free of loads.
8.5.1 Checking the electrical connec-
Hint! tion
Dimensioning of the inlet pipe cross-
Danger!
sections must be according to DIN
VDE 100 Part 520. Contact with live components is pro-
hibited.
Before starting work, make sure that all parts to be
connected are de-energised, e.g. by removing the Check that all electrical work has been carried out in
main fuse in all phases or installing a jumper wire. accordance with the standards (e.g.protective earth,
The insulation resistance of the electrical tools and insulation, shielding, covers). If necessary, an earth
fixtures and wiring is to be checked. The connection connection must be provided.
may only be undertaken if this value lies in the allow-
able range.
Connections and almost all external connections are 8.5.2 Leak test
pre-wired at the factory.
Hint!
Warning!
See type plate for permissible operat-
Produce the earth connection according pressure.
ing to the designation in the general
assembly drawing. See chapter "Des- The necessary safety precautions should be taken
ignation of the earth connection". before performing the leak test.
An approx. 3-hour pressure drop test with dry nitro-
The electrical consumers and sensor must be con- gen is used for the test. Test pressure: 7 bar
nected according to the circuit diagram. All electrical
A pressure drop of 2% is allowed during the 3 hours.
connections must be made according to the circuit
Fluctuations in the ambient temperature must be
diagram, e.g.
taken into account.
– Compressor drive motor

Grasso SP1
Caution!
Checking devices which could be
damaged by the specified test pres-
sure must be removed or blocked
before the leak test is performed.
A record should be kept of the pressure test, noting

the pressure in the pipes tested, the ambient temper-
ature and the outside temperature in the shade at
hourly intervals.
The removed measuring and control instruments
should be reinstalled after completion of the leak test
and if there are no leaks in the package/chiller.
Test strategy fig.27: Vacuum required to remove moisture from refrigerating
plants
Dry nitrogen is used as the test medium. After reach-
ing the test pressure, the pressure drop is measured X Room or Wall temperature in °C
via the differential pressure measurement. This may Y Vacuum in mbar
only change by 0.02 bar within an hour. If the display A Vacuum required to remove moisture from
device does not indicate a leakage through foam for- refrigerating plants
mation, the system is sealed.
Testing devices Measured values have to be checked and recorded
hourly after reaching the required vacuum. After the
A pressure gauge with an accuracy of 0.5% over the
vacuum pressure, the temperatures in the machine
entire measuring range, with a digital resolution of
house and the outdoor temperature in shade must
0.01 bar must be used for the measurement.
be entered in the log. After the vacuum test, the
The testing described here is based on pressure pressure compensation must be carried out with
gauges with pressure gauge and LEAK mode from NH3.
Keller.
Warning!
Display devices
A foaming agent must be used as the means to indi- Shut the oil pump during evacuation!
cate leakages. A solution of 50 parts water and 1
part detergent can be used as the foaming agent. See also "Evacuation on refrigerant side" in the
Leaks are detected through formation of foam. A chapter "Maintenance work".
leak detection spray can be used in problem areas.
Carrying out the test
1. Wet all connecting joints (welded seams, flange
connections, screw fastenings, etc.) with foaming
agent. Remedy any leaks detectable from the
noticeable formation of foam.
8.5.3 Drying, vacuum

After the leak tightness test has been completed, the
plant must be evacuated and undergo a vacuum test
for 3 hours. Evacuation is used to remove air and
moisture from the plant.
A vacuum pump must be used for evacuation.
The permissible increase in vacuum is maximum
6.66 mbar over a period of 3 hours.

Grasso SP1
8.5.4 Operating position of valves

For the positions of the manually controllable fittings for the operation of the package/chiller, see the P+I dia-
gram.
The layout and symbols used in the P+I diagram comply with the specifications of EN 1861, July 1998 Issue.
Caution!
The valves must be in operating position prior to the start-up of the package / chiller. Trouble-
free operation is only possible in this manner!
Stop valve open during normal operation
fig.28: Stop valve open
Stop valve closed during normal operation
fig.29: Stop valve closed
Check valve during normal operation
fig.30: Check valve
Shuttable check valve open during normal operation
fig.31: Shuttable check valve

Grasso SP1
Control valve adjusted:

– Start-up
– when operating conditions change
fig.32: Control valve
Shuttable check valve with integrated control function open dur-

ing normal operation
fig.33: Shuttable check valve
with integrated control function
Controlled by the controller (e.g. GEA Omni)
fig.34: Solenoid valve
Change-over valve (3-way valve), opened from below in arrow

direction
fig.35: Change-over valve
Operating position: shut

Δp x,x ± x bar control pressure to be set vis-à-vis reference pres-
sure (see P+I diagram)
fig.36: Oil pressure control valve
Caution!
An oil pressure being set too high or too low may result in serious compressor damage or
even the total breakdown of the compressor after just a short period of operation!

Grasso SP1
Overflow valve, safety valve
fig.37: Overflow valve, safety valve
controlled self-sufficient
fig.38: Pressure controlled check valve
manually operated if necessary
fig.39: Quick acting valve, spring-loaded
– ½” connections
– with cap
fig.40: Charging valve, drain valve
– Connection Rp ¼”
– For pressure gauge and pressure transmitter
fig.41: Service valve

Grasso SP1
controlled autonomously using control element
fig.42: Oil temperature limiter
Autonomous control via sensor
fig.43: Temperature controlled control valve
When charging with oil for the first time, oil must also
be charged via the service valve (135) too. To this
8.5.5 Oil charge end, the stop valve (065) must then be closed.
Caution! Caution!
Check the oil grade to be charged! See Due to the use of selected compo-
contract/project or recommendation of nents, the refrigerating machine oils
GEA Refrigeration Germany GmbH. A tend to absorb more moisture. There-
comprehensive overview of the allowa- fore, when charging a compressor the
ble oil types is provided in "Technical oil should be allowed to come into
information on lubricating oils". This contact with air for a short time only.
technical information is part of the The contents of an opened drum have
product documentation. to be used up within one working day,
For severely hygroscopic oils, the oil provided the drum is properly closed
container must be placed under a pro- between charging.
tective atmosphere.
The vacuum present in the screw compressor pack-

age/chiller before pressure compensation may be 8.5.5.1 Pressure compensation with
utilised for charging the package with oil. A separate the cooling system
oil charging pump is required after the pressure com-
pensation and for refilling with oil. Re-establish the vacuum. Carry out pressure com-
pensation via the service stop valve (285).
The connection of the oil draining or oil charging stop
valve (090) must be connected with the oil charging
container.
8.5.5.2 Checking the direction of rota-
Before charging with oil, switch the valves to the
tion of the oil pump motor
operating position.
Open the stop valve (090) until the oil level has The oil pump is started with the driving motor electri-
reached the top third of the sight glass assembly in cally blocked (service). The stop valves are in the
the oil separator sump. During operation of the pack- operating position.
age, the oil level should only reach the lower third of The direction of the arrow given for the oil pump
the sight glass assembly. must correspond to the direction of rotation of the oil
The oil separator is generally charged with oil via the pump motor.
oil cooler.

