carlyle service manual
DESCRIPTION
Carlyle compressor service manual for 06D/06E/06CC compressors used for refrigeration equipment.TRANSCRIPT
SERVICE GUIDE
06D/06E/06CCCOMPRESSORS
COMPLIMENTS OF:
CARLYLE COMPRESSOR DIVISION • © CARRIER CORPORATION 7/98P.O. Box 4808 • Syracuse New York 13221www.carlylecompressor.comIn U.S., Puerto Rico: 1-800-GO-CARLYLE (1-800-462-2759)In Canada: 1-800-258-1123In Mexico: 001-800-GO CARLYLE (001-800-462-2759)
Manufacturer reserves the right to discontinue or change at any time, specificationsor designs and prices without notice and without incurring obligations.
Rev 1/06 Lit No: 020-611 www.carlylecompressor.com
G#4322Cover020-611/21st 01/23/2006 8:08 AM Page 1
1
CONTENTS
1.0 GENERAL COMPRESSOR AND CUSTOMERINFORMATION1.1 Compressor Model Number Significance ...................................... 3
1.2 Nameplate Significance .................................................................. 6
1.3 Compressor Serial Number Significance ....................................... 8
1.4 Carlyle OEM Compressor Warranty .............................................. 9
1.5 Service Billing and Credit ............................................................ 10
1.6 Green Carpet Program, Parts and Stocking Policy ....................... 10
2.0 START-UP, TROUBLESHOOTING, AND SERVICE2.1 Technical Assistance - Carlyle OEM Compressors ...................... 10
2.2 Recommended Start-Up Procedure .............................................. 11
2.3 Troubleshooting Procedures ......................................................... 20
2.4 Service Procedures ....................................................................... 32
2.5 Connection Points — 06D, 06E, and 06CC Compressors ........... 44
2.6 Cross-Sectional View — 06D Semi-Hermetic Compressor ......... 54
2.7 Cross-Sectional View — 06E Semi-Hermetic Compressor ......... 55
2.8 Exploded View — 6-Cylinder 06D Compressor .......................... 56
2.9 Exploded View — 6-Cylinder 06E Compressor .......................... 58
2.10 Torque Guide –– All 06D and 16 to 37 Cfm 06CC Compressors 60
2.11 Torque Guide –– 06E and 06CC (50 to 99 Cfm) Compressors .... 61
3.0 COMPRESSOR AND PARTS DATA3.1 06D Series Compressors –– Physical Data .................................. 62
3.2 06E Series Compressors –– Physical Data ................................... 64
3.3 06CC Series Compressors –– Physical Data ................................ 66
3.4 06D, E High Efficiency (H.E.) Compressors ............................... 68
3.5 Compressor Bodies Without Oil ................................................... 68
3.6 Refrigerants and Oils for 06D, E Compressors ............................ 69
3.7 Refrigerants and Oils for 06CC Compressors .............................. 72
3.8 Oil and Refrigerant Change-Out Procedures ................................ 72
3.9 Oil Viscosity and Pour Points ....................................................... 72
3.10 Oil Additives ................................................................................. 73
3.11 Oil Pressure .................................................................................. 73
3.12 High Flow Oil Pump (Bearing Head) ........................................... 74
3.13 Replacement Oil Pump/Pump End Bearing Package ................... 74
Rev 1/06
2
3.14 Oil Safety Switch .......................................................................... 75
3.15 06CC, E Discharge Gas Cylinder Head Temperature Sensor ...... 76
3.16 06D, E Cylinder Head Cooling Fans ............................................ 77
3.17 Capacity Control Accessory Packages ......................................... 78
3.18 Capacity Control Coil Packages (06D, E) .................................... 80
3.19 Crankcase Heater Data ................................................................. 81
3.20 Compressor Mounting Data ......................................................... 82
3.21 Compressor Service Valves (06D, E, CC) .................................... 82
3.22 Service Valve Gaskets (06D, E, CC) ............................................ 82
3.23 Oil Drain Plug Adapter ................................................................. 83
3.24 Sight Glass Adapters for Oil Equalization ................................... 83
3.25 Replacement Sight Glass — Installation Tool .............................. 83
3.26 Replacement Motor End Mounting Foot ...................................... 83
3.27 Gaskets –– Cylinder Head and Valve Plate ................................. 84
3.28 Miscellaneous ............................................................................... 85
3.29 Valve Plate Packages, Service Replacement ................................ 86
3.30 Muffler Recommendations ........................................................... 87
3.31 Electrical Accessories ................................................................... 88
3.32 Baffle Plate Recommendations .................................................... 89
3.33 Interstage Pressure Tables (06CC Compressors Only) ................ 89
4.0 ELECTRICAL DATA4.1 06DR 3 Phase Electrical Specifications ........................................ 92
4.2 06DM, DA 3 Phase Electrical Specifications ................................ 94
4.3 06DR, DM Single Phase Electrical Specifications ........................ 96
4.4 06ER, EY 3 Phase Electrical Specifications .................................. 98
4.5 06EM, EZ 3 Phase Electrical Specifications ............................... 100
4.6 06EA, ET 3 Phase Electrical Specifications ................................ 102
4.7 06CC (16 to 37 Cfm) 3 Phase Electrical Specifications .............. 104
4.8 06CC (50 to 99 Cfm) 3 Phase Electrical Specifications .............. 106
4.9 06D Compressor Overloads ........................................................ 108
4.10 Electrical Hook-Up ...................................................................... 109
4.11 Voltage and Current Unbalance ................................................... 112
5.0 COMPRESSOR SERVICE WORKSHEETS06D, 06E COMPRESSOR SERVICE WORKSHEET ................................ 114
06CC COMPRESSOR SERVICE WORKSHEET ...................................... 115
SERVICE GUIDE INDEX ................................................ 116
3
1.0 — GENERAL COMPRESSOR AND CUSTOMER INFORMATION
1.1 — Compressor Model Number Significance06D COMPRESSORS
Hot GasBypassUnloading
Suction Cut-OffUnloading
}}
** Refrigeration Partner
Model = 0, Package = 1 or 9, A = Shipped Without Oil
Suction Cut-Off Unloading Designation for 06DR, DM Compressors:0 = All Models Except as Noted5 = No Oil7 = 1 Unloader, Suction Cutoff, Oil-less (DR, DM Only)8 = 2 Unloaders
Electrical Characteristics (XL Start Only, Unless Noted):High Efficiency Models Standard Efficiency Models31 = 575-3-60 01 = 575-3-60 12 = 208/230-3-6032 = 208/230-3-60 04 = 200-3-60 13 = 380-3-6033 = 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 OverloadsC = With Internal Thermostat and Without External Overloads
Suction Service Valve – Variables:Location, Orientation and Mounting Bolts
Compressor Identification Key:0 = New Compressor2 = New Compressor3 = New Compressor6 = Service Compressor, Remanufactured7 = Service Compressor, New Manufactured8 = New Compressor, Special9 = Service Compressor, Special
Displacement (CFM at 1750 rpm)
Motor Size – (Does Not Signify Horsepower)
Compressor Type:06DA = Compressor – A/C Duty No Unloading06DB = 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 Temperature06DR = Compressor Refrig. Duty Low Temperature06DM = Service Compressor – Replacement for new 06DA, DM
without Unloading06DS = 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
06DR 3 37 0 D A 36 5 A - (RP)**
4
06E COMPRESSORS
06ER 3 99 3 0 A - (RP)**
Suction Cut-OffUnloading
}}
Hot Gas BypassUnloading
** Refrigeration Partner
Model = 0, Package = 1 or 9, A = Shipped Without Oil
Design Variable:New Compressors:0 = OEM Model1 = Carrier A/C Model2 = Old Design Refrigeration Valve Plates
6 = Carrier A/C Model8 = OEM with DGT and Oil Charge9 = 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 = 208/230-3-601 = 575-3-603 = 208/230/460-3-50/60 (460v XL Only)4 = 200-3-605 = 230-3-606 = 400/460-3-50/608 = 230-3-509 = 220/380-3-60
Displacement (CFM at 1750 rpm)
Motor Size (Does Not Signify Horsepower)0,1,2 = Models With Oil3,4,5 = Models Without Oil7 = 1 Unloader, Suction Cutoff, Oil-less (ER, EM Only)8 = Special Order
Compressor Type:STD* REV†06EA 06EF Compressor – A/C Duty No Unloading06EB 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 – Service 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 – Service Compressor Refrig. Duty Replaces 06ER06EZ – Service Compressor Refrig. Duty Replaces 06EM
* Standard Center Cylinder Head.† Reversed Center Cylinder Head.
Service compressors shipped with a reverse center head havethe letter “R” after the serial number on the shipping box.
5
06CC COMPRESSORS
06CC 6 65 E 201
Design Variable:101 = Single Pack, W/O Valves, with Oil102 = Single Pack with Valves & Oil103 = Single Pack, Service W/O Valves, Term. Box or Oil201 = Single Pack, W/O Valves or Oil202 = Single Pack with Valves
Electrical Characteristics:A = 415-3-50, XL and PWB = 415-3-50, XLC = 415-3-50, PWD = 208/230-3-60, XLE = 208/230/400/460-3-50/60F = 400/460-3-50/60, XL and PWG = 400/460-3-50/60, XLH = 400/460-3-50/60, PWJ = 575-3-60, XL and PWK = 230-3-60, PWL = 220-3-50, XL and PWM = 220-3-50, XLN = 220-3-50, PWP = 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 Model06CY = Service Compressor06C8 = Compressor, Special
NOTE: USE OF “Cfm” AS MODEL SIZE DESIGNATION
Carlyle uses the “Cfm” designation in the model number to identify the compressor size. TheCfm values are the sixth and seventh digits of the model number. See example above.
Carlyle offers two series of compressors based on body size. The smaller compressors, from 8 to41 Cfm, are referred to as “D” size units (model number “06D”). The larger compressors, from50 to 99 Cfm, are referred to as “E” size units (model number “06E”).
The 06CC, or Compound Cooling compressors, are made in 16 to 37 Cfm and 50 to 99 Cfm sizes.The 16 to 37 Cfm compressors use “D” size bodies. The 50 to 99 Cfm compressors use “E” sizebodies.
NOTE: METRIC MEASUREMENTS
The compressors are built using English units: inches, foot-pounds, pints, etc. A correspondingmetric measurement has been added to all the English units in this guide. These metric measuresare a guide only, having been rounded to the nearest whole number, and therefore are not meantto be an exact mathematical conversion.
6
1.2 — Nameplate Significance
Explanation of the above items, starting clockwisefrom upper right:
MODEL NUMBER - Used when selecting and orderinga new compressor. Distributors use the model numberto obtain a proper service replacement.
NOTE: Model numbers on some compressors areidentified by the symbol “M/N” located in the upperright hand corner of the nameplate.
UL AND CSA - Single mark indicates that this com-pressor meets all the requirements for both UL (Under-writers’ Laboratory) and CSA (Canadian StandardsAssociation). All 60 Hz semi-hermetic Carlyle Com-pressors are UL and CSA recognized and comply withUL, CSA, and NEC (National Electrical Code) require-ments for internal motor protection.
MOTOR NUMBER - For Carlyle internal use only.
MODEL NUMBER
UL AND CSA
MOTOR NUMBER
TEST PRESSURES
CE MARK
SERIAL NUMBER
SERIAL NUMBERBAR CODE
ELECTRICALCHARACTERISTICS
MANUFACTURING NUMBER
MANUFACTURING NUMBERBAR CODE
7
TEST PRESSURES - Each Carlyle 06D/E/CC compres-sor is pressure tested at our factory. The “LS” pressuresare for the low side of the compressor. The “HS”pressures are for the high side of the compressors.
CE MARK - This CE Mark indicates this compressorcomplies with the European CE Mark requirements.
SERIAL NUMBER - The unique number given to eachcompressor. This number, along with the model numberand special order number, is normally all that is needed to obtain information about or order a service replace-ment compressor.
SERIAL NUMBER BAR CODE - For Carlyle internaluse only.
ELECTRICAL CHARACTERISTICS - are shown for allsemi-hermetic compressors. Voltages are shown withrespective operating ranges for both 50 and 60 cycleoperation. Electrical phase and LRA (Locked RotorAmps) information is also provided.
MANUFACTURING NUMBER - For Carlyle internaluse only.
MANUFACTURING NUMBER BAR CODE - ForCarlyle internal use only.
8
1.3 — Compressor Serial Number Significance
ALL NEW COMPRESSORS
Example: S/N 3695J00123
36 95 J 00123Numerical SequencePlant Location: J = Syracuse U = AtlantaYear of Manufacture: 93, 94, 95, etc.Week of Manufacture: 01 thru 52 Begin Jan.1st
ALL SERVICE COMPRESSORS
Example: S/N 3695UD012336 02 U D 0123
Numerical SequenceCompressor Type: D, EPlant Location: M = Atlanta P = PhoenixU = Atlanta (after 4/2001)Year of Manufacture: 93, 94, 95, etc.Week of Manufacture: 01 thru 52. Begin Jan. 1st
NEW AND SERVICE REPLACEMENT COMPRESSORS BUILT BETWEEN NOV. 1968 - OCT. 1978
Example: A2J0001A 2 J* 0001
Numerical SequencePlant Location: J = SyracuseYear 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.
9
1.4 — Carlyle OEM Compressor Warranty
Original OEM compressors are warranted to be free fromdefects in material and workmanship for a period of12 months from the date of original installation, or20 months from the date of manufacture, whichevercomes first.
When a service compressor is used to replace an originalcompressor, the remaining portion of the first-year OEMwarranty is transferred to the service compressor (withinthe United States and Canada).
Equipment may carry an extended OEM warranty if thatwarranty has been purchased from the OEM. The OEMissues the extended warranty, not Carlyle or its distribu-tors, and the OEM is responsible for providing the enduser with the credit.
If returning a compressor:
• place all parts back into compressor• seal all compressor openings (oil leakage may create
an environmental hazard)
NOTE: Opening a compressor for observation ordetermination of failure does not void warranty.
10
1.5 — Service Billing and Credit
Returns of in-warranty parts should be made to thesame Local Carlyle Distributor who supplies thesereplacement parts.
Local Carlyle Distributors will sell parts and servicecompressors only to credit-approved accounts (exceptfor cash sales).
1.6 — Green Carpet Program, Parts and Stocking Policy
The Carlyle Green Carpet program is a free servicecreated to assist users in obtaining service replace-ments. The Green Carpet Program supports replace-ment compressors for reported installations, ensuringavailability at the designated distributorship closest tothe end-user’s location. Green Carpet Customer ServiceRepresentatives can provide assistance in locating thenecessary distributor 24 hours a day, 365 days a year.
• U.S.A., Puerto Rico - 1 (800) GO-CARLYLE (462-2759)• Canada - 1 (800) 258-1123• Mexico - 001 (800) 462-2759
2.0 — START-UP, TROUBLESHOOTING,AND SERVICE
2.1 — Technical Assistance - Carlyle OEMCompressors
Carlyle Compressor Division sells compressors toOEMs (Original Equipment Manufacturers) that designand build the finished system. The OEM is the expert
11
on the entire system, including the Carlyle compressor.All system or compressor questions should be directedfirst to the OEM or the OEM’s local representative. Ifquestions cannot be answered by the OEM or thisService Guide, please contact the Carlyle engineeringgroup.
The following recommended start-up procedure forCarlyle 06D, 06E, and 06CC compressors will helpeliminate initial compressor failures caused by floodedstart, floodback, overheating, and running out of oil.
The Troubleshooting Procedures section (Section 2.3,pages 20 to 31) will help pinpoint compressor andsystem problems.
The Service Procedures section (Section 2.4, pages 32to 43) covers the replacement of valve plates andgaskets, service to the bearing head assembly contain-ing the oil pump, and a clean-up procedure to follow incase of motor burnout. Most other internal servicerequires replacement of the compressor.
2.2 — Recommended Start-Up Procedure
Reliability data of Carlyle’s 06D, 06E, and 06CCrefrigeration compressors indicate that at least half ofcompressor failures occur during the first two to fourmonths of operation. Many of these failures occurduring the initial start-up of the unit. In other cases,troubled start-ups lead to compressor damage severeenough to cause premature failures. The major causesof failures of these compressors are flooded start,floodback, overheating, and running out of oil. Most ofthese failures can be avoided by using more care duringthe initial start-up of the compressors. Therefore, thefollowing start-up procedure for 06D, 06E and 06CCcompressors is provided.
12
BEFORE START-UP
1. Verify that the compressor nameplate indicatesproper model and voltage. Do the values agree withsystem needs and available power?
2. Verify that there is oil in the system.
Since different refrigerants (CFC, HCFC, or HFC)require specific oils (mineral, alkylbenzene, orpolyolester [POE]), Carlyle ships most new andservice compressors without oil. The oil level for06CC size 16 to 37 Cfm compressors and all 06Dcompressors should be at 1/4 to 3/4 of the sightglass. The oil level for 06CC size 50 to 99 Cfmcompressors and all 06E compressors should be at1/8 to 3/8 of the sight glass. See Sections 3.6 and3.7, pages 69 to 72 for the proper Carlyle ap-proved oils for the selected refrigerant. Oil shouldbe added through the recommended oil fillconnection ports on the compressor as identifiedin the figures in section 2.5.Once the compressor system has been running for atleast 24 hours, the most accurate oil levels areobserved when the compressor is off. Oil levels inthe sight glass can be affected by the rotation of therunning gear.
RECOMMENDED 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)
13
! CAUTION
Do not add excess oil. It is especially important on the06E and 06CC (50 to 99 Cfm) compressors that excess oilnot be added to the system. Laboratory tests and fieldexperience indicate excessive oil levels can cause blownvalve plate and cylinder head gaskets, increase compres-sor operating temperatures, and cause oil equalizationproblems.
NOTE: All 06D compressors and 06CC (16 to 37 Cfm)compressors have one sight glass on the side of thecrankcase. All 06E compressors and 06CC (50 to99 Cfm) compressors have two sight glasses, on the oilpump end of the compressor.
Parallel compressor applications typically use an oil-control float system consisting of individual floats, aseparator and an oil reservoir. When using a floatsystem, do not interconnect the floats with an “equaliza-tion system” without approval from Carlyle applicationengineering. The use of a float “equalization system” canresult in system oil control problems.
An oil equalization line can be used instead of a floatsystem, except with 06CC compressors. The equaliza-tion line and the compressors must be level, and the linediameter must be large enough to allow both the refriger-ant and oil to equalize between all the interconnectedcompressors. If the line is not level, it is undersized orthe system contains too much oil, the oil level will risefilling the line, and oil control between compressors willbe lost. Typically, equalization lines are 1 1/8 in.(28 mm) in diameter or larger. For 06D compressors, asight glass in the line is required to determine the systemoil level.
