GEA Grasso DX RR 200 User manual

_601011_pi_dxr_gbr_1_.doc 1
Liquid Chiller Grasso DX R
200 ... 1600
Product Information

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
2 _601011_pi_dxr_gbr_1_.doc
COPYRIGHT
All Rights reserved. No part of this publication may be copied or published by means of printing, photocopying,
microfilm or otherwise without prior written consent of Grasso. This restriction also applies to the corresponding
drawings and diagrams.
LEGAL NOTICE
This publication has been written in good faith. However, Grasso cannot be held responsible, neither for any
errors occurring in this publication nor for their consequences.

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 3
SYMBOLS USED IN THIS MANUAL
Danger!
This is an important warning. Non-observance these warnings can cause accidents with relevant
damages on persons or serious damages on the compressor or refrigerating plant.
Warning!
Attention! Caution! Important!
Hint!
Tip! Note!

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 5
TABLE OF CONTENTS
1Function and design............................................................................................................................... 8
2Product range......................................................................................................................................... 9
3Designation .......................................................................................................................................... 12
4Description of Design and Function .................................................................................................... 13
4.1 Structure.................................................................................................................................. 13
4.2 Mode of operation ................................................................................................................. 13
4.3 Shell and tube evaporator...................................................................................................... 13
4.4 Condenser type ....................................................................................................................... 14
4.5 Control unit ............................................................................................................................. 14
4.6 Low voltage Power Panel ....................................................................................................... 14
4.7 safety devices against pressure exceedings............................................................................ 14
4.8 Reduce effects of released Ammonia..................................................................................... 14
4.9 Optional equipment................................................................................................................ 15
4.9.1 Pressure gauge kit....................................................................................................... 15
4.9.2 Dual oil filter ............................................................................................................... 15
4.9.3 Connection flanges ..................................................................................................... 15
4.9.4 Hydraulic Adjustment of theinternal volume ratio (Vi).......................................... 15
4.9.5 L2-Bus communication of compressor control device................................................ 15
4.9.6 Anti-vibration mounting ............................................................................................. 15
5P + I Diagrams ...................................................................................................................................... 16
5.1 P+I diagram for standard ammonia liquid chiller DX series, type RR 200 - RR 350 .............. 16
5.2 P+I diagram for standard ammonia liquid chiller DX series, type LR 200 - LR 350
(VR 200 - VR 350).................................................................................................................... 18
5.3 P+I diagram for standard ammonia liquid chiller DX series, type RR 450 - RR 800 .............. 20
5.4 P+I diagram for standard ammonia liquid chiller DX series, type LR 450 - LR 800
(VR 450 - VR 800).................................................................................................................... 22
5.5 P+I diagram for standard ammonia liquid chiller DX series, type RR 750 - RR 1600 ............ 24
5.6 P+I diagram for standard ammonia liquid chiller DX series, type LR 750 - LR 1600
(VR 750 - VR 1600).................................................................................................................. 26
6Power parameters................................................................................................................................ 28
7Weights and charges - Types RR 200 ... RR 350 .................................................................................. 32
8Weights and charges - Types RR 450 ... RR 800 .................................................................................. 33
9Weights and charges - Types RR 750 ... RR 1600 ................................................................................ 34
10 Modular Control................................................................................................................................... 35
11 Absorption device ................................................................................................................................ 38
11.1 General Information ............................................................................................................... 38
11.2 Functional description............................................................................................................. 38
11.3 Installation............................................................................................................................... 38
11.4 Main dimensions ..................................................................................................................... 39
11.5 Assembly.................................................................................................................................. 40
11.5.1 Positioning................................................................................................................. 40
11.5.2 Table of connecting sleeves...................................................................................... 41
12 Technical Data - Selection table........................................................................................................... 42

