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2. COMPRESSOR SIZE VOLTAGE CARLYLE NO NO REMARKS 0608109 208 230 1 60 HN69GZ025 8347 23 31 HN69GZ032 8347 23 42 start 06DM808 208 230 1 60 HN69GZ024 8347 23 63 0608013 HN69GZ014 8347 23 53 start 06DM313 HN69GZ106 8348A7 4 Common 06DM316 208 230 1 60 HN69GZ037 8347A23 40 start 0608316 0608718 208 230 HN69GZ007 8347A23 54 2 Required 0608109 460 HN69GZ015 8347 23 92 2 Required 575 HN69GZ011 8347 23 86 2 Required 06DM808 208 230 HN69GZ053 8347 23 19 2 Required 06DR013 460 HN69GZ012 8347A23 56 2 Required 575 HN69GZ012 8347A23 56 2 Required 06DM313 208 230 HN69GZ024 8347A23 63 2 Required 06DM316 0608316 460 HN69GZ014 8347 23 53 2 Required 06DR718 575 HN69GZ032 8347 23 42 2 Required 060 818 208 230 HN69GZ214 8348A17 9 2 Required 06DR820 460 HN69GZ038 8347A23 18 2 Required 06DR724 25 575 HN69GZ037 8347A23 40 2 Required 06DA824 25 208 230 HN69GZ306 8348B19 13 2 Required 0608228 460 HN69GZ010 8347A23 29 2 Required 575 HN69GZ053 8347A23 19 2 Required 06DA328 208 230 HN69GZ309 8348B19 11 3 Required 06DM337 460 HN69GZ024 8347A23 63 2 Required 06DR337 575 HN69GZ025 8347A23 31 2 Required 208 230 HN69GZ214 8348A17 9 4 Required 06DA537 HN69GZ106 8348A7 4 0608541 460 or HN69GZ307 or 8348A19 4 2 Required 575 HN69GZ301 8347 30 69 2 Required Basedon new high efficiency H E extended voltage compressor models T Voltage is 3 Ph
3. 9 Oil amp Refrigerant Change Out Procedures 72 Oil Additives Oil Charge Oil Control Parallel Compressor Applications 13 28 Oil Control Motor Barrel Interconnections 13 Oil Drain Plug Ad ptel 83 Oil Levelin Sight Glass e eR 12 Oil Operating Levels Oil Pressure Oil Pressure Problems Typical Causes Oil Pump See Bearing Head Oil Safety SWIICh idein Ee eni C o e 75 Oil Viscosity and Pour Points 20 72 Oils Approved for ntn eerie nep Operating Limits Typical 06CC Operating Limits Typical 06D E Overloads for 06D Compressors Overloads 06CC Compressors 16 37 104 119 Parallel Compressor Applications Control 28 Parts Identification 060 Compressor Exploded View 56 Parts Identification 06 Compressor Exploded View Physical Data 06CC Compressors Physical Data 06D Compressors Physical Data O6E Compressors 008 80 64 Pipe Rattles Typical Causes yi aiana aeaea iranda a aa
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6. Connection Points 060 4 Cylinder Models Connection Points 060 6 Cylinder Models Connection Points 4 Cylinder Models Connection Points 06 6 Cylinder Models Crankcase Heaters 117 Current Cycling Continuous Typical Causes Cycling Intermittent Typical Causes Cylinder Head Blown Cylinder Head Cooling Fans eese 77 Cylinder Head Disassembly esee 33 Cylinder Head Gasket Failure Causes ee 23 Cylinder Head Gaskets 84 Cylinder Head Reassembly Discharge Gas Temperature Sensor Electrical Hookup 06D Compressors Barrel Nut Tool 85 Electrical Hookup 06D Compressors 109 Electrical Hookup 06E Compressors Across the Line Start 110 Electrical Hookup 06E Compressors Part Winding Start 111 Electrical Specifications tae rte ei uae ee 92 Electrical Terminal Box 88 Flooding Typical Causes eunte 24 Gasket Terminal s ees 85 Gaskets Compound Compress
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8. 11 Start Up 16 Start Up Troubleshooting and Service 10 Start Up WiLNOE Stats eii deserat 22 Strap OrrElealers i eire pend eee ERES 81 Suction n eee d eee 78 SUCTION tee 36 Technical Assistance OEM 10 Technical Assistance 1 Terminal Box Package 88 Terminal Lug 5 88 Terminal Plate 85 Terminal Plate Jumper Bars 88 Terminal Posts Torque Guide 06D and 16 to 37 06CC Torque Guide and 06 50 to 99 Compressors Troubleskiootihg gni Eee pedi e EHE ERROR Troubleshooting 06 Desuperheater Connection Hot 31 Troubleshooting 06CC Discharge Pressure Intermediate Pressure 31 Troubleshooting 06CC Economizer Connection 31 Troubleshooting 06CC High Midstage Pressure 31 Troubleshooting 06CC Intermed
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19. Fig 2 Disassembly of Valve Plate Standard Efficiency Valve Plate Shown Pry up along sides of valve plate to remove valve plate from crankcase This provides access to suction reed valves see Fig 3 Remove suction valves from dowel pins On 06D and 06CC 16 to 37 Cfm compressors also remove the suction valve positioning springs see Fig 4 Inspect components for wear or damage If replacement 15 necessary replace as a complete assembly Individual parts must not be interchanged Alignment of high efficiency discharge valves 18 critical for proper seating See Sections 3 27 to 3 29 pages 84 87 for applicable replacement valve plate packages 34 VALVE PLATE SUCTION TION VALVE AM VALVE CYLINDER LATE DECK SUCTION VALVE Fig 3 Valve Plate Removed 06E Refrigeration Valve Plate Shown DISCHARGE PORT VALVE PLATE DOWEL PIN SUCTION OLDER STYLE SUCTION VALVE 06D VALVE SD AND O8GG NS 16 TO 37 ONLY Fig 4 Suction Valve and Positioning Springs in Place 06D Shown 35 REASSEMBLY 1 Ifreassembling existing components do not interchange valves or turn them over They must be reassembled in their original position Install the suction valve posi tioning springs 06CC size 16 to 37 Cfm and 06D compressors only on dowel pins Assemble positioning springs with spring ends bearing against cylinder deck Fig 4 spring bow upward
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21. systems have a film of oil on the inside surface of the piping At start up the lines are dry and the oil which coats the lines comes from the compressor crankcase Oil also traps in the low refrigerant velocity area of the system and must be made up by adding oil to the system On systems with hot gas defrost inspect the compressor for excessive oil after the defrost cycle has been completed The oil lost to the system must be replaced but take care not to add too much The 06E and 06CC 50 to 99 Cfm compressors have been successfully started in supermar ket refrigeration configurations by adding only 1 quart liter of additional oil per compressor The amount to be added will vary depending on the system but keeping the oil level between 1 8 and 3 8 level in the sight glass will eliminate the chance of excessive oil charges Adding excessive oil to the 06 06CC 50 to 99 cfm compressors can cause blown gasket problems When CFC or HCFC refrigerants are used with mineral or alkylbenzene oils foam in the sight glass normally indicates either that there 15 serious liquid refrigerant floodback or that the running gear is hitting the oil due to a very high oil level Very high oil levels are caused by either too much oil or excessive liquid refrigerant in the crankcase HFC refrigerants and POE oils do not foam easily so there will be less indication in the sight glass of either liquid
22. 9 Pin Term 208 230 460V Models 460V XL Start 2 HOLE See Fig 17 page 111 for detailed view of terminal post arrangement 110 06E COMPRESSORS PART WINDING START 6 Pin Term 6 Lead PW Start Omio HEAD C24 09 9 208 230 460V 300 Series Models 208 230 PW Start Only 0 4 624 3 HEAD G OD JUMPER Ol 9 3 HOLE 9 Term 460V 600 Series Models 460 PW Start WARNING With 208 230 460V 300 Series Models the 460V cannot be wired for PW RING TERMINAL JAM NUT 3 RING TERMINAL JUMPER BAR JAM NUT 2 PLASTIC INSULATOR JAM NUT 1 Fig 17 Terminal Post start Use distinct 460V Arrangement Detail View 06E 600 Series Models for any and 06CC 50 to 99 460V PW application See page 61 for torques of jam nuts 111 4 11 Voltage and Current Unbalance VOLTAGE UNBALANCE Maximum 2 Voltage unbalance can cause motors to overheat and fail Below is the recommended method for determining voltage unbalance Example Supply voltage is 240 3 60 243 volts 236 volts 238 volts Average Voltage 3 239 volts Determine maximum deviation from average voltage AB 243 239 4 volts BC 239 236 3 volts AC 239 238 1 volt Maximum deviation is 4 volts Determine voltage unbalance
23. COMPRESSOR USAGE VALVE PLATE PACKAGE 06D 06CC 16 to 41 Cfm Compressors O6DR if using 06DRO13 060 313 06DR316 or 06DM316 models see note 2 06DA660094 b 06DM DA if using 0608013 06DM313 06DR316 or 06DM316 models see note 2 06DA660120 c 06CC 16 to 37 Cfm low stage valve package 06CY660002 d 06CC 16 to 37 Cfm high stage valve package 06DA660120 06E 06CC 50 to 99 Compressors 06ER 06EA660143 b 06EM EA 06EA660137 c 06CC 50 to 99 Cfm low stage valve 06EA660159 d 06CC 50 to 99 high stage valve 06EA660137 ncludes relief valve for both low stage banks NOTES 1 Carlyle recommends the 06ER660017 service replacement valve plate kit for all 06 compressors in low temperature environmental chamber applications see Note 6 All high efficiency units with a 3 in the 11th digit of the model number 0604013 and 06DM313 06DR316 and 06DM316 models have a 2 diameter cylinder bore and use the above valve plate kits Older 13 and 16 cfm prior to 1985 models have a 1 13 16 diameter bore and cannot use these valve plate kits Kits for these models are no longer available Suction reed valve part no 6D45 1072 and discharge reed valve part no 6D75 1062 can be used for valve plate field repair Hot gas bypass unloading requires a special valve plate kit with gaskets as follows 06D 06DA660131 06E 06EA660105 The Carlyle recommended suction cut off unloading does
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26. ET Phase Electrical Specifications 102 EY Phase Electrical Specifications sss 98 06 EZ 3 Phase Electrical Specifications 100 Additives Oil Alkylbenzene Oil Use with CFC HCFC and HCFC Blends 69 cR 89 Bearing Head Oil Pump Replacement Procedures 38 Bearing Head High Flow Pump essere 74 Bearing Head P mp End Bearing Head Replacement Billing and Credit Capacity Control Unloading Accessory Packages 78 Capacity Control Coil Packages sese 80 CFCs Approved for 69 Cim Designation UE 5 Change Out Procedures Oil amp Refrigerant Clean Up Compressor Isolation Compressor Model Number Significance 3 Compressor Mounting 82 Compressor Problems see Troubleshooting 20 Gompressor Weight da Compressors without Oil Connection Points 06 16 to 37 Models Connection Points 06 50 to 99 Models Connection Points 060 2 Cylinder Models
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28. 26 Troubleshooting No Oil Pressure 2 26 Troubleshooting Noisy Compressor 25 Troubleshooting Oil Safety Switch Tripping eee 30 Troubleshooting Parallel Systems 28 Troubleshooting Pipe Rattle 25 Troubleshooting Running Hot 29 Troubleshooting Sight Glass Low or Empty 30 Troubleshooting Starting Problems 22 Troubleshooting Valve Plates Troubleshooting Will Not Start Troubleshooting Guide Unloading Capacity Control Valve Plate Gaskets 84 Valve Plate Gaskets Blown 23 Valve Plate Disassembly ccena reden ero dii nici ced adn 33 Valve Plate Packages eset e eie OR E Ie REN 86 Valve Plates Failure Causes 23 Valve Plates Replacement Procedures 32 Valve Plates Leak 2 32 Voltage Unbalance 112 Warranty MPa 9 Weight Compressor ie dee E RE e RP t 63 122 COMPLIMENTS OF Carly
29. Burdurejs pue pepueuiuooe esf 96 DOW SI 5 uiu mau 10 uwous pere YTH 08 oez zH 09 002 ove 097 zH 09 00 SALON n 12 Alea Jequinu 3y jo ow 159 eu 181 92 02 802 Sduty peo pave 2 ON 10104 S39NVU 9NILVH3dO 318VMOTTV Oct 982 097 009078 220 001 992 OF 097 09908 992 959 68 062 802 000178 SL 02 810 996 9 68 060 800 09178 96 622 ZE 9 4 00109055490 96 FOZ 974 09078 22 9090 98 Veo 15 097 009099 01 661 LE 097 059599 161 67 69 80 002174 Ol 991 920 800 262 c9 060 800 OSceVg 69 671 SC 9 6 0010vacgcev 90 EL 16 091 Sc 09 2 929 0915786868490 ZL 661 846 097 00908 66 82 872 097 09928 01 919 022 802 000178 8 82 190 861 SSE 456 060 800 0Sceva 99 69 9 9 00078 29287 090 oz 61 9 8 091 28928 7090 ZL 661 848 097 009078 66 871 872 097 OS9eVE 01 919 062 802 00619 8 82 12 0 861 SSE 999 062 802 0Gceva 99 69 928 0010957089490 02 61 9 6 05 0 807287090
