RC(U)6

Installation and Maintenance Manual

00.89.238 v004.00.02.en
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 Grasso
Refrigeration Division

All rights reserved. No part of this publication may be copied or published by means of printing,
photocopying, microfilm or otherwise without prior written consent of Grasso. This restriction
also applies to the corresponding drawings and diagrams.

For extra information as to adjustments, maintenance and repair, contact the Technical
Departmentof your supplier.
This publication has been written with great care. However, Grasso cannot be held responsible,
neither for any errors occurring in this publication nor for their consequences.

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 PREFACE
Grasso
Refrigeration Division

1. Document Information
• This ’lnstallation and Maintenance manual’ will
be supplied together with the compressor.
• This manual is suitable for both end-user and
contractor and will provide information on how
to transport, install, start-up and maintain the
compressor (package). It also contains a number
of "Engineering Data Sheets" and the current
"Parts List".

2. Additional Documentation
In addition to the above the following is available
for this series compressor:
• Engineering Data Sheets Book;
This book contains all engineering data for this
series compressor and the corresponding
recommended accessories. It is meant to be a
guide to the selection of these components.

• Parts book;
This book contains all current parts of the
compressor and accessories together with the
design changes applicable to earlier supplied
components ("History").

• Mounting and Installation Instructions for

Accessories;
If compressor is supplied with accessories, all the
relevant mounting and installation instructions
and spare parts information for those
accessories will be supplied together with the
compressor.

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 PREFACE
Grasso
Refrigeration Division

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 GENERAL SAFETY INSTRUCTIONS
Grasso
Refrigeration Division

This manual must be carefully read and

understood prior to installing the
compressor (package)

Installer-oriented information
The compressor (package) is filled with nitrogen to
prevent penetration of moisture. Therefore, keep
the compressor closed until the compressor
(package) is being installed. The compressor is not
filled with oil. How to charge the compressor
package with oil is discussed in Section A, §A2.3,
"Initial oil charge".
After the succesful initial run of the compressor
(package) the warranty chart must be filled in and
returned to Grasso. A warranty chart is attached
to each compressor.

Safety
This manual is written with great care, but the
contractor/installer is held responsible to examine
this information and to care of possible additional
and/ or deviated safety measures.

Safety instructions
It is the task of the contractor/installer to inform
and explain his client about the operation of the
compressor (Package).
Do respect all federal, state or local safety
regulations/legislations during installing,
connecting and operating this compressor
(package).

Typographic signs:

Indicates a caution, note or procedure to

which you should pay special attention.
Read it carefully!

Values Between [ ]
Values between [ ] are read-outs of Grasso’s
electronic control device Monitron.

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 GENERAL SAFETY INSTRUCTIONS
Grasso
Refrigeration Division

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 GENERAL INFORMATION AND SURVEY
Grasso OF SETTINGS AND LIMITS
Refrigeration Division

Operating limits and switch settings

(for values between [ ] brackets refer to the Instruction Manual of the Monitron)
Timers Time interval refer to chapter:

Switching frequency max. 6 starts per hour A2.10.1

Time interval between stopping and re-starting min. 2 minutes A2.10.2
Time interval between starting and re-starting min. 10 minutes A2.10.2
Time interval between unloading and loading min. 3 minutes B1.2

Oil system limits Value

Oil level 25 - 75% crankcase sight glass B4

Min. oil temperature warmer than surroundings and ≥ 20 °C (68 °F) A2.8
for NH3 and ≥ 30 °C (86 °F) for halocarbons
Max. oil temperature [max. Toil] see oil selection table in the appendix section B1.2
Lubricating oil pressure difference [min dOil] between 1.5 and 2.5 bar A2.5.2
Setting approx. 1.8 bar

Temperature and pressure limits Value

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

Pdischarge - Psuction < 24.0 bar
Superheat [dTo] ≥5K
Cooling water inlet temperature of cylinder ≥Tcond + 10 K
head cooling system
Pressure safety limits A2.5.2

General information

Subject Feature refer to chapter:

Oil viscosity ≥ 10 cSt during operation at location of bearings

Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end A2.6

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 GENERAL INFORMATION AND SURVEY
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Refrigeration Division

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 TA BLE OF CO NT EN TS
Grasso
Refrigeration Division

SUBJECT Page no.:

PREFACE ............................................................................................................................... V
GENERAL SAFETY INSTRUCTIONS ................................................................................................. VII
GENERAL INFORMATION AND SURVEY OF SETTINGS AND LIMITS .......................................... IX
SECTION A: INSTALLATION AND PREPARATIONS FOR USE ....................................................... A1.1
A1 INSTALLATION .......................................................................................................................... A1.1
A1.1 Moving instructions and storage ................................................................................. A1.1
A1.1.1 Hoisting and moving instructions ...................................................................... A1.1
A1.1.2 Storage ............................................................................................................... A1.2
A1.2 Required free space ....................................................................................................... A1.2
A1.3 Foundation requirements .............................................................................................. A1.2
A1.3.1 Concrete structure ............................................................................................. A1.3
A1.3.2 Anchoring ........................................................................................................... A1.4
A1.4 Concrete block mounting instructions .......................................................................... A1.4
A1.4.1 Mounting bare compressor on a concrete block ............................................. A1.4
A1.4.2 Mounting the base frame on a concrete block ................................................ A1.4
A1.5 Connecting to refrigerating system pipework ............................................................. A1.5
A1.6 Connecting the power supply ....................................................................................... A1.6
A1.7 Earthing connections ..................................................................................................... A1.6
A1.8 Separately delivered components.................................................................................. A1.6
A2 PREPARATIONS FOR USE ......................................................................................................... A2.1
A2.1 Leak test of compressor and system ............................................................................. A2.1
A2.2 Evacuation/drying the refrigerating system ................................................................. A2.1
A2.3 Initial oil charge .............................................................................................................. A2.1
A2.4 Initial refrigerant charge ................................................................................................ A2.2
A2.5 Adjustment of instruments and safety devices ............................................................ A2.2
A2.5.1 Monitron ............................................................................................................. A2.2
A2.5.2 Pressure safety switches ..................................................................................... A2.2
A2.5.3 Re-adjustment of oil pressure regulator ........................................................... A2.3
A2.6 Checking direction of rotation of motor shaft ............................................................. A2.4
A2.7 Installing the (drive) guards .......................................................................................... A2.4
A2.8 Initial oil warm-up .......................................................................................................... A2.4
A2.9 Initial start-up ................................................................................................................. A2.4
A2.9.1 Limitations part load operation and start-up .................................................... A2.4
A2.9.2 Pre-start check list .............................................................................................. A2.4
A2.10 Starting and stopping procedures ................................................................................ A2.4
A2.10.1 Starting for the very first time ......................................................................... A2.4
A2.10.2 Restart .............................................................................................................. A2.5
A2.10.3 Starting after a seasonal (1 till 6 months) standstill or maintenance operations A2.5
A2.10.4 Starting after a long standstill periode of time (more than 6 months) ........ A2.5
A2.10.5 Stopping the compressor ................................................................................. A2.5
SECTION B: INSPECTION, MAINTENANCE AND TROUBLE SHOOTING: .Table of contents ....... B.I
SECTION C: APPENDIX <Instructions & collection of data sheets>: .......Table of contents ...... C.I
SECTION D: STANDARD ILLUSTRATED SPARE PARTS LIST: ....................Table of contents ....... D.I
For oil selection table refer to "Engineering Data"

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 TA BLE OF CO NT EN TS
Grasso
Refrigeration Division

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 A: INSTALLATION AND PREPARATION FOR USE
Grasso
Refrigeration Division

The compressor is not charged with oil, A1.1 Moving instructions and storage
therefore, DO NOT start the compressor
before it has been installed and prepared For loose component or compressor package
according to the sections A1 and A2. weights, refer either to the relevant component
type plate or package lay-out or to the suppliers
document. For bare compressor weights, see
A1 INSTALLATION "Engineering Data".

This section contains instructions for the proper

installation of a Grasso compressor (package). Every precaution must be taken while
Before the compressor (package) is ready for the moving the package to its final location.
initial start up, the installation instructions in the Pushing, pulling or climbing on any
following paragraphs must be followed: package component or piping, can easily
create damage.
1. The Compressor (Package) should be levelled and
securely anchored to the foundation (see §A1.4).
2. All piping should be completed as in §A1.5.
3. The system and the compressor are to be pressure A1.1.1 Hoisting and moving instructions
tested for leaks (see §A2.1).
4. The system should be evacuated to remove air and
moisture (see §A2.2).
5. The electric wiring should be completed as per
wiring diagrams. Do not energize the main power
control cabinet until oil is added and the direction
of rotation has been checked.
6. The compressor is to be filled with the correct type
and amount of lubricating oil (see §A2.3).
7. The drive coupling or V-belt drive system should be
installed.
8. The system should be charged with the correct
amount of refrigerant.
9. The oil should be warmed up above minimum start
up oil temperature (see "Engineering Data").
Fig. A1.1 Hoisting a compressor-package
10. The control cabinet or Monitron CR should be
energized to check the package control Packaged base frame:
(see §A2.5). The only places that can be used for safe hoisting
of the package are the four hoisting eyes on the
steel base frame as shown in the above figure.
Prior to hoisting a compressor package with a
V-belt drive arrangement, the factory mounted
drive guard has to be removed. Attach spreader
bars to the slings so as to prevent damage to
piping and components.
DO NOT use the component hoisting
eyes to move the package!
These hoisting eyes are intended for
lifting loose components only and not for
the entire package!

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 A: INSTALLATION AND PREPARATION FOR USE
Grasso
Refrigeration Division

A1.1.2 Storage
Bare compressor or loose components:
Determine the dead weight of the par- The compressor (package) is filled with dry
ticular component (see "Engineering nitrogen. Keep the system closed until the
Data"), prior to moving a bare compres- package is
sor or loose component. Use the hoist- installed. If the compressor (package) is stored, it
ing eyes only to lift so, DO NOT sling should be kept at all times in a dry location to
from other compressor parts (see figure prevent corrosion damage. If the compressor
A1.1A). (package) is to be stored for a prolonged period
of time, it should be checked weekly to ensure
that the holding charge of dry nitrogen remains
above atmospheric pressure.

A1.2 Required free space

For easy operating, servicing and maintenance
access, the compressor (package) should be at
least installed with sufficient free space around it.

A1.3 Foundation requirements

This paragraph covers measures to be taken for a
compressor (package) on a concrete floor.
Two foundation arrangements are described:
Fig. A1.1A Hoisting angle bare shaft compressor • Compressor package with steel base frame
mounted on a concrete block.
Moving by fork-lift truck • Bare compressor direct mounted on a concrete
The bare compressor or package can be block via grouted machined anchors (see
transported with a fork-lift truck with the forks "Engineering Data"). The mounting surfaces of
spread as much as possible between the skids. To these machined anchors must be level without
simplify moving, the 2 wooden transport beams any deviation and projecting at least 10 mm
must still be mounted underneath the base frame above the concrete base.
and stored in this way, untill the package is
positioned above its approximate location. COMPRESSOR AND COMPRESSOR
PACKAGE TO BE MOUNTED ON A
CONCRETE BLOCK
On request, Grasso can calculate the
exact dimensions of the concrete block,
based on the compressor size and
operating conditions.

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 A: INSTALLATION AND PREPARATION FOR USE
Grasso
Refrigeration Division

A1.3.1 Concrete structure

The concrete block for compressor and motor or
compressor package should have a profile as
illustrated in fig. A1.2 and made according to the
following recommendations:

1 Corkboard A Chemical anchor

2 Concrete base B Grouted anchor, grounded to reinforcing steel
3 Basement floor

Fig. A1.3
Fig. A1.2
• The concrete block should be set on firm It is recommended to consult a concrete specialist/
footings or on a floor capable of carrying the constructor for the following items:
weight of the concrete block and capable to • The compounding of the concrete with/without
absorb the free forces and gas forces of the reinforcement.
compressor during operation. The ground under • The exact grouting depth (dependent on the
the concrete block should be horizontal and flat soil conditions).
(refer to fig. A1.2). • Installing foundation onto an existing floor, with
• The top surface of the block should be level and sealing corkboard or vibration isolators.
even.
• There should be sufficient free space around the
block to install corkboard (or similar).
• The block should be provided with anchor bolt
recesses or holes (fig A1.3.) according to the
anchor bolt spacing as per package lay out
drawing.

