Screw Compressor Package GEA Grasso SP1, SP2, SPduo and GEA Grasso M Product Information (Translation from the original language)
COPYRIGHT All Rights reserved. No part of this documentation may be copied or published by means of printing, photocopying, microfilm or otherwise without prior written consent of GEA Refrigeration Germany GmbH herein after referred to as the manufacturer. This restriction also applies to the drawings and diagrams contained in the documentation. LEGAL NOTICE This product information is a part of the documentation for the Grasso scope of delivery and serves as product presentation and customer advisory service. It contains important information and technical data regarding the product. The product information makes the technical, product related and commercial information available to the customer in detail before the sale of the product. This product information serves as a support and technical advisory service for our partners and customers as well as for the marketing team. Apart from serving as the medium for transfer of product know-how, it also forms the basis for product demonstrations, the organisation and conduction of technical seminars as well as the technical support at trade fairs. This product information should be supplemented with the information about the industrial safety and health related regulations at the site of installation of the product. The regulations vary form place to place as a result of the statutory regulations applicable at the site of installation of the product and are therefore have not been considered in this product information. In addition to this product information and the accident prevention regulations applicable for the respective country and area where the product is used, the accepted technical regulations for safe and professional work must also be observed. This product information has been written in good faith. However, GEA Refrigeration Germany GmbH cannot be held responsible for any errors that this document may contain or for their consequences. GEA Refrigeration Germany GmbH reserves the right to make technical changes during the course of further development of the equipment covered by this product information. Illustrations and drawings in this product information are simplified representations. As a result of the improvements and changes, it is possible that the illustrations do not exactly match the current development status. The technical data and dimensions are subject to change. No claims can be made on the basis of them. 2 26.07.2017
TABLE OF CONTENTS 1 Introduction 7 1.1 Product designation, screw compressor package 7 1.2 Scope of delivery 11 1.3 Service fluids 12 2 Series overview 13 2.1 Overview: GEA Grasso M 13 2.2 Overview: GEA Grasso SP1 14 2.3 Series 15 3 Operating limits 16 4 Technical specifications 18 4.1 GEA Grasso M compressor frame size C, D, E, G 18 4.2 GEA Grasso M compressor, frame size H, L, M, N 19 4.3 GEA Grasso M compressor, frame size H, L, M, N (52 bar version) 20 4.4 GEA Grasso SP1 compressor frame size P, R, S, T, V, W, Y 21 4.5 GEA Grasso SP1 compressor frame size Z, XA 22 4.6 GEA Grasso SP1 compressor frame size P, R, S, T, 23 4.7 GEA Grasso SP1 compressor frame size V, W, Y 24 4.8 GEA Grasso SP1 compressor frame size Z, XA 25 4.9 GEA Grasso SP1 compressor frame size XB, XC, XD, XE, XF 26 4.10 GEA Grasso SP1 compressor frame size XG, XH 28 4.11 GEA Grasso SP2 compressor frame size (LP) H, L, M, N, P, R 29 4.12 GEA Grasso SP2 compressor frame size (LP) S, T, V, W, Y, Z 30 4.13 GEA Grasso SPduo compressor frame size C, D, E, G 31 4.14 GEA Grasso SPduo compressor, frame size H, L 32 4.15 GEA Grasso SPduo compressor, frame size M, N 33 4.16 GEA Grasso SPduo compressor frame size P, R, S, T, 34 4.17 GEA Grasso SPduo compressor frame size V, W, Y 35 5 Option frequency inverter 36 6 GEA Omni control panel 38 6.1 Product Highlights 38 6.2 Input and Output Signals 42 7 Description of Design and Function 44 7.1 General functional description 44 7.2 Refrigerant circuit 44 7.3 Oil circuit 46 7.4 Oil separation 46 7.4.1 Oil separation (installed vertically) 46 7.4.2 Oil separation (installed horizontally) 46 7.5 Oil heater 46 7.6 Oil cooling 46 7.7 Oil filter 47 7.8 Oil pump 47 7.8.1 Oil pump (external) 47 7.8.2 Oil pumpe (without) 47 7.9 Oil injection 47 7.10 Oil circuit 48 7.11 Capacity control 48 7.12 Vi adjustment (optionally) 48 7.13 Information on noise emissions 49 8 Economizer 54 8.1 Economizer variants for single-stage screw compressor packages 54 8.1.1 Type A - economizer port pipe 54 8.1.2 Type B - Economizer for two-stage expansion (Open flash) with level control 55 8.1.3 Type C Economizer for single-stage expansion (Closed flash) with shell and tube heat exchanger 56 8.1.4 Type D Economizer for single-stage expansion (Closed flash) with plate heat exchanger 56 8.1.5 Type E Economizer for two-stage expansion (Open flash) with HP floater 57 8.2 Economizer variants for DuoPack screw compressor packages 58 8.2.1 Type A-Duo Economizer port pipe 58 8.2.2 Type B-Duo Economizer for two-stage expansion (Open flash) with level control 59 26.07.2017 3
8.2.3 Type C-Duo Economizer for single-stage expansion (Closed flash) with shell and tube heat exchanger 60 9 Enquiry sheet 62 10 Manufacturer information 63 4 26.07.2017
TABLE OF FIGURES Fig. 1 Types of GEA Grasso M 13 Fig. 2 Types of GEA Grasso SP1 14 Fig. 3 GEA Grasso M compressor frame size C, D, E, G 18 Fig. 4 GEA Grasso M compressor, frame size H, L, M, N 19 Fig. 5 GEA Grasso M compressor, frame size M, N (52 bar version) 20 Fig. 6 GEA Grasso SP1 compressor frame size P, R, S, T, V, W, Y 21 Fig. 7 GEA Grasso SP1 compressor frame size Z, XA 22 Fig. 8 GEA Grasso SP1 compressor frame size P, R, S, T, 23 Fig. 9 GEA Grasso SP1 compressor frame size V, W, Y 24 Fig. 10 GEA Grasso SP1 compressor frame size Z, XA 25 Fig. 11 GEA Grasso SP1 compressor frame size XB, XC, XD, XE, XF 26 Fig. 12 GEA Grasso SP1 compressor frame size XG, XH 28 Fig. 13 GEA Grasso SP2 compressor frame size (LP) H, L, M, N, P, R 29 Fig. 14 GEA Grasso SP2 compressor frame size (LP) S, T, V, W, Y, Z 30 Fig. 15 GEA Grasso SPduo compressor frame size C, D, E, G 31 Fig. 16 GEA Grasso SPduo compressor, frame size H, L 32 Fig. 17 GEA Grasso SPduo compressor, frame size M, N 33 Fig. 18 GEA Grasso SPduo compressor frame size P, R, S, T, 34 Fig. 19 GEA Grasso SPduo compressor frame size V, W, Y 35 Fig. 20 Power current panel and frequency inverter, view 36 Fig. 21 GEA Omni Enclosure without indicator lamps 39 Fig. 22 GEA Omni Enclosure with indicator lamps 39 Fig. 23 GEA Omni Enclosure interior 41 Fig. 24 Process flow diagram GEA Grasso SP1, GEA Grasso M 44 Fig. 25 Process flow diagram GEA Grasso SP2 45 Fig. 26 Process flow diagram GEA Grasso SPduo 45 Fig. 27 Economizer port pipe 54 Fig. 28 Economizer for two-stage expansion (Open flash) with level control 55 Fig. 29 Economizer for single-stage expansion (Closed flash) with shell and tube heat exchanger 56 Fig. 30 Economizer for two-stage expansion (Open flash) with HP floater 57 Fig. 31 Economizer port pipe 58 Fig. 32 Economizer for two-stage expansion (Open flash) with level control 59 Fig. 33 Fig. 34 Economizer for single-stage expansion (Closed flash), diagram 1 for higher power 60 Economizer for single-stage expansion (Closed Flash), diagram 2 for lower power 61 26.07.2017 5
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Introduction Product designation, screw compressor package 1 Introduction Complete screw compressor packages are available to ensure all necessary operating functions of the screw compressors. Grasso screw compressor packages are delivered as a single-stage, twostage or DuoPack packages depending on the required refrigerating capacity, the refrigerant, evaporating and condensing temperatures. 1.1 Product designation, screw compressor package GEA Grasso SP1, SP2, SPduo and GEA Grasso M series Product code description Code X Y Description Screw compressor package frame size (corresponds with the compressor housing size) The LP screw compressor will be provided for the screw compressor packages in the GEA Grasso SP2 series (two-stage). Design types of the screw compressor package 9 Screw compressor design types A (X1) Oil cooling Screw compressor frame size high pressure side Only for screw compressor packages in the GEA Grasso SP2 series (two-stage). 26.07.2017 7