30. uiu uo uexoig 49jeoujednsaqjieziuouo3 02 1oxse ueyoiq eDejs uo uwojq 10 ueyoig eunsseid 61 1exse ueyoiq abeys eu uo yeyse6 uayoug ainssaid yBIH 8 Aju ssossasduiog 2290 104 Adawag 3s vo 318 5508 NOILVAH3S80 31 2 4 Service Procedures The service section covers replacement of valve plates and gaskets service to the bearing head assembly containing the oil pump and a clean up procedure to follow in case of motor burn out Most other internal service requires replacement of the compressor REMOVE INSPECT AND REPLACE CYLINDER HEAD AND VALVE PLATE ASSEMBLY To test for leaking discharge valves or blown cylinder head or valve plate gaskets 1 Pump compressor down 2 Observe suction and discharge pressure equalization If valves are leaking or a gasket 1s blown the pressure will equalize rapidly Maximum allowable discharge pressure drop is 3 psi per minute after initial drop of 10 to 15 psi in first half minute New reed valves may require 24 to 48 hour run in time to seat completely A compressor bank head with a blown gasket can also usually be detected by touch since the head temperature will normally be much hotter than a bank with good gaskets 3 Ifthere is an indication of loss of capacity and dis
31. 2 Install suction valve on dowel pins as follows a 06D compressors install suction valves on top of positioning springs as mentioned in Step 1 above b 06 compressors if compressor uses a suction valve and a backer valve looks like a 1 2 a suction valve backer valve must be installed before installing full size suction valve Fig 5 DOWELS IN CYLINDER DOWEL DECK FOR SUCTION VALVE AND BACKER DOWEL HOLES BACKER PLACE AGAINST CYLINDER DECK UNDER SUCTION TOP VIEW SUCTION VALVE OF PISTON VALVE IN CYLINDER Fig 5 Piston Suction Valve and Backer Positions 06E 36 Install new valve plate gasket Using proper hold down torque will prevent leaks a Fiber gaskets can be installed dry or lightly oiled Do not soak gaskets in oil If an oil soaked gasket is overheated it will bind to the metal making the valve plate and or the head difficult to remove b Metal gaskets must be installed dry Place valve plate on cylinder deck Install cylinder head gasket NOTE The center cylinder heads and unloader side heads use different gaskets from the plain side head To confirm the gasket 15 correct place it over the cylinder head and verify all exposed machined surfaces will be covered by the gasket a Line up the gasket with the cylinder head and valve plate b 06E compressor secure the center rib with a cap screw and washer and torque to 4 to 6 ft Ibs 5 to 8 Nm Replace cylinde
32. Carlyle SERVICE GUID 06D 06E 06CC COMPRESSORS www carlylecompressor com CONTENTS 1 0 GENERAL COMPRESSOR AND CUSTOMER INFORMATION 1 1 Compressor Model Number Significance 3 12 Nameplate Significance seen 6 1 3 Compressor Serial Number Significance 8 1 4 Carlyle OEM Compressor Warranty 5 9 1 5 Service Billing and Credit 10 1 6 Green Carpet Program Parts and Stocking Policy 10 2 0 START UP TROUBLESHOOTING AND SERVICE 2 1 22 2 3 24 2 5 2 6 2 7 2 8 2 9 2 10 211 Technical Assistance Carlyle OEM Compressors Recommended Start Up Procedure Troubleshooting Procedures seen Service ac epe dieto e e e Ren een Connection Points 06D 06E and 06CC Compressors Cross Sectional View 06D Semi Hermetic Compressor Cross Sectional View 06E Semi Hermetic Compressor Exploded View 6 Cylinder 06D Compressor Exploded View 6 Cylinder 06E Compressor Torque Guide All 06D and 16 to 37 Cfm 06CC Compressors 60 Torque Guide 06E and 06CC 50 to 99 Cfm Compressors 61 3 0 COMPRESSOR AND PARTS DATA 3 1 3 2 3 3 3 4 3
33. Voltage unbalance 100 x 239 1 7 This amount of phase unbalance is satisfactory as it is below the maximum allowable of 296 IMPORTANT If the supply voltage phase unbalance is more than 290 contact your local electric utility company immediately 112 CURRENT UNBALANCE Maximum 10 Voltage unbalance will cause a current unbalance but a current unbalance does not necessarily mean that a voltage unbalance exists A loose terminal connection or a build up of dirt or carbon on one set of contacts using the example of L1 as the problem leg would cause a higher resistance on that leg L1 than on L2 and L3 The current follows the path of least resistance so the current increases in legs L2 and L3 Higher current causes more heat to be generated in the motor windings Percent 26 of current unbalance is calculated in the same way as voltage unbalance see the previous section with a maximum acceptable current unbalance of 1096 5 0 COMPRESSOR SERVICE WORKSHEETS Carlyle recommends that the Compressor Service Worksheets pages 114 and 115 be copied and enlarged if preferred and filled out for each compressor at initial start up and each time the compressor is serviced Comparing the data from current worksheets to past records will allow the service technician to diagnose system changes and prevent compressor failures This information is also very useful in preventing a repeat failure 113 06D 06
34. Shipped Without Oil Design Variable New Compressors 0 OEM Model 1 Carrier Model 2 Old Design Refrigeration Valve Plates 6 Carrier A C Model 8 OEM with and Oil Charge 9 Cemak Model Service Compressors 2 New Manufactured 4 Remanufactured Low Temp 6 Remanufactured A C 7 Remanufactured Med Temp Electrical Characteristics XL and PW Start Unless Noted 0 208 230 3 60 1 575 3 60 3 208 230 460 3 50 60 460 4 200 3 60 5 230 3 60 6 400 460 3 50 60 8 230 3 50 9 220 380 3 60 Displacement at 1750 rpm Motor Size Does Not Signify Horsepower 0 1 2 Models With 3 4 5 Models Without Oil 7 1 Unloader Suction Cutoff Oil less ER EM Only 8 Special Order Compressor Type STD REVf O6EF Compressor A C Duty Unloading 06 O6EJ Compressor A C Duty 1 Step Elec 06 O6EK Compressor A C Duty 2 Step Elec Hot Gas Bypass OGED O6EL Compressor A C Duty 1 Step Press Unloading 06 06 Compressor Duty 2 Step Press 06 2 0626 Compressor A C Duty 1 Step Elec 06E7 Compressor A C Duty 2 Step Elec Suction Cut Off 0664 06 8 Compressor A C Duty 1 Step Press Unloading 0625 O6E9 Compressor Duty 2 Step Press O6EM Compressor Refrig Duty Med Temp 06ER Compressor Refrig Duty Low Temp Service Compressor Duty Replaces 06E2 3
35. 009 98 891 965 oez 019074 629 0 004 821 Le 062 802 OScEVO 96 26 4 ooz 01 0 75 0 001 821 Le 055 805 056899 gre 29 v6 974 0110 4091 090 ee 07 69 801 9 9 0515909158490 882 55 vL 09 009074 ct sce 99 28 09 0S9EVO 9 9 90 8v4 oez 0050 180 721 0 2 802 092899 969 ooz 00v0v4 180 721 060 80 052270 69 974 0010 006 08090 05 yee Sv 4 929 OSLEWOOE 08090 895 6 gg 0092 9 v 692 Ge 99 09 09 ees 98 062 802 00cLVO Z FE FL ees 92 0 z 80z 096899 ele 6 9 74 1001 290601 1890 04 ve vv 9 9 051 906019090 MA 5 HOA Ipon xen BuipulM 10101 HOA JosseJduio Jossaidwog eyeq je2u129 3 je21129 3 5130011 A9N3I9I333 15 51390 2 443 H9IH MAN ENHA aseyd 3090 Et VIVA TVORLLOXT H 0t 92 m pue Burzis surup o UMOUS 9 0 dn ayip ued Jo 51010 pue 51 10 pue eouejsiseJ 10 UMOUS WYO
36. 44 06D 4 Cylinder Compressor 13 and 16 Connection Points 06D 4 Cylinder Compressor 18 and 20 Connection Points 06D 6 Cylinder Compressor 24 25 28 37 and 41 Cfm Connection Points 47 06D 6 Cylinder Compressor Exploded View 56 06D Compressor Cross Sectional 0 54 06D Compressor Model Numbers essere 3 06D Compressor Overloads 06D Compressors Physical Data 06D Compressors Torque Guide 060 E Service Worksheet O6DM DA Phase Electrical Specifications 94 O6DR Phase Electrical Specifications 92 O6DR DM Single Phase Electrical Specifications 96 06 4 Cylinder Compressor 50 and old 66 Connection Points 06 6 Cylinder Compressor 65 75 99 Connection Points 06 6 Cylinder Compressor Exploded View 06E Compressor Cross Sectional View 55 06 Compressor Model Numbers esee 4 06E Compressors Physical Data 64 06 Compressors Torque Guide 61
37. Compressor Special NOTE USE OF Cfm AS MODEL SIZE DESIGNATION Carlyle uses the Cfm designation in the model number to identify the compressor size The Cfm values the sixth and seventh digits of the model number See example above Carlyle offers two series of compressors based on body size The smaller compressors from 8 to 41 are referred to as D size units model number 06D The larger compressors from 50 to 99 are referred to as size units model number 06 The 06CC or Compound Cooling compressors are made in 16 to 37 Cfm and 50 to 99 Cfm sizes The 16 to 37 compressors use size bodies The 50 to 99 Cfm compressors use size bodies NOTE METRIC MEASUREMENTS The compressors are built using English units inches foot pounds pints etc A corresponding metric measurement has been added to all the English units in this guide These metric measures are a guide only having been rounded to the nearest whole number and therefore are not meant to be an exact mathematical conversion 1 2 Nameplate Significance MODEL NUMBER MER Carlyle OGER 9475900 CODE 00 ULAND CSA MANUFACTURING NUMBER 4 4603 14 1 MUN 3 RLA 5 SYN RPM CHARACTERISTICS 1800 Le 5e 2054225 173 0 1500 AGE RE 5 1800 TEST PRESSURES 3105 sss IM
38. PUMP END BEARING HEAD PACKAGE USAGE 06DA660126 06D 06CC 16 to 37 compressors 06EA660157 All 06 06 50 to 99 compressors NOTE The above pump end bearing head packages include a bearing head with the high side oil safety switch connection This pump is recommended for all CFC HCFC and HFC refrigeration applications 74 3 14 Safety Switch Carlyle uses as standard the 120 second time delay oil safety switch as this time period 5 preferred for HFC POE systems This is a change from the 45 to 60 second time delay used previously with CFC and HCFC systems It is not necessary to change out the older shorter time delay switch unless the unit is converted to an HFC POE system The oil safety switch protects the compressor when lubrication is lost for more than 120 seconds The switch closes the control circuit at start up allowing the compressor to run for 120 seconds Operating oil pressure must reach 11 psi above suction pressure within 120 seconds for the switch to remain closed which allows the compressor to run If the operating oil pressure falls to 4 psi above suction for longer than 120 seconds the switch will open the control circuit shutting down the compressor Carlyle has approved the following oil safety switches for all applications with 06D E CC compressors Danfoss Type MP54 See details below Penn Johnson electronic switch P445 PRESSURE CARLYLE DA
39. With Internal Thermostat and Without External Overloads Suction Service Valve Variables Location Orientation and Mounting Bolts Compressor Identification Key 0 New Compressor 2 New Compressor 3 New Compressor 6 Service Compressor Remanufactured 7 Service Compressor New Manufactured 8 New Compressor Special 9 Service Compressor Special Displacement CFM at 1750 rpm Motor Size Does Not Signify Horsepower Compressor Type 06DA Compressor A C Duty No Unloading 0608 Compressor A C Duty 1 Step Elec 060 Compressor A C Duty 2 Step Elec Hot Gas 0600 Compressor A C Duty 1 Step Press Bypass 06DE Compressor A C Duty 2 Step Press J Unloading O6DF Compressor A C Duty 1 Step Elec 0609 Compressor A C Duty 2 Step Elec Suction Cut Off 060 Compressor A C Duty 1 Step Press Unloading 06DJ Compressor A C Duty 2 Step Press 06DM Compressor Refrig Duty Medium Temperature 060 Compressor Refrig Duty Low Temperature 060 Service Compressor Replacement for new 06DA DM without Unloading 0605 Service Compressor Replacement new O6DF G H and J with suction cut off unloading Compressor has 1 Stage suction cut off unloading 060 Service Compressor Replacement for new 0608 C D and E with hot gas bypass unloading Compressor has 1 stage of bypass unloading 3 06 COMPRESSORS 0 Package 1 9
40. 1 4 28 12 15 16 20 Terminal box 12 15 16 20 Unloader valve 12 15 16 20 Discharge valve stop 12 15 16 20 pump drive segment 5 16 18 16 20 22 27 Cover plate bearing head 20 25 27 34 Discharge service valve 4 cyl 3 5 47 Terminal post jam nut 17 3 4 Terminal post jam nut 2 18 25 Terminal post jam nut 3 3 8 16 10 20 14 17 plug bearing head 30 35 40 48 Bottom plate crankcase 30 35 40 48 Compressor foot 30 35 40 48 Terminal block P E Bearing head at 10 O Clock 3 8 24 SAE 8 12 11 16 position 5 8 18 5 25 40 27 54 Access under motor barrel 716 14 55 60 75 81 Motor end cover crankcase 55 60 75 81 Bearing head crankcase 716 20 8 12 11 16 Oil drain on bottom plate 80 90 109 122 Discharge service valve 6 cyl 80 90 109 122 Interstage outlet CC 1 2 13 80 90 109 122 Suction service valve 1 5 8 85 100 115 136 Interstage manifold CC 85 100 115 136 Suction manifold 85 100 115 136 Cylinder head 1 2 Pipe 30 40 40 54 Cylinder head sensor 5 8 11 25 30 34 40 Rotor lock crankshaft 90 100 122 136 Suction service valve 2 1 8 3 4 16 50 60 68 81 Stator lock acorn nut 11 8 18 30 40 40 54 Pressure relief valve See Table 2 10 for Notes and Legend page 60 61 0 Jeau euo pue JOJO uo euo 9 95 penp 51055914 09 AS 5 2 2 dH Seu 055 eseud 601