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 A: INSTALLATION AND PREPARATION FOR USE
Grasso
Refrigeration Division

A1.3.2 Anchoring
After the concrete block has cured the anchors
should be installed as shown in figs. A1.3 and/or
A1.4 and in case of a package in accordance with
the package lay out drawing. Templates should be
made to locate the anchor bolts or chemical
anchors to match the holes in the bottom flange
of the base frame.
Grout the mortar as given by the supplier
instructions. Install chemical anchors as illustrated
in figure A1.4 and according the instructions of
the anchor supplier.

1 Installed chemical anchor before placing the base frame

2 Installing chemical anchor after placing the base frame (base
A Drilled chemical anchor (thread size M16) frame cannot removed easily)
B Grouted anchor recesses (thread size M16) 3 Drilling angle

Fig. A1.4 Anchoring details

A1.4 Concrete block mounting instructions A1.4.2 Mounting the base frame on a concrete
block
A1.4.1 Mounting bare compressor on a concrete
block General
After the space between base frame and concrete
If no base frame is applied the compressor and base is filled-up with a filling grout, the package
motor should be installed as discussed in §A1.3 base frame must be secured tightly to the
and "Engineering Data". foundation block or floor (refer to fig. A1.3).

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 A: INSTALLATION AND PREPARATION FOR USE
Grasso
Refrigeration Division

1 Self-levelling grout
2 Adjusting bolt (4x)
3 Washer
4 Temporary barrier strip around and inside frame
5 Complete cured concrete block
6 Grout layer

Fig. A1.5 Grouting details

be supported. Therefore, it is not allowed to use
• Levelling the base frame shims between concrete base and base frame.
Grouting must be carried out in accordance with
After the anchor filling mortar is completely cured the instructions provided by the grouting supplier.
the frame should be levelled with a space After complete de-aeration of the grouted layer,
between block and lower frame flange of 3 - 5 secure the base frame by tightening the anchor
mm. This space largely depends on the sort of bolt nuts and remove all adjusting bolts. At this
grout or mortar used. Determine this space as stage the drive system can be installed. These
given in the instructions of the grout or mortar (accessories) installation instructions can be found
supplier. This space is necessary for levelling using in the order manual.
the base frame adjusting bolts with metal washers
(supplied separately). The base frame should be
levelled on each frame side. Adjust the frame on A1.5 Connecting to refrigerating system pipe-
each adjusting place until all frame sides are
work
horizontal.
After the compressor (package) has been levelled
and secured to the foundation, the system piping
• Finishing with a self-levelling grout (See figure A1.5) may be connected. The suction line(s) and
discharge line(s) should be installed and supported
After levelling is completed the adjusting bolt such that there is no load exerted on the
ends must be greased to avoid bonding to the compressor. The size and location of the suction
self-levelling grout. The space between concrete and discharge connections, can be found in the
block and frame must be completely filled with "Engineering Data" (bare compressor) and in case
the self-levelling grout to ensure that the of a package, the package lay out drawing.
complete bottom surface of the base frame will

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 A: INSTALLATION AND PREPARATION FOR USE
Grasso
Refrigeration Division

If an oil rectifier system is applied in the re- A1.7 Earthing connections

frigeration system, the oil return line
must be connected to the oil return con- Grasso compressors and packages are equipped
nection. with litz-wires and earth connecting points.
Never connect the oil rectifier return line to To avoid leakage current flowing through the
the suction line or to the suction gas filter. components, disconnect all litz-wires when arc-
welding. After all installation functions are
completed, reconnect the litz-wires and ground
DO NOT ground through the compressor the package to earth.
when arc welding

A1.8 Separately delivered components

Suspension of system pipework
Mount the separately delivered set-components
To eliminate vibration transmission to the system e.g. oil charge and drain valve, according to the
piping, the following is recommended: instruction enclosed in each individual set.
• Install all piping free of tension.
• Secure the piping by clips or suspenders in two
directions.
• Install (stop) valves, piping and accessories such,
that there is no load exerted on the compressor.

A1.6 Connecting the power supply

Before leaving the factory the compressor
package is completely wired*. The connection to
be made by the installer is between main power
source and the Monitron CR (if ordered).
Information about further electrical connections
to be made (e.g. crankcase heater, drive motor
starting equipment, thermal protection of drive
motor, automatic start/ stop, motor current
transducer and other external electrical devices)
can be found in the order manual.

* If the standard recommended Monitron CR is applied.

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 A: INSTALLATION AND PREPARATIONS FOR USE
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A2 PREPARATIONS FOR USE d) Break vacuum by charging dry nitrogen into the
system.
After the Compressor (Package) has been installed
e) Repeat step ’c’.
(excl. final connection of drive device), the
following actions should be followed in the order f) Wait approx. 24 hours.
given: g) If pressure has been increased (system still contains
moisture), repeat steps ’d’, ’e’ and ’f’, otherwise,
A2.1 Leak test of compressor and system continue with the "Initial oil charge" procedure
§A2.3.
The compressor (package) has been pressure
tested prior to leaving the factory. In case an
A2.3 Initial oil charge
additional leak test is required, this test is should
be carried out with dry nitrogen under pressure Used or filtered oil should NEVER BE
up to a max. of 10 bar(a). added to a compressor under any
circumstance.
Do NOT add oil to the compressor prior Use only new oil to be selected from the
to pressure testing. oil table (see "Engineering Data").

a) STATUS: System is dried and still evacuated (refer to

A system leak test should be carried out over 24 §A2.2).
hours to ensure that the system is tightly sealed. b) Close suction and discharge stop valves of
Record during the pressure test, the pressure, compressor and oil return line of oil separator
ambient temperature and outside temperature. (if present).
During the initial 6 hours a pressure drop of 2% is
permissable. With respect to temperature c) Fill the compressor crankcase with oil (for oil
variations, no further pressure loss should be quantity see table overleaf) via the oil charge/ drain
detected in the remaining 18 hours. valve (for location of this valve refer to the
If the test pressure has not decreased by more "Engineering Data").
than 5% the system can be considered leak free. d) Open evacuation/purging valve(s) of the
compressor (for location of these valves refer to the
A2.2 Evacuation/drying the refrigerating system "Engineering Data") to bring the compressor to
atmospheric pressure.
For evacuation of compressor only, refer to §B5. e) Fill the following components with oil as given in
Procedure to evacuate and to dry a system: the table on the next page with/without pre-
a) STATUS: System is filled with nitrogen (refer to lubrication valves (explained hereafter) :
§A2.1) and no oil into the system (oil prevents any - Shaft seal housing via the oil filling opening.
trapped moisture from boiling off). - Oil pump housing via the oil filling opening.
b) Verify that all valves in that part of the system to be - Oil suction and discharge filter housings via the oil
evacuated are opened (refer also to the plant filling openings.
manual).
c) Connect vacuum pump to the evacuation/purging
valve(s) of the compressor (for location of these
valves refer to the "Engineering Data" or to a
connection as mentioned in the plant manual and
evacuate the system to approx.
5 mm Hg (=6.6 mBar).

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 A: INSTALLATION AND PREPARATIONS FOR USE
Grasso
Refrigeration Division

A2.4 Initial refrigerant charge

Refrigerant charging should be done in
accordance to the plant manual by qualified
refrigeration engineers.

Oil charging via the suction line of the

compressor is not allowed.

QUANTITY OF OIL TO BE FILLED (in dm3)

Compressor series RC6 Shaft seal housing Oil filters Oil pump Crankcase
RC46 11
RC66 ± 0.5 ± 1.0 ± 0.5 12
RC86 13

A2.5 Adjustment of instruments and safety

devices
A2.5.1 Monitron
For adjustments see table overleaf.

A2.5.2 Pressure safety switches

Refer to the table overleaf. Setting procedures are
described in the Safety Switch supplier instructions.

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 A: INSTALLATION AND PREPARATIONS FOR USE
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Settings of compulsory pressure safeties

Read-out Description Min. value Max. value (pre)-Setting
Monitron 1)
Psuc Suction pressure 0.3 bar (4.4 psia) NH3 6.2 bar (90 Psia) 5 °C (9 °F) below design
R22 6.8 bar (99 Psia) evaporating temperature
R134a 6.2 bar (90 Psia)
R404A 6.0 bar (87 Psia)
R507 5.8 bar (84 Psia)
Pdis Discharge pressure > Psuc 26.0 bar (377 Psia) 5 °C (9 °F) above design
condensing temperature
Pdis-Psuc > 0 bar 24.0 bar (348 Psia) < 24.0 bar (348 Psia)
dPoil Lubrication oil 1.5 bar (22 Psia) 2.5 bar (36 Psia) The oil pressure
pressure difference regulator is adjusted at
the works, but it may
occur that this setting
should be corrected
during the initial run
(see A2.5.3)
1
)In case of Monitron the values are measured via pressure transducers, otherwise protection via switches is compulsory.

A2.5.3 Re-adjustment of oil pressure regulator (re-

fer to fig. A2.1)
Re-adjustment procedure:
a) Run the compressor for 15 minutes until the d) Remove the cap nut (3) with alu ring (2), of the oil
crankcase oil is at its stable operating temperature [Toil]. pressure regulator if the pressure needs to be
b) Determine the oil pressure difference (difference re-adjusted.
between the pressure gauges of the oil and suction e) Turn the slotted pin (1) with a screwdriver clockwise
or [dOil]). or counter clockwise for a higher or lower oil
c) After approx. 15 minutes of operatinf and an oil pressure respectively, until the required oil pressure
temperature of 50 °C, the oil pressure difference differences has been achieved.
should be approx. 2.0-2.5 bar. f) Replace the cap nut (3) with alu ring (2).
During these first minutes the pressure should be
slightly higher.

1 slotted pin
2 alu ring
3 cap nut
4 return from oil separator
or oil rectifier
5 oil pressure regulator

Fig. A2.1 Oil pressure regulator

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 A: INSTALLATION AND PREPARATIONS FOR USE
Grasso
Refrigeration Division

A2.6 Checking direction of rotation of motor shaft Be sure that all necessary system valves are open
and that the refrigeration system is ready for start
Prior to installing the intermediate coupling element up. Use the following check to guarantee that no
or V-belts, the direction of rotation of the motor items of importance regarding the compressor
shaft must be checked either by bumping the (package) have been overlooked.
electrical drive motor or by measuring the rotation
a) System is charged with refrigerant.
of the field (direction of rotation normally counter
clockwise when facing compressor shaft end). b) Monitron (if present) is properly installed (refer to
the Monitron Instruction Manual).
c) Settings of safety limit switches are adjusted properly.
A2.7 Installing the (drive) guards (if present) d) Direction of rotation of compressor crankshaft is
correct.
Only after the compressor is ready for the initial
e) Oil level established in sight glass.
startup! Refer to the drive guard installing
procedures included in the order documentation. f) Stop valves to the pressure gauges are open (if
present).
g) Suction stop valve is closed (in case the evaporating
A2.8 Initial oil warm up temperature is much higher than the design
evaporating temperature) and the discharge stop
Prior to the initial start-up (refer to §A2.9), the valve is open.
crankcase heater (if present) must be energized. For h) Stop valve in the oil return line of the oil separator
the min. oil temperature (min. [Toil]) refer to page VII. (if present) is closed.