Grasso SP1
Caution! 9. Simulate the minimum end position of the control

slide and check the switching function of main
Since the slide ring shaft seal of the oil switch and star-delta contactor (for motors with
pump is dependent on the direction of star-delta starting).
rotation and can be damaged when
this direction is wrong, checking must 10. Checking the switching function of the solenoid
be reduced to a very short running valve by forcing the digital outputs.
period (less than 2 seconds). 11. Check the "Oil circuit monitoringfailure". only for
The adjusted differential pressure between the oil external oil pumpAfter 6s, the of the compres-
pump pressure side and the unit final pressure is sor drive motor must be shut off. To do so, the
checked with the oil pump rotating in the correct valve (70) must be throttled in such a manner
direction. It must not fall below the prescribed set that the alarm value for oil difference pressure as
value in the P+I diagram. stated on the parameter list is ot reached.
While the compressor is not running and the oil has 12. Set the motor current limitation acc. to nominal
not yet reached the operating temperature, the differ- motor data. See parameter list!
ential pressure can be slightly higher than the indica-
ted value.
The differential pressure can be changed by rotating 8.5.7 Adjustment of oil pressure
the spindle on the oil pressure control valve. (The dif-
Danger!
ferential pressure is increased by turning it inwards
and vice versa). The oil pressure being set too high or
too low may result in serious compres-
sor damage or even total breakdown
8.5.6 Checking the fault monitoring of the compressor after even a short
period of operation!
1. Disconnect the incoming feeder of the compres-
sor drive motor from the mains supply when Before the compressor drive motor and therefore the
checking the safety device (e.g. remove LV/HBC unit can be started, the oil pressure must be set cor-
fuse links). rectly by adjusting the oil pressure regulating valve
(075).
2. Apply voltage to the control device.
For adjustment solely the oil pump must be started.
3. Check the built-in pressure transducer and For units with the control GEA Omni, digital output
resistance thermometer for correct wiring. must be forced for this.
To do so, loosen the relevant contacts. The mes- The set value of the oil differential pressure should
sage "Broken wire <sensor XXX>" appears on be taken from the P+I flow chart of the specific
the display of the control. Check that the display project.
is correct after the contact has been re-estab-
Oil differential pressure = oil pressure item (110)
lished.
- discharge pressure item (105)
Further information can be found in the con-
The differential pressure can be changed by rotating
troller manual.
the spindle on the oil pressure regulating valve (the
4. Check limit values. differential pressure is increased by turning it
Limit value = see parameter list inwards and vice versa). To do so, the seal on the oil
pressure control valve (075) must be removed.
5. Switch on the screw compressor package/chiller
In comparison to normal operation conditions, the oil
from the controller.
differential pressure can be slightly higher if only the
6. "Oil circuit monitoring failure” must be indicated oil pump is operated or if the operating temperature
after a starting delay time of 20 sec. is not reached yet (with the valve open to the same
degree).
7. Reconnect the oil pump motor to the mains sup-
ply. In this case, the oil differential pressure should be
readjusted (according to the value in the P+I flow
8. Check the excitation of the solenoid valves of the chart) after start of the unit and reaching of the oper-
adjusting device for capacity control in the Mini- ation temperature.
mum direction.

Grasso SP1
8.5.8 Checking the direction of rotation – After checking the direction of rotation of the
of the drive motor drive motor, the coupling may be connected with
the motor.
Warning!
The coupling must not yet connect the
motor and compressor! 8.5.9 Mounting the coupling
– Secure the electric switchgear so as to prevent 1. The electric switchgear is secured to prevent it
the compressor drive motor from being switched from being switched on accidentally.
on accidentally.
2. Mount the coupling while observing the instruc-
– With the control slide in the MIN or MAX position, tions of the separate documentation.
it should be possible to rotate the compressor
3. The values for radial and angular deviations
shaft easily and smoothly by hand. When check-
given in the coupling documentation must be
ing the direction of rotation of the compressor
checked and corrected if necessary. The axis
driving motor pay attention to the conditions for
distance between the compressor drive motor
switching the compressor on.
and the compressor must be checked.
4. The real values have to record at data sheet of
coupling documentation. Please send back a
copy of the filled data sheet to:
Holzhauser Straße 165
13509 Berlin
Fax: +49 (0)30 - 43 592 759
Caution!
Observe the maintenance instruction!
fig.44: Motor direction of rotation
Regrease the coupling at the prescri-
A Compressor bed intervals if scheduled in the main-
B Motor tenance instruction for the coupling!
– The compressor drive motor is started directly

and then switched off again by forcing the digital 8.5.10 Checking the water circuits
outputs.
Check whether the cooling and cold water pumps
Hint! are running and the shut-off fittings in the cooling
Prior to the start-up of the compressor water circuit are in their operating positions.
drive motor, the manufacturer's infor- While the unit/ chiller is operating under project con-
mation, e.g. on the lubrication of the ditions, adjust the cooling water control so that the
motor, must be followed at all costs. condensing and oil temperature lies within the per-
missible range.
– If the direction of rotation of the motor is incor-
rect, it should be corrected while the electric
switchgear is secured to prevent the motor from
8.5.11 Initial start-up
being switched on accidentally. Then the motor
must work for at least 1 hour, unencumbered After carrying out the aforementioned works, the
and free from errors. This is important in order to SCP can be commissioned in accordance with the
dry out residual moisture in the motor (caused operating manual of the control device.
during transport or storage).
1. Switch on the control voltage of the control
– The coupling protection must be in place during device.
this start-up period as required by the labour
2. Remedy and acknowledge existing fault mes-
safety regulations.
sages.

Grasso SP1
3. Select manual operating mode. The water volume must be regulated so that the
cooling water volume corresponds to the project
4. Turn on SCP. value. The inlet and outlet temperatures must be
checked. The oil temperature adjusts automatically
via the 3-way valve.
8.5.12 Checking the adjustment of the
control slide Checking the oil cooling with refrigerant-cooled
oil cooler
1. SCP is running. No regulating or checking required.
2. Select manual operating mode.
3. The maximum end position (100%) must be
8.5.15 Adjusting the amount of injection
reached and signalled when the "Increase
power" button is pressed. oil and the oil temperature
4. The minimum end position (0%) must be
reached and signalled when the "Decrease
power" button is pressed. 8.5.15.1 Screw compressor packages
without refrigerant injection
5. Vent the adjusting device by moving the control
slide backwards and forwards about ten times. The amount of injection oil and the oil temperature
directly influence the discharge temperature of the
compressor. The amount of injection oil is adjusted
8.5.13 Checking the control slide adjust- under operating conditions through the injection oil
ment times control valve.
Caution! Standard values for discharge temperature