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 7
TABLE OF FIGURES
fig. 1: Isolator without foundation fixation ................................................................................................ 15
fig. 2: P+I diagram for standard ammonia liquid chiller DX series, type RR 200 - RR 350 ......................... 16
fig. 3: P+I diagram for standard ammonia liquid chiller DX series, type LR 200 - LR 350
(VR 200 - VR 350)............................................................................................................................... 18
fig. 4: P+I diagram for standard ammonia liquid chiller DX series, type RR 450 - RR 800 ......................... 20
fig. 5: P+I diagram for standard ammonia liquid chiller DX series, type LR 450 - LR 800
(VR 450 - VR 800)............................................................................................................................... 22
fig. 6: P+I diagram for standard ammonia liquid chiller DX series, type RR 750 - RR 1600 ....................... 24
fig. 7: P+I diagram for standard ammonia liquid chiller DX series, type LR 750 - LR 1600
(VR 750 - VR 1600)............................................................................................................................. 26
fig. 8: Ammonia liquid chiller - Types RR 200 ... RR 350.............................................................................. 32
fig. 9: Ammonia liquid chiller - Types RR 450 ... RR 800.............................................................................. 33
fig. 10: Ammonia liquid chiller - Types RR 750 ... RR 1600.......................................................................... 34
fig. 11: Display of the Grasso System Conrol (GSC)..................................................................................... 35
fig. 12: Absorption device ABSA, view ........................................................................................................ 40

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
8 _601011_pi_dxr_gbr_1_.doc
1 FUNCTION AND DESIGN
Introduction
The Ammonia Liquid Chillers (ALC) Programme for dry evaporation (DX) provides for proven components as
complete refrigeration systems for medium and large refrigeration and/or air conditioning needs.
Generally, these refrigeration systems use ammonia as refrigerant which is characterized by a high regrigeration
capacity, low energy consumption and a beneficial price and which is completely neutral towards the
environment.
Equipped with the Grasso screw compressor series, the DX chiller range covers the refrigeration range of 200 to
1600 kW for cold water.
The performance ranges are determined by 12 type sizes of the screw compressor series
The hole DX chiller programme consists of 3 series with different condenser types working according to principle
of dry evaporation.
Ammonia liquid chillers for dry evaporation (DX chiller) consists of the following main components:
1. Drive-line (screw compressor, driving motor, oil separator)
2. Evaporator with basic frame, carrying the drive-line
3. Condenser, alternative
—built on shell and tube type
—external evaporative condenser or air cooled condenser
4. Low-voltage supply with control unit
DX chiller can be delivered in version RR for complete capacity range of model types 200 - 1600 as standard ready
for connecting, complete with pipes and wiring.
The complete combination of drive line and evaporator can be delivered for versions LR and VR, so that the
condenser only have to connect on site.
The DX chillers are designed according to the 3 different concepts of Grasso screw compressors.
Because of that compact designed DX chiller carried out.
The standard model types valid for the named conditions (see overview - cold water 12°C/ 6°C and cooling water
26°C/ 32°C).
Each model size can be delivered with exact adapted evaporators and condensers deviating of standard as well as
with different secondary refrigerants and cooling mediums.
These special models require changes concerning the standard dimensions.
You'll find defined power parameters as selection tables in this product information. These table values serve for a
first model type selection. For the concrete application field the values have to confirm by Grasso.
Ammonia liquid chiller DX types are eqipped with a standard PLC (control device).
A background illumination LCD display allows reading of all operating and fault messages as well as process variables.
The display is operated via a robust keypad having 6 function and 24 system keys..
Each DX chiller can optionally be equipped with an absorption device for additional safety in case of havary.
The use of the absorption facility depends upon the installation conditions of the DX chiller and the design of the
machine room and ought to be checked in each individual case taking into account the relevant provisions.
The DX chillers are delivered with a dry nitrogen charge (0.5 bar g.p.).
Refrigerant and special refrigeration oil are included in scope of supply.
A user manual with description of refrigeration circuit, and instructions for commissioning, operating and
maintenance are belonging to each DX chiller supply.
For detailed informations regarding screw compressors see separate product informations.

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 9
2 PRODUCT RANGE
Basis for chiller series: Screw compressor series
Screw compressor
SH Series
Screw compressor
MC Series
Screw compressor
LT Series
Screw compressor: 4 types: C, D, E, G
Vth = 231 ... 375 m3/h
4 types: H, L, M, N
Vth = 450 ... 690 m3/h
4 types: P, R, S, V
Vth = 805 ... 1,640 m3/h
Chiller design: DX
Series: RR LR VR
Working principle: dry evaporation
Condenser types:
water cooled shell and
tube heat exchanger
R
air cooled condenser
L
evaporative condenser
V
Evaporator type:
R
shell and tube heat
exchanger
R
shell and tube heat
exchanger
R
shell and tube heat
exchanger
The DX chiller series consists of 12 model types with established Grasso screw compressors.
The capacity range covers from 200 kW up to 1600 kW regarding air conditioning application for manufacturing
cold water.
The only used refrigerant is ammonia.
The working principle is the dry evaporation with shell and tube heat exchangers as evaporator and condenser.
Only a very small refrigerant content is required for all models of this series complying with the highest safety and
environmental standards.
The standard RR Chiller is complete factory-assembled, with electric and tube lines and a l.v. switching station.
The complete combination of drive line and evaporator can be delivered for versions LR and VR.
The condenser has to be connected on site.

