Training screw compressors

09/12/2023
Service Department (ESS)
overview
* 2940 U/min (rpm)

09/12/2023
Service Department (ESS)
Designation code
Bezeichnung / Designation code

09/12/2023
Service Department (ESS)
Compression principle
Verdichtungsprinzip / Compression principle
Ansicht von oben /upper view - SUCTION PROCESS
Ansicht von unten /view from the bottom - COMPRESSION PROCESS

09/12/2023
Service Department (ESS)
Vi-Diagram
Vi-Diagramm / Vi-diagram

09/12/2023
Service Department (ESS)
LARGE - Compressor
Verdichter / Compressor - LARGE
Vi: variable

09/12/2023
Service Department (ESS)
LARGE – Drawing (top)
Verdichter / Compressor LARGE

09/12/2023
Service Department (ESS)
LARGE – Drawing (side)
Verdichter / Compressor LARGE
Vi: variable

09/12/2023
Service Department (ESS)
LARGE – Drawing (capacity control)
Verdichter / Compressor LARGE
Vi: fixed

09/12/2023
Service Department (ESS)
LARGE – oil connections
Verdichteranschlüsse / Oil connections LARGE

09/12/2023
Service Department (ESS)
LARGE – oil connections
Verdichteranschlüsse / Ports - LARGE

09/12/2023
Service Department (ESS)
Verdichter / Compressor LARGE (W,Z - XF)
Position MV-Block / Solenoid block

09/12/2023
Service Department (ESS)
Verdichter / Compressor LARGE (W,Z - XF)
Verdichteranschlüsse / Oil connections

09/12/2023
Service Department (ESS)
LARGE - Casing
Rotorgehäuse
Rotor casing
Druckgehäuse
Discharge casing
Vi: fixed

09/12/2023
Service Department (ESS)
LARGE – overview connections
Anschlüsse / Connections - Series LARGE

09/12/2023
Service Department (ESS)
LARGE – Listing connections
Anschlüsse / Connections - Series LARGE

09/12/2023
Service Department (ESS)
Vi-Regelung LARGE / Vi-Control LARGE
Regelung – Tandem Schiebersystem
Control – tandem slide system

09/12/2023
Service Department (ESS)
Vi-Regelung LARGE / Vi-Control LARGE
Leistungsregelung: 0%
Capacity: 0%
Solenoid valves Y2, Y3, Y5 constantly
energized
Capacity indication: 0%
Magnetventile Y2, Y3, Y5 mit
Dauersignal angesteuert
Leistungsanzeige: 0%
Startbedingung /Start Condition (INCREASE CAPACITY)

09/12/2023
Service Department (ESS)
1. Solenoid valves Y1, Y4 pulsed energized
(primary slide is controlled)
2. Solenoid valve Y5 constantly energized
(Vi-slide not controlled)
Capacity indication: primary slide position
Vi-Regelung LARGE / Vi-Control LARGE
Leistungsregelung: 0% -X%
Capacity: 0% - X%
MODE 1 (INCREASE CAPACITY):
1. Magnetventile Y1, Y4 gepulst angesteuert
(Ansteuerung von Primärschieber)
2. Magnetventile Y5 mit Dauersignal angesteuert
(Vi-Schlitten nicht angesteuert)
Leistungsanzeige: Pos. von Primärschieber
with X% = 73%- 100%
Depends on:
Vi (Po,Pk,refrigerant)
Compressor model

09/12/2023
Service Department (ESS)
Vi-Regelung LARGE / Vi-Control LARGE
End of MODE 1 (INCREASE CAPACITY):
1. Magnetventile Y1, Y4 gepulst angesteuert
(Ansteuerung von Primärschieber)
2. Magnetventile Y5 mit Dauersignal angesteuert
(Vi-Schlitten nicht angesteuert)
Leistungsanzeige: Pos. von Primärschieber
1. Solenoid valves Y1, Y4 pulsed energized
(primary slide is controlled)
2. Solenoid valve Y5 constantly energized
(Vi-slide not controlled)
Capacity indication: primary slide position
Leistungsregelung = X%
Capacity = X%
Bedingung/term:
Vi (Po,Pk,refr.)= opt.
X% > S(Gr)

