Grasso 12E

Reciprocating Compressors for industrial refrigeration
Series Grasso 12E
Installation and Maintenance Manual (IMM)

ca0132_0089282_imm_rc12e_v008_gbr
IMM0703/v008 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 1-

Copyright
All Rights reserved. No part of this publication may be The compressor is not filled with oil.
copied or published by means of printing, photocopying,
microfilm or otherwise without prior written consent of
Grasso.
This restriction also applies to the corresponding After the successful initial run of the compressor
drawings and diagrams. (package) the warranty chart must be filled in and
returned to Grasso. A warranty chart is attached to each
Legal Notice compressor.
This publication has been written in good faith.

However, Grasso cannot be held responsible, neither for Open compressor series and (semi) hermetic
any errors occurring in this publication nor for their compressor series;
consequences.
This manual includes procedures and checks for open
compressors and (semi) hermetic compressors.
a. Open compressor series are Grasso 12E, Grasso 12,
This manual must be carefull read and understood prior Grasso 6, Grasso 5HP and Grasso 10.
to installing and servicing the compressor (package) b. Semi hermetic compressor series are Grasso 7S and
Grasso 8S.
Safety
This manual is written with great care, but the
contractor/installer is held responsible to examine this
information and to take care of possible additional and/
or deviated safety measures.
Safety instructions
It is the task of the contractor/installer to inform and
explain to his client the operation of the compressor
(Package).
Do respect all federal, state or local safety
regulations/legislations during installing, connecting and
operating this compressor (package).
Construction changes
In compliance with the regulations of the Pressure

Equipment Directive it is mandatory that no changes be
made to the construction of pressurised parts such as the
crankcase housing, suction filter housing etc.
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.
- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E IMM0703/v008

Table of Contents
Section Title Page

1 INSTALLATION AND PREPARATION FOR USE 11
1.1 INSTALLATION 13
1.1.1 Moving instructions and storage 13
1.1.2 Storage 13
1.1.3 Hoisting and moving instructions 13
1.1.4 Required free space 14
1.1.5 Foundation requirements 14
1.1.5.1 Concrete structure 14
1.1.5.2 Anchoring 15
1.1.5.3 Mounting the base frame on a concrete block 15
1.1.5.3.1 Levelling the base frame 16
1.1.5.3.2 Finishing with a self-levelling grout 16
1.1.5.4 Mounting bare compressor on a concrete block 16
1.1.6 Connecting to refrigerating system pipework 16
1.1.7 Connecting the power supply 16
1.1.8 Earthing connections 16
1.1.9 Separately delivered components 17
1.2 PREPARATIONS FOR USE 19
1.2.1 Leak test of compressor and system 19
1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 19
1.2.3 Initial oil charge 19
1.2.3.1 Initial oil charge 19
1.2.4 Initial refrigerant charge 19
1.2.5 Adjustment of instruments and safety devices 19
1.2.5.1 Monitron CR and GSC 19
1.2.5.2 Refrigerants R717 and halocarbons 19
1.2.5.3 Re-adjustment of oil pressure regulator 20
1.2.6 Checking direction of rotation of motor shaft 20
1.2.7 Installing the drive guards (if present) 20
1.2.8 Initial oil warm up 21
1.2.9 Initial start-up 21
1.2.9.1 Limitations of part load operation and start-up 21
1.2.9.2 Wiring logic NO unloaded start solenoid 21
1.2.9.3 Frequency controlled compressor 21
1.2.9.4 Pre-start check list 21
1.2.10 Starting and stopping procedures 21
1.2.10.1 First start 21
1.2.10.2 Restart 22
1.2.10.3 Restart after a short standstill period of time (less than 1 month) 22
1.2.10.4 Restart after a long standstill period of time 22
1.2.10.5 Stopping the compressor 22

Section Title Page
2 INSPECTION, MAINTENANCE AND TROUBLE SHOOTING 23
2.1 INSPECTION 25
2.1.1 Periodical inspection 25
2.1.2 Survey of periodical inspections 25
2.1.2.1 Check list periodical inspection 26
2.2 MAINTENANCE (REFER Chapter 5) 27
2.2.1 Post start-up maintenance 27
2.2.2 First maintenance 27
2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 27
2.4 LUBRICATION DATA 27
2.4.1 Topping up oil with compressor operating 27
2.5 EVACUATION OF THE COMPRESSOR 27
2.6 DRAINING AND CHANGE OF OIL 28
2.6.1 DRAINING OIL REVERVOIR FOR MARINE USE (Optional) 28
2.7 REPLACEMENT OF OIL FILTERS 28
2.7.1 Oil discharge filter 28
2.7.2 Oil suction filter (Pos. B) 28
2.8 REPLACEMENT OF SUCTION GAS FILTER(S) 28
2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 28
2.10 COMPRESSOR PURGING 28
2.11 TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS 29
3 PARTS COMPRESSOR 33
4 SUPPLEMENTARY PARTS 73
5 MAINTENANCE 81
5.1 SMS FACTOR 81
5.2 Grasso 12E 83
5.3 Checklist 85
6 APPENDIX; Product Information (PI) 87
6.1 GENERAL DATA 89
6.1.1 TECHNICAL DATA 89
6.1.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 91
6.1.3 SHAFT END COMPRESSOR 93
6.2 Electrical wiring schematic oil differential pressostat (RT260A) 95
6.2.1 Method A, two timers, recommended 95
6.2.2 Method B, one timer (method A is recommended) 96
6.3 LIMITS OF OPERATION AND FIELDS OF APPLICATION 97
6.3.1 GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 12E 97
6.3.2 PRECISE FIELD OF APPLICATION 98
6.3.3 FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER 99
6.3.3.1 DIAGRAMS Grasso 12E 100
6.3.4 FIELDS OF APPLICATION TWO STAGE 102
6.3.4.1 FIELDS OF APPLICATION DIAGRAMS 102
6.3.5 LIMITATIONS OF PART-LOAD OPERATION 104

Section Title Page
6.3.6 STARTING UP OF TWO-STAGE COMPRESSORS 104
6.4 LUBRICATING OILS (choice and recommendations) 107
6.4.1 Oil selection table 107
6.4.1.1 Remarks 107
6.4.2 Strongly recommended oil types for Grasso reciprocating compressors 107
6.4.3 Accepted NH3 and HCFC oil types for Grasso reciprocating compressorss 108
6.4.4 Accepted HCFC oil types for Grasso reciprocating compressors 108
6.5 CAPACITY CONTROL SYSTEMS 108
6.5.1 SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START 108
6.5.2 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) 110
6.5.2.1 GENERAL DIAGRAM OF ELECTRICALLY OPERATED CAPACITY CONTROL 110
6.5.2.2 DIAGRAMS 111
6.5.3 MANUAL CAPACITY CONTROL 115
6.6 PACKAGED BASE FRAME AND FOUNDATION BLOCK 117
6.6.1 PACKAGED BASE FRAME 117
6.6.1.1 PACKAGED BASE FRAME 117
6.6.2 BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK 119
6.6.2.1 FOUNDATION BLOCK 120
6.7 CRANKCASE HEATER 120
6.7.1 HEATER FITTING DETAIL 121
7 NOTES 123

Preface 4) Installation and maintenance manual (IMM)
This preface gives a survey of the types of Contents

documentation available for reciprocating Grasso This manual will provide information on how to
compressor series. transport, install, start-up and maintain the compressor
(package). It also contains a number of "Product
Information Sheets" and the current "Parts List"
All documentation and selection software is on-line
available on www.grasso-global.com User group
To be used in the field by qualified personnel for both
end-user and contractor.
1) Product Information (PI)
Distribution
Contents Supplied together with the compressor.
All product information (engineering data) for this series
compressor and the corresponding recommended
accessories. It is meant to be a guide to the selection of 5) Product Descriptions, Instructions for Accessories
these components. (PD)
User group Contents

Project engineers, application engineers, sales managers, All the relevant mounting and installation instructions
product managers for both end-users and contractors. and spare parts information for those accessories
supplied with the compressor.
Distribution
Your Grasso contact only. User group
end-user and contractor.
2) Operating manual (OM)
Distribution
Contents
Supplied together with the compressor.
General operation guide lines; safety instructions,
periodical inspections, fault analysis, periodical
maintenance. 6) Parts list (PL)
User group Contents

To be used in the field by the end-user. All current parts of the compressor and accessories
together with the design changes applicable to previous
Distribution supplied components ("History").
Supplied together with the compressor.
User group
Service and parts department for both end-user and
3) Safety instructions refrigerant ammonia contractor.
Contents Distribution
Strict safety provisions have been defined to protect Your Grasso contact only.
human beings and facilities. Reference is made to the
main guidelines and provisions to be observed
inplanning and operating refrigerating plants. With 7) Service & Maintenance Schedules (SMS)
regard to their operation, the detailed operating
manuals of the plant manufacturers shall be taken into Contents
account as well. Manual will be supplied with all Complete set of service and maintenance schedules for
compressors 100 operating hours up to 48000 operating hours
(inspection, renewal, measuring, cleaning, ...) of the bare
User group shaft compressor.
end-user and contractor. User group
Service and parts department and in the field by
Distribution qualified personnel for both end-user and contractor.
(If applicable supplied together with the compressor)
Distribution
Your Grasso contact only.

8) Service Instruction Manual (SIM)
Contents
Description of (re)assembling, inspection, repair and part
or total overhaul of the bare shaft compressor. This
manual should be used together with the 'Installation
and Maintenance Manual'.
User group
To be used in the field by qualified personnel of
refrigeration installers or contractors.
Distribution
Your Grasso contact only.
9) Typographic signs
Indicates a WARNING. READ IT CAREFULLY!
Indicates an IMPORTANT note or procedure to which

you should pay special attention.
Indicates a HINT.

Main setup data Grasso 12E
When operating the compressor, none of the limits of
operation as stated in the table below and the product
information must be exceeded. Refer Section 6.3!
Table 1 Main setup data
Description Value Remark

Start frequency max. 6 starts per hour
Time interval between stopping and re-starting min. 2 minutes
Time interval between starting and re-starting min. 10 minutes
For continuous minimum part-load (i.e. more than 30
Time interval between capacity steps min. 3 minutes minutes) consult Grasso.
Adjust the steps between up and down loading, in
such a way that the system is running stable.
Oil level 25-75% crankcase sight glass
Min. oil temperature warmer than surroundings and ≥ 20 °C

for NH3 and ≥ 30 °C for halocarbons
Max. oil temperature Refer to oil selection table/applied type Required oil viscosity;
of oil ≥ 10 cSt during operation at location of bearings
Control oil pressure suction pressure + 8 bar
between 1.3 and 3.0 bar Setting approx. After a mimimum of 15 minutes running time at an oil
Lubricating oil pressure difference
2.0 bar temperature of approx. 50 oC (122 oF)
Max. discharge temperature 170 °C
Min. suction pressure 0.3 bar (a)
NH3 - 7.0 bar (a)
Max. intermediate pressure R22 - 7.0 bar (a)
Max. suction pressure R134a - 6.2 bar (a)
R404A - 6.0 bar (a)
Pdischarge - Psuction ≤19.0 bar
>0 K for NH3,
Superheat
>15 K for R404A, R507 and R134a
Oil suction filter Blue coloured filter element
Oil discharge - running in - filter Red coloured filter element Factory mounted; to be replaced after max. 100
running hours by permanent oil discharge filter
element
Oil discharge - permanent - filter Grey filter element Supplied loose; replacement for factory
mounted running in filter
Direction of rotation of compressor drive shaft Counterclockwise when facing shaft end
Cylinder numbering

Fig. 1 Cylinder numbering Grasso reciprocating compressors
Legend
1, 2, 3, ... Cylinder numbers
T Top view of compressor
M Motor/Drive end of compressor
O Oil pump of compressor
1. INSTALLATION AND PREPARATION
FOR USE
1. INSTALLATION AND PREPARATION FOR USE
Table of Contents
Section Title Page

1.1 INSTALLATION 13
1.1.1 Moving instructions and storage 13
1.1.2 Storage 13
1.1.3 Hoisting and moving instructions 13
1.1.4 Required free space 14
1.1.5 Foundation requirements 14
1.1.5.1 Concrete structure 14
1.1.5.2 Anchoring 15
1.1.5.3 Mounting the base frame on a concrete block 15
1.1.5.3.1 Levelling the base frame 16
1.1.5.3.2 Finishing with a self-levelling grout 16
1.1.5.4 Mounting bare compressor on a concrete block 16
1.1.6 Connecting to refrigerating system pipework 16
1.1.7 Connecting the power supply 16
1.1.8 Earthing connections 16
1.1.9 Separately delivered components 17
1.2 PREPARATIONS FOR USE 19
1.2.1 Leak test of compressor and system 19
1.2.2 EVACUATION/DRYING THE REFRIGERATING SYSTEM 19
1.2.3 Initial oil charge 19
1.2.3.1 Initial oil charge 19
1.2.4 Initial refrigerant charge 19
1.2.5 Adjustment of instruments and safety devices 19
1.2.5.1 Monitron CR and GSC 19
1.2.5.2 Refrigerants R717 and halocarbons 19
1.2.5.3 Re-adjustment of oil pressure regulator 20
1.2.6 Checking direction of rotation of motor shaft 20
1.2.7 Installing the drive guards (if present) 20
1.2.8 Initial oil warm up 21
1.2.9 Initial start-up 21
1.2.9.1 Limitations of part load operation and start-up 21
1.2.9.2 Wiring logic NO unloaded start solenoid 21
1.2.9.3 Frequency controlled compressor 21
1.2.9.4 Pre-start check list 21
1.2.10 Starting and stopping procedures 21
1.2.10.1 First start 21
1.2.10.2 Restart 22
1.2.10.3 Restart after a short standstill period of time (less than 1 month) 22
FOR USE
Section Title Page

1.2.10.4 Restart after a long standstill period of time 22
1.2.10.5 Stopping the compressor 22
FOR USE
1.1 INSTALLATION all times in a dry location to prevent corrosion damage.

If the compressor (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
The compressor is not charged with oil, therefore, DO above atmospheric pressure.
NOT start the compressor before it has been installed
and prepared according to Grasso’s instructions. 1.1.3 HOISTING AND MOVING INSTRUCTIONS
This section contains instructions for the proper
installation of a Grasso compressor (package). Before
the compressor (package) is ready for the initial start up,
the installation instructions in the following paragraphs
must be followed:
1. The Compressor (Package) should be levelled and
securely anchored to the foundation.
2. All piping should be completed.
3. The system and the compressor are to be pressure
tested for leaks (see. Section 1.2.1)
4. The system should be evacuated to remove air and
moisture.
5. The electric wiring should be completed as per wiring
diagrams. Do not energise the main power control
cabinet until oil is added and the direction of
rotation1 has been checked.
6. The compressor is to be filled with the correct type
and amount of lubricating oil.
7. ‘Open compressors’ only; Fig. 1.1-1 Hoisting a compressor package
1 Open compressors;
The drive system should be installed.
2 (Semi) hermitic compressors; Legend
Mark R-S-T-N power supply in the terminal box of
the motor. C Compressor
8. The system should be charged with the correct M Motor
amount of refrigerant.
9. The oil should be warmed up above minimum start Packaged base frame:
up oil temperature (see "Product Information"). The only places that can be used for safe hoisting of the
10.The control cabinet should be energised to check the package are the four hoisting eyes on the steel base
package controls. 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.
Do not forget to charge the oil separator (if present) Attach spreader bars to the slings so as to prevent
initially with oil, to the level of the float assembly damage to piping and components.
1.1.1 MOVING INSTRUCTIONS AND STORAGE

For loose component or compressor package weights, DO NOT use the compressor or motor or oil separator
refer either to the relevant component type plate or hoisting eyes to move the package! These hoisting eyes
package lay-out or to the suppliers document. For bare are intended for lifting loose components only and not
compressor weights, see "Product Information".
for the entire package!
Every precaution must be taken while moving the Bare compressor or loose components:
package to its final location. Pushing, pulling or climbing
on any package component or piping, can easily create Determine the dead weight of the particular component
damage. (see "Product Information (ED)"), prior to moving a bare
compressor or loose component. Use the hoisting eyes
only, DO NOT sling from other compressor parts (see Fig.
1.1.2 STORAGE 1.1-2).
The compressor (package) is filled with dry nitrogen.
Keep the system closed until the package is installed. If
the compressor (package) is stored, it should be kept at
1. The direction of rotation of the compressor cannot be checked for (semi)
hermetic compressors. For these compressors the electrical connection should
be marked, to be sure that the compressor has always the same direction of
rotation!
FOR USE
For more instalation details refer to; Section

1.1.5.1, Section 1.1.5.2Section 1.1.5.3, Section
1.1.5.3.1, Section 1.1.5.3.2.
b) Frame designed for mounting on vibration
dampers.
For more details in case mounting base frames on
vibration dampers is applied, refer to separate
instruction sheet and other order documentation
like package drawing, supplied with the
compressor package and consult Grasso if
required.
2. Bare compressor direct mounted on a concrete block
via grouted machined anchors (see "Product
Information (PI)"). The mounting surfaces of these
machined anchors must be level without any
deviation and projecting at least 10 mm above the
concrete base.
For more installation details refer to; Section 1.1.5.1,
Section 1.1.5.2, Section 1.1.5.4
1.1.5.1 CONCRETE STRUCTURE
Fig. 1.1-2 Hoisting angle
Moving by fork-lift truck

The bare compressor or package can be transported
with a fork-lift truck with the forks spread as much as Fig. 1.1-3 Concrete block
possible between the skids. To simplify moving, the 2
wooden transport beams must still be mounted
underneath the base frame and stored in this way, until Legend
the package is positioned above its approximate
1 Cork board
location.
2 Concrete base
1.1.4 REQUIRED FREE SPACE
3 (Concrete) Floor
For easy operating, servicing and maintenance access,
the compressor (package) should be installed with 4 Sand
sufficient free space around it. The concrete block for compressor and motor or
compressor package should have a profile as illustrated
in Table on Page 14and made according to the following
Refer to “Product Information“ for minimum recommendations:
requirements.
• The concrete block should be set on firm footings or
1.1.5 FOUNDATION REQUIREMENTS on a floor capable of carrying the weight of the
concrete block and capable of absorbing the free
forces and gas forces of the compressor during
operation. The ground under the concrete block
Compressor (package) has to be mounted on a should be horizontal and flat.
concreted block. On request, Grasso can calculate the • The top surface of the block should be level and even.
exact dimensions of the concrete block, based on the • There should be sufficient free space around the
compressor size and operating conditions. block to install corkboard (or similar).
This paragraph covers measures to be taken for a • The block should be provided with anchor bolt
compressor (package) mounting on a concrete block. recesses or holes according to the anchor bolt spacing
Two foundation arrangements are described: as per package lay out drawing.
1. Compressor package with steel base frame mounted
on a concrete block.
Following base frames are possible;
a) Frame designed for mounting on concrete block.
FOR USE
Table 1.1-1
Legend
A Chemical anchor
B Grouted anchor, grounded to reinforcing steel
It is recommended to consult a concrete specialist/

constructor for the following items:
• The compound of the concrete with/without
reinforcement.
• The exact grouting depth (dependent on the soil
conditions).
• Installing foundation onto an existing floor, with
sealing corkboard or vibration isolators.
1.1.5.2 ANCHORING
After the concrete block has cured the anchors should be
installed as shown above 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 according to the supplier instructions.
Install chemical anchors as illustrated in Fig. 1.1-4 and
according to the instructions of the anchor supplier.
Fig. 1.1-4 Anchoring details
Legend
A Drilled chemical anchor (M20)
B Grouted anchor recesses (M20)
1 Installed chemical anchor before placing the base frame
Installing chemical anchor after placing the base frame
2 (base frame cannot be removed easily)
3 Drilling angle
1.1.5.3 MOUNTING THE BASE FRAME ON A

CONCRETE BLOCK
FOR USE
General instructions can be found in the order manual.