41. 7 08 98 SEL 09 00927 98 891 955 oez 029074 529 0 001 641 Le 062 802 OScEVO 96 26 0 2 004 02 0 7 0 00 22 72 062 802 OScEVO gre 29 v6 9 74 0210 7 0808 1090 t Ov 69 801 929 0SLEVOOELEING90 882 64 vl 0290 9 992 99 8 09 0490 9 9 9 90 891 oez 02 0 9 11 80 2 062 800 OScevO geo OZ ooz 08 009 80 062 800 0522 9 EZ 69 929 1 0010290808 1090 09 Sv L 929 092 0808 090 WQ90 suyo eouejsisag HOA mE 19 DOW HOA 21429 Jossaidwog 5130011 A9N3I9I333 1 STAGOW 9 443 MAN 1 945 490 ct 94 UMOUS 956 0 dn 1ueJejJIp Jo 810 pue 10 uwous pue eouejsiseJ 10 UMOYS WYO Jexeo1q jo di jsnu uo puedep Jexeeiq e Aq 10sseJduioo 190 10 YTY eoueuuoped eq juo ueo 2112906 Aue Burejedo 1035949105 2 Bulzis pue Burzis
42. NOTE Not a field usable fitting 716 14 55 60 75 81 Motor end cover crankcase Oil drain on bottom cover plate 716 2084E 6 12 8 16 18 20 and 6 060 12 20 10 12 14 16 pressure regulator 1 2 13 80 90 109 122 Suction service valve 5 8 11 25 30 34 40 Equalization spinner tube assembly 1 1 2 18 35 45 48 61 Oil level sight glass CC Compound cooling compressors only Torque for jam nut 3 is for compressors manufactured NM Newton meter metric torque rating after 0203J For compressors built before this SAE Society of Automotive Engineers jumper bar must be under jam nut 3 or Loctite 089 See Fig 17 page 111 for jam locations applied to jam nut 2 or use 12 ft Ib NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included 60 2 11 Torque Guide 06E 06CC 50 to 99 Compressors SIZE TORQUE TORQUE DIAMETER Percy RANGE RANGE USAGE in FT LB NM 1 16 8 12 11 16 Pipe plug crankshaft 1 8 Pipe 10 12 14 16 Orifice crankcase No 10 32 4 6 5 8 Oil pump drive segment 14 20 10 12 14 16 cap screw 1 5 2 5 2 3 Motor lead set screw terminal plate 3 5 47 Sight glass 4 6 5 8 Cylinder head gasket tab screw
43. VALVE BLEED ASSY ORIFICE VALVE PLATE PRESSURE DISCHARGE SUCTION DISCHARGE VALVE VALVE UNLOADED OPERATION COIL UNLOADER UNLOADER UNLOADER HI PISTON EAD VALVE BODY ASSEMBLY SOLENOID UNLOADER VALVE SPRING VALVE PLATE PRESSURE SUCTION DISCHARGE Fig 16 Loaded and Unloaded Operation DISCHARGE SUCTION VALVE VALVE 3 18 Capacity Control Coil Packages 06D E COIL PACKAGE PART NUMBER VOLTAGE ALCO REF EF19ZE120 06DA402784 120 1 50 60 X13904 C7245 EF19ZE240 06DA401794 208 240 1 50 60 X13904 C7045 24 1 50 60 X13904 C7145 EF19ZE024 06DA401844 80 3 19 Crankcase Heater Data Crankcase heaters help reduce refrigerant migration to the compressor during shut down Crankcase heaters are designed to raise the temperature in the compressor oil compartment approximately 15 to 25 F 8 to 14 C Carlyle recommends crankcase heaters be wired so the heater is energized only when the compressor shuts off Crankcase heaters should be initially for 24 hours before starting the compressor All HFC POE applications require a crankcase heater STRAP ON HEATERS Mounted externally to the underside of the stamp steel bottom plate Install axially using 2 bottom plate bolts plus brackets and screws in package Used on 06D 808 109 013 313 and 316 compressors strap on heaters are 50 watts INSERTION HEATERS Insert into cast
44. amp 06CC 06 50 low and medium temperature 06DA660105 06 65 75 99 and all 06CC 50 to 99 low and medium temperature 06EA660145 Includes baffle plate and 2 gaskets t For single stage application When using as booster application use medium temperature baffle plate 3 33 Interstage Pressure Tables 06CC Compressors Only All 06CC compressors are a two stage design Therefore the pressure measurements are suction interstage and discharge The following tables list the interstage pressures using R 22 and R 404A 507 refrigerants 89 ejeudsounv WLY 10 d 001 L 310N UNNA 189 78 6679 82 86 9 24 299 99 069 19 88 7 99 9 09 9 sic soi c 01 979 64 S0 9 Z 699 29 62 S c9 v6 Y LS 09 04 9c v 27 16 c61 ctl 90 91 9079 Z 0 6 89 965 69 10 9 89 497 S 06 8 866 0 76 66 FOL 0c 02 S 89 965 69 10 S 89 79 667 67 90 vv 4476 0 046 96 7 06 Sc 965 69 8075 69 6 7 79 97 OS Sv 786 496 LE 626 66 se 67 06 8075 69 YS 9 09 67 9 169 69 86 966 76 8076 06 61 92 46 SE 627 78 97 09 97 169 ev 696 86 966 76 916 LE 887 Le 60 0 07 0v 97 OS 617 16 696 86 cv SE Ske Le 82 6 70 260 15 Sp 9v 16 ev
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46. tion line and the compressors must be level and the line diameter must be large enough to allow both the refriger ant and oil to equalize between all the interconnected compressors If the line is not level it is undersized or the system contains too much the oil level will rise filling the line and oil control between compressors will be lost Typically equalization lines are 1 1 8 in 28 mm in diameter or larger For 06D compressors a sight glass in the line 15 required to determine the system oil level Parallel systems using three 3 or more compressors require the use of a common motor barrel interconnec tion line between compressors Use of an interconnec tion line is strongly recommended on two 2 06E 13 compressor unit configurations This system prevents oil from building up in an 06E motor barrel during the off cycle thereby preventing an oil slug on start up The line is either 1 4 in 6 mm or 3 8 in 8 mm tubing interconnecting to fittings located the bottom of the 06E crankcases To connect to the 06E compressor motor barrel fitting P N 5F20 1311 5 8 in 18 x 1 4 in with 51 001 gasket is recommended Some 50 cfm compressors have a 1 4 in NPT connection and do not require the 5F20 1311 fitting The motor barrel interconnection line is in addition to either the crankcase oil equalization line or the oil floats Never interconnect the motor barrels of 06CC compres so
47. 1 uonons 8 yog 71 JOYSED uonons 9 20S AAPA uonons spee 104 1euuoJ5 6 euw JOAOD AU QN3931 2 sjueujeoe doJ S pue uDisep paunijoid sued awos uo 92u9J9J9J JO UMOUS sued Jossa iduro 190 9 MIAA 87 56 avs IIO Jaysemyoo07 5 ebseyosiq dos aner JOYSED dos oDueuosiq OALA poy Buroeuuo A quiessy poy Bunoeuuo 10N quiessy 001514 egn 1 201 10104 1010H 20104 10195 1571 yeysyuelg JayseM de peer Buueeg peer Buueeg SMAIDS deg SJOYSEMYIO deg 4 4
48. 2 to 1 8 Bars For new OEM 06E and 06CC 50 to 99 Cfm compres sors the pressure 15 18 to 34 psi 1 2 to 2 3 Bars Note that service compressors did not receive the new pump until serial number starting with S N 2994 and later BETWEEN MAY 1984 AND MARCH 1994 OR BETWEEN S N 2084J AND 1094J For all 06D E CC compressors the oil pressure is 16 to 22 psi 1 1 to 1 5 Bars BEFORE MAY 1984 OR BEFORE S N 2084J For all 06D E compressors the oil pressure is 12 to 18 psi 0 8 to 1 2 Bars For more information about the high flow oil pump see Section 3 12 73 3 12 High Flow Oil Pump Bearing Head Carlyle introduced a new high flow oil pump to provide improved lubrication with the new HFC refrigerants and POE lubricants The pump is a durable automatically reversible high flow design The high flow design improves lubrication especially with the new HFC POE combination and provides improved lubrication in the case of a flooded start This oil pump is standard on all new and service compressors See Section 3 11 above for details on oil pressure For service replacement authorized service locations will have the new high flow oil pump only See Section 3 13 below 3 13 Replacement Oil Pump Pump End Bearing Package The oil pump and pump end bearing are an integral part called the pump end bearing head If either the oil pump or the bearing requires replacement order part as noted below
49. 3 Phase Electrical Specifications 4 7 06CC 16 to 37 3 Phase Electrical Specifications 4 8 06CC 50 to 99 3 Phase Electrical Specifications 4 9 06D Compressor Overloads 4 10 Blectrical Hook Up Reihe ets 4 11 Voltage and Current Unbalance 5 0 COMPRESSOR SERVICE WORKSHEETS 06D 06E COMPRESSOR SERVICE WORKSHEET 114 06CC COMPRESSOR SERVICE WORKSHEET SERVICE GUIDE INDEX 116 1 0 GENERAL COMPRESSOR AND CUSTOMER INFORMATION 1 1 Compressor Model Number Significance Refrigeration Partner 06D COMPRESSORS 0 Package 1 or 9 Shipped Without Oil Suction Cut Off Unloading Designation for 0608 DM Compressors 0 Models Except as Noted 5 No Oil 7 1 Unloader Suction Cutoff Oil less DR DM Only 8 2 Unloaders Electrical Characteristics XL Start Only Unless Noted High Efficiency Models Standard Efficiency Models 31 575 3 60 01 575 3 60 12 208 230 3 60 32 208 230 3 60 04 200 3 60 13 380 3 60 33 208 230 1 60 05 230 3 60 14 200 3 60 PW 34 220 3 50 06 400 460 3 50 60 15 230 3 60 PW 36 400 460 3 50 60 08 220 3 50 18 220 3 50 PW Electrical Variables With Internal Thermostat and External Overloads C
50. 4 5 6 7 8 and 9 Compressor has 1 stage of suction cut off unloading O6EX Serv Compressor A C Duty Replaces 06EA B C D E F J KLL and Compressor has 1 stage of Bypass unloading Service Compressor Refrig Duty Replaces 06ER 06 2 Service Compressor Refrig Duty Replaces 06EM Standard Center Cylinder Head 1 Reversed Center Cylinder Head Service compressors shipped with a reverse center head have the letter R after the serial number on the shipping box Refrigeration Partner 06CC COMPRESSORS 06 6 65 E 201 Design Variable 101 Single Pack W O Valves with Oil 102 Single Pack with Valves amp Oil 103 Single Pack Service W O Valves Term Box or Oil 201 Single Pack W O Valves or Oil 202 Single Pack with Valves Electrical Characteristics A 415 3 50 XL and PW 415 3 50 XL 415 3 50 PW D 208 230 3 60 XL E 208 230 400 460 3 50 60 F 400 460 3 50 60 XL and PW 400 460 3 50 60 XL 400 460 3 50 60 PW J 575 3 60 XL and PW 230 3 60 PW 220 3 50 XL and PW M 220 3 50 XL N 220 3 50 PW P 220 346 380 3 50 60 XL and PW Displacement in Cfm at 1750 rpm See Note below Motor Size 14 ft lb 5 1 20 ft Ib 6 2 24 ft lb 7 3 27 ft Ib 1 4 Not Assigne HP 5 HP 5 HP ow coco Compressor Type 06CC Compound Cooling Model 06CY Service Compressor 06C8
51. 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 3 13 06D Series Compressors Physical Data 62 06E Series Compressors Physical 64 06CC Series Compressors Physical Data 66 06D E High Efficiency H E Compressors 68 Compressor Bodies Without Oil eee 68 Refrigerants and Oils for 06D E Compressors 69 Refrigerants and Oils for 06CC Compressors Oil and Refrigerant Change Out Procedures Oil Viscosity and Pour Points Oil Additives zero REOR me mtn erts OIL Pressute eese eite e RM a e EE a I High Flow Oil Pump Bearing Head Replacement Oil Pump Pump End Bearing Package 74 Rev 1 06 24 0 Safety Switch 75 3 15 06 E Discharge Gas Cylinder Head Temperature Sensor 76 3 16 06D E Cylinder Head Cooling Fans 77 3 17 Capacity Control Accessory Packages 78 3 18 Capacity Control Coil Packages 06D 80 3 19 Crankcase Heater Data 2 aethera 81 3 20 Compressor Mounting Data 82 3 21 Co
52. 5 BAR CODE U S A 4304001621 ees J MARK Explanation of the above items starting clockwise from upper right MODEL NUMBER Used when selecting and ordering a new compressor Distributors use the model number to obtain a proper service replacement NOTE Model numbers on some compressors are identified by the symbol M N located in the upper right hand corner of the nameplate UL AND CSA Single mark indicates that this com pressor meets all the requirements for both UL Under writers Laboratory and CSA Canadian Standards Association All 60 Hz semi hermetic Carlyle Com pressors are UL and CSA recognized and comply with UL CSA and NEC National Electrical Code require ments for internal motor protection MOTOR NUMBER For Carlyle internal use only TEST PRESSURES Each Carlyle 06D E CC compres sor is pressure tested at our factory The LS pressures are for the low side of the compressor The HS pressures are for the high side of the compressors CE MARK This CE Mark indicates this compressor complies with the European CE Mark requirements SERIAL NUMBER The unique number given to each compressor This number along with the model number and special order number is normally all that is needed to obtain information about or order a service replace ment compressor SERIAL NUMBER BAR CODE For Carlyle internal use only ELECTRICAL CHARACTERISTICS are shown for all