Introduction Product designation, screw compressor package X / (X1) Screw compressor package frame size 1 Code Theoretical Volume flow Code Theoretical Volume flow at 2940 min -1 in m³/h 1 at 2940 min -1 in m³/h 1 C 231 V 1740 D 265 W 1940 E 321 Y 2390 G 372 Z 2748 H 471 XA 3250 L 544 XB 4150 M 708 XC 4900 N 870 XD 5800 P 805 XE 7170 R 1040 XF 8560 S 1290 XG 9807 T 1460 XH 11467 Y Screw compressor package design type Design type Screw compressor package RF 2 RF 2 NH 3 R22 RF 2 HFC RF 2 R290 and R600a CO 2 and Special media Horizontal oil separator installed below A H R F O Oil separator installed vertically B K S G P Oil separator horizontally in series C L T GEA Grasso SPduo - DuoPack/multiple configuration D M V Y W GEA Grasso SP2 (two-stage) E N U 1 The frame size of the screw compressor package is defined by the frame size (housing size) of the compressor used. The theoretic volumetric flows specified always relate to the rotor size of the compressor. In certain application cases and under certain operating conditions, compressors with shortened rotors may be used so that the theoretical volumetric flow may not be derived from the frame size of the screw compressor package (compressor housing size)! The size of the rotors can be obtained from the precise compressor description in the technical specification. 2 Refrigerant 8 26.07.2017
Introduction Product designation, screw compressor package 9 Screw compressor design types Code Description Vi = 1 Standard refrigerating compressor 1.8; 2.0; 2.2; 2.6; 3.0 2 Standard refrigerating compressor 3.6 3 Standard refrigerating compressor 4.8 4 Standard refrigerating compressor 5.5 5 Standard refrigerating compressor variable 6 Booster fixed 7 Heat pump compressor fixed or variable 8 Swing compressor fixed or variable 9 -- -- A Oil cooling Code A B C D E F Oil cooling Water-cooled oil cooler Refrigerant cooled oil cooler Refrigerant injection Water and refrigerant cooled oil cooler Water or refrigerant cooled oil cooler and refrigerant injection Without oil cooler Examples of designation Examples XA B - 6 A T A - 2 A NA - 3 B Description Single stage screw compressor package GEA Grasso SP1 with screw compressor 3250 m³/h(xa), refrigerant NH 3 and vertically installed oil separator (B), booster with fixed internal volume ratio (6), with oil fine separation and watercooled oil cooler (A) Single stage screw compressor package GEA Grasso SP1 with screw compressor 1460 m³/h (T), refrigerant NH 3 and horizontally installed oil separator (A)fixed internal volume ratio Vi = 3.6 (2), with oil fine separation and water-cooled oil cooler (A) Single stage screw compressor package GEA Grasso M with screw compressor 873 m³/h (N), refrigerant NH 3 and horizontally installed oil separator (A)fixed internal volume ratio Vi = 4.8 (3), with fine oil separator and refrigerant cooled oil cooler (B) 26.07.2017 9
Introduction Product designation, screw compressor package Examples LD - 2 A W E - 6 A (L) Description Screw compressor package GEA Grasso SPduo with 2 of screw compressors 544 m³/h(l), refrigerant NH 3 and DuoPack design type or multiple configuration(d)fixed internal volume ratio Vi = 3.6 (2), with oil fine separation and watercooled oil cooler (A) Two-stage screw compressor package with LP screw compressor 1940 m³/h (W), refrigerant NH 3 two-stage compressor package(e), LP-compressor as booster (6), with oil fine separation and water-cooled oil cooler (A), HP-compressor 544 m³/h (L) 10 26.07.2017
Introduction Scope of delivery 1.2 Scope of delivery The screw compressor packages of the GEA Grasso SP1, M, SP2, and SPduo series consist of the following components: Screw compressor, Electric motor with coupling Oil supply system with oil separator, Oil cooler, Oil filter and oil pump, Suction filter, Check valves on the suction and discharge sides, Equipment for capacity control, Monitoring and safety devices, Compressor control system. All components are fully mounted. The compressor control system is wired. The oil separators are installed either horizontally or vertically. A fine separation stage is provided for the oil separators. The oil cooling is effected using water. Optionally solutions for heat recovery, refrigerant cooled oil cooler or a refrigerant injection system are available. By default, a rigid installation on the foundation is intended. An installation insulated against structure-borne sound is available optionally. All connections are closed tight. Painting The painting is done with 2 component EP paint RAL 5014 with a coating thickness of 120 µm. Other colours are optional or can be delivered on request. Approval After acceptance, the screw compressor packages of the above-mentioned series receive a CE label in accordance with the Pressure Equipment Directive 2014/68/EU. Documentation User documentation is delivered with each screw compressor package. The user documentation contains: Drawings and part lists, Safety Instructions, Operating manual (including the description of the refrigerant and oil circuits, the instructions for installation, start-up and maintenance), Documentation of the main components (e.g. electric motor, control), Maintenance schedule, Acceptance certificate for components requiring acceptance. 26.07.2017 11
Introduction Service fluids 1.3 Service fluids Notice! The screw compressor packages are delivered without refrigerant and refrigerating machine oil. They are filled with dry nitrogen (0.2 bar overpressure). Refrigerant The following refrigerants are provided: R717 R134a R404A R507 R410a R744 R22 3 R290 3 R600a 3 GEA Refrigeration Germany GmbH can provide assistance in the selection of a suitable refrigeration machine oil on request. Refrigeration machine oils The following oil grades are provided: Mineral oil Synthetic oil based on alkyl benzol Synthetic oil based on poly-alpha-olefin Synthetic oil based on polyolester 3 on request 12 26.07.2017
Series overview Overview: GEA Grasso M 2 Series overview 2.1 Overview: GEA Grasso M Fig.1: Types of GEA Grasso M y Volume flow in m³ at 2940 rpm x Compressor frame size 1 Oil separator (installed horizontally) 26.07.2017 13
Series overview Overview: GEA Grasso SP1 2.2 Overview: GEA Grasso SP1 Fig.2: y x Types of GEA Grasso SP1 Volume flow at 2940 rpm Compressor frame size 14 26.07.2017
Series overview Series 2.3 Series GEA Grasso M / GEA Grasso SP1 - single stage screw compressor packages The series of single stage screw compressor packages comprises 24 frame sizes subdivided into 2 series. GEA Grasso M series: The GEA Grasso screw compressors C, D, E, G, H, L, M, and N of the GEA Grasso M series screw compressor packages ensure a theoretical swept volume ranging from 231 to 870 m 3 /h. GEA Grasso SP1 series: The high performance screw compressors P, R, S, T, V, W, Y, Z, XA, XB, XC, XD, XE, XF, XG, and XH of the GEA Grasso SP1 series ensure a theoretical swept volume ranging from 805 to 11467 m 3 /h. GEA Grasso SP2 - two-stage screw compressor packages Two-stage screw compressor packages are equipped with a separately operated low- and highpressure compressor. Both compressors are mounted on a common base frame. There is a common oil circuit with a horizontal oil separator. The particularly compact and simple design of single stage screw compressor packages is effectively combined with energetically favourable two-stage operation. The GEA Grasso SP2 series of two-stage screw compressor packages comprises 16 frame sizes. GEA Grasso SPduo - DuoPack screw compressor packages The GEA Grasso SPduo series of screw compressor packages is offered to divide the capacity range to two compressors for energy-optimized partial load operation and as an alternative solution for two screw compressor packages, for cost- and space-saving, with two identical compressors. 26.07.2017 15