After the space between base frame and concrete base
has been filled-up with a filling grout, the package base 1.1.5.4 MOUNTING BARE COMPRESSOR ON A
frame must be secured tightly to the foundation block or CONCRETE BLOCK
floor. If no base frame is applied the compressor and motor
should be installed as described in the "Product
1.1.5.3.1 LEVELLING THE BASE FRAME Information (ED)".
1.1.6 CONNECTING TO REFRIGERATING SYSTEM

PIPEWORK
DO NOT ground through the compressor when arc

welding
After the compressor (package) has been levelled and
secured to the foundation, the system piping may be
connected. The suction line(s) and discharge line(s)
should be installed and supported such that there is no
load exerted on the compressor. The size and location of
the suction and discharge connections, can be found in
the "Product Information" (bare compressor) and in case
Fig. 1.1-5 Grouting details of a package, the package lay out drawing.
Legend
In order to ensure that suction gas strainer can be
1 Self-levelling grout removed easily, special attention for pipe work is
2 Adjusting bolts (4x) required for (semi) hermetic compressors.
3 Washer
4 Temporary barrier strip around and inside frame If an oil rectifier system is applied in the refrigeration
5 Complete cured concrete block system, the oil return line must be connected to the oil
return connection (see "Product Information").
6 Grout layer
After the anchor filling mortar has completely cured the

frame should be levelled with a space between block and Never connect the oil rectifier return line to the suction
lower frame flange of 3 - 5 mm*. This space is necessary line or to the suction gas filter.
for levelling using the base frame adjusting bolts with
metal washers (supplied separately). The base frame
should be levelled on each frame side. Adjust the frame Suspension of system pipework
on each adjusting place until all frame sides are To eliminate vibration transmission to the system piping,
horizontal. the following is recommended:
This space largely depends on the sort of grout or mortar • Install all piping free of tension.
used. Determine this space according to the instructions • Secure the piping by clips or brackets in two
of the grout or mortar supplier. directions.
• Install (stop) valves, piping and accessories such, that
1.1.5.3.2 FINISHING WITH A SELF-LEVELLING GROUT there is no load exerted on the compressor.
After levelling has been completed the adjusting bolt 1.1.7 CONNECTING THE POWER SUPPLY
ends must be greased to avoid bonding to the
self-levelling grout. The space between concrete block Information about further electrical connections to be
and frame must be completely filled with the made (e.g. crankcase heater, drive motor starting
self-levelling grout to ensure that the complete bottom equipment, thermal protection of drive motor,
surface of the base frame will be supported. Therefore, automatic start/ stop and other external electrical
it is not allowed to use shims between concrete base and devices) can be found in the plant manual (not supplied
base frame. by Grasso).
Grouting must be carried out in accordance with the
instructions provided by the grouting supplier. After
complete de-aeration of the grouted layer, secure the 1.1.8 EARTHING CONNECTIONS
base frame by tightening the anchor bolt nuts and Grasso compressors and packages are equipped with
remove all adjusting bolts. At this stage the drive system litz-wires and earth connecting points.
can be installed. These (accessories) installation To avoid leakage current flowing through the
FOR USE
components, disconnect all litz-wires when arc-welding.

After all installation functions are completed, reconnect
the litz-wires and ground the package to earth.
1.1.9 SEPARATELY DELIVERED COMPONENTS
Check whether the sets/parts/components belonging to

this compressor are supplied loose! (Refer to
confirmation of order)
Mount these separately delivered sets, components
and/or parts, according to the instruction as enclosed.
FOR USE
FOR USE
1.2 PREPARATIONS FOR USE 1.2.3 INITIAL OIL CHARGE

After the Compressor (Package) has been installed
(excluding final connection of drive device), the
following actions should be followed in the order given: Used or filtered oil should NEVER BE added to a
compressor under any circumstance.
1.2.1 LEAK TEST OF COMPRESSOR AND SYSTEM
The compressor (package) has been pressure tested
prior to leaving the factory. In case an additional leak Use only new oil as selected from the Grasso oil
test is required, this test is should be carried out with dry table.(Section 6.4)
nitrogen.
Oil charging via the suction line of the compressor is not

DO NOT add oil to the compressor prior to pressure allowed.
testing
A system leak test should be carried out over 24 hours to Procedure:
ensure that the system is tightly sealed.
Record during the pressure test, the pressure, ambient i) STATUS: System is dried and still evacuated.
temperature and outside temperature. During the initial ii) Charge the oil separator (if present) initially with oil .
6 hours a pressure drop of 2% is permissable. With iii) Close suction and discharge stop valves of compressor
respect to temperature variations, no further pressure and oil return line of oil separator (if present).
loss should be detected in the remaining 18 hours. iv) Charge the compressor crankcase with oil via the oil
charge valve.
1.2.2 EVACUATION/DRYING THE REFRIGERATING
SYSTEM
Pre-lubrication just before the first start is obligatory.
For evacuation of compressor only, refer to Section 2.5
Procedure to evacuate and to dry a system:
i) STATUS: System is filled with nitrogen and no oil has Filling of the afore mentioned components is also
been added (oil prevents any trapped moisture from possible by means of a separate oil filling pump via the
boiling off). oil charge valves mounted onto the oil pump housing.
ii) Verify that all valves in that part of the system to be
evacuated are opened (refer also to the plant 1.2.3.1 INITIAL OIL CHARGE
manual).
iii) Connect vacuum pump to the evacuation/purging
valve(s) of the compressor (for location of these QUANTITY OF OIL TO BE FILLED (IN dm3)
valves refer to the "Product Information" or to a Shaft seal
connection as mentioned in the plant manual and Number of housing incl. Oil Oil
evacuate the system to approx. 5 mm Hg (=6.6 mBar). Crankcase
cylinders internal circuit of filters pump
iv) Break vacuum by charging dry nitrogen into the crankshaft
system. 2 and 3 0.6 7.8
v) Repeat step iii, 'Connect vacuum pump ...'.
vi) Wait approx. 24 hours. 4 0.7 13.6
vii) If pressure has increased (system still contains 6 0.7 1.5 0.5 14.7
moisture), repeat steps iv, vand vi, otherwise, each
continue with the "Initial oil charge" procedure. 9 0.8 21.7
12 0.9 28.7
1.2.4 INITIAL REFRIGERANT CHARGE

Refrigerant charging should be done in accordance with
the plant manual by qualified refrigeration engineers.
1.2.5 ADJUSTMENT OF INSTRUMENTS AND

SAFETY DEVICES
1.2.5.1 MONITRON CR AND GSC

Refer to the Monitron CR resp. GSC Instruction
Manual(s).
1.2.5.2 REFRIGERANTS R717 AND HALOCARBONS
FOR USE
Legend
Pressure safety limit switches for R717 and halocarbons
Oil discharge filter
Setting 5oC below design REMARK: A running in filter is factory mounted; to
Suction pressurea evaporating temp. B be replaced after max. 100 running
Precondition Min. =0.3 bar(a) hours by permanent oil discharge filter
element
Max.= depends on
Suction and
intermediate Setting rotational speed, Oil charge valve for lubrication circuit.
refer to Product C
pressure Information (PI) REMARK: This connection to be used for
pre-lubrication of the oil circuit
5oC above design
Discharge pressure Setting Oil charge plug for oil suction filter (Hand operarated oil
condensing temp. D
pump and stop valve are not included)
Precondition Max. =24 bar(a)
E Connection to measure oil control pressure
Lubrication oil
pressure difference Setting Min. =1.3 bar F Hand operated oil charge pump (optional).
a. Settings Pdischarge - Psuction must never exceed max. value as

mentioned in Product Information Re-adjustment procedure:
Oil pressure regulators for R717 and halocarbons REMARK: For settings, refer .
Setting i) Run the compressor for 15 minutes until the
Lubrication oil 2.0 bar crankcase oil is at its stable operating temperature
pressure [Toil] of 50 oC at which:
differencea Precondition, Min. =1.3 bar
# The lubricating oil pressure difference should be (A)
at 50 oC oil temp. Max. =3.0 bar
according to .
Control oil
Setting 8.0 bar # The control oil pressure difference should be
pressure difference approx. (B) according to .
a. The oil pressure regulator is adjusted at the works, but it may occur After the initial run the oil pressure differences should
that this setting should be corrected during the initial run and also if be slightly higher.
the value <1.5 or >2.5 bar. The re-adjustment procedure is given in ii) Determine the lubricating oil pressure difference
section “Re-adjustment of oil pressure regulator.
(difference between the pressure gauges of the oil
and suction or [dOil]).
1.2.5.3 RE-ADJUSTMENT OF OIL PRESSURE iii) Determine the control oil pressure difference
REGULATOR (difference between the pressure gauges of oil pump
It is possible that after the compressor(package) has discharge 1 and suction.
been installed, the lubrication oil pressure regulator iv) Remove the cap nut of both oil pressure regulators if
(located on the left side of the pump) needs to be the pressures need to be re-adjusted.
re-adjusted. v) Turn the slotted pin with a screwdriver clockwise or
counter clockwise for a higher or lower oil pressure
Inside the oil pump two regulators are factory preset and respectively, until the required control & lubricating
installed; One control oil pressure regulator (right) to oil pressure differences have been achieved 2.
control the valve lifting mechanisms and one lubricating vi) Replace both cap nuts.
oil pressure regulator for lubrication.
REMARK: If the valve lifting fails, check the control oil
pressure regulator!
1.2.6 CHECKING DIRECTION OF ROTATION OF

MOTOR SHAFT
Prior to installing the intermediate coupling element or
V-belts, the direction of rotation of the motor shaft must
be checked. The direction of rotation can be determined
from the arrow-sticker on the oil pump.
1.2.7 INSTALLING THE DRIVE GUARDS (IF

PRESENT)
Fig. 1.2-1 Oil pressure regulator
Only after the compressor is ready for the initial startup!
Refer to the drive guard installing procedures included in
Legend the order documentation.
1 Lubricating oil pressure regulator
2 Control oil pressure regulator
1. To be measured by means of a special control oil pressure gauge to be
A Oil suction filter connected at position E on the oil pump.
2. Re-adjusting one regulator will affect the other one, so be sure that both
regulators are properly (re-)adjusted.
FOR USE
1.2.8 INITIAL OIL WARM UP 1. Set the electrical capacity control switch to the
Prior to the initial start-up, the crankcase heater (if position of the lowest part load step.
present) must be energised. For the min. oil temperature 2. Check whether the manual control lever of each
refer to “Product Information (PI)“. solenoid is in its lowest horizontal position.
1.2.9 INITIAL START-UP

If control lever of each solenoid is not in its lowest
1.2.9.1 LIMITATIONS OF PART LOAD OPERATION position, the compressor may be seriously damaged.
AND START-UP v) Oil level established in sight glass.
The capacity control serves to adapt the compressor vi) Stop valves to the pressure gauges are open.
capacity at any moment as closely as possible to the vii) Suction stop valve is closed (in case the evaporating
refrigerating capacity. In order to adjust the capacity, a temperature is much higher than the design
number of cylinders can be put in or out of action either evaporating temperature) and the discharge stop
individually or collectively by means of solenoid valves. valve is open and in case of two- stage compressors
that the stop valves in the intermediate circuit lines
are open.
viii)Stop valve in the oil return line of the oil separator (if
Due to start-up limitations and to limitations of part load present) is closed.
operation it may be that not all available part load steps
are allowed under certain conditions. Use of incorrect When all items are verified, the compressor (package) is
ready for the start-up.
control steps can damage compressor and/or
components. 1.2.10 STARTING AND STOPPING PROCEDURES
For a detailed description about start-up and part load
limitations refer to the software program “Comsel”.
For all limitations refer to "Main setup data Grasso 12E"
1.2.9.2 WIRING LOGIC NO UNLOADED START on Page 9! The values in the main setup data tables,
SOLENOID overrules the values as mentioned in the text.
1 If compessor is NOT running then NO-solenoid is not When starting the compressor a distinction should be
energised. made between:
2 Energise the NO-solenoid 10 seconds before starting.
3 If compressor starts then NO-solenoid is energised 1.2.10.1 FIRST START
and de-energised by means of an auxiliary time relay. i) Notice "Pre-start check list", also consult the plant
4 Ensure that the NO-solenoid valve is not de-energised manual and verify the following items:
until full speed has been achieved and the specified — Check the oil temperature (refer to the "Product
lubrication oil pressure has been established. Information").
5 Energise the NO-solenoid 5 seconds before stopping — Check crankcase oil level (refer to Section 2.4.1).
untill the compressor is stopped for 60 seconds. ii) Start the compressor and check whether the oil
pressure increases.
1.2.9.3 FREQUENCY CONTROLLED COMPRESSOR
The time interval between stopping and starting should

In case of frequency controlled compressors, a separate be at least 2 minutes and between starting and
instruction 00.87.041 is required. If you don’t have this re-starting 10 minutes.
instruction consult Grasso. iii) Slowly open suction stop valve and watch suction
pressure, which may not exceed the max. value.
1.2.9.4 PRE-START CHECK LIST
The following Paragraph covers only the initial start of Refrigerant liquid hammer, will damage the compressor;
the compressor and not the complete refrigeration Superheat is always necessary! R404A and R507
plant. dTo≥15K, other refrigerants dTo≥0K.
Be sure that all necessary system valves are open and iv) In case of electrically operated capacity control:
that the refrigeration system is ready for start up. Use a. Single-stage compressors: One or more cylinders
the following check to guarantee that no items of will be energized.
importance regarding the compressor (package) have b. Two-stage compressors: 3 - 5 minutes after
been overlooked. starting and only when HP-cylinder(s) is (are) in
i) System is charged with refrigerant. operation, the LP cylinders can be energised.
ii) Settings of safety limit switches are adjusted properly.
iii) Direction of rotation of compressor crankshaft is
correct.
iv) Check capacity control:
FOR USE
In the case of decreasing capacity for two stage

compressors, it is not allowed to cut out all LP-cylinders.
v) Watch maximum allowable motor current (refer to
motor type plate).
vi) Watch discharge temperatures LP and HP, max.
intermediate pressure and max. allowable motor
current (refer to motor type plate).
vii) Adjust pressure gauge stop valves, in order to avoid
vibration of the pointers.
viii)Open the stop valve in the oil return line from the oil
separator (if present).
ix) Open compressors only; After 50 hours of operation
retighten the coupling bolts or check and/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!).
1.2.10.2 RESTART
The time interval between stopping and starting should

be at least 2 minutes and between starting and
re-starting 10 minutes.
Proceed to the complete starting procedure of Section
1.2.10.1.
1.2.10.3 RESTART AFTER A SHORT STANDSTILL

PERIOD OF TIME (LESS THAN 1 MONTH)
• Refer to Section 1.2.10.2.
1.2.10.4 RESTART AFTER A LONG STANDSTILL

PERIOD OF TIME
After a seasonal standstill (1 till 6 months) or

maintenance operations;
• Check settings of control and safety equipment.
• Proceed to the complete starting procedure.
Restarting compressor after a standstill period of time

more than 6 months, consult your supplier. It is
recommended to proceed with the initial start up
procedure.
1.2.10.5 STOPPING THE COMPRESSOR

The compressor can be stopped at any moment,
however, consult the supplier if further actions are
required.
2. INSPECTION, MAINTENANCE AND
TROUBLE SHOOTING
2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING
Table of Contents
Section Title Page

2.1 INSPECTION 25
2.1.1 Periodical inspection 25
2.1.2 Survey of periodical inspections 25
2.1.2.1 Check list periodical inspection 26
2.2 MAINTENANCE (REFER Chapter 5) 27
2.2.1 Post start-up maintenance 27
2.2.2 First maintenance 27
2.3 STEPS FOR LONGER SHUT-DOWN PERIODS (> 6 months) 27
2.4 LUBRICATION DATA 27
2.4.1 Topping up oil with compressor operating 27
2.5 EVACUATION OF THE COMPRESSOR 27
2.6 DRAINING AND CHANGE OF OIL 28
2.6.1 DRAINING OIL REVERVOIR FOR MARINE USE (Optional) 28
2.7 REPLACEMENT OF OIL FILTERS 28
2.7.1 Oil discharge filter 28
2.7.2 Oil suction filter (Pos. B) 28
2.8 REPLACEMENT OF SUCTION GAS FILTER(S) 28
2.9 DISMANTLING, INSPECTION AND RE-ASSEMBLY OF SUCTION AND DISCHARGE VALVES 28
2.10 COMPRESSOR PURGING 28
2.11 TROUBLESHOOTING TABLE GRASSO RECIPROCATING COMPRESSORS 29
TROUBLE SHOOTING
TROUBLE SHOOTING
2.1 INSPECTION
2.1.1 PERIODICAL INSPECTION
These inspections should be made during the normal
shut-down periods as much as possible, so the
compressor is always ready to operate when required. If,
at that time, the number of running hours slightly differs
from the scheduled period below, the inspection should
nevertheless be carried out.
In this way it will not be necessary to stop the
compressor at inconvenient times.
The frequency of inspections is dependent on the type of
installation, operating conditions and local regulations.
In the case of automatically controlled plants, the
periodical inspection are particularly important. The
table below sums up all the points on the compressor
that have to be inspected or maintained along with
inspection and maintenance frequencies.
2.1.2 SURVEY OF PERIODICAL INSPECTIONS

Apart from the check points in the table below, the
sound produced by the compressor also provides an
indication of its mechanical condition. If abnormal
sounds are audible, their cause should be traced and
removed immediately in order to prevent serious
breakdowns.
TROUBLE SHOOTING
2.1.2.1 CHECK LIST PERIODICAL INSPECTION CHECK