When all items a) through h) are verified, the

A2.9 Initial start-up
compressor (package) is ready for the start-up.
A2.9.1 Limitations of part load operation and
start-up
A2.10 Starting and stopping procedures
The capacity control serves to adapt the compressor
capacity at any moment as closely as possible to the When starting the compressor a distinction should
refrigerating capacity. In order to adapt the capacity, be made between:
a number of cylinders can be put in or out of action
either individually or collectively.
A2.10.1 Starting for the very first time (between
Due to start-up limitations and to brackets [ ] are Monitron units)
limitations of part load operation it may a) Notice §A2.9.2 "Pre-start check list", consult also the
be that not all available part load steps plant manual and verify the following items:
are allowed under certain conditions. - Check the oil temperature [Toil] (refer to the
Use of incorrect control steps can "Engineering Data").
damage compressor and/or components. - Check crankcase oil level (refer to §B4.1).
In the case of a Monitron Controller, all these b) Start the compressor and check whether the oil
limitations will be checked automatically. pressure [Poil] increases.
For a detailed description about these start-up
and part load limitations refer to the "Engineering Maximum 6 starts per hour and at least 2
Data".
minutes between stopping and starting
and at least 10 minutes between starting
and re-starting
A2.9.2 Pre-start check list
The following Paragraph covers only the initial
start of the compressor and not the complete
refrigeration plant.

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 A: INSTALLATION AND PREPARATIONS FOR USE
Grasso
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c) Slowly open suction stop valve and watch suction A2.10.4 Starting after a long standstill period of
pressure [Psuc], which may not exceed the max. time (more than 6 months)
value as given for each refrigerant in §A2.5.2.
Consult your supplier. Monitron "standby" status
Refrigerant liquid hammer, will damage (ready to operate during this long period of time)
the compressor; is not allowed! It is recommended to
Superheat is always necessary! [dTo]≥5 K proceed with the "Initial start-up" procedure of
§A2.10.1.

d) More cylinders will be energized. A2.10.5 Stopping the compressor

The compressor can be stopped at any moment,
Watch maximum allowable motor current however, consult the supplier if further actions are
[Imot] (refer to motor type plate). required.

e) Adjust pressure gauge stop valves, in order to avoid

vibration of the pointers (if present).
f) Open the stop valve in the oil return line from the
oil separator (if present).

Retighten the coupling bolts or check or

correct the tension of the V-belts and
retighten the foundation bolts (with
due respect to the torque settings given
by the supplier of the fasteners!) after
50 hours of operation.

A2.10.2 Restart (not within 2 minutes after a

stop, respectively starting after a short
standstill period of time [les than 1
month]). If Monitron Controlled, refer to
the Monitron Instruction manual)
• Proceed to the starting procedure of §A2.10.1
point a), b) and d).

A2.10.3 Starting after a seasonal standstill (1 till

6 months) or maintenance operations
• Check settings of control and safety equipment
(refer to §A2.5).
• Proceed to the complete starting procedure of
§A2.10.1, items a) through f).

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 TA BLE OF CO NT EN TS
Grasso
Refrigeration Division

SUBJECT Page no.:

SECTION B: INSPECTION, MAINTENANCE AND TROUBLE SHOOTING ....................................... B1.1
B1 INSPECTION ................................................................................................................................ B1.1
B1.1 Periodical inspection ......................................................................................................... B1.1
B1.2 Survey of periodical inspections ....................................................................................... B1.1
B2 MAINTENANCE .......................................................................................................................... B1.2
B2.1 Post start-up maintenance ............................................................................................... B1.2
B2.2 First maintenance ............................................................................................................. B1.3
B3 STEPS FOR LONGER SHUT-DOWN PERIODS (more than 6 months) ....................................... B1.4
B4 LUBRICATION DATA .................................................................................................................. B1.4
B4.1 Topping up oil with compressor operating .................................................................... B1.4
B5 EVACUATION OF THE COMPRESSOR ....................................................................................... B1.5
B6 DRAINING AND CHANGE OF OIL ............................................................................................. B1.5
B7 CLEANING OF OIL FILTERS ........................................................................................................ B1.5
B8 CLEANING OF SUCTION GAS FILTER(S) .................................................................................... B1.6
B9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES .. B1.6
B10 COMPRESSOR PURGING ............................................................................................................ B1.7
B11 TROUBLE SHOOTING TABLE ..................................................................................................... B1.7

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Refrigeration Division

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 B: INSPECTION, MAINTENANCE
Grasso AND TROUBLE SHOOTING
Refrigeration Division

B1 INSPECTION In this way it will not be necessary to stop the

compressor at inconvenient times.
B1.1 Periodical inspection The frequency of inspections is dependent on the type
of installation and operating conditions. In the case of
These inspections should be made during the normal
automatically controlled plants, the periodical inspection
shut-down periods as much as possible, so the
are particularly important. The table below sums up all
compressor is always ready to operate when required. If,
the points on the compressor that have to be inspected
at that time, the number of running hours slightly differs
or maintained along with inspection and maintenance
from the scheduled period below, the inspection should
frequencies.
nevertheless be carried out.
B1.2 Survey of periodical inspections ("check list")
CHECK POINTS 1) FREQUENCY monthly REMARKS
weekly
daily

Oil level in crankcase Between 25% and 75% height of the sight glass. For topping up oil, refer to
• §B4.1.
Colour of the oil The oil should be transparently clear. A disappearing white colour points to
• dissolved refrigerant. Refer to § B2.2 for oil analysis frequency.
Lubricating oil pressure differ- The indication of the oil pressure gauge should be 1.5 - 2.5 bar higher than
ence [dOil] • the value shown by the suction pressure gauge.
Oil temperature max. [Toil] • Refer to the "Engineering Data".
Oil leakage of shaft seal max. • In case of more than 1 cc/hr contact supplier.
Suction pressure [Psuc] • Check against design conditions. Refer to plant manual.
Discharge pressure [Pdis] Refer to plant manual. For the max. allowable discharge pressure refer to the
• technical data of compressor.
Suction superheat [dTo] ³5K
Intermediate superheat [dTm] •
Discharge temperature max. • 155 °C (311 °F)
Cooling water temperature (if Actual condensing temperature + 10 K.
present) min. •
Oil temperature min. [Toil] During compressor standstill the lower part of the crankcase must remain
• warmer than the surroundings: ³ 20 °C (NH3) and³30 °C (halocarbons).
Condition of V-belts Check belts for:
1) Wear (fraying, cuts etc.) and ensure that they do not touch the groove
bottom.
• 2) Tension. Too low a tension gives rise to excessive flapping or oscillation in
operation. For correct tension consult the instructions given by the V-belt
supplier.
Adjustment and operation of Refer to §A2.5 and to instructions of switch manufacturer.
pressure safety switches •
Capacity control The time lag between the unloading and loading of one cylinder or cylinder
• group should generally be at least 3 - 5 minutes.
Switching frequency of the com- The time interval between stopping and starting should be at least 2 minutes
pressor • and between starting and restarting 10 minutes (see §A2.10.2).
Number of operating hours Check the number of operating hours in view of any maintenance operations
• to be carried out.
Apart from the above check points, the sound produced by the compressor provides an indication or its mechanical condition. If
abnormal sounds are audible, their cause should be traced and removed immediately in order to prevent serious breakdowns.
1
) During the first 50 operating hours the compressor should be checked regularly for all the points mentioned above, at least
twice every 24 hours and more frequently in cases where irregularities are found.

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 B: INSPECTION, MAINTENANCE
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Refrigeration Division

B2 MAINTENANCE (Contractor’s level)

B2.1 Post start-up maintenance
After the compressor has run for the initial 100
operating hours:
a) Drain the oil and refill the compressor with the
correct amount of fresh oil.
b) Exchange or clean the oil discharge filter element.
c) Exchange or clean oil suction filter element (pos 24
of fig. 2.1) as given in §B7.
d) Clean suction gas filter.
e) Check the compressor shaft seal for leakage.
If excessive (more than 1 cc/hr) replace the seal.
f) Check drive
f1) Retighten the coupling mounting bolts with the
torque settings as given by the coupling
manufacturer.
f2) Verify and if necessary, correct the tension of
the V-belts as given in the V-belt supplier’s
instructions.
g) Verify and if necessary, correct the torque settings
of all foundation bolts as given in § 7.2 of the
Compressor Service Instruction Manual.

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B2.2 First maintenance

The maintenance schedule below indicates after
how many operating hours maintenance
operations have to be carried out. This schedule
can be regarded as a directive, based on the
experience gained with a large number of
compressors.
For most of the maintenance operations the
compressor must be put out of action. In order to
avoid that this should take place at inconvenient
times, the operations should as much as possible
be affected during a stand-still period. The
schedule has been drawn up in such a way that
several operations can be carried out
sumultaneously, which results in reduced
maintenance costs.

MAINTENANCE SCHEDULE
Number of 100 ) 2500 2)
1
10,000 10,100 12,500 2) 20,000 etc.
operating
hours 5000 15,000
Maintenance
7500 2) 17,500 2)
Cleaning of oil suction filter and
$ $ $ $
Major inspection to be carried

Major inspection to be carried

renewal of oil discharge filter
out by installation engineer

out by installation engineer

(ref. to par. 9.6).
Cleaning of suction gas strainer
(ref. to par. 9.7). $ $ $ $
Inspection of suction and discharge
valves $ $
(ref. to par. 9.8)
Draining and change of oil 3)
(ref. to par. 9.5).
$ $ $ $

1
) time dependent on pollution.
2
) Only for NH3-compressors
3
) In the case of a possible rapid pollution of the oil, it should be drained and renewed sooner than at the times given

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 B: INSPECTION, MAINTENANCE
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Refrigeration Division

B3 STEPS FOR LONGER SHUT-DOWN PERIODS Without affecting the operation of the compressor,
(> 6 months) the oil may be topped up by means of a separate oil
pump. This pump enables the oil to be forced into the
To shut down a compressor for long term periods, crankcase via the oil charging valve, against suction
proceed as follows: pressure. If this oil pump is not available, oil can be
a) Tightly shut both the suction and discharge stop charged by reducing the crankcase pressure to below
valves and the stop valve of the oil return line (if atmospheric pressure.
present). The procedure is as follows:
b) Disconnect the power source from the compressor a) Connect a hose to the oil charging valve after
drive motor and the electrical control cabinet of the removing the cap nut.
Monitron CR (if present).
b) Fill the hose with oil and immerse its loose end in a
c) Place a moisture absorbing compound (eg a reservoir containing sufficient oil.
dessicant such as silica gel) inside the control cabinet.
c) Close the suction stop valve so, that the suction
d) Place warning tags on the electric system and all pressure falls below the atmospheric pressure.
closed stop valves.
Prior to starting up after a shut down, change the oil d) Keep the oil charge valve open as long as the oil in
(refer to §B6) and clean or exchange the oil filters (refer the crankcase has attained the required level again.
to §B7). Determine the starting and stopping Take care that no air is being drawn into the
procedure from §A2.10 prior to start the compressor. crankcase.
e) Slowly open the suction stop valve to avoid liquid
hammer which may damage the compressor.
B4 LUBRICATION DATA f) Remove the hose and replace the cap nut with
gasket onto the oil charging valve.
Determine max Toil and set this value in the safety
device (Monitron CR, if present).
Change the oil as soon as an oil analysis (refer to
§B2.2 for frequency) indicates contaminated oil.

It is expressly pointed out that it is not

permitted to mix different types of oil. If
another type of oil is used, first remove
all the stale oil in the filters, oil pump,
crankcase, shaft seal, oil separator and
oil drains of the installation.

B4.1 Topping up oil with compressor operating

Topping up oil is permitted during compressor
operation.
Fig. B1 Oil level in compressor sight glass
Be sure that this oil is the same as in the plant
(refer to §B4).