Operating limits 3 Operating limits The compressor packages can be operated under the specified operating conditions within the given operation limits. The listed operation limits of the compressor packages ensure trouble-free and reliable operation of the compressor packages for a long period of time. The values apply to the application as a refrigerant package. The manufacturer reserves the right to certain restrictions or extensions of the operation limits for specific applications. Special constructive designs are possible. Notice! Comply with the operation limits. For specific operations the selection and evaluation will take place within the manufacturer's compressor selection programme "GUD. Warning! A "zero flow" of the compressor package can cause damage to the compressor. To avoid damage, the minimum control slide position must be considered during ongoing operation. This must be secured by the control of the compressor package. Permissible minimum and maximum values for compressor packages in refrigerating mode Parameters maximum permitted pressure p Value < 52 bar (g.p.) Pressure ratio (p / p 0 ) π > 1.5 Pressure difference (p - p 0 ) Δp > 0.8 bar Suction temperature (compressor inlet) t 0h > -60 C Discharge temperature (compressor outlet) t e < 105 C Oil temperature t oil > 30 C Oil temperature t oil < 80 C Discharge temperature - condensation temperature Δt > 10 K Ambient temperature t u > 5 C Ambient temperature t u < 45 C Ambient humidity < 95 % 16 26.07.2017
Operating limits Driving power and speed performance GEA Grasso SP1, M, SP2 and GEA Grasso SPduo series Screw compressor Frame size C, D, E, G H, L, M, N P, R, S, T V, W, Y max. Driving power at 2950 min -1 3550 min -1 150 kw 180 kw 300 kw 360 kw 530 kw 640 kw 1250 kw 1500 kw Max. Nominal torque 500 Nm 960 Nm 1700 Nm 4000 Nm Max. Permissible speed 4500 min -1 4500 min -1 3600 min -1 3600 min -1 min. Permissible speed 1000 min -1 1000 min -1 1500 min -1 1500 min -1 Screw compressor Frame size Z, XA XB, XC, XD XE, XF XG, XH max. Driving power at at 2950 rpm at 3550 rpm 1250 kw 1500 kw 1800 kw 2160 kw 3000 kw 3600 kw 3472 kw 4193 kw Max. Nominal torque 4000 Nm 5750 Nm 9500 Nm 11278 Nm Max. Permissible speed 3600 min -1 3600 min -1 3600 min -1 3600 min -1 min. Permissible speed 1500 min -1 1500 min -1 1500 min -1 1500 min -1 The electric drive motors can be operated directly from the mains as well as via a frequency inverter. For compressor packages with compressors of frame size C to N, an external oil pump must be provided, in case the pressure difference between suction and discharge side does not ensure a sufficient oil supply. In general, the pressure difference must be higher than 4 bar. A variable internal volume ration is not available for booster applications. Refrigerant injection into the compressor as an oil cooling option is approved for R717 only. For all other oil cooling options, the oil temperature for R717 should be at least 5 K below the discharge temperature (10 K for freons). Note the manufacturer s oil recommendations when selecting the oil. Considering the solubility of the oils, the oil viscosity should be between 7 und 70 cst at the oil supply ports of the bearings. Should the given limits not be adhered to in individual cases, the manufacturer needs to be consulted. 26.07.2017 17
Technical specifications GEA Grasso M compressor frame size C, D, E, G 4 Technical specifications Notice! All data are subject to change. GEA Refrigeration Germany GmbH reserves the right to make technical changes during the course of further development of the product covered by this product information. Illustrations and drawings in this product information are simplified representations. The technical data and dimensions are subject to change. No claims can be made on the basis of them. 4.1 GEA Grasso M compressor frame size C, D, E, G (oil separator installed horizontally) Fig.3: GEA Grasso M compressor frame size C, D, E, G Technical specifications GEA Grasso compressor Nominal motor power (kw) Oil separator Ø D (mm) Oil charging quantity (l) Dimensions (mm) Nominal diameters L B H DN1 DN2 Weight without motor (kg) C 25...75 508 40-50 875 80-100 2200 1120 1725 50-100 D 22...90 508 40-65 975 508 2200 1220 1795 1075 E 30...132 40-65 610 2300 1250 1795 1200 100-120 65-125 580 2200 1220 1795 1175 G 45...132 40-80 610 2300 1250 1795 1300 18 26.07.2017
Technical specifications GEA Grasso M compressor, frame size H, L, M, N 4.2 GEA Grasso M compressor, frame size H, L, M, N (oil separator installed horizontally) Fig.4: GEA Grasso M compressor, frame size H, L, M, N Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H B DN1 DN2 Weight without motor (kg) H 37...160 L 45...160 508 610 508 610 711 120-180 160-210 120-180 160-210 200-260 2200 2300 2200 2300 2400 1850 1950 1850 1950 2050 1150 1250 1150 1250 1350 80-150 40-80 1275 1400 1325 1450 1750 M 55...200 N 55...250 508 610 711 508 610 711 813 130-190 170-220 210-270 130-190 170-220 210-270 270-315 2200 2300 2400 2200 2300 2400 2500 1950 2050 2150 1950 2050 2150 2250 1150 1250 1350 1150 1250 1350 1450 100-200 40-100 1475 1600 1900 1550 1675 1975 2300 26.07.2017 19
Technical specifications GEA Grasso M compressor, frame size H, L, M, N (52 bar version) 4.3 GEA Grasso M compressor, frame size H, L, M, N (52 bar version) (oil separator installed vertically) Fig.5: GEA Grasso M compressor, frame size M, N (52 bar version) Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) M 55...200 N 55...250 508 610 711 508 610 711 813 130-190 170-220 210-270 130-190 170-220 210-270 270-315 2080 2190 2275 2080 2190 2275 2385 1980 2000 2010 1980 2000 2010 2090 1740 1810 1870 1740 1810 1870 1880 1350 1400 1450 1350 1400 1450 1500 100-200 40-100 2500 2650 2800 2500 2650 2800 3100 L Motor for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 55 75 90 110 132 160 200 250 L motor IP23 709 747 823 823 935 935 935 1151 L motor IP55 965 965 1071 1071 1244 1244 1244 1353 20 26.07.2017
Technical specifications GEA Grasso SP1 compressor frame size P, R, S, T, V, W, Y 4.4 GEA Grasso SP1 compressor frame size P, R, S, T, V, W, Y (oil separator installed horizontally) Fig.6: GEA Grasso SP1 compressor frame size P, R, S, T, V, W, Y Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L1 4 H B DN1 DN2 Weight without motor (kg) P 55...250 508 610 130-170 170-190 3565 3765 2000 2100 1280 1380 2125 2225 R 75...355 S 90...400 508 610 140-180 180-200 3565 3765 3565 3765 2000 2100 2000 2100 1280 1380 1280 1380 100-250 40-125 2495 2575 2560 2650 T 90...400 508 610 150-220 220-290 3565 3765 2000 2100 1280 1380 2660 2750 V 110...550 508 610 160-240 220-270 3565 3765 2250 2350 1560 1660 3050 3350 W 110...630 508 610 711 190-270 250-310 290-350 3565 3765 3820 2250 2350 2500 1560 1660 1660 150-300 50-200 3100 3450 3800 Y 132...630 508 610 711 190-270 250-310 290-350 3565 3765 3820 2250 2350 2500 1560 1660 1660 3150 3500 3850 DN2 40 150 200 50 65 80 100 125 250 L2 235 475 525 255 285 310 365 420 615 4 total length = L1 + L2 26.07.2017 21
Technical specifications GEA Grasso SP1 compressor frame size Z, XA 4.5 GEA Grasso SP1 compressor frame size Z, XA (oil separator installed horizontally) Fig.7: GEA Grasso SP1 compressor frame size Z, XA Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Z 110... 750 XA 5 22 Diameter nominal (mm) Dimensions (mm) Oil charging quantity (l) L5 H B 610 711 813 270-350 310-390 340-420 3765 3820 4275 2550 2550 2800 1660 1660 1760 200... 900 610 711 813 270-350 310-390 340-420 3765 3820 4275 2550 2550 2800 1660 1660 1760 DN2 40 50 65 80 100 L2 235 255 285 310 365 DN1 DN2 Weight without motor (kg) 4350 4550 5000 200-400 50-250 125 150 200 250 420 475 525 615 4450 4650 5050 total length = L1 + L2 26.07.2017