FREQUENCY REMARKS
POINTSa
Table 2.1-1 Check list periodical inspection
monthly
weekly
daily
CHECK
POINTSa FREQUENCY REMARKS
monthly
weekly
Adjustment
daily
and operation Refer also to instructions of

of pressure • switch manufacturer.
safety switches
Between 25% and 75%
Oil level in height of the sight glass. Capacity
crankcase • For topping up oil, refer to control (if •
Section 2.4.1. provided)
Refer "Main setup data
The oil should be Switching Grasso 12E" on Page 9.
transparently clear. A frequency of
•
disappearing white colour the
Colour of the • points to dissolved compressor
oil
refrigerant. Refer to Check the number of
Section 2.2.2 for oil analysis Number of operating hours in view of
frequency. operating • any maintenance
Lubricating oil hours operations to be carried
pressure • out.
difference
a. During the first 50 operating hours the compressor should be checked
Min. control oil regularly for all the points mentioned above, at least twice every 24 hours
• and more frequently in cases where irregularities are found.
pressure
Oil
Refer to the "Product
temperature • Information"
max.
Oil leakage of • In case of more than 1
shaft seal max. cc/hr contact supplier.
Suction Check against design

• conditions. Refer to plant
pressure manual.
Refer to plant manual. For
the max. allowable
Discharge
pressure • discharge pressure refer to
the technical data of
compressor.
Suction
superheat ≥15 K required for R404A
• and R507, for other
Intermediate refrigerants ≥0 K
superheat
Discharge
temperature • 170 °C.
max.
During compressor
standstill the lower part of
Oil the crankcase must remain
temperature • warmer than the
min. surroundings: ≥ 20 °C
(NH3) and ≥ 30 °C
(halocarbons).
Cooling water Min. Actual condensing
temperature • temperature + 10 K
(if present) (≥ Tc + 10 K)
Check belts for:
1) Wear (fraying, cuts etc.)
and ensure that they do
not touch the groove
bottom.
Condition of • 2) Tension. Too low a
V-belts tension gives rise to
excessive flapping or
oscillation in operation. For
correct tension consult the
instructions given by the
V-belt supplier.
TROUBLE SHOOTING
2.2 MAINTENANCE (REFER CHAPTER 5) ii) Disconnect the power source from the compressor
drive motor and the electrical control cabinet.
2.2.1 POST START-UP MAINTENANCE iii) Place a moisture absorbing compound (eg a dessicant
such as silica gel) inside the control cabinet.
After the compressor has run for the initial 100 iv) Place warning tags on the electric system and all
operating hours: closed stop valves.
i) Drain the oil and refill the compressor with the Prior to starting up after a shut down, change the oil
correct amount of fresh oil. (refer to ) and exchange the oil filters. Determine the
ii) Replace the red marked oil discharge filter element starting and stopping procedure from prior to start the
with the grey marked filter element in accordance compressor.
with the filter replacement instructions. Refer also to
Section 2.7.
iii) Inspect suction gas filter (refer to the Compressor 2.4 LUBRICATION DATA
Service Instruction Manual). Determine max Toil and set this value in the safety
iv) Exchange or clean oil suction filter element (refer device.
Section 2.7). Change the oil as soon as an oil analysis indicates
v) Check the compressor shaft seal for leakage. If contaminated oil.
excessive (more than 1 cc/hr) replace the seal.
vi) 1) Retighten the coupling mounting bolts with the
torque settings as given by the coupling
manufacturer. It is expressly pointed out that it is not permitted to mix
2) Verify and if necessary, correct the tension of the different types of oil. If another type of oil is used, first
V-belts as given in the V-belt supplier's instructions. remove all the stale oil in the filters, oil pump, crankcase,
vii) Verify and if necessary, correct the torque settings of shaft seal, oil separator and oil drains of the installation.
all foundation bolts as given in Compressor Service
Instruction Manual.
2.4.1 TOPPING UP OIL WITH COMPRESSOR
2.2.2 FIRST MAINTENANCE OPERATING
For complete service schedules and required service sets
refer to Grasso's Service and Maintenance Schedules
(SMS). Use Grasso’s hand-operated oil pump, part. no.
18.13.121
Maintenance Number of operating hours Topping up oil is permitted during compressor
operation.
100a > 100
Renewal of oil discharge filter X
Be sure that this oil is the same as in the plant (refer to
Section 2.4).
Renewal of suction gas filter(s) X
Without affecting the operation of the compressor, the
Inspection of oil suction filter X refer to Service and oil may be topped up by means of a separate oil pump.
Maintenance
Oil analysis bc X Schedules (SMS) This pump enables the oil to be forced into the crankcase
via the oil charging valve, against suction pressure.
Inspection leakage shaft seal X
Inspection relief valve(s)d X
a. Time dependent on pollution.
b. Take an oil sample every 3,000 running hours or twice a year and renew if any
sign of discoloration and if the system is contaminated.
c. Consult your oil supplier.
d. If temperature of relief valve is close to (LP/HP) discharged temp, consult your
supplier.
Fig. 2.4-1 Oil level in compressor sight glass

After the refrigerating plant has been modified, the
suction gas filter(s), the oil filters and the oil should be
changed. 2.5 EVACUATION OF THE COMPRESSOR
2.3 STEPS FOR LONGER SHUT-DOWN Use always a vacuum pump to evacuate the compressor.
PERIODS (> 6 MONTHS) To evacuate the refrigeration system refer to Section
To shut down a compressor for long term periods, 1.2.2, Procedure to evacuate the compressor:
proceed as follows: i) Switch off main control panel.
i) Tightly shut both the suction and discharge stop ii) Remove main fuses.
valves and the stop valve of the oil return line (if iii) Remove the refrigerant by means of a vacuum pump,
present). via the evacuation/purging valve(s) as prescribed by
TROUBLE SHOOTING
local safety regulations. For the location of these 2.8 REPLACEMENT OF SUCTION GAS
valves refer to the "Product Information".
FILTER(S)
2.6 DRAINING AND CHANGE OF OIL
To top up oil see Section 2.4.1, Oil changing procedure: Running-in suction gas filter(s) is(are) factory mounted.
This(these) filter(s) must be exchanged after max. 100
i) Evacuate the compressor (refer to Section 2.5). running hours. Running-in filters can not be cleaned!
ii) Drain the oil via the oil charging/drain valve. Remove
the cover of one or more service openings on the
compressor side. Facts:
iii) Clean the inside of the crankcase with a non-fibrous
cloth (do not use cotton waste!). Filter type 2000 = installed in 2-3-4-6 cylinder
iv) Replace the service cover(s) with a new seal. compressors.
v) Charge crankcase with clean oil in accordance with Filter type 3000 = installed in 9 and 12 cylinder
the procedure. compressors.
2.6.1 DRAINING OIL REVERVOIR FOR MARINE USE Procedure:

(OPTIONAL)
i) Evacuate the compressor.
ii) Remove and exchange the suction gas filter(s).
iii) Purge the compressor.
In case an oil reservoir for marine use is applied, this oil
reservoir has also to be drained via the oil drain plug of
the oil reservoir. 2.9 DISMANTLING, INSPECTION AND
RE-ASSEMBLY OF SUCTION AND
2.7 REPLACEMENT OF OIL FILTERS DISCHARGE VALVES
A high working temperature and rapid temperature

Tools; Use the ring spanner for (dis)mounting the oil variations shorten the life time of the valves, which, for
filter cups (included in set of special Grasso tools) this reason, require regular inspection.
Evacuate (refer to Section 2.5) the compressor prior to The suction and discharge valves of a refrigeration
exchange the filter(s). compressor are parts that are heavily loaded both
Facts: mechanically and thermally. Wear and life time of the
Oil suction filter = BLUE coloured valves strongly depend on the working conditions of the
Oil discharge - running-in - filter = RED coloured compressor. It is recommended that valve condition is
Oil discharge - permanent - filter= GREY coloured. regularly checked.For dismantling, inspection and
re-assembly of the valves, refer to the relevant
2.7.1 OIL DISCHARGE FILTER paragraph of the Compressor Service Instruction
Manual.
An oil discharge (running-in) filter is factory mounted.

This filter must be exchanged after max. 100 running In order to reduce the downtime involved in the valve
hours. Oil filters can not be cleaned! inspection, it is recommended to have as many complete
Replace this filter according to the schedule in Section valve assemblies in stock as there are cylinders on the
2.2.2 and to the replacement instructions included in the compressor.These valves can be exchanged with the
filter set (GREY = permanent) or in case of a modified original valves; in this case, these original valves can be
plant (RED = running-in). inspected and repaired or replaced if necessary later.
2.7.2 OIL SUCTION FILTER (POS. B)

2.10 COMPRESSOR PURGING
The frequency of exchanging this filter depends on the
condition of the refrigeration system. It is recommended Procedure to purge the compressor(after maintenance
to exchange this filter when the compressor is jobs):
overhauled or when pressure drop exceeds 1 bar.
STATUS:
Stop valves of suction, discharge and oil return line are
still closed (refer to Section 2.5) and compressor is filled
with oil (refer to Section 2.6).
i) Connect a vacuum pump to the evacuation/purging
valve(s) and evacuate as prescribed by local
TROUBLE SHOOTING
regulations. For the location of these valves refer to

the "Product Information".
ii) When evacuation is completed open the discharge
stop valve.
iii) Watch suction and discharge pressure.
If suction pressure increases quickly, the discharge valve

assy is leaking.
iv) Start compressor.
v) Slowly open suction stop valve.
vi) Open the stop valve in the oil return line of the oil
separator (if present).
vii) For two stage compressor only;
a. Two-stage system A/B: open liquid supply to
interstage cooler.
b. Two-stage system C/D: refer to the plant manual.
viii)If a Self-Limiting Automatic Purger is not installed,
purge the refrigerating system (refer to the plant
manual).
2.11 TROUBLESHOOTING TABLE GRASSO

RECIPROCATING COMPRESSORS
The troubleshooting table shown overleaf 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.
TROUBLE SHOOTING
Table 2.11-1 Troubleshooting

FAULT CAUSE REMEDY
FAULT CAUSE REMEDY 1. Liquid refrigerant in
crankcase due to:
1. Discharge stop valve
not fully open Open fully E Crankcase Provide for crankcase
frosted or weta 1a. Room temperature heating or, if provided,
A Discharge 2. Discharge pressure
pressure too high gauge defective Repair or replace too low check it for proper
operation
3. Non-condensables in Purge with a Automatic Stop
1b. Oil return from
the system Purger compressor separator contains Consult plant manual
1. Discharge pressure and contact liquid refrigerant
too high See A installation 1c. Installation Re-adjust installation and
2. Too many cylinders engineer operates too wet provide for superheat
Cut in more cylinders
cut out 1d. Liquid separator
Consult plant manual
3. Suction pressure too too small
See D
low 1. Oil pressure for valve
4. Excessive superheat Eliminate excessive F All cylinders lifting mechanism too
of suction gas superheat inactive while low See J
compressor is (For Grasso 12, Grasso
5. For two-stage operating 12E and Grasso10 only)
B Discharge
temperature too compressors: Repair 2. Incorrect wiring of Refer to the "Product
interstage cooling does
high not operate properly capacity control Information”
6. Room temperature Ventilate engine room 1. Type of oil not

too high better according to oil Change oil type
lubrication oil table
7. Discharge valve (too thin oil)
defective Repair or renew
2. Compressor
8. Pressure relief valve operates unloaded too Refer to design calculations
is leaking Repair or renew frequently
9. Water cooling is not 3. No return from oil Check the operation of

working properly Repair separatorb float valve in oil separator
1. Capacity control G Too high oil 4. Restriction plug at

does not operate Repair the bottom of suction
consumption Clean plug
chamber in cylinder
2. Compressor capacity clogged
too small Refer to plant design
C Suction 5. Worn out oil scraper
ring(s) Replace ring(s)
pressure too high 3. Suction pressure Repair or renew
gauge defective
6. Loss of oil due to
leakage Repair
4. One or more suction
valves defective Renew suction valve rings
7. Leaking shaft seal
5. One or more (max. 1 cc/hr)
discharge valves Repair or renew (For Grasso 5HP, Repair shaft seal
defective Grasso 12, Grasso 12E Refer to Section 2.2
and Grasso10 and
6. Pressure relief valve Grasso 6 only)()
Repair or renew
is leaking
8. Oil level in crankcase
1. Suction stop valve Drain/Refill with oil
Open fully too high
not fully open
9. Oil separator is not Refer to section “Initial oil
2. Suction gas strainer initially filled with oil charge”
Renew
blocked
1. Lubricating oil
D Suction 3. Injection control not H Too high oil pressure regulator not Re-adjust or renew
Re-adjust control
pressure too low adjusted correctly pressure during adjusted properly or
normal defective
4. Too little refrigerant operation at
Top-up with refrigerant
in installation working 2. Defective oil
temperature pressure and/or
5. Suction pressure Repair or replace
Renew suction pressure gauge
gauge defective (if present)
TROUBLE SHOOTING
FAULT CAUSE REMEDY

1. Too little oil in
crankcase Top up oil
2. Disturbed oil circuit: Renew the element of oil

Oil suction and/or suction filter and/or oil
discharge filter is dirty discharge filter
J Too low
lubricating oil 3. Lubricating oil
pressure pressure regulator not Re-adjust or renew
adjusted properly or
defective
4. Liquid refrigerant in
See E
crankcase
5. Defective oil
pressure and/or Repair or renew
suction pressure gauge
(if present)
6. Worn bearings Renew bearings
K Too low or no 1. Failure of control oil Re-adjust or renew
control oil pressure regulator in
pressure oil pump regulator
(For Grasso 12,
Grasso 12E and 2. A lack of oil in oil
system Add oil to the system
Grasso10 only)
3. Oil pump defect Repair or renew oil pump
a. In case of R744 applications only, crankcase can be frosted or wet, during

normal operating conditions.
b. During the initial start-up, the oil separator (if present) consumes oil before the
first oil will be returned.
TROUBLE SHOOTING
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR
Table of Contents
Parts List Page Figure

COMPRESSOR HOUSING WITH CONNECTIONS AND MAIN COMPONENTS 34 Grasso 12E-01
BEARING COVER DRIVE SIDE AND INTERMEDIATE BEARINGS 36 Grasso

12E-02A
Grasso
BEARING COVER OIL PUMP SIDE: BRONZE SLIDE THRUST BEARING ( from serial number 03071378 ) 38 12E-02B
CRANKSHAFT 40 Grasso 12E-03
PISTON AND CONNECTING ROD 42 Grasso 12E-04
CYLINDER AND VALVE-LIFTING MECHANISM ( from serial no. 03091531 ) 44 Grasso 12E-05
Grasso
SUCTION AND DISCHARGE VALVE - Application: NH3 / in Single & HP two-stage compressors 46 12E-06A
Grasso
SUCTION AND DISCHARGE VALVE - Application: NH3 / in Booster & LP two-stage compressors 48 12E-06B
Grasso
SUCTION AND DISCHARGE VALVE ( Application: R22 / R134A 50 12E-06C
Grasso
SUCTION AND DISCHARGE VALVE ( Application: R404 / R507 52 12E-06D
Grasso
SUCTION AND DISCHARGE VALVE OVERVIEW 54 12E-06E
ROTARY SHAFT SEAL 56 Grasso 12E-07
OIL PUMP 58 Grasso 12E-08
OIL FILTERS 60 Grasso 12E-09
LUBRICATING OIL LINES 62 Grasso 12E-10
SUCTION GAS STRAINER 64 Grasso 12E-11
High / Low PRESSURE RELIEF VALVES 66 Grasso 12E-12
MAIN FLANGE SEALING RINGS 68 Grasso 12E-13
STANDARD SETS OF PARTS, SEALS AND TOOLS 70 Grasso 12E-14
3. PARTS COMPRESSOR
Item Description Dims. Ref. No. Qty Remarks

Fig. Grasso 12E-01 COMPRESSOR HOUSING WITH CONNECTIONS AND MAIN COMPONENTS
1 HEXAGON NUT M16 0115810 -
2 FLAT WASHER M16 1113801 -
3.A CYLINDER COVER 298.5P 0531997 - Without temp. sensor plug
3.B CYLINDER COVER 298.5P-13G 0531999 - With temp. sensor plug
4 GASKET 225X242X1.5 0903226 -
5 STUD M16x60 0151860 -
6 STUD M16x35 0151835 -
7 RESTRICTION NPTF13x0.5 0123020 -
NPTF All cylinders single stage compressors and
8 NON-RETURN VALVE -18-Lx1.5 0123138 - LP-cylinders two-stage compressors
9.a STUD M16x35 0151835 23
9.B STUD M16x55 0151856 3
10 O-RING 3.53x145 0955257 -
11 SERVICE COVER 195X16 0530196 -
12 HEXAGON HEAD BOLT M12x35 0110635 8
13 OIL CONNECTING LINE * - Refer to fig. Grasso12E-10
14 OIL SUCTION LINE * - Refer to fig. Grasso12E-10
15 ALU SEALING RING 21x27x2 0914023 1
16 PLUG G21 0136216 1
17.a POCKET 0385333 - For 2 and 3 cylinder compressors
17.b POCKET 0385335 - For 4 .. 12 cylinder compressors
19 HEXAGON NUT G33 0148331 1
21 O-RING 2.5X52 0952256 1
22 SIGHT GLASS 46X80 1224046 1
23.a SUCTION GAS STRAINER 2000 * - Refer to fig. Grasso 12E-11
23.b SUCTION GAS STRAINER 3000 * - Refer to fig. Grasso 12E-11
24 ALU SEALING RING 13.5x20x1 0912014 2
25 PLUG G13S 0136134 2
26 STOP VALVE TAH8-12 0607011 1
27 NIPPLE COUPLING 12G21 0338211 1
28 CONNECTION LINE 12X150 0412120 1
29 NIPPLE COUPLING 12 0336012 1
3. PARTS COMPRESSOR
Fig. 3-1 Grasso 12E-01
3. PARTS COMPRESSOR

Fig. Grasso 12E-02A BEARING COVER DRIVE SIDE AND INTERMEDIATE BEARINGS
BEARING COVER ASSY GRASSO12(E)
1 * 1 Oil groove pointing at 12 O'clock
(DRIVE SIDE)
1.1 BEARING COVER RC12 2138812 1
1.2 BEARING BUSH 90X96X103 1146291 1
1.3 ALU SEALING RING 21x27x2 0914023 1
1.4 PLUG G21-BZK 0365821 1
1.5 O-RING 3.53x21.8 0955212 1
3 BEARING BLOCK 90M 1169901 -
3.1 BEARING BLOCK HALVES 90M * 1 4, 6,9 and 12 cylinder compressor
3.2 BEARING SHELL 90x81 1144900 - In two pieces
3.3 HEXAGON HEAD BOLT M16 x 100 0110810 4
3.4 FLAT WASHER M16 1113801 4
3.5 DOWEL PIN 12x26 1106226 2
4 O-RING 5.33X240.67 0955375 2
5 LOCKING RING M20 1139100 2 For each intermediate bearing
7 FLAT WASHER M16 1113801 24
8 HEXAGON NUT M16 0115810 24
3. PARTS COMPRESSOR
Fig. 3-2 Grasso 12E-02A
3. PARTS COMPRESSOR