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 B: INSPECTION, MAINTENANCE
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Refrigeration Division

B5 EVACUATION OF THE COMPRESSOR B7 CLEANING OF OIL FILTERS

To evacuate the refrigeration system refer to §A2.2. In most cases the oil filters have to be cleaned for
Procedure to evacuate the compressor: the first time after 100 operating hours. Besides
a) Close the suction stop valve and the stop valve in thorough cleaning of the strainer element of the
the oil return line of the oil separator. oil suction filter, the paper filter element of the oil
b) Check that the discharge stop valve is open. discharge filter should be renewed. Also after the
installation has been extended or modified, the
c) Set suction pressure safety switch to 0.3 bar(a). filters should be cleaned as if the compressor had
d) Start the compressor (manual). just been put in operation. The time at which the
e) Wait until the compressor will be cut out of next cleaning has to be carried out highly depends
operation either by the min. suction pressure safety on the cleanliness of the installation.
switch [min Psuc] or the min. oil differential Small impurities in the refrigerant gas that are not
pressure safety switch [dOil]. retained by the suction strainer eventually find
their way in the lubricating oil and may cause
clogging of the oil suction filter. A strong pollution
Do not start the compressor again, but close the of this filter is indicated by a falling oil pressure; in
discharge stop valve as soon as possible. this case it is necessary to clean the filter. It is
Be sure the compressor will not start again! recommended, therefore, regularly to check the
oil pressure during the first 100 operating hours.
g) Remove the remainder of the refrigerant, via the When the filters remain practically clean, cleaning
evacuation/purging valve(s) as prescribed by local can take place simultaneously with the other
safety regulations. For the location of these valves maintenance operations.
refer to the "Engineering Data". The oil filters can be cleaned as follows:
h) Reset the suction pressure safety switch [Psuc]. a) Drain the oil via the oil charging valve.
b) Purge the compressor (refer to par. B5)
B6 DRAINING AND CHANGE OF OIL c) Remove the discharge filter housing and the
released paper filter element. Catch up the
To top up oil see § B4.1. remaining oil present in this housing. After draining
Oil changing procedure: the oil out of the crankcase, remove one of the side
a) Evacuate the compressor (refer to §B5). covers and remove the gauze filter element by
unscrewing it from the internal suction pipe.
b) Drain the oil via the oil charging/drain valve.
Remove the cover of one or more service openings d) Clean the gauze filter element of the oil suction
on the compressor side. filter in a receptacle containing oil or a solvent.
After cleaning, thoroughly dry the element; if
c) Clean the inside of the crankcase with a non-fibrous possible, blow through the filter element with
cloth (do not use cotton waste!). compressed air against the normal oil flow direction.
d) Replace the service cover(s) with a new gasket. e) Clean the discharge filter housing and dry it with a
e) Charge crankcase with clean or fresh oil in non-fibrous cloth.
accordance with the procedure of §A2.3. f) Refit the gauze filter element and place a new filter
element.
g) Fit the discharge filter housing against the
crankcase (do not forget the gasket); also check
that the filter element is perfectly fit.
h) Remove the plug on top of the shaft seal housing;
fill this housing with fresh oil and replace the plug.
j) Purge the compressor (refer to par. B10)
k) Check oil level and top up oil as per par. B4.1.

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 B: INSPECTION, MAINTENANCE
Grasso AND TROUBLE SHOOTING
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B8 CLEANING OF SUCTION GAS FILTER(S) The valve rings and valve seats must be undamaged;
even the slightest damage may easily cause breakage.
a) Evacuate the compressor (refer to §B5). Valve ring and/or seat should be replaced when, due
b) Remove the four bolts holding the suction stop valve to wear, the total score of valve ring and seat is over
and remove the valve. 0.2 mm.
c) Pull the strainer element out of the suction strainer
housing without damaging the gauze. (see also fig. The sinusoidal springs must also be undamaged and
RC6-11 on parts list page 12). must have sufficient slack height.
d) Clean element by rinsing it in a solvent. Then
thoroughly dry the element preferably with REMARK! All valve parts can be obtained
compressed air. separately, except the discharge valve
e) Check the gauze for damage. seat, stroke limitor and central bolt. If,
for example, the discharge valve seat is
f) Slide the strainer element again into the housing and fit
to be renewed, a complete discharge
the suction stop valve. Check the oilit gasket for proper
valve (including stroke limitor, valve
condition.
ring and sinusoidal springs) should be or-
c) Purge the compressor (refer to §B10). dered (also refer to the parts list).

h) Carefully clean all valve parts and slightly oil them with
B9 DISMANTLING, INSPECTION AND RE-ASSEM- compressor oil; then re-assemble the discharge valve.
BLY OF SUCTION AND DISCHARGE VALVES j) After reassembling the discharge valve, check
whether the valve ring and springs can be pressed
The suction and discharge valves of a refrigeration
against the stroke limitor, and when released, the
compressor are parts that are heavily loaded both
valve ring is properly pressed back on its seat.
mechanically and thermally. Wear and life time of the
valves strongly depend on the operating conditions k) Place the suction valve ring and the corresponding
of the compressor. A high working temperature and sinusoidal springs on the collar of the cylinder liner
rapid temperature variations shorten the life time of and install the discharge valve, buffer spring and
the valves, which, for this reason, require regular pressure ring.
inspection. l) Check the gasket of the cylinder head cover and lay
For dismounting, inspection and re-assembly of the cover onto the cylinder head.
the valves, proceed as follows: m) Screw all hexagonal bolts and firmly tighten them.
n) Purge the compressor (refer to par. B10).
a) Evacuate the compressor (refer to par. B5).
b) Remove the cylinder head covers.
c) Remove the pressure ring and buffer spring. REMARK! In order to reduce the down-
d) Lift the complete discharge valve out of the cylinder time involved in this valve inspection, it
liner. is recommended to have as many com-
plete valve assemblies in stock as there
e) Remove the suction valve ring and sinusoidal springs, are cylinders on the compressor.
which are loose on the collar of the cylinder liner. The valves can then be exchanged with
f) Unscrew and disassemble the discharge valve. the valves to be checked. The original
g) Clean all valve parts and check them for break of valves can then be inspected at leisure
damage. and, if necessary, repaired or replaced.

MIND! If it appears that valve parts are broken, also

the cylinder liner and piston of the relevant cylinder
must be checked for damage.

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 B: INSPECTION, MAINTENANCE
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Refrigeration Division

B10 COMPRESSOR PURGING

Procedure to purge the compressor
(after maintenance jobs):
STATUS:
Stop valves of suction, discharge and oil return line
are still closed (refer to §B5) and compressor is
filled with oil (refer to §B6).
a) Connect a vacuum pump to the evacuation/
purging valve(s) and evacuate as prescribed by local
regulations. For the location of these valves refer to
the "Engineering Data".
b) When evacuation is completed open the discharge
stop valve.
c) Watch suction and discharge pressure.

If suction pressure increases quickly, the

discharge valve assy is leaking.

d) Start compressor.
e) Slowly open suction stop valve.
f) Open the stop valve in the oil return line of the oil
separator (if present).
g) If a Self-Limiting Automatic Purger is not installed,
purge the refrigerating system (refer to the plant
manual).

B11 TROUBLESHOOTING TABLE

The troubleshooting table on the next pages may
be helpful to quickly trace and remedy failures
that interfere with the proper operation of the
compressor. It is emphatically pointed out that the
cause of a failure must often be sought in the
refrigeration installation itself. Therefore, it is
necessary besides this table also to consult the
plant manual.
For Monitron CR controlled installations refer also
to its own trouble shooting table.

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 B: INSPECTION, MAINTENANCE
Grasso AND TROUBLE SHOOTING
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FAULT CAUSE REMEDY

A Discharge pressure too high 1. Discharge stop valve not fully open 1. Open fully
2. Discharge pressure gauge defective 2. Renew
3. Non condensables in system 3. Purge system with
Grasso Automatic
Purger

B Discharge temperature too high 1. Discharge pressure too high 1. See A

2. Too many cylinders cut out 2. Cut in more cylinders
3. Suction pressure too low 3. See D
4. Exessive superheat of suction gas 4. Eliminate exessive
superheat
5. Room temperature too high 5. Ventilate engine room
better
6. Discharge valve defective 6. Renew
7. Pressure relief valve leaking 7. Renew

C Suction pressure too high 1. Capacity control does not operate 1. Repair
2. Compressor capacity too small 2. Consult installation
engineer
3. Suction pressure gauge defective 3. Repair or renew
4. One or more suction valves defective 4. Repair or renew
5. One or more discharge valves defective 5. Repair or renew
6. Pressure relief valve is leaking 6. Renew

D Suction pressure too low (suction 1. Suction stop valve not fully open 1. Open fully
pressure safety switch may 2. Suction gas strainer polluted 2. Clean
possibly become operative) 3. Too little refrigerant in installation 3. Top-up refrigerant
4. Suction pressure gauge defective 4. Renew

E Crankcase frosted or wet just after 1. Liquid refrigerant in crankcase due to: In the case of big
starting, possibly also during amount of refrigerant:
operation stop compressor and
contact installation
engineer
1a. Room temperature too low 1a. See 1a
1b. Return from oil separator mainly consists 1b. Contact installation
of liquid refrigerant engineer
1c. Installation operates too wet 1c. Re-adjust installation
and provide for
superheat
1d. Liquid separator too small 1d. Contact installation
engineer

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 B: INSPECTION, MAINTENANCE
Grasso AND TROUBLE SHOOTING
Refrigeration Division

FAULT CAUSE REMEDY

F Cylinders inactive while com- 1. Incorrect wiring of capacity control 1. Refer to the "Engineering Data"
pressor is operating

G Too high oil consumption 1. Type of oil not according to oil lubrication oil 1. Change oil type
table (too thin oil)
2. Compressor operates unloaded too frequently 2. Refer to design calculations
3. No return from oil separator* 3. Check the operation of float
valve in oil separator
4. Tube of pressure equalizing obstructed 4. Clean tube
5. Worn out oil scraper ring(s) 5. Replace ring(s)
6. Loss of oil due to leakage 6. Repair
7. Leaking shaft seal (max. 1 cc/hr) 7. Repair shaft seal
8. Oil level in crankcase too high 8. Refer to §B2

H Too high oil pressure during 1. Lubricating oil pressure regulator not adjusted 1. Re-adjust or renew
normal operation at working properly or defective
temperature 2. Defective oil pressure and/or suction pressure 2. Repair or replace
gauge (if present)

J Too low lubricating oil pressure 1. Too little oil in crankcase 1. Top up oil
2. Disturbed oil circuit: 2. Renew the element of oil
Oil suction and/or discharge filter is dirty suction filter and/or oil
discharge filter
3. Lubricating oil pressure regulator not adjusted 3. Re-adjust or renew
properly or defective
4. Liquid refrigerant in crankcase 4. See E
5. Defective oil pressure and/or suction pressure 5. Repair or renew
gauge (if present)
6. Worn bearings 6. Renew bearings

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

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 TABLE OF CONTENTS
Grasso
Refrigeration Division

SECTION C:

Engineerings Description Remarks

Data Sheet No.
1 Description and operation of capacity control
2 General data
3 Limits of operation and fields of applications
4 Drawings (design details)

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 TABLE OF CONTENTS
Grasso
Refrigeration Division

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 3. D ESC RI PT IO N AN D OP ER AT IO N
Grasso OF CA PA CI TY C ON TR OL
Refrigeration Division

