SERVICE GUIDE06D/06E/06CC COMPRESSORS

www.carlylecompressor.com

WHAT THIS GUIDE CAN DO FOR YOU

Carlyle Compressor Company provides this guide to aid the service specialist in proper installation, service, and maintenance of 06D, E, CC compressors. Following the procedures in this guide will extend the life of the system and improve performance.

This guide uses the terms DANGER, WARNING and CAUTION. These terms have specific meanings that identify the degree of hazard. Typically in the HVAC industry, these specific meanings are:

There is an immediate hazard which WILL result in severe personal injury or death.

HOW TO USE THIS GUIDEThis book is divided into four major sections (see Table of Contents):SECTION 1.0 - General Compressor and Customer InformationSECTION 2.0 - Start-Up, Troubleshooting, and ServiceSECTION 3.0 - Compressor Parts DataSECTION 4.0 - Electrical Data

An Index is provided in the back of this guide.

TO GET MORE HELP

Carlyle Compressor Company sells compressors to Carrier for use in their pack-aged units and to OEMs (Original Equipment Manufacturers) that design and build finished systems. The system manufacturer is the expert on the system, including the application of our compressor. All questions, on either the packaged system or the compressor in that system, should be first directed to the local Carrier distributor (for Carrier systems) or the OEM or its local representative (for other units). If this support, along with this service guide, cannot resolve your compressor problem, please contact our Carlyle engineering group.

CARLYLE COMPRESSOR THANKS YOU FOR SELECTING OUR EQUIPMENT

Hazards or unsafe practices which COULD result in severe personal injury or death.

Potential hazards or unsafe practices which COULD result in minor personal injury or equipment damage

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CARLYLE COMPRESSOR DIVISION • © CARRIER CORPORATIONP.O. Box 4808 • Syracuse, New York 13221In U.S., Puerto Rico: 1-800-GO-CARLYLE (1-800-462-2759)In Canada: 1-800-258-1123In Mexico: 001-800-GO-CARLYLE (001-800-462-2759)

Manufacturer reserves the rightto discontinue, or change at any

time, specifications or designsand prices without notice andwithout incurring obligations.

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CONTENTS

1.0 GENERAL COMPRESSOR AND CUSTOMER INFORMATION1.1 CompressorModelNumberSignificance........................................31.2 NameplateSignificance....................................................................61.3 CompressorSerialNumberSignificance..........................................81.4 CarlyleOEMCompressorWarranty...............................................91.5 ServiceBillingandCredit.............................................................101.6 CarlyleCompressorConnectionProgram,Partsand StockingPolicy..............................................................................10

2.0 START-UP, TROUBLESHOOTING, AND SERVICE2.1 TechnicalAssistance-CarlyleOEMCompressors........................102.2 RecommendedStart-UpProcedure................................................112.3 TroubleshootingProcedures...........................................................202.4 ServiceProcedures........................................................................322.5 ConnectionPoints—06D,06E,and06CCCompressors.............442.6 Cross-SectionalView—06DSemi-HermeticCompressor..........542.7 Cross-SectionalView—06ESemi-HermeticCompressor..........552.8 ExplodedView—6-Cylinder06DCompressor............................562.9 ExplodedView—6-Cylinder06ECompressor...........................582.10TorqueGuide––06Dand06CC(16to37Cfm)Compressors.....602.11 TorqueGuide––06Eand06CC(50to99Cfm)Compressors......61

3.0 COMPRESSOR AND PARTS DATA3.1 06DSeriesCompressors––PhysicalData...................................623.2 06ESeriesCompressors––PhysicalData....................................643.3 06CCSeriesCompressors––PhysicalData.................................663.4 06D,EHighEfficiency(H.E.)Compressors................................683.5 CompressorBodiesWithoutOil....................................................683.6 RefrigerantsandOilsfor06D,ECompressors.............................693.7 RefrigerantsandOilsfor06CCCompressors...............................723.8 OilandRefrigerantChange-OutProcedures.................................723.9 OilViscosityandPourPoints........................................................723.10OilAdditives..................................................................................733.11 OilPressure...................................................................................733.12HighFlowOilPump(BearingHead)............................................743.13ReplacementOilPump/PumpEndBearingPackage....................74

Rev 08/10

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3.14 OilSafetySwitch...........................................................................753.15 06CC,EDischargeGasCylinderHeadTemperatureSensor.........763.16 06D,ECylinderHeadCoolingFans..............................................773.17 CapacityControlAccessoryPackages............................................783.18 CapacityControlCoilPackages(06D,E)......................................803.19 CrankcaseHeaterData....................................................................813.20 CompressorMountingData............................................................823.21 CompressorServiceValves(06D,E,CC)......................................823.22 ServiceValveGaskets(06D,E,CC)...............................................823.23 OilDrainPlugAdapter...................................................................833.24 SightGlassAdaptersforOilEqualization......................................833.25 ReplacementSightGlass—InstallationTool................................833.26 ReplacementMotorEndMountingFoot........................................833.27 Gaskets––CylinderHeadandValvePlate.....................................843.28 Miscellaneous..................................................................................853.29 ValvePlatePackages,ServiceReplacement...................................863.30 MufflerRecommendations..............................................................873.31 ElectricalAccessories.....................................................................883.32 BafflePlateRecommendations.......................................................893.33 InterstagePressureTables(06CCCompressorsOnly)...................89

4.0 ELECTRICAL DATA4.1 06DR3PhaseElectricalSpecifications..........................................934.2 06DM,DA3PhaseElectricalSpecifications..................................954.3 06DR,DMSinglePhaseElectricalSpecifications.........................974.4 06ER,EY3PhaseElectricalSpecifications...................................994.5 06EM,EZ3PhaseElectricalSpecifications.................................1014.6 06EA,ET3PhaseElectricalSpecifications.................................1034.7 06CC(16to37Cfm)3PhaseElectricalSpecifications...............1054.8 06CC(50to99Cfm)3PhaseElectricalSpecifications...............1074.9 06DCompressorOverloads..........................................................1094.10 ElectricalHook-Up.......................................................................1104.11 VoltageandCurrentUnbalance....................................................113

5.0 COMPRESSOR SERVICE WORKSHEETS06D,06ECOMPRESSORSERVICEWORKSHEET..................................11506CCCOMPRESSORSERVICEWORKSHEET........................................116

SERVICEGUIDEINDEX..................................................117

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1.0 — GENERAL COMPRESSOR AND CUSTOMER INFORMATION

1.1 — Compressor Model Number Significance06DCOMPRESSORS

06DR 3 37 0 D A 36 5 A – (RP)**

Model = 0, Package = 1 or 9, A = Shipped Without Oil

Suction Cut-Off Unloading Designation for 06DR, DM Compressors: 0 = All Models Except as Noted 5 = No Oil 7 = 1 Unloader Elec. (DR, DM Only) 8 = 2 Unloaders

Electrical Characteristics (XL Start Only, Unless Noted): New H.E. Models Old Std. 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: A = With Internal Thermostat and External Overloads C = With Internal Thermostat and Without External Overloads Suction 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 (in Cfm at 1750 rpm)

Motor Size - (Does Not Signify Horsepower)

Compressor Type: 06DA = Compressor - A/C Duty No Unloading 06DB = Compressor - A/C Duty 1-Step Elec. 06DC = Compressor - A/C Duty 2-Step Elec. 06DD = Compressor - A/C Duty 1-Step Press. 06DE = Compressor - A/C Duty 2-Step Press. 06DF = Compressor - A/C Duty 1-Step Elec. 06DG = Compressor - A/C Duty 2-Step Elec. 06DH = Compressor - A/C Duty 1-Step Press. 06DJ = Compressor - A/C Duty 2-Step Press. 06DM = Compressor Refrig. Duty Medium Temperature 06DR = Compressor Refrig. Duty Low Temperature 06DM = Service Compressor-Replacement for new 06DA, DM without Unloading 06DS = Service Compressor-Replacement for new 06DF,G,H and J with

suction cut-off unloading. Compressor has 1-Stage suction cut-off unloading

06DX = Service Compressor-Replacement for new 06DB,C,D, and E with hot gas (bypass) unloading. Compressor has 1-stage of bypass unloading

**Refrigeration Partner

Hot Gas BypassUnloading

Suction Cut-OffUnloading

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06ECOMPRESSORS

06ER 3 99 3 0 A – (RP)**

Model = 0, Package = 1 or 9, A = Shipped Without Oil

Design Variable: New Compressors: 0 = OEM Model 1 = Carrier A/C Model 2 = Old Design Refrigeration Valve Plates 6 = Carrier A/C Model 9 = Cemak Model

Service Compressors: 2 = New Manufactured (A/C) 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 (460v XL Only) 4 = 200-3-60 5 = 230-3-60 6 = 400/460-3-50/60 8 = 230-3-50 9 = 220/380-3-60 Displacement (in Cfm at 1750 rpm) Motor Size (Does Not Signify Horsepower) 0, 1, 2 = Models With Oil 3, 4, 5 = Models Without Oil 7 = 1 Unloader, Suction Cut-off, Oil-less (ER, EM Only) 8 = Special Order

Compressor Type: STD* REV† 06EA 06EF Compressor - A/C Duty No Unloading 06EB 06EJ Compressor - A/C Duty 1-Step Elec. 06EC 06EK Compressor - A/C Duty 2-Step Elec. 06ED 06EL Compressor - A/C Duty 1-Step Press. 06EE 06EN Compressor - A/C Duty 2-Step Press. 06E2 06E6 Compressor - A/C Duty 1-Step Elec. 06E3 06E7 Compressor - A/C Duty 2-Step Elec. 06E4 06E8 Compressor - A/C Duty 1-Step Press. 06E5 06E9 Compressor - A/C Duty 2-Step Press. 06EM - Compressor - Refrig. Duty Med Temp. 06ER - Compressor - Refrig. Duty Low Temp. 06ET - Serv. Compressor A/C Duty Replaces 06E2,3,4,5,6,7,8, and 9. Compressor has 1 stage of suction cut-off unloading. 06EX - Serv. Compressor A/C Duty Replaces 06EA,B,C,D,E,F,J,K,L, and N. Compressor has 1 stage of Bypass unloading. 06EY - Serv. Compressor Refrig. Duty Replaces 06ER 06EZ - Serv. Compressor Refrig. Duty Replaces 06EM

* Standard Center Cylinder Head.† Reversed Center Cylinder Head.

Service compressors shipped with reverse center head have the letter “R” after the serial number on the shipping box.

**Refrigeration Partner

Hot Gas BypassUnloading

Suction Cut-OffUnloading

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06CCCOMPRESSORS

06CC 6 65 E 201

Design Variable: 101 = Single Pack, W/O Valves, with Oil 102 = Single Pack with Valves & Oil 103 = Single Pack, Service W/O Valves and 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 B = 415-3-50, XL C = 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 G = 400/460-3-50/60, XL H = 400/460-3-50/60, PW J = 575-3-60, XL and PW K = 230-3-60, PW L = 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: 0 = 14 ft.-lb (5 HP) 5 = 45 ft.-lb (15 HP) 1 = 20 ft.-lb (6.5 HP) 6 = 60 ft.-lb (20 HP) 2 = 24 ft.-lb (7.5 HP) 7 = 75 ft.-lb (25 HP) 3 = 27 ft.-lb (10 HP) 8 = 90 ft.-lb (30 HP) 4 = Not Assigned

Compressor Type: 06CC = Compound Cooling Model 06CY = Service Compressor 06C8 = Compressor, Special

NOTE:USEOF“Cfm”ASMODELSIZEDESIGNATION

Carlyleusesthe“Cfm”designationinthemodelnumbertoidentifythecompressorsize.TheCfmvaluesarethesixthandseventhdigitsofthemodelnumber.Seeexampleabove.

Carlyleofferstwoseriesofcompressorsbasedonbodysize.Thesmallercompressors,from8to37Cfm,arereferredtoas“D”sizeunits(modelnumber“06D”).Thelargercompressors,from50to99Cfm,arereferredtoas“E”sizeunits(modelnumber“06E”).

The06CC,orCompoundCoolingcompressors,aremadein16to37Cfmand50to99Cfmsizes.The16to37Cfmcompressorsuse“D”sizebodies.The50to99Cfmcompressorsuse“E”sizebodies.

NOTE:METRICMEASUREMENTS

ThecompressorsarebuiltusingEnglishunits:inches,foot-pounds,pints,etc.AcorrespondingmetricmeasurementhasbeenaddedtoalltheEnglishunitsinthisguide.Thesemetricmeasuresareaguideonly,havingbeenroundedtothenearestwholenumber,andthereforearenotmeanttobeanexactmathematicalconversion.

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1.2 — Nameplate Significance

Explanationoftheaboveitems,startingclockwisefromupperright:

MODELNUMBER-Usedwhenselectingandorderinganewcompressor.Distributorsusethemodelnumbertoobtainaproperservicereplacement.