Fig. Grasso 12E-02B BEARING COVER OIL PUMP SIDE: BRONZE SLIDE THRUST BEARING ( from
serial number 03071378 )
1 BEARING COVER ASSY RC12 BRONZE * 1
1.1 BEARING COVER RC12 BRONZE 2138825 1
1.10 HEXAGON HEAD BOLT M6x16 0110316 3
1.12 PLUG G21-BZK 0365821 3
1.13 DOWEL PIN 6x12 1106612 1
1.14 RESTRICTION M6x10x2 0123311 1
1.15 SETSCREW M12 X 16 X 2 0123617 1
1.2 BEARING BUSH 90x96x107A 1146195 1
1.3 THRUST RING RC12 BRONZE 1142013 1 From 03071378
1.4 NIPPLE COUPLING 8G13 0338138 1
1.5 DOWEL PIN 6x12 1106612 1
1.6 STUD M12x110 0151610 7
1.7 DOWEL PIN 4x8 1106408 1
1.8 OIL BAFFLE 1926200 1
1.9 TOOTHED SPRING WASHER M6 1113303 3
2 O-RING 5.33X240.67 0955375 2
3 HOLD DOWN DISC 149S 1125249 1
3.1 CARRIER DISC 149M10 * 1
3.2 DOWEL PIN 8x28 * 2
3.3 DOWEL PIN 5x20 * 1
4 SOCKET HEAD SCREW M10X40 0104540 4
3. PARTS COMPRESSOR
Fig. 3-3 Grasso 12E-02B
3. PARTS COMPRESSOR

Fig. Grasso 12E-03 CRANKSHAFT
1.1 CRANKSHAFT E/K-RC12E * 1
2x for 2-, 3-, 4- and 6-cyl. compressors, 6x for 9
1.2 COUNTERBALANCE WEIGHT * - cyl. compressors and 8x for 12 cyl. compressors
-
M16 /
1.3 LOCKING RING SET 1139800 - in two pieces
13-ST-G.V.
1.4 SOCKET HEAD SCREW M16x55 0104855 -
90X116X60S
1.5 SPACER ASSY 1112990 1
M
1.5.1 FITTED BOLT M8X10X10 0124410 2
1.5.2 SPACER 90x116x60E * 1
1.5.3 LOCKING NUT M8 0145400 2
1A.a CRANKSHAFT E-RC212ES 2271201 1 2-cyl. compressor
1A.b CRANKSHAFT K-RC211ES 2271211 1 2-cilinder compressor, with approval
1B.a CRANKSHAFT E-RC312ES 2271300 1 3-cylinder Compressor
1B.b CRANKSHAFT K-RC311ES 2271310 1 3 cylinder compressor, with approval
1C.a CRANKSHAFT E-RC412ES 2271400 1 4-cylinder compressor
1C.b CRANKSHAFT K-RC411ES 2271410 1 4 cylinder compressor, with approval
1D.a CRANKSHAFT E-RC612ES 2271600 1 6-cylinder compressor
1D.b CRANKSHAFT K-RC611ES 2271610 1 6 cylinder compressor, with approval
1E.a CRANKSHAFT E-RC912ES 2271901 1 9-cyinder. Compressor
1E.b CRANKSHAFT K-RC911ES 2271911 1 9 cylinder compressor, with approval
1F.a CRANKSHAFT E-RC1212ES 2271001 1 12-cylinder compressor
1F.b CRANKSHAFT K-RC1211ES 2271011 1 12 cylinder compressor, with approval
2 KEY 22X14X120 1102012 1
3 HUB FIXING M24X108 1915211 1
4 LOCKING PLATE M24xM12 1114248 1
5 FLAT WASHER M12 1113601 1
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-04 PISTON AND CONNECTING ROD
160X40X145
1 PISTON ASSY 2471012 1
RC12E
26X40X120-R
1.1 GUDGEON PIN 2470040 1
C12E
1.2 PISTON Grasso 10 * 1
1.3 LOCKING RING 40 1104040 2
160X40X145R
1.4 SET OF PISTON RINGS C12E 0974163 1
2.4 BEARING SHELL 90x53 1144590 1

2.5 CONNECTING ROD BOLT MF16 0111810 2
M16 /
2.6 LOCKING RING SET 1139800 2 in two pieces
13-ST-G.V.
2.7 HEXAGON NUT MF16 0147805 2
S 275 RC12E For single stage compressors and LP-cylinders in
2A CONNECTING ROD LD 2471510 - two stage compressors only
(aluminium
2A.1 CONNECTING ROD alloy) * 1
For single stage compressors and LP-cylinders in

2A.2 BEARING BUSH 40X50X58 1146640 1 two stage compressors only ( will be replaced by
p/n 1146641 )
S275 RC12E
2B CONNECTING ROD 2471520 - For HP-cylinders of two stage compressors only
HD
(aluminium
2B.1 CONNECTING ROD * -
alloy)
2B.2 NEEDLE BEARING NK 40/30 1163430 2 For HD-cylinders two stage compressors only
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-05 CYLINDER AND VALVE-LIFTING MECHANISM ( from serial no. 03091531 )
1.1.A CYLINDER LINER ASSY RC12ES - SL 2371013 NH3 / R22 / R134A
1.1.B CYLINDER LINER ASSY RC12ES - SH 2371213 R404 / R507
1.1 CYLINDER LINER RC12E S 2370013 1
1.2.A CYLINDRICAL PIN RC12E - SL 1106587 8 NH3 / R22 / R134A
1.2.B CYLINDRICAL PIN RC12E - SH 1106588 8 for R404A / R507
0,63X 6,3X
1.3 PRESSURE SPRING 12,5X 36,5 1131059 8
1.4 FLAT WASHER M 5B 1113001 8

1.5 LOCKING RING 5 1103205 8
1.6.A CAM RING GR12E - L 2771190 1 NH3 / R22 / R134A
1.6.B CAM RING GR12E - H 2771195 1 R404 / R507
2 O-RING 1,78 x 212,5 0952198 1
For compressors up to serial no. 03091531 this
3 VALVE LIFTING MECHANISM RC12E 2070136 - item has to be ordered in combination with item
9 and 10
3.1 LEVER RC12ES 2770113 1
3.2 SET SCREW G27x15 1116113 1
3.3 HEXAGON NUT G27 0148027 1
3.4 SOCKET HEAD SCREW M6x25 0104325 1
3.5 LOCKING RING M6 1113064 1
3.6 CARRIER DISC 46x12NS 1125015 1
3.7 CYLINDRICAL PIN 8X45 1106845 1
3.8 O-RING 3.53x59 0952376 1
For compressors up to serial no. 03091531 this
9 CONTROL PISTON ASSY 2070134 1 item has to be ordered in combination with item
3 and 10
9.1 O-RING 2.62x32.99 0952284 1
9.2 CONTROL PISTON N GR12E 2770671 1
9.3 O-RING 2.62x32.99 0952284 1
4,0x 32x 3,5x
9.4 PRESSURE SPRING 1131340 1
53,5
For compressors up to serial number 03091531
10 PISTON HOUSING RC12E 2770013 1 this item has to be ordered in combination with
item 3 and 9
11 FLAT WASHER M10 1113501 4
13 COVER 40 0533040 1
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-06A SUCTION AND DISCHARGE VALVE - Application: NH3 / in Single & HP
two-stage compressors
1 PRESSURE SPRING 19x 88.75x 1131190 1

4.75x 135
2 DISCHARGE VALVE ASSY 12E-FF-L 2771220 1 SINGLE & HP TWO STAGE
2.1 LOCKING NUT M12 0145600 1
2.2 LOCKING NUT M6 0145300 6
2.3 SOCKET HEAD SCREW M6 X 40 0104340 3
2.4 VALVE PLATE 12E-FF-INW 2770410 1
2.5 VALVE PLATE 12E-FF-MID 2770420 1
2.6 VALVE PLATE 12E-FF-UITW-L 2770440 1
2.7 SET OF DISCHARGE VALVE RINGS 12E FF 2070040 1
129,8x153,8x
2.7.1 VALVE RING * 1
4
2.7.2 VALVE RING 69,8x93,8x4 * 1
129,8x154,1x
2.7.3 SINUSOIDAL SPRING 0,8x11,5 * 1
69,8x93,0x0,8
2.7.4 SINUSOIDAL SPRING x4,2 * 1
2.8 STROKE LIMITOR 12E-FF-L 2770470 1

2.9 FLAT WASHER M12 1113601 1
2.10 WASHER M6 1113301 9
2.11 STUD M12x80 0151680 1
SET OF SUCTION VALVE RINGS & in combination with p/n 2371013 / cylinder liner
3.A RC12E - FF - L 2070036 1
SPRINGS with "slots"
3.A.1 SINUSOIDAL SPRING 171 x 200 / E 1133273 2 Not loose available, only in a set.
3.A.2 VALVE RING 162 x 199 x 4 1134163 1 Not loose available, only in a set.
3.B SET SUCTION VALVE RINGS RC12E 2070032 1 in combination with p/n 2371012 / cylinder liner
with "holes".
3.B.1 SINUSOIDAL SPRING 171 x 200 / E 1133273 2 Not loose available, only in a set.
3.B.2 VALVE RING 162 x 199 x 4 1134162 1 Not loose available, only in a set
For correct disassembly and assembly of the
4 SPECIAL TOOL "FREE-FLOW VALVE" RC12E 7343170 1 "free flow" discharge valve
3. PARTS COMPRESSOR
Fig. 3-7 Grasso 12E-06A
3. PARTS COMPRESSOR

Fig. Grasso 12E-06B SUCTION AND DISCHARGE VALVE - Application: NH3 / in Booster & LP
two-stage compressors
1 PRESSURE SPRING 19x 88.75x 1131190 1

4.75x 135
2 DISCHARGE VALVE ASSY 12E-FF-B 2771210 1 BOOSTER & LP TWO STAGE
2.1 LOCKING NUT M12 0145600 1
2.2 LOCKING NUT M6 0145300 6
2.3 SOCKET HEAD SCREW M6 X 40 0104340 3
2.4 VALVE PLATE 12E-FF-INW 2770410 1
2.5 VALVE PLATE 12E-FF-MID 2770420 1
12E-FF-UITW-
2.6 VALVE PLATE B 2770430 1
2.7 SET OF DISCHARGE VALVE RINGS 12E FF 2070040 1
2.7.1 VALVE RING 129,8x153,8x * 1

4
2.7.2 VALVE RING 69,8x93,8x4 * 1
129,8x154,1x
2.7.3 SINUSOIDAL SPRING * 1
0,8x11,5
69,8x93,0x0,8
x4,2
2.8 STROKE LIMITOR 12E-FF-L 2770470 1
2.9 FLAT WASHER M12 1113601 1
2.10 WASHER M6 1113301 9
2.11 STUD M12x80 0151680 1
3.A SET OF SUCTION VALVE RINGS & RC12E A3-S-LP 2070039 1 in combination with p/n 2371013 / cylinder liner
SPRINGS with "slots".
170,6x198,7x
3.A.3 VALVE RING 3 1134165 1 Not loose available, only in a set.
SET OF SUCTION VALVE RINGS & RC12E in combination with p/n 2371012 / cylinder liner
3.B SPRINGS A3-G-LP 2070031 1 with "holes"
170,6x198,7x
3.B.3 VALVE RING 1134165 1 Not loose available, only in a set.
3
For correct disassembly and assembly of the
4 SPECIAL TOOL "FREE-FLOW VALVE" RC12E 7343170 1
"free flow" discharge valve
3. PARTS COMPRESSOR
Fig. 3-8 Grasso 12E-06B
3. PARTS COMPRESSOR

Fig. Grasso 12E-06C SUCTION AND DISCHARGE VALVE ( Application: R22 / R134A
19x 88.75x
1 PRESSURE SPRING 1131190 1
4.75x 135
3-RINGS, marked on top/bottom with "H", for
2 DISCHARGE VALVE ASSEMBLY RC12E S - LH 2771135 1
refrigerant FREON only.
2.2 LOCKING NUT M16 0145800 1
2.3 FLAT WASHER M16 1113801 1
2.4 SET OF DISCHARGE RINGS & SPRINGS RC12E (3) 2070035 1
71,4 x 55,4 x
0,7
126,1 x 110 x
0,7
98,8 x 82,8 x
0,7
2.4.4 SET OF VALVE RINGS RC12E * 1
2.5 VALVE SEAT RC12E L 2770270 1
2.6 STROKE LIMITOR RC12E H 2770370 1
3.A RC12E - FF - L 2070036 1
SPRINGS with "slots"
3.B SET SUCTION VALVE RINGS RC12E 2070032 1 in combination with p/n 2371012 / cylinder liner
with "holes".
3. PARTS COMPRESSOR
Fig. 3-9 Grasso 12E-06C
3. PARTS COMPRESSOR

Fig. Grasso 12E-06D SUCTION AND DISCHARGE VALVE ( Application: R404 / R507
19x 88.75x
1 PRESSURE SPRING 1131190 1
4.75x 135
2 DISCHARGE VALVE ASSY RC12E S - HH 2771136 1 3-RINGS
2.2 LOCKING NUT M16 0145800 1
2.3 FLAT WASHER M16 1113801 1
2.4 SET OF DISCHARGE RINGS & SPRINGS RC12E (3) 2070035 1
71,4 x 55,4 x
2.4.1 SINUSOIDAL SPRING 0,7 * 1
126,1 x 110 x
98,8 x 82,8 x
2.4.4 SET OF VALVE RINGS RC12E * 1

2.5 VALVE SEAT RC12 H 2770275 1 for R404A / R507
2.6 STROKE LIMITOR RC12E H 2770370 1
3.A SPRINGS RC12E - SH 2070037 1 with "slots".
in combination with p/n 2371012 / cylinder liner
3.B SET SUCTION VALVE RINGS RC12E 2070030 1
with "holes".
3. PARTS COMPRESSOR
Fig. 3-10 Grasso 12E-06D
3. PARTS COMPRESSOR

Fig. Grasso 12E-06E SUCTION AND DISCHARGE VALVE OVERVIEW
NAN OVERVIEW GRASSO 12E VALVES *
3. PARTS COMPRESSOR
Fig. 3-11 Grasso 12E-06E
3. PARTS COMPRESSOR

Fig. Grasso 12E-07 ROTARY SHAFT SEAL
1 SHAFT SEAL HOUSING RC12 2638012 1
4 ALU SEALING RING 13.5x20x1 0912014 1
5 PLUG G13S 0136134 1
6 SHAFT SEAL SET 085B 2038100 1
6.1 COUNTER-SLIP RING ASSEMBLY * 1
6.1.1 O-RING 101.1x3.53 0952390 1
6.2 SLIP RING ASSEMBLY * 1
6.2.1 O-RING 84.95x4.0 0952340 1
6.3 O-RING 3.53x145 0955257 1
8 BENT STEEL PRECISION TUBE 12x530 4405012 1
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-08 OIL PUMP
Important: In case the direction of rotation of
the oil pump is counter clockwise, when facing
1 OIL PUMP SET RC12 2038116 1 the (mounted] oil pump housing, the
non-standard oil pump assembly 2028117 is
required.
1.1.A. OIL PUMP HOUSING RC12 2638520 1 Standard
For Mark 1 design
1.1.B. OIL PUMP HOUSING Mark 1 2638521
For use with heavy duty thrust bearing
1.2 PUMP ELEMENT 2638130 1
1.3 HEXAGON HEAD BOLT M6x20 0110320 8
1.4 WASHER M6 1113301 8
1.5 CARRIER DISC 55x8 1125006 1
1.6 DOWEL PIN 6x18x3 1106617 1
1.7 GASKET 83x115x0.5 0903083 1
CONTROL OIL PRESSURE REGULATOR
2 2038120 1
SET
2.3 O-RING 3.53x21.8 0955212 1
LUBRICATION OIL PRESSURE
3 2038118 1
REGULATOR SET
3.3 O-RING 3.53x21.8 0955212 1
5 PLUG G21-BZK 0365821 5
6 T-COUPLING 6x6x6 0340406 1
8 SOCKET NIPPLE G13xG21 0302213 1
9 MEASURING COUPLING 8 mm 0645608 1
10 O-RING 3.53x21.8 0955212 2
11 O-RING 3.53x145 0955257 1
12 FLAT WASHER M12 1113601 7
13 HEXAGON NUT M12 0115610 7
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-09 OIL FILTERS
for both suction and discharge side and without
1A/B OIL FILTER HOUSING 24 * 1
filter
1.1 FILTER UPPER HOUSING * 1
1.2 SET OF SEALS 0990030 1
1.3 FILTER CUP * 1
1.4 RING NUT * 1
SUCTION OIL FILTER SET (BLUE
1.5 24 2038128 1
MARKED)
DISCHARGE OIL FILTER SET (GREY
1.6A 24 2038124 1
MARKED)
Check if the length of the oil charge filter is
HIGH CAPACITY OIL FILTER SET (GREY equal to the length of the oil suction filter cup
1.6B 2038125 1 of the compressor involved, if si, a longer oil
MARKED) discharge filter cup with Ref. Nr. 07.02.675 is
also required!
4 PLUG G21-BZK 0365821 2
6 O-RING 2.65x25 0952281 4
7 SWIVEL COUPLING 12G21 0339212 1
8 STOP VALVE TAH8-12 0607011 1
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-10 LUBRICATING OIL LINES
13.a OIL CONNECTING LINE 22x2x535 0412253 1 For 2 and 4 cylinder compressors
13.b OIL CONNECTING LINE 22x2x865 0412286 1 For 4 cylinder compressor
13.c OIL CONNECTING LINE 22x2x925 0412292 1 For 6 cylinder compressors
13.d OIL CONNECTING LINE 22x2x1315 0412213 1 For 9 cylinder compressors
13.e OIL CONNECTING LINE 22x2x1705 0412217 1 For 12 cylinder compressors
14 OIL INTAKE LINE * -
14.1 BENDED STEEL PRECISION PIPE 22x2x35x320 0438290 1
14.2 NIPPLE COUPLING 22G22x1 0338273 1
14.3 O-RING 3.53x21.8 0955212 1
14.4 CONNECTION LINE 22x2x32 0412232 1
15 O-RING 3.53x21.8 0955212 1
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-11 SUCTION GAS STRAINER
1 piece for RC2112(E) / 4212(E) - 2 for RC212(E)
1A SUCTION GAS FILTER SET RC12-2000 2038130 -
/ 312(E) / 412(E) / 3112(E) / 5112(E) / 612(E)
1A.1 OILIT SEALING RING 170x230x1.5 0903168 1
1A.2 GAUZE FILTER ELEMENT 2000 * 1
1B SUCTION GAS FILTER SET RC12-3000 2038131 - 1 piece for RC6312(E) / 8412(E) - 2 for RC912(E)
/ 7212(E) / 1212(E) / 9312(E) / 10212(E)
1B.1 OILIT SEALING RING 195x255x1.5 0903195 1
1B.2 GAUZE FILTER ELEMENT 3000 * 1
1B.3 O-RING 2.65x13.95 0952269 1
1B.4 CIRCLIP RING 14 1103014 1
1.3 O-RING 2.65x13.95 0952269 1
1.4 CIRCLIP RING 14 1103014 1
2x for RC312(E) / 612(E) / 5112(E) and 1 for
2A.1 SUCTION HOUSING COVER 236x118 0530240 - RC2112(E) / 4212(E)
2A.2 SUCTION HOUSING COVER 236x74.5 0530239 2 For RC212(E) / 412(E) / 3112(E)
2A.3 SUCTION HOUSING COVER 236 0530241 1 For RC211(2)E / 4212(E)
1 piece for RC6312(E) / 8412(E) - 2 for RC912(E)
2B.1 SUCTION HOUSING COVER 260x118 0530263 -
/ 7212(E) / 1212(E) / 9312(E) / 10212(E)
2B.2 SUCTION HOUSING COVER 260 0530262 1
1 piece for RC12(E) 2112/4212/6312/8412 - 2
for RC12(E)
3 SPRING RETAINER 14.5x45 4836015 -
212/312/412/612/912/3112/5112/7212/1212/
9312/10212
1 piece for RC12(E) 2112/4212/6312/8412 - 2
for RC12(E)
4 PRESSURE SPRING 6x40x2.7x42 1131601 - 212/312/412/612/912/3112/5112/7212/1212/
9312/10212
5A HEXAGON HEAD BOLT M16x40 0185840 8
5B HEXAGON HEAD BOLT M16x45 0185845 8
3. PARTS COMPRESSOR
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3. PARTS COMPRESSOR