3.1 GENERAL the slide valve, the combination piston-rod-valve

will move to the rightmost position, causing the
The capacity control, i.e. the decrease in capacity slide valve to shut off entirely the permanent
at constant speed and under constant operating discharge chamber from the space direct above
conditions, takes place stepwise by successively the discharge valves (11) and the latter to be
cutting out cylinders in pairs. communicated via a ring of circular openings in
This is effected by isolating the discharge space the guide bush with the space between control
direct above the valves for each individual cylinder piston and slide valve (by-pass chamber), which is
head from the common discharge chamber in the in permanent communication with the common
compressor housing and by putting it into suction chamber (1) in the compressor housing.
communication with the common suction Both cylinders then operate unloaded as a result
chamber, also located in the compressor housing. of the by-pass thus effected. This situation is
This socalled “internal recirculation control” is, shown in the upper part of figure 3.1.
apart from the flow resistance in valves and
When the solenoid valve is being energized, line b
channels, free from losses because the cut out
is connected via line c to the control cylinder, so
cylinders do not compress gas but just circulate it
that there is no pressure difference across the
under suction pressure.
control piston and the combination
3.2 DESCRIPTION OF CAPACITY CONTROL piston-rod-valve is kept in its leftmost position by
the pressure prevailing in the permanent
As shown in figure 3.1, each controllable cylinder discharge chamber and exerted onto the
head cover is provided with a by-pass slide valve righthand face of the slide valve. The space direct
(item 9), which can move horizontally forward above the discharge valves then communicates,
and backward in a guide bush (10) and is via the afore mentioned circular openings in the
connected via a push rod (3) to a hot gas guide bush of the slide valve, with the permanent
operated control piston (5) in a horizontal control discharge chamber, so that both cylinders operate
cylinder (4). Slide valve, push rod and control normally. This situation is shown in the lower part
piston form one integral steel part. of figure 3.1.
Via a three-way solenoid valve (7,8), which is For the standard capacity control part-load steps of
mounted outside on top of the cylinder head the various compressor types and the corresponding
cover against the sealing cover (6) of the control energizing sequence of the solenoid valves, refer to
cylinder, the space to the left of the control piston the figures 3.2, 3.4 and 3.5 for compressor types
can be communicated either to suction pressure RC6 and to figures 3.6, 3.8 and 3.9 for compressor
(via lines c and b, the former connected to the type RC6W.
control cylinder and the latter to the by-pass
chamber 2) or to discharge pressure (via lines a 3.4 PARTIALLY UNLOADED STARTING
and c, the former connected to the permanent
discharge chamber 12 in the cylinder head cover). In order to be sure that all controllable cylinder
Actually, only line a, coming from the top pairs always operate fully unloaded when there is
connection of the solenoid valve, is an external no pressure difference between discharge and
one; the two others b and c are internal bores suction, a spring is mounted between each sealing
provided in the sealing cover of the control cover and control piston to ensure that in that
cylinder and in the walls of the cylinder head case all control pistons and slide valves are kept in
cover. These internal bores are not indicated in their rightmost position, regardless of whether the
the sections of figure 3.1. corresponding solenoid valves are energized or
not.
3.3 OPERATION OF CAPACITY CONTROL On the other hand, to create sufficient discharge
pressure to operate all available capacity control
If the solenoid valve is not energized, line a is slide valves when starting the compressor at zero
connected via line c to the control cylinder, so that pressure difference between discharge and
hot gas from the permanent discharge chamber suction, one cylinder head cover of each
enters this cylinder and, as the diameter of the compressor type is non-controllable, i.e. it has no
control piston is substantially larger than that of built-in slide valve and control piston, but is

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provided instead with only a simple vertical starting has to be accepted, inevitably resulting in
partition to keep the common suction and a more powerful electric motor to be installed, or
discharge chambers in the compressor housing special provisions are to be made by the installer
apart from each other. in the field to overcome this inconvenience, for
Consequently, when the discharge pressure is instance by applying an external line with solenoid
higher than the suction pressure, only partially valve (only open, so energized only during
unloaded starting is possible. starting) between the suction and discharge line
Therefore, it is recommended to always check the of the installation, combined with a non-return
electric drive motor in this respect, depending on valve in the same discharge line.
compressor design speed and starting conditions,
the procedure of which is set out in paragraph 4.7. Important installation requirement!
To prevent, during prolonged compressor
3.5 ALTERNATIVES TO CAPACITY CONTROL stand-still, a gradual pressure equalisation
between condenser and evaporator due to
The four-cylinder compressor types RC46 can also be slow leakage of refrigerant gas via the
delivered with an alternative capacity control, slide valve, a non-return valve should all
including three part-load steps (25, 50 and 75%) the times be mounted in the external
instead of only one (50%) in the standard version. discharge line.
For the switch sequence of cylinders and solenoid
valves of this alternative capacity control, refer to
figure 3.3 and figure 3.7 for compressor types
RC46 and RC46W respectively.
These additional steps are obtained by replacing
the non-controllable cylinder head cover of
cylinders nr. 1 and 3 (RC46 in fig. 3.3) or cylinders
nr. 2 and 4 (RC46W in fig. 3.7) by a partly
controllable one of special design, which means
that it has a partition in the middle of the space
direct above the discharge valves to separate the
two adjacent cylinders entirely from each other,
thereby causing the built-in control piston and
slide valve to be effective for cylinder nr. 1 (RC46)
or cylinder nr. 2 (RC46W) only and the discharge
valve of cylinder nr. 3 (RC46) or cylinder nr. 4
(RC46W) to be always in communication with the
permanent discharge chamber in the cylinder head
cover and the common discharge chamber in the
compressor housing.
So, only this one cylinder nr. 3 (RC46) or cylinder nr.
4 (RC46W) is always in operation, which has the
extra advantage of also reducing the starting load
from 50 to 25%.
On special order, just by adding the symbol Z after
the type designation, each standard compressor
type can also be delivered without any capacity
control. In that case not only one but all cylinder
head covers are of the non-controllable type, i.e. not
provided with built-in control piston and by-pass
slide valve.

However, the consequence of such a (cheaper)

choice is that either fully loaded compressor

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solenoid valve not energized

b b a CYLINDERS OUT OF OPERATION
a 8
9 10
c 11 12
7
6
5
c

4 ➙

3
➙

13

b b a solenoid valve energized

a 8
CYLINDERS IN OPERATION
9 10
c 11 12
7
6
5
c
➙ ➙ ➙
4
➙

3
➙

13

1. common suction chamber 6. sealing cover 9. (by-pass) slide valve

2. by-pass chamber 7. three-way solenoid valve with LED indication 10. guide bush
(schematic indication)
3. push rod 11. space direct above discharge valves
8. three-way solenoid valve (actual location) Grasso
4. control cylinder 12. permanent discharge chamber
code 06.80.111, suitable for 200-240V and 50/60Hz
5. control piston 13. common discharge chamber

Fig. 3.1 Principle of capacity control

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Number of solenoid valves: 1 (A,)

Number of control steps: 2 solenoid valves energized

- A ù Electrical
û control

50 100 % Capacity

No. of operating cylinders

A 1 1

- 2
1 RC46
3 3 (standard)
2
- 4

3
4

Fig. 3.2 Standard capacity control of compressor RC46

Number of solenoid valves: 2 (A,B)

Number of control steps: 4 solenoid valves energized

- - A A ù Electrical

- B - B û control

25* 50 75* 100 % Capacity

No. of operating cylinders

- 1 - 1

B - - 2 2
A RC46
3 3 3 3 (alternative)

- - 4 4
1
2 * Optional (see paragraph 3.5)

3
4

Fig. 3.3 Alternative capacity control of compressor RC46

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Number of solenoid valves: 2 (A,B)

Number of control steps: 3 solenoid valves energized

- - A ù Electrical

- B B û control

33.3 66.6 100 % Capacity

No. of operating cylinders

A 1 1 1
B
- 2 2
1
2 - - 3
3
4 4 4

- 5 5
RC66
4 - - 6
5
6

Fig. 3.4 Standard capacity control of compressor RC66

Number of solenoid valves: 3 (A,B,C)

Number of control steps: 4

solenoid valves energized

- - - A ù
Electrical
- B B B ê control
û
- - C C

25 50 75 100 % Capacity

No. of operating cylinders

C
B 1 1 1 1
A
- - 2 2
1
2 - 3 3 3
3
4
- - - 4

5 5 5 5
5
6 - - 6 6
8 7
- 7 7 7
RC86
- - - 8

Fig. 3.5 Standard capacity control of compressor RC86

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Number of solenoid valves: 1 (A)

Number of control steps: 2

solenoid valves energized

- A
ù Electrical
control
û
50 100 % Capacity
A
No. of operating cylinders

- 1
2 1
2 2

- 3
RC46W
(standard)
4 4

3
4

Fig. 3.6 Standard capacity control of compressor RC46W

Number of solenoid valves: 2 (A,B)

Number of control steps: 4 solenoid valves energized

- B - B ù Electrical

- - A A û control

25 50 75 100 % Capacity

No. of operating cylinders

- - 1 1
A
B
- 2 - 2

- - 3 3
1 RC46W
(alternative)
2 4 4 4 4

3
4

Fig. 3.7 Alternative capacity control of compressor RC46W

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Number of solenoid valves: 2 (A,B)

Number of control steps: 3

solenoid valves energized

- - B ù Electrical

- A A û control

33.3 66.6 100 % Capacity

A No. of operating cylinders

- - 1
B
- 2 2
1
3 2 3 3 3

- - 4

- 5 5
4 RC66W
5 6 6 6
6

Fig. 3.8 Standard capacity control of compressor RC66W

Number of solenoid valves: 3 (A,B,C)

Number of control steps: 4 solenoid valves energized

- - - C

- B B B
ù Electrical
ú control

- - A A
û

25 50 75 100 % Capacity
A
B No. of operating cylinders
C
- - - 1
1
2 - 2 2 2
3
4
- - 3 3

4 4 4 4
5 - - - 5
6
7
8 - 6 6 6

- - 7 7
RC86W
8 8 8 8

Fig. 3.9 Standard capacity control of compressor RC86W

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4.1 TECHNICAL DATA

Table 4.1 Technical data

COMPRESSOR TYPE RCF46/RCA46 RCF66/RCA66 RCF86/RCA86

Number of cylinders z 4 6 8

Cylinder arrangement 2xV 2xW 2 x VV

Cylinder bore D mm 85

Piston stroke S mm 66

Direction of rotation both directions permitted

Swept volume at full-load and n = 1450/min Vs m3/h 130.3 195.5 260.7

Standard compressor speeds (with V-belt drive)

motor speed 1450/min (50 Hz) 810 - 855 - 905 - 1015 - 1140 - 1215 - 1285 - 1450
n min-1
motor speed 1750/min (60 Hz) 800 - 875 - 980 - 1030 - 1095 - 1225 - 1380 - 1465

Standard steps of capacity control (expressed in 1

) % 100 - 50 100 - 67 - 33 100 - 75 - 50 - 25
percentage of full-load swept volume)

Main dimensions, connections and required free space Refer to par. 4.2.

Mass of bare compressor (without

kg 280 345 400
flywheel and other accessories)

2
Oil charge in crankcase (centre line of sight glass) ) dm3 9.2 (8.5) 10.0 (9.3) 10.8 (10.1)

Oil type to be used Refer to par. 4.3.

Starting torque Refer to par. 4.7.

Friction power at n = 1450/min and 55 oC oil temperature3) Pw kW 1.10 1.53 2.22

Mass moment of inertia of crank mechanism 4

) Id kg.m2 0.0361 0.0421 0.0478
(without flywheel)

5
Centre of gravity and free forces and moments ) Refer to par. 4.4.

6
Torsional elastic substitute systems of crankshaft ) Refer to par. 4.5.

Sound rating Refer to par. 4.8.

1 4
) See also Chapter 3. ) The mass moment of inertia Id, expressed in SI-units, is required to
2 determine the so-called coefficient of speed fluctuation.
) The figures between brackets indicate the smaller oil charge for the
5
RCA6W compressors due to the presence of an oil cooler. ) The centre of gravity and free forces and moments are of
3 importance when calculating a vibration-free mounting of the
) Pw is needed for calculating the condenser capacity Qc.
compressor.
See also paragraph 4.6.
Pw = (n/1000).(0.02293.z2 - 0.08207.z + 0.71931). 6
) These crankshaft substitute systems are required to carry out
torsional vibration calculations in case the compressor is driven by
an internal combustion engine.

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4.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS (for connections see table 4.2 ) All dimensions in mm.

For unobstructed removal of the crankcase inspection side covers,

a block of at least 40 mm height should be placed under each foot
when installing the compressor on a foundation or base frame.

Fig. 4.1a Dimensioned sketch of compressor RC46

For unobstructed removal of the crankcase inspection side covers,

a block of at least 40 mm height should be placed under each foot
when installing the compressor on a foundation or base frame.

Fig. 4.1b Dimensioned sketch of compressor RC46W

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For unobstructed removal of the crankcase inspection side covers,

a block of at least 40 mm height should be placed under each foot
when installing the compressor on a foundation or base frame.

Fig. 4.2a Dimensioned sketch of compressor RC66

For unobstructed removal of the crankcase inspection side covers,

a block of at least 40 mm height should be placed under each foot
when installing the compressor on a foundation or base frame.