Only adjustment times between 30 and
60 seconds are permissible. t tmax
The throttle valves of the solenoid valves are adjus- NH3/HP t ≥ toil + 20K 30K 95°C
ted in the factory in such a manner that they ensure
an optimal adjustment time of the control slide of
NH3/LP t ≥ toil approx. 45 ... 60°C 80°C
between 30 and 60 seconds.
While running at operating temperature and pressure
Freon/HD t ≥ toil + 15K 80°C
conditions, determine the adjustment times needed
when the control slide is continually moved from the
maximum end position to the minimum end position R22/LP t ≥ 45 ... 60°C 80°C
and back. For the automatic system to run smoothly,
the adjustment times in either direction must be
approximately the same.
8.5.15.2 Compressor units with refriger-
The adjustment time can be adjusted with the help of
throttle valves DS5 and DS6. ant injection
Hint! The oil temperature is changed by setting the injec-

tion oil control valve. The more the shut-off valve is
See the assembly instructions for the throttled, the more the oil temperature decreases. If
screw compressor. the oil temperature becomes too low or reaches the
lower range, the setpoint for the discharge tempera-
ture should be set higher accordingly. In the first set-
ting of the oil circuit, the control valve for injection oil
8.5.14 Checking the oil cooler
is opened approximately half a turn.
Guide value for oil temperature = see parameter The discharge temperature is then regulated to the
list value indicated in the parameter list by means of the
thermostatic expansion valve.
Oil cooling with water-cooled oil cooler

Grasso SP1
Guide value for compressor end temperature: te

= 60 + 10°C (for NH3)
Other refrigerants on request.
8.6 Start-up after long standstill periods

1. Inserting the main fuse
2. Switching on the control unit according to the
operating manual.
3. Checking all parameters on the control unit dis-
play. See parameter list.
4. Checking the settings of all control and safety
devices.
8.7 Restarting after approx. 1 year

standstill
• Change the oil filter inserts (see maintenance
instruction).
• Switch on the oil heater at least one hour before
starting the screw compressor package/chiller.
• Open the stop valve on the suction side and the
pressure side (or check valves which can be
shut off).
• If fitted: Open the stop valves (or shuttable check
valves) in the suction line of the economiser.
• If fitted: Open the refrigerant supply to the ther-
mosyphon - oil cooler.
• If fitted: Open the manual stop valve of the refrig-
erant injection.
• Remove all non-condensable gases by venting.
To this end, check the condensing pressure and
temperature (see parameter list).
• Check the oil collection sump and drain if neces-
sary.
• Switch on the compressor and observe the oper-
ating instructions of the electrical switchgear.
Make a screw compressor package/chiller test
run in order to test the sensor and actor technol-
ogies (for operation and indicating precision).

Use, operation, control Operating Manual | Large Series
Grasso SP1
9 USE, OPERATION, CONTROL

4. The oil level in the oil separator must be within
the permissible range.
9.1 Important information for the opera-
tor 5. The cooling and cold water pumps must be in
operation.
The screw compressor package must be only be
operated by trained and qualified personnel who are 6. The supply of cooling water or coolant to the oil
familiar with the contents of the operating manual for cooler must be ensured.
GEA Refrigeration Germany GmbH screw compres- 7. The oil heater in the oil separator must have
sor packages. heated the oil sufficiently.
The safety regulations for refrigeration plants must
Hint!
always be observed in order to prevent damage to
the screw compressor package and injury to the The oil heater in the oil separator can
operating staff. be switched on while the screw com-
pressor package is not running. It is
Hint!
then automatically switched off when
The screw compressor package is the screw compressor package is star-
operated via the control panel of the ted and switched on when it is shut
control unit. If the control is included down. If the ambient temperature is
in the scope of delivery, the operating below 5°C, the oil heater must be
staff must be familiar with the contents switched on at least one hour before
of the complete documentation of the the screw compressor package is star-
control unit. The documentation for ted.
the control unit is an integral part of
the product documentation. 8. The rated current limitation has been set accord-
ing to the motor rating.
® The screw compressor package can be switched
on as per the controller operating manual.
9.2 Prerequisite for switching on
The screw compressor package has been designed
for automatic operation; the control unit controls the
switching on and off of the compressor and its
capacity adjustment.
Continuous operation and observation of the screw
compressor package is not necessary in automatic
mode. The necessary steps for switching on the
screw compressor package can be found in the con-
troller documentation.
If the screw compressor package is controlled man-
ually, it must be operated from the refrigerator room.
In particular, the repair and maintenance instructions
must be complied with.
The following prerequisites must be fulfilled for
switching on the screw compressor package:
1. The main power must be available and switched
on.
2. The screw compressor package must be suffi-
ciently filled with refrigerant and oil.
3. The valves must be in the operating position.

Operating Manual | Large Series Use, operation, control
Grasso SP1
9.2.1 Overview of the operating modes
Modes Signal for …
Name Remark Start/Stop Capacity +/-
0 Service Oil pump by itself

Compressor motor blocked
1 Manual Manual control via Touch Panel (TP) Manual Manual

+ Manual
2 Manual + Auto Manual Start/Stop via TP and full automatic local Manual Auto
capacity control
3 Auto + Auto Full automatic start/stop and local capacity control Auto Auto
4 Remote Start/stop and capacity demand via digital contacts External External
+ HW (cont) (hardware) from a remote master controller. The GSC continuous
TP derives from the continuous +/- signals the pulses
for capacity (indirect).
5 Remote Start/stop and capacity demand via digital contacts External External
+ HW (pulse) (hardware) from a remote master controller. The mas- pulses
ter also generates the +/- signals as pulses for control-
ling the slide capacity directly.
6 Remote Start/Stop from a remote master controller via digital External Local
+ HW (loc. contacts (hardware). The GSC TP controls the output + setpoint Setpoint
SW) depending on a local setpoint (TP) and from this set- deviation
point also automatically switches the product ON/OFF.
7 Remote Start/Stop from a remote master controller via digital External Remote
+ HW (ext. contacts (hardware). The GSC TP controls the output + setpoint Setpoint
SW) depending on an external setpoint (analog input) and deviation
from this setpoint also automatically switches the
product ON/OFF.
8 Remote Start/stop and capacity demand via network from a Network Network
+ Net (cont) remote master controller. The GSC TP derives from continuous
the continuous +/- signals the pulses for controlling the
capacity (indirect).
9 Remote Start/stop and capacity demand via network from a Network Network
+ Net (pulse) remote master controller. The master also generates pulses
the +/- signals as pulses for controlling the capacity
directly.

Grasso SP1
Modes Signal for …
10 Remote Start/stop from a central master controller via a bus Network Local
+ Bus (loc. signal. The GSC TP controls the output depending on + setpoint Setpoint
SW) a local setpoint (TP) and from this setpoint also auto- deviation
matically switches the product ON/OFF.
11 Remote Start/stop from a central master controller via a bus Network Network
+ Bus (net. signal. The GSC TP controls the output depending on + setpoint Setpoint
SW) an external setpoint sent externally via the network deviation
and from this setpoint also automatically switches the
product ON/OFF.