Fig. Grasso 12E-12 High / Low PRESSURE RELIEF VALVES
On LP-side of two-stage compr. RC12(E)
(14.0 BAR) RELIEF VALVE - PRESSURE
1A DEPENDENT RC12-14 2839814 - 2112/311E/4212/5112/6312/7212/8412/9312/
10212
1B (22 BAR) RELIEF VALVE - PRESSURE RC12E-22 2839822 - For single stage compr./booster compr. RC12(E)
DEPENDENT 212/312/412/612/912/1212
1.1 VALVE GROUP 48 4827048 -
(23.0 BAR) RELIEF VALVE - PRESSURE On HP-side of two-stage compr./ single stage
2 RC12-23 2839823 - compr. and booster compr. acc. to DIN 8975
INDEPENDENT (whole range)
2.1 RELIEF VALVE HOUSING 48 1249212 1
2.2 O-RING 3.53x66.27 0955231 1
2.3 RELIEF VALVE ASSY 4827423 1
5 HEXAGON HEAD BOLT M12X95 0110696 2
9 O-RING 3.53x59 0952376 2
10 HEX. HEAD BOLT M12X40B 0110641 3
11 BLIND FLANGE 90X102 0504890 2
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-13 MAIN FLANGE SEALING RINGS
RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/
1.a GASKET 106x120x2 0904106 1
8412/ 9312/ 10212/ 412
RC12(E) 412/ 4212/ 6312/ 7212/ 8412/ 9312/
1.b GASKET 129x149x2 0904129 1
10212/ 612/ 912/ 1212
1.c GASKET 155x175x2 0904155 1 RC12(E) 612/ 912/ 1212/ 5112
RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/
1.d GASKET 95x109x2 0904095 1
8412/ 9312/ 10212
2.a GASKET 61x75x2 0904061 1 RC12(E) 2112/ 3112
RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/
2.b GASKET 95x109x2 0904095 1 8412/ 9312/ 10212
3.a GASKET 73x87x2 0904073 1 RC12(E) 2112/ 3112
3.b GASKET 106x120x2 0904106 1 RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212/ 412
4.a GASKET 95x109x2 0904095 1 RC12(E) 2112/ 3112/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212
4.b GASKET 106x120x2 0904106 1 RC12(E) 212/ 312/ 4212/ 5112/ 6312/ 7212/
8412/ 9312/ 10212/ 412
4.c GASKET 129x149x2 0904129 1 RC12(E) 412/ 4212/ 6312/ 7212/ 8412/ 9312/
10212/ 612/ 912/ 1212
4.d GASKET 73x87x2 0904073 1 RC12(E) 2112/ 3112
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR

Fig. Grasso 12E-14 STANDARD SETS OF PARTS, SEALS AND TOOLS
A BASIC GASKET / O-RING SET 2038017 1
for every two cylinders 1 set / for three cyl.
B ADDITIONAL GASKET / O-RING SET RC12(E) 2038018 - compr. 2 sets, for nine cyl. compr. 5 sets
C SET OF SPARE PARTS 2038021 1 for whole range
D SHAFT SEAL SET 085B 2038100 1
E SET OF TOOLS GRASSO 12E Grasso 12E 2070010 1 GRASSO 12E
3. PARTS COMPRESSOR
3. PARTS COMPRESSOR
4. SUPPLEMENTARY PARTS
Table of Contents
Parts List Page Figure

Grasso
THRUST BEARING MARK1.1. (from serial no. 03071378) 74 12E-E01
Grasso
COMPRESSOR HOUSING MARK1.1. 76
12E-E02
Grasso
OIL COOLER 78
12E-E03

Fig. Grasso 12E-E01 THRUST BEARING MARK1.1. (from serial no. 03071378)
For Mark 1 design
1 OIL PUMP HOUSING Mark 1 2638521 1
For use with heavy duty thrust bearing
140 x 95 x
2 SPRING RETAINER 2738700 1
23,5 MARK1
RC12(E)
3 DIE SPRING 1135225 6
MARK1
4 BEARING COVER P.Z. RC12(E) 2138824 1

MARK1
5 HOUSING RING 152 x 135 x 0938135 1

37,5 MARK1
6 THRUST WASHER RC12(E) 1148004 1

MARK1
7 CYLINDRICAL ROLLER THRUST RC12(E) 1148008 1

BEARING MARK1
8 SHAFT WASHER 133 x 90 x 76 x 1138090 1

15,5
9 NEEDLE THRUST BEARING RC12(E) * 1

MARK1
10 HOUSING WASHER RC12(E) 1148006 1

MARK1
11 CARRIER DISC 100 x 76 x 36 S 1125176 1
90 x 96 x 93
12 BEARING BUSH RC12(E) 1146093 1
MARK1
13 SETSCREW M12 x 16 0123616 1
SET OF SPARE PARTS THRUST BEARING
X 2038104 1
MARK1
COMPLETE SET THRUST BEARING
Y 2038105 1
MARK1
Fig. 4-1 Grasso 12E-E01

Fig. Grasso 12E-E02 COMPRESSOR HOUSING MARK1.1.
1 STUD ELBOW 22 x G27 0341322 1
2 STUD ELBOW 22 x G21 0341323 1
3 SERVICE COVER RC12(E) S 0530193 1

MARK1
4 BEARING COVER P.Z. RC12(E) 2138824 1

MARK1
5 PIPE STEEL 22 x 2 6105022 1

Fig. Grasso 12E-E03 OIL COOLER
1 SOCKET NIPPLE G33 x G27 0302228 2
2 STUD ELBOW 22 x G27 0341322 3
3 STUD ELBOW 22 x G21 0341323 1
RC12(E) S
4 SERVICE COVER 0530193 1
MARK1
5 OIL COOLER LKI 110 0726015 1
6 OIL COOLER VAN LKI 110 230V 0726014 1
7 THERMOSTAT RT 101 1256415 1
8 PIPE STEEL 22 x 2 6105022 2
5. MAINTENANCE
5. MAINTENANCE
Table of Contents
Section Title Page

5.1 SMS FACTOR 81
5.2 Grasso 12E 83
5.3 Checklist 85
5.1 SMS FACTOR
General
The running hours mentioned in the SMS tables should

only be used as a reference for maintenance intervals.
The running hours mentioned in the tables are based on

a single stage compressor running at -10oC/+35oC, NH3
at nominal speed. In this case the SMS factor = 1, in all
other cases the maintenance intervals have to be
adjusted accordingly.
The number of running hours mentioned in the SMS

tables have to be adjusted accordingly depending on the
operating conditions of the compressor (speed,
evaporating temperature, condensing temperature,
refrigerant, start frequency, capacity control steps, etc..
This means that the service intervals could be
significantly different.
5. MAINTENANCE
5. MAINTENANCE
5.2 GRASSO 12E
SERVICE AND MAINTENANCE SCHEDULES GRASSO 12E

Actions
Running hours * 1000a
3 6 - - -
9 - 12 - -
Item
Description Checkpoint
15 - 18 -
0.1 YEARLY
21 - - 24 - -
27 30 - - -
33 - - - 36
1 CL RE CL RE RE RE RE RE Oil suction filter
2 REb RE RE RE RE RE RE RE Oil discharge filterc
3 Oil - ME ME ME ME ME ME ME Oil analysis
Oil refreshment (If hygroscopical oil is used replace this
4 RE RE - RE RE RE RE RE always after each opening of compressor or
installation)
5 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Housing and element
Oil pump
6 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Control and lubrication oil pressure regulator
7a - - - - - - IC/ME IC/ME Main and intermediate bearing bushes
Running surfaces main and intermediate bearings
7b Crankshaft - - - - - - IC/ME IC/ME
crankshaft
8 - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Running surfaces con. rods
9 Shaft seal - IC IC IC IC IC IC IC Oil/refrigerant leakage
10 Conrod - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Big and small end bearings
11 - IC - IC IC IC IC IC Piston
12 Pistons - IC - IC IC IC IC IC Piston rings
13 - IC/ME - IC/ME IC/ME IC/ME IC/ME IC/ME Gudgeon pin
14 Thrust bearing - IV/ME - IV/ME IV/ME IV/ME IV/ME IV/ME Running surfaces/Axial play
15 IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Solenoid valves and coils
16 Capacity control - RE - RE IV IV RE RE Seals of cap. control piston
17 - IC - IC IC IC IC IC Cap. Control mechanism
18 IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV IC/IV Crankcase heater
19 CL CL - CL CL CL CL CL Crankcase
20 Compressor - - - - IC IC IC IC Non return valves LP/Restrictions HP
housing
21 - IV - IV IV IV IV IV Relief valves
d
22 RE IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL IC/CL Suction gas filter
23 Discharge valvese - IC - IC RE RE IC RE Valves, springs and damper rings
24 - IC/CL - IC/CL IC/CL IC/CL IC/CL IC/CL Stroke limitor/Discharge valve seat
25 Suction valvesf - IC - IC RE RE IC RE Valves, springs and damper rings
26 - IV - IV IV IV IV IV Cap. Control lifting mechanism
Cylinder liners
27 - IV/ME - IV/ME IV/ME IV/ME IV/ME IV/ME Dimension and running profile
28 IC IC IC IC IC IC IC IC Alignment
Drive
29 IC IC IC IC IC IC IC IC V-belts
30 Electric motor Refer to specifications of motor manufacturer
5. MAINTENANCE
SERVICE AND MAINTENANCE SCHEDULES GRASSO 12E

Actions
Running hours * 1000a
3 6 - - -
9 - 12 - -
Item
Description Checkpoint
15 - 18 -
0.1 YEARLY
21 - - 24 - -
27 30 - - -
33 - - - 36
31 IC IC IC IC IC IC CL/IC CL/IC Oil level switch
32 IC IC IC IC IC IC IC IC Safety switches
33 IC IC IC IC IC IC IC IC Gauges
34 IC IC IC IC IC IC IC IC Thermostats
35 IC IC IC IC IC IC IC IC Thermometers
36 IC IC IC IC IC IC IC IC Electrical control system
37 IC IC IC IC IC IC CL/IC CL/IC Valve oil return protection
38 IV IV IV IV IV IV IV IV Thermistors
39 Optionals IC IC IC IC IC IC IC IC Vibration dampers and bolts
40 IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME IC/ME Intermediate cooler and injection valve
Oil separator refreshing oil and cleaning/testing of float
41 CL CL - CL CL CL CL CL
valve
42 - IC IC IC IC RE IC IC Heavy duty thrust bearing
43 CL CL CL CL CL CL CL CL Oil cooler, air side
44 RE RE - RE RE RE RE RE Oil cooler, oil side, refrigeration oil
45 Refer to specifications of motor manufacturer Oil cooler, electic motor (fan)
46 ME ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL ME/CL Cylinder head water cooling system
a. Check after every maintenance job the settings and working of all safety devices, regulators and the running conditions according to the Service Instruction Manual
(SIM)
b. A running-in oil discharge filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter
is supplied togehter with the compressor.
c. Oil discharge filter change every 3000 hours or check optional pressure drop indicator
d. A running-in suction gas filter is factory mounted. This running-in filter has to be replaced after max. 100 running hours by a permanent filter. One permanent filter
is supplied together with the compressor
e. Discharge valves for compressors < machine number 00081502 must be changed every 6000 running hours in case not converted to latest standard
f. If the machine is running on refrigerant R507 or 404A suction valves must always be changed every 3000 running hours
Legend for service and maintenance schedules (SMS)

Item Code/Action Description
1 IC Inspection / Alternatively renewal - correcting / Testing
2 IV Inspection Visual / Alternatively electrical testing
3 RE Renewal
4 ME Measure
5 CL Clean
5. MAINTENANCE
5.3 CHECKLIST
SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS

Item
Description Checked/Remarks/Notes Checkpoint/Setting/Value
A Compressor type
B Machine number
C Date
D Running hours
E Refrigerant
E Evaporating temperature/pressure To/Po
F Intermediate temperature/pressure Tm/Pm
G Discharge temperature/pressure Tc/Pc
H Oil lubricating pressure
I Oil control pressure
J General Notes
1 Oil suction filter

2 Oil discharge filter
3 Oil Oil analysis
4 Oil refreshment (If hygroscopic oil is used replace this always after each
opening of compressor or installation)
5 Housing and element
Oil pump
6 Control and lubrication oil pressure regulator
7 Main and intermediate bearing bushes and running surfaces
Crankshaft
8 Running surfaces con. rods
9 Shaft seal Oil/refrigerant leakage
10 Conrod Big and small end bearings
11 Piston
12 Pistons Piston rings
13 Gudgeon pin
14 Thrust bearing Running surfaces/Axial play
15 Solenoid valves and coils
Capacity
16 Seals of cap. control piston
control
17 Cap. Control mechanism
5. MAINTENANCE
SERVICE AND MAINTENANCE SCHEDULES GRASSO RECIPROCATING COMPRESSORS

Item
Description Checked/Remarks/Notes Checkpoint/Setting/Value
18 Crankcase heater
19 Crankcase
20 Compressor Non return valves LP/HP
housing
21 Relief valves
22 Suction gas filter
23 Discharge Valves, springs and damper rings
valves
24 Stroke limitor/Discharge valve seat
25 Suction valves Valves, springs and damper rings
26 Cap. Control lifting mechanism
Cylinder liners
27 Dimension and running profile
28 Alignment
Drive
29 V-belts
30 Electric motor Consult motor manufacturer
31 Oil level switch
32 Safety switches
33 Gauges
34 Thermostats
35 Thermometers
36 Electrical control system
37 Valve oil return protection
38 Thermistors
Optionals
39 Vibration dampers and bolts
40 Intermediate cooler and injection valve
41 Oil separator refreshing oil and cleaning/testing of float valve
42 Heavy duty thrust bearing
43 Oil cooler, air side
44 Oil cooler, oil side, refrigeration oil
45 Consult motor manufacturer Oil cooler, electric motor (fan)
46 Cylinder head water cooling system
Table 5.3-1 Settings pressure safeties
Safety Remark Value

1 Suction pressure
2 LP discharge pressure (safety) two stage only
3 LP discharge pressure (limitor) two stage only, TUV
4 High pressure suction (safety) two stage only
5 High pressure (safety)
6 High pressure (limitor) TUV only
7 OIl differential pressure
6. APPENDIX; Product Information (PI)
Table of Contents
Section Title Page

6.1 GENERAL DATA 89
6.1.1 TECHNICAL DATA 89
6.1.2 MAIN DIMENSIONS AND SPACE REQUIREMENTS 91
6.1.3 SHAFT END COMPRESSOR 93
6.2 Electrical wiring schematic oil differential pressostat (RT260A) 95
6.2.1 Method A, two timers, recommended 95
6.2.2 Method B, one timer (method A is recommended) 96
6.3 LIMITS OF OPERATION AND FIELDS OF APPLICATION 97
6.3.1 GENERAL LIMITS AND FIELDS OF OPERATION GRASSO 12E 97
6.3.2 PRECISE FIELD OF APPLICATION 98
6.3.3 FIELDS OF APPLICATION SINGLE-STAGE AND BOOSTER 99
6.3.3.1 DIAGRAMS Grasso 12E 100
6.3.4 FIELDS OF APPLICATION TWO STAGE 102
6.3.4.1 FIELDS OF APPLICATION DIAGRAMS 102
6.3.5 LIMITATIONS OF PART-LOAD OPERATION 104
6.3.6 STARTING UP OF TWO-STAGE COMPRESSORS 104
6.4 LUBRICATING OILS (choice and recommendations) 107
6.4.1 Oil selection table 107
6.4.1.1 Remarks 107
6.4.2 Strongly recommended oil types for Grasso reciprocating compressors 107
6.4.3 Accepted NH3 and HCFC oil types for Grasso reciprocating compressorss 108
6.4.4 Accepted HCFC oil types for Grasso reciprocating compressors 108
6.5 CAPACITY CONTROL SYSTEMS 108
6.5.1 SURVEY CAPACITY CONTROL SYSTEMS AND UNLOADED START 108
6.5.2 ELECTRIC CAPACITY CONTROL AND FAST PULL DOWN (FPD) 110
6.5.2.1 GENERAL DIAGRAM OF ELECTRICALLY OPERATED CAPACITY CONTROL 110
6.5.2.2 DIAGRAMS 111
6.5.3 MANUAL CAPACITY CONTROL 115
6.6 PACKAGED BASE FRAME AND FOUNDATION BLOCK 117
6.6.1 PACKAGED BASE FRAME 117
6.6.1.1 PACKAGED BASE FRAME 117
6.6.2 BARE COMPRESSOR ON CONCRETE FOUNDATION BLOCK 119
6.6.2.1 FOUNDATION BLOCK 120
6.7 CRANKCASE HEATER 120
6.7.1 HEATER FITTING DETAIL 121
6.1 GENERAL DATA