Fig. 4.2b Dimensioned sketch of compressor RC66W

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For unobstructed removal of the crankcase inspection side covers,

a block of at least 40 mm height should be placed under each foot
when installing the compressor on a foundation or base frame.

Fig. 4.3a Dimensioned sketch of compressor RC86

For unobstructed removal of the crankcase inspection side covers,

a block of at least 40 mm height should be placed under each foot
when installing the compressor on a foundation or base frame.

Fig. 4.3b Dimensioned sketch of compressor RC86W

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Table 4.2 Connections of RC6 and RC6W-compressors

COMPRESSOR TYPE RC46(W) RC66(W) RC86(W)
MAIN CONNECTIONS * outer pipe diameter of welding neck in flange
suction 1 DN40 DN50 DN50
discharge 2 DN32 DN40 DN50
AUXILIARY CONNECTIONS
1
suction pressure 3 /4“ BSP
1
discharge pressure 4 /4“ BSP
1
oil pressure 5 /8“ BSP
Remark:
1
crankcase pressure 6 /4“ BSP
return from oil separator or 1 connections 3, 4, 5, 6, 7, 9 and 10 are plugged off.
7 /4“ BSP
oil rectifier
1
oil charge and drain valve 8 /4“ BSP
1
oil temperature 9 /4“ BSP
1
crankcase heating 10 /2“ BSP female to suit thread of heating element
oil leakage drain of rotary shaft seal 11 clamp coupling provided with Ø6 x 1 mm steel precision tube
water inlet/outlet (RCA6W only) 12 Ø19 mm hose connector
* Provided with a purging and evacuation stop valve type TAH8 (standard on discharge connection and optional on suction connection).

Fig. 4.4 Dimensions of shaft end

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4.3 LUBRICATING OILS (choice and recommendations) Table 4.4 Approved oil types for Grasso reciprocating
For lubrication of refrigeration compressors, several compressors
brands and types of specially developed lubricating oils Refrigerant
Brand Type designation
ISO VG
are on the market. The choice of oil depends not only used number 1)
2
on its good lubrication properties (viscosity) and AVIA Avilub FC 46/68 )
chemical stability at the operating conditions of the BP Energol LPT-F 46 46
Energol LPT-F 68 68
compressor, but also on the operating conditions of the 2
CASTROL Icematic 299 )
refrigerating plant (solidifying and floc point, solubility). 2
CPI CP-1009-68 ) (NH3 only!)
2
Grasso has tested and approved for use in its ELF Elfrima FR 68 )
reciprocating-compressors the brands and types of oil Zerice 46 46
as listed in the adjacent table 4.4. ESSO Zerice 68 68
Zerice S 46 46
The choice of the viscosity of the lubricating oil Zerice S 68 68
depends on the operating conditions of the FINA Purfrigol MP 68 68
compressor. The oil viscosity should always be more KC 46 46
FUCHS
than 15 cSt (based on bearing construction NH3 KC 68 68
2
requirements of the compressor). For the selection of KROON OIL Carsinus FC 46/68 )
and 2
the oil viscosity grade number, refer to table 4.3 below. MOBIL Arctic oil 300 )
A higher viscosity should be chosen, when a high oil R22 PETRO
Reflo 68A 2
) (NH3 only!)
temperature is expected, due to arduous operating CANADA
2
condition such as: Q8 Stravinsky B )
2
Stravinsky C )
• high evaporating temperature; Clavus 46 46
• large superheat of the refrigerant suction vapour; Clavus 68 68
• prolonged part-load operation with a large number SHELL Clavus G 46 46
Clavus G 68 68
of cylinders cut-out; Clavus G 100 100
• a high surrounding temperature; Suniso 3.5 GS 2
)
• large pressure ratio. SUN-OIL Suniso 4 GS 2
2
)
Remark Suniso 5 GS )
2
Suniso 4 SA ) (NH3 only!)
For the oil types mentioned in the table 4.4, applied TEXACO Capella WF 68 68
with the refrigerants R22, NH3 and R134a, the TOTAL Lunaria S 46/68 2
)
minimum requirement of the actual oil viscosity of Icematic SW 68 68
15 cSt is fulfilled, but only when the maximum oil CASTROL
Icematic SW 100 100
2
temperature as mentioned in the table 4.3 below is CPI Solest 68 )
2
not exceeded. Solest 120 )
2
Triton SE 55 )
2
DEA Triton SE 80 )
2
Table 4.3 Oil selection table Triton SE 120
2
)
ELF Planetelf ACD 68 )
Max. Maximum allowable Planetelf ACD 100 2
)
R134a
allowable crankcase oil temperature* Purfrigol ST VG 68 2
)
Refrigerant FINA
evaporating ISO VG-number Purfrigol ST VG 100 2
)
used and
temperature
o 46 68 100 FUCHS Reniso E 68 68
to,max. ( C)
R404A 3) Reniso E 100 100
NH3 - 60 68 76 2
ICI Emkarte RL 68S )
-64 59 68 76 2
-30 56 66 74 Emkarte RL 100S )
2
-20 54 64 71 MOBIL EAL Arctic 68 )
R22 EAL Arctic 100 2
)
-10 51 62 68
2
0 44 56 64 Clavus R68 )
+10 29 47 56 SHELL 2
Clavus R100 )
-50 - 74 83 SUN-OIL Suniso Excel 2
)
-30 - 71 80
-20 - 69 79 TEXACO Capella HFC 68 68
R134a Capella HFC 100 100
-10 - 67 77
0 - 61 74 Some of the oil types listed in the table may be marketed under other
+10 - 47 67 names and/or designations; these oils can also be used, provided
* Data based on minimum oil viscosity of 15 cSt at the bearing their identity can be proved beyond any doubt. Application of other
surfaces, which is derived from the oil type, solubility of the oils is not permitted without written consent of Grasso.
refrigerant in the oil (halocarbon refrigerants only) and operating 1
) Viscosity grade number designation according to ISO Standard
conditions. Assumed is that the oil temperature at the bearing
3448.
surfaces = 6 K above crankcase oil temperature. 2
) Consult your oil supplier to determine the maximum allowable oil
The grey areas show the recommended ISO VG-numbered oils. temperature at an oil viscosity of 15 cSt, under prevailing operating
Example: R22, to,max. = 0 oC : recommended oil type is ISO VG100 3
conditions and refrigerant used.
NH3 under normal operating conditions, oil type with ) In case of R404A always consult your oil supplier in advance for
ISO VG68 is recommended. advise.

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5.1 INDIVIDUAL LIMITS OF OPERATION Note:

In practice it is not so much the individual limits
With an operating compressor several working of operation, described in this paragraph, as
conditions arise which one by one are bound to certain combinations of them that are decisive for the
limits. These so-called “individual operation limits” are conditions under which a compressor may
determined by structural limitations of the compressor operate. To check the various possibilities in this
itself or they are based on thermodynamic and respect, use should be made of the “fields of
practical considerations. They apply to both single-stage application” according to the figures 5.1 to 5.5.
and booster compressors.
When operating the compressor, none of the limits of
operation as stated in the table 5.1 below must be
exceeded.
Table 5.1
REFRIGERANT NH3 R22 R134a R404A

min. 800
Compressor speed n min-1
max. 1500

Suction pressure min. 0.3

1
= evaporating pressure ) po bar(a)*
= crankcase pressure max. 6.2 6.8 6.2 6.0

Evaporating temperature min. -55.1 -63.8 -50 -68.1

1 o
= saturation temperature ) to C
at suction pressure max. +10.2 +10.0 +22.6 -0.1
2 o
Actual suction temperature ) ta C min. -50

Suction superheat ∆to K min. 5

3
Discharge pressure = condensing pressure ) pc bar(a)* max. 26
Condensing temperature o
tc C max. +59.8 +63.2 +79.5 +55.6
= saturation temperature at discharge pressure
4 o
Discharge temperature ) te C max. +155

5 min. 1.5
Pressure ratio (pc/po) ) j -
max. 10 15
6
Pressure difference (pc-po) ) ∆p bar* max. 24

7 o min. +20 +30

Oil temperature in crankcase ) toil C
max. refer to pragraph 4.3

* 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.

1 5
) The minimum values of po and to are only of importance for ) Pressure ratio limits are not absolute but arbitrary values based on
booster applications. In that case the maximum value of to also practical considerations.
applies to the saturation intermediate temperature (tm). 6
) The standard built-in overflow safety valve between suction and
For halocarbon refrigerants the maximum values of po and to are
discharge chamber in the compressor housing has been factory-set
based on a density of the suction gas of 30 kg/m3.
to 24.5 (+10%) bar to prevent advanced opening during normal
During start-up and immediately thereafter, po,max. may be
exceeded slightly [up to 11 bar(a) max.] and temporarily, but no operation at ∆p ≤ 24 bar.
longer than about 5 minutes. 7
) Indicated minimum value is the lowest oil temperature at which
The maximum static crankcase pressure during compressor compressors are allowed to be started.
standstill is 21.5 bar(a). The maximum oil temperature depends on the operating
2
) Only of importance for booster application. conditions of the compressor, the oil type used and (for halocarbon
refrigerants only) the solvability of the refrigerant in the oil. A
3
) This pressure is also the maximum allowable pre-set value of the HP minimum actual oil viscosity of 15 cSt is always required.
safety switch. When using ammonia as refrigerant, the maximum oil temperature
4
) This is the actual discharge temperature, measured directly in the will be exceeded only when a combination occurs of high ambient
gas flow inside the cylinder head covers, just above the discharge temperature, high suction superheat and part-load operation. In
valves. that case an oil cooler is required. A water-cooled oil cooler always
form part of the standard delivery of a RC6W-compressor.

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5.2 FIELDS OF APPLICATION FOR SINGLE-STAGE

AND BOOSTER OPERATION.

The following 5 diagrams, related to the refrigerants

R134a, R22, R404A and NH3 represent the fields of
application at continuous operation with different
conditions at any speed between 800 and
1500/min. In case of RC6 and booster application
the compressor manufactuer should be consulted. In
each diagram the area comprising all allowable
combinations of evaporating temperature to and
condensing temperature tc (general field of
application) is enclosed by a broken bold line, of
which each line section corresponds to one of the
individual operation limits as stated in table 5.1.
Symbols used in diagrams:
to = evaporating temperature
po = evaporating pressure
tc = condensing temperature
pc = condensing pressure
j = pressure ratio = (pc/po)
∆p = pressure difference = (pc-po)
∆to = suction superheat
te = discharge temperature in cylinder head covers
Vs = part-load swept volume (= part-load capacity)
expressed in percentage of full-load (100%)

Fig. 5.2 Field of application for RC6 with refrigerant R22

Fig. 5.1 Field of application for RC6 with refrigerant R134a Fig. 5.3 Field of application for RC6 with refrigerant R404A

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Fig. 5.4 Field of application for compressor type RC6 with NH3

Fig. 5.5 Field of application for compressor type RC6W with NH3

5.3 LIMITATIONS OF PART-LOAD OPERATION

If a RC46 or RC86 is to be operated continuously In case of a RC6W-compressor, however, there are

at the minimum part-load step of 25%, the no part-load restrictions. In other words, the
manufacturer should be consulted first to check general field of application as shown in fig. 5.5,
whether this is allowed under the expected design also remains valid for part-load operation down to
conditions. and including the standard minimum capacity
In case of a RC6-compressor operating control step of Vs = 25%.
continuously at part-load, the general field of
application is reduced in the sense that for each
step of capacity reduction the limit line for te =
155 oC moves to the right as shown in fig. 5.4, by
four Vs-indications in percentage.