NOTE: Modelnumbersonsomecompressorsareidentifiedbythesymbol“M/N”locatedintheupperrighthandcornerofthenameplate.

ULANDCSA-SinglemarkindicatesthatthiscompressormeetsalltherequirementsforbothUL(Underwriters’Laboratory)andCSA(CanadianStandardsAssociation).All60Hzsemi-hermeticCarlyleCompressorsareULandCSArecognizedandcomplywithUL,CSA,andNEC(NationalElectricalCode)requirementsforinternalmotorprotection.

MOTORNUMBER-ForCarlyleinternaluseonly.

MODEL NUMBER

UL AND CSA

MOTOR NUMBER

SPECIAL ORDER NUMBER (WHEN APPLICABLE)

CE MARK

MANUFACTURING NUMBER BAR CODE

MANUFACTURING NUMBER

ELECTRICAL CHARACTERISTICS

SERIAL NUMBER BAR CODE

SERIAL NUMBER

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TESTPRESSURES-EachCarlyle06D/E/CCcompressorispressuretestedatourfactory.The“LS”pressuresareforthelowsideofthecompressor.The“HS”pressuresareforthehighsideofthecompressors.

CEMARK-ThisCEMarkindicatesthiscompressorcomplieswiththeEuropeanCEMarkrequirements.

SERIALNUMBER-Theuniquenumbergivento

eachcompressor.Thisnumber,alongwiththemodelnumberandspecialordernumber,isnormallyallthatisneededtoobtaininformationaboutororderaservicereplacementcompressor.

SERIALNUMBERBARCODE-ForCarlyleinternaluseonly.

ELECTRICALCHARACTERISTICS-areshownforallsemi-hermeticcompressors.Voltagesareshownwithrespectiveoperatingrangesforboth50and60cycleoperation.ElectricalphaseandLRA(LockedRotorAmps)informationisalsoprovided.

MANUFACTURINGNUMBER-ForCarlyleinternaluseonly.

MANUFACTURINGNUMBERBARCODE-ForCarlyleinternaluseonly.

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1.3 — Compressor Serial Number Significance

ALLNEWCOMPRESSORSExample: 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

ALLSERVICECOMPRESSORSExample: S/N 3602UD0123

36 02 U D 0123 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

NEWANDSERVICEREPLACEMENTCOMPRESSORSBUILTBETWEENNOV.1968-OCT.1978

Example: A2J0001

A 2 J* 0001 Numerical Sequence Plant Location: J = Syracuse Year of Manufacture: 9= 69, 0 = 70, 1 = 71, etc. Month of Manufacture: A=Jan, B=Feb, etc.; skip I;

M=Dec

*An “X”, “A” or “P” in this location indicates service compressor.

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1.4 — Carlyle OEM Compressor Warranty

OriginalOEMcompressorsarewarrantedtobefreefromdefectsinmaterialandworkmanshipforaperiodof12monthsfromthedateoforiginalinstallation,or

20monthsfromthedateofmanufacture,whichevercomesfirst.Termsandconditionsofthecompressorwarrantyarespecifiedinthelistpricepages.

Whenaservicecompressorisusedtoreplaceanoriginalcompressor,theremainingportionofthefirst-yearOEMwarrantyistransferredtotheservicecompressor(withintheUnitedStatesandCanada).

EquipmentmaycarryanextendedOEMwarrantyifthatwarrantyhasbeenpurchasedfromtheOEM.TheOEMissuestheextendedwarranty,notCarlyleoritsdistribu-tors,andtheOEMisresponsibleforprovidingtheenduserwiththecredit.

Ifreturningacompressor:

• placeallpartsbackintocompressor • sealallcompressoropenings(oilleakagemaycreate

anenvironmentalhazard)

NOTE:Openingacompressorforobservationordeterminationoffailuredoesnotvoidwarranty.

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1.5 — Service Billing and Credit

Returnsofin-warrantypartsshouldbemadetothesameLocalCarlyleDistributorwhosuppliesthesereplacementparts.

LocalCarlyleDistributorswillsellpartsandservicecompressorsonlytocredit-approvedaccounts(exceptforcashsales).

1.6 — Carlyle Compressor Connection Program, Parts and Stocking Policy

TheCarlyleCompressorConnectionprogramisafreeservicecreatedtoassistusersinlocatingservicereplacementsthroughournationaldistributionnetwork.Theprogramsupportsfindingreplacementcompres-sorsforreportedinstallations,ensuringavailabilityatthedesignateddistributorshipclosesttotheend-user’slocation.CarlyleCustomerServiceRepresentativescanprovideassistanceinlocatingthenecessarydistributor24hoursaday,365daysayear.

•U.S.A.,PuertoRico-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

CarlyleCompressorDivisionsellscompressorstoOEMs(OriginalEquipmentManufacturers)thatdesignandbuildthefinishedsystem.TheOEMistheexpert

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ontheentiresystem,includingtheCarlylecompressor.AllsystemorcompressorquestionsshouldbedirectedfirsttotheOEMortheOEM’slocalrepresentative.IfquestionscannotbeansweredbytheOEMorthisServiceGuide,pleasecontacttheCarlyleengineeringgroup.

Thefollowingrecommendedstart-upprocedureforCarlyle06D,06E,and06CCcompressorswillhelpeliminateinitialcompressorfailurescausedbyfloodedstart,floodback,andrunningoutofoil.

TheTroubleshootingProceduressection(Section2.3,pages20to31)willhelppinpointcompressorandsystemproblems.

TheServiceProceduressection(Section2.4,pages32to43)coversthereplacementofvalveplatesandgaskets,servicetothebearingheadassemblycontain-ingtheoilpump,andaclean-upproceduretofollowincaseofmotorburnout.Mostotherinternalservicerequiresreplacementofthecompressor.

2.2 — Recommended Start-Up Procedure

ReliabilitydataofCarlyle’s06D,06E,and06CCrefrigerationcompressorsindicatethatatleasthalfofcompressorfailuresoccurduringthefirsttwotofourmonthsofoperation.Manyofthesefailuresoccurduringtheinitialstart-upoftheunit.Inothercases,troubledstart-upsleadtocompressordamagesevereenoughtocauseprematurefailures.Themajorcausesoffailuresofthesecompressorsarefloodedstart,floodback,andrunningoutofoil.Mostofthesefailurescanbeavoidedbyusingmorecareduringtheinitialstart-upofthecompressors.Therefore,thefollowingstart-upprocedurefor06D,06Eand06CCcompressorsisprovided.

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BEFORESTART-UP

1. Verifythatthecompressornameplateindicatespropermodelandvoltage.Dothevaluesagreewithsystemneedsandavailablepower?

2. Verifythatthereisoilinthesystem.

Sincedifferentrefrigerants(CFC,HCFC,orHFC)requirespecificoils(mineral,alkylbenzene,orpolyolester[POE]),Carlyleshipsmostnewandservicecompressorswithoutoil.Theoillevelfor06CCsize16to37Cfmcompressorsandall06Dcompressorsshouldbeat1/4to3/4ofthesightglass.Theoillevelfor06CCsize50to99Cfmcompressorsandall06Ecompressorsshouldbeat1/8to3/8ofthesightglass.See Sections 3.6 and 3.7, pages 69 to 72 for the proper Carlyle approved 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 secton 2.5.Oncethecompressorsystemhasbeenrunningforatleast24hours,themostaccurateoillevelsareobservedwhenthecompressorisoff.Oillevelsinthesightglasscanbeaffectedbytherotationoftherunninggear.

OPERATING OIL LEVELS

06CC (16 TO 37 CFM) AND 06D

3/4 (MAX)

1/4 (MIN)

06CC (50 TO 99 CFM) AND 06E

3/8 (MAX)

1/8 (MIN)

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Do not add excess oil.Itisespeciallyimportantonthe06Eand06CC(50to99Cfm)compressorsthatexcessoilnotbeaddedtothesystem.Laboratorytestsandfieldexperienceindicateexcessiveoillevelscancauseblownvalveplateandcylinderheadgaskets,increasecompres-soroperatingtemperatures,andcauseoilequalizationproblems.

NOTE: All06Dcompressorsand06CC(16to37Cfm)compressorshaveonesightglassonthesideofthecrankcase.All06Ecompressorsand06CC(50to

99Cfm)compressorshavetwosightglasses,ontheoilpumpendofthecompressor.

Parallel compressor applicationstypicallyusean

oil-controlfloatsystemconsistingofindividualfloats,aseparatorandanoilreservoir.Whenusingafloatsystem,donotinterconnectthefloatswithan“equaliza-tionsystem”withoutapprovalfromCarlyleapplicationengineering.Theuseofafloat“equalizationsystem”canresultinsystemoilcontrolproblems.

Anoilequalizationlinecanbeusedinsteadofafloatsystem,exceptwith06CCcompressors.Theequaliza-tionlineandthecompressorsmustbelevel,andthelinediametermustbelargeenoughtoallowboththerefrig-erantandoiltoequalizebetweenalltheinterconnectedcompressors.Ifthelineisnotlevel,itisundersizedorthesystemcontainstoomuchoil,theoillevelwillrisefillingtheline,andoilcontrolbetweencompressorswillbelost.Typically,equalizationlinesare11/8in.(28mm)indiameterorlarger.For06Dcompressors,asightglassinthelineisrequiredtodeterminethesystemoillevel.

Parallelsystemsusingthree(3)ormore06Ecompressorsrequiretheuseofacommonmotorbarrelinterconnec-tionlinebetweencompressors.Useofaninterconnectionlineisstrongly recommendedontwo(2)06E

CAUTION!

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compressorunitconfigurations.Thissystempreventsoilfrombuildingupinan06Emotorbarrelduringtheoffcycle,therebypreventinganoilslugonstart-up.Thelineiseither1/4in.(6mm)or3/8in.(8mm)tubinginter-connectingtofittingslocatedinthebottomofthe06Ecrankcases.Toconnecttothe06Ecompressormotorbarrel,fittingP/N5F20-1311(5/8in.-18x1/4in.NPT)withAU51YA011gasketisrecommended.Some50cfmcompressorshavea1/4in.NPTconnectionanddonotrequirethe5F20-1311fitting.Themotorbarrelinter-connectionlineisinadditiontoeitherthecrankcaseoilequalizationlineortheoilfloats.

Neverinterconnectthemotorbarrelsof06CCcompres-

sors,astheoilsumpofthesecompressorsareatinterme-diatepressure.

06E compressors will not tolerate excessive oil charges.Laboratorytestsandfieldexperienceconfirmthatexcessoil,especiallyin06Ecompressors,cancausecylinderheadgasketsandvalveplatestofail,increasecompressoroperatingtemperatures,andleadtooilcontrolproblems.Page12notesthecorrectoillevels.

CAUTION!

Do not charge oil through the suction line or through the compressor suction access fittings. SeethecompressorfiguresinSection2.5forthelocationoftherecommendedoilchargingports.Addingoilintothesuctionsideofthecompressorcanresultinoilintakedirectlyintothecylindersresultinginsuction/dischargevalve,pistonand/orconnectingroddamage.

CAUTION!

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Use only Carlyle approved oil appropriate for the refrigerant being used.Sections3.6and3.7on

pages69-72listalltheapprovedoils.Section3.11onpage73 notesthecorrectoilpumppressureinrelationtoageofthecompressor.

3. Leaktest,evacuate,anddehydratethesystem.

4. Chargethesystem.Wheninitiallychargingthehighsideofthesystemwithliquidrefrigerant,allservicevalvesshouldbeclosed(frontseated).Thiswillpreventrefrigerantfrommigratingtothecompressorcrankcaseandintotheoil,causingafloodedstart.

Thesystemisnowchargedandreadyforstart-up.Rechecktheoillevelsandaddorremoveoilasneces-sary.Open(backseat)thedischargeservicevalveandanyoilequalizationlinesonparallelsystems.Openthesuctionservicevalve1/2to1turn,orenoughtoallowthecompressortorunwithouttrippingthelow-pressureswitch.Thisistopreventdamagetothecompressorfromanyliquidrefrigerantfloodback.

5. Onwater-cooledcondensingsystems,openwatersupplyvalveandallowwatertoreachcondenser.Onair-cooledcondensingsystems,turncondenserfanonwhenthecompressorunitisstarted.

6. Ensurethatallevaporatorconnectionsareopenedandfansstarted.

7. Onsystemswithmorethanonecompressorinparallel,startonecompressoratatime.

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COMPRESSORSTART-UP

1. AftercircuitbreakerandcontrolcircuitswitchesareplacedintheONpositionandthecompressorstarts,listenforunusualsounds.Ifunusualsoundsareheard,shutdownthecompressor,investigatethecause,andcorrect.Possibleproblemsare:

•excessivevibration•excessiveoil•liquidslugging•lowoil

2. Afterthecompressorhasrun10to15minutesandnoliquidfloodbackisevident,completelyopensuctionservicevalve.Theothercompressorswithinthesystemshouldbestartedinthesamemanner.