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
10 _601011_pi_dxr_gbr_1_.doc
Series RR - overview
Chiller Type: Compressor Chiller capacity (kW) 1Motor nom. capacity (kW)
RR 200 C 191 55
RR 250 D 227 75
RR 300 E 272 75
RR 350 G 322 90
RR 450 H 411 110
RR 500 L 485 132
RR 600 M 615 160
RR 750 N 748 200
RR 800 P 798 200
RR 1000 R 966 250
RR 1200 S 1198 315
RR 1600 V 1547 355
Series LR - overview
Chiller Type: Compressor Chiller capacity (kW) 2Motor nom. capacity (kW)
LR 200 C 187 75
LR 250 D 221 75
LR 300 E 265 90
LR 350 G 314 110
LR 450 H 402 132
LR 500 L 474 160
LR 600 M 601 200
LR 750 N 731 250
LR 800 P 787 250
LR 1000 R 945 315
LR 1200 S 1171 355
LR 1600 V 1506 450
1water outlet evaporator 6°C, water outlet condenser 32°C
2water outlet evaporator 6°C, condensing temperature 50°C

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 11
Series VR - overview
Chiller Type: Compressor Chiller capacity (kW) 3Motor nom. capacity (kW)
VR 200 C 191 55
VR 250 D 227 75
VR 300 E 272 75
VR 350 G 322 90
VR 450 H 411 110
VR 500 L 485 132
VR 600 M 615 160
VR 750 N 748 200
VR 800 P 798 200
VR 1000 R 966 250
VR 1200 S 1198 315
VR 1600 V 1547 355
Hint!
For information on the dimensions, weights, charging quantities and connections see separate data
sheets.
3water outlet evaporator 6°C, condensing temperature 32°C

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
12 _601011_pi_dxr_gbr_1_.doc
3 DESIGNATION
Explanations on the product key, example: DX RR 800 S NH3
DX Series: dry evaporation
RCondenser type: R- shell and tube heat exchanger
L- air-cooled condenser
V- evaporative condenser
REvaporator type: R- shell and tube heat exchanger
800 Nominal chiller capacity (kW) related to cold water operation
S
Design of liquid chiller: without marking - Standard design
S- Special design related to heat
exchangers and optional equipment
NH3Refrigerant

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 13
4 DESCRIPTION OF DESIGN AND FUNCTION
4.1 Structure
Ammonia liquid chillers for dry evaporation (DX Series) consists of the following main components:
1. Drive line (screw compressor, driving motor, oil separator)
2. Evaporator with basic frame, carrying the drive line
3. Condenser, alternative
—built on shell and tube type
—external evaporative condenser or
—air cooled condenser
4. Low voltage system with control
5. common base frame
Ammonia liquid chiller can be delivered in version RR for complete capacity range of model types 200 - 1600 as
standard ready for connecting, complete with pipes and wiring.
The complete combination of drive line and evaporator can be delivered for versions LR and VR.
So the condenser only have to connect on site.
4.2 Mode of operation
Compressor sucks refrigerant gas out of evaporator and brought up to condensation pressure. The refrigerant
turns to liquid as it is cooled and ease about a solenoid valve directly into the evaporator. The solenoid valve is
controlled by suction gas overheat. The refrigerant evaporates by taking up heat (delivered by secondary
refrigerant).
During the operation of the screw compressor, oil is injected into the working chamber and then separated again
from the refrigerant in the discharge side oil separator. The oil in compressor heated is either cooled via a oil
cooler to inlet temperature or liquid refrigerant is injected into the screw compressor for reaching a discharge
temperature, which is agree with the permissible oil temperature.
The oil passes through oil filter before it returns to the compressor.
Despite of the highly effective oil separation system, oil penetrates to the low pressure side of the Chiller. A
special, by Grasso GmbH Refrigeration Technology used oil, makes the oil able to flowing so that it can be sucked
from screw compressor again. This is a basic precondition for a fault-free operation of the evaporator system.
The capacity control of the screw compressor operates infinitely variable by volume flow control (internal bypass)
and thus adapts optimally to the refrigeration capacity being effectively required and ranging from 100% to
approx. 15%.
4.3 Shell and tube evaporator
—one- or double-circuit design, as a water-(glycol)-cooler with plain tubes
—in accordance with pressure vessel regulations, valid on site of installation
—standard insulation with insulating material Armaflex
—with ports for draining and venting