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 DE S IG N DE TA IL S OF S TA ND AR D
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Refrigeration Division

30
33
1 6
2

1. cylinder head cover

(water-cooled)
32
2. lifting eye
8 3. suction connection
3 9 4. oil differential pressure
safety switch (optional)
4
5. crankcase heater (optional)
10 6. suction and discharge
valve assembly
11
7. cylinder liner
5 12 8. piston and connecting rod
31 9. discharge connection
10. oil return check valve
11. sight glass
12. inspection side cover
13. 3-way solenoid valve
14. by-pass slide valve
15. suction chamber
16. tube for pressure equalizing
17. rotary shaft seal
18. crankshaft
19. shaft seal housing
20. oil leakage drain
21. oil suction filter
22. crankcase
23. discharge chamber
24. oil discharge filter
25. oil filter housing
26. oil pump
27. bearing cover
28. oil charge and drain valve
29. oil cooler (water-cooled)
30. cooling water hose
31. water inlet connection
32. water outlet connection
‘ 33. cast-in channel
for cooling water
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34. Plug cooling water channel

Fig. 2.1 Construction of standard bare compressor (RC66W)

v001.99.01.en Installation and Maintenance Manual RC(U)6 page C4.1

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 DE S IG N DE TA IL S OF S TA ND AR D
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Refrigeration Division

12 13

1. shaft seal housing

2. O-ring
3. counter-slip ring
1
4. slip ring
2
5. flexible elastomer bellows
3
➙ 6. spring
4
5 7. spring holder
6 8. driving band
7 ➙
9. supporting ring

➙
8
9 10. retainer shell
14 11. oil leakage drain
10
12. main bearing bush
13. crankcase
14. oil supply from internal
11 lubricating circuit in crankcase

Fig. 2.2 Rotary shaft seal

11 1 2

3
4
1. central bolt
2. discharge valve stroke limitor
5
7 3. pressure ring
6
4. sinusoidal buffer spring
5. discharge valve seat, also
8 suction stroke limitor
6. cylinder liner, also suction
9 valve seat
7. O-ring
8. suction valve ring with two (RCF6) or
one (RCA6) sinusoidal spring(s)
9. discharge valve ring with two (RCF6)
Ý ß or one (RCA6) sinusoidal spring(s)
DISCHARGE SUCTION 10. O-ring in crankcase partition
10 11. head plate
12. crankcase partition

12

Fig. 2.3 Suction and discharge valve assembly

page C4.2 Installation and Maintenance Manual RC(U)6 v001.99.01.en

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 DE S IG N DE TA IL S OF S TA ND AR D
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Refrigeration Division

➊ ➋ ➊ ➋

aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aaa a a a a a a a a a a a a a a a
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a a a a a a
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a a a a a a
aaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a a a a a a

➌ ➍ ➌ ➍ ➎
1. crankcase 3. suction chamber 1. crankcase 3. suction chamber
2. suction welding 4. strainer element 2. discharge welding 4. discharge chamber
neck flange neck flange
5. overflow safety valve

Fig. 2.4 Suction gas strainer Fig. 2.5 Pressure relief valve

1. oil discharge filter

2. oil pump
3. oil suction strainer
4. connections for external
oil return line with
lubricating oil pressure
regulator and for (optional)
oil pressure safety switch
5. oil leakage drain

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Fig. 2.6 Lubrication system

v001.99.01.en Installation and Maintenance Manual RC(U)6 page C4.3

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 DE S IG N DE TA IL S OF S TA ND AR D
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Refrigeration Division

page C4.4 Installation and Maintenance Manual RC(U)6 v001.99.01.en

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 TABLE OF CONTENTS
Grasso
Refrigeration Division

SUBJECT Page no.:

SECTION D: STANDARD ILLUSTRATED PARTS LIST .....................................................................
D1 Spare parts list RC6 .................................................................................................................... C1 - C16
....................................................................................................................................... A1 - A8

v001.99.01.en Installation and Maintenance Manual RC(U)6 D.I

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 TABLE OF CONTENTS
Grasso
Refrigeration Division

D.II Installation and Maintenance Manual RC(U)6 v001.99.01.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

The illustrated parts list on the following pages is meant for identification and accurate specification of
spare parts. In order to facilitate quick retrieval of the required parts, the list and corresponding figures
is divided into the following groups of parts:

GROUP OF PARTS PARTS LIST CORRESPONDING FIGURE

Page: No.:
• Compressor housing with connections 2 RC6-1
• Main bearings 2 RC6-2
• Crankshaft 5 RC6-3
• Piston and connecting rod 5 RC6-4
• Suction and discharge valve 6 RC6-5
• Rotary shaft seal 9 RC6-6
• Oil pump 9 RC6-7
• Capacity control mechanism 10 RC6-8
• Oil discharge filter 10 RC6-9
• Flanged main connections 13 RC6-10
• Suction gas strainer 13 RC6-11
• Oil suction filter 14 RC6-12
• Oil differential pressure safety switch 14 RC6-13
• Oil pressure regulator 14 RC6-14
• Standard sets of parts and seals 16 ---------

Figures tely.
When for some part no quantity has been given, the
All parts shown in the figures bear an item number. quantity required depends on the compressor size.
Assemblies are indicated by a dotted frame with
When determining the required quantity of parts, it
separate item number around the parts included in
that particular assembly; should be considered that the listed quantities relate
the parts themselves bear the same item number, to the corresponding figure and not to the compres-
followed by a sequence number (e.g. 2.1, 2.3, 2.3, etc.). sor as a whole. When ordering, for example, valve
rings for two discharge valves, the quantities stated
Parts lists in the relevant list must be doubled, because these
apply to one discharge valve only.
The parts are specified by the headings “Item”,
“Description” “Ref. no.” and “Qty” (= Quantity).
RC6W
* If an asterisk is used instead of the Ref. no., this me- This is a RC6 compressor, including water cooled cylin-
ans that the relevant part cannot be obtained separa- der heads

How to order!
It is emphatically pointed out that a prompt despatch of the correct spare parts can be
guaranteed only if the following information is given:
1. Type designation of the compressor
shown on the compressor name plate
2. Serial number of the compressor
3. Quantity, Description and Ref. No. of the required parts.

0089238-v004.00.02.en RC6 C1

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Refrigeration Division

Item Description Ref. No. Qty Remarks

COMPRESSOR HOUSING WITH CONNECTIONS FIG. RC6-1
1 Cylinder head cover assy * — with capacity control
1.1A Cylinder head cover RC6-2CR 23.36.521 — with cap. control for 2 cyl.
Cylinder head cover RC6-2CR 23.36.525 — RC6W: with cap. control for 2 cyl.
1.1B Cylinder head cover RC6-1CR 23.36.510 — with cap. control for 1 cyl.
Cylinder head cover RC6-1CR 23.36.515 — RC6W: with cap. control for 1 cyl.
1.2 Hex. head bolt M10x120 01.10.512 2
1.3A Oilit gasket 190x405x1.5-2CR 09.07.192 — on item 1.1A
1.3B Oilit gasket 190x405x1.5-1CR 09.07.191 — on item 1.1B

2 Cylinder head cover assy * — without capacity control

2.1 Cylinder head cover RC6-0CR 23.36.500 —
Cylinder head cover RC6-0CR 23.36.505 on type RC6W only
2.2 Oilit gasket 190x405x1.5-0CR 09.07.190 —

3 Hex. head bolt M10x100 01.10.510 20 18 on item 1 (for RC6 types only)
Hex. head bolt M10x120 01.10.512 20 18 on item 1 (for RC6W types only)
4 Washer M10 11.13.501 36
5 Crankcase * 1
6 Oilit gasket 175x290x1.5 09.07.175 1
7 Inspection side cover 175x290 05.30.175 2 RC6 (2x), RC6W (1x)
Inspection side cover 175x290WK 05.30.178 2 RC6W (1x)
8 Hex. head bolt M10x40 01.10.540 16
9 O-ring 2.62x32.99 09.52.284 1
10 Sight glass 2.9x60 12.24.029 1
11 Hex. head bolt M6x16 01.10.316 3
12 Eye bolt M16 01.18.812 2
13 Safety relief valve 26 5G33 12.49.333 1
14 Plug G13S 01.36.134 5 if connection not in use
15 Crankcase heating element 13.72.203 1
16 Stop valve TAH8-12 06.07.011 1
17 Oil return orifice 01.23.139 2
18 Alu sealing ring 21x25x1 09.12.021 2 in RC46(W) compressor only
19 Plug G21 01.36.216 3
Plug G21 01.36.216 1 in types RC66(W) & RC86(W)
20 Alu sealing ring 21x27x2 09.14.023 1
21 Alu sealing ring 13,5x20x1 09.12.014 5
22 Nipple coupling 12G13 03.38.131 1
23 Nipple coupling 12G21 03.38.211 1

MAIN BEARINGS FIG. RC6-2

1 Flange bearing 60x15x11.5 11.43.600 1 driving end

2 Bearing assy * 1
2.1 Pump housing RC6 ––––- 1 refer to page 9
2.2 O-ring 3.53x209.14 09.52.365 1
2.3 Flange bearing 60x50xM10 11.43.651 1 oil pump end from 95.08.1648
2.4 Socket head screw M10x100 01.04.510 4

3 Washer M10 11.13.501 16

4 Hex. head bolt M10x40 01.10.540 8
5 Hex. head bolt M10x35 01.10.535 8

C2 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

RC6-1

2.3 2.2

2.1

2.4
1

3
5

4
3

RC6-2

0089238-v004.00.02.en RC6 C3

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

RC6-3

RC6-4

C4 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

Item Description Ref. No. Qty Remarks

CRANKSHAFT FIG. RC6-3
1A Crankshaft E-RC6 22.36.400 1 4-cylinder compressor
Crankshaft K-RC6 (with approval) 22.36.410 1
1B Crankshaft E-RC6 22.36.600 1 6-cylinder compressor
Crankshaft K-RC6 (with approval) 22.36.610 1
1C Crankshaft E-RC6 22.36.800 1 8-cylinder compressor
Crankshaft K-RC6 (with approval) 22.36.810 1
1.1 Crankshaft E/K-RC6 * 1

2 Key 14x9x70 11.02.570 1

3 Carrier disc 60x5 11.25.106 1 from 95.08.1648
4 Socket head screw M10x25 01.04.525 2

PISTON AND CONNECTING ROD FIG. RC6-4

1 Piston assy 85RC6 24.36.010 1
1.1 Piston 85RC6H * 1
1.2 Gudgeon pin 26x18x69RC6 24.36.260 1
1.3 Safety ring * 2
1.4 Set of piston rings 85RC6 09.74.084 1

2 Connecting rod assy 60x170xRC6 24.36.500 1

2.1 Con rod 170RC6 * 1
2.2 Con rod bolt MF8x1 01.11.401 2
2.3 Locking plate M8 11.39.400 2
2.4 Hex. nut MF8x1 01.47.405 2

0089238-v004.00.02.en RC6 C5

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Refrigeration Division

Item Description Ref. No. Qty Remarks

SUCTION AND DISCHARGE VALVE FIG. RC6-5
1 Hex. head bolt M10x40 01.10.540 4
2 Washer M10 11.13.501 4
3 Pressure ring RC6 27.36.410 1
4 Sinusoidal buffer spring 87x124x4 11.33.087 1

5 Discharge valve assy RC6 27.36.113 1 Option ’L’(Low)

27.36.103 1 Option ’H’(High)
5.1 Locking nut M8 01.45.400 1 refer
5.2 Washer M8 11.13.401 1 table
5.3 Discharge valve stroke limitor * 1 below
5.4 Sinusoidal spring 64x76x0.5 * 1 Option ’L’ (Low)
2 Option ’H’(High)
5.5 Discharge valve ring 64x76x1 * 1
5.6 Suction stroke limitor * 1
5.7 Fitted bolt M8x40 * 1

6 Damper ring 108x87x4 * 1

7 Sinusoidal spring 88x108x0.7 * 1

8 Suction valve ring 88x108x0.7 * 1

9 O-ring 3.53x117.07 09.52.362 1
10 Cylinder liner 85RC6 23.36.120 1
11 O-ring 3.53x91.67 09.52.361 1

12L Discharge valve ring and spring(s) Option L 11.34.110 1

12H Discharge valve ring and spring(s) Option H 11.34.105 1

13 Suction valve ring, spring and damper ring 11.34.115 1

Source of table below; 00.87.315

C6 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Refrigeration Division

RC6-5H RC6-5L

0089238-v004.00.02.en RC6 C7

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

RC6-6

RC6-7

C8 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

Item Description Ref. No. Qty Remarks

ROTARY SHAFT SEAL FIG. RC6-6
1 Shaft seal housing RC6 26.36.100 1
2A Plug G13S 01.36.134 1
2B Plug NPT13 03.65.513 1
3 Nipple coupling 6N10 03.38.810 1
4 O-ring 3.54x158.34 09.52.364 1
5 Hex. head bolt M10x35 01.10.535 8
6 Washer M10 11.13.501 8
7 Shaft seal assy 54RC6 09.62.900 1