53. 5 to 8 Nm 1 4 in 6 mm screw 12 to 15 ft lb 16 to 20 Nm IMPORTANT The 1 4 in snorkle tube should face away from the crankshaft Fig 6 Insert the oil feed guide vane with the large diameter inward Place the oil feed vane spring over small diameter of guide vane do not install spring before installing guide vane Install pump cover plate bolt torque 16 to 20 ft Ib or 22 to 27 Nm NOTE Do not over torque or aluminum threads in bearing head could be stripped 41 MOTOR BURNOUT CLEAN UP PROCEDURE When a hermetic motor burns out the stator winding decomposes and forms carbon water and acid which contaminate refrigerant systems These contaminants must be removed from the system to prevent repeat motor failures See Carlyle Carrier recommendation procedures for clean up after burnout in semi hermetic compressors form 06DA604782 WARNING Before attempting service work on the compressor see safety precautions listed in Section 2 3 pages 20 to 31 and on compressor terminal box cover Also follow any installation instructions provided with the replacement compressor Failure to follow these instructions could result in equipment damage or serious personal injury 1 Determine cause of burnout and make necessary corrections a Inspect control box for blown fuses welded starter contacts welded overload contacts or burned out heater elements Inspect compressor terminal plate for bu
54. 8 Wire Size 06D and 06CC 50 to 99 1 to 4 Wire Size TERMINAL PLATE JUMPER PACKAGE FOR 06E 06CC 50 TO 99 Cfm This package consists of jumper bars terminal nuts and instructions to interconnect terminal studs for proper motor starting P W or X L and voltage JUMPER PACKAGE NUMBER USAGE 06EA660141 208 230 460 triple voltage 06EA660097 208 230 460 575 distinct voltage NOTE With 06 multi volt 208 230 460 compressors the 460 volt motor can be connected only for across the line start A compressor with a distinct 460 volt motor or designated P W must be used for part winding start 88 3 32 Baffle Plate Recommendations Baffle plates can be used to reduce compressor discharge gas pulsations Recommended baffle plate assemblies are shown below These plates are designed to create a 6 to 10 psi 0 4 to 0 7 Bars pressure drop in the discharge gas Use only the baffle plate recommended for the application These baffle plates sandwiched between two gaskets are installed between the compressor discharge service valve and the compressor crankcase or cylinder head For further details see Carlyle OEM Bulletins No 118 and 119 BAFFLE PLATE COMPRESSOR APPLICATION PART NUMBER 06D 13 16 and 20 Cfm low and medium temperature 06DA660103 06D 24 25 28 37 and 41 Cfm low temperature only 1 06DA660104 06D 24 25 28 37 Cfm and all medium temperature 06DA660105 06 16 to 37
55. Compressor Service Worksheet Mechanic Date From Compressor Nameplate Model No Serial No Motor No Voltage Allow compressor to run for 30 minutes then obtain the pressures and body temperature at the locations shown below Check for proper oil return in sight glass See Compressor Operating Limits Refrigerant Page 18 Outdoor Temp DB Hot Gas Line Temp _____ Head Pressure 5 Line Temp Suction Pressure Motor Barrel Temps Top Side Bottom Underside of Cylinder Head s Crankcase Temp Liquid Line Temp Leaving Condenser Oil Pressure COMPRESSOR VOLTAGE AMP VALUES PH VOLTAGE CURRENT C R 16 C S R R S S L L 2 n C es 30 PART WINDING L L Ly 1 L L Make copies of this worksheet to record data at initial start up and whenever the compressor is serviced LEGEND C Common Run Start 114 06CC Compressor Service Worksheet Mechanic Date From Compressor Nameplate Model No Serial No Motor No Voltage Allow compressor to run for 30 minutes then obtain the pressures and body temperature at the locations shown below Check for proper oil return in sight glass See Compressor Operating Limits page 19 SUCTION MANIFOLD SUCTION PRESSURE SUCTION LINE INTERSTAGE P PRESSURE iNTERSTAGE Ro
56. HEAD NEW MODELS ONLY COOLING FAN ONU NAMEPLATE LOCATION CRANKCASE MOTOR a 1 4 HIGH BARREL LEFT SIDE PRESSURE CONNECTION SUCTION A VALVE 14 NPT LOW ON MOTOR END COVER CONNECTI lt OIL DRAIN CONNECTION FACTORY SUPPLIED MOTOR SCHRADER TYPE gt FITTING 7 DO HERE CRANKCASE MOTOR BARREL BEARING HEAD BLANK PLATE REMOVE FOR CONTAINS OIL PUMP EQUALIZING LINE i OR OIL FLOAT D 1 4 2 CONNECTIONS CONNECTION 1 ABOVE SIGHTGLASS 1 ABOVEBLANK PLATE USED FOR 1 4 NPT OIL PUMP A OIL FILL CONNECTION PRESSURE CONNECTION x LOW SWITCH OIL SAFETY OIL PRE SWITCH CONNECTION SSURE ACCESS TEE TO BE INSTALLED IN THIS CONNECTION CRANKCASE HEATER HIGH SIDE CONNECTION OF OIL ACCESSORY PRESSURE SWITCH BE CONNECTED 7 6 20SAEOILDRAIN LEVELSIGHT GLASS INSATS INTO WELL TO FLARED ENO OF INSTALLED TEE CONNECTION aren AE IN BOTTOM COVER SUMP WITH BLANK PLATE NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included Fig 12 06 4 Cylinder Compressor 50 and old 66 Connection Points 48 1 47 HIGH PRESSURE CONNECTION DISCHARG
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58. months from the date of manufacture whichever comes first When a service compressor is used to replace an original compressor the remaining portion of the first year OEM warranty is transferred to the service compressor within the United States and Canada Equipment may carry an extended OEM warranty if that warranty has been purchased from the OEM The OEM Issues the extended warranty not Carlyle or its distribu tors and the OEM is responsible for providing the end user with the credit If returning a compressor place all parts back into compressor sealall compressor openings oil leakage may create an environmental hazard NOTE Opening a compressor for observation or determination of failure does not void warranty 1 5 Service Billing and Credit Returns of in warranty parts should be made to the same Local Carlyle Distributor who supplies these replacement parts Local Carlyle Distributors will sell parts and service compressors only to credit approved accounts except for cash sales 1 6 Green Carpet Program Parts and Stocking Policy The Carlyle Green Carpet program is a free service created to assist users in obtaining service replace ments The Green Carpet Program supports replace ment compressors for reported installations ensuring availability at the designated distributorship closest to the end user s location Green Carpet Customer Service Representatives can provide assistance in locatin
59. not require a special valve plate Suction cutoff unloading uses the standard high efficiency valve plate kit which includes the needed gasket 86 4 Service valve plate kits include 1 valve plate assembly 2 suction reed valves 3 cylinder head gaskets side center and suction gas unloading 1 valve plate gasket and for 06D compressors there are 2 suction valve position springs 5 All new high efficiency 06DM 06DA and 06CC 16 to 37 compressors have flat top pistons All new high efficiency O6DR and 06 compressors have one step contoured pistons All new high efficiency 06 06 and 06 50 to 99 compressors have two step contoured pistons 6 The outer edges of the valve plates have ears that are visible when installed on the compressor All new high efficiency valve plates have one elongated ear versus one or two rounded ears on the older standard efficiency valve plates Note the valve plate supplied in package 06ER660017 for environmental chambers has two rounded ears 3 30 Muffler Recommendations Mufflers can reduce discharge gas pulsation and effec tively eliminate vibration problems downstream They should be placed as close to the compressor as possible to maximize efficiency and minimize vibration Mufflers should be used on all 06 66 and 99 Cfm compressor models used on all 06E compressors with capacity control considered for use w
60. to the increased use of HFC refrigerants which operate at lower temperatures 3 16 06D E Cylinder Head Cooling Fans Cylinder head cooling fans are recommended on all applications where the saturated suction temperature SST is below 18 C A cylinder head cooling fan must be used for all R 22 single stage applications 74 below 18 C and all 404 507 single stage applications below 25 F 32 C A cylinder head cooling fan is recommended but not required for any two stage Compound Cooling applications CYLINDER HEAD COOLING FAN REPLACEMENT PARTS 06D 13 41 Cfm 06 06CC 06CC 16 37 Cfm 50 to 99 Cfm Complete fan package 06DR660014 06 660011 Replacement motor 208 230 1 60 HC27GB230 HC27GB230 Replacement blade package 06DR660012 06ER660007 Fan Guard 06DA401763 06EA401293 Cylinder head stud standard cyl head 06DA503213 06EA501973 Cylinder head stud with unloader cyl head 06DA680047 06D Only Mounting stud nuts 3 8 16 1 2 13 3 17 Capacity Control Accessory Packages Suction Cut Off Unloading Type The following suction cut off capacity control packages are available to field convert those 06D 06 compressors without unloading With the exception of the 06D 2 cylinder models these packages can be added to any new replacement or existing 06D or 06 compressors See Fig 16 NOTE Before adding a suction cut off control package to a compressor currently wi
61. until all electrical sources have been disconnected A DANGER When leak testing semi hermetic compressors check around the terminal box COVER Test around the wire entry point s of the COVER because refriger ant is likely to concentrate there Do not remove the terminal cover to perform this leak testing because bodily injury or death can result from fire and or explosion if cover is removed or unsecured before power is disconnected and pressure is relieved Electrical terminal pins may blow out causing injury and fire 20 COMPRESSOR ISOLATION If you have determined there is no refrigerant leak around the terminals and the compressor must be replaced proceed beginning with Step 1 l Shut off suction and discharge service valves to isolate compressor and slowly remove all refrigerant in com pressor Appropriate service practices should be fol lowed to properly reclaim refrigerant removed from the compressor Disconnect all electrical wiring to compressor Unbolt suction and discharge service valves from compressor REMINDER These valves may be sealing off refriger ant from the rest of the system Do not open these valves without first determining whether there is refrigerant in the system 21 peoy obeys 10 294074 suiejqoid 10 Y49949 e pue abejsiajul ueewjeq 91155910 q eDejsiojul pue
62. uq sossa 7 SIIS 5590 L E 67 3 4 06D E High Efficiency H E Compressors High efficiency compressors were phased in between 1985 and 1987 A high efficiency compressor can be identified as follows 06D H E compressors new or service replacement have the number 3 in the 11th digit of the model number See page 3 for examples The 06E compressor model numbers did not change To determine if a 06E compressor is high efficiency check the serial number The following serial numbers indicate high efficiency models start with S N 4585J 06 models start with S N 0786 OGER models start with S N 2287 06CC compressors are H E design service compressors are high efficiency except for some body units without a 37 in the 11th digit of the model numbers NOTE The 06E H E valve plates are identified by an elongated ear protruding from the side of the valve plate in contrast to the standard efficiency valve plates which have one A C EM EZ etc or two refrigeration ER EY rounded ears 3 5 Compressor Bodies Without Oil In 1995 Carlyle began supplying new and service compressors with no oil in the crankcase due to the introduction of HFC POE systems This eliminates the need to drain mineral oil from the crankcase when alkylbenzene or POE oil is to be used POE oil is very hygroscopic will readily pick up and retain moisture 68 fr