6.1.1 TECHNICAL DATA
Table 6.1-1 Technical Data of Grasso 12E compressors
COMPRESSOR TYPE Grasso Single-stage Two-stage

12E 2 3 4 6 9 12 21 31 42 51 63 72 84 93 102
zL 2 3 4 5 6 7 8 9 10
Number of cylinders 2 3 4 6 9 12
zH 1 1 2 1 3 2 4 3 2
Cylinder
1xV 1xW 2xV 2xW 3xW 4xW 1xW 2xV 2xW 2xW 3xW 3xW 4xW 4xW 4xW
arrangement
Cylinder bore D 160
mm
Piston stroke S 110

n= 1200/min-1 n= 1500/min-1
(NH3)
398 597 796 1194 1792 2389 398 597 796 995 1194 1393 1592 1792 1991
LP Swept
m3/h
volume at Vs
(Halocarbons)
full-load and:
318 478 637 955 1433 1911 318 478 637 795 955 1115 1274 1433 1592
Ratio LP/HP swept

volume (ZL/ZH) at ϕ 2 3 2 5 2 3.5 2 3 5
full load
Standard direction
of rotation counter-clockwise when facing shaft end
1775 min-1 1475 min-1
(50 Hz)
Standard 585-656-738-831-937-1054-1171-1316a-1475a
compres-sor
min-1
speeds (with
V-belt drive) n
(60 Hz)
at motor
speed: 563-631-704-789-888-1000-1127-1268a-1409a
manual control:
100- 100- 100-

Sb 100- 100- 100- 83- 67- 89- 67- 83- 67-
50 67- 33 75- 50
50 - 33 44- 33 50- 25
100- 100-
100- 100- 100- 100-
Bc 50 67- 33 75- 50 83- 67- 67- 44 75- 58-
Standard 50 42
steps of
capacity 100-
100- 92- 83-
control 100- 100- 100- 100- 89- 78- 75- 67-
(expressed in Sb 83- 67-
% of % 50 67- 33 75- 50 50- 33 67- 56- 58- 50-
electrical control
44- 33 42- 33-

full-load 25
swept
volume): 100- 100-
Bc 100- 100- 100- 83- 67- 100- 75- 58-
50 67- 33 75- 50 67- 44
50 42
100- 100- 100-
100- 100-
Td 100 100- 100- 80- 60- 100- 86- 72- 75- 50- 78- 67- 80- 70-
67 75- 50 67- 33 57- 43- 56- 45- 60- 50-
40 29 25 33 30
Mass of bare
compressor
(without flywheel kg 553 660 810 1050 1390 1630 660 885 1100 1100 1440 1440 1700 1700 1700
and other
accessories)
COMPRESSOR TYPE Grasso Single-stage Two-stage

12E 2 3 4 6 9 12 21 31 42 51 63 72 84 93 102
Shipping mass kg 623 730 880 1150 1505 1760 730 955 1200 1200 1555 1555 1830 1830 1830
(approx.)
m3
Shipping volume 1.75 1.75 2.2 2.5 3.5 4.0 1.75 2.2 2.5 2.5 3.5 3.5 4.0 4.0 4.0
Oil charge in
dm3
crankcase and oil

circuit (centre line of 7.7 7.7 13.6 14.7 21.7 28.6 7.7 13.6 14.7 14.7 21.7 21.7 28.6 28.6 28.6
sight glass)
Mass moment of
0.3094
0.3527
0.4167
0.5018
0.7171
0.8939
0.3527
0.4167
0.5018
0.5018
0.7171
0.7171
0.8939
0.8939
0.8939
kg.m2
inertia of crank
mechanism Id
(without flywheel)
a. not applicable for halocarbons
b. Single stage
c. Booster
d. Two stage
6.1.2 MAIN DIMENSIONS AND SPACE

REQUIREMENTS
Table 6.1-2
COMPRESSOR
212 312 412 612 912 1212 2112 3112 4212 5112 6312 7212 8412 9312 10212
TYPE
Length A 977 987 1307 1377 1792 2182 987 1307 1377 1377 1792 1792 2182 2182 2182
Width B 1077 1171 1077 1171 1171 1171 1171 1110 1171 1171 1171 1171 1171 1171 1171
Height C 881 931 884 931 931 931 931 876 931 931 931 931 931 931 931
D 876 848 876 848 848 848 848 876 848 848 848 848 848 848 848
E 881 688 884 871 871 871 871 864 871 871 871 871 871 871 871
F 316 522 316 548 560 950 786 790 795 795 795 795 795 795 795
G 0 406 0 189 189 189 648 745 688 688 688 688 688 688 688
H 530 541 548 548 560 560 950 950 950
J 509 903 913 913 1315 1315 1705 1705 1705
K 149 224 163 163 163 163 163 163 163
L 195 108.5 195 195 195 195 195 195 195
M 406 331 406 406 406 406 406 406 406
N 205 205 205 205 217 217 205 205 205 205 217 217 217 217 217
O 295 295 625 685 1075 2x732.5 295 625 685 685 1075 1075 2x732.5 2x732.5 2x732.5
P 345 345 345 345 369 369 345 345 345 345 369 369 369 369 369
COMPRESSOR
212 312 412 612 912 1212 2112 3112 4212 5112 6312 7212 8412 9312 10212
TYPE
MINIMUM REQUIRED FREE SPACE for removal of:
flywheel U 700 700 700 700 700 700 700 700 700 700 700 700 700 700 700
crankshaft V 875 875 1205 1265 1655 2045 875 1205 1265 1265 1655 1655 2045 2045 2045
piston and Wa 1010 1160 1010 1160 1160 1160 1160 1010 1160 1160 1160 1160 1160 1160 1160
cylinder liner X 460 595 460 595 595 595 595 460 595 595 595 595 595 595 595
LOCATION OF CENTRE OF GRAVITY
length Y 197 197 280 405 600 795 197 280 405 405 600 600 795 795 795
width Z 405 423 423 435 440 445 423 423 435 435 440 440 445 445 445
MAIN CONNECTIONS DN (mm)
(LP) suction 1 80 80 100 125 125 125 65 65 100 125 100 100 100 100 100
LP dicharge/
2/3 50 50 80 80 80 80 80 80 80
HP suction
(HP) discharge 4 65 65 80 100 100 100 40 40 65 65 65 65 65 65 65
AUXILIARY CONNECTIONS
b
suction 5
pressure
LP discharge 6
pressureb
HP suction 7
pressure
dicharge 8 1/4” BSP (plugged off)
pressureb
Crankcase 9
pressure
lubricating oil 10
pressure
Oil 11
temperature
Oil charge and 12 1/2” BSP (plugged off; separate stop valve, type TAH8, supplied loose with the compressor)
drain valve
Return from oil
separator or 13 1/2” BSP (plugged off; separate swivel coupling, supplied loose with the compressor)
rectifier
Crankcase
heater 14 1/2” BSP (plugged off) to suit thread of heating element
Oil leakage
drain of rotary 15 clamp coupling provided with ø12x1.5 mm steel precision tube
shaft seal
Control oil
16 T-coupling
pressure
a. Minimum required free space for interstage cooling system A or B.
b. When a microprocessor is applied (see also the relevant Data Sheet), these auxiliary connections are provided with a swivel coupling with two connections. The
straight-through and side connection of this swivel coupling are provided with a clamp coupling for ø6x1 mm steel precision tube, in order to accomodate the
temperature sensor element and the steel precision tube for the pressure transducer respectivily.
6.1.3 SHAFT END COMPRESSOR
Fig. 6.1-1 Shaft end compressor
6.2 ELECTRICAL WIRING SCHEMATIC OIL There are 2 methods by which to protect the
compressor, method A and method B, as described
DIFFERENTIAL PRESSOSTAT (RT260A) below.
General
If timer 1 (T1) has expired and the required oil pressure
The oil differential pressure switch should be overridden: has not been reached then the compressor must be
i) during starting (to allow the compressor to achieve
the required oil pressure) stopped inmediately
ii) during normal operation (to avoid nuisance trips due
to system fluctuations 6.2.1 METHOD A, TWO TIMERS, RECOMMENDED
Fig. 6.2-1 Recommended wiring diagram, incl. start-up delay timer
By the use of 2 timers:

1 Timer 1 (T1) for the avoidance of nuisance trips
during running. Set time is a maximum of 10 seconds
2 Timer 2 (T2) for start-up override. Set time is a
maximum of 30 seconds and is active once from
start-up. This timer overrides Timer 2
6.2.2 METHOD B, ONE TIMER (METHOD A IS

RECOMMENDED)
Fig. 6.2-2 Alternative wiring diagram method B, without start-up delay

timer
By the use of one timer (T1) set at a maximum of 15

seconds for both starting and running.
6.3 LIMITS OF OPERATION AND FIELDS OF The diagrams overleaf represent the overall fields of
application in which the individual operation limits are
APPLICATION taken into account.
6.3.1 GENERAL LIMITS AND FIELDS OF OPERATION Table 6.3-1 General limits and fields of operation
GRASSO 12E
1. In practice, it is not so much the individual operation limits as combinations of
When operating the compressor, none of the limits of them that are decisive for the conditions under which a compressor may
operation as stated in the table below must be operate. To check the various possibilities in this respect, use should be made
exceeded.1 of the "fields of application" ).
REFRIGERANT NH3 R22 R134a R404Aa R507a

min. 500
Compressor speed n min-1
max. 1500 1200
min. 0.3
Suction pressure = evaporating pressure c -1
po bar(a) >= 1100 min 3.7
=crankcase pressureb max. 7.0 6.2
< 1100 min-1 4.7
min. -55.1 -63.8 -50 -68.1 -68.5
Evaporating temperature = saturation -1
to °C >= 1100 min -14.0 -15.0
temperature at suction pressureb max. +13.8 +10.9 +22.6
-1
< 1100 min -7.0 -8.0
Suction superheat/intermediate superheat ∆t °C min. 0 15
min. 0.3
-1
Intermediate pressure c pm bar(a) >= 1100 min 3.7
max. 7.0 6.2
< 1100 min-1 4.7
min. -55.1 -63.8 -50 -68.1 -68.5
-1
Intermediate temperature tm °C >= 1100 min -14.0 -15.0
max. +13.8 +10.9 +22.6
< 1100 min-1 -7.0 -8.0
Actual suction temperature ta °C min. -50
cd
Discharge pressure = condensing pressure pc bar(a) max. 24.0
Design pressuree bar(a) - 26.5
Condensing temperature = saturation
temperature at discharge pressure tc °C max. +56.5 +59.5 +75.8 +52.0 +52.8
f
Discharge temperature te °C max. +170
min. 1.5
g
Pressure ratio per stage (pc/po or pc/pm or pm/po) j -
max. 10 15
Pressure difference ch ∆p bar max. 19.0
min. +20 +30
i
Oil temperature in crankcase toil °C
max. depending on type of oil, refer Section 6.4
a. Minimum superheat 15 K. Grasso advises a condensing temperature > +35 oC, to avoid condensation of refrigerant in the compressor.
b. For halocarbon refrigerants the maximum values of p0 and t0 are based on a density of the suction gas of 30 kg/m3. In single stage operation during start-up and
immediately thereafter, t0, max may be exceeded slightly and only temporarily. In any case p0 should drop to at least given value in table within 5 minutes after
starting.
c. 1 bar = 105 N/m2 = 100 kPa = 1.02 kgf/cm2 = 14.5 psi.
d. This pressure is also the maximum allowable pre-set value of the HP safety switch. CAUTION!: When adjusting the HP and/or LP safety switch, care should be taken
that the pressure difference ∆p=(pC-po) never exceeds 19.0 bar.
e. This pressure deviates from the so called max. discharge pressure=condensing pressure (allowed during operation) as stated in the table.
f. This is the actual discharge temperature, measured directly in the gas flow just before the discharge connection. The given value also applies to the LP stage of
two-stage compressors.
g. Pressure ratio limits are not absolute but arbitrary values based on practical considerations.
h. The standard built-in overflow safety valve(s) between suction and discharge side has been factory-set to 22.0 ≤ 1.5 bar to prevent advanced opening during normal
operation at ∆p = (pc - po) ≤19.0 bar.
i. Indicated minimum value is the lowest oil temperature at which the compressor is allowed to be started. The maximum oil temperature depends on the operating
conditions of the compressor, the oil type used and (for halocarbon refrigerants only) the solubility of the refrigerant in the oil. A minimum actual oil viscosity of 10
cSt is always required.
6.3.2 PRECISE FIELD OF APPLICATION
The field of application diagrams as shown in this manual

can vary slightly from the actual field of application for
each particular selection.
The actual field of application is dependent on

refrigerant, type of compressor, speed, suction
superheat, partload steps (different pressure ratios) and
interstage cooling system.
Always consult Grasso's software program, COMSEL, to

determine the precise field of application for an actual
compressor selection.
6.3.3 FIELDS OF APPLICATION SINGLE-STAGE AND

BOOSTER
General
Application of part-load operation for a long period of
time and/or superheat > 0 K results in higher discharge
temperatures. Consequently the fields of application for
single-stage and booster compressors will be reduced. So
line te-max will shift downwards for NH3.
Symbols used in diagrams

to = evaporating temperature
po = evaporating pressure
tc = condensing temperature
pc = condensing pressure
∆to = suction superheat
j = pressure ratio = (pc / po)
∆p = pressure difference = (pc - po)
te,max = maximum discharge temperature
↓ = Line shift downwards for ∆to > 0 K and/or
part-load operation
Procedure and data

• Diagrams in Section 6.3.3 are based on continuous
full-load operation, suction superheat = 0 K.(15 K for
R404A and R507)
• For continuous minimum part-load (i.e. more than 30
minutes) consult Grasso.
Hatched section ‘A’; These parts of the general field of

application are not covered by the compressor selection
software COMSEL. Please consult Grasso to make a
selection of those applications.
6.3.3.1 DIAGRAMS GRASSO 12E
Fig. 6.3-1 Fields of application NH3
Fig. 6.3-2 Fields of application
REMARK: A) not allowed for speeds > 1100 min-1
6.3.4 FIELDS OF APPLICATION TWO STAGE
General
The fields of application for two stage compressors are
(besides superheat and part-load operation) very
dependant on ϕ(ratio LP/HP swept volume; full-load and
part-load can have different values). Because each
capacity control step can have a different ϕ, it is very
important to check for every control step (especially
during starting up!) that the compressor will run with-in
its limits of operation.
Refer to Starting Up Procedure and Limitations of

Partload Operation (Section 6.3.5/Section 6.3.6)
Symbols used in diagrams

to = evaporating temperature
po = evaporating pressure
tc = condensing temperature Fig. 6.3-3 Dummy diagram
pc = condensing pressure
Table 6.3-2 Dummy Diagram; Explanation two stage field of
tm = saturation intermediate temperature
application
j = pressure ratio = (pc / po, pc / pm or pm / po)
∆p = pressure difference = (pc - po) Legend
te,max = maximum discharge temperature
teH,max = maximum discharge temperature HP Area on the right side of this line indicates the
single stage field of operation (starting up). This
ϕ = ratio LP/HP swept volume (full-load and part-load line shifts down in case of continuous part-load
can have different values) Jmax / te,max
operation and/or (intermediate) superheat.
↓ = Line shift downwards for ∆to > 0 K and/or Superheat also results in limited part-load
part-load operation operation.
Maximum HP-discharge temperature (not
applicable for halocarbons). This line shifts down
Procedure and Data teH,max / te,max in case of continuous part-load operation and/or
• Two stage fields of application are variable (intermediate) superheat. Superheat also results
in limited part-load operation.
depending on types of compressors and/or part-load
steps. Each ϕ (phi) has its own field of appication. The
All compressor types are included within the total ϕ higher this value, the lower possible evaporating
temperature. For each capacity control step field
field of application. of application must be verified in relation with ϕ.
• Diagrams overleaf are based on LP and HP suction
superheat 0 K resp. 15 K1. Po,min Minimum suction pressure (evaporating)
tm,max Maximum intermediate pressure.
For continous part-load (i.e. more than 30 minutes)

6.3.4.1 FIELDS OF APPLICATION DIAGRAMS
consult Grasso.
• The Dummy diagram shows field of application for
different ϕ's.
• Shaded areas are fields of single-stage operation
(used and allowed only during starting up
compressor).
• Each ϕ has its own field of application (Example; see
dummy diagram ϕ= X area)
• ϕ = 1 is "Fast Pull Down" capacity control step
(option), to be used during starting up compressor
only. Refer to starting up procedure (Section 6.3.6)
1. Minimum superheat R404A and R507; 15K
Fig. 6.3-4 Field of application two-stage NH3
Fig. 6.3-5 Field of application two-stage R404A and R507
Fig. 6.3-6 Field of application two-stage R22
6.3.5 LIMITATIONS OF PART-LOAD OPERATION that, when cylinders are switched on or off under
constant (design) conditions of operation, the
corresponding working point (= combination of
Limitations of part-load operation for single-stage condensing temperature tc and evaporating
compressors temperature to) lies outside one or more of the relevant
In the case of continuous single-stage part-load fields of application.
operation of Grasso compressors with the refrigerant This implies that it is not allowed to use the part load
NH3, not all standard capacity control steps can be used steps concerned, either on account of too high a H.P.
under all operating conditions. There is a limitation with discharge temperature in case of NH3 only (working
respect to minimum capacity, which, depending on the point lies to the left of the field of application), or on
amount of suction superheat, is determined by the account of too high a saturation intermediate
maximum discharge temperature of 170 °C. This means temperature / intermediate pressure (working point to
that the full-load field of application as shown in the the right of the field of application). In the case of
NH3- diagram, is reduced at top-left for part-load electrical capacity control, such disallowed part-load
operation in a way as indicated by the arrows in the the steps can easily be avoided in actual practice by adapting
relevant diagram. accordingly the wiring diagram for energising the
This part-load restriction cannot be eliminated by three-way solenoid valves.
applying a cooling system on the cylinder head.
When, on the contrary, the refrigerants R134a, R22,
R404A and R507 are used for continuous single-stage Electrical capacity control is mandatory for two-stage
part-load operation of all standard capacity control compressors.
steps, the same operating conditions are allowed as for
full-load operation with all cylinders energised. In other
words, the full-load fields of application, also remain Apart from the above-mentioned inadmissibility of
valid for part-load operation down to and including the
standard minimum capacity step. certain standard part-load control steps, care should
Only under very extreme conditions with respect to always be taken to ensure that the capacity of two-stage
ambient temperature (e.g. above approx. +40 °C) compressors is never reduced to such an extent that only
and/or suction superheat (e.g. more than approx. 30 K) H.P. cylinders remain operative.
the situation may occur that during part-load operation
the maximum discharge temperature of 170 °C and/or For then the compressor would operate as a single- stage
the maximum oil temperature are/is exceeded, which machine, but under two-stage conditions, which would
implies that in these cases it is not permitted to switch off result, in particular for NH3, in an unacceptably high
cylinders down to the standard minimum capacity. discharge temperature. This restriction means that the
In such a case the oil temperature is the decisive factor, three-way solenoid valves should be wired so that, when
the limitation mentioned before can be avoided by the compressor is running under design conditions, at
applying an oil cooler. For these special cases, always least one solenoid valve remains energised.
consult Grasso.
6.3.6 STARTING UP OF TWO-STAGE COMPRESSORS
In general the rule is that, irrespective of refrigerant and Procedure for starting from compressor standstill
conditions of operation, it is never allowed to run a In the case of two-stage compressors it is very important
compressor during a prolonged period of time fully that immediately after the period of automatic fully
unloaded, i.e. with all cylinders switched off. unloaded start (ensured by the corresponding three-way
solenoid valve in the control pressure supply line from
When using a Grasso compressor equipped with a the oil pump; only one or more H.P. cylinders become
standard capacity control such a situation is impossible operative, viz. only those cylinders of which the suction
because then, apart from the starting period, always one valve lifting mechanism is directly and permanently
or more cylinders are permanently connected to the connected to the control pressure supply of the oil pump
control oil pressure. via the starting solenoid valve mentioned. This means
that during starting none of the three-way solenoid
Limitations of part-load operation for two-stage valves for the capacity control are allowed to be
energized.
compressors
From the diagrams, it appears that for two-stage
compressors the field of application depends not only on Procedure to move on to two-stage operation and to
the kind of refrigerant but also on the ratio ϕ of L.P. and increase capacity.
H.P. swept volume. Once properly started, as indicated in the previous
This means (since the standard capacity control steps of paragraph, the compressor has to be switched over to
the individual two-stage types have not always the same two-stage operation with minimum capacity, followed, if
ϕ-value) that for the successive capacity control steps of and when required, by gradual stepping up to maximum
a certain compressor type different fields of application capacity.
may be valid. If this is the case, the situation may occur The procedure thereby to be applied depends on the
installation operating conditions during starting which