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
14 _601011_pi_dxr_gbr_1_.doc
4.4 Condenser type
Three design series of DX R Chillers are offered.
All series are equipped with shell and tube heat exchangers as evaporator.
The condenser can be a shell and tube heat exchanger (standard), air cooled condenser or evaporative condenser
as required.
DX Chiller with water cooled shell and tube heat exchangers as condenser (RR types) are equipped with a water-
cooled oil cooler.
The types LR and VR are designed with a thermosysphon oil cooler
Hint!
Pay attention to altitude differences between chiller and condenser!
The required HP-receiver is built-on the chiller.
Chillers RR series are delivered with condenser. Chillers LR and VR series require general a separate delivery
(without condenser).
The components are connected on site (split installation).
4.5 Control unit
In the standard design, the ALC are equipped with a standard SPC. The SIMATIC guarantees the control and safety
monitoring for all chiller components. A background illumination LCD display allows reading of all operating and
fault messages as well as process variables. The display is operated via a robust keypad having function and system
keys.
4.6 Low voltage Power Panel
The low voltage power panel is completely wired with all chiller sensors and actuators as well as prepared for
connection with the external incoming-feeder cable.
4.7 safety devices against pressure exceedings
The chiller is equipped with a safety pressure limiter (TÜV-application) and a pressure transducer, which prevent
exceeding the discharge pressure limitation value (demand of UVV VBG 20).
The pressure relief valve prevents pressure exceeding higher than the permissible limitation value.
Blow-off safety valves are mounted only in that case, if it is required by specifications valid on site of installation.
4.8 Reduce effects of released Ammonia
Effects of released Ammonia can be reduced depending on installation conditions by:
—enforced venting with ventilators,
—absorption by insertion into a water vessel or
—neutralization with suited substances as CO2or venegar acidity.
Grasso GmbH Refrigeration Technology offers fittings for required precautions.
Depending on machine room situation and refrigerant charging Grasso GmbH Refrigeration Technology offers a
series of absorption devices.

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 15
4.9 Optional equipment
4.9.1 Pressure gauge kit
The pressure gauge kit in addition to compressor control device consists of pressure gauges for:
—suction pressure (evaporator, compressor),
—discharge pressure (compressor, condenser),
—Oil pressure
4.9.2 Dual oil filter
A second oil filter can be installed for changing oil filter during compressor operation.
4.9.3 Connection flanges
Evaporator Connection flanges without counter flange are the standard application for all model types.
Counter flanges at evaporator are optional.
Condensers are without flanges for DX chiller model types RR 200 - RR 350 (standard application).
Counter flanges for condensers are optional.
4.9.4 Hydraulic Adjustment of the internal volume ratio (Vi)
The compressor may have a fixed or a hydraulically adjustable internal volume ratio (Vi) depending on its design.
A hydraulic Vi-adjusting system guarantees compression at the lowest loss possible under the respective operating
conditions and thus saves drive power (see the Screw Compressor Datasheet).
The internal volume ratio is variable, depending on the design and type of the compressor, across a range from Vi
= 2.6 to Vi = 5.5.
4.9.5 L2-Bus communication of compressor control device
All analogue signals of DX chiller can pass on via the SINEC-L2 interface.
The master control has to be controled with the same software protocol.
One master control can be connect with up to 32 chillers.
4.9.6 Anti-vibration mounting
In this form of installation, the DX chiller is erected on vibration isolators which are bolted by screws to the DX
chiller but not to the levelled concrete foundation.
fig. 1: Isolator without foundation fixation
The isolators retain their permanent resilience under design load. The levelling range is 20 mm. The Chiller has a
firm stand due to its design surface pressure and the resulting friction coefficient between isolator and
foundation.