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68. 3 Oil Drain Plug Adapter new compressors except for 06D 808 109 013 313 and 316 models are built with a 7 16 20 SAE fitting and O ring as the oil drain plug Carlyle offers an oil drain adapter P N DE14CA126 which replaces the SAE plug This adapter allows the installation of a 1 4in NPT angle valve as a drain fitting 3 24 Sight Glass Adapters for Oil Equalization ADAPTER PACKAGE COMPRESSOR USAGE P N 06DA900072 P N 06EA660127 For all 06D and 06CC 16 to 37 Cfm For 06E and 06CC 50 to 99 Cfm 3 25 Replacement Sight Glass Installation Tool SIGHT GLASS PACKAGE INSTALLATION TOOL COMPRESSOR USAGE 5F20 152 Sight Glass S G 06EA402403 S G without O ring KK71GW015 O ring for S G T133300B 1 Installation Tool 5 20 152 sight glass assembly includes 5F20 1631 gasket 0605 and 06 16 to 37 All 06 and 06 50 to 99 All 06 06 50 to 99 0605 and 06CC 16 to 37 3 26 Replacement Motor End Mounting Foot MOTOR END FOOT P N 6D40 1042 COMPRESSOR USAGE 2 cylinder 06D All 4 cyl 13 amp 16 CFM 06D All 6 cyl 06DA A C duty models MOUNTING HOLE WIDTH IN 8 875 6D48 2063 All 4 cyl 18 amp 20 CFM 06D 8 25 06 500052 6 06DR 4 4 06 16 10 37 D All O6EA duty models 8 875 8 11 375 06 501172 83 0
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70. 6 50 to 99 E amp 06 Refrig duty models 8 875 amp 11 375 3 27 Gaskets Cylinder Head and Valve Plate GASKET TYPE PART NUMBER 06D COMPRESSORS 1 Cylinder head gaskets a Side bank no unloading 05GA502213 b Side bank with unloading suction cut off design 05GA502223 c Side bank with unloading hot gas bypass design 05GA502183 d Center bank 05GA502173 2 Valve plate gaskets a Standard 2 diameter cylinder bore 05DA500153 b Old design 1 13 16 diameter cylinder bore 6D40 1073 c Blank off special used only on old standard 16 Cfm models with suction valve at P E and using H E valve plates 06DA502923 06E COMPRESSORS 1 Cylinder head gaskets a Side bank no unloading 06EA503304 b Side bank with unloading Suction cut off design 06 503334 c Side bank with unloading hot gas bypass design 06EA503314 d Center bank standard or reversed 06EA503314 2 Valve plate gaskets a H E low temperature ER EY 028 036 Package 06ER660012 contains 1 06EA504884 gasket 2 suction valves b H E medium temperature EM EZ 067 072 06 504884 fiber 06 506414 metal H E high temperature EA ET 067 072 06 504884 fiber 06 506414 metal d Old standard low temperature ER EY 035 041 06 8660012 Old standard medium temperature EM EZ 035 041 06ER660012 f Old standard high temperature
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75. AGE DISCHARGE SUCTION VALVE LOCATION TO LOW STAGE CYLINDERS 1 4 HIGH SIDE OIL SAFETY SWITCH CONNECTION SUCTION MANIFOLD TOLOW STAGE CYLINDERS 1 4 LOW STAGE PRESSURE TAP NOT SHOWN BOTTOM OF CYLINDER 14 NPT OIL FILL SUMP 70167 20 SAE OIL HEAD HAS A BOSS AND CONNECTION ALSO DRAIN CONNECTION 1 4 NPT JUST LIKE LOW SIDE OIL SAFETY WAS 1 47 THE TOP SWITCH LOCATION NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included Fig 14A 06CC Compressor 16 to 37 Cfm 06D Body Pump End Connection Points 50 CYLINDER HEAD 1 4 HIGH STAGE SENSOR HIGH STAGE PRESSURE DISCHARGE TEMP SHOWN IF AVAILABLE USE PORT ON SERVICE VALVE TO DESUPERHEAT LOW STAGE DISCHARGE IF PORT AVAILABLE NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included Fig 14B 06CC Compressor 16 to 37 Cfm 06D Body Motor End Connection Points 51 SUCTION VALVE CYLINDER HEAD NAMEPLATE 1 4 HIGH STAGE LOCATION SENSOR HI
76. E PACKAGE No 06EA 660096 This universal mounting plate will accommodate any size 06D 06E and 06CC compressor Mount plate to existing base and mount the Carlyle compressor to the plate Package includes pre drilled mounting plate spacers and template 3 21 Compressor Service Valves 06D E CC VALVE SENSOR VALVE PACKAGE ODS BOLT HOLE VALVE PACKAGE INCLUDES 12mm SAE in SPACING NUMBER NO FITTING FOR TRANSDUCER 06DA660060 06 900412 5 8 55 1 5 8 EN32AA250 06DA660061 06EA900422 7 8 BRASS 1 5 8 7 271 06DA660062 06EA900432 7 8 BRASS 1 3 4 ENO7AA284 06DA660063 06EA900442 1 1 8 BRASS 2 1 2 sq 07 033 06DA660064 06EA900452 1 1 8 BRASS 1 3 4 7 48 06DA660065 06EA900462 1 3 8 BRASS 2 1 2 sq 07 039 06EA660090 06EA900472 1 5 8 BRASS 2 1 2 sq 07 041 06EA660091 2 1 8 BRASS 3 1 16 sq EM13FA516 06DA660164 06EA900482 2 1 8 STEEL 3 1 16 sq ENO7EA510 Valve packages consist of 1 service shut off valve and required gasket and mounting bolts NOTE Sensor Valve Packages required with Carlyle Sentinel module 3 22 Service Valve Gaskets 06D E CC FIBER VALVE GASKET METAL VALVE DESCRIPTION PACKAGE GASKET PACKAGE 2 bolt 1 5 8 spacing 6023 1421 060504143 2 bolt 1 3 4 spacing 6040 1131 060 504163 4 bolt 2 1 2 square 6068 1131 060 504153 Circular Holes 6065 1061 Service package contains 12 gaskets 82 3 2
77. E VALVE AND LIFTING LUG LOCATION 14 LOW PRESSURE CONNECTION FACTORY SUPPLIED SCHRADER TYPE FITTING NOT ADO HERE BLANK PLATE REMOVE FOR EQUALIZING LINE OR FLOAT CONNECTION 147 OIL PUMP PRESSURE CONNECTION OIL PRESSURE ACCESS TEE TO BE INSTALLED IN THIS CONNECTION HIGH SIDE CONNE CTION OF OIL PRESSURE SWITCH TO BE CONNECTED TO FLARED END OF INSTALLED TEE OIL LEVEL SIGHT GLASS INTERCHANGEABLE WITH BLANK PLATE SUCTION VALVE LOCATION MOTOR IND COVER 5 818 SAE OIL DRAIN CRANKCASE MOTOR BARREL BEARING HEAD CONTAINS PUMP 14 CONNECTIONS t ABOVE GLASS 1 ABOVE BLANK PLATE USED OIL FILL CONNECTION LOW SIDE OIL SAFETY CRANKCASE HEATER ACCESSORY INSERTS INTO WELL IN BOTTOM COVER 7 16 20 SAE OIL DRAIN CONNECT CRANKCASE SUMP NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included Fig 13 06E 6 Cylinder Compressor 65 75 99 Cfm Connection Points INTERSTAGE 1 2 13 UNC 1 4 INTERSTAGE MANIFOLD LIFTING LUG CONNECTION PRESSURE EXCHANGER SEE FIG LUG NOT SUPPLIED 148 FOR PORT WITH COMPRESSOR FITTING TO RELIEVE DESUPERHEAT LOW CRANKCASE PRESSURE ST
78. EA EX 067 072 06EA504884 06CC COMPRESSORS 16 to 37 a Oylinder head 05GA502213 b Valve plate 06DA500153 c Suction manifold 6D40 1131 d Interstage manifold 5D40 1131 Liquid injection 6D23 1421 f Interstage tube 6D23 1421 50 to 99 Cfm a Oylinder head 06EA503304 b Valve plate 06EA504884 c Suction manifold 6D68 1131 d Interstage manifold 6D68 1131 Liquid injection 6D23 1421 f Interstage tube 6D68 1131 Service package contains 12 gaskets NOTE H E and Old Standard are designations based on date of manufacture see Section 3 4 p 68 for details 84 3 28 Miscellaneous Terminal Plate Gasket COMPRESSOR USAGE 06D 06CC 16 TO 37 06 06CC 50 TO 99 PART NUMBER 6D40 1061 6645 1082 Sensor Block Gasket Used between transducer sensor block and bearing head with Johnson P445 06DA660115 oil safety switch COMPRESSOR USAGE PART NUMBER 06D 06 06CC 06DA680063 Electrical Terminal Barrel Nut Tool Socket tool used for installation of terminal nuts COMPRESSOR USAGE PART NUMBER 06D 06 16 TO 37 920 0009 3 29 Valve Plate Packages Service Replacement Carlyle began installing high efficiency valve plates in the mid 1980 s With a few exceptions noted the valve plates fit all current and older Carlyle compressors Check notes below the table for exceptions
79. EW MODELS ONLY LOCATION SINGLE PHASE MODELS SUCTION VALVE LOCATED AT MOTOR END 1 4 CONNECTION USED FOR THREE PHASE MODELS LOW PRESSURE SUCTION VALVE CONNECTION LOCATION b LOW SIDE OIL SAFETY SWITCH 1 4 HIGH INECTION PRESSURE OIL FILL SUMP CONNECTION CONNECTION 1 4 NPT PUMP NAMEPLATE PRESSURE SIGHT GLASS HIGH SIDE OIL SAFETY SWITCH CRANKCASE HEATER CONNECTION ACCESSORY MOUNTS TO UNDERSIDE OF 7 16 20 SAE OIL DRAIN CONNECTION BOTTOM COVER INSTALLED ON MODELS MANUFACTURED AFTER 0100 NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included 1 8 OIL PRESSURE TAP OLD STYLE 06D BEARING HEAD ASSEMBLY Fig 8 06D 2 Cylinder Compressor Connection Points 44 1 4 HIGH PRESSURE CONNECTION 1 4 LOW PRESSURE CONNECTION DO NOT ADD OIL HERE DISCHARGE VALVE LOCATION CYLINDER HEAD 4 b COOLING FAN 7 SUCTION VALVE MOUNTING STUDS LOCATION FOR NEW REFRIGERATION d HIGH EFFICIENCY MODELS ONLY MODELS ON MOTOR OPTIONAL SERVICE SUCTION VALVE lt LOCATION NAMEPLATE ANDA 1 4 NPT OIL FILL OLDER MODELS SEE NOTE BELOW BUMP CONNECTION ALSO LOW SIDE OIL 1 4 NPT OI
80. GH STAGE PRESSURE DISCHARGE TEMP 1 4 NPT INTERMEDIATE STAGE PRESSURE CONNECTION FACTORY SUPPLIED SCHRADER TYPE FITTING DO NOT ADD OIL HERE 1 4 NPT 2 CONNECTIONS 1 ABOVE SIGHT GLASS 1 ABOVE BLANK PLATE USED FOR A OIL FILL CONNECTION p CRANKCASE HEATER B LOW SIDE OIL SAFETY ACCESSORY SWITCH CONNECTION INSERTS INTO WELL IN BOTTOM COVER OIL LEVEL 7167 20 SAE OILDRAIN DISCHARGE VALVE SIGHTGLASS CONNECTION LOCATION WAS 1 47 NPT NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included Fig 15A 06CC Compressor 50 to 99 Cfm 06E Body Pump End Connection Points 52 CONNECTION FROM SUBCOOLING 3 4 10 UNC SUCTION MANIFOLD HEAT EXCHANGER OR PORT LIFTING LUG CONN TO LOW STAGE CYLINDERS TO DESUPERHEAT LOW LUG NOT SUPPLIED STAGE DISCHARGE IF PORT NOT AVAILABLE TAP TUBING HERE IF AVAILABLE USE PORT ON SERVICE 1 47 LOW STAGE VALVE TO DESUPERHEAT INPUT PRESSURE LOW STAGE DISCHARGE HIGH STAGE INLET NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing com
81. L PUMP SAFETY SWITCH PRESSURE HIGH CONNECTION SIDE OIL SAFETY SIGHT GLASS CONNECTION CRANKCASE HEATER ACCESSORY MOUNTS 1 4 NPT OIL DRAIN 1 TO UNDERSIDE OF CONNECTION BOTTOM COVER NOTES 1 Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included 2 The 13 and 16 Cfm service compressors are made with dual suction ports 1 8 OIL PRESSURE OLD STYLE 06D BEARING HEAD ASSEMBLY Fig 9 06D 4 Cylinder Compressor 13 and 16 Cfm Connection Points 45 DISCHARGE VALVE LIFTING LUG 1 4 NPT HIGH LOCATION NEW MODELS ONLY PRESSURE CONNECTION 1 4 NPT LOW PRESSURE CONNECTION NOT ADD OIL HERE 1 ___ 1 SUCTION VALVE EAR LOCATION MOTOR REFRIGERATION MODELS ONLY NAMEPLATE 4 4 1 4 NPT OIL FI 1 4 NPT OIL PUMP SUMP ENS PRESSURE HIGH gt t CONI TH SIDE OIL SAFETY a ANO LOW SIUE SWITCH SAFETY SWITCH CONNECTION x CONNECTION SIGHT GLASS 147 DRAIN CRANKCASE HEATER ACCESSORY INSERTS INTO WELL IN BOTTOM COVER 7 16 205 DRAIN CONNECTION NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to pr
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83. NFOSS TIME DIFF PSI REMOTE PART PART DELAY CONN VOLTS ALARM NO NO SEC CIRCUIT Cut In Cutout P529 2430 060B2109 120 8 11 4 8 115 230 Manual Yes lares 36 Long Capacity P529 2410 060B2164 120 Tube 8 11 4 8 115 230 Manual Yes 1 4 SAE Nuts 75 Use of an oil safety switch is recommended required by Carlyle as noted in the chart below OF SYSTEM COMPRESSORS COMPRESSORS COMPRESSORS Petommended Required Required Single ied Recommended Required N A Required Required Reduied Required 3 15 06 06E Discharge Gas Cylinder Head Tempera ture Sensor amp 06E Pressure Relief Valve OEM Carlyle 06EA EM ER compressors since 1982 are equipped with a discharge gas temperature sensor The sensor is installed in the discharge or center head on all six cylinder three head models The four cylinder 06 two heads have the sensor in the left side head as viewed from the oil pump end All 06CC compressors have the sensor located in the discharge high stage head Pressure Relief Valve 06E compressors and all 06CC 50 99cfm compres sors are equipped with a pressure relief valve that relieves from discharge pressure to crankcase pressure It 1s located under the center cylinder head on all 6 cylinder 06 and 06 compressors and under the discharge se
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86. R 13 and R 503 contact Carlyle Engineering for correct oil 69 FOR BLENDS Carlyle s engineering efforts were directed toward testing the new HFC refrigerants not the interim HCFC blends Carlyle provides tentative approvals of the following blends based on tests by the refrigerant manufacturer and feedback from field applications not on testing undertaken by Carlyle For Low Temperature applications R 402A HP 80 and R408A FX10 For Medium Temperature applications R 401A MP 39 R 402B HP 81 and R409A FX56 NOTE Carlyle compressors require alkylbenzene oil such as P903 2001 or Shrieve Chemical Zerol 150 whenever an HCFC blend is used In a retrofit application the amount of mineral oil cannot exceed 25 when mixed with alkylbenzene Carlyle does not recommend the use of POE lubricants with HCFC blends A WARNING A number of HCFC blends are not approved Some may create a hazardous situation Carlyle requires all refrigerants used in our compressors to be low flammability low toxicity The rating is based on ASHRAE 34 safety standard Not all A1 refrigerants are approved for use in Carlyle compressors Some of the refrigerants or blends available are either flammable 1 2 or A1 A3 and or toxic 1 1 or 1 83 Some 1 1 refrigerants can change ratings if contaminated Any replacement refrigerant must operate with the same pressure levels and temperature r