Technical specifications GEA Grasso SP1 compressor frame size P, R, S, T, 4.6 GEA Grasso SP1 compressor frame size P, R, S, T, (oil separator installed vertically) Fig.8: GEA Grasso SP1 compressor frame size P, R, S, T, Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) P 55...250 R 75...355 508 610 508 610 711 110-155 180-205 120-155 180-205 190-225 2050 2150 2350 2400 2450 2050 2100 2050 2100 2150 1900 1960 1900 1960 2010 1400 1450 1400 1450 1450 100-200 40-100 2500 2650 2750 2900 3050 S T 90...400 508 610 711 508 610 711 813 130-185 180-205 190-225 130-185 180-205 190-225 210-270 2350 2400 2450 2350 2400 2450 2550 2050 2100 2150 2050 2100 2150 2190 1900 1960 2010 1900 1960 2010 2010 1400 1450 1450 1400 1450 1450 1680 100-250 40-125 2750 2900 3050 2750 2900 3050 3350 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 55 75 90 110 132 160 200 250 280 315 355 400 L motor IP23 709 747 823 935 1151 1465 L motor IP55 965 1071 1244 1353 1412 1607 26.07.2017 23
Technical specifications GEA Grasso SP1 compressor frame size V, W, Y 4.7 GEA Grasso SP1 compressor frame size V, W, Y (oil separator installed vertically) Fig.9: GEA Grasso SP1 compressor frame size V, W, Y Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor V 110...550 610 711 813 200-255 220-270 240-290 2550 2600 2650 2100 2150 2190 1960 2010 2010 150-250 50-150 3400 3500 3800 W 110...630 Y 132...630 610 711 813 711 813 914 200-255 220-270 240-290 200-275 245-280 280-335 2550 2600 2650 2600 2650 3000 2100 2150 2190 2150 2190 2290 1960 2010 2010 2010 2010 2010 1800 150-300 50-200 3400 3500 3800 3500 3800 4000 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 110 132 160 200 250 280 315 355 400 450 500 560 630 L motor IP23 823 935 1151 1465 1650 L motor IP55 1071 1244 1353 1412 1607 2075 2240 24 26.07.2017
Technical specifications GEA Grasso SP1 compressor frame size Z, XA 4.8 GEA Grasso SP1 compressor frame size Z, XA (oil separator installed vertically) Fig.10: GEA Grasso SP1 compressor frame size Z, XA Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) Z 160...750 XA 200...900 813 914 1016 813 914 1016 265-340 310-385 320-395 275-350 310-385 320-395 2800 3150 3800 2800 3150 3800 2190 2290 2850 2010 2010 2200 1800 200-400 50-250 4000 4200 4400 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 160 200 250 280 315 355 400 450 500 560 630 700 710 800 900 L motor IP23 935 1151 1465 1650 L motor IP55 1244 1353 1412 1607 2075 2240 2380 2620 26.07.2017 25
Technical specifications GEA Grasso SP1 compressor frame size XB, XC, XD, XE, XF 4.9 GEA Grasso SP1 compressor frame size XB, XC, XD, XE, XF (oil separator installed vertically) Fig.11: GEA Grasso SP1 compressor frame size XB, XC, XD, XE, XF Technical specifications GEA Grasso compressor Nominal motor power (kw) Ø D (mm) Oil filling capacity Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) XB 250...1200 813 914 1016 285-410 395-520 330-455 3850 3900 3950 2675 2775 2975 2010 2010 2200 7500 7700 7900 XC 315...1500 XD 355...1800 914 1016 1200 395-520 330-475 540-660 340-495 395-520 560-680 3900 3950 4150 2775 2975 2975 2010 2200 2200 1820 250-500 65-300 7700 7900 8900 XE XF 400...3000 1016 1200 1400 340-495 560-680 670-750 340-495 560-680 680-760 4250 4450 4650 3150 2300 100-350 9600 10400 11400 L Motor (mm) for standard motors IP23 and IP55, 400 V, style IMB3 (with stand) Capacity (kw) 250 280 315 355 400 450 500 560 630 710 800 900 1000 L motor IP23 1151 1465 1628 L motor IP55 1353 1412 1607 2075 2240 2380 2620 26 26.07.2017
Technical specifications GEA Grasso SP1 compressor frame size XB, XC, XD, XE, XF L Motor (mm) for standard mean voltage motors IP55, 6 kv, style IMB3 (with stand) Capacity (kw) 1100 1200 1300 1400 1500 1600 1800 L motor IP55 2375 2580 3200 26.07.2017 27
Technical specifications GEA Grasso SP1 compressor frame size XG, XH 4.10 GEA Grasso SP1 compressor frame size XG, XH (oil separator installed vertically) Fig.12: GEA Grasso SP1 compressor frame size XG, XH Technical specifications GEA Grasso compressor XG XG Nominal motor power (kw) Ø D (mm) XG 1600 400...3400 XH 1800 Oil filling capacity 1200 6 600-700 1400 6 690-790 770-870 850-950 Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 4450 4650 4850 5550 3150 2350 3250 1820 250-500 200-400 Weight without motor (kg) 11000 11750 12750 13750 XH 2000 XH 2200 1030-1130 1120-1220 5250 5450 3450 2020 2220 14750 1575 L Motor (mm) for standard motors IP23 and IP55, 400 V, style IMB3 (with stand) Capacity (kw) 250 280 315 355 400 450 500 560 630 710 800 900 1000 L motor IP23 1151 1465 1628 L motor IP55 1353 1412 1607 2075 2240 2380 2620 L Motor (mm) for standard mean voltage motors IP55, 6 kv, style IMB3 (with stand) Capacity (kw) 1100 1200 1300 1400 1500 1600 1800 L motor IP55 (mm) 2375 2580 3200 6 For dimensions, see Grasso SP1 (Large) with Grasso SC frame size: XB, XC, XD, XE, XF 28 26.07.2017
Technical specifications GEA Grasso SP2 compressor frame size (LP) H, L, M, N, P, R 4.11 GEA Grasso SP2 compressor frame size (LP) H, L, M, N, P, R (oil separator installed horizontally) Fig.13: GEA Grasso SP2 compressor frame size (LP) H, L, M, N, P, R Technical specifications GEA Grasso compressor Nominal motor Oil Dimensions (mm) Diameter nominal (mm) Weight power (kw) charging Ø D without (mm) motor LP (kw) HP (kw) quantity L H B DN1 DN2 DN3 (kg) (l) H 37 2300 37...75 2750 1970 1000 100-125 40-65 25-40 L 45 2400 150-190 M 55...90 45...90 3400 508 3050 2150 1100 100-150 N 75...110 55...132 3600 50-65 30-50 P 55...90 45...90 2150 2900 180-210 2750 1200 100-150 R 75...110 55...132 2330 3100 L Motor (mm) for standard motors IP23 and IP55, design IMB5 (with flange) (for HP compressor frame size C, D, E, G) Capacity (kw) 37 45 55 75 90 110 132 L motor IP23 624 671 709 747 823 935 L motor IP55 767 856 965 1071 1244 26.07.2017 29
Technical specifications GEA Grasso SP2 compressor frame size (LP) S, T, V, W, Y, Z 4.12 GEA Grasso SP2 compressor frame size (LP) S, T, V, W, Y, Z (oil separator installed horizontally) Fig.14: GEA Grasso SP2 compressor frame size (LP) S, T, V, W, Y, Z Technical specifications GEA Grasso compressor Nominal motor Oil Diameter nominal Dimensions (mm) power (kw) charging (mm) Ø D (mm) LP (kw) HP (kw) quantity L H B DN1 DN2 DN3 (l) Weight without motor (kg) S 90...132 3200 180-210 2400 1200 125-200 50-80 T 90...160 3350 75...160 110...16 V 180-250 40-65 3400 0 W Y Z 132...20 0 90...200 132...25 0 132...25 160...31 0 5 711 240-310 3580 2550 1480 150-300 65-100 50-80 4000 4200 280-350 4400 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 75 90 110 132 160 200 250 280 315 355 L motor IP23 747 823 935 1151 L motor IP55 965 1071 1244 1353 1412 30 26.07.2017
Technical specifications GEA Grasso SPduo compressor frame size C, D, E, G 4.13 GEA Grasso SPduo compressor frame size C, D, E, G (oil separator installed vertically) Fig.15: GEA Grasso SPduo compressor frame size C, D, E, G Technical specifications GEA Grasso Compressor Nominal motor power (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) C 22...75 D 22...90 E 30...132 G 45...132 508 610 508 610 120-145 3600 2280 2350 2360 2430 1900 1960 1500 1650 1550 1750 1600 1800 1950 2050 80-100 40-65 100-125 40-80 2250 2400 2250 2450 2400 2650 2550 2850 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 22 30 37 45 55 75 90 110 132 160 L motor IP23 577 586 624 671 709 747 823 935 L motor IP55 664 767 856 965 1071 1244 26.07.2017 31
Technical specifications GEA Grasso SPduo compressor, frame size H, L 4.14 GEA Grasso SPduo compressor, frame size H, L (oil separator installed vertically) Fig.16: GEA Grasso SPduo compressor, frame size H, L Technical specifications GEA Grasso Compressor Nominal motor power 2x (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) H 37...160 L 45...160 508 610 508 610 711 120-180 160-210 120-180 160-210 200-260 2550 2600 2550 2600 2650 2430 2500 2430 2500 2560 1900 1960 1900 1960 2010 2250 80-150 40-125 3900 4100 3900 4100 4250 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 37 45 55 75 90 110 132 160 200 250 L motor IP23 624 671 709 747 823 935 1151 L motor IP55 767 856 965 1071 1244 1353 32 26.07.2017