give rise to two distinct possibilities, viz.:
1. The compressor is started at low evaporating
temperatures, this being approx. the (design) value
during normal (full-load) operation.
This situation occurs after the compressor has been
stopped for a certain period of time because of low
capacity requirements of the installation. Under these
circumstances it is permitted to switch over to the
two-stage part-load step of minimum capacity
immediately after proper starting with H.P. cylinders
in operation.
In the case of NH3, this is even a necessity, for
otherwise the compressor would be running in
single-stage under two-stage conditions, resulting in
too high a discharge temperature.
2. The compressor is started at a relatively high
evaporating temperature, that is to say much
higher than under design conditions and in any case
not suitable for two-stage operation.
Such a situation may occur after a prolonged period
of compressor standstill or when the compressor
operates on a batch type freezing tunnel, just loaded
with warm products. Under these circumstances it is
not permitted to switch over to two-stage operation
with minimum capacity until the H.P. cylinders
already in operation have lowered (in single-stage)
the evaporating temperature so that the
corresponding working point at the condensing
temperature tc, lies inside the field of application of
the two-stage minimum part-load step concerned.
Only then, after this step has been energized, the
saturation intermediate temperature tm will be
below its maximum value. Consequently, the
maximum value of to at which it is allowed to switch
over to two-stage operation, is determined by the
intersection of the near-vertical line which represents
the right hand limitation of the relevant field of
application and the horizontal line which represents
the condensing temperature tc.
Likewise, during further stepping up to maximum
capacity, the evaporating temperature has to be
pulled down by each intermediate part-load step so
far that the corresponding working point at given
condensing temperature lies each time just inside the
field of application of the next part-load step of
higher capacity, before that step is energized.
Fast pull-down part-load control steps

When using the standard capacity control steps of the
two-stage compressor types, the pull-down procedure to
achieve full-load operation at design conditions, as
described in the previous paragraph, is rather often very
time consuming. This is due to the fact that all
compressor types are always started with only one HP
cylinder in operation and that the minimum LP/HP swept
volume ratio for any part-load step is ϕ = 2.
Therefore, for all Grasso two-stage types a fast pull-
down electric capacity control system has been
developed, which allows the compressors to be started
with two or more HP cylinders in operation and which
includes one or more part-load steps with volume ratio ϕ
= 1.
6.4 LUBRICATING OILS (CHOICE AND a. to,max is the saturated temperature, corresponding to maximum crankcase
RECOMMENDATIONS) pressure where at the usual oil temperatures the oil/refrigerant mixture has a
viscosity of > 10 cSt.
b. Refer to Section 6.4.1.1.
The choice of oil for a refrigeration compressor should be 6.4.1.1 REMARKS

made by taking into account the entire refrigeration 1. Using ISO VG100 oils to increase viscosity at high
system design and operation as well as the operating expected cranckcase-temperatures makes no sense as
conditions of the compressor. the friction-heat will increase that much, that the
oil-temperature limit related to the minimum viscosity
For lubrication of refrigeration compressors, several of 10 cSt will also be exceeded. Only in case of
brands and types of specially developed lubricating oils expected high refrigerant-concentrations in the
are on the market. The choice of oil depends not only on cranckcase this viscosity-gradeoil is an alternative!
its good lubrication properties (viscosity) and chemical 2. Using ISO VG46 oils to meet low pour point
stability at the operating conditions of the compressor, requirements is only acceptable if coupled to a high
but also on the operating conditions of the refrigerating viscosity-index of at least 100, otherwise the working
plant (solidifying and floc point, solubility). limits are so limited (again concerning the minimum
required oil-viscosity of 10 cSt) that it can be used in
Grasso has tested and approved for use in its medium evaporation-pressures, making no sense to
reciprocating-compressors the brands and types of oil as use them als a low pourpoint alternative!
listed tables below.
The choice of the lubricating oil depends on type of
refrigerant and the operating conditions of the Some of the oil types listed in the tables may be
compressor. marketed under other names and/or designations; these
The oil viscosity should always be more than 10 cSt. oils can also be used, provided their identity can be
A higher ISO-VG number should be chosen when proved beyond any doubt. Application of
refrigerant solubility in crankcase is expected to be high other/alternavive oils is not permitted without the
especially in case of HCFC’s and HFC’s. written consent of Grasso.
OIL SELECTION PROCEDURE:
Use the oil viscosity selection table to select oil viscosity 6.4.2 STRONGLY RECOMMENDED OIL TYPES FOR
required. The following page lists all oils approved by GRASSO RECIPROCATING COMPRESSORS
Grasso for reciprocating compressors.
Table 6.4-2 Strongly recommended oil types for Grasso reciprocating
6.4.1 OIL SELECTION TABLE compressors
Table 6.4-1 Oil selection table Refrigerant

Brand Type designation
used
Max. allowable CPI CP-1009-68

Refrigerant evaporating ISO VG-number, according to
used temperature ISO 3448 PETRO CANADA Reflo 68A
to,max (°C)a EXXON MOBIL SHC NH68a
46 68 100 NH3
NH3 - vb v vb Klüber Summit RHT-68
-50 v TEXACO Capella Premium 68
-30 v v SHELL Clavus S-68
-20 v a. Recommended for evaporating temperatures below -37 oC

HCFC’s
(R22) -10 v v
0 v
+10 v
-50 v v
-30 v v
HFC’s -20 v v
(R134a, R507,
R404A) -10 v v
0 v
+10 v
For all other refrigerants contact Grasso
Legend v Approved by Grasso
6.4.3 ACCEPTED NH3 AND HCFC OIL TYPES FOR 6.4.4 ACCEPTED HCFC OIL TYPES FOR GRASSO
GRASSO RECIPROCATING COMPRESSORSS RECIPROCATING COMPRESSORS
Table 6.4-3 Accepted NH3 and HCFC (e.g. R22) oil types for Grasso Table 6.4-4 Accepted HFC (e.g. R134a, R404A, R407c, R507) oil types
reciprocating compressors for Grasso reciprocating compressors
Brand Type designation ISO VG numbera Brand Type designation ISO VG

numbera
FC 46 44
AVIA Icematic SW 68 67
FC 68 65 CASTROL
Icematic SW 100 100
Energol LPT-F 46 54
BP Solest 68 64
Energol LPT 68b 68 CPI
Solest 120 131
CASTROL Icematic 299 56
ACD 68 M 70
CPI CP-1009-68 69 TOTAL
ACD 100 FY 98
Zerice S46 48
Reniso E 68 68
Zerice S68 68 FUCHS
EXXON MOBIL Reniso E 100 100
Arctic 300 68
Emkarate RL 68H 68
SHC NH68 68 ICI
Emkarate RL 100H 100
Reniso KS 46 47
FUCHS EXXON MOBIL EAL Arctic 68 63
Reniso KC 68 68
Clavus R68 66
KROON OIL Carsinus FC 46/68 46 SHELL
Clavus R100 94
PETRO CANADA Reflo 68Ac 58
Capella HFC 55 52.5
Kuwait Petroleum Q8 Stravinsky C 55
TEXACO Capella HFC 80 80
Clavus 46 46
Capella HFC 120 118
Clavus 68 68
a. Viscosity grade number designation according to ISO Standard 3448.
SHELL Clavus G 46d 46
Clavus G 68d 68
6.5 CAPACITY CONTROL SYSTEMS
Clavus G 100d 95
Suniso 3.5 GSc 43 6.5.1 SURVEY CAPACITY CONTROL SYSTEMS AND
Suniso 4 GSc 55
UNLOADED START
SUN-OIL
Suniso 5 Gc 94
General
Suniso 4 SAc 57
Capacity control of the compressor will be enabled by
Capella WF 68 65 raising and lowering the suction valves, by means of the
TEXACO
Capella Premium 68 67 control oil pressure from the oil pump. One of the
options mentioned below is compulsory.
TOTAL Luneria FR 68 68
Klüber Summit RHT-68 68
One of the options must be applied;
a. Viscosity grade number designation according to ISO Standard 3448. • Electric (compulsory for two-stage compressors);
b. Not miscible with R22 at low temperatures
c. NH3 only • Standard (recommended for single-stage and
d. For NH3 only possible if water and air are not present! booster compressors)
• 'Fast pull down' (FPD); obligatory for R404A and
R507 applications; recommended for all two-stage
compressors
• Manual (Not allowed for two-stage compressors)
In case manual or electric capacity control is applied, fully

unloaded starting of the compressor is ensured.
Unloaded start
Fully unloaded compressor starting is enabled by
energising the solenoid valve for unloaded starting. This
is a Normally Open valve in contrast with the solenoid
valves for capacity control which are Normally Closed.
This NO-solenoid valve has to be energised when starting
the electric motor and has to be De-energised when the
compressor is running (and the specified lubricating oil
pressure is reached), by means of an auxiliary time relay.
Time relay is not included within the scope of supply.
After fully unloaded compressor starting, this solenoid
valve must be DE-engergised allowing control oil
pressure to the control pistons of the cylinders and
causing these cylinders to become operative
automatically.
In the case of single-stage compressors, they are at the
same time the minimum number of cylinders that must
always remain energised during continuous operation.
For two-stage compressors only HP cylinders are
initialised, which, however, do not at the same time
represent the minimum capacity.
The other cylinders can be energised or de-energised in
one or more steps in a standard sequence for each type
of compressor.
It is possible that control oil pressure can remain in the

capacity control loading system even after the
compressor has been de-activated. On re-starting this
can cause the compressor to have partially loaded
cylinders.To prevent this, the remaining oil pressure has
to be released from the control system. Therefore, the
“NO” solenoid valve should be activated a minimum of
10 seconds before the compressor is started to ensure all
cylinders are fully unloaded. Furthermore, for a smooth
stopping characteristic, the “NO” solenoid valve can be
activated a maximum of 5 seconds before stopping the
compressor.
6.5.2 ELECTRIC CAPACITY CONTROL AND FAST

PULL DOWN (FPD)
General
Electric capacity control is compulsory in the standard
scope of supply for two stage compressors.
Procedure and data

• Refer to diagrams and figures below.
• The possible control steps and the number of
solenoid valves depends on type of compressor
Standard scope of supply

• One NO-solenoid valve (with LED indicator) for
unloaded starting (mounted).
• A number of NC- solenoid valves (each with LED
indicator; mounted).
• Oil pressure lines (mounted).
Options (for two-stage compressors only)

• Fast Pull Down control system
FPD is compulsory for R404A and R507.

The standard starting procedure which is contained in
the standard electrical capacity control, is only
suitable if the compressor is being started at design
evaporating temperature.
In case the compressor has to start frequently with
high evaporating temperatures (batch freezing, etc),
fast pull down capacity control is necessary to avoid
that the compressor runs continuously in part-load.
Legend
6.5.2.1 GENERAL DIAGRAM OF ELECTRICALLY
OPERATED CAPACITY CONTROL A Top view of compressor
B Valve lifting mechanism
C Oil return from valve lifting mechanisms to crankcase
D Oil pump
E Electrical wiring to star/delta switch of the motor
H Supply of oil (control pressure)
NO Normally Open; 3-way solenoid valve for unloaded starting
NC Normally Closed; 3-way solenoid valve for capacity control
6.5.2.2 DIAGRAMS
Table 6.5-1 Solenoid valve/cylinder numbering for electric capacity

control
HP cilinders No.
Solenoid
FPDb UNLd No. 1 No. 2 No. 3 No. 4
Compressor NC c
NOe
NC NC NC NC
typea
Cylinder number / solenoid valves
4 - - 1+2 3 4 - -
6
- - 1+3 6 4 5 2
Single stage
2+3+
6 Booster - - 6 4 1 -
5
9 1+2+ 4+7+
- - 8 5+6 -
Single stage 3 9
9 1+3+ 4+7+
- - 2+6 - -
Booster 5+8 9
12 1+2+ 4 + 10 6 + 7 +
- - 11 5+8
Single stage 3 + 12 9
1+2+
12 7 + 10
Booster - - 3+4+ 5+8 6 + 11 + 12 -
9
31 2 - 2 1+3 4 - -
31 + FPD 2 1 2 3 4 - -
42 3+6 - 3 1+2 5 4+6 -
42 + FPD 3+6 6 3 1+2 5 4 -
51 3 - 3 1+2 6 5 4
51 + FPD 3 1 3 2 6 5 4
63 3+6 - 3 1+ 2 5+8+ 4+7+ -

+9 9 6
63 + FPD 3+6 6 3 1+ 2 5+8+ 4+7 -

+9 9
72 3+6 - 3 1+2 7 5+6+ 4+9

8
72 + FPD 3+6 6 3 1+2 7 5+8 4+9
3+6
5+7+ 8+9+ 4+6+
84 +9+ - 3 1+2 12 11 10
12
3+6 8+9+ 4+6+
84 + FPD +9+ 12 3 1+2 5+7
12 11 10
3+6 1+5+ 2 + 4 + 6 + 11
93 +9 - 3 7 8 9 + 10 + 12
3+6 1+5+ 2+4+ 11 +
93 + FPD +9 6 3 7 8 9 + 10 12
1+2+ 10 + 7+8+
102 3+6 - 3+6 9 4+5 12 11
10 + 7+8+
102 + FPD 3+6 9 3+6 1+2 4+5 12 11
a. Explanation; 2=Grasso 12(E), 21=Grasso 2112(E)
b. FPD= Fast Pull-Down
c. NC= Normally closed
d. UNL= Unloaded starting
e. NO= Normally open
Table 6.5-2 Capacity control steps
Capacity %a
Solenoids
Capacity %a
Compressor
Solenoids
type Remarks Cylinders ϕb
Compressor b
type Remarks Cylinders ϕ
25 - 1+2+3 - -
50 - 1+2 - - 33 - 1 + 2 + 3 + 11 1 -
4
single stage & 75 - 1+2+3 1 - 1+2+3+5
Booster 42 - +8 2 -
100 - 1+2+3+4 1+2 -
1+2+3+5
33 - 1+3 - - 50 - 1+2 -
+ 8 + 11
50 - 1+3+6 1 - 1+2+3+4
67 - 1+3+4+6 1+2 - 58 - + 10 + 11 + 1+3 -
6 12
single stage 1+3+4+5 1+2+
83 - +6 3 - 1+2+3+4
67 - + 5 + 8 + 10 + 2+3 -
1+2+3+4 1+2+ 12 12
100 - +5+6 3+4 - single stage
1+2+3+5
50 - 2+3+5 - - 75 - +6+7+8+ 1+2+ -
4
9 + 11
67 - 2+3+5+6 1 -
1+2+3+4
6 1+3+
2+3+4+5 83 - +6+7+9+ 4 -
Booster 83 - 1+2 - 10 + 11 + 12
+6
1+2+3+4 1+2+ 1+2+3+4 2+3+
100 - - 92 - +6+7+8+ -
+5+6 3 4
9 + 10 + 12
33 - 1+2+3 - -
1+2+3+4
44 - 1+2+3+8 1 - +5+6+7+ 1+2+
100 - -
8 + 9 + 10 + 3 + 4
56 - 1+2+3+5 2 - 11 + 12
+6
42 - 1+2+3+4 - -
67 - 1+2+3+5 1+2 - +9
+6+8
9 1+2+3+4
single stage 1+2+3+4 58 - 1 -
78 - 1+3 - +5+8+9
+7+8+9
12 1+2+3+4
1+2+3+4 booster 75 - +5+6+8+ 1+2 -
89 - +5+6+7+ 2+3 - 9 + 11
9
1+2+3+4
1+2+3+4 +5+6+7+ 1+2+
100 - +5+6+7+ 1+2+ - 100 -
8 + 9 + 10 + 3
-
3
8+9 11 + 12
44 - 1+3+5+8 - - 0 Starting only 2 - 0.0
1+2+3+5 31 67 - 1+2+3 1 2.0
9 67 - +6+8 1 -
Booster 100 - 1+2+3+4 1+2 3.0
1+2+3+4
100 - +5+6+7+ 1+2 - 0 Starting only 2 - 0.0
8+9
33 Starting only 1+2 FPD 1.0
31 + FPD 1+
67 - 1+2+3 FPD 2.0
1+2+
100 - 1+2+3+4 FPD 3.0
0 Starting only 3 - 0.0

50 - 1 + 2+ 3 1 2.0
42 75 - 1+2+3+5 1+2 3.0
1+2+3+4 1+2+
100 - +5+6 3 2.0
Capacity %a
Capacity %a
Solenoids
Solenoids
Compressor Compressor
type Remarks Cylinders ϕb type Remarks Cylinders ϕb
0 Starting only 3 - 0.0 0 Starting only 3 - 0.0

0 Starting only 3+6 FPD 0.0 29 - 1+2+3 1 2.0
50 - 1+2+3 1 2.0 43 - 1+2+3+7 1+2 3.0
50 Starting only 1+2+3+6 1+ 1.0 57 - 1+2+3+5 1+3 2.0

FPD +6+8
42 + FPD
75 - 1+2+3+5 1+2 3.0 72 1+2+3+5 1+2+
72 - +6+7+8 3 2.5
75 - 1+2+3+5 1+2+ 1.5
+6 FPD 1+2+3+4
86 - +5+6+8+ 1+3+ 3.0
4
1+2+3+4 1+2+ 9
100 - 3+ 2.0
+5+6 FPD 1+2+3+4
1+2+
100 - +5+6+7+ 3+4 3.5
0 Starting only 3 - 0.0 8+9
40 - 1+2+3 1 2.0 0 Starting only 3 - 0.0
60 - 1 + 2 +3 + 6 1+2 3.0 0 Starting only 3+6 FPD 0.0
51
1+2+3+5 1+2+ 29 - 1+2+3 1 2.0
80 - +6 3 4.0
29 Starting only 1+2+3+6 1+ 1.0