3. Toensureoperatingoillevelsarewithinacceptablelimits,closelyobservetheoillevelinthecompressorsuntilthesystemhasstabilized.Duringoperationallrefrigerationsystemswilllosesomecompressoroiltothesystembecause:

•Allsystemshaveafilmofoilontheinsidesurfaceofthepiping.Atstart-up,thelinesaredryandtheoilwhichcoatsthelinescomesfromthecompressorcrankcase.

•Oilalsotrapsinthelowrefrigerantvelocityareaofthesystemandmustbemadeupbyaddingoiltothesystem.Onsystemswithhotgasdefrost,inspectthecompressorforexcessiveoilafterthedefrostcyclehasbeencompleted.

Theoillosttothesystemmustbereplaced,buttakecarenottoaddtoomuch.The06Eand06CC(50to99Cfm)compressorshavebeensuccessfullystartedinsupermar-ketrefrigerationconfigurationsbyaddingonly1quart

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(liter)ofadditionaloilpercompressor.Theamounttobeaddedwillvarydependingonthesystem,butkeepingtheoillevelbetween1/8and3/8levelinthesightglasswilleliminatethechanceofexcessiveoilcharges.

Addingexcessiveoiltothe06Eand06CC(50to99cfm)compressorscancauseblowngasketproblems.

WhenCFCorHCFCrefrigerantsareusedwithmineraloralkylbenzeneoils,foaminthesightglassnormallyindicateseitherthatthereisseriousliquidrefrigerantfloodbackorthattherunninggearishittingtheoilduetoaveryhighoillevel.Veryhighoillevelsarecausedbyeithertoomuchoilorexcessiveliquidrefrigerantinthecrankcase.HFCrefrigerantsandPOEoilsdonotfoameasily,sotherewillbelessindicationinthesightglassofeitherliquidrefrigerantfloodbackortoomuchoilinthesystem.

Liquidrefrigerantshouldneverbeallowedtofloodbacktothecompressor.Itmaywashoutbearingsanddamagegaskets.Ifliquidfloodbackisoccurring,adjusttheexpansionvalveormakeotheradjustmentsasnecessarytoeliminatethiscondition.

NOTE: Onepossiblecauseoffloodingisimpropercontrolofthedefrostcycle.Ensuredefrostcyclesarestaggeredsonomorethanonethirdofthesystemisondefrostatanytime.

COMPRESSOROPERATINGLIMITS

Figures1Aand1BshowthecomponentsandtypicaloperatingrangesoftheCarlyle06D,Eand06CCcompressors.

CAUTION!

CAUTION!

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Fig. 1A — Typical 06D, E Operating Limits

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Fig. 1B –– Typical 06CC Operating Limits

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2.3 — Troubleshooting Procedures

Beforeattemptingserviceworkonthecompressor,thefollowingsafetyprecautionsmustbestrictlyobserved.Failuretofollowtheseinstructionscouldresultin

seriouspersonalinjuryordeath.SeeWarningLabel.

Follow recognized safety practicesandwearprotectivegoggles.

Do not operate compressororprovideelectricpowertothisunitunlessthecompressorterminalboxcoverisinplaceandsecured.

Do not provide power to unitorturnoncompressorunlesssuctionanddischargeservicevalvesareopen.

Do not removethecompressorterminalboxcoveruntilallelectricalsourceshavebeendisconnected.

Whenleak-testingsemi-hermeticcompressors,checkaroundtheterminalbox COVER. Testaroundthewireentrypoint(s)ofthe COVER becauserefriger-antislikelytoconcentratethere. 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.

DANGER!

DANGER!

21

COMPRESSORISOLATION

Ifyouhavedeterminedthereisnorefrigerantleakaroundtheterminalsandthecompressormustbereplaced,proceedbeginningwithStep1:

1. Shutoffsuctionanddischargeservicevalvestoisolatecompressorandslowlyremoveallrefrigerantincompressor.Appropriateservicepracticesshouldbefollowedtoproperlyreclaimrefrigerantremovedfromthecompressor.

2. Disconnectallelectricalwiringtocompressor.

3. Unboltsuctionanddischargeservicevalvesfromcompressor.

REMINDER:Thesevalvesmaybesealingoffrefrigerantfromtherestofthesystem.Donotopenthesevalveswithoutfirstdeterminingwhetherthereisrefrigerantinthesystem.

22

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24

25

26

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30

31

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32

2.4 — Service Procedures

Theservicesectioncoversreplacementofvalveplatesandgaskets,servicetothebearingheadassemblycontainingtheoilpump,andaclean-upproceduretofollowincaseofmotorburnout.Mostotherinternalservicerequiresreplacementofthecompressor.

REMOVE,INSPECTANDREPLACECYLINDERHEADANDVALVEPLATEASSEMBLY

Totestforleakingdischargevalvesorblowncylinderheadorvalveplategaskets:

1. Pumpcompressordown.

2. Observesuctionanddischargepressureequalization.Ifvalvesareleakingoragasketisblown,thepressurewillequalizerapidly.

Maximumallowabledischargepressuredropis3psiperminuteafterinitialdropof10to15psiinfirsthalfminute.

Newreedvalvesmayrequire24to48hourrun-intimetoseatcompletely.

Acompressorbank(head)withablowngasketcanalsousuallybedetectedbytouchsincetheheadtemperaturewillnormallybemuchhotterthanabankwithgoodgaskets.

3. Ifthereisanindicationoflossofcapacity,anddischargevalvesarefunctioningproperly,removevalveplateassemblyandinspectsuctionvalves.

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 disassembling valve plate.

33

DISASSEMBLY

1. Disassemblecylinderheadsbyremovingcylinderheadbolts.Leaveatleast2boltspartiallythreadedtopreventanyproblemsifrefrigerantisaccidentallyleftinthecompressorunderpressure.Toseparatethecylinderheadfromthevalveplate,pryupbetweentheheadandvalveplate.Whenthecylinderheadisseparatedfromthecompressorbodyremovethelastthreadedbolts.

Donothitthecylinderheadtobreakitfreeofthevalveplate.Thismayshearthevalveplatedowelpins.Sheareddowelpinsusuallyrequirethatthecompres-sorbereplaced.

2. Inspectcylinderheadsforwarping,cracks,ordamagetogasketsurfaces.Replaceifnecessary.

3. Afterthecylinderheadisoff,thevalveplatemayberemovedasfollows:

a. Removeonevalvestopcapscrewandloosentheother.

b. Swivelvalvestoptoallowaccesstoholefromwhichthecapscrewwasremoved.

c. Re-insertcapscrewandtightentobreakvalveplateawayfromcompressor.(Jackscrewmethod,seeFig.2.)For06Evalveplates,pryagainsttheraisedtabtobreakvalveplateawayfromthecompressor.

CAUTION!

34

4. Pryupalongsidesofvalveplatetoremovevalveplatefromcrankcase.Thisprovidesaccesstosuctionreedvalves(seeFig.3).Removesuctionvalvesfromdowelpins.On06Dand06CC(16to37Cfm)compressors,alsoremovethesuctionvalvepositioningsprings(seeFig.4).

5. Inspectcomponentsforwearordamage.Ifreplacementisnecessary,replaceasacompleteassembly.Individualpartsmustnotbeinterchanged.Alignmentofhighefficiencydischargevalvesiscriticalforproperseating.SeeSections3.27to3.29,pages84-87forapplicablereplacementvalveplatepackages.

Fig. 2 –– Disassembly of Valve Plate(Standard Efficiency Valve Plate Shown)

35

Fig. 3 –– Valve Plate Removed(06E Refrigeration Valve Plate Shown)

Fig. 4 –– Suction Valve and PositioningSprings in Place (06D Shown)

36

REASSEMBLY

1. Ifreassemblingexistingcomponents,donotinterchangevalvesorturnthemover.Theymustbereassembledintheiroriginalposition.Installthesuctionvalvepositioningsprings(06CCsize16to37Cfmand06Dcompressorsonly)ondowelpins.Assemblepositioningspringswithspringendsbearingagainstcylinderdeck(Fig.4),springbowupward.

2. Installsuctionvalveondowelpinsasfollows:

a. 06Dcompressors:installsuctionvalvesontopofpositioningspringsasmentionedinStep1above.

b. 06Ecompressors:ifcompressorusesasuctionvalveandabackervalve(lookslikea1/2asuctionvalve),backervalvemustbeinstalledbeforeinstallingfullsizesuctionvalve(Fig.5).

Fig. 5 –– Piston, Suction Valve, and BackerPositions (06E)

DOWELHOLES

DOWELHOLES

DOWELS IN CYLINDERDECK FOR SUCTIONVALVE AND BACKER

SUCTIONVALVE

BACKER

PLACE AGAINSTCYLINDER DECKUNDER SUCTION

VALVE

TOP VIEWOF PISTON

IN CYLINDER

37

3. Installnewvalveplategasket.Usingproperhold-downtorquewillpreventleaks.

a. Fibergasketscanbeinstalleddryorlightlyoiled.Do notsoakgasketsinoil.Ifanoil-soakedgasketisoverheated,itwillbindtothemetal,makingthevalveplateand/ortheheaddifficulttoremove.

b. Metalgasketsmustbeinstalleddry.

4. Placevalveplateoncylinderdeck.

5. Installcylinderheadgasket.

NOTE:Thecentercylinderheadsandunloadersideheadsusedifferentgasketsfromtheplainsidehead.Toconfirmthegasketiscorrect,placeitoverthecylinderheadandverifyallexposedmachinedsurfaceswillbecoveredbythegasket.

a. Lineupthegasketwiththecylinderheadandvalveplate.

b. 06Ecompressor:securethecenterribwithacapscrewandwasherandtorqueto4to6ft-lbs.(5to8Nm).

6. Replacecylinderhead.Topreventhightolowsideleakincenterofcylinderheadgasket,torque06Dcylinderheadcapscrewsto30to35ft-lbs.(40to48Nm),and06Ecyl-inderheadcapscrewsto90-100ft-lbs.(122to136Nm).

NOTE:Torqueboltsinanalternatingsequencepattern(toptobottom,lefttoright).Donottorqueboltsinacircularpattern.

38

7. Certainhighcompressionratioapplicationsdevelophighdischargegastemperatureswhichmaycausethecylinderheadandfibervalveplategasketstodevelopaset.Undertheseconditionsthecapscrewsmaylosehold-downtorque.Itisrecommendedthatallgearcapscrewsbere-torqued24hoursafternewfibergasketsareinstalled.

NOTE:Compressorswithmetalcoregasketsdonotrequirere-torque.

REMOVE,INSPECTANDREPLACEBEARINGHEADASSEMBLY

Anoilpressuretapislocatedinthebearingheadassemblyusedonall06Drefrigerationduty,newer06DA/Cduty,andall06ErefrigerationandA/Cdutycompressors(Fig.6andFig.7).

For06D,E,CCoilpressure,seepage73,Section3.11.

Theoilpumpassemblyiscontainedinthepumpendbearingheadaluminumcasting.Thepumpendmainbearingisamachinedpartofthiscasting.Noinsertbearingisrequired.

39

1. a.Todisassemble,firstremovefour(4)capscrewsfromthebearingheadcoverplateandremovetheoilfeedguidevaneandspring.

b.Removethetwo(2)drivesegmentcapscrewsfromtheendofthecrankshaft(seeFig.6andFig.7).These screws must be removed before the bearing head can be removed.

2. Removetheeight(8)capscrewsholdingthebearinghead

assemblytothecrankcase.Removethebearingheadassemblybypullingforward.

Fig. 6 –– Removing Pump End Bearing Head(06D Compressor)

40

3. Inspectthebearingsurfacesforevidenceofwearordamage.Ifbearingsurfaceiswornorscored,oriftheoilpumpisdefective,thecompletebearingheadmustbereplaced(seereplacementbearingheadpackagelistedbelow).

Whilebearingheadisremoved,inspectinternalrunninggearforobviousproblems(brokenrodsorpistons).

Fig. 7 –– Removing Pump End Bearing Head(06E Compressor)

41

4. Toreassemble,boltthebearingheadtothecrankcase.Bolttorque:

• 06CC,16to37Cfm,andall06D:30to35ft-lb.(40to48Nm)

• 06CC,50to99Cfm,andall06E:55to60ft-lb.(75to81Nm)

5. Boltthedrivesegment(replaceifworn)tothecrankshaft.Bolttorque:

• No.10Screw:4to6ft-lb.(5to8Nm)• 1.4in.(6mm)screw:12to15ft-lb.(16to20Nm)

IMPORTANT: The1/4in.snorkletubeshouldfaceawayfromthecrankshaft(Fig.6).

6. Inserttheoilfeedguidevanewiththelarge diameter inward.Placetheoilfeedvanespringover small diameterofguidevane(do not install spring before installing guide vane).Installpumpcoverplate(bolttorque:16to20ft-lb.or22to27Nm).

NOTE: Donotover-torqueoraluminumthreadsinbearingheadcouldbestripped.

42

MOTOR BURNOUT CLEAN-UP PROCEDUREWhen 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 literature #020-262.