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
16 _601011_pi_dxr_gbr_1_.doc
5 P + I DIAGRAMS
5.1 P+I diagram for standard ammonia liquid chiller DX series, type RR 200 - RR 350
fig. 2: P+I diagram for standard ammonia liquid chiller DX series, type RR 200 - RR 350
A Water
W Cooling water
010 Compressor
012 Control slide position indicator
015 Compressor drive motor
016 Motor current limiter
017 Motor winding protection
020 Oil separator
030 Water cooled oil cooler
040 Oil pump
050 Solenoid valve block for capacity control
065 Stop valve - oil circuit
075 Oil pressure regulating valve

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 17
085 Stop valve - venting
090 Stop valve - oil draining, oil charging
095 Coupling
100 Pressure transducer -suction pressure
105 Pressure transducer - discharge pressure
110 Pressure transducer -oil pressure
115 Resistance thermometer - suction temperature
120 Resistance thermometer - compression end temperature
125 Resistance thermometer -oil temperature
250 Check valve -hot gas line
255 Stop valve - bypassing valve (250)
285 Stop valve -bypassing integrated check valve
350 Safety pressure limiter
360 Oil heater
365 Stop valve - oil separators oil drain
395 Pressure transducer - oil pressure after filter
420 Stop valve - compressor housing draining
450 Service port
455 Service port
470 Stop valve - oil pump suction side
475 Stop valve - oil pump discharge side
500 Condenser
505 Service port
510 Expansion valve
520 Evaporator
530 Resistance thermometer - water flow
535 Flow controller
540 refrigerant draw-in valve
545 Service port
550 Solenoid valve –liquid line
560 Venting - water side
565 Draining - water side
580 Stop valve - liquid line
585 Stop valve –suction line
590 Stop valve –discharge line
595 Sight glass - liquid line

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
18 _601011_pi_dxr_gbr_1_.doc
5.2 P+I diagram for standard ammonia liquid chiller DX series, type LR 200 - LR 350 (VR 200 - VR 350)
fig. 3: P+I diagram for standard ammonia liquid chiller DX series, type LR 200 - LR 350 (VR 200 - VR 350)
A Water
B Scope of supply Grasso
010 Compressor
012 Control slide position indicator
015 Compressor drive motor
016 Motor current limiter
017 Motor winding protection
020 Oil separator
040 Oil pump
050 Solenoid valve block for capacity control
065 Stop valve - oil circuit
075 Oil pressure regulating valve
085 Stop valve - venting
090 Stop valve - oil draining, oil charging
095 Coupling
100 Pressure transducer – suction pressure
105 Pressure transducer –discharge pressure
110 Pressure transducer –oil pressure

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
_601011_pi_dxr_gbr_1_.doc 19
115 Resistance thermometer -suction temperature
120 Resistance thermometer -compression end temperature
125 Resistance thermometer – oil temperature
200 Refrigerant cooled oil cooler
205 Sight glass - oil cooler
210 Stop valve –oil cooler oil drain, refrigerating side
250 Check valve –hot gas line
255 Stop valve - bypassing valve (250)
285 Stop valve –bypassing integrated check valve
350 Safety pressure limiter
360 Oil heater
365 Stop valve - oil separators oil drain
395 Pressure transducer –oil pressure after filter
420 Stop valve - compressor housing draining
450 Service port
455 Service port
470 Stop valve - oil pump suction side
475 Stop valve - oil pump discharge side
500 Condenser
505 Service port
510 Expansion valve
515 Safety valve
520 Evaporator
530 Resistance thermometer -water flow
535 Flow controller
540 refrigerant draw-in valve
545 Service port
550 Solenoid valve –liquid line
560 Venting - water side
565 Draining - water side
580 Stop valve - liquid line
585 Stop valve –suction line
590 Stop valve –discharge line
595 Sight glass - liquid line
600 Liquid receiver
605 Safety valve –liquid receiver
610 Stop valve –pressure relief line
615 Stop valve –pressure relief line

PRODUCT INFORMATION
LIQUID CHILLER GRASSO DX R
200 ... 1600
20 _601011_pi_dxr_gbr_1_.doc
5.3 P+I diagram for standard ammonia liquid chiller DX series, type RR 450 - RR 800
fig. 4: P+I diagram for standard ammonia liquid chiller DX series, type RR 450 - RR 800
A Water
B Cooling water
010 Compressor
012 Control slide position indicator
015 Compressor drive motor
016 Motor current limiter
017 Motor winding protection
020 Oil separator
025 Oil filter with multi-function block
030 Water cooled oil cooler
036 Oil filter element
040 Oil pump
050 Solenoid valve block for capacity control
065 Stop valve - oil circuit
070 Stop valve - oil pump discharge side
075 Oil pressure regulating valve
080 Control valve –injection oil
085 Stop valve - venting suction filter