Parallel systems using three (3) or more 06E compressorsrequire the use of a common motor barrel interconnec-tion line between compressors. Use of an interconnec-tion line is strongly recommended on two (2) 06E
CAUTION!
14
compressor unit configurations. This system prevents oilfrom building up in an 06E motor barrel during the offcycle, thereby preventing an oil slug on start-up. Theline is either 1/4 in. (6 mm) or 3/8 in.(8 mm) tubinginterconnecting to fittings located in the bottom of the06E crankcases. To connect to the 06E compressormotor barrel, fitting P/N 5F20-1311 (5/8 in.-18 x 1/4 in.NPT) with AU51YA001 gasket is recommended. Some50 cfm compressors have a 1/4 in. NPT connection anddo not require the 5F20-1311 fitting. The motor barrelinterconnection line is in addition to either the crankcaseoil equalization line or the oil floats.
Never interconnect the motor barrels of 06CC compres-sors, as the oil sump of these compressors are at interme-diate pressure.
06E compressors will not tolerate excessiveoil charges. Laboratory tests and fieldexperience confirm that excess oil, especiallyin 06E compressors, can cause cylinder headgaskets and valve plates to fail, increasecompressor operating temperatures, and leadto oil control problems. Page 12 notes thecorrect oil levels.
CAUTION!
Do not charge oil through the suction lineor through the compressor suction accessfittings. See the compressor figures in Section2.5 for the location of the recommended oilcharging ports. Adding oil into the suctionside of the compressor can result in oil intakedirectly into the cylinders resulting in suction/discharge valve, piston and/or connecting roddamage.
CAUTION!
15
Use only Carlyle approved oil appropriate for therefrigerant being used. Sections 3.6 and 3.7 onpages 69-72 list all the approved oils. Section 3.11 onpage 73 notes the correct oil pump pressure in relation toage of the compressor.
3. Leak test, evacuate, and dehydrate the system.
4. Charge the system. When initially charging the high sideof the system with liquid refrigerant, all service valvesshould be closed (front seated). This will preventrefrigerant from migrating to the compressor crankcaseand into the oil, causing a flooded start.
The system is now charged and ready for start-up.Recheck the oil levels and add or remove oil as neces-sary. Open (backseat) the discharge service valve andany oil equalization lines on parallel systems. Open thesuction service valve 1/2 to 1 turn, or enough to allowthe compressor to run without tripping the low-pressureswitch. This is to prevent damage to the compressorfrom any liquid refrigerant floodback.
5. On water-cooled condensing systems, open water supplyvalve and allow water to reach condenser. On air-cooledcondensing systems, turn condenser fan on when thecompressor unit is started.
6. Ensure that all evaporator connections are opened andfans started.
7. On systems with more than one compressor in parallel,start one compressor at a time.
16
COMPRESSOR START-UP
1. After circuit breaker and control circuit switches areplaced in the ON position and the compressor starts,listen for unusual sounds. If unusual sounds are heard,shut down the compressor, investigate the cause, andcorrect. Possible problems are:
• excessive vibration• excessive oil• liquid slugging• low oil
2. After the compressor has run 10 to 15 minutes and noliquid floodback is evident, completely open suctionservice valve. The other compressors within the systemshould be started in the same manner.
3. To ensure operating oil levels are within acceptablelimits, closely observe the oil level in the compressorsuntil the system has stabilized. During operation allrefrigeration systems will lose some compressor oil to thesystem because:
• All systems have a film of oil on the inside surfaceof the piping. At start-up, the lines are dry and theoil which coats the lines comes from the compressorcrankcase.
• Oil also traps in the low refrigerant velocity area ofthe system and must be made up by adding oil to thesystem. On systems with hot gas defrost, inspectthe compressor for excessive oil after the defrostcycle has been completed.
The oil lost to the system must be replaced, but take carenot to add too much. The 06E and 06CC (50 to 99 Cfm)compressors have been successfully started in supermar-ket refrigeration configurations by adding only 1 quart
17
(liter) of additional oil per compressor. The amount to beadded will vary depending on the system, but keeping theoil level between 1/8 and 3/8 level in the sight glass willeliminate the chance of excessive oil charges.
Adding excessive oil to the 06E and 06CC (50 to 99 cfm)compressors can cause blown gasket problems.
When CFC or HCFC refrigerants are used with mineralor alkylbenzene oils, foam in the sight glass normallyindicates either that there is serious liquid refrigerantfloodback or that the running gear is hitting the oil due toa very high oil level. Very high oil levels are caused byeither too much oil or excessive liquid refrigerant in thecrankcase. HFC refrigerants and POE oils do not foameasily, so there will be less indication in the sight glass ofeither liquid refrigerant floodback or too much oil in thesystem.
Liquid refrigerant should never be allowed to flood backto the compressor. It may wash out bearings and damagegaskets. If liquid floodback is occurring, adjust theexpansion valve or make other adjustments as necessaryto eliminate this condition.
NOTE: One possible cause of flooding is impropercontrol of the defrost cycle. Ensure defrost cycles arestaggered so no more than one third of the system is ondefrost at any time.
COMPRESSOR OPERATING LIMITS
Figures 1A and 1B show the components and typicaloperating ranges of the Carlyle 06D, E and 06CCcompressors.
CAUTION!
CAUTION!
18
Fig. 1A –– Typical 06D, E Operating Limits
19
Fig. 1B –– Typical 06CC Operating Limits
20
2.3 — Troubleshooting Procedures
Before attempting service work on the compressor, thefollowing safety precautions must be strictly observed.Failure to follow these instructions could result inserious personal injury or death. See Warning Label.
Follow recognized safety practices and wear protectivegoggles.
Do not operate compressor or provide electric power to thisunit unless the compressor terminal box cover is in place andsecured.
Do not provide power to unit or turn on compressor unlesssuction and discharge service valves are open.
Do not remove the compressor terminal box cover until allelectrical sources have been disconnected.
When leak-testing semi-hermetic compressors, checkaround the terminal box COVER. Test around thewire entry point(s) of the COVER because refriger-ant is likely to concentrate there. Do not remove theterminal cover to perform this leak testingbecause bodily injury or death can result from fireand/or explosion if cover is removed or unsecuredbefore power is disconnected and pressure isrelieved. Electrical terminal pins may blow out,causing injury and fire.
DANGER!
DANGER!
21
COMPRESSOR ISOLATION
If you have determined there is no refrigerant leakaround the terminals and the compressor must be replaced,proceed beginning with Step 1:
1. Shut off suction and discharge service valves to isolatecompressor and slowly remove all refrigerant in com-pressor. Appropriate service practices should be fol-lowed to properly reclaim refrigerant removed from thecompressor.
2. Disconnect all electrical wiring to compressor.
3. Unbolt suction and discharge service valves fromcompressor.
REMINDER: These valves may be sealing off refriger-ant from the rest of the system. Do not open these valveswithout first determining whether there is refrigerant inthe system.
22
Tro
ub
lesh
ooti
ng G
uid
e -
06D
,06E
an
d 0
6C
C C
om
pre
ssors
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
tratstonlliw
rosserpmoC.1
fforewoP
gniriw
dnasesuf,hcti
wsnia
mkceh
C
nepodaolrevotnerru
Cyllauna
mteseR
nepohcti
wsytefasli
Oyllauna
mteseR
gniriw
ytluafrosnoitcennoclacirtcele
esooLeri
werdna
gniriw
kcehC
.snoitcennocnethgiT
.yrassecenfi
tuodenrubroto
mrosserpmo
C.evitcefedfirosserp
mocecalper
dnatcepsnI
llupot
ytilibaniro
yticapacrosserp
mocwoL.2
metsysn
wodsnotsipro
sdorgnitcennoc
nekorBrosserp
mocecalpe
R
:ylnoC
C60roFteksag
daehrednilycroetalp
evlavn
wolB3.o
NeeS
staesevlav
nrowro
setalpevlav
ykaeLylb
messaetalp
evlavecalpe
R
sevlavnoitcus
nekorbroykaeL
enimaxe,daehrednilyc
evomer,n
wodp
muP.yrassecenfi
ecalpeR
.staesevlav
dnasevlav
,noitcusnee
wtebecnereffid
erusserpkceh
C:fi
egrahcsiddna
egatsretni
dnanoitcus
neewteb
wolsi
erusserp.aegatsretni
dnaegatsretni
neewteb
wolsi
erusserp.begrahcsid
sdaehegats
wolni
smelborprof
kcehC.a
daehegats
hgihni
smelborprof
kcehC.b
23
NOIT
AVRES
BO
ESU
AC
ELBISS
OPY
DEME
Rsteksag
daehrednilyc
roetalp
evlavn
wolB.3
deuqrotylreporpton
stlobdaeh
rednilyC
steksagecalpe
R.a:ot
stlobdaeh
rednilyceuqrote
R.b
:)mf
C14
ot61(
CC60
dnaD60
)m
N84
ot04(
bl-.tf53
ot03
:)mf
C99
ot05(
CC60
dnaE60
)m
N631
ot221(
bl-.tf001
ot09
)mf
C99
ot05(
CC60
dnaE60
nilioevissecxE
serusserprednilyc
ciluardyhsesuac
srosserpmoc
levelliolitnulioevissecxe
evome
R.athgis
ehtpu
8/3ot
8/1nee
wtebdeniatnia
Mssalg
dda,stinurosserp
mocE60
elpitlum
nO.b
enilnoitazilauqeliolerrab
rotom
liolerrabroto
ma
esutono
D:ETO
Nsrosserp
mocC
C60hti
wenil
noitazilauqe
tratsdedoolf
rokcabdoolftnaregirfer
diuqiL)gnidoolF(
7.oN
eeS
yltnettimretni
selcycrosserp
moC.4
noitareponi
citarrehcti
wserusserp-
woLro
deggolcfiees
othcti
wsot
gnibutkceh
C.a
hctiwsfo
gnittesreporp
yfireV.b
metsysnitnaregirfertneiciffusnI
tnaregirferddA
desolcevlav
ecivresnoitcuS
evlavnep
O
deggolcro
resnednochguorht
gniwolf
retawtneiciffusnI
resnednocresnednoc
otevlav
gnitalugerreta
wtsujdA.aresnednoc
naelC.b
nepoyllufton
evlavecivres
egrahcsiD
evlavnep
O
metsysni
riAegrahcer
dnamialce
R
selcycyllaunitnoc
rosserpmo
C.5statserusserp
ytluaFecalper
roriape
R
tatserusserpot
gnibutni
noitcirtserrotri
Dgnibut
naelcdna
kcehC
egrahc-revotnaregirferyb
decuderyticapac
resnednoC
erusserpegrahcsid
hgihyb
deinapmocca
tnaregirferssecxe
evome
R
reird-retlifdeggulP
retlifecalpe
R
24
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
erusserpegrahcsid
woL.6resnednoc
hguorhtwolfreta
wevissecxE
evlavgnitalugerreta
wtsujdA
desolcyllaitrap
evlavecivres
noitcuSevlav
ehtnep
O
sevlavnoitcusrosserp
mocykaeL
sevlaveni
maxe,daehrednilyceht
evomer,n
wodp
muPyrassecenfi
ecalpeR
.staesevlav
dna
sgnirnotsip
nroW
roserpmoc
ecalpeR
gnidoolF.7rosserp
mocot
diuqils
wollagnipip
metsysreporpmI
gnipiptcerroC
yltcerrocgnitarepotonrotes
ylreporpmi
elcyctsorfeD
tatsorfedno
metsysfo3/1
nahtero
mwollaton
oD
metsystsorfedfonoitareporeporp
yfireV.e
mityna
evlavnoisnapxetes
ylreporpmiro
evitcefeD
evlavecalperrotaehrepus
esaercnI
eruliafnafrotaropavE
nafecalperro
melborptcerroC
erusserpnoitcus
woL.8metsys
nitnaregirfertneiciffusnItnaregirfer
ddA
eruliafnafrotaropavE
nafecalperro
melborptcerroC
25
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
ysionrosserp
moC.9tnaregirferfo
kcabdoolfot
eudgniggulS
gnidoolF7.o
NeeS
noitalucricnilio
ssecxeot
eudkconk
ciluardyH
liossecxe
evome
R.a
sezisepip
dnametsys
nruterliokcehce
R.b
liofossolfo
esuacebdega
madsgniraeB
metsysllagni
mrifnocretfaylno(lio
ddA.a)rosserp
moceht
otdenruter
sahlio
ezisgnipip
dnametsys
nruterliokceh
C.b
dna)leveLliO
smetsySlellaraP(
51.oN
eeS.c)erusserPli
O(11.o
N
lortnoceruliaflio
evitcefedrofkceh
C.d
gnipipfonoitalosirotroppusreporp
mIbrosba
otgnipip
nisdneb
elgnathgirtneiciffusedivorP
sregnahelbatius
htiw
ylmriftroppus
dnanoitarbiv
detnuom
ylmriftonrosserp
moC
stnuom
esoolrofkceh
C
evitcefeddap
noitarbivrodetalosi
ylreporptontinU
noitalosievitcefedrof
kcehcronoitalosi
noitarbivddAsdap
raeggninnurrehtoro
sevlav,sdorgnitcennoc
nekorBrosserp
mocecalpe
R
elttarepiP.01
snoitcennocepip
esoolrognipip
detroppusyletauqedanI
snoitcennocepip
kcehcro/dnasepiptroppuS.a
etalpelffabrorelffu
mddA.b
26
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
erusserplioon
rolamron
nahtre
wolerusserpli
O.11egrahclio
woLstne
meriuqerlevellioyfireV
tnemges
evirdp
muplioytluaF
tnemges
ecalpeR
kcabdoolFtnaregirfeR
)gnidoolF(7.o
NeeS
nepokcuts
VXTgnitaehrepuse
DVXT
ecalpeR
pmuplio
nroW
ylbmessa
daehgniraeb
ecalpeR
sgniraebrosserpmoc
nroW
rosserpmoc
ecalpeR
tegrahcsidro
srotcetorproto
mrosserp
moC.21gnilcyc
rognippirt
rosneserutarep
metrosserp
mocerutarep
metwol
noerusserp
noitcushgi
Hward
pma
evissecxesesuac
noitcuselttorht,evlav
RPEevahton
seodmetsysfI
nwod
sllupmetsyslitnu
evlavecivres
erusserpegrahcsid
hgiH
resnednocdekcolb,reta
wresnednocfossolrof
kcehC
rotom
nafevitcefedro,liocro
naf
woloot
gnittesp
mapirttsu
mroyaler
daolrevotcerrocnIyaler
daolrevotcerrochti
wecalpe
R
rekaerbtiucricroyaler
daolrevoevitcefe
Decalpe
R
erutarepmet
noitcushgi
Hrotne
mtsujdaVXT
yberutarep
metnoitcus
ecudeR
gnitaehrepusededivorp
noitcennocgniri
wtiucriclortnocrorewop
esooLsnoitcennoctiucriclortnoc
dnarewoplla
kcehC
rotom
evitcefeD
rosserpmoc
ecalpeR
.trohsrodnuorgroto
mrofkceh
Cdnuoffi
ecivednoitcetorproto
mytluaF
lamreht
ehtkcehc,srosserp
mocC
C60dna
E60llan
Ofirosnes
daehecalpe
R.daehrednilyc
ehtnirosnesyrassecen
ootgnisnednoc/
woloot
noitcus(oitar
noisserpmoc
hgiH
stimil
noitacilppaevoba
erutarepmet
sagnruter:)hgih
epolevnelanoitareporosserpmoctsujdA
:ylnosrosserp
mocC
C60roFteksag
egatshgih
nwolbro
egatshgih
noevlav
nekorBrosserp
mocriapeR
gnitaehrepusedtneiciffusnIevlav
gnitaehrepusedtsujdA
27
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
rotordekcol
noselcyc
rosserpmoC.31
egatlovenil
woLfo
noitacoleni
mreteddna
egatlovenil
erusaeM
pordegatlov
dnaylb
messadaeh
gniraebevo
mer(rosserpmoc
dezieS)tfahsknarc
etatorottp
mettarosserp
mocecalpe
R
evitcefedrotomrosserp
moC
dnuorgrotrohsgnidni
wrotomrof
kcehC
gnisahpelgniS
.rotcatnoctasgel
3llassorca
egatloverusae
Mmelborpfo
ecruostcerroC
rednilycni
gnisnednoctnaregirferdiuqiL
setalpevlav
ecalperdna
kcehC
fotesdnoces
eht,srosserpmoctrats
gnidniw-trap
nO
dezigreneebton
yam
sgnidniw
ecalper-rotcatnocytluaF.a
ecalper-yaler
yaled-emit
ytluaF.b
tuonruBroto
M.41dedle
w,stcatnocretratsdedle
wrofxoblortnoctcepsnI
stnemeleretaehtuo
denrubro,stcatnocdaolrevo
.rosserpmoc
dnastnenop
mocevitcefed
ecalpeR
naelcdna
noitanimatnocroflio
dnatnaregirferkceh
Ceruliaftaepertneverp
ot
rotomro
sgniraebnro
wrofrosserpmoc
deliaftcepsnInoitani
matnoctnemtrap
mocroflio
dnatnaregirferkceh
C.rosserp
mocecalpe
Reruliaftaepertneverp
otnaelc
dnanoitani
matnoc
28
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
levellio,snoitallatsnirosserp
moclellarapn
O.61eveltnatsnoc
atania
merro
ezilauqetonseod
srosserpmoclla
ni
noitazilauqesag
gnitneverpleveltonenil
noitazilauqeliO
CC60
htiw
desuebtonnac
senilnoitazilauqeli
O:ETO
Ndesu
ebtontsum
metsystaolfA
.srosserpmoc
enilnoitazilauqelioleveL
:ylnO
srosserpmo
CE60
rotorrotom
ehtni
evlavkcehc
noitazilauqeerusserP
llaroeno
nituotfelneeb
evahya
mtlobkcol
srosserpmoc
metsystaolfhti
wderiuqerton
evlavkcehc:ET
ON
evlavkcehcrof
kooldna
evlavecivres
noitcusevo
meR
.tfahsknarcehtfo
dneehttatlob
kcolrotorrotom
nini
srosserpmoc
E60llano
deriuqersi
evlavkceh
Clellarap
enilnoitazilauqelio
ehtgnisu
smetsys
noitacolssalgthgis
ehttadetcennoc
rosevlav,sgnir
nrow-
esacknarcotni
yb-wolb
evissecxEteksag
nwolb
rosserpmocro,etalp
evlav,teksagecalpe
R
gnizisenil
noitcusreporpmI
senilezise
R
erusserpgnor
wrodab
evlavkcehcriovreserli
Oderiuqer
evlavkcehcisp
02;evlavkcehc
ecalpeR
:metsyStaolF
htiW
ssalgthgisni
dezilauqetonsili
O
staolfevitcefed
ecalpeR
.staolfkceh
C.a
sgnittesdna
snoitcelesreporprofkceh
C.b
4/3ot
4/1-C
C60mf
C73
ot61
dnaD60llA-
ssalgthgis
8/3ot
8/1-)mf
C99
ot05(
CC60
dnaE60-
ssalgthgis
neewteb
enileht,enil
noitazilauqeevah
staolffI.ctcatno
C.devo
mereb
otevah
yam
staolfeht
gnireenigneelylra
C
29
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
tohgninnur
rosserpmoC.61
teksagdaehrednilycro
etalpevlav
nwolB
)etalPevlaV
nwolB(
3.oN
eeS
evlavegrahcsidro
noitcusnekorB
yrassecenfietalp
evlavdna
sevlavecalpe
R
hgihoot
oitarnoisserp
moC
erusserpwol
dnahgihfo
gnittesreporpyfireV.a
sehctiws
gniggulpresnednocroftcepsnI.b
erasnafresnednoc
dnarotaropavellaerusnE.c
ylreporpgnitarepo
erutarepmet
noitcushgi
Hrotne
mtsujdaVXT
yberutarep
metnoitcus
ecudeR
gnitaehrepusededivorp
tcerrocnirognitarepoton
nafgnilooc
daehrednilyC
rotom
nafrofegatlov
egatlovelbaliava
yfirevrotrapevitcefed
ecalpeR
egatlovrotom
nafhti
wseerga
:ylnosrosserp
moC)
mfC
99ot
05(C
C60dna
E60
evlavfeilererusserplanretni
gnitaes-noN
yrassecenfiecalper,gnitaehrevofo
sngisrofkceh
C
levelliohgi
Hlevelliore
woL
rosevlav,sgnir
nrow-
esacknarcotni
yb-wolb
evissecxEteksag
nwolb
rosserpmocro,etalp
evlav,teksagecalpe
R
30
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
pirthcti
wsytefasli
O.71
ytpme
sraeppassalgthgisfI.a
lamron
sraeppassalgthgisfI.b
sgnitteserusserplioro
hctiws
ytluaF
gnimrifnoctsriftuohti
wmetsys
ehtotlio
ddareveN:ET
ON
ehtni
deppartylp
miston,tsolyllacisyhp
neebsahliotaht
elcyctsorfedaretfa
slevelliokceh
C.