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.

b. Inspect compressor terminal plate for burned or damaged terminals and insulation, and shorted or grounded terminals.

c. Inspect unit wiring for loose power connections.

d. 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.

b. Remove damaged compressor and replace with a new compressor.

c. On severe motor burnouts, be sure shut-off valves and suction or discharge lines are not contaminated. If contaminated, they

WARNING!

43

should be thoroughly cleaned or replaced before connecting to replacement compressor.

4. Install new liquid line filter-drier. If the system has a suction line filter-drier, replace the core.

5. 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, determine 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).

6. 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.

7. 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.

44

2.5 –– Connection Points, - 06D, 06E, and 06CC Compressors

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. 8 –– 06D 2-Cylinder CompressorConnection Points

45

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.

Fig. 9 –– 06D 4-Cylinder Compressor (13 and 16 Cfm)Connection Points

46

Fig. 10 –– 06D 4-Cylinder Compressor (18 and 20 Cfm)Connection Points

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.

47

Fig. 11 –– 06D 6-Cylinder Compressor (24, 25, 28, 37 and 41 Cfm) Connection Points

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.

48

Fig. 12 –– 06E 4-Cylinder Compressor (50 and old 66 Cfm) Connection Points

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 threded portions of the casing, comparable metric measurements are not included.

1/4" NPT OIL PUMPPRESSURE CONNECTIONOIL PRESSURE ACCESS TEETO BE INSTALLED IN THIS CONNECTIONHIGH SIDE CONNECTION OF OILPRESSURE SWITCH TO BE CONNECTEDTO FLARED END OF INSTALLED TEE

BLANK PLATEREMOVE FOREQUALIZING LINEOR OIL FLOATCONNECTION

1/4" NPT LOWPRESSURECONNECTIONFACTORY SUPPLIEDSCHRADER TYPEFITTING(DO NOT ADD OIL HERE)

1/4" NPT HIGHPRESSURECONNECTION

CYLINDER HEADCOOLING FANMOUNTING STUDS(06ER MODELS ONLY)

TEMPERATURE SENSORCYLINDER HEADDISCHARGE GAS

DISCHARGE VALVELOCATION

LIFTING LUG(NEW MODELS ONLY)

NAMEPLATE LOCATIONCRANKCASE MOTORBARREL-LEFT SIDE

SUCTION VALVELOCATION(ON MOTOR END COVER)

1/4" NPT OR5/8-18 SAE OIL DRAINCRANKCASE MOTCOMPARTMENT6:00 POSITIONCRANKCASE MOTORBARREL

BEARING HEAD(CONTAINS OIL PUMP)1/4" NPT (2) CONNECTIONS(1) ABOVE SIGHTGLASS(1) ABOVE BLANK PLATE

USED FOR:A) OIL FILL CONNECTIONB) LOW SWITCH OIL SAFETY

SWITCH CONNECTION

CRANKCASE HEATER(ACCESSORY)INSERTS INTO WELLIN BOTTOM COVER

OIL LEVEL SIGHTGLASSINTERCHANGEABLEWITH BLANK PLATE

7/16"-20 SAE OIL DRAINCONNECTIONCRANKCASE OIL SUMP

49

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

50

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 BodyPump End Connection Points

51

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 BodyMotor End Connection Points

IF AVALABLE USEPORT ON SERVICEVALVE TO DESUPERHEATLIQUID INJECTION FITTING PN 2TA1004

52

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

53

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. 15B –– 06CC Compressor (50 to 99 Cfm), 06E Body Motor End Connection Points

IF AVAILABLE USEPORT ON SERVICEVALVE TO DESUPERHEATLIQUID INJECTION FITTINGPN 2TA1004

54

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– C

ylin

der H

ead

- Sid

e Ba

nk

(Unl

oade

r Hea

d N

ot S

how

n)22

– In

tern

al R

elie

f Val

ve23

– C

rank

case

Oil

Filte

r Scr

een

24 –

Oil

Sigh

t Gla

ss A

ssem

bly

25 –

Oil

Sigh

t Gla

ss “O

” Rin

g G

aske

t26

– O

il Si

ght G

lass

Scr

ew27

– O

il Si

ght G

lass

Loc

k W

ashe

r28

– P

ipe

Plug

Gas

ket (

Hex

Hea

d)29

– B

otto

m C

over

Pla

te30

– P

ump

End

Bear

ing

Hea

d As

sem

bly

31 –

Pum

p R

otor

32 –

Pum

p Va

ne33

– P

ump

V ane

Spr

ing

34 –

Pum

p Va

ne S

prin

g G

uide

35 –

Ret

aini

ng S

prin

g G

uide

36 –

Oil

Feed

Gui

de V

ane

37 –

Oil

Feed

Gui

de V

ane

Sprin

g 38

– O

il Pu

mp

Driv

e Se

gmen

t39

– S

crew

, Soc

Hea

d 1/

4 –

28 x

5/8

-in.

40 –

Scr

ew, S

oc H

ead

#10

– 32

x 1

/2-in

.41

– C

over

Pla

te42

– C

over

Pla

te C

ap S

crew

43 –

Oil

Rel

ief P

isto

n44

– C

rank

shaf

t45

– B

earin

g W

ashe

r46

– P

isto

n R

ings

(Oil

and

Com

pres

sion

)

47 –

Pis

ton,

Pis

ton

Pin

and

Ret

aini

ng R

ing

Asse

mbl

y48

– C

onne

ctin

g R

od a

nd C

ap A

ssem

bly

49 –

Val

ve P

late

Ass

embl

y50

– V

alve

Pla

te51

– D

isch

arge

Val

ve S

top

52 –

Dis

char

ge V

alve

53 –

Val

ve S

top

Supp

ort

54 –

Cap

Scr

ew, V

alve

Sto

p55

– S

uctio

n Va

lve

(Bac

kers

For

A/C

Mod

els

Not

Sho

wn

se

e Fi

g. 5

, pag

e 36

)56

– C

heck

Val

ve (U

se O

nly

with

Par

alle

l Com

pres

sor

In

stal

latio

ns)

60

2.10 – Torque Guide – 06D and 06CC (16 to 37 Cfm) Compressors

(CC) - Compound cooling compressors only Torque for jam nut #3 for compressors manufacturedNM - Newton meter (metric torque rating) after 0203J--. For compressors built before thisSAE - 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. lb.

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.

61

2.11 – Torque Guide – 06E and 06CC (50 to 99 Cfm) Compressors

See Table 2.10 for Notes and Legend (page 60).

62

3.0

– C

OM

PRES

SOR

AN

D P

AR

TS D

ATA

3.1

– 06

D S

erie

s Com

pres

sors

– P

hysic

al D

ata

(pag

e 1

of 2

)

* Cyl

inde

r hea

d fa

n re

quire

d at

SST

of -

25 D

eg. F

. (-3

2 D

eg. C

.) an

d be

low

for R

-404

A/R

-507

/R-4

07A,

R-4

07C

and

R-5

02.

† C

ylin

der h

ead

fan

requ

ired

at S

ST o

f 0 D

eg. F

. (-1

8 D

eg. C

.) an

d be

low

for R

-22.

(a) A

ppro

xim

ate

cond

ensi

ng te

mpe

ratu

re ra

nges

. CH

ECK

ACTU

AL P

ERFO

RM

ANC

E D

ATA

FOR

AN

Y N

EW A

PPLI

CAT

ION

ES

PEC

IALL

Y AT

OR

NEA

R U

PPER

OR

LO

WER

LIM

IT: L

.T.=

70 to

120

Deg

.F. (

21 to

49

Deg

.C.),

M.T

.=80

to 1

30 D

eg.F

. (2

7 TO

54

Deg

.C.)

and

H.T

. (R

-22

and

R-4

07A,

C o

nly)

= 8

0 TO

150

Deg

.F. (

27 to

66

Deg

.C.).

(b) T

he 0

6DR

109

sin

gle

phas

e co

mpr

esso

r has

a 3

HP

(2.2

kW

) mot

or.

(c) S

ervi

ce c

ompr

esso

rs h

ave

dual

suc

tion

serv

ice

valv

e lo

catio

ns, o

ne o

n m

otor

end

and

one

nea

r the

oil

pum

p.

63

3.1

– 06

D S

erie

s Com

pres

sors

– P

hysic

al D

ata

(pag

e 2

of 2

)

64

* Cyl

inde

r hea

d fa

n re

quire

d at

SST

of -

20 D

eg. F

. (-2

9 D

eg. C

.) an

d be

low

for R

-404

A/R

-507

and

R-5

02.

† C

ylin

der h

ead

fan

requ

ired

at S

ST o

f 0 D

eg. F

. (-1

8 D

eg. C

.) an

d be

low

for R

-22.

(a) A

ppro

xim

ate

cond

ensi

ng te

mpe

ratu

re ra

nges

. CH

ECK

ACTU

AL P

ERFO

RM

ANC

E D

ATA

FOR

AN

Y N

EW A

PPLI

CAT

ION

, ES

PEC

IALL

Y AT

OR

NEA

R U

PPER

OR

LO

WER

LIM

IT: L

.T.=

70 to

120

Deg

.F. (

21 to

49

Deg

.C.),

M.T

.=80

to 1

30 D

eg.F

. (2

7 TO

54

Deg

.C.)

and

H.T

. (R

-22

and

R-4

07A

only

) = 8

0 TO

150

Deg

.F. (

27 to

64

Deg

.C.).

(d) T

he m

odel

s sh

own

are

new

oil-

less

mod

els.

Mod

els

with

oil

had

a 0,

1 o

r 2 in

the

5th

digi

t of t

he m

odel

num

ber.

(e) T

he 0

6ER

166

and

06EM

266

mod

els

are

no lo

nger

bui

lt ne

w, b

ut s

ervi

ce re

plac

emen

ts a

re b

uilt

and

avai

labl

e. F

or n

ew a

pplic

atio

ns, t

he

06ER

166

and

06EM

266

mod

els

have

bee

n re

plac

ed b

y th

e 06

ER46

5 an

d 06

EA56

5.

3.2

– 06

E Se

ries

Com

pres

sors

– P

hysic

al D

ata

(pag

e 1

of 2

)

65

3.2

– 06

E Se

ries

Com

pres

sors

– P

hysic

al D

ata

(pag

e 2

of 2

)

66

3.3

– 06

CC

Ser

ies C

ompr

esso

rs –

Phy

sical

Dat

a (p

age

1 of

2)

(f) A

ppro

xim

ate

cond

ensi

ng te

mpe

ratu

re ra

nges

. CH

ECK

ACTU

AL P

ERFO

RM

ANC

E D

ATA

FOR

AN

Y N

EW A

PPLI

CAT

ION

, ES

PEC

IALL

Y AT

OR

NEA

R U

PPER

OR

LO

WER

LIM

IT: L

.T. =

70

to 1

30 D

eg.F

. (21

to 5

5 D

eg.C

.).(g

) To

prov

ide

a 6-

cylin

der b

ody

need

ed fo

r Com

poun

d C

oolin

g, th

e no

rmal

4-c

ylin

der m

odel

16,

18

and

50 C

fm c

ompr

esso

rs a

re b

uilt

usin

g th

e 24

, 18,

and

65

Cfm

6-c

ylin

der b

odie

s re

spec

tivel

y. Th

e ac

tual

Cfm

redu

ctio

n is

ach

ieve

d by

mod

ifyin

g th

e ru

nnin

g ge

ar.

(h) R

404A

/R-5

07 C

ANN

OT

be u

sed

in th

e sm

all “

D” b

ody

size

Com

poun

d C

oolin

g co

mpr

esso

rs (1

6 to

37

Cfm

), m

anuf

actu

red

prio

r to

Ser

ial N

o. 2

099J

.(i)

R-1

34a

and

R-1

2 C

ANN

OT

be u

sed

in a

ny C

ompo

und

Coo

ling

com

pres

sor.

67

3.3

– 06

CC

Ser

ies C

ompr

esso

rs –

Phy

sical

Dat

a (p

age

2 of

2)

68

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:

All 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:

06EA models start with S/N 4585J...06EM models start with S/N 0786J...06ER models start with S/N 2287J...

All 06CC compressors are H.E. design.

All service compressors are high efficiency, except for some “D” body units without a “3” 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 com-pressors with no oil in the crankcase due to the introduc-tion 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 from the air)

69

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® Part Numbers for available oils:

The following MINERAL/ALKYLBENZINE are approved oils for CFCs and HCFCs:

NOTE: Carlyle does not recommend the use of POE oil with R-22. Totaline ............................... P903-2001 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 R-13 and R-503 (contact Carlyle Engineering for correct oil).

* Do not use in low temperature applications.