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89. TEMPERTURE PRESSURE MOTR BARREL TEMP SIDE BOTTOM HOT GAS LINE Z HEAD PRESSURE UNDERSIDE OF HIGH STAGE CYLINDER HEAD TEMP CRANKCASE TEMP BELOW SIGHT GLASS COMPRESSOR VOLTAGE AMP VALUES PH VOLTAGE CURRENT C R C 16 C S R R S S L L L L L L L L 3 PART WINDING L L L L L L L L L Make copies of this worksheet to record data at initial start up and whenever the compressor is serviced LEGEND C Common R Run S Start 115 Service Guide Index Page 06 16 to 37 CFM Phase Electrical Specifications 104 06 50 to 99 Phase Electrical Specifications 106 06 16 to 37 Torque Guide esee 60 06 50 to 99 Torque Guide esee 61 06 Compressor 16 to 37 Model Connection Points Motor End 51 06CC Compressor 16 to 37 Model Connection Points Pump End 50 06CC Compressor 50 to 99 Cfm Model Connection Points Motor End 06CC Compressor 50 to 99 Model Connection Points Pump End 52 06CC Compressor Model Numbers 5 06CC Compressors Physical Data eese 66 06CC Service 5 eee Regine 115 06D 2 Cylinder Compressor Connection Points
90. URE SEE COMPRESSORS LOCATED ON PE FACE OF COMPRESSOR PAGE 73 SECTION 3 11 Fig 1A Typical 06D E Operating Limits 18 SUCTION VALVE LOCATION MAXIMUM PREFERRED RGT FOR RA404A R507 AND R 22 IS S5 F 50 2 C 10 C MOTOR BARREL 1 4 NPT OIL PUMP UT PRESSURE CONNECTION 27 C TO 65 C SEE PAGE 73 SECTION 3 11 CRANKCASE SUMP 100 F 130 F 38 TO 54 C MEASURE BELOW CRANKCASE OIL LEVEL MAXIMUM ALLOWABLE 165 F 74 C OIL LEVEL SIGHT GLASS FOR 06CC 16 TO 37 DISCHARGE VALVE LOCATION 1 4 4 SIGHT GLASS SIGHT GLASS FOR D SIZE MAXIMUM TEMP AT 16 TO 37 Ctm IS ON THE SIDE OF THE COMPRESSOR DICHARGE IS 250 F 6 120 C BODY FOR 06CC 50 TO 99 1 8 TO 3 8 SIGHT GLASS 150mm FROM SERVICE VALVE Fig 1B Typical 06CC Operating Limits 19 2 3 Troubleshooting Procedures A DANGER Before attempting service work on the compressor the following safety precautions must be strictly observed Failure to follow these instructions could result in serious personal injury or death See Warning Label Follow recognized safety practices and wear protective goggles Do not operate compressor or provide electric power to this unit unless the compressor terminal box cover is in place and secured Do not provide power to unit or turn on compressor unless suction and discharge service valves are open Do not remove the compressor terminal box cover
91. anges as the CFC or HCFC being replaced Do not use any refrigerant not specifically approved in this guide unless you have obtained approval from the Carlyle Com pressor engineering department 70 FOR HFCs Carlyle has approved R 134a R404A R 507 and R 407C The following POLYOL ESTER POE are approved oils for HFCs Totaline see Note 5 P903 1001 1701 Castrol see Note 5 E68 ICI Emkerarate RL68H CPI 5a ees 29165 Solest 68 BP Marine Enersyn 568 POE oils are very hygroscopic will pick up and retain moisture from the air and should be used completely once the container is opened It is extremely difficult to reseal the oil container effectively enough to prevent moisture absorption which in turn forms damaging acids NOTES 1 The use of any non approved refrigerant may be dangerous and will void the warranty 2 Using the wrong type or weight of oil for the refrigerant selected will void the warranty 3 Follow the refrigerant and or oil manufacturer instructions when installing or retrofitting 4 Contact the Carlyle Compressor engineering department before using any refrigerant or oil not listed in this guide as approved for use in a Carlyle semi hermetic compressor 5 Castrol SW68 Totaline P903 1001 is approved for use in Carrier chill
92. ase 60 cycle unless noted as single phase 60 cycle Two overloads in parallel in legs 1 and 3 NOTE Most 06D compressors have internal thermostat installed in mo or and wire across terminals 8 and 9 at the terminal block It trips opens control circuit at 221 105 and resets at 181 F 83 108 4 10 Electrical Hook Up Consult wiring diagram located inside compressor terminal box cover and reference diagrams shown below for wiring hook up connection locations See 3 31 pg 88 for Terminal Box Packages Co Oud fu 1 060 4 Single inside motor esL Phase ee H 2 2 Capacitor 1 rt Stat Roy Capacitor 06D Single Phase Wiring T Cowo Wiring Power Wiring SINGLE PHASE INTERNAL THERMOSTAT OVERLOADS 5 1 PHASE BARRIER 5 CONTACTOR 06D NO 1 OPT ONAL OVERLOAD P i ee 1 Customer wiring shown dotted 8rd overload required on some compressors See 4 9 06D compressor overloads Three Phase Across the Line Start Internal Thermostat 109 06E COMPRESSORS ACROSS THE LINE XL START 6 Pin Term 3 Lead XL Start JUMPER HOLE 9 Pin Term 208 230 460V 300 Series Models 208 230 XL Start JUMPER 2 HOLE
93. ation compressors indicate that at least half of compressor failures occur during the first two to four months of operation Many of these failures occur during the initial start up of the unit In other cases troubled start ups lead to compressor damage severe enough to cause premature failures The major causes of failures of these compressors are flooded start floodback overheating and running out of oil Most of these failures can be avoided by using more care during the initial start up of the compressors Therefore the following start up procedure for 06D 06E and 06CC compressors is provided BEFORE START UP 1 Verify that the compressor nameplate indicates proper model and voltage Do the values agree with system needs and available power 2 Venfy that there 1s oil in the system Since different refrigerants CFC HCFC or HFC require specific oils mineral alkylbenzene or polyolester POE Carlyle ships most new and service compressors without oil The oil level for 06CC size 16 to 37 Cfm compressors and all 06D compressors should be at 1 4 to 3 4 of the sight glass The oil level for 06 size 50 to 99 Cfm compressors and all 06E compressors should be at 1 8 to 3 8 of the sight glass See Sections 3 6 and 3 7 pages 69 to 72 for the proper Carlyle ap proved oils for the selected refrigerant Oil should be added through the recommended oil fill connection ports on the compressor as identified in the figures in secti
94. charge valves are functioning properly remove valve plate assembly and inspect suction valves NOTE This test procedure is not applicable to compressors equipped with pressure actuated unloader valves due to rapid pressure equalization rate Inspect suction and discharge valves by disas sembling valve plate 32 DISASSEMBLY l Disassemble cylinder heads by first loosening cylinder head bolts Leave at least 2 bolts partially threaded to prevent any problems if refrigerant 15 accidentally left in the compressor under pressure To separate the cylinder head from the valve plate pry up between the head and valve plate When the cylinder head is separated from the compressor body remove the last threaded bolts CAUTION Do not hit the cylinder head to break it free of the valve plate This may shear the valve plate dowel pins Sheared dowel pins usually require that the compressor be replaced Inspect cylinder heads for warping cracks or damage to gasket surfaces Replace if necessary After the cylinder head is off the valve plate may be removed as follows a Remove one valve stop cap screw and loosen the other b Swivel valve stop to allow access to hole from which the cap screw was removed c Re insert cap screw and tighten to break valve plate away from compressor Jack screw method see Fig 2 For valve plates pry against the raised tab to break valve plate away from the compressor 33
95. er applications as well as Carrier and Carlyle semi hermetic compressors for air conditioning and medium temperature applications Castrol SW68 Totaline P903 1001 cannot be used in any new low temperature refrigeration applications using Carlyle OEM semi hermetic compressors Castrol E68 is approved for use in Carlyle OEM compressors for low medium and high temperature ranges 6 HFC POE applications require a crankcase heater 7 Moisture must be kept below 50 ppm for POE oils 8 In retrofit applications a high flow oil pump is required 71 3 7 Refrigerants and Oils for 06CC Compressors All 06CC compressors are approved for R 22 R 404A and R 507 except compressors in the 16 to 37 Cfm range Compressors in this size range cannot be used with R 404A and R 507 prior to Serial No 2099 without installing a retrofit compressor valveplate Part No 06CY 660 002 kit See Section 3 6 on page 69 for further information about refrigerants and oils See Section 3 6 on pages 69 amp 71 for the correct oil for each refrigerant Contact Carlyle Engineering for correct oil for R 23 and R 508A SUVA 95 3 8 Oil and Refrigerant Change Out Procedures To change from a CFC or HCFC to either an HFC or an HCFC blend follow the refrigerant and oil manufacturer installation procedures Select a Carlyle approved refrigerant and appropriate oil as noted in Sections 3 6 3 7 above System cleanliness is extremely imp
96. etermine if it is compatible with the refrigerant If the oil is not compatible use the drain connection to remove the oil Dispose of the removed oil following the appropriate environmental guidelines Since the compressor has not been run a thorough draining is all that is needed to remain within the limits of residual oil levels There is no need to flush the compressor with the replacement oil Once the oil is removed add the appropriate oil see above Place compressor in operation After 2 to 4 hours of operation inspect compressor oil for discoloration and or acidity If oil shows signs of contamination replace oil and filter driers and clean the suction strainer NOTE When testing for moisture and acidity be sure the test kit used is appropriate for the refrigerant CFC HCFC or HFC and the oil mineral alkylbenzene or POE in the system Carrier s Total Test Kit is accurate for CFC and HCFC air conditioning applications If used with POE oils Total Test Kit will indicate acid but is not an accurate indicator of moisture Inspect oil daily for discoloration and acidity If oil stays clean and acid free the system is clean If oil shows signs of contamination change oil change filter drier and clean suction strainer If filter drier or suction strainer is dirty or discolored repeat this step until system is cleaned 43 2 5 Connection Points 06D 06 and 06CC Compressors LIFTING LUG DISCHARGE VALVE N
97. event possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included 1 8 NPT OIL PRESSURE TAP OLD STYLE 06D BEARING HEAD ASSEMBLY Fig 10 06D 4 Cylinder Compressor 18 and 20 Cfm Connection Points 46 1 4 HIGH 1 4 NPT LOW PRESSURE CONNECTION PRESSURE CONNECTION BEHIND CYLINDER HEAD SUCTION VALVE DO NOT ADD OIL HERE LOCATION MOTOR BARREL DISCHARGE VALVE LOCATION M END CYLINDER HEAD COOLING FAN MOUNTING STUDS 0608 MODELS ONLY CYLINDER HEAD COOLING FAN 1 4 NPT PUMP MOUNTING STUDS PRESSURE HIGH SIDE OIL SAFETY NAMEPLATE SWITCH CONNECTION SIGHT GLASS 1 4 NPT OIL FILL SUMP CONNECTION CRANKCASE HEATER SAFETY SWITCH M CONNECTION INTO WELL IN BOTTOM COVER BEARING HEAD 7 16 20 SAE OIL DRAIN CONNECTION OLDER MODELS HAVE 1 4 NOTE Bolt sizes and thread pitch Compressors are built using English unit bolts The bolts have no exact metric equivalents Therefore to prevent possible cross threading loose bolts or damage to threaded portions of the casing comparable metric measurements are not included 1 8 NPT OIL PRESSURE TAP OLD STYLE 06D BEARING HEAD ASSEMBLY Fig 11 06D 6 Cylinder Compressor 24 25 28 37 and 41 Cfm Connection Points 47 TEMPERATURE SENSOR DISCHARGE VALVE CYLINDER HEAD LOCATION LIFTING LUG CYLINDER