09/12/2023
Service Department (ESS)
Vi-Regelung LARGE / Vi-Control LARGE
MODE 2 (INCREASE CAPACITY): :
Leistungsregelung: X% - 100%
Capacity: X% - 100%
1. Magnetventile Y6 gepulst angesteuert
(Vi-Schlitten angesteuert)
2. Stellung Primärschieber wird gemäß Betriebs-
bedingungen nachgeregelt
(Y1, Y4 oder Y2,Y3 gepulst angesteuert)
Leistungsanzeige:
(Position von Primärschieber + 100%) / 2
1. Solenoid valve Y6 pulsed energized
(Vi-slide controlled)
2. primary slide is readjusted according to
operating values
(Y1, Y4 or Y2, Y3 pulsed energized)
Capacity indication:
(primary slide position + 100%) / 2

09/12/2023
Service Department (ESS)
Vi-Regelung LARGE / Vi-Control LARGE
MODE 3:
1. Magnetventile Y6 mit Dauersignal angesteuert
(Vi-Schlitten angesteuert)
2. Stellung Primärschieber wird nachgeregelt
(Y1, Y4 oder Y2, Y3 gepulst angesteuert)
Leistungsanzeige: 100%
1. Solenoid valve Y6 constantly energized
(Vi-slide controlled)
2. primary slide is readjusted according to
operating values
(Y1, Y4 or Y2,Y3 pulsed energized)
Capacity indication: 100%
Leistungsregelung: 100%
Capacity: 100%

09/12/2023
Service Department (ESS)
MEDIUM Compressor
Verdichter / Compressor MEDIUM
Vi: variable

09/12/2023
Service Department (ESS)
MEDIUM Compressor
Verdichter / Compressor MEDIUM
Vi: variable

09/12/2023
Service Department (ESS)
MEDIUM - ports for internal oil circuit
interner Ölkreislauf / Internal oil circuit
Vi: variable

09/12/2023
Service Department (ESS)
MEDIUM – drawing (top)
Verdichter / Compressor MEDIUM

09/12/2023
Service Department (ESS)
MEDIUM – drawing (side)
Verdichter / Compressor MEDIUM
Vi: fixed

09/12/2023
Service Department (ESS)
MEDIUM – Drawing (capacity control)
Verdichter / Compressor MEDIUM

09/12/2023
Service Department (ESS)
MEDIUM – Drawing (solenoid valve block)
Verdichter / Compressor MEDIUM

09/12/2023
Service Department (ESS)
MEDIUM - internal oil circuit
Verdichter / Compressor MEDIUM

09/12/2023
Service Department (ESS)
MEDIUM – Hydraulic chambers
Verdichter / Compressor MEDIUM

09/12/2023
Service Department (ESS)
MEDIUM – oil management: MM11
Ölversorgungssystem mit integrierter Ölpumpe
Oil management with integrated oil pump
MM 11

09/12/2023
Service Department (ESS)
MEDIUM – oil management: MM12
Ölversorgungssystem mit externer Ölpumpe
Oil management with external oil pump
MM12

09/12/2023
Service Department (ESS)
MEDIUM – Listing connections

09/12/2023
Service Department (ESS)
MEDIUM: Verdichteranschlüsse / Ports
MEDIUM - ports

09/12/2023
Service Department (ESS)
MEDIUM – oil connection ports
MEDIUM - Verdichteranschlüsse / Oil connections

09/12/2023
Service Department (ESS)
MEDIUM – connection ports
MEDIUM - Verdichteranschlüsse / Oil connections

09/12/2023
Service Department (ESS)
MEDIUM – damped Check valve
Einführung / Introduction: 05/2000
Check Valve - damping device non-adjustable
Rückschlagventil – nicht einstellbare Dämpfungseinrichtung