70

FOR HCFC 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 Totaline® P903-2001or 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 number of HCFC blends are not approved. Some may create a hazardous situation. Carlyle requires all refrigerants used in our compressors to be A1/A1 (low flammability/low toxicity). The rating is based on ASHRAE 34 safety standard. Not all A1/A1 refrigerants are approved for use in Carlyle compressors. Some of the refrigerants or blends available are either flammable (A1/A2 or A1/A3) and/or toxic (A1/B1 or A1/B3). Some A1/A1 refrigerants can change ratings if contaminated. Any replacement refrigerant must operate with the same pressure levels and temperature ranges 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 Compressor engineering department.

WARNING!

71

FOR HFCs:Carlyle has approved R-134a, R404A, R-507, R-407C and R-407A.

The following POLYOL-ESTER (POE) are approved oils for HFCs:

Totaline® (see Note 5).......P903-1001, 1701Castrol (see Note 5) ............................. E68ICI Emkerarate ................................RL68HCPI ............................................. CP-2916SCPI ............................................... Solest 68BP Marine Enersyn ........................MP-S68

All POE oils are very hygroscopic (will readily pick up and retain moisture from the air) and should be used complete-ly 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 chiller 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. All 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.

72

3.7 — Refrigerants and Oils for 06CC Compressors

All 06CC compressors are approved for R-22, R-404A, R-407A and R-507 except compressors in the 16 to 37 cfm range. Compressors in this size range can-not be used with R-404A and R-507 prior to Serial No. 2099J---- without installing a retrofit compressor valveplate (Part No. 06CY660-002) kit. See Section 3.6 on page 69 for further information about refrigerants and oils.

See Section 3.6 on pages 69 & 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 and 3.7 above. System cleanliness is extremely important. To ensure a trouble-free change out, Carlyle Engineering has made specific guidelines available. We strongly recommend a copy of our guidelines be request-ed 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 viscos-ity 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.

73

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.

3.11 — Oil Pressure

All 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 is 18 to 26 psi (1.2 to 1.8 Bars)

• For new OEM 06E and 06CC (50 to 99 Cfm) compres-sors, the pressure is 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 2994M 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.

74

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, automati-cally 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:

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.

75

3.14 — Oil Safety Switch

Carlyle uses as standard the 120-second time delay oil safety switch, as this time period is preferred for HFC/POE systems. This is a change from the 45 to 60-second time delay used previously with CFC and HCFC sys-tems. 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: • Penn/Johnson electronic switch - P545

and 82C

• Danfoss - Type MP54. See details below:

76

Use of an oil safety switch is recommended/required by Carlyle as noted in the chart below:

3.15 — 06CC, 06E Discharge Gas Cylinder Head Temperature Sensor & 06E Pressure Relief Valve

All 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 06Es (two heads) have the sensor in the left side head as viewed from the oil pump end. All 06CC compres-sors have the sensor located in the discharge (high stage) head.

Pressure Relief Valve

All 06E compressors and all 06CC 50-00cfm compres-sors are equipped with a pressure relief valve that relieves from discharge pressure to crankcase pressure. It is located under the center cylinder head on all 6 cylinder 06E and 06CC compressors, and under the discharge service valve on all 4 cylinder 06E compressors. The relief valve is sealed with a metal gasket:

Part Number Description EB51FN272 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.

77

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 = 1.04A. The sensors are threaded into the head without a well. Therefore, when changing a sensor, the compressor must first be isolated and evacuated.

NOTES: 1. Since 1993 all Carrier 06 series air conditioning

compressors have been made without a sensor. All 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 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 0°F (-18°C). A cylinder head cooling fan must be used for all R-22 single stage applications

78

below 0°F (-18°C) and all R404A/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

DESCRIPTION06D, 06CC

(16 to 37 Cfm)06E, 06CC

(50 to 99 Cfm)

Head cooling fan assembly – 208/230V 06DA680070 06DA680072Head cooling fan assembly – 460V 06DA680071 06DA680073Head cooling fan assembly, less mounting – 208/230V 06DA680074 06DA680074Head cooling fan assembly, less mounting – 460V 06DA680075 06DA680075Mounting kit 06DA680076 06DA680077Replacement motor – 208/230V 06DA680079 06DA680079Replacement motor – 460V 06DA680078 06DA680078Replacement fan blade 06DA680080 06DA680080Mounting 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, 06E 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 06E compressors. See Fig.16.

NOTE: Before adding a suction cut-off control package to a compressor currently without unloading, consider all line piping sizes and design to ensure proper oil return to compressor with reduced (unloaded) refrigerant flow rates.

79

CAPACITY CONTROL PACKAGES

CAPACITY CONTROL PACKAGES

COMPRESSOR TYPE PACKAGE NUMBER

BARE UNLOADER VALVE

06D Electric 06EA660135 06DA40883406D Pressure 06EA660100 06EA66010006E Electric 06EA660135 06DA40883406E Pressure 06EA660100 06EA660100

* Coil NOT included, order separately (see Section 3.18).† 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 P.E. of compressor):

06D 4-cyl - left hand cylinder deck 06E 4-cyl - right hand cylinder deck 06D, 06E 6-cyl - either cylinder deck (both when applicable)4. Unloader valve gasket part number 06EA501253.5. Unloader is not available for 06CC compressors.

80

3.18 — Capacity Control Coil Packages (06D, E)

Fig. 16–– Loaded and Unloaded Operation

LOADED OPERATION

UNLOADED OPERATION

COIL PACKAGEPART NUMBER VOLTAGE

)487204AD60(021EZ91FE)497104AD60(042EZ91FE)448104AD60(420EZ91FE

06/05-1-02106/05-1-042/802

06/05-1-42

81

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 “ON” 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. All strap-on heaters are 50 watts.

INSERTION HEATERS:

Insert into cast 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 06E and all 06CC compressors. Insertion heaters are available in 125 and 180 watt sizes.

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).

82

3.20 — Compressor Mounting Data

Mountingpackagesareavailabletomountindividualcom-pressors.Packagecontainsmountingsprings,threadedstuds,snubbers,springcups,nuts,andwashersfor(1)compressor.

COMPRESSORMOUNTINGPLATEPACKAGE No.06EA660096 Thisuniversalmountingplatewillaccommodateanysize

06D,06E,and06CCcompressor.MountplatetoexistingbaseandmounttheCarlylecompressortotheplate.Packageincludespre-drilledmountingplate,spacers,andtemplate.

3.21 — Compressor Service Valves (06D, E, CC)

3.22 — Service Valve Gaskets (06D, E, CC)

* Service package contains 12 gaskets.

* Valve packages consist of (1) service shut-off valve and required gasket and mounting bolts.NOTE: Sensor Valve packages required with Carlyle Sentinel module.

Adapter for 06CC Liquid Injection Port PN 2TA1004.

83

3.23 — Oil Drain Plug Adapter

Allnewcompressors,exceptfor06D()808,109,013,313,and316models,arebuiltwitha7/16-20SAEfittingandO-ringastheoildrainplug.Carlyleoffersanoildrainadapter,P/NDE14CA126,whichreplacestheSAEplug.Thisadapterallowstheinstallationofa1/4in.NPTanglevalveasadrainfitting.

3.24 — Sight Glass Adapters for Oil Equalization

3.25 — Replacement Sight Glass/Installation Tool

3.26 — Replacement Motor End Mounting Foot

* 5F20-152 sight glass assembly includes 5F20-1631 gasket.

*

84

3.27 — Gaskets – Cylinder Head and Valve Plate

* 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.

EPYTTEKSAG ER BMUNTRAP

SROSSERPMOCD60steksagdaehrednilyC:1

gnidaolnuon,knabediS.a)ngisedffo-tucnoitcus(gnidaolnuhtiw,knabediS.b)ngisedssapybsagtoh(gnidaolnuhtiw,knabediS.c

knabretneC.d

312205AG50322205AG50381205AG50371205AG50

steksagetalpevlaV:2

erobrednilycretemaid"2dradnatS.aerobrednilycretemaid"61/31-1ngiseddlO.b

sledommfC61dradnatsdlonoylnodesu)laiceps(ffo-knalB.csetalpevlav.E.Hgnisudna.E.Ptaevlavnoitcushtiw

351005AD503701-04D6

329205AD60

SROSSERPMOCE60steksagdaehrednilyC.1

gnidaolnuon,knabediS.a)ngisedffo-tucnoitcuS(gnidaolnuhtiw,knabediS.b)ngisedssapybsagtoh(gnidaolnuhtiw,knabediS.c

)desreverrodradnats(knabretneC.d

403305AE60433305AE60413305AE60413305AE60

steksagetalpevlaV.2

"630./"820.)YE,RE(erutarepmetwol,.E.H.a

"270./"760.)ZE,ME(erutarepmetmuidem,.E.H.b

"270./"760.)TE,AE(erutarepmethgih,.E.H.c"140./"530.)YE,RE(erutarepmetwol,dradnatsdlO.d

"140./"530.)ZE,ME(erutarepmetmuidem,dradnatsdlO.e"270./"760.)XE,AE(erutarepmethgih,dradnatsdlO.f

210066RE60#egakcaPsniatnoc

/teksag358105AE60)1(sevlavnoitcus)2(

ro)rebif(488405AE60)latem(414605AE60

488405AE60210066RE60210066RE60488405AE60

SROSSERPMOCCC60mfC73ot61

.a

.b

.c

.d

.e

daehrednilyCetalpevlaV

dlofinamnoitcuSdlofinamegatsretnI

noitcejnidiuqiLebutegatsretnI

daehrednilyCetalpevlaV

dlofinamnoitcuSdlofinamegatsretnI

noitcejnidiuqiLebutegatsretnI

.f

312205AG50351005AD50*1311-04D6*1311-04D6*1241-32D6*1241-32D6

mfC99ot05

.a

.b

.c

.d

.e.f

06EA50333406EA506414

*1311-86D6*1311-86D6*1241-32D6*1311-86D6

85

3.28 — MiscellaneousTerminal Plate Gasket

COMPRESSOR USAGE GASKET

06D, 06CC (16 TO 37 CFM)06E, 06CC (50 TO 99 CFM)

6D40-10616G45-1082

Sensor Block Gasket (Used between transducer sensor block and bearing head with Johnson P545 (06DA660115) oil safety switch)

Electrical Terminal Barrel Nut Tool (Socket tool used for installation of terminal nuts)

COMPRESSOR USAGE GASKET

All 06D, 06CC (16 TO 37 cfm) P920-0009

86

3.29 — Valve Plate Packages, Service Replacement

Carlylebeganinstallinghighefficiencyvalveplatesinthemid1980’s.Withafewexceptionsnoted,thevalveplatesfitallcurrentandolderCarlylecompressors.Checknotesbelowthetableforexceptions.

* Includes relief valve for both low stage banks.

NOTES:1. Carlyle recommends the 06ER660017 service replacement valve plate kit for all 06ER

compressors in low temperature environmental chamber applications (see Note 6, next page).2. All high efficiency (units with a “3” in the 11th digit of the model number) 06DR013 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.

3. Hot gas bypass unloading requires a special valve plate kit with gaskets as follows:06D ..................06DA66013106E ..................06EA660105

The Carlyle recommended suction cut-off unloading does not require a special valve plate. Suction cutoff unloading uses the standard high efficiency valve plate kit, which includes the needed gasket.

87

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 Cfm) compressors have flat top pistons. All new high efficiency 06DR and 06ER compressors have one step contoured pistons. All new high efficiency 06EM, 06EA, and 06CC (50 to 99 Cfm) 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

Mufflerscanreducedischargegaspulsationandeffec-tivelyeliminatevibrationproblemsdownstream.Theyshouldbeplacedasclosetothecompressoraspossibletomaximizeefficiencyandminimizevibration.Mufflersshouldbe:

• usedonall06E66and99Cfmcompressormodels.• usedonall06Ecompressorswithcapacitycontrol.• consideredforusewithall06D37and41Cfm

compressormodels.• consideredforusewithall06D6-cylindercompres-

sorswithcapacitycontrol.

Mufflerscanbemountedhorizontallyorvertically.

88

3.31 — Electrical Accessories

BOXPACKAGE-Thisconsistsofterminalbox,cover,andnecessarymountingcomponents.

TERMINALLUGPACKAGE-Thisconsistsof6screw-onterminallugswithsetscrews.Strippowerwire1/2in.,insertintoterminallugs,andsecureinplacewithsetscrew.

TERMINALPLATEJUMPERPACKAGEFOR06E,06CC50TO99Cfm-Thispackageconsistsofjumperbars,terminalnutsandinstructionstointerconnectterminalstudsforpropermotorstarting(P/WorX/L)andvoltage.

NOTE: With 06E 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.

89

3.32 — Baffle Plate Recommendations

Baffleplatescanbeusedtoreducecompressordischargegaspulsations.Recommendedbaffleplateassembliesareshownbelow.Theseplatesaredesignedtocreatea6to10psi(0.4to0.7Bars)pressuredropinthedischargegas.Useonlythebaffleplaterecommendedfortheapplication.Thesebaffleplates,sandwichedbetweentwogaskets,areinstalledbetweenthecompressordischargeservicevalveandthecompressorcrankcaseorcylinderhead.Forfurtherdetails,seeCarlyleOEMBulletinsNo.118and119.