metsys
tahtkcehc,tcerrocfI
.erusserpliorofkcehc
yllaunaM
ees(sgnittesreporp
sahdnaledo
mtcerrocsi
hctiws
)41.3noitceS,57
egap
metsyseht
nideppartli
O
raeppaya
mssalgthgis
eht,semittA
:ETO
Nlluf
yletelpmoc
sitiyllautca
nehw
ytpme
otgnizisreporprof
sresirdna
gnizisenil
kcehC.a
lionruter
dnagnittesreporprof
kcehc,desugnieb
erastaolffI.b
ytilanoitcnufreporp
esacknarcnitnaregirfer
diuqiLnruter
nachcih
wstaehrepus
wolrofkceh
C.ataehrepus
esiar-tnaregirferdiuqil
-elcyc
FFO
gnirudnoitargi
mdiuqilrof
kcehC.b
noitcetorpn
wodpmuprof
mrofa
edivorp
31
LEG
END
EPR
- Ev
apor
ator
Pre
ssur
e R
egul
ator
TXV
- The
rmos
tatic
Exp
ansi
on V
alve
NOITAVRESB
OESUAC
ELBISSOP
YDEMER
:ylnO
srosserpmoC
CC60roF
erusserpegatsdi
mhgiH.81
egatshgih
ehtnoteksag
nwolbro
evlavnekorB
teksagrosevlav
nekorbecalpe
R
erusserpegatsdi
mwoL.91
egatswol
ehtnoteksag
nwolbro
evlavnekorB
teksagrosevlav
nekorbecalpe
R
retaehrepuseD/rezimonocE.02
tohnoitcennoc
egatshgih
noevlav
nekorBsevlav
nekorbecalpe
R
teksagegats
hgihn
wolBteksag
ecalpeR
ehtslauqe
erusserpetaide
mretnI.12erusserp
egrahcsidn
wolbsiteksag
etalpevlav
egatswolretne
Cro
kcabdoolfdiuqil
yvaehyb
desuacyllacipyt(
)tratsdedoolf
teksagecalper
dnakcabdoolf
etanimilE
ecivresegrahcsid
htiw
detratsrosserpmo
Cdesolc
evlavevlav
ecivresegrahcsid
nepO
egatswol
ehtno
sietalp
evlavegats
hgiH
daehrednilyceht
nosi
etalpevlav
egatshgih
ossetalp
evlavhcti
wSdaehrednilyc
egatshgih
esoolevlavfeilerlanretnI
evlavfeilerlanretninethgiT
nwolb
evlavfeilerlanretnIevlavfeilerlanretni
ecalpeR
32
2.4 — Service Procedures
The service section covers replacement of valve platesand gaskets, service to the bearing head assemblycontaining the oil pump, and a clean-up procedure tofollow in case of motor burn out. Most other internalservice requires replacement of the compressor.
REMOVE, INSPECT AND REPLACE CYLINDERHEAD AND VALVE PLATE ASSEMBLY
To test for leaking discharge valves or blown cylinderhead or valve plate gaskets:
1. Pump compressor down.
2. Observe suction and discharge pressure equalization.If valves are leaking or a gasket is blown, thepressure will equalize rapidly.
Maximum allowable discharge pressure drop is 3 psiper minute after initial drop of 10 to 15 psi in firsthalf minute.
New reed valves may require 24 to 48 hour run-intime to seat completely.
A compressor bank (head) with a blown gasket canalso usually be detected by touch since the headtemperature will normally be much hotter than a bankwith good gaskets.
3. If there is an indication of loss of capacity, anddischarge valves are functioning properly, removevalve plate assembly and inspect suction valves.
NOTE: This test procedure is not applicable tocompressors equipped with pressure actuatedunloader valves due to rapid pressure equalizationrate. Inspect suction and discharge valves by disas-sembling valve plate.
33
DISASSEMBLY
1. Disassemble cylinder heads by first loosening cylinderhead bolts. Leave at least 2 bolts partially threaded toprevent any problems if refrigerant is accidentally left inthe compressor under pressure. To separate the cylinderhead from the valve plate, pry up between the head andvalve plate. When the cylinder head is separated fromthe compressor body remove the last threaded bolts.
Do not hit the cylinder head to break it free of thevalve plate. This may shear the valve plate dowelpins. Sheared dowel pins usually require that thecompressor be replaced.
2. Inspect cylinder heads for warping, cracks, or damage togasket surfaces. Replace if necessary.
3. After the cylinder head is off, the valve plate may beremoved as follows:
a. Remove one valve stop cap screw and loosen theother.
b. Swivel valve stop to allow access to hole fromwhich the cap screw was removed.
c. Re-insert cap screw and tighten to break valve plateaway from compressor. (Jack screw method, seeFig. 2.) For 06E valve plates, pry against the raisedtab to break valve plate away from the compressor.
CAUTION!
34
4. Pry up along sides of valve plate to remove valve platefrom crankcase. This provides access to suction reedvalves (see Fig. 3). Remove suction valves from dowelpins. On 06D and 06CC (16 to 37 Cfm) compressors,also remove the suction valve positioning springs (seeFig. 4).
5. Inspect components for wear or damage. If replacementis necessary, replace as a complete assembly. Individualparts must not be interchanged. Alignment of highefficiency discharge valves is critical for proper seating.See Sections 3.27 to 3.29, pages 84-87 for applicablereplacement valve plate packages.
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. If reassembling existing components, do not interchangevalves or turn them over. They must be reassembled intheir original position. Install the suction valve posi-tioning springs (06CC size 16 to 37 Cfm and 06Dcompressors only) on dowel pins. Assemble positioningsprings with spring ends bearing against cylinder deck(Fig. 4), spring bow upward.
2. Install suction valve on dowel pins as follows:
a. 06D compressors: install suction valves on top ofpositioning springs as mentioned in Step 1 above.
b. 06E compressors: if compressor uses a suctionvalve and a backer valve (looks like a 1/2 a suctionvalve), backer valve must be installed beforeinstalling full size suction valve (Fig. 5).
Fig. 5 –– Piston, Suction Valve, and BackerPositions (06E)
37
3. Install new valve plate gasket. Using proper hold-downtorque will prevent leaks.
a. Fiber gaskets can be installed dry or lightly oiled. Donot soak gaskets in oil. If an oil-soaked gasket isoverheated, it will bind to the metal, making the valveplate and/or the head difficult to remove.
b. Metal gaskets must be installed dry.
4. Place valve plate on cylinder deck.
5. Install cylinder head gasket.
NOTE: The center cylinder heads and unloader sideheads use different gaskets from the plain side head. Toconfirm the gasket is correct, place it over the cylinderhead and verify all exposed machined surfaces will becovered by the gasket.
a. Line up the gasket with the cylinder head and valveplate.
b. 06E compressor: secure the center rib with a cap screwand washer and torque to 4 to 6 ft-lbs. (5 to 8 Nm).
6. Replace cylinder head. To prevent high to low side leak incenter of cylinder head gasket, torque 06D cylinder headcap screws to 30 to 35 ft-lbs. (40 to 48 Nm), and 06Ecylinder head cap screws to 90-100 ft-lbs. (122 to 136 Nm).
NOTE: Torque bolts in an alternating sequence pattern(top to bottom, left to right). Do not torque bolts in acircular pattern.
38
7. Certain high compression ratio applications develophigh discharge gas temperatures which may cause thecylinder head and fiber valve plate gaskets to develop aset. Under these conditions the cap screws may losehold-down torque. It is recommended that all gear capscrews be re-torqued 24 hours after new fiber gasketsare installed.
NOTE: Compressors with metal core gaskets do notrequire re-torque.
REMOVE, INSPECT AND REPLACE BEARING HEADASSEMBLY
An oil pressure tap is located in the bearing head assemblyused on all 06D refrigeration duty, newer 06D A/C duty, andall 06E refrigeration and A/C duty compressors (Fig. 6 andFig. 7).
For 06D, E, CC oil pressure, see page 73, Section 3.11.
The oil pump assembly is contained in the pump end bearinghead aluminum casting. The pump end main bearing is amachined part of this casting. No insert bearing is required.
39
1. a. To disassemble, first remove four (4) cap screws from the bearing head cover plate and remove the oil feed guide vane and spring.
b. Remove the two (2) drive segment cap screws from the end of the crankshaft (see Fig. 6 and Fig. 7). These screws must be removed before the bearing head can be removed.
2. Remove the eight (8) cap screws holding the bearing headassembly to the crankcase. Remove the bearing headassembly by pulling forward.
Fig. 6 –– Removing Pump End Bearing Head(06D Compressor)
40
3. Inspect the bearing surfaces for evidence of wear ordamage. If bearing surface is worn or scored, or if the oilpump is defective, the complete bearing head must bereplaced (see replacement bearing head package listedbelow).
rosserpmoC egakcaPdaeHgniraeBtnemecalpeR
D60lladna,mfC73ot61,CC60 621066AD60
E60lladna,mfC99ot05,CC60 751066AE60
While bearing head is removed, inspect internal runninggear for obvious problems (broken rods or pistons).
Fig. 7 –– Removing Pump End Bearing Head(06E Compressor)
41
4. To reassemble, bolt the bearing head to the crankcase.Bolt torque:
• 06CC, 16 to 37 Cfm, and all 06D: 30 to 35 ft-lb.(40 to 48 Nm)
• 06CC, 50 to 99 Cfm, and all 06E: 55 to 60 ft-lb.(75 to 81 Nm)
5. Bolt the drive segment (replace if worn) to the crank-shaft. Bolt torque:
• No. 10 Screw: 4 to 6 ft-lb. (5 to 8 Nm)• 1.4 in. (6 mm) screw: 12 to 15 ft-lb. (16 to 20 Nm)
IMPORTANT: The 1/4 in. snorkle tube should faceaway from the crankshaft (Fig. 6).
6. Insert the oil feed guide vane with the large diameterinward. Place the oil feed vane spring over smalldiameter of guide vane (do not install spring beforeinstalling guide vane). Install pump cover plate (bolttorque: 16 to 20 ft-lb. or 22 to 27 Nm).
NOTE: Do not over-torque or aluminum threads inbearing head could be stripped.
42
MOTOR BURNOUT CLEAN-UP PROCEDUREWhen a hermetic motor burns out, the stator winding decomposes andforms carbon, water, and acid, which contaminate refrigerant systems.These contaminants must be removed from the system to prevent repeatmotor failures. See Carlyle/Carrier recommendation procedures for clean-up after burnout in semi-hermetic compressors - form #06DA604782.
Before attempting service work on the compressor, see safetyprecautions listed in Section 2.3, pages 20 to 31, and on compressorterminal box cover. Also follow any installation instructionsprovided with the replacement compressor. Failure to follow theseinstructions could result in equipment damage or seriouspersonal 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 damagedterminals 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 removethe refrigerant from the compressor using environmentallyapproved methods. Leave remaining refrigerant in system.
3. Remove damaged compressor and replace.
a. Remove suction and discharge shut-off valve bolts and allother connections to damaged compressor.
b. Remove damaged compressor and replace with a newcompressor.
c. On severe motor burnouts, be sure shut-off valves and suctionor discharge lines are not contaminated. If contaminated, they
WARNING!
43
should be thoroughly cleaned or replaced before connecting toreplacement compressor.
4. Install new liquid line filter-drier. If the system has a suction linefilter-drier, replace the core.
5. Evacuate and dehydrate replacement compressor. Ensure oil incompressor is at the proper level.
NOTE: Since most new and service compressors are now shippedwithout oil in the crankcase, you must check to see if there is oil.Adding or charging oil is usually easier prior to installing thecompressor.
• If there is no oil, add the appropriate oil for the service. Oilcharges 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 removethe oil. Dispose of the removed oil following the appropriateenvironmental guidelines. Since the compressor has not beenrun, a thorough draining is all that is needed to remain withinthe limits of residual oil levels. There is no need to “flush” thecompressor 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 showssigns of contamination, replace oil and filter-driers and clean thesuction strainer.
NOTE: When testing for moisture and acidity be sure the test kitused is appropriate for the refrigerant (CFC, HCFC, or HFC) andthe oil (mineral, alkylbenzene, or POE) in the system. Carrier’sTotal Test Kit is accurate for CFC and HCFC air-conditioningapplications. If used with POE oils, Total Test Kit will indicateacid, but is not an accurate indicator of moisture.
7. Inspect oil daily for discoloration and acidity. If oil stays clean andacid-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 untilsystem is cleaned.
44
2.5 –– Connection Points, - 06D, 06E, and 06CCCompressors
NOTE: Bolt sizes and thread pitch: Compressors are built using Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, 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 preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, 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 Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, 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 Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, 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 Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, comparable metric measurements are not included.
49
NOTE: Bolt sizes and thread pitch: Compressors are built using Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, 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 Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, 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 Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, comparable metric measurements are not included.
Fig. 14B –– 06CC Compressor (16 to 37 Cfm), 06D BodyMotor End Connection Points
52
NOTE: Bolt sizes and thread pitch: Compressors are built using Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, comparable metric measurements are not included.
Fig. 15A–– 06CC Compressor (50 to 99 Cfm), 06E BodyPump End Connection Points
53
NOTE: Bolt sizes and thread pitch: Compressors are built using Englishunit bolts. The bolts have no exact metric equivalents. Therefore, to preventpossible cross-threading, loose bolts, or damage to threaded portions of thecasing, comparable metric measurements are not included.
Fig. 15B –– 06CC Compressor (50 to 99 Cfm), 06E BodyMotor End Connection Points
54
2.6
–– C
ross
-Sec
tion
al V
iew
, 06D
Sem
i-H
erm
etic
Com
pres
sor
55
2.7
–– C
ross
-Sec
tion
al V
iew
, 06E
Sem
i-H
erm
etic
Com
pres
sor
56
2.8
–– E
xplo
ded
Vie
w –
6-C
ylin
der
06D
Com
pres
sor
Com
plet
e pa
rts
brea
kdow
n sh
own
for
refe
renc
e on
ly.
Som
epa
rts
may
be
pict
ured
prio
r to
des
ign
chan
ges
and
not a
llpa
rts
are
avai
labl
e as
repl
acem
ents
.