09/12/2023
Service Department (ESS)
MEDIUM – damped Check valve
Check Valve - damping device adjustable
Rückschlagventil – einstellbare Dämpfungseinrichtung
Einführung / Introduction: 03/2002

09/12/2023
Service Department (ESS)
SMALL Compressor
Verdichter / Compressor SMALL
Vi: variable

09/12/2023
Service Department (ESS)
SMALL – main components I

09/12/2023
Service Department (ESS)
SMALL – main components II

09/12/2023
Service Department (ESS)
SMALL – drawing (top)
Verdichter / Compressor SMALL

09/12/2023
Service Department (ESS)
SMALL – drawing (side)
Verdichter / Compressor SMALL
Vi: variable

09/12/2023
Service Department (ESS)
SMALL – drawing (front)
Verdichter / Compressor SMALL

09/12/2023
Service Department (ESS)
SMALL – drawing (oil pump)
Verdichter SMALL
Compressor SMALL

09/12/2023
Service Department (ESS)
SMALL – ports & connectors

09/12/2023
Service Department (ESS)
SMALL – Listing ports

09/12/2023
Service Department (ESS)
SMALL - internal oil circuit
Verdichter / Compressor SMALL

09/12/2023
Service Department (ESS)
SMALL – oil management: SM11
Ölversorgungssystem mit integrierter Ölpumpe/
Oil management with integrated oil pump
SM11

09/12/2023
Service Department (ESS)
SMALL – oil management: SM12
Ölversorgungssystem mit externer Ölpumpe
Oil management with external oil pump
SM12

09/12/2023
Service Department (ESS)
SMALL – oil filter
Alte Ausführung: bis ~ 01/1999
Old design: till ~01/1999

09/12/2023
Service Department (ESS)
SMALL – oil management block 1 & 2
Oil management block 1
Oil management block 2
for mono packs
for Duo-packs

09/12/2023
Service Department (ESS)
SMALL – oil managements
SD12-R1 (Duo-Pack)
SM12 (Mono Pack)

09/12/2023
Service Department (ESS)
SMALL – Picture I

09/12/2023
Service Department (ESS)
SMALL – Picture II

09/12/2023
Service Department (ESS)
Positionsanzeige / Positioning indication
Funktionsschema der Positionsanzeige
Functional scheme of positioning indication

09/12/2023
Service Department (ESS)
Standard Positionsanzeige / Standard Positioning indication
HDT am Sauggehäuse / positioning sensor at suction end

09/12/2023
Service Department (ESS)
XB, XC, XD: Positionsanzeige / Standard Positioning indication
XB, XC, XD,XE,XF:
HDT Funktionschema
Function scheme for positioning sensor
HDT am Rotorgehäuse
positioning sensor at rotor casing

09/12/2023
Service Department (ESS)
Wegsensor (HDT) / positioning indicator

09/12/2023
Service Department (ESS)
Einstellung HDT / Adjustment positioning sensor
Calibrating:
1. Bring the control slide (113) to the MIN-position (pull it along the threaded rod towards the discharge side as far as the limit stop). With the slide in its MIN-position, use the adjustment controller "O" to set the value of 4+0,2 mA.
2. Bring the control slide to the MAX-position (push it towards the suction side as far as the limit stop by means of the threaded rod). With the slide in its MAX-positon, use the adjustment controller "V" to correct the midpoint between the actual value and the setpoint as accurately as possible (see figure 11.2).
3. With the slide in its MAX-position, use the adjustment controller "O" to set the output end value of 20+0,5 mA.
Einstellung:
1. Regelschieber (113) in MIN-Stellung bringen (an der Gewindestange in Richtung Druckseite bis zum Anschlag ziehen). In MIN-Position des Schiebers am Einstellregler "O" 4+0,2 mA einstellen.
2. Regelschieber in MAX-Stellung bringen (mit der Gewindestange in Richtung Saugseite bis zum Anschlag schieben).
In MAX-Position des Schiebers am Einstellregler "V" möglichst genau auf den Mittelwert zwischen Ist- und Sollwert korrigieren (siehe Abb. Justierung des Wegsensors).
3. In MAX-Position des Schiebers am Einstellregler "O" den Ausgangsendwert 20+0,5mA einstellen.