OIL PUMP FIG. RC6-7

1 Pump cover RC6 26.36.700 1
2 Pump element RC6 26.36.601 1
3 Bearing 26.36.710 1
4 Hex. head bolt M6x16 01.10.316 3
5 O-ring 3.53x209.14 09.52.365 1
6 O-ring 3.53x136.12 09.52.363 1
7 Pump housing RC6 26.36.503 1 from 88.11.2400

0089238-v004.00.02.en RC6 C9

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Item Description Ref. No. Qty Remarks

CAPACITY CONTROL MECHANISM FIG. RC6-8
1 Flange capacity control 27.36.702 1
2 Cylinder head screw M4x10 01.68.210 4
3 Piston 27.36.600 1
4 Compression spring 1.25x10x11.5x51 11.31.132 1
5 Rectangular ring 56x51.3x2 09.70.056 1
6 Washer M10 11.13.501 4 per controlled cylinder cover
7 Hex. head bolt M10x40 01.10.540 4
8 Oilit gasket 87x94x1.5 09.07.087 1
9 Cylinder 27.36.500 1
10 Rectangular ring 40x36.6x2 09.70.040 1

11A Solenoid valve 110/120V * 1

11.1A Valve body * 1
11.2A Coil 110/120V 9W 13.16.311 1

11B Solenoid valve 220/240V 06.80.111 1 NH3/R

11.1B Valve body * 1

11.2B Coil 220/240V 9W 13.16.322 1

12 Connector 13.16.610 1 for valves 11A/11B, without LED

13.16.611 1 With 220 V-AC/DC LED
13.16.615 With 48 V-AC/DC LED
13 Nipple coupling 6G10 03.37.106 1
14 Set screw M5x10 01.23.010 1
15 Socket head scew M8x1 03.65.708 3
16 O-ring 09.51.093 2

OIL DISCHARGE FILTER FIG. RC6-9

1 Filter set 07.11.900 1
1.1 O-ring 3.53x136.12 09.52.363 1
1.2 Filter cartridge 480x15 *

2 Hex. nut M6 01.45.300 1

3 Stud M6x20 01.51.320 1
4 Filter housing 130 07.02.130 1
5 Hex. head bolt M10x75 01.10.575 6
6 Washer M10 11.13.501 6

C10 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

RC6-8

RC6-9

0089238-v004.00.02.en RC6 C11

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

RC6-10

aa a a a a a a a a a a
aaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a
aaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaa
aaaaaaaaaaaaaaaaaaaaaaa
a a a a a a a a a a a a

RC6-11

C12 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
Grasso
Refrigeration Division

Item Description Ref. No. Qty Remarks

FLANGED MAIN CONNECTIONS FIG. RC6-10
1A Shoulder flange RC46 05.39.045 1
1B Shoulder flange RC66 05.39.051 1
1C Shoulder flange RC86 05.39.063 1

2 Hex. head bolt M16x40 01.10.840 4 per flanged connection

3 Oilit ring 67x81x1.5 09.03.067 1 per flanged connection
4 Relief valve 12.49.333
SUCTION GAS STRAINER FIG. RC6-11
1A Shoulder flange RC46 05.39.048 1
1B Shoulder flange RC66/RC86 05.39.060 1

2 Oilit ring 67x81x1.5 09.03.067 2

3 Wired mesh filter 544x100 07.16.544 1

0089238-v004.00.02.en RC6 C13

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Refrigeration Division

Item Description Ref. No. Qty Remarks

OIL SUCTION FILTER FIG. RC6-12
1 Oil filter 149x16 07.16.164 1
from 95.08.1648
2 Swivel coupling 16G21 03.39.216 1

OIL DIFFERENTIAL PRESSURE SAFETY SWITCH FIG. RC6-13

1 Oil pressure safety switch 12.60.232 1 NH3
12.61.232 1 R
2 Bracket 63x115 * 1
3 Angle coupling 6x6x6 (complete) 03.40.406 2
4 Socket coupling 6G17 (complete) 03.37.176 2
5 Union nut 03.10.006 6
6 Steel precision pipe ø6x1 mm * 2
7 Nipple coupling 6G10 03.38.106 1 Possibly 6N13 (03.38.813) or 6G13
8 Clamp but sleeve P6 * 8 (03.38.136) are applied

OIL PRESSURE REGULATOR FIG. RC6-14

1 Oil return line SAM RC6 12.41.140 1 lubricating oil pressure regulator
included
1.1 Steel precision pipe K12x1.5 and valve housing 12.41.012 1
1.2 Alu sealing ring 21.5x27x1 09.12.022 1
1.3 Ball W16 11.19.010 1
1.4 Spring 1.25x14x9x35.5 11.31.134 1
1.5 Thrust bolt G21x60S 01.35.218 1
1.6 O-ring 1.78x8.73 09.52.184 1
1.7 Nipple G21CxG21 03.04.921 1
1.8 Alu sealing ring 10x18x1 09.12.010 1
1.9 Cap nut GK21R 01.17.021 1

2 Nipple coupling 12G13 ---------- 1 refer to fig. RC6-6

3 Nipple coupling 12G21 ---------- 1 refer to fig. RC6-1

C14 RC6 0089238-v004.00.02.en

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Refrigeration Division

RC6-12 RC6-13

2
1

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9

RC6-14

0089238-v004.00.02.en RC6 C15

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 STANDARD ILLUSTRATED PARTS LIST RC6
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Refrigeration Division

Item Description Ref. No. Qty Remarks

STANDARD SETS OF PARTS, SEALS AND TOOLS FIG. RC6- (no figure)
1 Set of gaskets and seals 09.90.046 1 for RC46
09.90.066 1 for RC66
09.90.086 1 for RC86

2 Set of spare parts (containing valve rings and

sinusoidal springs) * 1

3 Set of basic spare parts * 1 for all types

4 Tire clamp (coupling tool) 15.08.232 1 for coupling element 42

15.08.244 1 for coupling element 61
15.08.280 1 for coupling element 91

C16 RC6 0089238-v004.00.02.en

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

The illustrated parts list of the accessories on the following pages is meant for identification and
accurate specification of current spare parts. In order to facilitate quick retrieval of the required parts,
the list and corresponding figures is divided into the following groups of parts:
GROUP OF PARTS PARTS LIST CORRESPONDING FIGURE
Page No.:
o Pressure gauges and safety switches 2 RC6-A1
o Direct drive 5 RC6-A2
o Cooling water device 6 RC6-A3

Figures
When for some part no quantity has been given, the
All parts shown in the figures bear an item number. quantity required depends on the compressor size.
Assemblies are indicated by a dotted frame with
When determining the required quantity of parts, it
separate item number around the parts included in
that particular assembly; should be considered that the listed quantities relate
the parts themselves bear the same item number, to the corresponding figure and not to the compres-
followed by a sequence number (e.g. 2.1, 2.3, 2.3, etc.). sor as a whole. When ordering, for example, valve
rings for two discharge valves, the quantities stated
Parts lists in the relevant list must be doubled, because these
apply to one discharge valve only.
The parts are specified by the headings “Item”,
“Description” “Ref. no.” and “Qty” (= Quantity).
RC6W
* If an asterisk is used instead of the Ref. no., this means This is a RC6 compressor, including water cooled cylin-
that the relevant part cannot be obtained separately. der heads

How to order!
It is emphatically pointed out that a prompt despatch of the correct spare parts can be
guaranteed only if the following information is given:
1. Type designation of the compressor
shown on the compressor name plate
2. Serial number of the compressor
3. Quantity, Description and Ref. No. of the required parts.

v002.99.05.en RC6 Accessories 1

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

Item Description Ref. No. Qty Remarks

PRESSURE GAUGES AND SAFETY SWITCHES FIG. RC6-1A
1a Pressure gauge and safety switch cabinet NH3 - std 12.08.301 1 with two safety switches
R22 - std 12.08.601 1 with an additional safety
R134a - std 12.08.701 1 switch to meet German
R404A - std 12.08.801 1 UVV-VBG20 regulations

1b Pressure gauge and safety switch cabinet NH3 - UVV-VB420 12.08.302 1

12.08.602 1
12.08.702 1
12.08.802 1

1.1 Pressure gauge discharge pressure NH3 - R-P-63 12.10.065 1

R22 - 63 12.12.065 1
R134a - 63 12.12.066 1
R404A 12.12.067 1

1.2 Pressure gauge suction pressure NH3 - R-Z-63 12.10.066 1

R22 - Z-63-12 12.12.068 1
R134a - Z-63-12 12.12.069 1
R404A - Z-63-12 12.12.070 1

1.3 Pressure gauge oil pressure R-O-63 12.15.065 1

1.4 Oil pressure safety switch type NH3 MP55A 12.60.232 1

R MP55 12.61.232 1

1.5a Combined suction and discharge pressure safety switch type

NH3 KP15A 12.60.615 1
R KP15 12.61.615 1

1.5b Combined discharge pressure limitor and safety switch type

NH3 kP7ABS 12.60.618 1
R kP7BS 12.61.618 1

1.6 Suction pressure safety switch type NH3 KP1A 12.60.608 1

R KP1 12.61.608 1

Accessories 2 RC6 v002.99.05.en

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

RC6-1A

v002.99.05.en RC6 Accessories 3

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

electric
motor

compressor

1.1

RC6-2A

Accessories 4 RC6 v002.99.05.en

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

Item Description Ref. No. Qty Remarks

DIRECT DRIVE FIG. RC6-2A
1a Coupling type 42 (complete) * 1 to facilitate mounting, a steel strip
1.1a Coupling element 55 19.18.842 1 is clamped around the coupling
1b Coupling type 61 (complete) * 1 element, which must be removed
1.1b Coupling element 80 19.18.861 1 before putting the compressor into
1c Coupling type 91 (complete) * 1 operation
1.1c Coupling element 120 19.18.891 1

2 Clamping sleeve * 1

v002.99.05.en RC6 Accessories 5

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

Item Description Ref. No. Qty Remarks

COOLING WATER DEVICE FIG. RC6-3A
1 Hose, rubber 19W 15.18.019 1
2 Hose clamp 19-28 mm 15.08.600 1 twice per hose
3 Spigot nipple 19xG21 15.55.419 1 per cyl. head cover connection
4 Angle socket coupling G21xG21 03.72.441 1
5 Socket nipple G21xG42 03.02.471 1
6 Nipple coupling 16G21 03.38.212 1
6.1 Clamping sleeve P16 03.34.516 1 per coil connection

7 Coil cooler 16x1.5x64x280 04.10.364 1

8 Water cooled cylinder cover without control 23.36.505 1
9 Water cooled cylinder cover with control 23.36.515 1
10 Side cover for oil cooler coil 05.30.178 1

Accessories 6 RC6 v002.99.05.en

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

RC6-3A

v002.99.05.en RC6 Accessories 7

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 PARTS LIST RC6
Grasso ACCESSORIES
Refrigeration Division

Accessories 8 RC6 v002.99.05.en

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 Grasso
Refrigeration Division

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 Please contact your office:

Grasso Products B.V. P.O. Box 343 • 5201 AH ’s-Hertogenbosch • The Netherlands
Phone: +31 (0)73 - 6203 911 • Fax: +31 (0)73 - 6231 286 • E-Mail: products@grasso.nl

Grasso GmbH Holzhauser Straße 165 • 13509 Berlin • Germany

Refrigeration Technology Phone: +49 (0)30 - 43 592 6 • Fax: +49 (0)30 - 43 592 777

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