Grasso SP1
9.2.2 Setting of setpoint and limiting GEA Omni performs the following functions as
values as well as safety devices standard:
Caution! – Display of all important physical and technical

parameters, e.g. pressure, temperature, motor
The correct setting of all setpoint and current, capacity, number of operating hours,
limiting values is a prerequisite for the operating mode and status signals
safe operation of the SCP.
– automatic start up and shut down of the com-
For the setting of the setpoint and limiting values, the pressor package and capacity control dependent
on the relevant parameter for the application
1. details (steps) in the control operating manual
(e.g. the suction pressure or an external temper-
and ature),
2. the project-related data are – Monitoring of all operating parameters,
instrumental. The program-based setpoint and limit-
– Compressor capacity limitation if the measured
ing values as well as the setting values of the safety
discharge pressure, suction pressure, secondary
device are stated in the project-based parameter
refrigerant temperature or motor current indicate
list. The parameter list forms part of the documenta-
an overload,
tion for the controller.
– Fault memory with date and time,
– Wire failure detection for all analogue input sig-
9.3 Operation of the screw compressor nals
package
– Password protection for preventing unauthorised
Caution! access to important parameters
Read the control documentation care- – Non-volatile saving of programme,

fully. – MPI communication with a master controller
Contact the GEA Refrigeration Ger- (optionally via Profibus-DP, Modbus RTU or
many GmbH technical customer serv- Modbus TCP).
ice if you require assistance.
The screw compressor package is operated using

9.4 Instructions regarding failures, their
the control (standard: GEA Omni).
causes and remedies
The GEA Omni is mounted directly on the screw
compressor package as standard, but can also be The screw compressor packages/ chillers manufac-
arranged in a control centre. tured by GEA Refrigeration Germany GmbH are
The GEA Omni consists of the control unit with oper- highly advanced, automatic and extremely efficient
ator keypad and display unit (TouchPanel), indicator systems. Nevertheless, faults can occur and may
lights for "Running", "Warning" and "Alarm", the complicate any continuous operation of the plant or
emergency stop button, the output relays and the cause a failure of a part or the entire plant.
casing.
All switching, operating and control actions are car-
ried out via this TouchPanel. The TouchPanel is the
interface between the man and the machine.

Grasso SP1
Table of malfunctions
Fault Cause Remedy
The suction pressure is too low, Slow loss of refrigerant through Check the entire system for leaks.
performance is reduced and the leaks in the refrigerant circuit. Eliminate leakage, replenish refrig-
system overheats. erant if necessary.
Pressure sensor defective. Replace pressure sensor.
Defective capacity control devices Check capacity control devices,

in the compressors especially connections of solenoid
valves
Suction filters are clogged Clean or replace the filter insert.
The suction pressure increases, the The compressor/s are sucking in Check the filling of the system,
compressor(s) frost up to impermis- wet steam or liquid when started drain any refrigerant, repair safety
sibly high level or make noises that up. The safety device to prevent a device. Check for superheating.
suggests fluid (refrigerant) in the too-high liquid level is not respond-
compressor. ing.
The condensation pressure is too There is air or other non-condensa- Vent the refrigerant circuit.
high. ble gases in the refrigerant circuit.
The compressor(s) will not start-up The electrical circuit is interrupted Turn on the power, check safety
after switching on or it shuts down by a unit in the safety chain. devices and replace or correctly
immediately after starting again. adjust if necessary.
No oil pressure is building up in the Exchange or clean oil filter ele-

package/chiller. The oil circuit is ments, eliminate leaks and replen-
disturbed by clogged oil filters or ish oil.
leaks.
The compressors do not adapt to The capacity control device is mal- Check the oil circuit. The compres-
the required capacity. functioning due to disturbances in sors should only be repaired by
the oil circuit or mechanical influen- experts. Check the position detec-
ces. tor of the compressor control slide.
The compressors are shut off very The condensation pressure is too See above.
often by the maximum pressure high.
governor.
The maximum pressure governor is Remove the maximum pressure
defective or set wrongly. governor, repair it, set it correctly or
replace it.
The compressors are shut off very The suction pressure is too low. Open all valves on the suction side
often by the minimum pressure of the compressors.
governor.

Grasso SP1
Table of malfunctions
Fault Cause Remedy
The pressure governor is defective Remove the minimum pressure

or set wrongly. governor, repair it, set it correctly or
replace it.
The heat transfer capacity of the Check the evaporator for elevated
evaporator decreases. oil concentration, drain oil if neces-
sary.
When operting, the package/chiller The compressor(s) or the drive Inform the GEA Refrigeration Ger-
is louder than permitted. motor(s) is/are defective. many GmbH customer service

Cleaning, maintenance, repair Operating Manual | Large Series
Grasso SP1
10 CLEANING, MAINTENANCE, REPAIR

Hint!
The obligation for signage to prevent unintentional switch-on of the plant during cleaning,
maintenance and repair must be observed.
All maintenance and service tasks have to be carried

out with care to preserve the functionality of the
10.1 Important information for service screw compressor package. Guarantee claims will
personnel not be valid if the customer failed to follow the main-
tenance instructions.
The following chapter is primarily aimed at the main-
tenance and service personnel of the screw com-
pressor package.
10.2 Cleaning the heat exchanger
Hint!
Heed all safety instructions in this
manual. 10.2.1 Mechanical cleaning
Familiarise yourself with the local con-
Mechanical cleaning is a maintenance measure in
ditions of the screw compressor pack-
order to ensure the continuous safe operation of the
age installation site.
Adhere to all legal and local regula-
Components of the screw compressor packages
tions of health, work and fire protec-
(e.g.suction filter) can be removed for manual
tion as well as the regulations which
mechanical cleaning. Proceed in accordance with
must be heeded concerning the gases
the details in the applicable component documenta-
to be compressed.
tion. After completing cleaning work, properly mount
Please read this manual carefully and the component and check for leakage.
completely prior to working on the
Familiarise yourself with the special 10.2.2 Chemical cleaning
features of the screw compressor
package. Chemical cleaning of the screw compressor package
is not recommended by GEA Refrigeration Germany
Caution! GmbH.
There is an increased danger of slip-
ping due to contact of operating media
with the floor!
The screw compressor package must be serviced by

appropriately trained operating staff only. For all
maintenance work, the maintenance instructions
must be complied with.
A maintenance checklist is part of the product docu-
mentation. The maintenance certificates in the main-
tenance checklist are completed and signed as part
of the inspection and maintenance by authorised fit-
ters as evidence of the work done.
During the guarantee period, these confirmed main-
tenance certificates are a prerequisite for any claims
under the guarantee.
The responsible certified specialist company must be
informed if any repairs are required.

Operating Manual | Large Series Cleaning, maintenance, repair
Grasso SP1
10.3 Maintenance
– complete draining of the respective part of equip-

ment,
10.3.1 General instructions
– cleaning with the appropriate cleaning agents,
Danger!
– concentration measurements,
hibited. – ensuring sufficient ventilation and venting,
Maintenance work on the running – performance of all welding work with the use of
screw compressor package is not performing gas.
mitted. If gas filled pipes are opened for maintenance work,
these pipes must be in a gas-free condition.
Work involving intervention in the refrigerant circuit
must only be carried out by qualified engineers in
accordance with the guarantee conditions.
The screw compressor package must always be
switched off before being dismantled. Before begin-
ning the work, it must be ensured that all parts sub-
ject to maintenance/servicing are de-energised(e.g.
by removing the main fuse or installing a shorting
bridge).
The refrigerant must be removed from the applicable
parts of the system parts. This work must be carried
out with great care, taking into account the safety
regulations, so that the maintenance personnel are
not injured by the refrigerant or by the refrigeration
unit oil present in the system.
Parts of the system under pressure must be com-
pletely vented before opening. While carrying out the
repair, it is must always be ensured that a complete
pressure balance of the affected pressure chambers
with the environment is preserved.
During cleaning, repair or maintenance work, the
screw compressor package or its components must
be protected against the penetration of moisture in
order to prevent impairment of the function of the
components.
The chief principle must be to keep air and moisture
entering the screw compressor package to an abso-
lute minimum. All foreign substances must kept as
far away as possible or eliminatedincluding
– welding residues,
– sealing remnants,
– auxiliary materials such as grease, oil or sol-
vents.
Welding and soldering work may only be performed
with written permission. The requisite protective
measures must be defined. These include:
– personal protective measures when opening the
respective part of the system,