09/12/2023
Service Department (ESS)
Magnetventilblock / solenoid valve block

09/12/2023
Service Department (ESS)
Magnetventilblock / solenoid valve block

09/12/2023
Service Department (ESS)
Magnetventilblock / solenoid valve block
Steuerung/ Control
to MAX:
Y1, Y4 - auf/open
Y2, Y3 - zu/closed
to MIN:
Y1, Y4 - zu/closed
Y2, Y3 - auf/open

09/12/2023
Service Department (ESS)
MVBL intern / solenoid valve block – internal piping

09/12/2023
Service Department (ESS)
MVBL – Anschlüsse
Solenoid valve block - Ports
Magnetventilblock – Anschlüsse

09/12/2023
Service Department (ESS)
MVBL – Anschlüsse
Solenoid valve block - Ports
Magnetventilblock – Anschlüsse

09/12/2023
Service Department (ESS)
Reparatur Verdichter / repair compressor
Austausch Gleitringdichtung
Exchange shaft seal
SMALL & MEDIUM:
Ausbau Ausgleichskolben
Dismantling balance piston

09/12/2023
Service Department (ESS)
Reparatur Verdichter / repair compressor
Demontage Wegsensorsystem
Dismantling position indication system

09/12/2023
Service Department (ESS)
Reparatur Verdichter / repair compressor
Demontage Leistungsverstellung
Dismantling capacity control system

09/12/2023
Service Department (ESS)
Axial play
Einstellung Stirnspalt / Messung Axialspiel
Face gap adjustment / Measurement axial play

09/12/2023
Service Department (ESS)
Stirnspalteinstellung / Face gap adjustment
Werkseinstellung: MIN 0,04mm – MAX 0,1mm (baureihenabhängig)
Adjusted Value: Min 0.04mm - Max 0.1mm (model dependent)
Stirnspalt – bei Herstellung
Face gap – at Factory first build up
Rotor
Housing / Gehäuse
Discharge side
Druckseite
Face gap
Stirnspalt

09/12/2023
Service Department (ESS)
Stirnspalteinstellung / Face gap adjustment
Stirnspalteinstellung – bei Herstellung
Face gap adjustment – at Factory first build up
Stirnspaltvergrößerung – Einschleifen des äußeren Distanzrings
face gap increases if the outer ring is ground down

09/12/2023
Service Department (ESS)
Stirnspalteinstellung / Face gap adjustment
Stirnspalteinstellung – bei Herstellung
Face gap adjustment – at Factory first build up
Stirnspaltverkleinerung – Einschleifen des inneren Distanzrings
face gap decreases if the inner ring is ground down
Rotor
Housing / Gehäuse
Discharge side
Druckseite
Face gap
Stirnspalt

09/12/2023
Service Department (ESS)
Standard face gap measurement
Vorbereitung zur Stirnspaltmessung
Preparation for face gap measurement
Depressurize compressor
Remove coupling guard
Loosen coupling seat
Loosen tension spring
Remove cover plates, plate springs,
Remove thrust piece(discharge side)
Install gauge
Verdichter drucklos machen
Abbau Kupplungschutz
Lockern Kupplungsitz
Zugfeder lösen
Abbau druckseitiger Abschlußflansch
Druckstück herausnehmen
Meßuhr installieren

09/12/2023
Service Department (ESS)
Standard Stirnspaltmessung/ Standard face gap measurement
Rotor forced to
Discharge side
Meßwert = 0 / Meßuhr auf 0 setzen
Measured value = 0 / Reset gauge to continue
Meßposition (Druckseite)
End position (discharge side)
Rotor
Housing / Gehäuse
Discharge side
Druckseite
Measured value = 0

09/12/2023
Service Department (ESS)
Standard Stirnspaltmessung/ Standard face gap measurement
Rotor forced to
suction side
Meßwert: Axialversatz = Stirnspalt + Axialspiel (Spiel des inneren Lagers)
Measured value: Axial displacement = Face gap + axial play (clearance of loaded inner bearing)
Meßposition (Saugseite)
End position (suction side)