LE
GE
ND
2
–Te
rmin
al B
ox C
over
3
–Te
rmin
al B
ox
4–
Term
inal
Pla
te A
ssem
bly
9
–G
rom
met
(fo
r po
wer
lead
s) 1
4–
Suc
tion
Ser
vice
Val
ve 1
5–
Suc
tion
Ser
vice
Val
ve S
eal C
ap 1
6–
Suc
tion
Ser
vice
Val
ve G
aske
t 1
7–
Suc
tion
Ser
vice
Val
ve B
olt
18
–S
uctio
n S
ervi
ce V
alve
Bol
t Was
her
19
–D
isch
arge
Ser
vice
Val
ve 2
0–
Dis
char
ge S
ervi
ce V
alve
Sea
l Cap
21
–D
isch
arge
Ser
vice
Val
ve G
aske
t 2
2–
Dis
char
ge S
ervi
ce V
alve
Bol
t 2
3–
Dis
char
ge S
ervi
ce V
alve
Bol
t Was
her
29
–S
tand
ard
Sid
e B
ank
Cyl
inde
r H
ead
57
30
–C
ente
r B
ank
Cyl
inde
r 3
1–
Sta
ndar
d S
ide
Ban
k C
ylin
der
Hea
dG
aske
t (U
nloa
der
Sid
e B
ank
Hea
d no
t sho
wn)
33
–C
ente
r B
ank
Cyl
inde
r H
ead
Gas
ket
34
–C
ylin
der
Hea
d C
ap S
crew
35
–C
ylin
der
Hea
d C
ap S
crew
Gas
ket
36
–O
il F
ilter
Scr
een
Ass
embl
y 3
7–
Oil
Suc
tion
Tub
e 3
8–
Oil
Rel
ief V
alve
Ass
embl
y 4
0–
Oil
Leve
l Sig
ht G
lass
Ass
embl
y 4
1–
Oil
Leve
l Sig
ht G
lass
Gas
ket
44
–M
otor
End
Cov
er 4
5–
Mot
or E
nd C
over
Gas
ket
46
–M
otor
End
Cov
er C
ap S
crew
47
–M
otor
End
Cov
er C
ap S
crew
Was
her
48
–B
otto
m C
over
Pla
te 4
9–
Bot
tom
Pla
te G
aske
t 5
0–
Bot
tom
Pla
te C
ap S
crew
51
–B
otto
m P
late
Cap
Scr
ew W
ashe
r 5
2–
Com
pres
sor
Foo
t 5
3–
Com
pres
sor
Foo
t Scr
ew 5
4–
Com
pres
sor
Foo
t Eve
rlock
was
her
55
–S
uctio
n S
trai
ner A
ssem
bly
56
–O
il B
ypas
s P
lug
57
–O
il R
etur
n C
heck
Val
ve A
ssem
bly
58
–P
ump
End
Bea
ring
Hea
d A
ssem
bly
59
–B
earin
g H
ead
60
–P
ump
Rot
or 6
4–
Pum
p R
otor
Ret
aini
ng R
ing
66
–D
rive
Seg
men
t 6
7–
Oil
Fee
d G
uide
Van
e 6
8–
Oil
Fee
d V
ane
Spr
ing
69
–C
over
Pla
te 7
0–
Cov
er P
late
Cap
Scr
ew 7
1–
Cov
er P
late
Cap
Scr
ew G
aske
t 7
2–
Cov
er P
late
Gas
ket
73
–B
earin
g H
ead
Gas
ket
74
–C
ap S
crew
s &
Loc
kwas
hers
75
–C
ap S
crew
s &
Loc
kwas
hers
76
–C
ap S
crew
s &
Loc
kwas
hers
77
–C
ap S
crew
s &
Loc
kwas
hers
78
–B
earin
g H
ead
Cap
Scr
ew 7
9–
Bea
ring
Hea
d C
ap S
crew
Was
her
80
–C
rank
shaf
t 8
1–
Thr
ust W
ashe
r 8
2–
Spi
rol P
in 8
3–
Rot
or D
rive
Key
84
–R
otor
Was
her
85
–R
otor
Loc
kwas
her
86
–E
qual
izer
Tub
e A
ssem
bly
87
–P
isto
n A
ssem
bly
91
–O
il R
ing
(Not
All
Mod
els)
92
–C
ompr
essi
on R
ing
93
–C
onne
ctin
g R
od &
Cap
Ass
embl
y 9
4–
Con
nect
ing
Rod
Cap
Scr
ew 9
6–
Suc
tion
Val
ve 9
7–
Suc
tion
Val
ve P
ositi
onin
g S
prin
g 9
8–
Dis
char
ge V
alve
99
–D
isch
arge
Val
ve S
top
100
–V
alve
Pla
te G
aske
t10
1–
Dis
char
ge V
alve
Sto
p C
ap S
crew
102
–D
isch
arge
Val
ve S
top
Lock
was
her
103
–V
alve
Pla
te D
owel
104
–O
il D
rain
Plu
g, (
New
Des
ign
SA
EF
ittin
g an
d O
-Rin
g)
58
2.9
–– E
xplo
ded
Vie
w –
6-C
ylin
der
06E
Com
pres
sor
Com
plet
e pa
rts
brea
kdow
n sh
own
for
refe
renc
e on
ly.
Som
epa
rts
may
be
pict
ured
prio
r to
des
ign
chan
ges
and
not a
llpa
rts
are
avai
labl
e as
repl
acem
ents
.
LE
GE
ND
1–
Com
pres
sor
Mot
or –
Sta
tor
and
Rot
or 2
–M
otor
Key
3–
Rot
or P
late
Was
her
4–
Rot
or L
ock
Was
her
5–
Rot
or L
ock
Bol
t 6
–M
otor
Loc
k B
ushi
ng 7
–R
oll P
in 8
–A
corn
Nut
and
Gas
ket
59
10–
Term
inal
Box
Ass
embl
y12
–Te
rmin
al P
late
Ass
embl
y14
–Te
rmin
al B
olt A
ssem
bly
18–
Com
pres
sor
Cra
nkca
se19
–M
otor
End
Cov
er20
–C
ylin
der
Hea
d -
Cen
ter
Ban
k21
–C
ylin
der
Hea
d -
Sid
e B
ank
(Unl
oade
r H
ead
Not
Sho
wn)
22–
Inte
rnal
Rel
ief V
alve
23–
Cra
nkca
se O
il F
ilter
Scr
een
24–
Oil
Sig
ht G
lass
Ass
embl
y25
–O
il S
ight
Gla
ss “
O”
Rin
g G
aske
t26
–O
il S
ight
Gla
ss S
crew
27–
Oil
Sig
ht G
lass
Loc
k W
ashe
r28
–P
ipe
Plu
g G
aske
t (H
ex H
ead)
29–
Bot
tom
Cov
er P
late
30–
Pum
p E
nd B
earin
g H
ead
Ass
embl
y31
–P
ump
Rot
or32
–P
ump
Van
e33
–P
ump
Van
e S
prin
g34
–P
ump
Van
e S
prin
g G
uide
35–
Ret
aini
ng S
prin
g G
uide
36–
Oil
Fee
d G
uide
Van
e37
–O
il F
eed
Gui
de V
ane
Spr
ing
38–
Oil
Pum
p D
rive
Seg
men
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
(O
il an
d C
ompr
essi
on)
47–
Pis
ton,
Pis
ton
Pin
and
Ret
aini
ng R
ing
Ass
embl
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
Sup
port
54–
Cap
Scr
ew, V
alve
Sto
p55
–S
uctio
n V
alve
(B
acke
rs F
or A
/C M
odel
s N
ot S
how
nse
e F
ig. 5
, pag
e 36
)56
–C
heck
Val
ve (
Use
Onl
y w
ith P
aral
lel C
ompr
esso
rIn
stal
latio
ns)
60
2.10 – Torque Guide – All 06D and 16 to 37 Cfm 06CCCompressors
(CC) - Compound cooling compressors onlyNM - Newton meter (metric torque rating)SAE - Society of Automotive Engineers* See Fig 17 page 111 for jam locations
NOTE: Bolt sizes and thread pitch: Compressors are built using English unit bolts. The bolts have noexact metric equivalents. Therefore, to prevent possible cross-threading, loose bolts, or damage tothreaded portions of the casing, comparable metric measurements are not included.
EZISRETEMAID
).ni(
SDAERHTHCNIREP
EUQROTEGNAR)BL-TF(
EUQROTEGNAR
)MN(EGASU
61/1 epiP 21-8 61-11 tfahsknarcgulpepiP
8/1 epiP 01-6 41-8 evlavkcehcnruterliO
01.oN 23 6-4 8-5 tnemgesevirdpmupliO
4/1 epiP 52-02 43-72 gulpepiP
4/1 02 21-01 61-41 wercspacdor-noC
4/1 82 51-21 02-61
tfahsknarcetalpelffaBdleihsediS
tnemgesevirdpmupliOredaolnU
61/5 81
02-6102-6102-6102-6102-6102-6152-0252-02
72-2272-2272-2272-2272-2272-2243-7243-72
daehgniraebetalprevoCwercspacetalplanimreT
)CC(teltuoegatsretnI)CC(dlofinamegatsretnI
)CC(noitcejnidiuqiL)CC(dlofinamnoitcuS
evlavecivresnoitcuSevlavecivresegrahcsiD
8/3 61 53-03 84-04
esacknarc,daehgniraeb.E.Pesacknarc,etalpmottoB
toofrosserpmoCdaehrednilyC
esacknarc,revocdnerotoM
8/3 EAS-42 21-6 61-8kcolc'O-01tadaehgniraeb.E.P
noitisopgnittifelbasudleifatoN:ETON
61/7 41 06-55 18-57 esacknarc,revocdnerotoM
61-7 EAS-02 21-6 61-8 etalprevocmottobno,niardliOD60lyc-6dna)mfC02-81(lyc-4
2/1 02 21-01 61-41 rotalugererusserpliO
2/1 31 09-08 221-901 evlavecivresnoitcuS
8/5 11 03-52 04-43 ylbmessaebutrennipsnoitazilauqE
2/1-1 81 54-53 16-84 ssalgthgislevelliO
Torque for jam nut #3 is for compressors manufacturedafter 0203J---. For compressors built before this,jumper bar must be under jam nut #3 or Loctite #089applied to jam nut #2, or use 12 ft. lb.
61
2.11 – Torque Guide – 06E and 06CC (50 to 99 Cfm)Compressors
See Table 2.10 for Notes and Legend (page 60).
EZISRETEMAID
).ni(
SDAERHTHCNIREP
EUQROTEGNAR)BL-TF(
EUQROTEGNAR
)MN(EGASU
61/1 epiP 21-8 61-11 tfahsknarcgulpepiP
8/1 epiP 21-01 61-41 esacknarcecifirO
01.oN 23 6-4 8-5 tnemgesevirdpmupliO
4/1 02 21-015.2-5.1
61-413-2
wercspacdor-noCetalplanimretwercstesdaelrotoM
4/1 82
5-36-4
51-2151-2151-2151-21
7-48-5
02-6102-6102-6102-61
ssalgthgiSwercsbatteksagdaehrednilyC
xoblanimreTevlavredaolnU
potsevlavegrahcsiDtnemgesevirdpmupliO
61/5 81 02-6152-02
72-2243-72
daehgniraebetalprevoC).lyc-4(evlavecivresegrahcsiD
8/3 61
5-3381
02-0153-0353-0353-03
7-4452
71-4184-0484-0484-04
*1#tunmajtsoplanimreT*2#tunmajtsoplanimreT*3#tunmajtsoplanimreT
daehgniraebgulpliOesacknarc,etalpmottoB
toofrosserpmoCkcolblanimreT
8/3 EAS-42 21-8 61-11 kcolC'O01tadaehgniraeB.E.Pnoitisop
8/5 EAS-81 04-52 45-72 lerrabrotomrednutropsseccA
61/7 41 06-5506-55
18-5718-57
esacknarc,revocdnerotoMesacknarc,daehgniraeB
61/7 EAS-02 21-8 61-11 etalpmottobno,niardliO
2/1 31
09-0809-0809-08001-58001-58001-58
221-901221-901221-901631-511631-511631-511
).lyc-6(evlavecivresegrahcsiD)CC(teltuoegatsretnI
)8/51(evlavecivresnoitcuS)CC(dlofinamegatsretnI
)CC(dlofinamnoitcuSdaehrednilyC
2/1 epiP 04-03 45-04 rosnesdaehrednilyC
8/5 11 03-52001-09
04-43631-221
tfahsknarckcolrotoR)8/12(evlavecivresnoitcuS
4/3 61 06-05 18-86 tunnrocakcolrotatS
8/11 81 04-03 45-04 evlavfeilererusserP
62
3.0
– C
OM
PR
ESS
OR
AN
D P
AR
TS
DA
TA
3.1
– 06
D S
erie
s C
ompr
esso
rs –
Phy
sica
l Dat
a (p
age
1 of
2)
* Cyl
inde
r hea
d fa
n re
quire
d at
SST
of -
20 D
eg. F
. (-2
9 de
g. 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 de
g. C
.) an
d be
low
for R
-22.
(a) A
ppro
xim
ate
cond
ensi
ng te
mpe
ratu
re ra
nges
. C
HEC
K AC
TUAL
PER
FOR
MAN
CE
DAT
A FO
R A
NY
NEW
APP
LIC
ATIO
N,
ESPE
CIA
LLY
AT O
R N
EAR
UPP
ER O
R L
OW
ER L
IMIT
: L.T
.=70
to 1
20 D
eg.F
. (21
to 4
9 D
eg.C
.), M
.T.=
80 to
130
Deg
.F.
(27
TO 5
4 D
eg.C
.) an
d H
.T. (
R-2
2 on
ly) =
80
TO 1
50 D
eg.F
. (27
to 6
6 D
eg.C
.).(b
) The
06D
R 1
09 s
ingl
e ph
ase
com
pres
sor h
as a
3 H
P (2
.2 k
W) m
otor
.(c
) Ser
vice
com
pres
sors
hav
e du
al s
uctio
n se
rvic
e va
lve
loca
tions
, one
on
mot
or e
nd a
nd o
ne n
ear t
he o
il pu
mp.
† † † † † † † † † †
† † † † † † † † † †
/REIRRACELYLRAC
LEDO
MREB
MUN
DRADNATSECIVRES
TNEMECALPERLED
OM
)a(...E
GNARERUTAREP
METN
OITCUS
205-R&
705/A404-R21-R
&a431-R
22-R
F.geDC.geD
F.geDC.geD
F.geDC.geD
...0808M
D60...0901
RD60
...0310R
D60...0313
MD60
...0613R
D60...0613
MD60
...0817R
D60...2818A
D60...0028
RD60
...0427R
D60...0527
RD60
...2428AD60
...2528AD60
...0822R
D60...2823A
D60...0733
RD60
...0733M
D60...2735A
D60...0145
RD60
...6808M
D60)b(...6901
RD60
)c(...6310R
D60)c(...6313
MD60
)c(...6613R
D60)c(...6613
MD60
...6817R
D60...6818A
D60...6028
RD60
...6427R
D60...6527
RD60
...6428AD60
...6528AD60
...6822R
D60...6823A
D60...6733
RD60
...6733M
D60...6735A
D60...6145
RD60
05ot
0*0
ot04-
*0ot
04-05
ot0
*52ot
04-52
ot0
*0ot
04-05
ot0
*04ot
04-*52
ot04-
*52ot
04-05
ot0
05ot
0*52
ot04-
05ot
0*52
ot04-
52ot
005
ot0
*52ot
04-
01ot
81-*81-
ot04-
*81-ot
04-01
ot81-
*4-ot
04-4-
ot81-
*81-ot
04-01
ot81-
*4ot
04-*4-
ot04-
*4-ot
04-01
ot81-
01ot
81-*4-
ot04-
01ot
81-*4-
ot04-
01ot
81-01
ot81-
*4-ot
04-
-55
ot01-
55ot
01--
55ot
01-55
ot01-
55ot
01--
55ot
01-55
ot01-
55ot
01-- -
55ot
01--
55ot
01-55
ot01-
- -
-31
ot32-
31ot
32--
31ot
32-31
ot32-
31ot
32--
31ot
32-31
ot32-
31ot
32-- -
31ot
32--
31ot
32-31
ot32-
- -
55ot
00
ot53-
0ot
53-54
ot0
52ot
53-54
ot0
0ot
53-55
ot0
52ot
04-52
ot04-
52ot
04-55
ot0
55ot
052
ot04-
55ot
052
ot04-
54ot
055
ot0
52ot
04-
31ot
81-81-
ot73-
81-ot
73-7
ot81-
4-ot
73-7
ot81-
81-ot
73-31
ot81-
4-ot
04-4-
ot04-
4-ot
04-31
ot81-
31ot
81-4-
ot04-
31ot
81-4-
ot04-
7ot
81-31
ot81-
4-ot
04-
63
3.1
– 06
D S
erie
s C
ompr
esso
rs –
Phy
sica
l Dat
a (p
age
2 of
2)
/REIRRACELYLRAC
LEDO
MREB
MUN
ROT
OM
EZISTNE
MECALPSIDMPR
0571tA.
ONF
OLYC
EROB
EKORTS
LIO
EGRAHC
TENTH
GIEW
PHWk
MFCM/L
HFCH/L
)000,(.ni
mm
.nim
mstniP
sretiLbL
gK
...0808M
D60...0901
RD60
...0310R
D60...0313
MD60
...0613R
D60...0613
MD60
...0817R
D60...2818A
D60...0028
RD60
...0427R
D60...0527
RD60
...2428AD60
...2528AD60
...0822R
D60...2823A
D60...0733
RD60
...0733M
D60...2735A
D60...0145
RD60
3)b(
23 5 5 5 5
2/16
2/16
2/16
2/16
2/17
2/17
2/17
01 01 01 51 51
2.25.12.27.37.37.37.39.49.49.49.46.56.56.55.75.75.72.112.11
0.87.80.310.319.519.513.813.81
029.329.329.329.32
82 821.731.731.730.14
7226428638630540548158156657767767767763973970501050105011611
0842256876874594590011001100215341534153415341086108615222522252220642
95.3187.4162.2262.2210.7210.7290.1390.1300.3306.0406.0406.0406.0475.7475.7430.3630.3630.3666.96
2 2 4 4 4 4 4 4 4 6 6 6 6 6 6 6 6 6 6
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
8.058.058.058.058.058.058.058.058.058.058.058.058.058.058.058.058.058.058.05
4/11
8/31
1 14/1
14/1
161/7
161/7
161/9
14/1
14/1
14/1
14/1
123/51
123/51
161/51
161/51
161/51
123/5
2
8.139.434.524.528.138.135.635.637.938.138.138.138.133.733.732.942.942.946.45
3 32/1
42/1
42/1
42/1
42/1
52/1
52/1
58 8 8 8 8 8 8 8 8 8
4.14.11.21.21.21.26.26.26.28.38.38.38.38.38.38.38.38.38.3
061091032532532532052052062013513013513513513523523523523
37 37401701701701311311811141341141341341341741741741741
64
* Cyl
inde
r hea
d fa
n re
quire
d at
SST
of -
20 D
eg. F
. (-2
9 de
g. 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 de
g. C
.) an
d be
low
for R
-22.
(a) A
ppro
xim
ate
cond
ensi
ng te
mpe
ratu
re ra
nges
. C
HEC
K AC
TUAL
PER
FOR
MAN
CE
DAT
A FO
R A
NY
NEW
APP
LIC
ATIO
N,
ESPE
CIA
LLY
AT O
R N
EAR
UPP
ER O
R L
OW
ER L
IMIT
: L.T
.=70
to 1
20 D
eg.F
. (21
to 4
9 D
eg.C
.), M
.T.=
80 to
130
Deg
.F.
(27
TO 5
4 D
eg.C
.) an
d H
.T. (
R-2
2 on
ly) =
80
TO 1
50 D
eg.F
. (27
to 6
6 D
eg.C
.).(d
) The
mod
els
show
n ar
e ne
w o
il-le
ss m
odel
s. M
odel
s w
ith o
il ha
d a
0, 1
or 2
in th
e 5t
h di
git o
f the
mod
el n
umbe
r.(e
) The
06E
R16
6 an
d 06
EM26
6 m
odel
s ar
e no
long
er b
uilt
new
, but
ser
vice
repl
acem
ents
are
bui
lt an
d av
aila
ble.