98. g the necessary distributor 24 hours a day 365 days a year e U S A Puerto Rico 1 800 GO CARLYLE 462 2759 Canada 1 800 258 1123 Mexico 001 800 462 2759 2 0 START UP TROUBLESHOOTING AND SERVICE 2 1 Technical Assistance Carlyle OEM Compressors Carlyle Compressor Division sells compressors to OEMs Original Equipment Manufacturers that design and build the finished system The OEM is the expert the entire system including the Carlyle compressor system or compressor questions should be directed first to the OEM or the OEM s local representative If questions cannot be answered by the OEM or this Service Guide please contact the Carlyle engineering group The following recommended start up procedure for Carlyle 06D and 06CC compressors will help eliminate initial compressor failures caused by flooded start floodback overheating and running out of oil The Troubleshooting Procedures section Section 2 3 pages 20 to 31 will help pinpoint compressor and system problems The Service Procedures section Section 2 4 pages 32 to 43 covers the replacement of valve plates and gaskets service to the bearing head assembly contain ing the oil pump and a clean up procedure to follow in case of motor burnout Most other internal service requires replacement of the compressor 2 2 Recommended Start Up Procedure Reliability data of Carlyle s 06D 06E and 06CC refriger
99. iate Pressure Discharge Pressure 31 Troubleshooting O6CC Low Midstage Pressure 31 Troubleshooting Cannot Pull Down esee 22 Troubleshooting Compressor Isolation Procedures 21 Troubleshooting Cycling Continuous 23 Troubleshooting Cycling Intermittent Troubleshooting Cylinder Head Gasket Troubleshooting Desuperheater Connection Hot 06 Troubleshooting Discharge Temperature Sensor Troubleshooting Economizer Connection Hot O6CC 31 Troubleshooting 24 Troubleshooting Locked Rotor Cycling On 27 Troubleshooting Low Discharge Pressure 24 Troubleshooting High Midstage Pressure 06 31 Troubleshooting Low Midstage Pressure O6CC 31 121 Troubleshooting Low On Capacity Troubleshooting Low or No Oil Pressure Troubleshooting Low Suction Pressure Troubleshooting Motor Burnout Troubleshooting Motor Protection Tripping
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101. ith all 06D 37 and 41 Cfm compressor models considered for use with all 06D 6 cylinder compres sors with capacity control WEIGHT INLET OUTLET COMPRESSOR MUFFLER LB KG in SIZED BY CFM 060 605594 5 23 5 8 ODM 08 09 13 16 060605604 5 23 7 8 18 20 24 06DA605614 5 23 1 1 8 ODF 28 37 41 06 500302 10 45 1 3 8 50 LM10HH100 6 2 7 1 3 8 ODF 65 75 and 06E 399 06 500712 7 3 2 1 78 ODF O6E 499 599 and 06 899 Mufflers can be mounted horizontally or vertically 87 3 31 Electrical Accessories BOX PACKAGE This consists of terminal box cover and necessary mounting components TERMINAL BOX PACKAGE NUMBER TYPE COMPRESSOR USAGE AND SIZE 06DA660078 Drawn Steel 06DA660075 Fabricated 06DA660088 Fabricated 06EA660095 Drawn Steel 060 2 cyl 6 x 5 3 4 15 2cm x 14 6cm 060 4 cyl 6 x 5 15 2cm x 12 7 06D 6 cyl and 06CC 16 to 37 6 x 8 15 2 x 20 3cm 06 4 6 cyl compressors and 06 50 to 99 7 x7 17 8cm x 17 8cm TERMINAL LUG PACKAGE This consists of 6 screw on terminal lugs with set screws Strip power wire 1 2 in insert into terminal lugs and secure in place with set screw TERMINAL LUG PACKAGE NUMBER COMPRESSOR USAGE 06EA660095 85 008 85 004 All 06D and 06 16 to 41 06 and 06 50 to 99 4 to
102. le CARLYLE COMPRESSOR DIVISION CARRIER CORPORATION 7 98 Box 4808 Syracuse New York 13221 www carlylecompressor com In U S Puerto Rico 1 800 GO CARLYLE 1 800 462 2759 In Canada 1 800 258 1123 In Mexico 001 800 60 CARLYLE 001 800 462 2759 Manufacturer reserves the right to discontinue or change at any time specifications or designs and prices without notice and without incurring obligations 1 06 Lit No 020 611
103. m the bearing head cover plate and remove the oil feed guide vane and spring b Remove the two 2 drive segment cap screws from the end of the crankshaft see Fig 6 and Fig 7 These screws must be removed before the bearing head can be removed 2 Remove the eight 8 cap screws holding the bearing head assembly to the crankcase Remove the bearing head assembly by pulling forward 39 OIL PRESSURE 1 47 BEARING HEAD SCREWS 8 SEGMENT CAP SCREWS 2 BEARING HEAD COVER OIL FEED GUIDE CAP SCREWS 4 VANE AND SPRING Fig 7 Removing Pump End Bearing Head 06E Compressor 3 Inspect the bearing surfaces for evidence of wear or damage If bearing surface is worn or scored or if the oil pump is defective the complete bearing head must be replaced see replacement bearing head package listed below Compressor Replacement Bearing Head Package 06CC 16 to 37 and all 060 06DA660126 06 50 to 99 and all 06 06EA660157 While bearing head is removed inspect internal running gear for obvious problems broken rods or pistons 40 To reassemble bolt the bearing head to the crankcase Bolt torque e 06 16 to 37 Cfm and all 06D 30 to 35 ft lb 40 to 48 Nm 06 50 to 99 Cfm and all 06E 55 to 60 ft lb 75 to 81 Nm Bolt the drive segment replace 1f worn to the crank shaft Bolt torque No 10 Screw 4 to 6 ft lb
104. mpressor Service Valves 06D E 82 3 22 Service Valve Gaskets 06D E CC 82 3 23 Oil Drain Plug Adapter 83 3 24 Sight Glass Adapters for Equalization 83 3 25 Replacement Sight Glass Installation Tool 83 3 26 Replacement Motor End Mounting 83 3 27 Gaskets Cylinder Head and Valve Plate 84 3 28 Miscellaneous er ree DOR 85 3 29 Valve Plate Packages Service Replacement 86 3 30 Muffler Recommendations 87 3 31 Electrical AGCeSSOFIes iniit eerte 88 3 32 Baffle Plate Recommendations 89 3 33 Interstage Pressure Tables 06CC Compressors Only 89 4 0 ELECTRICAL DATA 4 1 06DR 3 Phase Electrical Specifications 4 2 06DM DA 3 Phase Electrical Specifications 4 3 06DR DM Single Phase Electrical Specifications 44 6 EY 3 Phase Electrical Specifications 4 5 06 EZ 3 Phase Electrical Specifications 4 6 06 ET
105. na iaeia 25 Piston Suction Valve and Backer Positions 36 POE Oils To Use with HFC Refrigerants Ti Pump End Bearing Head Pre Start Up Procedures Pressure Relief Valve Rated Load Amps Opa A r eeu Refrigerant and Change Out Procedures 72 Refrigerants and Oils for OCC Compressors 72 Refrigerants and Oils for 06D E Relief Valve 06 4 06 50 99 Compressors Serial Number Service Billing Service Proced res osuere er 32 Service Procedures Bearing Head Oil Pump 38 Service Procedures Cylinder Head and Valve Plate Assembly 32 Service Procedures Motor Burnout Clean Up Service Valve Gaskets Service Valves Service Worksheet OO O O 115 Service Worksheet 06D 114 Sight Glass Adapters Equalization 83 SIGht Glass Oil LOVE ML 12 Sight Glass Replacement Installation Tool Special Order Number Start Up Before Starting Start Up Recommended Procedures
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107. oil as neces sary Open backseat the discharge service valve and any oil equalization lines on parallel systems Open the suction service valve 1 2 to 1 turn or enough to allow the compressor to run without tripping the low pressure switch This 1 to prevent damage to the compressor from any liquid refrigerant floodback On water cooled condensing systems open water supply valve and allow water to reach condenser On air cooled condensing systems turn condenser fan on when the compressor unit is started Ensure that all evaporator connections are opened and fans started On systems with more than one compressor in parallel start one compressor at a time COMPRESSOR START UP l After circuit breaker and control circuit switches are placed in the ON position and the compressor starts listen for unusual sounds If unusual sounds are heard shut down the compressor investigate the cause and correct Possible problems are excessive vibration excessive oil liquid slugging low oil After the compressor has run 10 to 15 minutes and no liquid floodback is evident completely open suction service valve The other compressors within the system should be started in the same manner To ensure operating oil levels are within acceptable limits closely observe the oil level in the compressors until the system has stabilized During operation all refrigeration systems will lose some compressor oil to the system because
108. om the air and should be added just prior to system start up only See Section 2 2 page 11 for Carlyle approved system start up instructions and Section 3 6 below for the proper refrigerant oils 3 6 Refrigerants and Oils for 06D E Compressors The introduction of HFC POE systems has led to confusion as to what refrigerants and oils are approved for use in Carlyle compressors For 06CC compressors see Section 3 7 page 72 The following sections list approved refrigerants and oils for Carlyle 06D E compressors Refer to the following chart for Totaline 9 Part Numbers for available oils Patio ALKYLBENZEN AB Zerol 150 P903 2001 1 Gal P903 2005 5 Gal P903 2025 1 Quart MINERAL OIL P903 0101 1 Gal P903 0125 5 Gal P903 0155 55 Gal POLYOL ESTER POE OIL Do not use in low P903 1001 1 Gal x P903 1025 1 Quart temperature applications P903 1005 5 Gal POLYOL ESTER POE OIL P903 1705 5 Gal The following MINERAL ALKYLBENZINE are approved oils for CFCs and NOTE Carlyle does not recommend the use of POE oil with R 22 903 2001 Witco Suniso 3GS Shrieve Chemical Zerol 150 Texaco Capella WFI 32 150 IGI Petroleum Ind CRYOL 150 FOR CFCs AND HCFCs Carlyle has approved the use of R 12 R 500 R 502 and R 22 Selected OEMs of ultra low temperature equipment are approved to use
109. on 2 5 Once the compressor system has been running for at least 24 hours the most accurate oil levels are observed when the compressor is off Oil levels in the sight glass can be affected by the rotation of the running gear RECOMMENDED OIL LEVELS 06 16 TO 37 CFM AND 06D 06 50 99 AND 06 3 4 3 8 MAX 1 8 MIN 1 4 MIN Do not add excess oil It is especially important the and 06CC 50 to 99 Cfm compressors that excess oil not be added to the system Laboratory tests and field experience indicate excessive oil levels can cause blown valve plate and cylinder head gaskets increase compres sor operating temperatures and cause oil equalization problems NOTE 06D compressors and 06CC 16 to 37 Cfm compressors have one sight glass on the side of the crankcase All 06E compressors and 06CC 50 to 99 Cfm compressors have two sight glasses on the oil pump end of the compressor Parallel compressor applications typically use an oil control float system consisting of individual floats a separator and an oil reservoir When using a float system do not interconnect the floats with an equaliza tion system without approval from Carlyle application engineering The use of a float equalization system can result in system oil control problems An oil equalization line can be used instead of a float system except with 06CC compressors The equaliza
110. oq peeu jepui o Sejo o Ajjenunuoo 1055 2 75 Ajuaywuayul sejo o 105594905 p 1 1epurj o ejejd aSNY 318155064 NOILVAH3S80 23 ue Jo 109107 Jojejode 3 45 8 eoejdei 10 199407 Jojelode 3 eoejdoi jeeuiedns uoisuedxe 195 10 Weis s 1soJjep jueA euim Aue je 150 uo uiejs s jo ou oq you 10 195 yiedodui ajoAo 150494 129 109 Josse1duioo 0 5 4 Jose1duioo eoejdeg sBuu uojsid pue peeu y duing 205591909 feo y uedo jfeiued saem 15 Jesuepuoo 1 9 599 3 abseyosip 79 85 9 31815504 NOILVAH3S80 2
111. or tant To ensure a trouble free change out Carlyle Engineering has made specific guidelines available We strongly recommend a copy of our guidelines be re quested and procedures carefully followed to avoid problems 3 9 Oil Viscosity and Pour Points The viscosity of oils used in Carlyle reciprocating compressors is ISO 68 centistoke for all POE oils and 150 Saybolt Seconds Universal 150 SSU or 150 SUS or ISO 32 for mineral and alkylbenzene oils Using oil with a different viscosity without approval from the Carlyle Engineering Department will void the warranty The oils listed in Sections 3 6 and 3 7 and the viscosity listed above can be used down to 40 F 40 C If your system runs at a lower temperature please contact Carlyle Engineering for an oil recommendation 72 3 10 Oil Additives No oil additive is allowed without written approval from the Carlyle Engineering Department The use of any unauthorized additive will void the warranty Oil Pressure new 06D E CC compressors are supplied with oil safety switch connections Carlyle has introduced a new high flow oil pump and changed oil pressure specifica tions due to changes in lubricants and refrigerants The following data notes the proper oil pressure range based on the compressor s date of manufacture STARTING MARCH 1994 WITH S N 1094J AND LATER For new OEM 06D and 06CC 16 to 37 Cfm compres sors the pressure 1 18 to 26 psi 1