Technical specifications GEA Grasso SPduo compressor, frame size M, N 4.15 GEA Grasso SPduo compressor, frame size M, N (oil separator installed vertically) Fig.17: GEA Grasso SPduo compressor, frame size M, N Technical specifications GEA Grasso Compressor Nominal motor power 2x (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) M 55...200 N 55...250 508 610 711 508 610 711 813 130-190 170-220 210-270 130-190 170-220 210-270 270-315 2550 2600 2650 2550 2600 2650 2700 2460 2530 2590 2460 2530 2590 2600 1900 1960 2010 1900 1960 2010 2010 2350 100-200 40-150 5250 5400 5550 5250 5400 5550 5850 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 37 45 55 75 90 110 132 160 200 250 L motor IP23 624 671 709 747 823 935 1151 L motor IP55 767 856 965 1071 1244 1353 26.07.2017 33
Technical specifications GEA Grasso SPduo compressor frame size P, R, S, T, 4.16 GEA Grasso SPduo compressor frame size P, R, S, T, (oil separator installed vertically) Fig.18: GEA Grasso SPduo compressor frame size P, R, S, T, Technical specifications GEA Grasso compressor Nominal motor power 2x (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L B H1 H2 DN1 DN2 Weight without motor (kg) P 55...250 5450 5600 6200 R 75...355 S T 90...400 610 711 813 610 711 813 914 120-190 170-230 220-280 120-190 170-230 220-280 260-340 2550 2600 2650 2550 2600 2650 2700 2370 2370 2370 2370 2600 2100 2150 2190 2100 2150 2190 2290 1960 2010 2010 1960 2010 2010 2010 125-200 40-150 5900 6050 6700 5950 6100 6750 6000 6150 6800 7000 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 55 75 90 110 132 160 200 250 280 315 355 400 L motor IP23 709 747 823 935 1151 1465 L motor IP55 965 1071 1244 1353 1412 1607 34 26.07.2017
Technical specifications GEA Grasso SPduo compressor frame size V, W, Y 4.17 GEA Grasso SPduo compressor frame size V, W, Y (oil separator installed vertically) Fig.19: GEA Grasso SPduo compressor frame size V, W, Y Technical specifications GEA Grasso compressor Nominal motor power 2x (kw) Ø D (mm) Oil charging quantity (l) Dimensions (mm) Diameter nominal (mm) L H1 H2 B DN1 DN2 Weight without motor (kg) V W 110...550 Y 132...630 813 914 1016 1200 250-310 290-350 330-410 390-470 3000 3100 3650 3800 2190 2290 2850 2975 2010 2010 2200 2200 2750 2750 2900 2900 150-300 65-250 7550 7800 8250 9350 L Motor (mm) for standard motors IP23 and IP55, design IMB3 (with stand) Capacity (kw) 110 132 160 200 250 280 315 355 400 450 500 560 630 L motor IP23 823 935 1151 1465 1650 L motor IP55 1071 1244 1353 1412 1607 2075 2240 26.07.2017 35
Option frequency inverter 5 Option frequency inverter Fig.20: Power current panel and frequency inverter, view The screw compressor packages with screw compressors and frequency controllers are driven at a minimum speed of 1000 rpm (compressor series M) or 1500 rpm (compressor series LT). The permissible max. speed is 4500 rpm (compressor series M) or 3600 rpm (compressor series LT). The power current panel with frequency inverter is delivered loose and is connected to the compressor drive motor using shielded cables on-site. When connecting, the output side power cables must be kept as short as possible for minimising the electromagnetic disturbances. The communication of the control unit with the frequency inverter is effected via hardware cabling. The drive power of the compressor drive motors of the series of the screw compressor packages with frequency controls is limited to 710 kw. Higher capacities are possible only on request. The capacity is regulated using a combined slider/speed regulation. Technical data of frequency inverter (default by GEA Refrigeration Germany GmbH) Parameters Description Operating frequency 25-50 Hz Operating voltage 3 phase, 400 V +/- 5% Filter EMC filter class A according to EN 55011 Communication Hardware cabling Display Display for displaying operating parameters, error and warning messages Type of control Sine weighted pulse width modulation, constant U/f characteristic curve Protective functions Overcurrent Resonance protection Suppressible frequency bands Conditions of use < 93 % rel. humidity, +5 C to +40 C, max. 1000 m above mean sea level 36 26.07.2017
Option frequency inverter Power current panel The power current panel includes the control with operating / display unit, the input and output assemblies as well as the frequency inverter with the described components. Oil pump and oil heater are switched on/off using the MCBs included in the power current panel. Motor current transformer, motor winding protection and EMERGENCY STOP switch are integrated into the power current panel. Compressor drive motor For a screw compressor package with frequency controller, compressor drive motors with special roller bearings corresponding to the requirements of the frequency inverter operation are used. The sound power level in case of operation with frequency controller increases by 4 db - 8 db. Further technical specifications (power current panel with frequency inverter) Nominal motor power (kw) Weight (kg) Dimensions (mm) B H T 45 210 800 2160 400 55 210 800 2160 400 75 210 800 2160 400 90 210 1200 2160 600 110 285 1200 2160 600 132 285 1200 2160 600 160 285 1200 2160 600 200 435 1600 2160 600 250 435 1600 2160 600 315 435 1600 2160 600 355 510 1600 2160 600 As an alternative to the described complete solution, the screw compressor package can be delivered without the power current panel. In this case, the screw compressor package is delivered with a built-on control. The frequency inverter is provided as a built-in device (IP20). The customer takes over the complete responsibility for the installation as well as the wiring of the frequency inverter with the compressor drive motor and the control in accordance with the EMC Directive 2004/108/EC (shielded cables, separate cable ducts). 26.07.2017 37
GEA Omni control panel Product Highlights 6 GEA Omni control panel 6.1 Product Highlights GEA is synonymous with precision-engineered solutions, and the GEA Omni control panel extends its history of leadership and innovation. Featuring a high-definition, multi-touch screen, GEA Omni delivers the ease of use and technical wow factor that industry professionals have come to expect from GEA. Powerful, yet approachable. Cerebral, yet intuitive. Sophisticated, yet simple. Simply - GEA Omni. GEA Omni offers what operators expect from a control panel: maximum efficiency and reliable operation of their system. This next-generation control panel integrates and optimally coordinates all required system components, resulting in a demand-driven and highly energy-efficient facility operations. The GEA Omni advantage: Complete system control in one panel Control your entire refrigeration or gas compression system with one GEA Omni High-definition display 1366 x 768 resolution Multi-touch display Natural and intuitive input Field configurability Easy retrofit panel installation Configurable Modbus TCP Ethernet communications Read/Write information from other controllers without additional wiring Hardware layout Standard industrial components with modular layout Unique user setup and auditing Create unique users and monitor usage/actions Drawings, manuals and videos Documentation at your fingertips with helpful videos available on the panel display Predictive maintenance Notifications for recommended service GEA OmniLink Application to remotely view and manage your GEA Omni control panels with Ethernet file transfer GEA OmniHistorian Application to view historical data from GEA Omni control panels and perform detailed analysis Global product with local sales and support Single design Manufactured in North America, Europe, and Asia 38 26.07.2017