For
new
app
licat
ions
, the
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 S
erie
s C
ompr
esso
rs –
Phy
sica
l Dat
a (p
age
1 of
2)
† † † † †
† † † † †
REIRRACELYLRAC
LEDO
M)d(...
REBMUN
DRADNATSECIVRES
TNEMECALPERLED
OM
)a(...E
GNARERUTAREP
METN
OITCUS
205-R&
705/A404-R21R
&a431-R
22-R
F.geDC.geD
F.geDC.geD
F.geDC.geD
...054RE60
...054ME60
...055AE60)e(...661
RE60)e(...662
ME60...564
RE60...565AE60...574
RE60...574
ME60...575AE60...993
RE60...994
ME60...995AE60
...054YE60...054ZE60...052TE60...664YE60...662ZE60...564YE60...562TE60...574YE60...574ZE60...572TE60...993YE60...994ZE60...992TE60
*0ot
04-52
ot0
05ot
00
ot04-
*54ot
0*0
ot04-
05ot
0*0
ot04-
04ot
005
ot0
*0ot
04-04
ot0
05ot
0
*81-ot
04-4-
ot81-
01ot
81-*81-
ot04-
7ot
81-*81-
ot04-
01ot
81-*81-
ot04-
4ot
81-01
ot81-
*81-ot
04-4
ot81-
01ot
81-
55ot
01-55
ot01-
-55
ot01-
55ot
01-55
ot01-
55ot
01-55
ot01-
55ot
01--
55ot
01-55
ot01-
-
31ot
32-31
ot32-
-31
ot32-
31ot
32-31
ot32-
31ot
32-31
ot32-
31ot
32--
31ot
32-31
ot32-
-
0ot
53-54
ot0
55ot
00
ot53-
05ot
00
ot53-
55ot
00
ot53-
54ot
055
ot0
0ot
53-54
ot0
55ot
0
81-ot
73-7
ot81-
31ot
81-81-
ot73-
01ot
81-81-
ot73-
31ot
81-81-
ot73-
7ot
81-31
ot81-
81-ot
73-7
ot81-
31ot
81-
65
3.2
– 06
E S
erie
s C
ompr
esso
rs –
Phy
sica
l Dat
a (p
age
2 of
2)
/REIRRACELYLRAC
LEDO
MREB
MUN
ROT
OM
EZISTNE
MECALPSIDMPR
0571tA.
ONF
OLYC
EROB
EKORTS
LIO
EGRAHC
TENTH
GIEW
PHWk
MFCM/L
HFCH/L
)000,(.ni
mm
.nim
mstniP
sretiLbL
gK
...054RE60
...054ME60
...055AE60)e(...661
RE60)e(...662
ME60...564
RE60...565AE60...574
RE60...574
ME60...575AE60...993
RE60...994
ME60...995AE60
51 51 02 02 52 02 52 02 52 03 03 53 04
2.112.119.419.416.819.416.819.416.814.224.221.628.92
3.053.053.050.660.663.863.864.574.574.570.990.990.99
4241424142419681968143914391531253125312308230823082
6103610361030693069369046904425442544254049504950495
54.5854.5854.581.2111.2110.6110.6111.8211.8211.8212.8612.8612.861
4 4 4 4 4 6 6 6 6 6 6 6 6
61/112
61/112
61/112
61/112
61/112
61/112
61/112
61/112
61/112
61/112
61/112
61/112
61/112
3.863.863.863.863.863.863.863.863.863.863.863.863.86
61/32
61/32
61/32
8/72
8/72
46/361
46/361
61/32
61/32
61/32
8/72
8/72
8/72
6.556.556.550.370.374.054.056.556.556.550.370.370.37
41 41 41 41 41 91 91 91 91 91 91 91 91
6.66.66.66.66.60.90.90.90.90.90.90.90.9
034034034034034084584094094094005505025
591591591591591812022222222222722922632
66
3.3
– 06
CC
Ser
ies
Com
pres
sors
– P
hysi
cal D
ata
(pag
e 1
of 2
)
(f) A
ppro
xim
ate
cond
ensi
ng te
mpe
ratu
re ra
nges
. C
HEC
K AC
TUAL
PER
FOR
MAN
CE
DAT
A FO
R A
NY
NEW
APP
LIC
ATIO
N,
E
SPEC
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. T
he
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.
REIRRACELYLRAC
LEDO
MREB
MUN
DRADNATSECIVRES
TNEMECALPERLED
OM
)f(...E
GNARERUTAREP
METN
OITCUS
705/A404-RA431-R
22-R
)h(F.geD)h(C.geD
F.geDC.geD
F.geDC.geD
)g(...610C
C60)g(...810
CC60
...421C
C60...521
CC60
...822C
C60...733
CC60
)g(...055C
C60...566
CC60
...576C
C60...998
CC60
...610YC60
...810YC60
...421YC60
...521YC60
...822YC60
...733YC60
...055YC60
...566YC60
...576YC60
...998YC60
01-ot
04-01-
ot04-
01-ot
06-01-
ot06-
01-ot
06-01-
ot06-
01-ot
04-01-
ot06-
01-ot
06-01-
ot06-
32-ot
04-32-
ot04-
32-ot
15-32-
ot15-
32-ot
15-32-
ot15-
32-ot
04-32-
ot15-
32-ot
15-32-
ot15-
)i( )i( )i( )i( )i( )i( )i( )i( )i( )i(
)i( )i( )i( )i( )i( )i( )i( )i( )i( )i(
01-ot
04-01-
ot04-
01-ot
04-01-
ot04-
01-ot
04-01-
ot04-
01-ot
04-01-
ot04-
01-ot
04-01-
ot04-
32-ot
04-32-
ot04-
32-ot
04-32-
ot04-
32-ot
04-32-
ot04-
32-ot
04-32-
ot04-
32-ot
04-32-
ot04-
67
3.3
– 06
CC
Ser
ies
Com
pres
sors
– P
hysi
cal D
ata
(pag
e 2
of 2
)
/REIRRACELYLRAC
LEDO
MREB
MUN
ROT
OM
EZISTNE
MECALPSIDMPR
0571tATNE
MECALPSIDMPR
0571tA.
ONF
OLYC
EROB
EKORTS
LIO
EGRAHC
TENTH
GIEW
YDOB
EZISPH
WkMFC
M/LHFC
H/L)000,(
.nim
m.ni
mm
stniPsretiL
bLgK
)g(...610C
C60)g(...810
CC60
...421C
C60...521
CC60
...822C
C60...733
CC60
)g(...055C
C60...566
CC60
...576C
C60...998
CC60
5 52/1
62/1
62/1
701 51 02 02 03
7.37.39.49.46.55.72.119.419.414.22
9.513.819.329.32
821.733.053.864.570.99
05481577677639705014241439153123082
459001153415341086152226103690442540495
10.7290.1306.0406.0475.7430.3654.580.6111.8212.861
6 6 6 6 6 6 6 6 6 6
2 2 2 2 2 261/11
261/11
261/11
261/11
2
8.058.058.058.058.058.053.863.863.863.86
4/11
23/511
4/11
4/11
23/511
61/511
46/361
46/361
61/32
8/72
8.133.738.138.133.732.944.054.056.550.37
5.95.95.95.95.95.9 91 91 91 91
5.45.45.45.45.45.40.90.90.90.9
033523533043043543545555555085
051741251451451651742252252362
D D D D D D E E E E
68
3.4 — 06D, E High Efficiency (H.E.) Compressors
High efficiency compressors were phased in between1985 and 1987. A high efficiency compressor can beidentified as follows:
All 06D H.E. compressors (new or service replacement)have the number “3” in the 11th digit of the modelnumber. See page 3 for examples.
The 06E compressor model numbers did not change. Todetermine if a 06E compressor is high efficiency, checkthe serial number. The following serial numbers indicatehigh 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 forsome “D” body units without a “3” in the 11th digit of themodel numbers.
NOTE: The 06E H.E. valve plates are identified by anelongated ear protruding from the side of the valve plate,in contrast to the standard efficiency valve plates whichhave 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 servicecompressors with no oil in the crankcase due to theintroduction of HFC/POE systems. This eliminates theneed to drain mineral oil from the crankcase whenalkylbenzene or POE oil is to be used. POE oil is veryhygroscopic (will readily pick up and retain moisture
69
from the air) and should be added just prior to systemstart-up only. See Section 2.2, page 11 for Carlyleapproved system start-up instructions and Section 3.6below for the proper refrigerant oils.
3.6 — Refrigerants and Oils for 06D, E Compressors
The introduction of HFC/POE systems has led toconfusion as to what refrigerants and oils are approvedfor use in Carlyle compressors. For 06CC compressors,see Section 3.7, page 72. The following sections listapproved refrigerants and oils for Carlyle 06D, Ecompressors:
Refer to the following chart for Totaline®
Part Numbers for available oils:
The following MINERAL/ALKYLBENZINE are approved oils forCFCs and HCFCs:
NOTE: Carlyle does not recommend the use of POE oil with R-22.Totaline.........................P903-2001Witco...........................Suniso 3GSShrieve Chemical............Zerol 150Texaco Capella...........WFI-32-150IGI 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 temperatureequipment are approved to use R-13 and R-503 (contactCarlyle Engineering for correct oil).
* Do not use in low
temperature applications.
LIO .oNtraP
051loreZ
51OR
*86WS
86E
LIO)BA(ENEZNEBLYKLA)laG1(1002-309P)laG5(5002-309P
)trauQ1(5202-309P
LIOLARENIM)laG1(1010-309P)laG5(5210-309P
)laG55(5510-309P
LIO)EOP(RETSE-LOYLOP)laG1(1001-309P
)trauQ1(5201-309P)laG5(5001-309P
LIO)EOP(RETSE-LOYLOP)trauQ1(5271-309P
)laG1(1071-309P)laG5(5071-309P
70
FOR HCFC BLENDS:Carlyle’s engineering efforts were directed towardtesting the new HFC refrigerants, not the interim HCFCblends. Carlyle provides tentative approvals of thefollowing blends based on tests by the refrigerantmanufacturer and feedback from field applications, noton 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-Zerol150, whenever an HCFC blend is used. In a retrofitapplication the amount of mineral oil cannot exceed25% when mixed with alkylbenzene. Carlyle does notrecommend the use of POE lubricants with HCFCblends.
A number of HCFC blends are not approved.Some may create a hazardous situation. Carlylerequires all refrigerants used in our compressors to beA1/A1 (low flammability/low toxicity). The rating isbased on ASHRAE 34 safety standard. Not all A1/A1 refrigerants are approved for use in Carlylecompressors. Some of the refrigerants or blendsavailable are either flammable (A1/A2 or A1/A3)and/or toxic (A1/B1 or A1/B3). Some A1/A1refrigerants can change ratings if contaminated. Anyreplacement refrigerant must operate with the samepressure levels and temperature ranges as the CFC orHCFC being replaced. Do not use any refrigerantnot specifically approved in this guide unless youhave obtained approval from the Carlyle Com-pressor engineering department.
WARNING!
71
FOR HFCs:Carlyle has approved R-134a, R404A, R-507, and R-407C.
The following POLYOL-ESTER (POE) are approvedoils for HFCs:
Totaline® (see Note 5).......P903-1001, 1701Castrol..(see Note 5) ............................ E68ICI Emkerarate .............................. RL68HCPI ............................................. CP-2916SCPI ............................................... Solest 68BP Marine Enersyn ....................... MP-S68
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 notlisted in this guide as approved for use in a Carlylesemi-hermetic compressor.
5. Castrol SW68 (Totaline® P903-1001) is approved foruse in Carrier chiller applications as well as Carrierand Carlyle semi-hermetic compressors for airconditioning and medium temperature applications.Castrol SW68 (Totaline® P903-1001) cannot beused in any new low temperature refrigerationapplications using Carlyle OEM semi-hermeticcompressors. Castrol E68 is approved for use inCarlyle OEM compressors for low, medium, andhigh 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.
All POE oils are very hygroscopic (will readily pick up andretain moisture from the air) and should be used completelyonce the container is opened. It is extremely difficult to resealthe oil container effectively enough to prevent moistureabsorption, which in turn forms damaging acids.
72
3.7 — Refrigerants and Oils for 06CC Compressors
All 06CC compressors are approved for R-22, R-404Aand R-507 except compressors in the 16 to 37 Cfmrange. Compressors in this size range cannot be usedwith R-404A and R-507 prior to Serial No. 2099J ----without installing a retrofit compressor valveplate (PartNo. 06CY660-002) kit. See Section 3.6 on page 69 forfurther information about refrigerants and oils.
See Section 3.6 on pages 69 & 71 for the correct oil foreach refrigerant. Contact Carlyle Engineering for correctoil 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 anHCFC blend, follow the refrigerant and oil manufacturerinstallation procedures. Select a Carlyle approvedrefrigerant and appropriate oil as noted in Sections 3.6and 3.7 above. System cleanliness is extremely impor-tant. To ensure a trouble-free change out, CarlyleEngineering has made specific guidelines available. Westrongly recommend a copy of our guidelines be re-quested and procedures carefully followed to avoidproblems.
3.9 — Oil Viscosity and Pour Points
The viscosity of oils used in Carlyle reciprocatingcompressors is ISO 68 (centistoke) for all POE oils and150 Saybolt Seconds Universal (150 SSU or 150 SUS)or ISO 32 for mineral and alkylbenzene oils. Using oilwith a different viscosity without approval from theCarlyle Engineering Department will void the warranty.
The oils listed in Sections 3.6 and 3.7 and the viscositylisted above can be used down to -40°F (-40°C). If yoursystem runs at a lower temperature, please contactCarlyle Engineering for an oil recommendation.
73
3.10 — Oil Additives
No oil additive is allowed without written approval fromthe Carlyle Engineering Department. The use of anyunauthorized additive will void the warranty.
3.11 — Oil Pressure
All new 06D, E, CC compressors are supplied with oilsafety switch connections. Carlyle has introduced a newhigh flow oil pump and changed oil pressure specifica-tions due to changes in lubricants and refrigerants. Thefollowing data notes the proper oil pressure range basedon the compressor’s date of manufacture:
STARTING MARCH 1994 WITH S/N 1094J ANDLATER:
• 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 newpump until serial number starting with S/N 2994M andlater.
BETWEEN MAY 1984 AND MARCH 1994 ORBETWEEN S/N 2084J AND 1094J:
• For all 06D, E, CC compressors, the oil pressure is 16to 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 to18 psi (0.8 to 1.2 Bars)
• For more information about the high flow oil pump, seeSection 3.12.
74
3.12 — High Flow Oil Pump (Bearing Head)
Carlyle introduced a new high flow oil pump to provideimproved lubrication with the new HFC refrigerants andPOE lubricants. The pump is a durable, automaticallyreversible, high flow design. The high flow designimproves lubrication, especially with the new HFC/POEcombination, and provides improved lubrication in thecase of a flooded start. This oil pump is standard on allnew and service compressors. See Section 3.11 abovefor details on oil pressure. For service replacement,authorized service locations will have the new high flowoil pump only. See Section 3.13 below.
3.13 — Replacement Oil Pump/Pump End BearingPackage
The oil pump and pump end bearing are an integral partcalled the pump end bearing head. If either the oil pumpor the bearing requires replacement, order part as notedbelow:
NOTE: The above pump end bearing head packages include a bearing headwith the high side oil safety switch connection. This pump is recommended forall CFC, HCFC, and HFC refrigeration applications.
DNEPMUPEGAKCAPDAEHGNIRAEB EGASU
621066AD60 srosserpmoc)mfC73ot61(CC60,D60llA
751066AE60 srosserpmoc)mfC99ot05(CC60,E60llA
75
3.14 — Oil Safety Switch
Carlyle uses as standard the 120-second time delay oilsafety switch, as this time period is preferred for HFC/POE systems. This is a change from the 45 to 60-secondtime delay used previously with CFC and HCFCsystems. It is not necessary to change out the older,shorter time delay switch unless the unit is converted toan HFC/POE system.
The oil safety switch protects the compressor whenlubrication is lost for more than 120 seconds. The switchcloses the control circuit at start-up allowing thecompressor to run for 120 seconds. Operating oilpressure must reach 11 psi above suction pressure within120 seconds for the switch to remain closed, whichallows the compressor to run. If the operating oilpressure falls to 4 psi above suction for longer than120 seconds, the switch will open the control circuit,shutting down the compressor.
Carlyle has approved the following oil safety switchesfor all applications with 06D, E, CC compressors:
• Danfoss - Type MP54. See details below• Penn/Johnson electronic switch - P445
ELYLRACTRAP.ON
SSOFNADTRAP.ON
EMITYALED)CES(
.NNOC
ERUSSERP)ISP(.FFID
STLOV TESERETOMER
MRALATIUCRIC
nI-tuC tuotuC
0342-925P 9012B060 021elaM4/1
seralF11-8 8-4 032/511 launaM seY
0142-925P 4612B060 021
gnoL"63yticapaC
ebuTEAS"4/1
stuN
11-8 8-4 032/511 launaM seY
76
Use of an oil safety switch is recommended/required by
Carlyle as noted in the chart below:
METSYSFOEPYT D60GNISUSROSSERPMOC
E60GNISUSROSSERPMOC
CC60GNISUSROSSERPMOC
rosserpmoCelgniSgnidaolnUtuohtiw dednemmoceR deriuqeR deriuqeR
rosserpmoCelgniSgnidaolnUhtiw dednemmoceR deriuqeR A/N
srosserpmoCelpitluMgnidaolnUtuohtiw deriuqeR deriuqeR deriuqeR
srosserpmoCelpitluMgnidaolnUhtiw deriuqeR deriuqeR A/N
3.15 — 06CC, 06E Discharge Gas Cylinder Head Tempera-ture Sensor & 06E Pressure Relief Valve
All OEM Carlyle 06EA, EM, ER compressors since 1982are equipped with a discharge gas temperature sensor.The sensor is installed in the discharge or center head onall six-cylinder (three-head) models. The four cylinder06Es (two heads) have the sensor in the left side head asviewed from the oil pump end. All 06CC compressorshave the sensor located in the discharge (high stage)head.
Pressure Relief Valve
All 06E compressors and all 06CC 50-99cfm compres-sors are equipped with a pressure relief valve thatrelieves from discharge pressure to crankcase pressure. Itis located under the center cylinder head on all 6 cylinder06E and 06CC compressors, and under the dischargeservice valve on all 4 cylinder 06E compressors. Therelief valve is sealed with a metal gasket:Part Number DescriptionEB51FN272 400psi Relief Valve (differential pressure)6G65-1251 Relief Valve, GasketAn 11/16" drag link socket can be useful for removing/installing the relief valve.