112. or Manifold 84 Gaskets Cylinder Head and Valve Plates 84 Gasket Sensor Block nente de e eR x dead c 85 Gaskets Service Valves Gaskets Leak Testing Green Carpet Program HCFC Blends Approved for Use 70 HCFCs Approved for 0 69 Heaters CrankCase t e dee un 81 Help Where to Get More sess 1 HFCs Approved for Use High Efficiency Compressors 06D E Insertion Heaters Interstage Pressure Tables O6CC seen 89 Jumper Plate Packages Connection essen 88 110 118 Locked Rotor Cycling On Typical Causes 27 Low Compressor Capacity eee RARE Re nent 22 Metric Conversions and Measurements Mineral Oils To Use With CFC and HCFC Refrigerants Model Number Motor Burnout Motor Barrel Interconnection 18 Motor End Mounting 83 Motor Burnout Clean up Procedure Motor Protection Tripping Typical Causes Mounting Data Compressor Mounting Plate Compressors xerit 87 Nameplate Significance 6
113. parable metric measurements are not included Fig 15B 06CC Compressor 50 to 99 Cfm 06E Body Motor End Connection Points 53 1908 H31V3H 3SVONNYHO JAWA 03H29 Nuni3 10 N33H2S 10 1 1 935 55 10 awassy dviNd 10 1108 80108 N33H2S A31NI NOLLONS 1HOd Nou ons 18 355 3901 AWM A39 9 21 0 13 5 9 31 1 JAVA 38055384 3SVOXNVHO 1355 9 QV3H 591 96 190 MAA EUOTJ29S SSO 17 9 7 54 1909 H31V3H 35 2 8782 1908 1 10 HOSS3Hdi OO 8 TaTWHVd aan 11 9 10 N33H9S 10 10 1108 5 1904 55 19 195 0105 10 1313110 AVS RIVED 18N3SSV 10 YO 3unss3ud Nou ns 901 YOLVLS 38ni 9 1211 003 aay ree 38055384 3SVOXNYUS Qv3H JOSSIIAUIOD 96 390 euorpog sso 7 7 55 1epuiKo epis 5 62 JeuseM EZ zz 197589 12 eDJeuosiq 02 A AAPA amaS 61 jeuseM yog
114. r head To prevent high to low side leak in center of cylinder head gasket torque 06D cylinder head cap screws to 30 to 35 ft Ibs 40 to 48 Nm and cylinder head cap screws to 90 100 ft Ibs 122 to 136 Nm NOTE Torque bolts in an alternating sequence pattern top to bottom left to right Do not torque bolts in a circular pattern 37 7 Certain high compression ratio applications develop high discharge gas temperatures which may cause the cylinder head and fiber valve plate gaskets to develop a set Under these conditions the cap screws may lose hold down torque It is recommended that all gear cap screws be re torqued 24 hours after new fiber gaskets are installed NOTE Compressors with metal core gaskets do not require re torque REMOVE INSPECT AND REPLACE BEARING HEAD ASSEMBLY An oil pressure tap is located in the bearing head assembly used on all 06D refrigeration duty newer 06D A C duty and all O6E refrigeration and A C duty compressors Fig 6 and Fig 7 For 06D E CC oil pressure see page 73 Section 3 11 The oil pump assembly is contained in the pump end bearing head aluminum casting The pump end main bearing is a machined part of this casting No insert bearing is required 38 SUCTION STRAINER ASSEMBLY PRESSURE 1 47 BEARING HEAD SCREWS 8 Fig 6 Removing Pump End Bearing Head 06D Compressor 1 a To disassemble first remove four 4 cap screws fro
115. refrigerant floodback or too much oil in the system CAUTION Liquid refrigerant should never be allowed to flood back to the compressor It may wash out bearings and damage gaskets If liquid floodback is occurring adjust the expansion valve or make other adjustments as necessary to eliminate this condition NOTE One possible cause of flooding is improper control of the defrost cycle Ensure defrost cycles are staggered so no more than one third of the system 1 on defrost at any time COMPRESSOR OPERATING LIMITS Figures and show the components and typical operating ranges of the Carlyle 06D E and 06CC compressors TEMP AT DISCHARGE IS 275 F 6 135 C 150mm FROM SERVICE VALVE 250 120 C PREFERRED WITH POE OILS CRANKCASE AT SUMP 100 F TO 130 F 38 C TO 54 C MEASURE BELOW LEVEL CRANKCASE MAXIMUM ALLOWABLE TEMP 165 F 74 C RETURN GAS TEMP RGT MEDIUM TEMP AND R 22 134 404 R 507 R 502 AND 12 65 18 C MAXIMUM PREFERRED RGT FOR LOW TEMP R 22 R 404a R 507 AND 502 IS 35 F SOF 2 C 10 C MOTOR BARREL 80 F TO 125 F 27 TO 52 F SIGHT GLASS 707 LOCATION SHOWN OPERATING LEVEL RECOMMENDATIONS 0 COMPRESSORS 1 4 3 4 GLASS COMPRESSORS BOTTOM OF CYLINDER HEAD 1 8 TO V8 GLASS 80 F 120 F 27 TO 49 C NOTE SIGHT GLASS OF ALL 06E NORMAL PRESS
116. rned or damaged terminals and insulation and shorted or grounded terminals Inspect unit wiring for loose power connections Check for power supply fluctuation beyond design limits voltage too high or too low If power supply is a problem provide the appropriate system protector 2 Close compressor suction and discharge service valves and remove the refrigerant from the compressor using environmentally approved methods Leave remaining refrigerant in system 3 Remove damaged compressor and replace a Remove suction and discharge shut off valve bolts and all other connections to damaged compressor Remove damaged compressor and replace with a new compressor On severe motor burnouts be sure shut off valves and suction or discharge lines are not contaminated If contaminated they 42 should be thoroughly cleaned or replaced before connecting to replacement compressor Install new liquid line filter drier If the system has a suction line filter drier replace the core Evacuate and dehydrate replacement compressor Ensure oil in compressor is at the proper level NOTE Since most new and service compressors are now shipped without oil in the crankcase you must check to see if there is oil Adding or charging oil is usually easier prior to installing the compressor If there is no oil add the appropriate oil for the service Oil charges are listed in Sections 3 1 to 3 3 pages 62 67 If there is oil d
117. rs as the oil sump of these compressors are at interme diate pressure CAUTION 06E compressors will not tolerate excessive oil charges Laboratory tests and field experience confirm that excess oil especially in 06E compressors can cause cylinder head gaskets and valve plates to fail increase compressor operating temperatures and lead to oil control problems Page 12 notes the correct oil levels CAUTION Do not charge through the suction line or through the compressor suction access fittings See the compressor figures in Section 2 5 for the location of the recommended oil charging ports Adding oil into the suction side of the compressor can result in oil intake directly into the cylinders resulting in suction discharge valve piston and or connecting rod damage 14 Use only Carlyle approved appropriate for the refrigerant being used Sections 3 6 and 3 7 on pages 69 72 list all the approved oils Section 3 11 on page 73 notes the correct oil pump pressure in relation to age of the compressor Leak test evacuate and dehydrate the system Charge the system When initially charging the high side of the system with liquid refrigerant all service valves should be closed front seated This will prevent refrigerant from migrating to the compressor crankcase and into the oil causing a flooded start The system 15 now charged and ready for start up Recheck the oil levels and add or remove
118. rvice valve on all 4 cylinder 06E compressors The relief valve is sealed with a metal gasket Part Number Description 51 272 400psi Relief Valve differential pressure 6G65 1251 Relief Valve Gasket An 11 16 drag link socket can be useful for removing installing the relief valve 76 When the discharge gas temperature in the cylinder head exceeds the sensor trip setting see below the sensor will open the control circuit and shut off the compressor The head sensor must be wired into the control circuit by the OEM and is pilot duty only at 240V 0 52A at 115V 1 04 The sensors are threaded into the head without a well Therefore when changing a sensor the compressor must first be isolated and evacuated CYLINDER HEAD TEMPERATURE SPECIFICATIONS Refrigeration from 1982 to mid 1998 All 06 and 06CC for 06 EY and EZ Compressors Part Number 06EA0512283 HN68GA242 Opens 325 8 F 163 4 C 295 5 146 3 Closes 250 x12 F 121 7 C 235 F minimum 113 C Wire Color Silver Grey Black Thread 1 2 NPT 1 2 NPT NOTES 1 Since 1993 all Carrier 06 series air conditioning compressors have been made without a sensor Carlyle OEM 06 series compressors are equipped with a sensor 2 Starting in mid 1998 all Carlyle OEM compressors including 06EA EM ER and all 06CC models are built using the HN68GA242 sensor The change to a single sensor model is due
119. semi hermetic compressors Voltages are shown with respective operating ranges for both 50 and 60 cycle operation Electrical phase and LRA Locked Rotor Amps information is also provided MANUFACTURING NUMBER For Carlyle internal use only MANUFACTURING NUMBER BAR CODE For Carlyle internal use only 1 3 Compressor Serial Number Significance ALL NEW COMPRESSORS Example S N 3695J00123 36 95 J 00123 Numerical Sequence Plant Location J Syracuse U Atlanta Year of Manufacture 93 94 95 etc Week of Manufacture 01 thru 52 Begin Jan 1st ALL SERVICE COMPRESSORS Example S N 3695UD0123 36 02 U D 0123 L Numerical Sequence Compressor Type D E Plant Location M Atlanta P Phoenix U Atlanta after 4 2001 Year of Manufacture 93 94 95 etc Week of Manufacture 01 thru 52 Begin Jan 1st NEW AND SERVICE REPLACEMENT COMPRESSORS BUILT BETWEEN NOV 1968 OCT 1978 Example A2J0001 A 2 J 0001 L Numerical Sequence Plant Location J Syracuse Year of Manufacture 9 69 0 70 1 71 etc Month of Manufacture A Jan B Feb skip M Dec An X A or P in this location indicates service compressor 1 4 Carlyle Compressor Warranty Original OEM compressors are warranted to be free from defects in material and workmanship for a period of 12 months from the date of original installation or 20
120. thout unloading consider all line piping sizes and design to ensure proper oil return to compressor with reduced unloaded refrigerant flow rates 78 CAPACITY CONTROL PACKAGES PACKAGE BARE UNLOADER COMPRESSOR TYPE NUMBER VALVE 06D Electric 06DA660089 06EA660135 06D Pressure 06DA660090 06 6601001 06 Electric 06EA660138 06EA660135 06 Pressure 06EA660139 06 6601001 Coil NOT included order separately see Section 3 18 1 Special Allen head wrench to change valve is part number 06EA680036 NOTES 1 Each package unloads 2 cylinders 1 step and includes 1 cylinder head assembly with applicable unloader valve electric or pressure and necessary gaskets 2 When adding the suction cut off unloading feature to any compressor it is no longer necessary to change the valve plate The suction cut off method of unloading functions independently of the valve plate 3 To avoid interfering with hi lo pressure connections or cylinder head sensor install the unloader cylinder head as follows viewed from of compressor 06D 4 cyl left hand cylinder deck 06 4 cyl right hand cylinder deck 06D O6E 6 cyl either cylinder deck both when applicable 4 Unloader valve gasket part number 06EA501253 5 Unloader is not available for 06CC compressors 79 LOADED OPERATION UNLOADER UNLOADER UNLOADER PISTON ASSEMBLY COIL CLOSE P VALVE BODY ORT UNLOADER VALVE SPRING SOLENOID
121. well hole in cast iron bottom plate Circular clip with barbs secures heater Used on 06D 718 818 and 820 4 cylinder compressors all 6 cylinder 06D compressors all 06 and all 06CC compressors Insertion heaters are available in 125 and 180 watt sizes CRANKCASE HEATER PACKAGES CRANKCASE CONDUIT WIRE HEATER HEATER LENGTH PACKAGE TYPE NUMBER VOLTAGE WATTS in in cm 06DA660091 Strap on 115 50 24 61 39 99 06DA660092 Strap on HT33BK310 230 50 24 61 39 99 06 660165 Insertion HT36DM132 115 180 19 48 24 61 06EA660167 Insertion HT36DM134 115 180 52 132 73 185 06 660166 Insertion HT36DM432 230 180 19 48 24 61 06 660168 Insertion HT36DM434 230 180 52 132 73 185 06DA660076 Insertion HT36DL480 480 125 E 24 61 NOTES 1 Insertion heaters use AS8IVF056 tubular clip 2 Thermal grease is provided and must be used with 180 watt heaters grease packet P N 38AQ680001 81 3 20 Compressor Mounting Data Mounting packages are available to mount individual compressors Package contains mounting springs threaded studs snubbers spring cups nuts and washers for 1 compressor USE WITH MOUNTING PACKAGE NUMBER BODY STYLE 06DA660058 06D 2 cyl 06DA660056 06D 4 06DA660057 06D 06CC 16 to 41 6 cyl 06 660089 4 and 6 and 06CC 50 to 99 COMPRESSOR MOUNTING PLAT

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