* Includes baffle plate and 2 gaskets.† For single-stage application. When using as booster application, use medium temperature

baffle plate.

3.33 — Interstage Pressure Tables (06CC Compressors Only)

All06CCcompressorsareatwo-stagedesign.Therefore,thepressuremeasurementsaresuction,interstage,anddischarge.ThefollowingtableslisttheinterstagepressuresusingR-22andR-404A/507refrigerants.

90

* Ind

icat

es V

acuu

m –

Inch

es o

f Hg.

NO

TE: 1

BAR

= 1

00 k

Pa o

r 1 A

TM (A

tmos

pher

e) P

ress

ure

91

R-4

07A

APP

RO

XIM

ATE

INTE

RST

AG

E PR

ESSU

RE

± 10

PSI

(.7

BA

R) W

ITH

SU

BC

OO

LER

Satu

rate

d Su

ctio

n Te

mp.

F (C

)

Suct

ion

Pres

sure

PS

IG (B

AR

)

Satu

rate

d C

onde

nsin

g Te

mpe

ratu

re, F

(C)

60

(16)

70

(21)

80

(27)

90

(32)

100

(38)

110

(43)

120

(49)

130

(54)

Con

dens

ing

Pres

sure

, PSI

G (B

AR

)

125.

2 (8

.63)

148.

8 (1

0.26

)17

5.3

(12.

09)

204.

8 (1

4.12

)23

7.6

(16.

38)

273.

9 (1

8.88

)31

4 (2

1.65

)35

7.9

(24.

68)

-60

(-5

1)14

.5*

(0.5

2) 8

(

1.5)

10

(1.7

)11

(1

.8)

12

(1.8

)13

(1

.9)

15

(2.0

)19

(2

.3)

36

(2.8

)-5

5

(-48)

11.9

* (0

.61)

10

(1.7

)13

(1

.9)

14

(2.0

)15

(2

.1)

17

(2.2

)20

(2

.4)

24

(2.7

)41

(3

.1)

-50

(-4

5)8.

9*

(0.7

1)12

(1

.9)

15

(2.1

)18

(2

.2)

19

(2.3

)21

(2

.5)

24

(2.7

)29

(3

.0)

46

(3.5

)-4

5

(-43)

5.6*

(0

.82)

15

(2.0

)19

(2

.3)

21

(2.5

)23

(2

.6)

26

(2.8

)29

(3

.0)

34

(3.3

)51

(3

.8)

-40

(-4

0)2.

1*

(0.9

4)18

(2

.2)

22

(2.5

)25

(2

.7)

27

(2.9

)30

(3

.1)

34

(3.3

)39

(3

.7)

56

(4.2

)-3

5

(-37)

1.0

(1

.08)

21

(2.4

)26

(2

.8)

29

(3.0

)32

(3

.2)

35

(3.4

)39

(3

.7)

44

(4.0

)62

(4

.5)

-30

(-3

4)3.

3

(1.2

4)25

(2

.7)

30

(3.1

)34

(3

.4)

37

(3.6

)40

(3

.8)

44

(4.1

)49

(4

.4)

67

(4.9

)-2

5

(-32)

5.7

(1

.41)

29

(3.0

)35

(3

.4)

39

(3.7

)43

(3

.9)

46

(4.2

)50

(4

.5)

55

(4.8

)73

(5

.4)

-20

(-2

9)8.

5

(1.6

0)34

(3

.4)

40

(3.8

)45

(4

.1)

49

(4.4

)52

(4

.6)

56

(4.9

)62

(5

.3)

80

(5.8

)-1

5

(-26)

11.5

(1

.81)

40

(3.7

)46

(4

.2)

51

(4.6

)55

(4

.8)

59

(5.1

)63

(5

.4)

69

(5.8

)87

(6

.3)

-10

(-2

3)14

.9

(2.0

4)46

(4

.2)

53

(4.7

)59

(5

.1)

63

(5.4

)67

(5

.6)

71

(5.9

)77

(6

.3)

94

(6.8

)

* Ind

icat

es V

acuu

m –

Inch

es o

f Hg.

NO

TE: 1

BAR

= 1

00 k

Pa o

r 1 A

TM (A

tmos

pher

e) P

ress

ure

92

* Ind

icat

es V

acuu

m –

Inch

es o

f Hg.

NO

TE: 1

BAR

= 1

00 k

Pa o

r 1 A

TM (A

tmos

pher

e) P

ress

ure

* *

93

4.0

— E

LEC

TRIC

AL

DAT

A 4.

1 —

06D

R 3

Pha

se E

lect

rica

l Spe

cific

atio

ns

94

LEG

END

LRA

- Loc

ked

Rot

or A

mps

MC

C -

Max

miu

m C

ontin

uous

Cur

rent

RLA

- R

ated

Loa

d Am

ps* T

he la

st tw

o di

gits

of t

he c

ompr

esso

r mod

el n

umbe

r may

var

y. Se

e pa

ge 3

.

NO

TES:

1. R

LA (r

ated

load

am

ps) v

alue

sho

wn

for n

ew h

igh

effic

ienc

y m

odel

s is

MC

C ÷

1.5

6 =

RLA

. Use

this

re

com

men

ded

(and

min

imum

) RLA

val

ue to

det

erm

ine

nam

epla

te s

tam

ping

, min

imum

con

tact

or s

izin

g an

d w

ire s

izin

g.2.

Com

pres

sor o

pera

ting

amps

at a

ny s

peci

fic c

ondi

tions

can

onl

y be

det

erm

ined

from

a p

erfo

rman

ce c

urve

.3.

RLA

val

ues

for 0

6D c

ompr

esso

r pro

tect

ed b

y a

calib

rate

d ci

rcui

t bre

aker

will

depe

nd o

n m

ust-t

rip v

alue

of c

ircui

t bre

aker

.4.

Ohm

val

ues

show

n fo

r res

ista

nce

are

appr

oxim

ate

and

show

n fo

r ref

eren

ce o

nly.

Mot

ors

from

diff

eren

t ven

dors

and

m

otor

s of

diff

eren

t effi

cien

cies

can

diff

er u

p to

15%

from

dat

a sh

own.

Max kW

95

4.2

— 0

6DM

, DA

3 Ph

ase

Elec

tric

al S

peci

ficat

ions

Max kW

96

LEG

END

LRA

- Loc

ked

Rot

or A

mps

MC

C -

Max

miu

m C

ontin

uous

Cur

rent

RLA

- R

ated

Loa

d Am

ps* T

he la

st tw

o di

gits

of t

he c

ompr

esso

r mod

el n

umbe

r may

var

y. Se

e pa

ge 3

.

NO

TES:

1. R

LA (r

ated

load

am

ps) v

alue

sho

wn

for n

ew h

igh

effic

ienc

y m

odel

s is

MC

C ÷

1.5

6 =

RLA

. Use

this

re

com

men

ded

(and

min

imum

) RLA

val

ue to

det

erm

ine

nam

epla

te s

tam

ping

, min

imum

con

tact

or s

izin

g

and

wire

siz

ing.

2. C

ompr

esso

r ope

ratin

g am

ps a

t any

spe

cific

con

ditio

ns c

an o

nly

be d

eter

min

ed fr

om a

per

form

ance

cur

ve.

3. R

LA v

alue

s fo

r 06D

com

pres

sor p

rote

cted

by

a ca

libra

ted

circ

uit b

reak

er w

ill de

pend

on

mus

t-trip

val

ue o

f circ

uit b

reak

er.

4. O

hm v

alue

s sh

own

for r

esis

tanc

e ar

e ap

prox

imat

e an

d sh

own

for r

efer

ence

onl

y. M

otor

s fro

m d

iffer

ent v

endo

rs a

nd

mot

ors

of d

iffer

ent e

ffici

enci

es c

an d

iffer

up

to 1

5% fr

om d

ata

show

n.

97

4.3

— 0

6DR

, DM

Sin

gle

Phas

e El

ectr

ical

Spe

cific

atio

ns

*The

last

two

digi

ts o

f the

com

pres

sor m

odel

num

ber m

ay v

ary.

See

page

3.

98

*The

last

two

digi

ts o

f the

com

pres

sor m

odel

num

ber m

ay v

ary.

See

page

3.

99

4.4

— 0

6ER

, EY

3 P

hase

Ele

ctri

cal S

peci

ficat

ions

* The

last

two

digi

ts o

f the

com

pres

sor m

odel

num

ber m

ay v

ary.

See

page

4. T

he fi

fth d

igit

in (

) of t

he c

ompr

esso

r mod

el n

umbe

r re

pres

ents

mod

els

with

or w

ithou

t oil.

0, 1

, 2 s

igni

fies

olde

r mod

els

with

oil;

3, 4

, 5 s

igni

fies

new

er m

odel

s w

ithou

t oil.

See

pag

e 4.

MA

XkW

100

LEG

END

:LR

A - L

ocke

d R

otor

Am

psM

.H. -

Mus

t Hol

d Am

psM

.T. -

Mus

t-Trip

Am

psPW

- Pa

rt-W

indi

ng (S

tart)

RLA

- R

ated

Loa

d Am

psXL

- Ac

ross

-the-

Line

(Sta

rt)

NO

TES:

1. C

ompr

esso

r mus

t-trip

(M.T

.) am

ps a

nd R

LA v

alue

s ar

e m

axim

um fi

gure

s.2.

LR

A va

lues

for P

W s

econ

d w

indi

ng =

1/2

the

LRA

-XL

valu

e.3.

3-P

ole

XL c

ircui

t bre

aker

s sh

own,

oth

er 3

-Pol

e XL

alte

rnat

es a

nd 6

-Pol

e PW

bre

aker

s av

aila

ble.

Ter

min

al lu

gs fo

r circ

uit b

reak

ers

avai

labl

e in

pa

ckag

e 06

EA66

0152

.4.

Rec

omm

ende

d R

LA v

alue

sho

wn

is d

eter

min

ed b

y: c

ircui

t bre

aker

mus

t trip

val

ue ÷

1.4

0. U

se th

is re

com

men

ded

(and

min

imum

) RLA

val

ue to

de

term

ine

nam

e pl

ate

stam

ping

, min

imum

con

tact

or s

izin

g, a

nd w

ire s

izin

g. R

ECO

MM

END

ED R

LA F

OR

06E

CO

MPR

ESSO

RS

EQU

ALS:

MU

ST-

TRIP

(M.T

.) O

F C

ARLY

LE A

PPR

OVE

D O

VER

CU

RR

ENT

DEV

ICE

BEIN

G U

SED

÷ 1

.40.

5. 0

6ER

166

New

OEM

Mod

els

no lo

nger

pro

duce

d, re

plac

ed b

y 06

ER16

5.6.

Com

pres

sor o

pera

ting

amps

at a

ny s

peci

fic c

ondi

tion

can

only

be

dete

rmin

ed fr

om a

per

form

ance

cur

ve.

7. O

hm v

alue

s fo

r res

ista

nce

are

appr

oxim

ate

and

show

n fo

r ref

eren

ce p

urpo

ses

only.

Mot

ors

from

diff

eren

t ven

dors

and

mot

ors

of d

iffer

ent e

ffici

enci

es

can

diffe

r up

to 1

5% fr

om d

ata

show

n.

101

4.5

— 0

6EM

, EZ

3 Ph

ase

Elec

tric

al S

peci

ficat

ions

* The

last

two

digi

ts o

f the

com

pres

sor m

odel

num

ber m

ay v

ary.

See

page

4. T

he fi

fth d

igit

in (

) of t

he c

ompr

esso

r mod

el n

umbe

r re

pres

ents

mod

els

with

or w

ithou

t oil.

0, 1

, 2 s

igni

fies

olde

r mod

els

with

oil;

3, 4

, 5 s

igni

fies

new

er m

odel

s w

ithou

t oil.

See

pag

e 4.

102

LEG

END

:LR

A - L

ocke

d R

otor

Am

psM

.H. -

Mus

t Hol

d Am

psM

.T. -

Mus

t-Trip

Am

psPW

- Pa

rt-W

indi

ng (S

tart)

RLA

- R

ated

Loa

d Am

psXL

- Ac

ross

-the-

Line

(Sta

rt)

NO

TES:

1. C

ompr

esso

r mus

t-trip

(M.T

.) am

ps a

nd R

LA v

alue

s ar

e m

axim

um fi

gure

s.2.

LR

A va

lues

for P

W s

econ

d w

indi

ng =

1/2

the

LRA

-XL

valu

e.3.

3-P

ole

XL c

ircui

t bre

aker

s sh

own,

oth

er 3

-Pol

e XL

alte

rnat

es a

nd 6

-Pol

e PW

bre

aker

s av

aila

ble.

Ter

min

al lu

gs fo

r circ

uit b

reak

ers

avai

labl

e in

pa

ckag

e 06

EA66

0152

.4.