1+2+3+4 1+2+ FPD
100 - +5+6 3+4 5.0
43 - 1+2+3+7 1+2 3.0
1+2+3+6 1+2+
20 Starting only 1+3 FPD 1.0 43 - 1.5
+7 FPD
1+ 72 + FPD 1+2+3+5 1+3+
40 - 1+2+3 2.0 57 - 2.0
FPD +6+8 FPD
1+2+ 1+2+
60 - 1+2+3+6 3.0 1+2+3+5
51 + FPD FPD 72 - 3+ 2.5
+6+7+8
FPD
1+2+
1+2+3+5
80 - +6 3+ 4.0 1+2+3+4 1+3+
FPD 86 - +5+6+8+ 4+ 3.0
9 FPD
1+2+3+4 1+2+
100 - 3+4+ 5.0 1+2+3+4 1+2+
+5+6 FPD 100 - +5+6+7+ 3+4+ 3.5
8+9 FPD
33 - 1+2+3 1 2.0
25 - 1+2+3 1 2.0
1+2+3+5
63 67 - 1+2 2.0
+8+9 1+2+3+5
50 - 1+2 2.0
+ 7 + 12
1+2+3+4
1+2+
100 - +5+6+7+ 3 2.0 84 1+2+3+5 1+2+
8+9 75 - +7+8+9+ 2.0
11 + 12 3
1+2+3+4
0 Starting only 3+6 FPD 0.0 +5+6+7+ 1+2+
100 - 2.0
8 + 9 + 10 + 3 + 4
33 - 1+2+3 1 2.0 11 + 12
33 Starting only 1+2+3+6 1+ 1.0
FPD
63 + FPD 1+2+3+5
67 - 1+2 2.0
+8+9
67 - 1+2+3+5 1+2+ 1.3

+6+8+9 FPD
1+2+3+4 1+2+
100 - +5+6+7+ 3+ 2.0
8+9 FPD
Capacity %a
Capacity %a
Solenoids
Solenoids
Compressor Compressor
type Remarks Cylinders ϕb type Remarks Cylinders ϕb
0 Starting only 3 - 0.0 0 Starting only 3+6 - 0.0

0 Starting only 3 + 12 FPD 0.0 1+2+3+6
30 - 1 1.5
+9
25 - 1+2+3 1 2.0
1+2+3+6
1+ 50 - 1+2 2.5
25 Starting only 1 + 2 + 3 + 12 1.0 + 9 + 10 + 12
FPD
1+2+3+6
1+2+3+5 1+2+ 60 - +7+8+9+ 1+4 3.0
84 + FPD 50 - + 7+ 12 FPD 2.0
11
1+2+3+5 1+2+ 102 1+2+3+4
75 - +7+8+9+ 3+ 2.0 70 - +5+6+9+ 1+2+ 3.5
11 + 12 FPD 3
10 + 12
1+2+3+4 1+2+3+6
1+2+ 1+2+
100 - +5+6+7+ 3+4+ 2.0 80 - +7+8+9+ 4.0
8 + 9 + 10 + 4
FPD 10 + 11 + 12
11 + 12
1+2+3+4
0 Starting only 3 - 0.0 +5+6+7+ 1+2+
100 - 8 + 9 + 10 + 3 + 4 5.0
33 - 1+3+5+7 1 3.0 11 + 12
2+3+4+8 0 Starting only 3+6 - 0.0
45 - 2+3 2.0
+ 9 + 10
20 Starting only 1+2+3+6 1 1.0
1+3+5+6
56 - 1+4 2.5
+ 7 + 11 + 12 1+2+3+6 1+
30 - 1.5
+9 FPD
1+2+3+4
93 67 - +5+7+9+ 1+3 3.0
40 - 1+2+3+6 1+2 2.0
10 + 10 + 12
1+2+3+4 1+2+ 1+2+3+6 1+2+
78 - +5+7+8+ 3.5 50 - 2.5
3 + 9 + 10 + 12 FPD
9 + 10
1+2+3+6 1+4+
1+2+3+4 60 - +7+8+9+ 3.0
+5+6+7+ 1+2+ 11 FPD
100 - 3.0
8 + 9 + 10 + 3 + 4
11 + 12 102 + FPD 1+2+3+4 1+2+
70 - +5+6+9+ 3+ 3.5
0 Starting only 3 - 0.0 10 + 12 FPD
0 Starting only 3+6 FPD 0.0 1+2+3+6 1+2+
80 - +7+8+9+ 4+ 4.0
33 - 1+3+5+7 1 3.0 10 + 11 + 12 FPD
33 - 1+3+5+6 1+ 1.5 1+2+3+4

+7 FPD +5+6+7+ 1+2+
90 - 8 + 10 + 11 + 3 + 4 4.5
44 - 2+3+4+8 2+3 2.0 12
+ 9 + 10
1+2+3+4
1+3+5+6 1+4+ 1+2+
56 - 2.5 100 - +5+6+7+ 3+4+ 5.0
93 + FPD + 7 + 11 + 12 FPD 8 + 9 + 10 +
11 + 12 FPD
1+2+3+4
67 - +5+7+9+ 1+3 3.0
a. Refer to the swept volume expressed as a percentage of the full-load swept
10
volume for single stage compressors, resp. LP full-load swept volume for
1+2+3+4 two-stage compressors.
78 - +5+7+8+ 1+2+ 3.5 b. Number of LP/ Number of HP cylinders
3
9 + 10
1+2+3+4
1+2+
100 - +5+6+7+ 3+4+ 3.0
8 + 9 + 10 +
11 + 12 FPD
6.5.3 MANUAL CAPACITY CONTROL
General
Instead of the recommended electric capacity control, a
manual operated capacity control system can be
delivered for single stage and booster compressors.
Electrical supply still required for the NO three-way

solenoid valve.
Manual capacity control system is equal to standard

electric control system with an extra an oil distributor
switch.
Capacity control steps are equal to electric capacity

control.
Procedure and data

• Refer to figure (oil distributor positioned in unloaded
start).
• Depending on type of compressor one or more of the
distributor ports may not be in use.
• Survey of capacity control steps for each position of
oil distributor handle refer to the relevant table in this
chapter.
• Electrical supply required for three-way solenoid valve
for unloaded starting.

• Three-way NO-solenoid valve for unloaded starting
(mounted on suction housing, not wired; refer to
Section 6.5.1.
• Oil distributor (mounted on suction filter housing).
• Oil pressure lines (mounted).
Fig. 6.5-1 Diagram of manually operated capacity control system
Legend
A Top view of compressor
B Valve lifting mechanism
C Oil return to crankcase
D Oil pump
E Electrical wiring to star/delta switch of the motor
G Solenoid valve for unloaded starting (NO)
H Supply of oil pressure
J Solenoid valve(s) for capacity control
NO/NC Normally Open/Normally Closed
ES Manual capacity control switch
Table 6.5-3 Solenoid valve/cylinder numbering for standard capacity

control steps
Capacity %
Cylinder number
Compressor
Remarks Position of handle of oil distributor
type
1 2 3 4 5
50 single stage and 2 - - - -
212 booster
100 - 1-2
33 3 - - - -
single stage and
312 67 booster - 1-3 - - -
100 - - 1-2-3 - -
50 1-2 - - - -
single stage and
412 75 booster - 1-2-3 - - -
100 - - 1-2-3-4 - -
33 1-3 - 4 5 2
50 - 1-3-6 - - -
67 single stage - - 1-3-4-6 - -
83 - - - 1-3-4-5-6 -
612 100 - - - - 1-2-3-4-5-6
50 2-3-5 - - - -
67 - 2-3-5-6 - - -
booster
83 - - 2-3-4-5-6 - -
100 - - - 1-2-3-4-5-6 -
38 1-2-3 - - - -
44 - 1-2-3-8 - - -
67 single stage - - 1-2-3-5-6-8 - -
88 - - - 1-2-3-4-5-6-7-8 -
912
100 - - - - 1-2-3-4-5-6-7-8-9
44 1-3-5-8 - - - -
67 booster - 1-2-3-5-6-8 - - -
100 - - 1-2-3-4-5-6-7-8-9 - -
25 1-2-3 - - - -
50 - 1-2-3-5-8-11 - - -
67 - - 1-2-3-4-5-7-8--11- - -
12
single stage
83 - - - 1-2-3-4-5-6-7-8--9 -
-11
1212 100 - - - - 1-2-3-4-5-6-7-8-9-

10-11-12
42 1-2-3-4-9 - - -
58 - 1-2-3-4-5-8-9 - -
booster 1-2-3-4-5-6-8-9-1
75 - - 1 - -
1-2-3-4-5-6-7-8-9-
100 - - - 10-11-12 -
6.6 PACKAGED BASE FRAME AND

FOUNDATION BLOCK
6.6.1 PACKAGED BASE FRAME
General
For mounting on a concrete foundation block, Grasso
can supply a standard welded steel base frame to
support compressor, motor and accessoiries.
Especially for vibration free operation on floors and on
roof tops, a base frame with vibration dampers can be
delivered (concrete foundation block can be omitted).
A. BASE FRAME FOR MOUNTING ON CONCRETE BLOCK

(“TRANSPORT BASE FRAME“)
Design Data
• Base frame to be placed on concrete foundation
block. For foundation block dimensions consult
Grasso. Fig. 6.6-1 Packaged base frame, direct drive with oil separator
• There should never be a direct rigid connection
whatsoever between the foundation block and the
floor or any other main part of the building.
• The concrete block should be extended down to any
subsoil.
Scope of supply
• Steel base frame, incl mounting of compressor,
electric motor and accessories.
B. BASE FRAME FOR MOUNTING ON VIBRATION

DAMPERS (TORSIONAL STIFF)
Design Data
• Frame to be placed direct on elevated floors and on
roof tops (structural floor should be designed to take
the weight of the packaged unit).
• Concrete foundation block can be omitted.
• The first two pipe supports must be secured to a solid
foundation.
• Horizontal piping must be arranged parallel to the
crankshaft of the compressor. Fig. 6.6-2 Packaged base frame, V-belt drive with oil separator
• Always consult Grasso for installation advice.
Scope of supply
• Steel closed box profile base frame, including
mounting of compressor, electric motor and
accessories.
• Set of vibration dampers.
6.6.1.1 PACKAGED BASE FRAME
Fig. 6.6-3 Packaged base frame (DD=Direct driven, VD=V-belt driven)
Dimensions Frames on vibration dampers
All dimensions and weights as mentioned are estimated Packaged base frame for mounting on vibration
values. Consult Grasso to determine exact values. dampers can be determined by Grasso on request.
Table 6.6-1 Weights and dimensions, direct driven 6.6.2 BARE COMPRESSOR ON CONCRETE
FOUNDATION BLOCK
Approx. dimensions and weights
Direct driven
Compressor type (kg) L(mm) W(mm) H(mm)
For direct driven compressors, a packaged base frame is
4 2120 2750 1400 1850 strongly recommended
6 2760 2830 1500 2200 General
9 3400 3370
In case a base frame is not applied, a V-belt driven
1660 2330 compressor can be mounted direct on a concrete
12 4020 3760 foundation block.
31 1915 2570 1600 1850 This Data Sheet should not be considered to be a guide
42 to the design and lay-out of the foundation block as
2400 2830 2200 such.
51
1500 This matter requires practical experience and a detailed
63 knowledge of the situation on the spot. Therefore it is
3230 3330
72 strongly recommended to leave the design and carrying
out of foundations entirely to qualified firms, which, at
84 2330 the same time, are prepared to take full responsiblility
93 3700 3640 1550 for the job.
102
Selection and Data
Table 6.6-2 Weights and dimensions, V-belt driven • Consult grasso to determine dimensions of concrete
Approx. dimensions and weights
foundation block
V-belt driven • There should never be a direct rigid connection
whatsoever between the foundation block and the
Compressor type (kg) L(mm) W(mm) H(mm) floor or any other main part of the building.
4 2220 1750 1750 • The concrete block should extend down to any
2300 subsoil.
6 2860 1960 2100 • Dimensions in table below are directly related to the
9 3500 2330 2150 compressor and the drive. Other dimensions are
2230 determined by amongst others, the electric motor.
12 4120 2450 2580
31 2015 2240 1640 1750
42
2500 2350 1880 2100
51
63
3330 1980
72
84 2560 2230
93 3860 2450
102
6.6.2.1 FOUNDATION BLOCK Legend Dimensions in mm

Compressor dimension O (Section 6.1.2)
2 /3 /21a 295
4 /31 625
C-O
6 /42 /51 685
9 /63 /72 1075
12 /84 /93 /102 2x732.5
2 /3 /21 /4 /31 --
bb 6 /42 /51 /9 /63 / 72 /12 /84
/93 /102 660
2 /3 /21 /4 /31 /6 /42 /51 85

c 110 (for 3-, 6- and 8-groove
9 /63 /72 /12 / 84 /93 /102 flywheel) 60 (for 10-groove
flywheel)
2.5 x diameter of foundation anchor (= 50 mm for Grasso
e 12-compressor; only valid when using filling compound)
h Total height of concrete block (consult Grasso)
a. 21 is compressor with 2 low stage cylinders and 1 high stage cylinder
b. Measure b applies to L-shaped foundation blocks only. The blocks for 2-, 3- and
4-cylinder compressors are always rectangular. The blocks for 6-, 9- and
12-cylinder compressors may be L-shaped or rectangular.
6.7 CRANKCASE HEATER
Recommended for all compressors and all conditions of

operation.
General
Fig. 6.6-4 Foundation top
During standstill of the compressor, refrigerant may
Table 6.6-3 dissolve in the oil charge of the crankcase or it may even
condense, both due to an increase of crankcase pressure,
Legend Dimensions in mm a decrease of crankcase temperature and/or possible
temperature differences between crankcase and
FW Flywheel
evaporator.
MP Motor pulley
Excessive foaming of oil in crankcase, can occur when
CLC Centre line compressor starting the compressor after a long period of standstill
CLM Centre line motor with relatively low oil temperature which may result in
damaging the compressor by a lack of lubrication.
Foundation anchor
Low oil temperatures may also cause a high oil viscosity,
number of foundation which may result in troublesome starting.
Compressor model: anchors:
fa
2 /3 /21( a)/4 /31 / 6 /42 /51
/9 /63 /72 4 Selection and Data standard heater
12 /84 /93 /102 6 • Refer to table.
• Engine room temperatures below 20 °C.
fb Foundation block • Wiring: If 'compressor NOT running' then 'element is
fc Filling compound energised'.
cc Concrete
• Heater element (mounted, not wired).
Not included:
• Auxiliary relais K1 (refer Fig. 6.7-4)
Table 6.7-2 Max. number of special cranckcase heaters, each 600
Watt
Number of cylinders Max. number of heating elements

Fig. 6.7-1 Standard crankcase heater 4-6 2
9 3
Legend
12 4
CE Cable entry
RC Removable cap to protect connections
Mentioned power in Watt; Standard voltages are

110-120 V and 220-240 V.
6.7.1 HEATER FITTING DETAIL
The standard crankcase heater is fitted into a sleeve so

can be exchanged while compressor is in operation. Fig. 6.7-3 Alternative crankcase heating element
Table 6.7-1
Number of
Installed power of
compressor heater element Dimension L (mm)
cylinders
4 - 6 -9 - 12 525 600
Fig. 6.7-4 Electrical wiring schematic
Legend
E1, 2, 3 Heater element
Fig. 6.7-2 Locations of crankcase heaters (Std=standard; XY45 Temperature controlled relay
Alt=alternavive)
K1 Relay
Options
Grasso can supply alternative crankcase heating
elements, recommended for low ambient or engine
room temperatures below +15 oC.
Included are:
• Up to 4 alternative crankcase heating elements,
600W each (mounted on special service covers).
• Thermostat and sensor PT100, supplied loose.
7. NOTES
7. NOTES

Grasso 12E

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Grasso 12E

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Reciprocating Compressors for industrial refrigeration

Series Grasso 12E

Installation and Maintenance Manual (IMM)

IMM0703/v008 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 1-

This publication has been written in good faith.

In compliance with the regulations of the Pressure

Installer oriented information

- 2- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E IMM0703/v008

Section Title Page

IMM0703/v008 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 3-

- 4- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E IMM0703/v008

IMM0703/v008 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 5-

This preface gives a survey of the types of Contents

User group Contents

User group Contents

IMM0703/v008 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 7-

Indicates a WARNING. READ IT CAREFULLY!

Indicates an IMPORTANT note or procedure to which

- 8- Reciprocating Compressors for industrial refrigeration / Series Grasso 12E IMM0703/v008

Table 1 Main setup data

Description Value Remark

Min. oil temperature warmer than surroundings and ≥ 20 °C

IMM0703/v008 Reciprocating Compressors for industrial refrigeration / Series Grasso 12E - 9-

1. INSTALLATION AND PREPARATION FOR USE

Section Title Page

Section Title Page

1.1 INSTALLATION all times in a dry location to prevent corrosion damage.

1.1.1 MOVING INSTRUCTIONS AND STORAGE

For more instalation details refer to; Section

1.1.5.1 CONCRETE STRUCTURE

Fig. 1.1-2 Hoisting angle

Moving by fork-lift truck

It is recommended to consult a concrete specialist/

Fig. 1.1-4 Anchoring details

1.1.5.3 MOUNTING THE BASE FRAME ON A

General instructions can be found in the order manual.

1.1.6 CONNECTING TO REFRIGERATING SYSTEM

DO NOT ground through the compressor when arc

After the anchor filling mortar has completely cured the

components, disconnect all litz-wires when arc-welding.

1.1.9 SEPARATELY DELIVERED COMPONENTS

Check whether the sets/parts/components belonging to

1.2 PREPARATIONS FOR USE 1.2.3 INITIAL OIL CHARGE

Oil charging via the suction line of the compressor is not

1.2.4 INITIAL REFRIGERANT CHARGE

1.2.5 ADJUSTMENT OF INSTRUMENTS AND

1.2.5.1 MONITRON CR AND GSC

1.2.5.2 REFRIGERANTS R717 AND HALOCARBONS

a. Settings Pdischarge - Psuction must never exceed max. value as

1.2.6 CHECKING DIRECTION OF ROTATION OF

1.2.7 INSTALLING THE DRIVE GUARDS (IF

1.2.9 INITIAL START-UP

The time interval between stopping and starting should

In the case of decreasing capacity for two stage

The time interval between stopping and starting should

1.2.10.3 RESTART AFTER A SHORT STANDSTILL

1.2.10.4 RESTART AFTER A LONG STANDSTILL

After a seasonal standstill (1 till 6 months) or

Restarting compressor after a standstill period of time

1.2.10.5 STOPPING THE COMPRESSOR

2. INSPECTION, MAINTENANCE AND TROUBLE SHOOTING

Section Title Page

2.1.2 SURVEY OF PERIODICAL INSPECTIONS

2.1.2.1 CHECK LIST PERIODICAL INSPECTION CHECK