GEA Omni control panel Product Highlights Preconfigured in more than 25 languages GEA peace of mind Invented, manufactured, and backed by the worldwide leader in refrigeration and gas compression control panel technology GEA Omni Overview Fig.21: GEA Omni Enclosure without indicator lamps Fig.22: GEA Omni Enclosure with indicator lamps Standard functions, typical for compressor control The GEA Omni performs the following standard functions: Display of all important physical and technical parameters, e.g. pressure, temperature, motor current, capacity, number of running hours, operating mode and status signals Hint: Certain parameters and menus are hidden when not used. Automatic start up and shut down of the compressor unit and capacity regulation dependent on: suction pressure discharge pressure external pressure external temperature network temperature inlet temperature (evaporator, secondary refrigerant) outlet temperature (evaporator, secondary refrigerant) inlet temperature (condenser) outlet temperature (condenser) Monitoring of all operating parameters Compressor capacity limitation, in case the discharge pressure, suction pressure, secondary refrigerant temperature, motor current or discharge temperature (reciprocating compressors only) limits are approached Annunciation history (notifications, warnings and shutdowns) with date and time 26.07.2017 39
GEA Omni control panel Product Highlights Wire failure detection for all analog input signals Password protection for preventing unauthorized access to important parameters Program, configuration and settings saved in non-volatile memory Control by potential-free contacts by a higher-level controller Communication via Allen-Bradley DF1, EtherNet/IP, Modbus RTU or Modbus TCP with central controller or building management system The GEA Omni consists of: Enclosure (of various sizes and mounting options shown in ) - IEC standard IP54 / NEMA 4 minimum rating Enclosure door with: Industrial Panel PC, consisting of an IPC with multi-touch screen and high-definition display for the user interface Emergency stop button directly connected to starter outputs for immediate stop of all rotating equipment USB connector with IP54 cover, for transfer of data into and out of IPC Optional indicator lamps for: Running indicates compressor is starting, running, or stopping Warning indicates operating condition has exceeded a warning setting Shutdown indicates compressor has been stopped because operating condition has exceeded a shutdown setting Enclosure interior (see ): Power supply for IPC, input circuits, output circuits and sensors I/O system provides interface to all digital and analog inputs monitored and outputs controlled Terminals for incoming supply power and for field wiring terminations Fuses and circuit breakers for short circuit and overcurrent protection; IPC and I/O logic protected by a fuse; control and sensor power connections protected by circuit breaker Wire duct to provide conduit for wiring inside enclosure 40 26.07.2017
GEA Omni control panel Product Highlights Fig.23: GEA Omni Enclosure interior 26.07.2017 41
GEA Omni control panel Input and Output Signals 6.2 Input and Output Signals Low-voltage switchgear - GEA Omni from low-voltage switchgear to GEA Omni INPUTS from GEA Omni to low voltage switchgear OUTPUTS Hint: Not applicable if the low-voltage switchgear is included in the scope of supply. Supply: 100... 240 V, 50/60 Hz digital Motor feedback digital Run compressor Motor protection compressor Run oil pump Feedback oil pump analogue (4-20 ma) Motor current compressor Compressor motor speed 7 analogue (4-20 ma) Compressor motor speed setpoint 7 Remote master or BMS - GEA Omni from remote master (BMS) to GEA Omni INPUTS digital External On/Off External "MORE" External "LESS" External motor start release from GEA Omni to remote master (BMS) OUTPUTS digital Ready for external mode signal Signal Compressor runs Main failure auxiliary output 1 External reset Changeover to 2nd setpoint Compressor blocked analogue (4-20 ma) external setpoint analogue (4-20 ma) Control slide position Refrigeration plant - GEA Omni from refrigeration plant to GEA Omni INPUTS digital External EMERGENCY STOP from GEA Omni to refrigeration plant OUTPUTS digital: -- Separator level 8 Eco level 8 Gas sensor analogue (4-20 ma): -- analogue (4-20 ma): -- 7 option, only for operation with frequency inverter 8 option 42 26.07.2017
GEA Omni control panel Screw compressor package - GEA Omni from screw compressor package to GEA Omni INPUTS digital Discharge pressure safety switch Oil level min. 8 Oil level max. 8 from GEA Omni to screw compressor package OUTPUTS digital Solenoid valve capacity control max 9 Solenoid valve capacity control, min 9 Solenoid valve - suction side check valve 8, 9 Solenoid valves - Vi control 8, 9 Solenoid valve - economiser operation 8 Solenoid valve start-up unloading 8 analogue (4-20 ma) Control slide position 9 Suction pressure analogue (4-20 ma) Setpoint IntelliSOC injection valve 8 Setpoint level control 8 Discharge pressure Oil pressure Pressure after oil filter 9 Suction temperature Discharge temperature Oil temperature Eco temperature 8 Eco pressure 8 VI slider position 8, 9 9 depending on compressor frame size 26.07.2017 43
Description of Design and Function General functional description 7 Description of Design and Function 7.1 General functional description The screw compressor packages are components of refrigerating plants and serve to compress all usual refrigerants. Use as a heat pump is also possible. 7.2 Refrigerant circuit The screw compressor draws in refrigerant vapour via the suction check valve and suction filter and then discharges the compressed vapour into the plant via the oil separator and discharge check valve. The suction-side check valve prevents a sudden pressure compensation with the low pressure side of the chiller, while also preventing reverse rotation of the screw compressor. The pressure side check valve prevents refrigerant from re-condensing in the oil separator. Hint: The discharge side check valve can be integrated into the oil separator for compressor packages with discharge side diameters nominal up to NB 150. The suction filter prevents dirt particles carried by the suction flow from penetrating into the compressor. The filter element is characterized by a very large filtering area. The filter fineness is max. 140 μm. Gas vibrations which can arise in the compressor compression chamber at high pressure ratios in the zero discharge zone are avoided by a gas vibration protection device. This consists of a pressure compensation line between the oil separator and the compressor working chamber. Process flow diagrams Fig.24: Process flow diagram GEA Grasso SP1, GEA Grasso M 1 Suction side 2 Compressor 3 Oil separator 4 Discharge side 44 26.07.2017
Description of Design and Function Refrigerant circuit Fig.25: Process flow diagram GEA Grasso SP2 1 Suction side 2 Low pressure compressor 3 High pressure compressor 4 Oil separator 5 Discharge side Fig.26: Process flow diagram GEA Grasso SPduo 1 Suction side 2 Compressor 1 3 Compressor 2 4 Oil separator 5 Discharge side 26.07.2017 45