Rec

omm

ende

d R

LA v

alue

sho

wn

is d

eter

min

ed b

y: c

ircui

t bre

aker

mus

t trip

val

ue ÷

1.4

0. U

se th

is re

com

men

ded

(and

min

imum

) RLA

val

ue to

de

term

ine

nam

e pl

ate

stam

ping

, min

imum

con

tact

or s

izin

g, a

nd w

ire s

izin

g. R

ECO

MM

END

ED R

LA F

OR

06E

CO

MPR

ESSO

RS

EQU

ALS:

M

UST

-TR

IP (M

.T.)

OF

CAR

LYLE

APP

RO

VED

OVE

RC

UR

REN

T D

EVIC

E BE

ING

USE

D ÷

1.4

0.5.

06E

M26

6 N

ew O

EM M

odel

s no

long

er p

rodu

ced,

repl

aced

by

06EA

265.

6. C

ompr

esso

r ope

ratin

g am

ps a

t any

spe

cific

con

ditio

n ca

n on

ly b

e de

term

ined

from

a p

erfo

rman

ce c

urve

.7.

Ohm

val

ues

for r

esis

tanc

e ar

e ap

prox

imat

e an

d sh

own

for r

efer

ence

pur

pose

s on

ly. M

otor

s fro

m d

iffer

ent v

endo

rs a

nd m

otor

s of

diff

eren

t effi

cien

cies

ca

n di

ffer u

p to

15%

from

dat

a sh

own.

103

4.6

— 0

6EA

, ET

3 Ph

ase

Elec

tric

al S

peci

ficat

ions

* The

last

two

digi

ts o

f the

com

pres

sor m

odel

num

ber m

ay v

ary.

See

page

4. T

he fi

fth d

igit

in (

) of t

he c

ompr

esso

r mod

el n

umbe

r re

pres

ents

mod

els

with

or w

ithou

t oil.

0, 1

, 2 s

igni

fies

olde

r mod

els

with

oil;

3, 4

, 5 s

igni

fies

new

er m

odel

s w

ithou

t oil.

See

pag

e 4.

104

LEG

END

:LR

A - L

ocke

d R

otor

Am

psM

.H. -

Mus

t Hol

d Am

psM

.T. -

Mus

t-Trip

Am

psPW

- Pa

rt-W

indi

ng (S

tart)

RLA

- R

ated

Loa

d Am

psXL

- Ac

ross

-the-

Line

(Sta

rt)

NO

TES:

1. C

ompr

esso

r mus

t-trip

(M.T

.) am

ps a

nd R

LA v

alue

s ar

e m

axim

um fi

gure

s.2.

LR

A va

lues

for P

W s

econ

d w

indi

ng =

1/2

the

LRA

-XL

valu

e.3.

3-P

ole

XL c

ircui

t bre

aker

s sh

own,

oth

er 3

-Pol

e XL

alte

rnat

es a

nd 6

-Pol

e PW

bre

aker

s av

aila

ble.

Ter

min

al lu

gs fo

r circ

uit b

reak

ers

avai

labl

e in

pa

ckag

e 06

EA66

0152

.4.

Rec

omm

ende

d R

LA v

alue

sho

wn

is d

eter

min

ed b

y: c

ircui

t bre

aker

mus

t trip

val

ue ÷

1.4

0. U

se th

is re

com

men

ded

(and

min

imum

) RLA

val

ue to

de

term

ine

nam

e pl

ate

stam

ping

, min

imum

con

tact

or s

izin

g, a

nd w

ire s

izin

g. R

ECO

MM

END

ED R

LA F

OR

06E

CO

MPR

ESSO

RS

EQU

ALS:

M

UST

-TR

IP (M

.T.)

OF

CAR

LYLE

APP

RO

VED

OVE

RC

UR

REN

T D

EVIC

E BE

ING

USE

D ÷

1.4

05.

Com

pres

sor o

pera

ting

amps

at a

ny s

peci

fic c

ondi

tion

can

only

be

dete

rmin

ed fr

om a

per

form

ance

cur

ve.

6. O

hm v

alue

s fo

r res

ista

nce

are

appr

oxim

ate

and

show

n fo

r ref

eren

ce p

urpo

ses

only.

Mot

ors

from

diff

eren

t ven

dors

and

mot

ors

of d

iffer

ent e

ffici

enci

es

can

diffe

r up

to 1

5% fr

om d

ata

show

n.

105

4.7

— 0

6CC

(16

to 3

7 C

fm) 3

Pha

se E

lect

rica

l Spe

cific

atio

ns

MA

XkW

106

LEG

END

LRA

- Loc

ked

Rot

or A

mps

MC

C -

Max

miu

m C

ontin

uous

Cur

rent

RLA

- R

ated

Loa

d Am

ps

NO

TES:

1. R

LA (r

ated

load

am

ps) v

alue

sho

wn

for n

ew h

igh

effic

ienc

y m

odel

s is

MC

C ÷

1.5

6 =

RLA

. Use

this

re

com

men

ded

(and

min

imum

) RLA

val

ue to

det

erm

ine

nam

epla

te s

tam

ping

. Min

imum

con

tact

or s

izin

g an

d w

ire s

izin

g.2.

Com

pres

sor o

pera

ting

amps

at a

ny s

peci

fic c

ondi

tions

can

onl

y be

det

erm

ined

from

a p

erfo

rman

ce c

urve

.3.

RLA

val

ues

for 0

6D c

ompr

esso

r pro

tect

ed b

y a

calib

rate

d ci

rcui

t bre

aker

will

depe

nd o

n m

ust-t

rip v

alue

of c

ircui

t bre

aker

.4.

Ohm

val

ues

show

n fo

r res

ista

nce

are

appr

oxim

ate

and

show

n fo

r ref

eren

ce o

nly.

Mot

ors

from

diff

eren

t ven

dors

and

mot

ors

of d

iffer

ent e

ffici

enci

es

can

diffe

r up

to 1

5% fr

om d

ata

show

n.

107

4.8

– 06

CC

(50

to 9

9 C

fm) 3

Pha

se E

lect

rica

l Spe

cific

atio

ns

108

LEG

END

:LR

A - L

ocke

d R

otor

Am

psM

CC

-Max

imum

Con

tinuo

us C

urre

ntR

LA-R

ated

Loa

d Am

ps

NO

TES:

1. C

ompr

esso

r mus

t-trip

(M.T

.) am

ps a

nd R

LA v

alue

s ar

e m

axim

um fi

gure

s.2.

LR

A va

lues

for P

W s

econ

d w

indi

ng =

1/2

the

LRA

-XL

valu

e.3.

3-P

ole

XL c

ircui

t bre

aker

s sh

own,

oth

er 3

-Pol

e XL

alte

rnat

es a

nd 6

-Pol

e PW

bre

aker

s av

aila

ble.

Ter

min

al lu

gs fo

r circ

uit b

reak

ers

avai

labl

e in

pa

ckag

e 06

EA66

0152

.4.

Rec

omm

ende

d R

LA v

alue

sho

wn

is d

eter

min

ed b

y: c

ircui

t bre

aker

mus

t trip

val

ue ÷

1.4

0. U

se th

is re

com

men

ded

(and

min

imum

) RLA

val

ue to

de

term

ine

nam

e pl

ate

stam

ping

, min

imum

con

tact

or s

izin

g, a

nd w

ire s

izin

g. R

ECO

MM

END

ED R

LA F

OR

06C

C C

OM

PRES

SOR

S EQ

UAL

S:

MU

ST-T

RIP

(M.T

.) O

F C

ARLY

LE A

PPR

OVE

D O

VER

CU

RR

ENT

DEV

ICE

BEIN

G U

SED

÷ 1

.40.

5. C

ompr

esso

r ope

ratin

g am

ps a

t any

spe

cific

con

ditio

n ca

n on

ly b

e de

term

ined

from

a p

erfo

rman

ce c

urve

.6.

Ohm

val

ues

for r

esis

tanc

e ar

e ap

prox

imat

e an

d sh

own

for r

efer

ence

pur

pose

s on

ly. M

otor

s fro

m d

iffer

ent v

endo

rs a

nd m

otor

s of

diff

eren

t effi

cien

cies

ca

n di

ffer u

p to

15%

from

dat

a sh

own.

109

4.9 — 06D Compressor Overloads*

* Based on new high efficiency (H.E.) extended voltage compressor models.† Voltage is 3 Phase 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 motor and wire across terminals 8 and 9 at the terminal block. It trips (opens) control circuit at 221°F (105°C) and resets at 181°F (83°C)

110

Three Phase Across-The-Line StartInternal Thermostat

Single Phase Internal Thermostat

06DSinglePhase

06DThreePhase

* 3rd overload required on some compressors. See 4.9 06D compressor overloads.

4.10 — Electrical Hook-Up Consultwiringdiagramlocatedinsidecompressor

terminalboxcoverandreferencediagramsshownbelowforwiringhook-upconnectionlocations.See3.31,pg88forTerminalBoxPackages.

06DCOMPRESSORS

111

06ECOMPRESSORS(ACROSS-THE-LINE[XL]START)

See Fig.17, page 111, for detailed view of terminal post arrangement.

112

06ECOMPRESSORS(PARTWINDINGSTART)

Fig. 17 – Terminal Post Arrangement, Detail View (06E

and 06CC 50 to 99 Cfm)

113

4.11 — Voltage and Current Unbalance

VOLTAGEUNBALANCE(Maximum2%)

Voltageunbalancecancausemotorstooverheatandfail.Belowistherecommendedmethodfordeterminingvolt-ageunbalance.

Example:Supplyvoltageis240-3-60

AverageVoltage=

Determinemaximumdeviationfromaveragevoltage: (AB)243–239=4volts (BC)239–236=3volts (AC)239–238=1volt

Maximumdeviationis4volts. Determine%voltageunbalance:

%Voltageunbalance=100x

=1.7%

Thisamountofphaseunbalanceissatisfactoryasitisbelowthemaximumallowableof2%.

IMPORTANT:Ifthesupplyvoltagephaseunbalance ismorethan2%,contactyourlocalelectricutility

companyimmediately.

4239

243+236+2383

= 7173

=239volts

AB=243voltsBC=236voltsAC=238volts

114

CURRENTUNBALANCE(Maximum10%)

Voltageunbalancewillcauseacurrentunbalance,butacurrentunbalancedoesnotnecessarilymeanthatavoltageunbalanceexists.Alooseterminalconnectionorabuild-upofdirtorcarbonononesetofcontacts(usingtheexampleofL1astheproblemleg)wouldcauseahigherresistanceonthatleg(L1)thanonL2andL3.Thecurrentfollowsthepathofleastresistance,sothecurrentincreasesinlegsL2andL3.Highercurrentcausesmoreheattobegeneratedinthemotorwindings.

Percent(%)ofcurrentunbalanceiscalculatedinthesamewayasvoltageunbalance(seetheprevioussection),withamaximumacceptablecurrentunbalanceof10%.

5.0 COMPRESSOR SERVICE WORKSHEETS

CarlylerecommendsthattheCompressorServiceWork-sheets(pages115and116)becopied(andenlarged,ifpreferred)andfilledoutforeachcompressoratinitialstart-upandeachtimethecompressorisserviced.Comparingthedatafromcurrentworksheetstopastrecordswillallowtheservicetechniciantodiagnosesystemchangesandpreventcompressorfailures.Thisinformationisalsoveryusefulinpreventingarepeatfailure.

115

06D, 06E Compressor Service WorksheetMechanic:____________________ Date:________________FromCompressorNameplate:ModelNo.:_________________________________________SerialNo.:_________________________________________MotorNo.:_________________________________________Voltage:___________________________________________Allowcompressortorunfor30minutes,thenobtainthepressuresandbodytemperatureatthelocationsshownbelow.Checkforproperoilreturninsightglass.

COMPRESSOR VOLTAGE/AMP VALUES PH VOLTAGE CURRENT C-R:___________________ C:___________________ 1φ C-S:___________________ R:___________________ R-S:___________________ S:___________________

L1-L2:_________________ L1:__________________ L1-L3:_________________ L2:__________________ L2-L3:_________________ L3:__________________ 3φ PART WINDING L7-L8:_________________ L7:__________________ L7-L9:_________________ L8:__________________ L8-L9:_________________ L9:__________________

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

116

06CC Compressor Service WorksheetMechanic:____________________ Date:________________FromCompressorNameplate:ModelNo.:_________________________________________SerialNo.:_________________________________________MotorNo.:_________________________________________Voltage:___________________________________________Allowcompressortorunfor30minutes,thenobtainthepressuresandbodytemperatureatthelocationsshownbelow.Checkforproperoilreturninsightglass.

SeeCompressorOperatingLimits,page19.

Make copies of this worksheet to record data at initial start-up and whenever the compressor is serviced.