77
When the discharge gas temperature in the cylinder headexceeds the sensor trip setting (see below), the sensor willopen the control circuit and shut off the compressor. Thehead sensor must be wired into the control circuit by theOEM and is pilot duty only at 240V = 0.52A, at 115V =1.04A. The sensors are threaded into the head without awell. Therefore, when changing a sensor, the compressormust first be isolated and evacuated.
NOTES:1. Since 1993 all Carrier 06 series air conditioning
compressors have been made without a sensor. AllCarlyle OEM 06 series compressors are equipped witha sensor.
2. Starting in mid-1998 all Carlyle OEM compressors,including 06EA, EM, ER and all 06CC models, arebuilt using the HN68GA242 sensor. The change to asingle sensor model is due to the increased use of HFCrefrigerants, which operate at lower temperatures.
3.16 — 06D, E Cylinder Head Cooling Fans
Cylinder head cooling fans are recommended on allapplications where the saturated suction temperature(SST) is below 0°F (-18°C). A cylinder head cooling fanmust be used for all R-22 single stage applications
SNOITACIFICEPSERUTAREPMETDAEHREDNILYC
8991-dimot2891morfnoitaregirfeRZEdnaYE,ME,RE60rof ZEdnaYE,ME,RE60rof ZEdnaYE,ME,RE60rof ZEdnaYE,ME,RE60rof ZEdnaYE,ME,RE60rof
CC60dnaE60llAsrosserpmoC srosserpmoC srosserpmoC srosserpmoC srosserpmoC
rebmuNtraPsnepO snepO snepO snepO snepOsesolC sesolC sesolC sesolC sesolC
roloCeriW roloCeriW roloCeriW roloCeriW roloCeriWdaerhT daerhT daerhT daerhT daerhT
3822150AE60)C°4±°361(F°8±°523)C°7±°121(F°21±°052
yerGrevliSTPN"2/1
242AG86NH)C°3±°641(F°5±°592)C°311(muminimF°532
kcalBTPN"2/1
78
below 0°F (-18°C) and all R404A/507 single stageapplications below -25°F (-32°C). A cylinder headcooling fan is recommended (but not required) for anytwo-stage (Compound Cooling) applications.
3.17 — Capacity Control Accessory Packages(Suction Cut-Off Unloading Type)
The following suction cut-off capacity control packagesare available to field convert those 06D, 06E compressorswithout unloading. With the exception of the 06D2-cylinder models, these packages can be added to anynew, replacement, or existing 06D or 06E compressors.See Fig.16.
NOTE: Before adding a suction cut-off control packageto a compressor currently without unloading, consider allline piping sizes and design to ensure proper oil return tocompressor with reduced (unloaded) refrigerant flowrates.
STRAPTNEMECALPERNAFGNILOOCDAEHREDNILYC
)mfC14-31(D60)mfC73-61(CC60
CC60,E60)mfC99ot05(
egakcapnafetelpmoC)06-1-032/802(rotomtnemecalpeR
egakcapedalbtnemecalpeRdrauGnaF
)daeh.lycdradnats(dutsdaehrednilyC)daeh.lycredaolnuhtiw(dutsdaehrednilyC
stundutsgnitnuoM
410066RD60032BG72CH210066RD60367104AD60312305AD60
)ylnOD60(740086AD6061-8/3
110066RE60032BG72CH700066RE60392104AE60379105AE60
---31-2/1
79
CAPACITY CONTROL PACKAGES
ROSSERPMOC EPYT EGAKCAPREBMUN
REDAOLNUERABEVLAV
D60D60E60E60
cirtcelEerusserP
cirtcelEerusserP
*980066AD60090066AD60*831066AE60
931066AE60
531066AE60†001066AE60531066AE60†001066AE60
* 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) andnecessary gaskets.
2. When adding the suction cut-off unloading feature to any compressor, itis no longer necessary to change the valve plate. The suction cut-offmethod of unloading functions independently of the valve plate.
3. To avoid interfering with hi-lo pressure connections or cylinder headsensor, install the unloader cylinder head as follows (viewed from P.E. ofcompressor):
06D 4-cyl - left hand cylinder deck06E 4-cyl - right hand cylinder deck06D, 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
EGAKCAPLIOC EGAKCAPLIOC EGAKCAPLIOC EGAKCAPLIOC EGAKCAPLIOCREBMUNTRAP REBMUNTRAP REBMUNTRAP REBMUNTRAP REBMUNTRAP EGATLOV EGATLOV EGATLOV EGATLOV EGATLOV )FER(N/POCLA )FER(N/POCLA )FER(N/POCLA )FER(N/POCLA )FER(N/POCLA
)487204AD60(021EZ91FE)497104AD60(042EZ91FE)448104AD60(420EZ91FE
06/05-1-02106/05-1-042/802
06/05-1-42
5427C-40931X5407C-40931X5417C-40931X
81
3.19 — Crankcase Heater Data
Crankcase heaters help reduce refrigerant migration to thecompressor during shut-down. Crankcase heaters aredesigned to raise the temperature in the compressor oilcompartment approximately 15 to 25°F (8 to 14°C).Carlyle recommends crankcase heaters be wired so theheater is energized only when the compressor shuts off.Crankcase heaters should be “ON” initially for 24 hoursbefore starting the compressor. All HFC/POE applicationsrequire a crankcase heater.
STRAP-ON HEATERS:
Mounted externally to the underside of the stamp steelbottom plate. Install axially using (2) bottom plate boltsplus brackets and screws in package. Used on 06D( )808,109, 013, 313, and 316 compressors. All strap-on heatersare 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 06Dcompressors, all 06E and all 06CC compressors. Insertionheaters 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).
SEGAKCAPRETAEHESACKNARC
ESACKNARCRETAEHEGAKCAP EPYT
RETAEHREBMUN EGATLOV STTAW
TIUDNOC
)mc(.ni
ERIWHTGNEL)mc(.ni
190066AD60290066AD60
no-partSno-partS
003KA33TH013KB33TH
511032
0505
)16(42)16(42
)99(93)99(93
561066AE60761066AE60
noitresnInoitresnI
231MD63TH431MD63TH
511511
081081
)84(91)231(25
)16(42)581(37
661066AE60 noitresnI 234MD63TH 032 081 )84(91 )16(42
861066AE60670066AD60
noitresnInoitresnI
434MD63TH084LD63TH
032084
081521
)231(25-
)581(37)16(42
82
3.20 — Compressor Mounting Data
Mounting packages are available to mount individualcompressors. Package contains mounting springs, threadedstuds, snubbers, spring cups, nuts, and washers for (1)compressor.
COMPRESSOR MOUNTING PLATE PACKAGENo. 06EA660096
This universal mounting plate will accommodate any size06D, 06E, and 06CC compressor. Mount plate to existingbase and mount the Carlyle compressor to the plate. Packageincludes pre-drilled mounting plate, spacers, and template.
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.
REBMUNEGAKCAPGNITNUOMHTIWESU
ELYTSYDOB ELYTSYDOB ELYTSYDOB ELYTSYDOB ELYTSYDOB
850066AD60650066AD60750066AD60980066AE60
lyc-2D60lyc-4D60
lyc-6)mfC14ot61(CC60,D60)mfC99ot05(CC60dnalyc-6dna4E60
EVLAVEGAKCAP
*.ON
*EGAKCAPEVLAVROSNESEASmm21SEDULCNI
RECUDSNARTROFGNITTIF
SDO).ni(
ELOHTLOBGNICAPS
).ni(
EVLAVREBMUN
060066AD60160066AD60260066AD60360066AD60460066AD60560066AD60090066AE60190066AE60461066AD60
214009AE60224009AE60234009AE60244009AE60254009AE60264009AE60274009AE60
-284009AE60
SSARB8/5SSARB8/7SSARB8/7SSARB8/1-1SSARB8/1-1SSARB8/3-1SSARB8/5-1SSARB8/1-2LEETS8/1-2
8/5-18/5-14/3-1
.qs2/1-24/3-1
.qs2/1-2
.qs2/1-2.qs61/1-3.qs61/1-3
052AA23NE172AA70NE482AA70NE330AE70NE843AA70NE930AE70NE140AE70NE615AF31ME015AE70NE
NOITPIRCSED TEKSAGEVLAVREBIF*EGAKCAP
EVLAVLATEMEGAKCAPTEKSAG
gnicaps"8/5-1tlob-2gnicaps"4/3-1tlob-2erauqs"2/1-2tlob-4seloHoN,ralucriC
1241-32D61311-04D61311-86D61601-56G6
341405AD60361405AD60351405AD60
-
83
3.23 — Oil Drain Plug Adapter
All new compressors, except for 06D( )808, 109, 013,313, and 316 models, are built with a 7/16-20 SAE fittingand O-ring as the oil drain plug. Carlyle offers an oildrain adapter, P/N DE14CA126, which replaces the SAEplug. This adapter allows the installation of a 1/4in. NPTangle valve as a drain fitting.
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.
EGAKCAPRETPADA EGASUROSSERPMOC
270009AD60:N/P721066AE60:N/P
)mfC73ot61(CC60dnaD60llaroF)mfC99ot05(CC60dnaE60roF
N/PTOOFDNEROTOM EGASUROSSERPMOC HTDIWELOHGNITNUOM).NI(
2401-04D6 D60rednilyc2llAD60MFC61&31.lyc4llA
C/AAD60.lyc6llAsledomytud
578.8
3602-84D6 D60MFC02&81.lyc4llA 52.8
250005AE60 &MD&RD60.lyc6llAMFC73ot61(CC60
)ydoB”D“sledomytudC/AAE60llA
573.11&578.8
271105AE60 MFC99ot05(CC60ME/RE60llA&)ydoB"E"
sledomytud.girfeR
573.11&578.8
LOOTNOITALLATSNI/EGAKCAPSSALGTHGIS EGASUROSSERPMOC
).G.S(ssalGthgiS251-02F5)gnir-Otuohtiw.G.S(304204AE60
).G.Srofgnir-O(510WG17KK)looTnoitallatsnI(1-B003331T
)mfC73ot61(CC60dnasD60llA)mfC99ot05(CC60dnasE60llA)mfC99ot05(CC60dnasE60llA)mfC73ot61(CC60dnasD60llA
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 REBMUNTRAPSROSSERPMOCD60
steksagdaehrednilyC: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
/teksag488405AE60)1(sevlavnoitcus)2(
ro)rebif(488405AE60)latem(414605AE60
ro)rebif(488405AE60)latem(414605AE60
210066RE60210066RE60488405AE60
SROSSERPMOCCC60mfC73ot61
daehrednilyC.aetalpevlaV.b
dlofinamnoitcuS.cdlofinamegatsretnI.d
noitcejnidiuqiL.eebutegatsretnI.f
312205AG50351005AD60
*1311-04D6*1311-04D5*1241-32D6*1241-32D6
mfC99ot05
daehrednilyC.aetalpevlaV.b
dlofinamnoitcuS.cdlofinamegatsretnI.d
noitcejnidiuqiL.eebutegatsretnI.f
403305AE60488405AE60
*1311-86D6*1311-86D6*1241-32D6*1311-86D6
85
3.28 — Miscellaneous
Terminal Plate Gasket
Sensor Block Gasket (Used between transducer sensorblock and bearing head with Johnson P445 (06DA660115)oil safety switch)
Electrical Terminal Barrel Nut Tool (Socket tool used forinstallation of terminal nuts)
EGASUROSSERPMOC REBMUNTRAP
CC60,E60,D60 360086AD60
EGASUROSSERPMOC REBMUNTRAP
)MFC73OT61(CC60,D60llA)MFC99OT05(CC60,E60
1601-04D62801-54G6
EGASUROSSERPMOC REBMUNTRAP
)mfc73OT61(CC60,D60llA 9000-029P
86
3.29 — Valve Plate Packages, Service Replacement
Carlyle began installing high efficiency valve plates inthe mid 1980’s. With a few exceptions noted, the valveplates fit all current and older Carlyle compressors.Check notes below the table for exceptions.
EGASUROSSERPMOC EGAKCAPETALPEVLAV
srosserpmoC)mfC14ot61(CC60,D60
,613RD60,313MD60,310RD60gnisufi(RD60.a)2etoneessledom613MD60ro
,613RD60313MD60,310RD60gnisufi(AD,MD60.b)2etoneessledom613MD60ro
egakcapevlavegatswol)mfC73ot61(CC60.cegakcapevlavegatshgih)mfC73ot61(CC60.d
490066AD60
021066AD60200066YC60021066AD60
srosserpmoC)mfC99ot05(CC60,E60
RE60.aAE,ME60.b
*evlavegatswol)mfC99ot05(CC60.cevlavegatshgih)mfC99ot05(CC60.d
341066AE60731066AE60951066AE60731066AE60
NOTES:1. Carlyle recommends the 06ER660017 service replacement valve plate kit for all 06ER compressors in low temperature environmental chamber applications (see Note 6).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 theabove valve plate kits. Older 13 and 16 cfm (prior to 1985) models have a 1-13/16" diameterbore 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 beused 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.
* Includes relief valve for both low stage banks.
87
4. Service valve plate kits include:(1) valve plate assembly, (2) suction reed valves, (3) cylinder head gaskets (side, center andsuction gas unloading), (1) valve plate gasket; and for 06D compressors there are (2) suctionvalve position springs.
5. All new high efficiency 06DM, 06DA, and 06CC (16 to 37 Cfm) compressors have flat toppistons. 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-stepcontoured pistons.
6. The outer edges of the valve plates have “ears” that are visible when installed on thecompressor. All new high efficiency valve plates have one elongated “ear” versus one or tworounded “ears” on the older standard efficiency valve plates. Note the valve plate supplied inpackage 06ER660017 for environmental chambers has two rounded ears.
3.30 — Muffler Recommendations
Mufflers can reduce discharge gas pulsation and effec-tively eliminate vibration problems downstream. Theyshould be placed as close to the compressor as possibleto maximize efficiency and minimize vibration. Mufflersshould be:
• used on all 06E 66 and 99 Cfm compressor models.• used on all 06E compressors with capacity control.• considered for use with all 06D 37 and 41 Cfm
compressor models.• considered for use with all 06D 6-cylinder compres-
sors with capacity control
Mufflers can be mounted horizontally or vertically.
RELFFUM THGIEW)GK(BL
TELTUO/TELNI).ni(
ROSSERPMOCMFCYBDEZIS
495506AD60406506AD60416506AD60203005AE60001HH01ML217005AE60
)3.2(5)3.2(5)3.2(5)5.4(01)7.2(6)2.3(7
MDO8/5FDO8/7FDO8/1-1FDO8/3-1FDO8/3-1FDO8/7-1
61,31,90,8042,02,8114,73,82
05993)(E60dna57,56
998CC60dna995,994)(E60
88
3.31 — Electrical Accessories
BOX PACKAGE - This consists of terminal box, cover,and necessary mounting components.
LANIMRETXOB
EGAKCAPREBMUN
EPYTEGASUROSSERPMOC
EZISDNA
870066AD60570066AD60880066AD60590066AE60
leetSnwarDdetacirbaFdetacirbaF
leetSnwarD
)mc6.41xmc2.51()"4/3-5x"6(.lyc-2D60llA)mc7.21xmc2.51()"5x"6(.lyc-4D60llA
)mc3.02xmc2.51()"8x"6(mfC73ot61CC60dna.lyc-6D60llAdnasrosserpmoc.lyc-6dna-4E60llA
)mc8.71xmc8.71()"7x"7(mfC99ot05CC60
TERMINAL LUG PACKAGE - This consists of 6screw-on terminal lugs with set screws. Strip power wire1/2 in., insert into terminal lugs, and secure in place withset screw.
GULLANIMRETREBMUNEGAKCAP EGASUROSSERPMOC
590066AE60800BT58YH400BT58YH
mfC14ot61CC60dnaD60llAeziSeriW8#ot4#mfC99ot05CC60dnaE60llAeziSeriW4#ot1#mfC99ot05CC60dnaD60llA
TERMINAL PLATE JUMPER PACKAGE FOR 06E,06CC 50 TO 99 Cfm - This package consists of jumperbars, terminal nuts and instructions to interconnectterminal studs for proper motor starting (P/W or X/L)and voltage.
EGAKCAPREPMUJREBMUN EGASU
141066AE60790066AE60
)egatlovelpirt(064/032/802)egatlovtcnitsid(575/064/032/802
NOTE: With 06E multi-volt (208/230/460) compressors, the 460-volt motor can beconnected 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
Baffle plates can be used to reduce compressor dischargegas pulsations. Recommended baffle plate assembliesare shown below. These plates are designed to createa 6 to 10 psi (0.4 to 0.7 Bars) pressure drop in thedischarge gas. Use only the baffle plate recommended forthe application. These baffle plates, sandwiched betweentwo gaskets, are installed between the compressordischarge service valve and the compressor crankcase orcylinder head. For further details, see Carlyle OEMBulletins No. 118 and 119.
* 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 CompressorsOnly)
All 06CC compressors are a two-stage design. Therefore,the pressure measurements are suction, interstage, anddischarge. The following tables list the interstagepressures using R-22 and R-404A/507 refrigerants.
†
ROSSERPMOC NOITACILPPA ETALPELFFAB*REBMUNTRAP
mfC02dna,61,31-D60mfC14dna73,82,52,42-D60lladnamfC73,82,52,42-D60
mfC73ot61CC60
erutarepmetmuidemdnawolylnoerutarepmetwolerutarepmetmuidem
CC60&
301066AD60401066AD60501066AD60
mfC05-E60mfC99ot05CC60lladnamfC99,57,56-E60
erutarepmetmuidemdnawolerutarepmetmuidemdnawol
501066AD60541066AE60
90
* Ind
icat
es V
acuu
m.