Description of Design and Function Oil circuit 7.3 Oil circuit The screw compressors operate oil-flooded. During the compression process, refrigerating machine oil is supplied to the compressor for lubrication, sealing, noise reduction, and absorption of part of the compression heat. After the compression process, the oil is separated again from the refrigerant in the oil separator. 7.4 Oil separation 7.4.1 Oil separation (installed vertically) The refrigerant-oil mixture is led into the oil separator. The oil separator consists of two chambers where the three-phase separation of the oil from the refrigerant is performed. The first chamber employs gravity separation and drop separation in the demistor. This separated oil collects on the bottom of the first chamber. At the same time, this part of the oil separator serves as an oil collector. The fine separation of the aerosol-type oil portion from the refrigerant is performed in the second part of oil separator by means of replaceable oil fine separation cartridges. The oil separated in the fine separation part of the oil separator is returned to the compressor via an additional orifice. 7.4.2 Oil separation (installed horizontally) The refrigerant-oil mixture is led into the first part of oil separator. The oil separator consists of three chambers. The first chamber employs gravity separation. The hot gas passes the demister while flowing out of the first chamber into the second chamber. The oil separated thereby is collected in the second chamber. Both the chambers simultaneously serve as oil collector. The fine separation of the aerosol-type oil portion from the refrigerant is performed in the third chamber of oil separator by means of replaceable oil fine separation cartridges. The oil separated in the fine separation part of the oil separator is returned to the compressor via an additional orifice. 7.5 Oil heater The oil heater on the oil separator is to be started when the package is shut down in order to ensure a minimum oil temperature and sufficient oil viscosity required for restarting the package. The oil heater is used in a regulated and non-regulated version. The maximum temperature of the heating rod is restricted. 7.6 Oil cooling Before it is returned to the compressor for use, the oil heated up in the compressor has to be cooled down to a temperature at which it has sufficient viscosity. The following oil cooling types are available: 46 26.07.2017
Description of Design and Function Oil filter 1. liquid cooling water (non corrosive) propylene-glycol ethylene-glycol other cooling media on request 2. thermosysphon cooling 3. DX oil cooling 4. refrigerant injection into the compressor 7.7 Oil filter After cooling, the oil passes into the oil filter which holds back solid particles from the full oil flow. Due to its large surface, the star-folded glass fibre element has a high absorbing capacity and thus a long operating lifetime. The relative filter fineness is 25 μm. 7.8 Oil pump 7.8.1 Oil pump (external) The oil pump runs for prelubrication and during the entire operation of the compressor. It draws the refrigerating machine oil from the collection room in the oil separator, via the oil cooler and oil filter and pumps it to the bearings, the balance piston, the shaft seal, to the capacity control system and, if fitted, to the compressor's hydraulic Vi adjustment system. The oil pump pumps more oil than the compressor uses. This surplus quantity of oil is returned to the oil pump suction side via the spring loaded oil pressure control valve. The oil pressure control valve regulates the pressure difference between the oil pump pressure side and the discharge pressure. 7.8.2 Oil pumpe (without) No additional pressure increase is necessary to supply the capacity control, bearings and the compression chamber with oil. The pressure difference between the suction and discharge sides of the compressor is used to ensure the oil supply. The pressure difference between the suction and pressure side must be higher than 3 bar. The oil pressure must be at least 2 bar above the suction pressure. 7.9 Oil injection The injection oil is supplied without a pump via the oil injection control valve. The oil injection control valve is used to adjust the required discharge temperature. The control valve is provided with a check valve function to prevent sucking refrigerant through the oil pump. 26.07.2017 47
Description of Design and Function Oil circuit 7.10 Oil circuit The oil is sucked from the oil storage of the oil separator. It is then cooled in the oil cooler (exception: packages with refrigerant injection). The following three-way valve mixes warm oil from the oil separator with cooled oil from the oil cooler to ensure a predefined optimum oil temperature. This is followed by the cleaning of the oil in the oil filter. The oil is charged with or without oil pump in the compressor (depending on the type of the package). The three-way valve and the oil filter are integrated (for small and medium-sized packages) in the OMC block. The external oil pump (if present) is flanged on the oil management block as oil distribution system. The oil flow is distributed via the bore-holes and channels to functional ranges of the screw compressor. All regulating valves and shut-off valves necessary for the oil circuit control are integrated into the block. As a result, a centralised service unit is available for the screw compressor package. The oil filter with OMC block is fitted with an oil draining and oil charging stop valve which may be connected to a separate oil pump or receiver. Vent valves are fitted to oil filters for maintenance and repair purposes. The oil in oil filter may be drained for changing oil filter via a separate stop valve. For Large series packages and special designs without OMC block, all components are arranged decentrally in the oil supply system. 7.11 Capacity control The screw compressors are fitted with a continuous capacity control with a range of 0-100%. Output is adjusted by shortening the screw compressor stroke. The defining factor for the compression process is the effective rotor length; this is altered by a hydraulically operated control slide. The position of the control slide is recorded by the position sensor. The reaching of the MIN or MAX end position of the control slide is signalled at the control equipment and the relative control slide position can be shown as a percentage at the touch panel. The hydraulic adjustment of the control slide is done using four solenoid valves which are integrated into a single block. The control slide adjustment speeds in the MIN and MAX directions should be the same as much as possible during operation to ensure better compressor control. To do this, throttle screws are available on the solenoid valve block for influencing the adjustment speed. The time for manual continuous adjustment from an end position should be on average between 30 and 45 seconds. 7.12 Vi adjustment (optionally) The dimension of compressor volume flow is adapted by a hydraulically operated secondary slide to prevent an improper compression. Depending on the current operating conditions, thereby getting the best efficiency is ensured. 48 26.07.2017
Description of Design and Function Information on noise emissions 7.13 Information on noise emissions The noise information provides approximate parameters and applies to the installation without any secondary noise protection measures. The information has a tolerance of ±3 db. The precise data depend closely on the emission values for the motors, which are manufacturer dependent. Should local conditions require adherence to noise levels, a calculation should be made using the specific motor data in individual cases. Noise protection measures such as motor encapsulation e.g. complete package encapsulation can achieve a considerable noise reduction. Wearing hearing protection with sufficient noise reduction is recommended in rooms with running compressor packages. Caution! According to EU Directive 2003/10/EC, the permitted exposure threshold regarding the level of daily noise exposure is 80 db(a). Should noise levels rise above this threshold, the system operator must provide the operator with information on exposure to noise and personal hearing protection and ensure that this is also worn (2003/10/EC Article 6). Hint: The individual emission data for the motor-compressor combinations can be found in the tables and added using logarithms for compressor package and chillers (DuoPack version) as well as two-stage compressor packages. 26.07.2017 49
Description of Design and Function Information on noise emissions Sound power level L WA at compressor frame size C to M Compressor drive motor at 40 C P e in kw 22 30 37 45 55 75 90 110 132 160 200 Compressor frame size/theoretical swept volume in m 3 /h at 2940 rpm L WA in db(a) mains operation 400 V / 50 Hz C 231 D 265 E 321 Max 91 91 91 Min 84 84 84 G 372 Max 92 92 92 92 Min 85 85 85 85 H 471 Max 93 93 93 93 93 Min 86 86 86 86 86 Max 94 94 94 94 94 94 Min 87 87 87 87 87 87 L 544 Max 95 95 95 95 95 95 95 Min 88 88 88 88 88 88 88 Max 96 96 96 96 96 96 96 Min 89 89 89 89 89 89 89 Max 97 97 97 97 97 97 97 Min 90 90 90 90 90 90 90 Max 98 98 98 98 98 98 Min 91 91 91 91 91 91 Max 98 99 99 99 99 Min 92 92 92 92 92 Max 100 100 100 Min 93 93 93 Max 101 Min 94 M 708 50 26.07.2017