Grasso SP1
10.3.2 Repair work New inspection and approval is required after pres-
sure vessels that are subject to approval have been
Modifications and repair work may only be carried
repaired or changed. Welding may only be carried
out by qualified persons or persons with suitable
out by approved welders with a valid welder’s card.
training with the manufacturer's consent and must
strictly comply with the rules set out in the mainte-
nance instruction for the components concerned.
10.3.3 Maintenance intervals
Hint!
Caution!
The following maintenance notes must
be observed: The maintenance intervals in accord-
ance with maintenance checklist must
Only spare parts made by the original component be observed.
manufacturer may be used for repairs and for replac-
ing wearing parts. These are available from the The maintenance checklist is part of the product doc-
spare parts department. umentation. The attached maintenance checklist
contains all the maintenance instructions and certifi-
cations for the first 10 years of performance of the
10.3.2.1 Repair information screw compressor package. The maintenance certifi-
cates are completed and signed as part of the
Important features of the technology and production inspection and maintenance by authorized fitters as
process must be taken into account when repairing evidence of the work done.
the plant: During the warranty period, these validated mainte-
– complete sealing of all devices and pipes. nance certificates also serve as a precondition for
any warranty claim put to GEA Refrigeration Ger-
– Dryness and cleanliness of the entire plant. many GmbH.
– Use of welding methods causing only a minimum
amount of dirt to collect in the plant.
10.3.4 Maintenance work
– Pipes bent on a pipe-bending machine only
using refrigerating oil. Hint!
– If repairing the piping system from your own The documentation for the main com-
stocks, we recommend that you use a pipe with ponents is a part of the product docu-
NBK surface quality (annealed and descaled, mentation. This contains important
mechanically or chemically descaled after information to be considered before
annealing). beginning the maintenance work.
– When carrying out repairs to piping systems,
care should be taken to maintain the original pip-
ing routes. 10.3.4.1 Maintenance of the screw
– Only pipes of sufficient material quality, which compressor
are certified according to DIN 10216-2 should be
used. The following maintenance work must be performed
on the screw compressor at regular intervals (see
maintenance checklist):
10.3.2.2 Repairs of pressure vessels – Measure axial play of bearings,
subject to approval inspection – Check shaft seal,
Hint! – Check primary slide movement,
The responsible monitoring body – Check the adjustment of the position sensor.
(e.g.TÜV) must be notified in advance. After 50,000running hours or in the 10th running
year, a general check of the screw compressor is
provided by the manufacturer. Contact Customer
Service in this regard.

Grasso SP1
10.3.4.2 Changing the block mounting 10.3.4.3 Maintenance of suction filter

filter element combination SFC
Hint!
When must the filter element be 10.3.4.3.1 Changing the filter element
replaced or cleaned?
The oil filter element must be replaced The maintenance interval for changing or cleaning
as specified in the maintenance check- the filter element is specified by the manufacturer of
list for the total product from GEA the refrigeration system.
Refrigeration Germany GmbH. The contamination level and mechanical condition of
Loss in pressure during operation is the filter element must be inspected at least once a
monitored by the internal control – year.
including a preliminary alarm function Before opening the filter, always make sure the filter
for preventative replacement. housing is not under pressure.
The following applies as a guide value Caution!
for replacement: The filter element
should be replaced after every 5000 Refrigerant may leak out on opening
operating hours or once each year. the filter. The safety data sheets for
the refrigerants in question must be
Changing the filter element consulted and any prescribed protec-
tive measures observed.
1. Shut down the screw compressor package/chiller
and depressurise the blocked mounting filter on To remove the element, proceed as follows:
the pressure side.
1. Unscrew the cover.
2. Remove the filter cover by loosening the four
2. Pull out the cover with the filter element.
cover screws.
3. Remove the spring wire clamp.
3. Remove the filter element by slightly turning the
mounting pin in the filter head. 4. Twist the element away from the cover to
release the bayonet catch.
4. Check the O-ring and support ring in the filter
bowl for damage and correct positioning. 5. Detach the element from the cover.
Replace parts if required.
6. Allow the element to drain off into a suitable con-
5. Replace glass fibre element, clean or replace tainer.
wire mesh.
Caution!
The efficiency of the cleaning depends on the
type of dirt and the level of differential pressure When carrying out maintenance,
before replacing the filter element. If, after always inspect the sealing ring (O-
replacing the filter element, the differential pres- ring) of the cover for mechanical dam-
sure is more than 50% of the value before age and replace it if necessary.
replacing the filter element, wire mesh must also
7. Reassemble all parts with the new or cleaned fil-
be replaced.
ter element following the same procedure in
6. Check that the type designation/manufacturer ID reverse order.
number on the replacement element matches
the type designation/ID number on the filter’s rat-
ing plate.
7. Place the replaced or cleaned filter element back
on the mounting pin by turning it slightly.
8. Reposition the filter cover and tighten the four
cover screws. Ensure that installation occurs
without mechanical tension.
9. Vent the housing of the block mounting filter.

Grasso SP1
10.3.4.3.2 Cleaning the filter element – if the oil becomes unacceptably contaminated-
The metal-gauze element used in the filter can be due to a major accident (e.g. water penetration
cleaned and reused several times before it has to be into the refrigerant circuit).
changed. The degree to which oil in refrigeration plants has
aged must be checked by analysis and in compari-
Manual cleaning son of the data with those of fresh oil. Oil ageing can
Immerse the soiled metal-gauze element in a clean, also be judged from the darkening of the oil colour
grease-dissolving liquid, then blow it through with and the deposits found in the oil filters. If the degree
compressed air from the outside inwards. Here it is of ageing cannot be assessed reliably by laboratory
important to place a cylindrical part – possibly wrap- analysis and the results of visual examination, it is
ped in corrugated cardboard – inside the element to advisable to change the oil at the following intervals
catch the dirt particles. (see maintenance checklist).
The assessment of the condition of the refrigerating
Caution!
machine oil by means of a general visual inspection
Never use wire brushes for cleaning. (contamination) or laboratory analysis must be car-
ried out:
Hint! – after 5000 operating hours:
To avoid fatigue failures of the metal or
gauze, strainer elements should be
replaced with new, original filter ele- – at the end of one year's operation
ments after being cleaned 4 – 5 times. or
– after remedying major damage.
or
10.3.4.4 Oil draining, oil filling, oil – if the oil is dark coloured or very cloudy.
change
10.3.4.4.2 Oil change, maintenance

10.3.4.4.1 Importance of oil change work
Aged oil demonstrates an increasing loss of ability to Take oil samples for analysis and comparison with
lubricate. Because of this, all rotating components of the fresh oil data at regular intervals. Check the col-
the compressor are endangered. The filter elements ouration of the oil visually and assess the degree of
become prematurely clogged and must be cleaned contamination.
and replaced at shorter intervals. Depending on the results, the user must decide
The oil in the screw compressor package/chiller must whether to approve the postponement of filling the oil
be changed: until the next assessment date or whether to have
the oil changed.
– when the operating time of the oil charge has
reached the technically specified oil change Inadmissibly damp oil must be removed from the
interval, compressor unit/chiller immediately.
Warning!
Oil change intervals 10.3.4.4.3 Changing the oil
Oil change with ammonia as the refrig- 1. The screw compressor package/chiller must be
erant after every 5,000operating hours run for at least half an hour to reach its operating
or after 1 year at the latest. temperature before the oil can be changed.
Oil change with freon as the refrig-
2. First shut down the screw compressor package/
erant after 10,000operating hours or
chiller as described in the operating instructions.
after 2 years at the latest.