COMPRESSOR VOLTAGE/AMP VALUES PH VOLTAGE CURRENT C-R:___________________ C:___________________ 1φ C-S:___________________ R:___________________ R-S:___________________ S:___________________

L1-L2:_________________ L1:__________________ L1-L3:_________________ L2:__________________ L2-L3:_________________ L3:__________________ 3φ PART WINDING L7-L8:_________________ L7:__________________ L7-L9:_________________ L8:__________________ L8-L9:_________________ L9:__________________

LEGEND: C - Common R - Run S - Start

117

Service Guide Index

Page

06CC(16to37CFM)3PhaseElectricalSpecifications................................... 10506CC(50to99Cfm)3PhaseElectricalSpecifications.................................... 10706CC(16to37Cfm)TorqueGuide..................................................................... 6006CC(50to99Cfm)TorqueGuide..................................................................... 6106CCCompressor16to37CfmModel,ConnectionPoints—MotorEnd......... 5106CCCompressor16to37CfmModel,ConnectionPoints—PumpEnd......... 5006CCCompressor50to99CfmModel,ConnectionPoints—MotorEnd......... 5306CCCompressor50to99CfmModel,ConnectionPoints—PumpEnd......... 5206CCCompressorModelNumbers...................................................................... 506CCCompressors—PhysicalData................................................................. 6606CCServiceWorksheet.................................................................................. 11606D2-CylinderCompressor,ConnectionPoints................................................. 4406D4-CylinderCompressor(13and16Cfm),ConnectionPoints...................... 4506D4-CylinderCompressor(18and20Cfm),ConnectionPoints...................... 4606D6-CylinderCompressor(24,28,and37Cfm),ConnectionPoints............... 4706D6-CylinderCompressor,ExplodedView...................................................... 5606DCompressor,Cross-SectionalView............................................................. 5406DCompressorModelNumbers......................................................................... 306DCompressorOverloads.............................................................................. 10906DCompressors—PhysicalData.................................................................... 6206DCompressors—TorqueGuide.................................................................... 6006D,EServiceWorksheet................................................................................ 11506DM,DA3PhaseElectricalSpecifications....................................................... 9506DR3PhaseElectricalSpecifications.............................................................. 9306DR,DMSingle-PhaseElectricalSpecifications............................................... 9706E4-CylinderCompressor(50andold66Cfm),ConnectionPoints................ 4806E6-CylinderCompressor(65,75,99Cfm),ConnectionPoints...................... 4906E6-CylinderCompressor,ExplodedView....................................................... 5806ECompressor,Cross-SectionalView.............................................................. 55

118

06ECompressorModelNumbers......................................................................... 406ECompressors—PhysicalData.................................................................... 6406ECompressors—TorqueGuide..................................................................... 6106EA,ET3PhaseElectricalSpecifications...................................................... 10306ER,EY3PhaseElectricalSpecifications........................................................ 9906EM,EZ3PhaseElectricalSpecifications...................................................... 101Additives,Oil........................................................................................................ 73AlkylbenzeneOil,UsewithCFC,HCFC,andHCFCBlends............................... 69BafflePlates........................................................................................................ 89BearingHead(OilPump),ReplacementProcedures.......................................... 38BearingHead,HighFlowOilPump..................................................................... 74BearingHead,PumpEnd.................................................................................... 39BearingHead,Replacement............................................................................... 38BillingandCredit................................................................................................. 10CapacityControlUnloadingAccessoryPackages............................................... 78CapacityControlCoilPackages.......................................................................... 80CarlyleCompressorConnection.......................................................................... 10CFCs,ApprovedforUse...................................................................................... 69CfmDesignation.................................................................................................... 5ChangeOutProcedures,Oil&Refrigerant......................................................... 72Clean-Up............................................................................................................. 42CompressorIsolation........................................................................................... 21CompressorModelNumberSignificance.............................................................. 3CompressorMountingData................................................................................. 82CompressorProblems—see“Troubleshooting”................................................ 20CompressorWeight............................................................................................. 63CompressorswithoutOil..................................................................................... 68ConnectionPoints,06CC16to37CfmModels............................................ 50,51ConnectionPoints,06CC50to99CfmModels............................................ 52,53ConnectionPoints,06D2-CylinderModels......................................................... 44ConnectionPoints,06D4-CylinderModels................................................... 45,46ConnectionPoints,06D6-CylinderModels......................................................... 47ConnectionPoints,06E4-CylinderModels......................................................... 48

119

ConnectionPoints,06E6-CylinderModels......................................................... 49CrankcaseHeaters.............................................................................................. 81CurrentUnbalance............................................................................................ 114Cycling,Continuous—TypicalCauses............................................................... 23Cycling,Intermittent—TypicalCauses............................................................... 23CylinderHead,Blown.......................................................................................... 23CylinderHeadCoolingFans................................................................................ 77CylinderHeadDisassembly................................................................................ 33CylinderHeadGasket—FailureCauses............................................................ 23CylinderHeadGaskets........................................................................................ 84CylinderHeadReassembly................................................................................. 36DischargeGasTemperatureSensor................................................................... 76ElectricalHookup,06DCompressors................................................................ 110ElectricalHookup,06ECompressors—Across-the-LineStart..........................111ElectricalHookup,06ECompressors—PartWindingStart............................. 112ElectricalSpecifications....................................................................................... 93Flooding—TypicalCauses................................................................................. 24Gasket,TerminalPlate........................................................................................ 85Gaskets,CylinderHeadandValvePlates........................................................... 84Gaskets,ServiceValves...................................................................................... 82Gaskets,LeakTesting......................................................................................... 32HCFCBlends,ApprovedforUse......................................................................... 70HCFCs,ApprovedforUse................................................................................... 69Heaters,Crankcase............................................................................................. 81Help—WheretoGetMore................................................................................... 1HFCs,ApprovedforUse...................................................................................... 71HighEfficiencyCompressors,06D,E................................................................. 68InsertionHeaters................................................................................................. 81InterstagePressureTables(06CC)..................................................................... 89JumperPlatePackagesConnection............................................................88,111LockedRotor,CyclingOn—TypicalCauses...................................................... 27LowCompressorCapacity.................................................................................. 22MetricConversionsandMeasurements................................................................ 5MineralOils,ToUseWithCFCandHCFCRefrigerants..................................... 69

120

ModelNumber................................................................................................... 3,6MotorBurnout...................................................................................................... 27MotorBarrelInterconnection............................................................................... 13MotorEndMountingFoot.................................................................................... 83MotorBurnout—Clean-upProcedure................................................................ 42MotorProtectionTripping—TypicalCauses...................................................... 26MountingData,Compressor................................................................................ 82MountingPlate,Compressors............................................................................. 82Mufflers................................................................................................................ 87NameplateSignificance......................................................................................... 6OEM...................................................................................................................... 9Oil&RefrigerantChangeOutProcedures.......................................................... 72OilAdditives......................................................................................................... 73OilCharge........................................................................................................... 63OilControl—ParallelCompressorApplications........................................... 13,28OilControl—MotorBarrelInterconnections....................................................... 13OilDrainPlugAdapter......................................................................................... 83OilLevelinSightGlass....................................................................................... 12OilOperatingLevels............................................................................................ 12OilPressure......................................................................................................... 73OilPressureProblems—TypicalCauses........................................................... 26OilPump–SeeBearingHeadOilSafetySwitch................................................................................................. 75OilViscosityandPourPoints.............................................................................. 72Oils,ApprovedforUse......................................................................................... 69OperatingLimits,Typical—06CC...................................................................... 19OperatingLimits,Typical—06D,E..................................................................... 18Overloadsfor06DCompressors....................................................................... 109ParallelCompressorApplications,OilControl..................................................... 28PartsIdentification—06DCompressor,ExplodedView..................................... 56PartsIdentification—06ECompressor,ExplodedView..................................... 58PhysicalData—06CCCompressors................................................................. 66PhysicalData—06DCompressors.................................................................... 62PhysicalData—06ECompressors.................................................................... 64

121

PipeRattles—TypicalCauses........................................................................... 25Piston,SuctionValve,andBackerPositions....................................................... 36POEOils,ToUsewithHFCRefrigerants............................................................ 71PumpEndBearingHead..................................................................................... 39PreStart-UpProcedures..................................................................................... 12RatedLoadAmps(RLA)...................................................................................... 93RefrigerantandOilChange-OutProcedures...................................................... 72RefrigerantsandOilsfor06CCCompressors..................................................... 72RefrigerantsandOilsfor06D,ECompressors................................................... 69SerialNumber........................................................................................................ 8ServiceBilling...................................................................................................... 10ServiceProcedures............................................................................................. 32ServiceProcedures—BearingHead(OilPump)............................................... 38ServiceProcedures—CylinderHeadandValvePlateAssembly...................... 32ServiceProcedures—MotorBurnoutCleanUp................................................. 42ServiceValveGaskets......................................................................................... 82ServiceValves..................................................................................................... 82ServiceWorksheet,06CC................................................................................. 116ServiceWorksheet,06D,E............................................................................... 115SightGlassAdapters—OilEqualization............................................................ 83SightGlass,OilLevel.......................................................................................... 12SightGlassReplacement—InstallationTool...................................................... 83SpecialOrderNumber........................................................................................... 7Start-Up—BeforeStarting.................................................................................. 12Start-Up—RecommendedProcedures.............................................................. 11Start-Up,Compressor.......................................................................................... 16Start-Up,TroubleshootingandService................................................................ 10Start-Up,WillNotStart........................................................................................ 22Strap-OnHeaters................................................................................................ 81SuctionCut-OffControl....................................................................................... 78SuctionValve....................................................................................................... 36TechnicalAssistance,OEM................................................................................. 10TechnicalAssistance,ToGet................................................................................. 1TerminalLugPackage......................................................................................... 88

122

TerminalPlateGasket......................................................................................... 85TerminalPlateJumperBars,06E........................................................................ 88TerminalPosts................................................................................................... 112TorqueGuide—06Dand06CC(16to37Cfm)Compressors........................... 60TorqueGuide—06Eand06CC(50to99Cfm)Compressors........................... 61Troubleshooting................................................................................................... 20Troubleshooting—06CCDesuperheaterConnectionHot................................. 31Troubleshooting—06CCDischargePressure=IntermediatePressure............ 31Troubleshooting—06CCEconomizerConnectionHot...................................... 31Troubleshooting—06CCHighMidstagePressure............................................. 31Troubleshooting—06CCIntermediatePressure=DischargePressure............ 31Troubleshooting—06CCLowMidstagePressure............................................. 31Troubleshooting—CannotPullDown................................................................ 22Troubleshooting—CompressorIsolationProcedures........................................ 21Troubleshooting—Cycling,Continuous............................................................. 23Troubleshooting—Cycling,Intermittent............................................................. 23Troubleshooting—CylinderHeadGasket.......................................................... 23Troubleshooting—DesuperheaterConnectionHot,06CC................................ 31Troubleshooting—DischargeTemperatureSensor............................................ 26Troubleshooting—EconomizerConnectionHot,06CC..................................... 31Troubleshooting—Flooding............................................................................... 24Troubleshooting—LockedRotor,CyclingOn.................................................... 27Troubleshooting—LowDischargePressure...................................................... 24Troubleshooting—HighMidstagePressure,06CC............................................ 31Troubleshooting—LowMidstagePressure,06CC............................................ 31Troubleshooting—LowOnCapacity.................................................................. 22Troubleshooting—LoworNoOilPressure........................................................ 26Troubleshooting—LowSuctionPressure.......................................................... 24Troubleshooting—MotorBurnout...................................................................... 27Troubleshooting—MotorProtectionTripping..................................................... 26Troubleshooting—NoOilPressure.................................................................... 26Troubleshooting—NoisyCompressor................................................................ 25Troubleshooting—OilSafetySwitchTripping.................................................... 30Troubleshooting—ParallelSystems.................................................................. 28

123

Troubleshooting—PipeRattle............................................................................ 25Troubleshooting—RunningHot......................................................................... 29Troubleshooting—SightGlass,LoworEmpty................................................... 30Troubleshooting—StartingProblems................................................................. 22Troubleshooting—ValvePlates.......................................................................... 23Troubleshooting—WillNotStart........................................................................ 22TroubleshootingGuide........................................................................................ 22Unloading—CapacityControl............................................................................ 78ValvePlateGaskets............................................................................................ 84ValvePlateGaskets,Blown................................................................................. 23ValvePlateDisassembly..................................................................................... 33ValvePlatePackages.......................................................................................... 86ValvePlates—FailureCauses........................................................................... 23ValvePlates—ReplacementProcedures........................................................... 32ValvePlates—LeakTesting............................................................................... 32VoltageUnbalance............................................................................................ 113Warranty................................................................................................................ 9Weight,Compressor............................................................................................ 63

COMPLIMENTS OF:

CARLYLE COMPRESSOR DIVISION • © CARRIER CORPORATIONP.O. Box 4808 • Syracuse New York 13221www.carlylecompressor.comIn U.S., Puerto Rico: 1-800-GO-CARLYLE (1-800-462-2759)In Canada: 1-800-258-1123

Manufacturer reserves the right to discontinue or change at any time, specificationsor designs and prices without notice and without incurring obligations.

Rev 8/10 Lit No: 020-611