Description of Design and Function Information on noise emissions Sound power level L WA at compressor frame size N to W Compressor drive motor at 40 C P e in kw 55 75 90 110 132 160 200 250 315 400 450 500 560 630 Compressor frame size/theoretical swept volume in m 3 /h at 2940 rpm L WA in db(a) mains operation 400 V / 50 Hz P 805 N 870 Max 95 95 Min 88 88 R 1040 Max 96 96 96 Min 89 89 89 S 1290 Max 97 97 97 97 Min 90 90 90 90 T 1460 V 1640 Max 98 98 98 98 98 98 Min 91 91 91 91 91 91 Max 99 99 99 99 99 99 99 Min 92 92 92 92 92 92 92 W 1990 Max 100 100 100 100 100 100 100 Min 93 93 93 93 93 93 93 Max 101 101 101 101 101 101 101 Min 94 94 94 94 94 94 94 Max 102 102 102 102 102 102 102 Min 95 95 95 95 95 95 95 Max 103 103 103 103 103 Min 96 96 96 96 96 Max 104 104 104 104 104 Min 97 97 97 97 97 Max 104 104 104 104 Min 98 98 98 98 Max 105 105 105 Min 98 98 98 Max 105 105 105 Min 99 99 99 Max 105 Min 99 26.07.2017 51
Description of Design and Function Information on noise emissions Sound power level L WA at compressor frame size Y to XC Compressor drive motor at 40 C P e in kw 132 160 200 250 315 400 450 500 560 630 710 800 900 1000 Compressor frame size/theoretical swept volume in m 3 /h at 2940 rpm L WA in db(a) mains operation 400 V / 50 Hz Y 2296 Max 99 Min 92 Z 2748 Max 100 100 Min 93 93 XA 3250 Max 101 101 101 Min 94 94 94 XB 4150 Max 102 102 102 103 Min 95 95 95 100 XC 4900 Max 103 103 103 104 104 Min 96 96 96 100 100 Max 104 104 104 104 104 Min 97 97 97 100 100 Max 104 104 104 104 104 Min 98 98 98 100 100 Max 105 105 105 105 105 Min 98 98 99 100 100 Max 105 105 105 105 105 Min 99 99 100 100 100 Max 105 105 105 106 106 Min 99 99 99 100 100 Max 105 106 106 106 Min 99 99 100 100 Max 106 106 106 106 Min 99 99 100 100 Max 107 107 Min 100 100 Max 107 Min 100 52 26.07.2017
Description of Design and Function Sound power level L WA at compressor frame size XD to XH Compressor drive motor at 40 C P e in kw 315 400 450 500 560 630 710 800 900 1000 Compressor frame size/theoretical swept volume in m 3 /h at 2940 rpm L WA in db(a) mains operation 400 V / 50 Hz XD 5800 Max 105 Min 101 XE 7170 XF 8560 Max 105 105 105 Min 101 102 102 XG 9807 XH 11467 Max 105 105 105 106 106 Min 101 102 102 103 103 Max 105 105 105 106 106 Min 101 102 102 103 103 Max 105 105 105 106 106 Min 101 102 102 103 103 Max 106 106 106 107 107 Min 101 102 102 103 103 Max 106 106 106 107 107 Min 101 102 102 103 103 Max 106 106 106 107 107 Min 101 102 102 103 103 Max 107 107 107 107 107 Min 101 102 102 104 104 Max 107 107 107 108 108 Min 101 102 102 104 104 26.07.2017 53
Economizer Economizer variants for single-stage screw compressor packages 8 Economizer 8.1 Economizer variants for single-stage screw compressor packages 8.1.1 Type A - economizer port pipe Fig.27: Economizer port pipe P Pressure sensor (optional) T Temperature sensor (optional) Suction line, mounted on the screw compressor package, consisting of: Stop valve Suction filter Check valve Thermometer/ Service valve Optional: Pressure and temperature sensors, Pressure controller Notice! Several packages can be connected to an economizer in parallel. When doing so, each connection line must be provided with a pressure controller (constant/differential pressure controller). 54 26.07.2017
Economizer Economizer variants for single-stage screw compressor packages 8.1.2 Fig.28: Type B - Economizer for two-stage expansion (Open flash) with level control Economizer for two-stage expansion (Open flash) with level control P Pressure sensor (optional) T Temperature sensor (optional) LSA level monitor LC Level control 1 from condenser 2 to evaporator 3 Open flash vessel (vertical) Scope of delivery: Suction line according type A Open flash vessel, separate mounted, with level controlled injection, filter and stop valves at the inlet side Constant pressure valve (differential pressure valve) in the vapour outlet of the economizer Maximum level limiter with trigger Safety valve Oil drain valve Pressure and temperature sensors Notice! Economizer for two-stage expansion with inlet control system in the economizer - especially for use of NH3(Open flash): Refrigerant collector in the high pressure part is required! 26.07.2017 55
Economizer Economizer variants for single-stage screw compressor packages 8.1.3 Type C Economizer for single-stage expansion (Closed flash) with shell and tube heat exchanger Fig.29: Economizer for single-stage expansion (Closed flash) with shell and tube heat exchanger P Pressure sensor (optional) T Temperature sensor (optional) 1 from condenser 2 to evaporator 3 Side load connection (optional) Scope of supply: Suction line according Type A Shell and tube heat exchanger mounted at the screw compressor package Expansion valve Stop valve, filter, solenoid valve Safety valve Optional: Pressure and temperature sensors Side load connection 8.1.4 Type D Economizer for single-stage expansion (Closed flash) with plate heat exchanger The scheme is adequate to Type C. 56 26.07.2017
Economizer Economizer variants for single-stage screw compressor packages 8.1.5 Fig.30: Type E Economizer for two-stage expansion (Open flash) with HP floater Economizer for two-stage expansion (Open flash) with HP floater P Pressure sensor (optional) T Temperature sensor (optional) LSA Level monitor LC Level controller 1 from condenser 2 to evaporator 3 Open flash vessel (vertical) Notice! Scope of delivery: order-related Economizer for two-stage expansion (Open flash) with HP floater at the inlet and outlet sides, refrigerant reservoir in the low stage liquid separator mainly for NH3. 26.07.2017 57
Economizer Economizer variants for DuoPack screw compressor packages 8.2 Economizer variants for DuoPack screw compressor packages 8.2.1 Type A-Duo Economizer port pipe Fig.31: Economizer port pipe P Pressure sensor (optional) T Temperature sensor (optional) Suction line (mounted on the screw compressor package) consisting of: Stop valve10 Suction filter10 Check valve10 Thermometer/ Service valve10 Optional: 10 58 Pressure and temperature sensors10 in duplicate 26.07.2017
Economizer Economizer variants for DuoPack screw compressor packages 8.2.2 Fig.32: Type B-Duo Economizer for two-stage expansion (Open flash) with level control Economizer for two-stage expansion (Open flash) with level control P Pressure sensor (optional) T Temperature sensor (optional) LSA Level monitor LC Level control 1 from condenser 2 to evaporator 3 Open flash vessel (vertical) Scope of supply: order-related 26.07.2017 59
Economizer Economizer variants for DuoPack screw compressor packages 8.2.3 Type C-Duo Economizer for single-stage expansion (Closed flash) with shell and tube heat exchanger Fig.33: Economizer for single-stage expansion (Closed flash), diagram 1 for higher power P Pressure sensor (optional) T Temperature sensor (optional) 1 from condenser 2 to evaporator Scope of supply: Suction line according Type A-Duo Dual tube bundle heat exchanger, mounted at the screw compressor package Expansion valve11 Stop valve11, filter11, solenoid valve11 Safety valve Optional: Pressure and temperature sensors11 Side load connection11 11 60 in duplicate 26.07.2017
Economizer Fig.34: Economizer for single-stage expansion (Closed Flash), diagram 2 for lower power P Pressure sensor (optional) T Temperature sensor (optional) 1 from condenser 2 to evaporator Scope of supply: Suction line according Type A-Duo Circuit tube bundle heat exchanger, mounted at the screw compressor package Thermostatic expansion valve Stop valve, filter, solenoid valve Safety valve Constant pressure valve11 Optional: Pressure and temperature sensors11 26.07.2017 61
Enquiry sheet 9 Enquiry sheet 62 26.07.2017