Grasso SP1
3. Open the stop valve in the bypass line around 10.3.4.4.4 Used oil
the check valve on the suction side and the stop Refrigeration machine oil drained from the circuit is
valve on the suction side to equalise the pres- no longer suitable for use in refrigeration plants. It
sure between the screw compressor package/ has to be stored or transported in appropriately label-
chiller and suction line. If screw compressor led containers in accordance with the legal provi-
packages operated in parallel or other separate sions. The operator is responsible for its proper dis-
chillers are present, the refrigerant should pref- posal.
erably be drawn off at a pressure which is
approx. 1 to3 bar above atmospheric pressure.
Then re-close the stop valves bypass and the
10.3.4.4.5 Draining the oil
suction-side stop valve. Otherwise the pressure
can be reduced by opening the vent valve on the It may be necessary to drain the oil:
suction filter and then disposing of the refrigerant
– to inspect or repair the compressor
as specified by law.
and
4. Then drain the used oil through the oil
draining/oil charging valves and dispose of it – if there is too much oil in the circuit.
(Caution! hazardous waste!). Once this has The oil must be drained in accordance with points 1
been done, re-close the valve and if possible to 6 of the chapter entitled "Carrying out oil change".
continue to draw off the refrigerant with a com- The oil must be drained through the filling hose and
pressor connected in parallel or a disposal into a container suitable for waste oil.
device until atmospheric pressure is almost
reached.
5. Otherwise depressurise the screw compressor 10.3.4.4.6 Checking the oil level
package/chiller by opening the vent valve on the The oil level is checked visually in the sight glass of
suction filter, taking into account the safety rules the oil separator.
for refrigeration systems.
The filling level should be 1/2 to 3/4 of the height of
6. Open the drain plugs and valves on the oil the sight glass.
cooler, oil separator and OMC block to drain any If the filling level is too low, replenish the oil. The fill-
residual oil. Then re-close the drain plugs and ing amount must be documented in an appropriate
valves. log.
7. Replace the filter element of the oil filter; replace
and/or clean the filter element of the suction filter
combination. 10.3.4.4.7 Charging with oil, topping
8. Evacuate the screw compressor package/chiller up with oil
using a vacuum pump. See chapter entitled "Start-up, charging with oil".
Warning! Hint!
Shut off the oil pump! For permissible types of oil, please
refer to the technical information enti-
9. Pressurise the screw compressor package/chiller tled "Lubricating oils".
with a slight overpressure via the stop valve
Oil removed from the compressor
bypass check valve on the pressure side.
must not be re-used. Always use fresh
10. Then check all components for leakages. On oil from sealed containers! Do not mix
successful completion, perform a complete pres- with other types of oil.
sure compensation with the discharge line fol-
lowed by a repeated leakage test of the screw
compressor package/chiller. The oil charge oil
and start-up of the screw compressor package/
chiller must be accomplished in accordance with
the operating instructions.

Grasso SP1
10.3.4.5 Oil pump maintenance 5. Dismantle the check valve installed in the oil
Assuming correct installation in accordance with the separator. This step is omitted if a check valve
conditions of use and correct fitting, gear pumps which can be shut off is used on the pressure
have the design prerequisites for long and fault-free side.
operation. 6. Remove the securing wire [3].
The gear pumps require a minimum of maintenance 7. Loosen the hexagon head screws/tie rod [2]
which is, however, indispensable for fault-free opera-
used to attach the oil fine separation cartridges.
tion since experience has shown that a high percent-
age of the faults and damage which occur are attrib- 8. Remove the fine oil separation cartridge [1].
utable to the ingress of dirt and inadequate mainte- 9. Install the new fine oil separation cartridge in
nance. reverse order.
The maintenance intervals have been defined in the
maintenance checklist (part of the product documen- Warning!
tation). Securing wire [3] must be re-attached!
An oil leakage of up to one drop/minute is required Max. tightening torque = 15 Nm
for the lubrication of the shaft seal and is permissi-
ble.
The shaft seal is maintenance-free. If the oil leakage
is too great, replace it according to the oil pump doc-
umentation.
Hint!
The regular examination of all operat-
ing data, such as pressure, tempera-
ture, power consumption, degree of fil-
ter fouling, etc., helps in the early
detection of potential failure!
10.3.4.6 Changing the fine oil separa-

tion cartridges
The fine oil separation cartridges must be changed
after 20,000operating hours or 3 years at the latest.
If the oil carry-over of the screw compressor pack- fig.45: Fine oil separation cartridge
age/chiller increases severely (oil recharging at
1 Fine oil separation cartridge
unusually short intervals), this may be necessary
2 Tie rod
even earlier.
3 Securing wire
Changing the fine oil separation cartridges
1. Close the pressure and suction side shut-off fit-
tings.
2. Suction refrigerant. Evacuate the screw com- 10.3.4.7 Tightening screw fastenings
pressor package/chiller. Screw fastenings of components can become loose
3. Check the pressure on the display of the control due to vibration or movement. Screw fastenings
unit or by connection of a test pressure gauge. must therefore be checked regularly to ensure they
are tight and retightened if necessary.
4. Dismantle the pipe bend on the oil separator.
Screw fastenings must only be tightened to the maxi-
mum tightening torques.

