Grasso

Refrigeration Division

Guide line frequency control 00.87.041

V005 July 2007

General
The purpose of a frequency converter is to generate, by means of changing frequency, a continuously variable speed for a reciprocating compressor/package in order to create a continuously variable capacity control. This method is preferable to a constant speed machine, with cylinder capacity control, due to a smooth capacity regulation, better C.O.P. values during part load running and longer life time of running parts.. The allowable frequency band depends on the max. and min. speed of selected compressor and electric motor ( 4, 6 or 8 poles). In this case a star-delta or soft starter equipment is not required!

For a correct system the following points must be followed : Equipment

Compressor All open type Grasso reciprocating compressors are suitable for variable speed control, however, the limits as stated in the product information of the specific series has to be considered at all times. The compressor in question will always be fitted with the standard cylinder capacity control to be able to start unloaded and at the same time offer extra capacity steps at minimum speed, if required. Drive system Whilst frequency control is more suited Direct Drive systems, it can also be applied to V-belt drive as well. For direct drive systems, however, the total speed range has to be checked for so called black spots. The supplier (Grasso) of the package will perform this calculation* and supply a table of possible black spots(critical speed), if any. * for correct calculation all package equipment, running & start/stop data must be available Electric drive motor The electric drive motor must be suitable for frequency control. The following points have to be checked/considered: 1) Necessity of isolated bearing construction (depending of motor size & make) due to current loops running through the bearings, stator and rotor causing premature bearing failure. At lower speed, capacity of standard cooling fan could be too small and may require down-rating of nominal motor power. (depending of motor size & make) Possibility to fit a separate fan/motor assembly so that down-rating of motor, as described under 2, is no longer necessary. Thermistor circuit for winding temperature. Star-delta connections in terminal box are not necessary (Direct on line configuration)

2) 3) 4) 5)

Grasso Economisers systems A&B for two stage compressors The standard economiser (with TEV & AKVA injection system) is suitable down to 33% part load operation on nominal speed. However, a new selection must be made if additional part load steps, by means of cylinder capacity control, are required at minimum speed.

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Grasso
Refrigeration Division

Guide line frequency control 00.87.041

V005 July 2007

Frequency Converter Selection of the frequency converter (FC) depends on installed electric motor and type of compressor. Please be aware that the FC requires an external 4-20mA signal. It is advisable and some times compulsory to fit filters and chokes to protect the public power net from electronic/RF interference. The processor integrated in the FC must be able to skip through black spots as required by design and/or as found during commissioning. The manufacturers technical datasheets will indicate correct selection. If the frequency controller is ordered at Grasso, Agilium module, the correct selection will be made by Grasso.

Operation
Start-up procedure
In order to guarantee all cylinders are fully unloaded during starting and stopping the following procedure must be followed: Fully unloaded compressor starting is enabled by energising the solenoid valve for unloaded starting. This is a Normally Open (NO) valve in contrast with the solenoid valves for capacity control which are Normally Closed (NC). This NO-solenoid valve has to be energised 20 seconds before starting the compressor motor. The NO-solenoid has to be de-energised between 10 and 20 seconds after starting the compressor motor to enable the motor to reach the minimum speed and the compressor to develop the required oil pressure. In the case of single-stage compressors, the NO-solenoid valve controls the minimum required cylinders, these cylinders should always be activated during operation unless the limits of application and system balance demand otherwise. In the case of two-stage compressors, HP cylinders only are activated during starting which, however, do not at the same time represent the minimum capacity. The other cylinders can be energised or de-energised in one or more steps in a standard sequence for each type of compressor within the limits of operation and system balance. Acceleration time from zero to the so-called minimum starting speed should be 4 6 seconds to build up oil pressure. (The minimum starting speed may vary according to compressor type) Reduce the speed to minimum allowable running speed according to product information. At this minimum speed the cylinder capacity control system can become operational. Minimum speed will remain until all cylinders are activated. When all cylinders are activated the speed control can become operative.

Running
During running the compressor speed is allowed to vary between the boundaries as given by the manufacturer. Depending on compressor model, running conditions and chosen motor drive line black spots (critical speeds) may occur. It is not allowed to run in the critical speed area. The passing time should not take longer than 6 seconds and, ideally, less than 4 seconds Changing the speed as a result of capacity change should be done as smooth as possible to maintain stable operation conditions.

Stop procedure
Reduce the compressor to the minimum allowable speed with all cylinders in operation. De-energise the NC solenoid valves step by step to the minimum capacity (remark, For two stage compressors do not run on only HP cylinders) then the NO-solenoid valve must be activated 5 seconds before stopping the compressor. Keep the NO-solenoid valve energized until the compressor has fully stopped.

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Grasso
Refrigeration Division

Guide line frequency control 00.87.041

V005 July 2007

Remarks
1. Between the minimum and maximum speeds all cylinders must be fully loaded unless otherwise stated by the manufacturer. 2. Only at the lowest allowable speed can cylinder capacity steps be regulated, unless otherwise specified. Keep compressor within the limits of application. 3. To prevent exceeding the maximum allowable compressor speed the corresponding maximum frequency should be set in the software. 4. Never use the break option of the frequency converter.

Commissioning
The following checks must be made: Black spots (critical speeds) It is possible that the calculated black spots deviate in practice. It is therefore necessary to perform a practical test during commissioning to determine their actual location. Oil pressure The oil pressure must be measured and adjusted at the min. speed Resonant frequencies Besides black spots in the compressor/motor drive line, the installation must be checked for resonance. Electrical wiring The electrical wring must be installed according to local regulations and the wiring diagram of the FC supplier.

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