09/12/2023
Service Department (ESS)
Grenwerte / Limit values for Grasso screw compressors
Type of the compressor Face gap (mm) * Axial play (mm)
C, D, E, G 0,04 - 0,07 0,15
H, L 0,04 - 0,07** 0.15
M, N 0,05 - 0.08 0,15
P 0,07 - 0,10 0,2
R, S 0,07 - 0,10 0,2
V,W, Y 0,07 - 0,10 0,25
Z, Xa, Xb, Xc, Xd 0,07 - 0,10 0,3
Maximal zulässige Axialspiele / Maximum permissible axial plays
Die Axiallager sind zu ersetzen, wenn die unten angegebenen Axialspiele überschritten werden oder:
die Lager einen unnormalen Geräuschpegel aufweisen
Unnormales Laufbild (z.B.Vibrationen) auftritt
Optische Mängel am Lager (z.B Käfigverschleiß) festzustellen ist
The axial bearings have to be exchanged if the axial play is greater than the mentioned limit or:
if they are making strange noise
Unnormal operating characteristics (e.g. vibrations)
Optical defect are recognizable
*adjusted at newly built compressor in the Grasso company/ Einstellung bei Verdichterneubau
** Before 2003 - Face gap (H,L-compressors): 0.05 – 0.08mm

09/12/2023
Service Department (ESS)
Stirnspaltmessung – neue Methode / NEW face gap measurement
1. Meßposition (Saugseite)
1st end position (suction side)

09/12/2023
Service Department (ESS)
Stirnspaltmessung – neue Methode / NEW face gap measurement
2. Meßposition (Druckseite)
2nd end position (discharge side)
1. Meßwert (Druckseite) – 2. Meßwert (Saugseite) = Axialspiel
1nd Value (discharge) – 2st Value (suction) = Axial play

09/12/2023
Service Department (ESS)
Reparatur Verdichter / repair compressor
Ausbau Axiallager I
Exchange of angular ball bearings I

09/12/2023
Service Department (ESS)
Reparatur Verdichter / repair compressor
Ausbau Axiallager II
Exchange of angular ball bearings II

09/12/2023
Service Department (ESS)
Anzugsmomente Axiallager / Tightening torgue axial bearings
Type of the compressor Male Rotor Female Rotor
C, D, E, G 150Nm 150Nm
H, L, M, N 400Nm 400Nm
P 400Nm 400Nm
R, S 500Nm 400Nm
V,W, Y 500Nm 500Nm
Z, XA 600Nm 500Nm
XB, XC, XD 900Nm 700Nm
Anzugmoment - Nutmuttern Axiallager
Tightening torque – grooved nut of axial bearing
*auch im Bedienungshandbuch nachzuschlagen
*see also user manual

09/12/2023
Service Department (ESS)
Gleitringdichtung / shaft seal
Art der eingebauten GLRD ist Kompressortypabhängig
Type of installed shaft seal is compressor type dependend
Typen - Gleitringdichtung
Type of shaft seals
*
*Vor Einbau bitte Madenschraube entfernen
Before assembling grub screw has to be removed

09/12/2023
Service Department (ESS)
Gleitringdichtung / shaft seal
Type of the compressor oil leakage rate
C, D, E, G ~0,5ml/h ~1..2 drops/ min
H, L, M, N ~1,0ml/h ~2...3 drops/ min
P, R, S ~3,5ml/h ~9...10 drops/ min
V,W, Y, Z, XA ~9,0ml/h ~20…22 drops/ min
XB, XC, XD ~10,0ml/h
Tolerierte Leckraten von GLRD
Tolerated Leakage rates of shaft seals

09/12/2023
Service Department (ESS)
Rückholfeder / tension spring
Rückholfeder / Tension spring (SMALL & MEDIUM)
Alte Ausführung / Old design
till: 08/1999
Neue Ausführung / New design
from: 09/1999