Grasso SP1
Unless otherwise stated by warning signs, the tight- Lower refrigerant levels in the containers are due to
ening torque is dependent on the size and strength loss of refrigerant as a result of leaks. For this rea-
of the screw fastening. son, all pipes, connections and valve glands should
be checked regularly, especially in the initial period
of assembly.
10.3.4.8 Coupling maintenance The most striking feature if there is a leak in the filled
refrigerant circuit is the smell of refrigerant. The
1. Switch the screw compressor package/ chiller
odour threshold of ammonia in the air is approx. 5
off.
ppm and thus well below the permitted MAK values.
2. Secure the electric motor against accidentally Methods of leak detection:
being switched on.
– Regular visual inspections.
3. Visually inspect the disk packs.
– Smudges/dirt stains indicate leaking
4. Check the tightening torques of the fit screws. refrigerant/oil mixture.
5. Check the alignment of the electric motor and – Leak tests with nitrogen with a max. of 0.5%
correct it according to the steel lamination cou- ammonia by volume, an elapsed time of more
pling documentation, if required. than 3 hours and application of a foaming agent
6. Re-grease the coupling (if provided for in the to all the joints with a brush. Oil-filled compres-
maintenance instructions for the coupling). sors or circuit sections must only be charged
with nitrogen – not air – to generate pressure.
– Use of an NH3 leak detector.
10.3.4.9 Checking the function of check
– Ammonia produces the following colours when
valves
leak tests are performed:
In order for a check valve to be effective, it is impor- – Red litmus paper turns blue,
tant to perform function checks at regular intervals.
– Blotting paper impregnated with phenolph-
An inspection is carried out by checking the noise
thalein turns red (moisten).
behaviour of the valves during operation. After
switching off the screw compressor package, mal- Caution!
function on the suction side is indicated by prolonged
turning back of the compressor. Malfunction on the Due to the danger of explosion, oxy-
pressure side leads to an increase of the standstill gen must never be used to build up
pressure in the package to the pressure level of the the pressure!
system pressure side. Generate a test pressure in the refrigerant circuit that
meets the intended operating pressure for the leak
tightness test to determine leaks on the refrigerant
10.3.4.10 Searching for leaks on the side, e.g. in the case of escaped inert gas or refriger-
refrigerant side / leak test ant. When system parts are individually tested, the
maximum operating pressure indicated on the
The absence of leaks is a precondition for perfect
respective system part for the corresponding pres-
functioning of the compressor unit/chiller unit. Leak-
sure chamber must not be exceeded. The use of
ing parts or connecting elements will lead to the loss
foaming agents gives the best results at test pres-
of refrigerant and oil as well as the penetration of air
sures < 5 bar.
and moisture into the low pressure side. The site of
the leak must therefore be located and remedied if If leaks are determined, these must be sealed imme-
there is: diately. Release the test pressure before beginning
repair! Evacuate the system after repairs are com-
– Loss of the inert gas charge (delivery state), plete and after rechecking for leaks.
– Loss of the entire refrigerant charge
or
– underfilling.

Grasso SP1
10.3.4.11 Venting the refrigerant circuit 10.3.4.14 Checking the solenoid valves
for capacity control
When air penetrates the refrigerant circuit, this
makes itself felt in a fall-off in performance and the See the following sections in the start-up chapter:
manometer on the discharge side of the compressor
indicates a higher pressure compared to the conden- • "Checking the control slide adjustment"
sation temperature. Any leaks must be remedied. In • "Checking the control slide adjustment times"
extreme cases, air in the circuit may interrupt the
flow of refrigerant and cause the oil cooling to fail.
There are several ways of venting the system. The 10.3.4.15 Checking the oil heater
air or the NH3-air mixture is vented via the vent
Check the electrical function using a clamp-on
valves of the condenser or the suction filter in water
ammeter.
filled vessels when the package is at a standstill.
Check the outer temperature of the oil separator and
If air is in the mixture, the venting ammonia is absor-
compare with the temperature of the machine room
bed from water.
(while the screw compressor package is at a stand-
Hint! still).
Continuous venting using a Grasso
purger is recommended.
10.3.4.16 Maintenance of the compres-
sor drive motor
10.3.4.12 Refrigerant evacuation Hint!
The compressor drive motor must be
Hint!
maintained in accordance with the
Shut the oil pump during evacuation! "Motor documentation".
The purpose of evacuating the system is to remove Maintenance of the compressor drive motor includes
air and moisture from the refrigerant circuit. the following activities:
Evacuation is required: – Lubrication of the motor
– after intervention in the refrigerant circuit and Lubrication intervals and quantities according to
elimination of leaks, the "Motor documentation" or "Type plate".
– before the start-up/restarting. – Cleaning of the motor (externally)

Evacuate the screw compressor package using a Select a suitable cleaning agent according to the
vacuum pump. The screw compressor must not be "Motor documentation".
used for evacuation.
During evacuation, all affected parts of the circuit
should be at room temperature at least because cold 10.3.4.17 Checking the start regime
parts hinder the removal of moisture. See the operating manual of the compressor control
If there is still any moisture in the screw compressor system.
package, this will lead to a rise in pressure. Evacua-
tion must continue until the pressure no longer
increases. A pressure comparison is based on a 10.3.4.18 Checking the safety devices
constant ambient temperature.
See section entitled "Checking the fault monitoring"
in the start-up chapter.
10.3.4.13 Checking the bearing noise The safety devices are checked by moving to the
switching points (limiting values). For details, see
The bearings of the drive motor and the compressor also the operating manual of the compressor control
must be checked for unusual running noise, espe- system.
cially in comparison to previous maintenance. Recur-
Limiting value = parameter list
rent vibration measurements are recommended.

Grasso SP1
Moving to the switching point is achieved by throt-

tling the pressure-side stop valve.
10.3.4.19 Checking the operating parameters

Hint!
The operating parameters are checked via the TouchPanel. The checking intervals recommen-
ded in the table must be observed. The project-related setting values and limits are given in
the parameter list.
Inform the GEA Refrigeration Germany GmbH technical customer service if the parameters
are outside of the allowable limits.
Parameter to be Every 24
Weekly Monthly Remark
checked to 72 hrs
Minimum superheat must not be less than 25 K.

Maximum discharge temperature 100°C, in indi-
Discharge temperature X vidual cases (e.g. heat pump applications) this
may be exceeded in agreement with the manu-
facturer.
See parameter list!

Oil temperature X The viscosity must not be less than 7 cSt at
max. speed (rpm).
The oil pressure must be at least 0.5 bar above

Oil pressure X the final discharge pressure. An oil pressure
fault may be caused by a clogged oil filter.
See project value (parameter list). Determine

Discharge pressure X the superheat on the pressure side by compari-
son with the final discharge temperature.
An oil level must be visible in the sight glass at

Oil level in oil separa-
X all times. If the oil level is below the bottom third
tor
of the sight glass, recharge oil.
When compressor is shut down, the heater

must automatically start. If the thermostatic cut-
Oil heater X
out (limiter) switches off the heater, this may be
an indication of an oil shortage.
Setting the safety devi-

X See set values in the parameter list.
ces

Grasso SP1
Parameter to be Every 24
Weekly Monthly Remark
checked to 72 hrs
Solenoid valves must switch audibly when the

Capacity control X capacity is adjusted. Check in operating mode
"1 (manual + manual)“.
See maintenance checklist for maintenance

Number of operating
X work to be carried out according to the number
hours
of operating hours.
10.3.4.23 Check of the tightening torque

on the adjusting elements of
10.3.4.20 Maintenance of the switching
the fixing base.
cabinet
The tightening torques vary depending on the
Terminal screws must be checked for tightness and, strength and size of the screw used. The values for
if necessary, tightened at regular intervals (every tightening torques are to be taken from the applica-
5,000 operating hours or at least once per year). The ble DIN, unless otherwise specified.
contacts of the contactors must be checked for loss
of contact material. Hint!
The tightening torques for the adjust-
ing elements should be obtained from
10.3.4.21 Checking the earth connection the data sheet. The data sheet forms
Check the function of the earth connection frequently part of the product documentation.
(see the general assembly drawing and the indica-
tions on the product).
Only a specialist company must be commissioned
with inspections.
10.3.4.22 Insulation
Check the insulation (if present) on components,
containers and piping for damage.
Damaged insulation must be replaced. The insula-
tion strength must be selected according to the tem-
perature and humidity at the place of installation.
Details on the insulation can be found in the P+I dia-
gram.
Caution!
No screw connections must be used
under the insulation if the piping is
insulated. The pipes must be welded.