NO
TE: 1
BAR
= 1
00 k
Pa o
r 1 A
TM (A
tmos
pher
e) P
ress
ure
ERUSSERPE
GATSRETNIETA
MIXORPPA
22-R±
RELO
OCBUSHTI
W)RAB7.(
isp01
detarutaSnoitcuS
)C(F,p
meT
noitcuSerusserP
)RAB(GISP
)C(F,erutarep
meTgnisnednoC
detarutaS
06)61(
07)12(
08)72(
09)23(
001)83(
011)34(
021)94(
031)45(
)RAB(GISP,erusserP
gnisnednoC
6.101)20.8(
4.121)93.9(
6.341)29.01(
4.861)36.21(
9.591)25.41(
4.622)36.61(
9.952)49.81(
8.692)84.12(
)15-(06-
)84-(55-
)54-(05-
)34-(54-
)04-(04-
)73-(53-
)43-(03-
)23-(52-
)92-(02-
)62-(51-
)32-(01-
)116.0(*9.11
)207.0(*2.9
)708.0(*1.6
)229.0(*7.2
)50.1(5.0
)91.1(6.2
)53.1(9.4
)25.1(4.7
)17.1(1.01
)29.1(2.31
)51.2(5.61
)91.2(71
)93.2(02
)35.2(22
)37.2(52
)88.2(72
)80.3(03
)92.3(33
)05.3(63
)07.3(93
)19.3(24
)91.4(64
)93.2(02
)06.2(32
)37.2(52
)49.2(82
)51.3(13
)63.3(43
)75.3(73
)77.3(04
)89.3(34
)62.4(74
)64.4(05
)06.2(32
)37.2(52
)49.2(82
)51.3(13
)63.3(43
)36.3(83
)48.3(14
)50.4(44
)23.4(84
)06.4(25
)88.4(65
)18.2(62
)10.3(92
)22.3(23
)24.3(53
)36.3(83
)19.3(24
)21.4(54
)93.4(94
)76.4(35
)49.4(75
)22.5(16
)49.2(82
)22.3(23
)24.3(53
)36.3(83
)19.3(24
)91.4(64
)64.4(05
)37.4(45
)10.5(85
)92.5(26
)75.5(66
)51.3(13
)24.3(53
)36.3(83
)19.3(24
)91.4(64
)64.4(05
)37.4(45
)10.5(85
)63.5(36
)36.5(76
)89.5(27
)34.3(53
)36.3(83
)19.3(24
)91.4(64
)64.4(05
)37.4(45
)80.5(95
)63.5(36
)07.5(86
)50.6(37
)93.6(87
)36.3(83
)19.3(24
)91.4(64
)64.4(05
)37.4(45
)80.5(95
)63.5(36
)07.5(86
)50.6(37
)64.6(97
)18.6(48
91
* Ind
icat
es V
acuu
m.
NO
TE: 1
BAR
= 1
00 k
Pa o
r 1 A
TM (A
tmos
pher
e) P
ress
ure
ERUSSERPE
GATSRETNIETA
MIXORPPA
705R/A404R±
RELO
OCBUSHTI
W)RAB7.(
isp01
detarutaSnoitcuS
)C(F,p
meT
erusserPnoitcuS
)RAB(GISP
)C(F,erutarep
meTgnisnednoC
detarutaS
06)61(
07)12(
08)72(
09)23(
001)83(
011)34(
021)94(
)RAB(GISP,erusserP
gnisnednoC
7.921)69.9(
6.351)16.11(
3.081)54.31(
2.012)15.51(
5.342)18.71(
6.082)73.02(
9.123)12.32(
)15-(06-
)84-(55-
)54-(05-
)34-(54-
)04-(04-
)73-(53-
)43-(03-
)23-(52-
)92-(02-
)62-(51-
)32-(01-
)418.0(*9.5
)929.0(*3.2
)80.1(9.0
)32.1(1.3
)93.1(5.5
)85.1(2.8
)87.1(1.11
)00.2(3.41
)42.2(8.71
)15.2(7.12
)97.2(8.52
)18.2(62
)10.3(92
)92.3(33
)34.3(53
)07.3(93
)89.3(34
)91.4(64
)64.4(05
)47.4(45
)10.5(85
)92.5(26
)80.3(03
)92.3(33
)75.3(73
)07.3(93
)50.4(44
)62.4(74
)35.4(15
)18.4(55
)80.5(95
)34.5(46
)07.5(86
)92.3(33
)75.3(73
)77.3(04
)50.4(44
)23.4(84
)06.4(25
)88.4(65
)51.5(06
)05.5(56
)48.5(07
)21.6(47
)75.3(73
)77.3(04
)91.4(54
)23.4(84
)76.4(35
)49.4(75
)22.5(16
)75.5(66
)19.5(17
)62.6(67
)06.6(18
)77.3(04
)50.4(44
)93.4(94
)76.4(35
)10.5(85
)92.5(26
)36.5(76
)89.5(27
)23.6(77
)76.6(28
)80.7(88
)50.4(44
)23.4(84
)76.4(35
)49.4(75
)63.5(36
)07.5(86
)50.6(37
)93.6(87
)47.6(38
)51.7(98
)75.7(59
)23.4(84
)76.4(35
)10.5(85
)92.5(26
)07.5(86
)50.6(37
)93.6(87
)18.6(48
)22.7(09
)36.7(69
)50.8(201
92
4.0
— E
LE
CT
RIC
AL
DA
TA
4.1
— 0
6DR
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
SLEDO
MYCNEICIFFE
HGIH
WENSLED
OM
YCNEICIFFEDRADNATS
DLO
rosserpmoC
*ledoM
ataDlacirtcelE
PHrosserp
moC*ledo
M
ataDlacirtcelE
tloVCC
MALR
ARLgnidni
Wroto
M)s
mhO(
ecnatsiseRxa
MWk
tloVCC
MALR
ARL
0513AG0901
RD60
0523AG
0563AG
575032/802
064
4.41.21
5.5
8.26.75.3
3.123.353.62
0.71.14.4
1.32
0012C
G0901R
D600021A
G0062A
G
575032/802
064
9.31.21
5.5
- 6.89.3
3.123.353.62
0513AC0310
RD60
0523AC
0523AC
0563AC
575032/802032/802
064
7 4.714.71
7.8
5.42.112.11
6.5
4.8217 175.53
0.518.018.0
2.3
3.43
0010AF0310R
D600040AF0050AF0060AF
575002032064
9.5 718.41
4.7
2.41.216.01
3.5
325.365.758.82
0513AC0613
RD60
0523AC
0523AC
0063AC
575032/802032/802
064
8.0172 725.31
9.63.713.71
6.8
04001001
05
3.345.045.0
1.2
52.65
0110AF0613R
D600140AF0150AF0160AF
575002032064
4.9 725.328.11
7.63.918.61
4.8
5.4359 68 34
0513AD0817
RD60
0523AD
0523AD
0563AD
575032/802032/802
064
8.0172 725.31
9.63.713.71
6.8
04001001
05
3.345.045.0
1.2
52.65
0110AD0817
RD60
0140AD
0150AD
0160AD
575002032064
4.9 725.328.11
7.63.918.61
4.8
5.4359 68 34
0513AD0028
RD60
0523AD
0563AD
575032/802
064
6.7144 22
3.112.821.41
46061
08
6.224.0
7.18.9
5.60010A
D0028R
D600021A
D0060A
D
575032/802
064
6.718.84
22
6.219.437.51
05731
26
93
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. S
ee p
age
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
reco
mm
ende
d (a
nd m
inim
um) R
LA v
alue
to d
eter
min
e na
mep
late
sta
mpi
ng, m
inim
um c
onta
ctor
siz
ing
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 m
otor
s of
diff
eren
t effi
cien
cies
can
diffe
r up
to 1
5% fr
om d
ata
show
n.
SEGNAR
GNITAREPO
ELBAW
OLLA
EGATL
OVLANI
MON
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
Not Applicable
SLEDO
MYCNEICIFFE
HGIH
WENSLED
OM
YCNEICIFFEDRADNATS
DLO
rosserpmoC
*ledoM
ataDlacirtcelEXA
MWk
PH*ledo
Mrosserp
moCataDlacirtcelE
tloVCC
MALR
ARLgnidni
Wroto
M)s
mhO(
ecnatsiseRtloV
CCM
ALRARL
0513AD0427
RD60
0523AD
0563AD
575032/802
064
6.7144 22
3.112.821.41
46061
08
6.224.0
7.18.9
5.60010A
D0427R
D600021A
D0060A
D
575032/802
064
6.718.84
22
6.219.437.51
05731
260513A
D0527R
D600523A
D0563A
D
575032/802
064
6.7144 22
3.112.821.41
46061
08
6.224.0
7.18.9
5.60010A
D0427R
D600021A
D0060A
D
575032/802
064
6.718.84
22
6.219.437.51
05731
260513A
D0822R
D600523A
D0563A
D
575032/802
064
2.225.558.72
2.416.538.71
97891
99
0.213.0
3.18.21
80010A
D0822R
D600021A
D0060A
D
575032/802
064
2.225.558.72
9.519.349.91
26071
770513A
D0733R
D600523A
D0563A
D
575032/802
064
52 26 13
0.617.939.91
19822411
7.162.0
0.15.61
010010A
D0733R
D600021A
D0060A
D
575032/802
064
52 96 13
9.713.941.22
96191
680510A
D0145R
D600521A
D0560A
D
575032/802
064
23 98 04
5.021.756.52
69662021
2.181.027.0
7.0251
94
4.2
— 0
6DM
, DA
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
SLEDO
MYCNEICIFFE
HGIH
WENSLED
OM
YCNEICIFFEDRADNATS
DLO
rosserpmoC
*ledoM
ataDlacirtcelExa
MWk
PH*ledo
Mrosserp
moCataDlacirtcelE
tloVCC
MALR
ARLgnidni
Wroto
M)s
mhO(
ecnatsiseRtloV
CCM
ALRARL
MD600513A
G0808M
D600523A
G0523A
G0563A
G
575032/802032/802
064
7 4.714.71
7.8
5.42.112.11
6.5
4.8217 175.53
0.587.087.0
1.3
1.43
0210C
G0808M
D600340
CG
0250AG
0260AG
575002032064
9.50.718.41
4.7
- 1.216.01
3.5
325.365.758.82
0513AC0313
MD60
0523AC
0523AC
0063AC
575032/802032/802
064
8.0172 725.31
9.63.713.71
6.8
04001001
05
3.35.05.01.2
52.65
0210AF0808M
D600240AF0250AF0260AF
575002032064
4.90.725.328.11
7.63.918.61
4.8
5.4359 68 34
0513AC0613
MD60
0523AC
0523AC
0563AC
575032/802032/802
064
8.0172 725.31
9.63.713.71
6.8
04001001
05
3.35.05.01.2
52.65
0210AF0613M
D600240AF0250AF0260AF
575002032064
4.90.725.328.11
7.63.918.61
4.8
5.4359 68 34
0513AD0733
MD60
0523AD
0563AD
575032/802
064
52 26 13
0.617.939.91
19822411
7.162.0
0.15.61
010210A
D0733M
D600221A
D0260A
D
575032/802
064
52 96 13
9.713.941.22
96191
68
AD600513AA2818A
D600523AA0563AA
575032/802
064
6.7144 22
3.112.821.41
46061
08
6.224.0
7.181.9
5.60010AA2818A
D600021AA0060AA
575032/802
064
6.718.84
22
6.219.437.51
05731
26
MAX kW
95
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. S
ee p
age
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
reco
mm
ende
d (a
nd m
inim
um) R
LA v
alue
to d
eter
min
e na
mep
late
sta
mpi
ng, m
inim
um c
onta
ctor
siz
ing
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 m
otor
s of
diff
eren
t effi
cien
cies
can
diffe
r up
to 1
5% fr
om d
ata
show
n.
SLEDO
MYCNEICIFFE
HGIH
WENSLED
OM
YCNEICIFFEDRADNATS
DLO
rosserpmoC
*ledoM
ataDlacirtcelEXA
MWk
PH*ledo
Mrosserp
moCataDlacirtcelE
tloVCC
MALR
ARLgnidni
Wroto
M)s
mhO(
ecnatsiseRtloV
CCM
ALRARL
deunitnocAD60
0513AB2428AD60
0523AB0563AB
575032/802
064
2.225.558.72
2.415.538.71
97891
99
0.213.0
3.18.21
80010AB2428A
D600021AB0060AB
575032/802
064
2.225.168.72
9.519.349.91
26071
77
0513AB2528AD60
0523AB0563AB
575032/802
064
2.225.558.72
2.415.538.71
97891
99
0.213.0
3.18.21
80010AB2528A
D600021AB0060AB
575032/802
064
2.225.168.72
9.519.349.91
26071
77
0513AB2823AD60
0523AB0563AB
06-3-575032/802
064
52 26 13
0.617.939.91
19822411
7.162.0
0.15.61
010010AB2823A
D600021AB0060AB
575032/802
064
52 96 13
9.713.941.22
96191
68
0510AB2735AD60
0521AB0560AB
575032/802
064
23 98 04
5.021.756.52
69662021
2.181.027.0
7.0251
0010AB2735AD60
0021AB0060AB
575032/802
064
23 98 04
9.226.366.82
69662021
SEGNAR
GNITAREPO
ELBAW
OLLA
EGATL
OVLANI
MON
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
96
4.3
— 0
6DR
, DM
Sin
gle
Pha
se E
lect
rica
l Spe
cifi
cati
ons
ROSSERP
MOC
ELBAIRAV
LEDO
MR
OSSERPM
OC
*0533AC0808MD60
*0533AC0901RD60*0533AC0310RD60
*0533AC0313MD60
*0533AC0613RD60*0533AD0817RD60
rewopesro
Hlanimo
N3
33
55
roticapaCtratSN/P
dnaV
023@
DFM
6916981-182P
V023
@DF
M691
6981-182PV
023@
DFM
8326612-182P
V023
@DF
M832
6612-182PV
023@
DFM
8326612-182P
roticapaC
nuR
N/Pdna
V044
@DF
M53
4053-192PV
044@
DFM
534053-192P
V044
@DF
M04
4004-192PV
044@
DFM
054005-192P
V044
@DF
M05
4005-192P
toH
ataD
yaleRtratS
N/Pdna
egatloVp
U-kciP
V42-022
ro120BK16
NH
3199-382P
V042-022
ro120BK16
NH
3199-382P
V082-062
ro220BK16
NH
8199-382P
V073-053
2199-382PV
073-0532199-382P
egatloVp
U-kciPdlo
CV
932/802V
932-802V
072-932V
653-823V
653-823
egatloVtuoporD
V011-05
V011-05
V011-05
V121-06
V121-06
egatloVlioC
V573
V573
V573
V024
V024
CC
M82
426.23
0404
ALR
021.71
3.326.82
6.82
ARL
011011
001051
051
97
*The
last
two
digi
ts o
f the
com
pres
sor m
odel
num
ber m
ay v
ary.
See
pag
e 3.
ROSSERP
MOC
ELBAIRAV
LEDO
MR
OSSERPM
OC
*0533AC0808MD60
*0533AC0901RD60*0533AC0310RD60
*0533AC0313MD60
*0533AC0613RD60*0533AD0817RD60
).oN.I.T(
daolrevO
nom
moC
)36-32A7438(420Z
G96N
H)13-32A7438(
520ZG96
NH
)36-32A7438(420Z
G96N
H)4-91A8438(703Z
G96N
H)4-91A7438(703Z
G96N
H
).I.T(daolrev
OtratS)35-32A7438(
410ZG96
NH
)24-32A7438(230Z
G96N
H)35-32A7438(
410ZG96
NH
)04-32A7438(730Z
G96N
H)04-32A7438(
730ZG96
NH
EGNAR
GNITAREPO
ELBAW
OLLA LANIM
ONE
GATLOV
MUMIXA
MMU
MINIM
06-1-032/802V
452V
781
98
4.4
— 0
6ER
, EY
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
* The
last
two
digi
ts o
f the
com
pres
sor m
odel
num
ber m
ay v
ary.
See
pag
e 4.
The
fifth
dig
it in
( ) o
f the
com
pres
sor m
odel
num
ber
repr
esen
ts m
odel
s w
ith o
r with
out o
il. 0
, 1, 2
sig
nifie
s ol
der m
odel
s w
ith o
il; 3
, 4, 5
sig
nifie
s ne
wer
mod
els
with
out o
il. S
ee p
age
4.
ATADR
OTO
MR
OSSERPM
OCATAD
REKAERBTIUCRIC
ROSSERP
MOC
*LEDO
MTL
OVXA
MWk
PH
1ET
ONEES
2ET
ONEES
ROT
OM
GNIDNIW
ECNATSISER)s
mhO(
3ET
ONEES
.H.M
.T.M
ARL
4ET
ONEES
mumixa
MpirTtsu
Msp
mA
-mixa
MmuALR
LX-ARLWP-ARLtsrif(
)gnidniw
dednem
moceRrekaerBtiucriC
.oNtraP
dednem
moceRALR
00005)4/1(RE60
00105)4/1(00605)4/1(00305)4/1(
032/802575064
064/032/802
0.2251
09 83 6464/09
27 13 6363/27
38289241
241/382
07195 58
58/071
44.08.28.1
22.0/44.0
626BX38H
H064AX364AX364AX/626BX
87 92 0404/87
095.33
6464/09
05279051
051/052
3.469.329.33
9.33/3.46
00066)4/1(RE60
00166)4/1(00666)4/1()5
etoN
eeS(
032/802575064
3.5202
80154 45
78 63 44
543021371
70227401
23.02.23.1
526BX38H
H164AX424AX
19 33 24
40183 94
053421571
3.471.72
53
00056)4/1(RE60
00156)4/1(00656)4/1(00356)4/1(
032/802575064
064/032/802
3.5202
80154 45
45/801
78 63 4444/78
543021371
371/543
70227401
401/702
23.02.23.1
61.0/23.0
526BX38H
H164AX424AX424AX/526BX
19 33 2424/19
40183 94
94/401
053421571
571/053
3.471.72
5353/3.47
00057)4/1(RE60
00157)4/1(00657)4/1(00357)4/1(
032/802575064
064/032/802
3.5202
80154 45
45/801
78 63 4444/78
543021371
371/543
70227401
401/702
23.02.23.1
61.0/23.0
526BX38H
H164AX424AX424AX/526BX
19 33 2424/19
40183 94
94/401
053421571
571/053
3.471.72
5353/3.47
00099)3/0(RE60
00199)3/0(00699)3/0(00399)3/0(
032/802575064
064/032/802
1.9303
86156 48
48/861
53125 86
86/531
605671352
352/605
403601251
251/403
22.03.188.0
11.0/22.0
935CX38
HH
034AX874AX874AX/935
CX
24105 56
76/241
36185 67
67/361
705861472
472/705
4.6114.143.45
3.45/4.611
99
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
p
acka
ge 0
6EA6
6015
2.4.
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
d
eter
min
e na
me
plat
e st
ampi
ng, m
inim
um c
onta
ctor
siz
ing,
and
wire
siz
ing.
REC
OM
MEN
DED
RLA
FO
R 0
6E 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. 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
. M
otor
s fro
m d
iffer
ent v
endo
rs a
nd m
otor
s of
diff
eren
t effi
cien
cies
c
an d
iffer
up
to 1
5% fr
om d
ata
show
n.