Operating Manual | Large Series Decommissioning
Grasso SP1
11 DECOMMISSIONING
3. Switch off the main switch of the three-phase
electric system.
11.1 Shut-down in the event of danger-
ous situations 4. If necessary, shut off the secondary refrigerant,
heating agent or the cooling water supply.
The safety equipment of the screw compressor pack-
age complies with EN 378. 5. Ensure that the venting slots of the electric
motors are covered under all circumstances!
By means of automatic monitoring of the individual
operating parameters, the control unit detects haz- ® Shut-down has been carried out
ardous situations in good time and automatically
switches off the screw compressor package.
The cause of the fault is displayed on the control unit 11.3 Standstill for a period >48 hours
and can then be corrected.
Hint!
Among other things, the concept of the screw com-
pressor packages is based onlow maintenance The obligation to label the plant as
refrigerant circuits that are as well sealed as possi- "Plant not in operation" must be
ble. However, residual risks remain, especially due observed!
to possible leaks or escaping refrigerant or rotating
drive parts. If the screw compressor package is shut down for a
period >48 hours, the following activities must be
Hint! performed:
The EMERGENCY STOP switch in the 1. Switch off the compressor in accordance with the
switching cabinet is used to quickly operating instructions for the electrical switch-
switch off the chiller whenever neces- gear.
sary.
2. Switch off all ancillary drives.
Leaking refrigerant can be detected with a gas 3. Switch off the main switch of the three-phase
detector (not included in the scope of delivery). This electric system.
detector can be integrated in the automatic safety
4. Close the stop valve (or combined stop/check
chain.
valves) on the suction side and the pressure
Please consult the safety regulations in this docu- side.
mentation for information about what to do in the
case of leaking refrigerant. 5. Close the stop valves (or shuttable check valves)
in the suction line of the economiser.
6. Shut off the secondary refrigerant, heating agent
11.2 Standstill for a period <48 hours or cooling water.
Hint! 7. Close the manual stop valve of the refrigerant

injection.
The obligation to label the plant as
"Plant not in operation" must be 8. Ensure that the venting slots of the electric
observed! motors are covered under all circumstances!
® Shut-down has been carried out
If the screw compressor package is shut down for a
period <48 hours, the following activities must be
performed:
11.4 Measures during shutdowns
1. Switch off the compressor in accordance with the
operating instructions for the electrical switch- Even though the screw compressor package/ chiller
gear. is under overpressure, check the moisture content of
the refrigerant and lubricating oil in case it is shut-
2. If necessary, shut down all ancillary drives. down for a period longer than half a year. The mois-

Decommissioning Operating Manual | Large Series
Grasso SP1
ture content must not differ substantially from the ini-

tial values.
11.4.1 Monthly measures during stand-

still
– Check that the screw compressor package/
chiller is constantly under overpressure. Check
the screw compressor package/chiller for leaks
using a leak detector.
– Start the oil pump for approx. 5 minutes.
– Manually rotate the compressor shaft (min. 10
revolutions).
11.4.2 Four weeks before restarting

– Check the moisture content and ageing condition
of the refrigerating machine oil. Analyse the oil
for this purpose. Compare the results of the anal-
ysis with the values for fresh oil. We recommend
an oil change after 1 year (ammonia as refriger-
ant) (see Maintenance Instructions).
– Check the insulation resistance of the drive
motors (see the operating manual for the electric
motor).
– Switch on the oil pump.
– Check the screw compressor package/chiller for
leakages.

Operating Manual | Large Series Decommissioning, disposal
Grasso SP1
12 DECOMMISSIONING, DISPOSAL
Preparatory measures – National regulations (e.g. EN 378-4, Appendix A)
Hint! must be observed for the reclamation and dis-
posal of operating media (oil).
The information in the chapter
"Decommissioning" must be – No unauthorised persons must be within the
observed. installation area of the plant during decommis-
sioning, as they could come into contact with
refrigerant.
Hint!
– All components of the plant which are not to be
Care must be taken during disposal re-used, as well as refrigerant and operating
and devaluation that the various mate- media, must be stored in suitable separate con-
rials are separated and taken for recy- tainers. They must be treated as waste and dis-
cling. Disposal of component remains posed of safely.
and components in the domestic ref-
uge or on refuse tips is not permitted. Hint!
The legal regulations applicable to the Re-use of operating media is not pos-
place of installation regarding the dis- sible!
posal of electrical equipment must be
taken into account.
Dismantled components must be dis-
posed of correctly and according to
legal requirements.
– The dismantling and disposal of the package/

chiller must be carried out in such a way that:
• the plant is free of voltage and is protected
against unintentional reconnection of the
voltage.
• Accidents to persons are prevented,
• material damage is prevented,
• uncontrolled escape of refrigerant or oil is
prevented.
– Disposal and decommissioning work must only
be carried out by personnel who are qualified
according to EN 13313.
– Components may be under elevated pressure
and the pressure must be released before open-
ing them.
– In case of contact with refrigerant or operating
media, their hazardous properties (e.g. toxicity,
inflammability) must be taken into account (see
also the safety data sheet for the refrigerant).
Personal protective equipment compliant with
EN 378-3 must be worn.
– National regulations (e.g. EN 378-4, Section 6)
must be observed for the reclamation and dis-
posal of refrigerants.

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Screw Compressor Packages Grasso SP1 Large Series

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Screw Compressor Packages

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SYMBOLS USED IN THIS MANUAL

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Bullet points and numbered list characters

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7.7 General functional description 49

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10.3.2 Repair work 76

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Qualification – Only the fuses specified in the electrical circuit

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1.3 Legal foundations (Germany) The additional safety instructions as

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Failure to observe the safety instructions can lead to

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1.4 Specified Use the manufacturer – is responsible for all personal

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– control and regulation units including control sys-

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GEA Refrigeration Germany GmbH

GEA Refrigeration Germany GmbH

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– failure of the control circuit or control loop,

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Hint! The screw compressor packages are

fig.2: Designation of the attaching points.

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Caution! member or the company is responsible for ensuring

Position the screw compressor unit on the transport

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Warning! 5. Then re-fit the cover of the shaft seal.

The screw compressor package is fil- Warning!

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1. Visual inspection of the general condition of the

3. Check the transport fill pressure with a pressure

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The manufacturer will not accept liability for damage

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6.6 Information about noise emissions

Noise level LWA

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

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Noise level LWA

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Max 100 100 100

Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Max 100 100 100 100 100 100 100

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Compressor type/theoretical throughput volume in m3/H at 2940 RPM

Max 101 101 101 101 101 101 101

Max 102 102 102 102 102 102 102

Max 103 103 103 103 103

Max 104 104 104 104 104

Max 104 104 104 104

Max 105 105 105