EGNAR
GNITAREPO
ELBAW
OLLA LANIM
ONE
GATLOV
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
100
4.5
— 0
6EM
, EZ
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
* The
last
two
digi
ts o
f the
com
pres
sor m
odel
num
ber m
ay v
ary.
See
pag
e 4.
The
fifth
dig
it in
( ) o
f the
com
pres
sor m
odel
num
ber
repr
esen
ts m
odel
s w
ith o
r with
out o
il. 0
, 1, 2
sig
nifie
s ol
der m
odel
s w
ith o
il; 3
, 4, 5
sig
nifie
s ne
wer
mod
els
with
out o
il. S
ee p
age
4.
ATADR
OTO
MR
OSSERPM
OCATAD
REKAERBTIUCRIC
ROSSERP
MOC
*LEDO
MTL
OVXA
MWk
PH
1ET
ONEES
2ET
ONEES
ROT
OM
GNIDNIW
ECNATSISER)s
mhO(
3ET
ONEES
.H.M
.T.M
ARL
4ET
ONEES
mumixa
MpirTtsu
Msp
mA
mumixa
MALR
-ARLLX
WP-ARLtsrif(
)gnidniw
dednem
moceRrekaerBtiucriC
.oNtraP
dednem
moceRALR
00005)4/1(ME60
00105)4/1(00605)4/1(00305)4/1(
032/802575064
064/032/802
0.2251
09 83 6464/09
27 13 6363/27
38289241
241/382
07195 58
58/071
44.08.28.1
22.0/44.0
626BX38H
H064AX364AX364AX/626BX
87 92 0404/87
095.33
6464/09
05279051
051/052
3.469.329.33
9.33/3.46
00066)5/2(ME60
00166)5/2(00666)5/2()5
etoN
eeS(
032/802575064
6.3352
04175 07
21164 65
644461322
86289431
72.06.11.1
905CX38
HH
964AX624AX
01164 55
72135 46
024461012
7.099.737.54
00057)4/1(ME60
00157)4/1(00657)4/100357)4/1(
032/802575064
064/032/802
6.3352
04175 07
07/041
21164 65
65/211
644461322
322/644
86289431
431/862
71.06.11.1
41.0/72.0
905CX38
HH
964AX624AX624AX/905
CX
01164 55
55/011
72135 46
46/721
024461012
012/024
7.099.737.54
7.54/7.09
00099)4/1(ME60
00199)4/1(00699)4/1(00399)4/1(
032/802575064
064/032/802
6.7453
39177 69
69/391
55126 77
77/551
016212503
503/016
663721381
381/663
81.01.117.0
90.0/81.0
235CX38
HH
354AX745AX745AX/235
CX
85186 77
77/851
28187 88
88/281
095632382
382/095
0317.559.26
9.26/031
101
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
p
acka
ge 0
6EA6
6015
2.4.
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
d
eter
min
e na
me
plat
e st
ampi
ng, m
inim
um c
onta
ctor
siz
ing,
and
wire
siz
ing.
REC
OM
MEN
DED
RLA
FO
R 0
6E 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. 0
6EM
266
New
OEM
Mod
els
no lo
nger
pro
duce
d, re
plac
ed b
y 06
EA26
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
. M
otor
s fro
m d
iffer
ent v
endo
rs a
nd m
otor
s of
diff
eren
t effi
cien
cies
c
an d
iffer
up
to 1
5% fr
om d
ata
show
n.
EGNAR
GNITAREPO
ELBAW
OLLA LANIM
ONE
GATLOV
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
102
4.6
— 0
6EA
, ET
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
* The
last
two
digi
ts o
f the
com
pres
sor m
odel
num
ber m
ay v
ary.
See
pag
e 4.
The
fifth
dig
it in
( ) o
f the
com
pres
sor m
odel
num
ber
repr
esen
ts m
odel
s w
ith o
r with
out o
il. 0
, 1, 2
sig
nifie
s ol
der m
odel
s w
ith o
il; 3
, 4, 5
sig
nifie
s ne
wer
mod
els
with
out o
il. S
ee p
age
4.
ATADR
OTO
MR
OSSERPM
OCATAD
REKAERBTIUCRIC
ROSSERP
MOC
*LEDO
MTL
OVXA
MWk
PH
1ET
ONEES
2ET
ONEES
ROT
OM
GNIDNIW
ECNATSISER)s
mhO(
3ET
ONEES
.H.M
.T.M
ARL
4ET
ONEES
mumixa
MpirTtsu
Msp
mA
mumixa
MALR
-ARLLX
WP-ARLtsrif(
)gnidniw
dednem
moceRrekaerBtiucriC
.oNtraP
-nem
moceRdedALR
00005)5/2(AE6000105)5/2(00605)5/2(00305)5/2(
032/802575064
064/032/802
3.5202
80154 45
45/801
78 63 4444/78
543021371
371/543
70227401
401/702
23.02.23.1
61.0/23.0
526BX38H
H164AX424AX424AX/526BX
19 33 2424/19
40183 94
94/401
053421571
571/053
3.471.72
5353/3.47
00056)5/2(AE6000156)5/2(00656)5/2(00356)5/2(
032/802575064
064/032/802
6.3352
04175 07
07/041
21164 65
65/211
644461322
322/644
86289431
431/862
72.06.11.1
41.0/72.0
905CX38
HH
964AX624AX624AX/905
CX
01164 55
55/011
72135 46
46/721
024461012
012/024
7.099.737.54
7.54/7.09
00057)5/2(AE6000157)5/2(00657)5/2(00357)5/2(
032/802575064
064/032/802
1.9303
86156 48
48/861
53125 86
86/531
605671352
352/605
403601251
251/403
22.03.19.0
11.0/22.0
935CX38
HH
034AX874AX874AX/935
CX
24105 56
76/241
36185 67
67/361
705861472
472/705
4.6114.143.45
3.45/4.611
00099)5/2(AE6000199)5/2(00699)5/2(00399)5/2(
032/802575064
064/032/802
0.4504
63249811
811/632
98157 59
59/981
096672543
543/096
414561702
702/414
51.0 1 85.070.0/51.0
735CX38
HH
155AX055AX055AX/735
CX
78147 29
29/781
51258601
601/512
636632592
592/636
6.3517.067.57
7.57/6.351
103
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
p
acka
ge 0
6EA6
6015
2.4.
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
d
eter
min
e na
me
plat
e st
ampi
ng, m
inim
um c
onta
ctor
siz
ing,
and
wire
siz
ing.
REC
OM
MEN
DED
RLA
FO
R 0
6E 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.
Mot
ors
from
diff
eren
t ven
dors
and
mot
ors
of d
iffer
ent e
ffici
enci
es
can
diff
er u
p to
15%
from
dat
a sh
own.
SEGNAR
GNITAREPO
ELBAW
OLLA
EGATL
OVLANI
MON
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
104
4.7
— 0
6CC
(16
to
37 C
fm)
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
ATADR
OTO
MR
OSSERPM
OC
ROSSERP
MOC
LEDO
MXA
MWk
PH
ATADLACIRTCELE
DAOLREV
OELYLRAC.
ONTRAP
.ON
TRAP.
ON.I.TSTL
OVCC
MALR
ARLGNIDNI
WR
OTO
MECNATSISER
)smh
O(
101J610C
C60101
D101
G52.6
5575
032/802064
8.01725.31
9.63.71
7.8
04001
05
3.345.0
1.2
230ZG96
NH
420ZG96
NH
410ZG96
NH
24-32A743836-32A743835-32A7438
101J810C
C60101
D101
G52.6
5575
032/802064
8.01725.31
9.63.71
7.8
04001
05
3.345.0
1.2
230ZG96
NH
420ZG96
NH
410ZG96
NH
24-32A743836-32A743835-32A7438
101J421C
C60101
D101
G81.9
5.6575
032/802064
2.31335.61
5.82.126.01
46061
08
6.224.0
7.1
730ZG96
NH
412ZG96
NH
830ZG96
NH
04-32A74389-32A843881-32A7438
101J521C
C60101
D101
G81.9
5.6575
032/802064
2.31335.61
5.82.126.01
46061
08
6.224.0
7.1
730ZG96
NH
412ZG96
NH
830ZG96
NH
04-32A74389-32A843881-32A7438
101J822C
C60101
D101
G8.21
5.7575
032/802064
7.616.149.02
2.017.624.31
97891
99
0.213.0
3.1
400ZG96
NH
603ZG96
NH
010ZG96
NH
91-32A743831-32B743892-32A7438
101J733C
C60101
D101
G5.61
01575
032/802064
8.815.643.32
1.218.929.41
19822411
7.162.0
0.1
520ZG96
NH
903ZG96
NH
420ZG96
NH
13-32A743811-32B743836-32A7438
105
SEGNAR
GNITAREPO
ELBAW
OLLA
EGATL
OVLANI
MON
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
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
reco
mm
ende
d (a
nd m
inim
um) R
LA v
alue
to d
eter
min
e na
mep
late
sta
mpi
ng. M
inim
um c
onta
ctor
siz
ing
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 m
otor
s of
diff
eren
t effi
cien
cies
can
diffe
r up
to 1
5% fr
om d
ata
show
n.
106
4.8
– 06
CC
(50
to
99 C
fm)
3 P
hase
Ele
ctri
cal S
peci
fica
tion
s
ATADR
OTO
MR
OSSERPM
OCATAD
REKAERBTIUCRIC
ROSSERP
MOC
LEDO
MTL
OVXA
MWk
PH
1ET
ONEES
2ET
ONEES
ROT
OM
GNIDNIW
ECNATSISER)s
mhO(
3ET
ONEES
.H.M
.T.M
ARL
4ET
ONEES
mumixa
MpirTtsu
Msp
mALX-ARL
WP-ARLtsriF(
)gnidniW
dednem
moceRrekaerBtiucriC
.oNtraP
dednem
moceRALR
102F055C
C60102J055102E055
064575
064/032/8020.22
5123 72
23/86
24189382
58 95071
8.28.1
22.0/44.0
414BX38H
H834BX414BX/554BX
72 32 95
23 72 86
54168542
32 91 94
102F566C
C60102J566102E566
064575
064/032/8023.52
0205 83
05/001
371021
371/543
40127702
2.23.1
61.0/23.0
734BX38H
H164AX734BX/673BX
34 33 37
05 83 58
671421333
63 72 16
102F576C
C60102J576102E576
064575
064/032/8023.52
0205 83
05/001
371021
371/543
40127702
2.23.1
61.0/23.0
734BX38H
H164AX734BX/873BX
34 33 77
05 83 98
671421563
63 72 46
102F998C
C60102J998102E998
064575
064/032/8021.93
0385 85
37/141
352671
352/605
251601403
3.188.0
11.0/22.0
234BX38H
H034AX234BX/604
CX
36 05221
37 85141
042861464
25 14101
107
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
p
acka
ge 0
6EA6
6015
2.4.
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
d
eter
min
e na
me
plat
e st
ampi
ng, m
inim
um c
onta
ctor
siz
ing,
and
wire
siz
ing.
REC
OM
MEN
DED
RLA
FO
R 0
6CC
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.
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
. M
otor
s fro
m d
iffer
ent v
endo
rs a
nd m
otor
s of
diff
eren
t effi
cien
cies
c
an d
iffer
up
to 1
5% fr
om d
ata
show
n.
SEGNAR
GNITAREPO
ELBAW
OLLA
EGATL
OVLANI
MON
MUMIXA
MMU
MINIM
032/802064575
)zH
05(004
)zH
05(002
452925166064032
781414815243081
108
4.9 — 06D Compressor Overloads* (see 4.7, pg 104 for 06CC (16-37 cfm) 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 theterminal block. It trips (opens) control circuit at 221°F (105°C) and resets at 181°F (83°C)
EZISROSSERPMOC EGATLOV † .ONELYLRAC .ON.I.T SKRAMER
901RD60 06-1-032/802 520ZG96NH230ZG96NH
13-32A743824-32A7438
nommoCtrats
808MD60310RD60
06-1-032/802 420ZG96NH410ZG96NH
36-32A743835-32A7438
nommoCtrats
313MD60613MD60613RD60817RD60
06-1-032/802601ZG96NH730ZG96NH
4-7A843804-32A7438
nommoCtrats
901RD60
032/802 700ZG96NH 45-32A7438 deriuqeR2
064 510ZG96NH 29-32A7438 deriuqeR2
575 110ZG96NH 68-32A7438 deriuqeR2
808MD60 032/802 350ZG96NH 91-32A7438 deriuqeR2
310RD60 064 210ZG96NH 65-32A7438 deriuqeR2
575 210ZG96NH 65-32A7438 deriuqeR2
313MD60613MD60613RD60817RD60
032/802 420ZG96NH 36-32A7438 deriuqeR2
064 410ZG96NH 35-32A7438 deriuqeR2
575 230ZG96NH 24-32A7438 deriuqeR2
818AD60 032/802 412ZG96NH 9-71A8438 deriuqeR2
028RD60 064 830ZG96NH 81-32A7438 deriuqeR2
)52(427RD60 575 730ZG96NH 04-32A7438 deriuqeR2
)52(428AD60 032/802 603ZG96NH 31-91B8438 deriuqeR2
822RD60 064 010ZG96NH 92-32A7438 deriuqeR2
575 350ZG96NH 91-32A7438 deriuqeR2
823AD60 032/802 903ZG96NH 11-91B8438 deriuqeR3
733MD60 064 420ZG96NH 36-32A7438 deriuqeR2
733RD60 575 520ZG96NH 13-32A7438 deriuqeR2
032/802 412ZG96NH 9-71A8438 **deriuqeR4
735AD60145RD60 064 601ZG96NH
703ZG96NHro4-7A8438
4-91A8438ro deriuqeR2
575 103ZG96NH 96-03A7438 deriuqeR2
109
4.10 — Electrical Hook-UpConsult wiring diagram located inside compressorterminal box cover and reference diagrams shown belowfor wiring hook-up connection locations. See 3.31, pg 88for Terminal Box Packages.
Three Phase Across-the-Line StartInternal Thermostat
06DSinglePhase
06DThreePhase
* 3rd overload required on some compressors. See 4.9 06D compressor overloads.
SINGLE PHASE INTERNAL THERMOSTAT
1
1
2
2
4
4
R/1
S/3
C/2N/Cinternal ‘statinside motor 8
3
3
OL-2Start
OL-1Common
Compressor Terminal Box
T1
L1 L2
T2
06D Single Phase Wiring
Control Wiring Power Wiring
5
1
2
RunCapacitor
StartCapacitorStart
Relay
R S
7
110
06E COMPRESSORS(ACROSS-THE-LINE [XL] START)
See Fig.17, page 111, for detailed view ofterminal post arrangement.
111
06E COMPRESSORS(PART WINDING START)
Fig. 17 – Terminal PostArrangement, Detail View (06E
and 06CC 50 to 99 Cfm)See page 61 for
torques of jam nuts
112
4.11 — Voltage and Current Unbalance
VOLTAGE UNBALANCE (Maximum 2%)
Voltage unbalance can cause motors to overheat and fail.Below is the recommended method for determiningvoltage unbalance.
Example: Supply voltage is 240-3-60
Average Voltage =
Determine maximum deviation from average voltage:(AB) 243 – 239 = 4 volts(BC) 239 – 236 = 3 volts(AC) 239 – 238 = 1 volt
Maximum deviation is 4 volts.Determine % voltage unbalance:
% Voltage unbalance = 100 x
= 1.7%
This amount of phase unbalance is satisfactory as it isbelow the maximum allowable of 2%.
IMPORTANT: If the supply voltage phase unbalanceis more than 2%, contact your local electric utilitycompany immediately.
4239
243 + 236 + 2383
= 7173
= 239 volts
AB = 243 voltsBC = 236 voltsAC = 238 volts
113
CURRENT UNBALANCE (Maximum 10%)
Voltage unbalance will cause a current unbalance, but acurrent unbalance does not necessarily mean that avoltage unbalance exists. A loose terminal connection ora build-up of dirt or carbon on one set of contacts (usingthe example of L1 as the problem leg) would cause ahigher resistance on that leg (L1) than on L2 and L3. Thecurrent follows the path of least resistance, so the currentincreases in legs L2 and L3. Higher current causes moreheat to be generated in the motor windings.
Percent (%) of current unbalance is calculated in thesame way as voltage unbalance (see the previoussection), with a maximum acceptable current unbalanceof 10%.
5.0 COMPRESSOR SERVICE WORKSHEETS
Carlyle recommends that the Compressor ServiceWorksheets (pages 114 and 115) be copied (and enlarged, ifpreferred) and filled out for each compressor at initial start-up and each time the compressor is serviced. Comparing thedata from current worksheets to past records will allow theservice technician to diagnose system changes and preventcompressor failures. This information is also very useful inpreventing a repeat failure.
114
06D, 06E Compressor Service WorksheetMechanic:____________________ Date: ________________From Compressor Nameplate:Model No.: _________________________________________Serial No.: _________________________________________Motor No.: _________________________________________Voltage: ___________________________________________Allow compressor to run for 30 minutes, then obtain the pressures andbody temperature at the locations shown below. Check for proper oilreturn in sight glass.
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 WINDINGL7-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
115
06CC Compressor Service WorksheetMechanic:____________________ Date: ________________From Compressor Nameplate:Model No.: _________________________________________Serial No.: _________________________________________Motor No.: _________________________________________Voltage: ___________________________________________Allow compressor to run for 30 minutes, then obtain the pressures andbody temperature at the locations shown below. Check for proper oilreturn in sight glass.
See Compressor Operating Limits, page 19.
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 WINDINGL7-L8:_________________ L7:__________________L7-L9:_________________ L8:__________________L8-L9:_________________ L9:__________________
LEGEND: C - Common R - Run S - Start
116
Service Guide Index
Page
06CC (16 to 37 CFM) 3 Phase Electrical Specifications ................................... 104
06CC (50 to 99 Cfm) 3 Phase Electrical Specifications .................................... 106
06CC (16 to 37 Cfm) Torque Guide .................................................................... 60
06CC (50 to 99 Cfm) Torque Guide .................................................................... 61
06CC Compressor 16 to 37 Cfm Model, Connection Points — Motor End ........ 51
06CC Compressor 16 to 37 Cfm Model, Connection Points — Pump End ........ 50
06CC Compressor 50 to 99 Cfm Model, Connection Points — Motor End ........ 53
06CC Compressor 50 to 99 Cfm Model, Connection Points — Pump End ........ 52
06CC Compressor Model Numbers ...................................................................... 5
06CC Compressors — Physical Data ................................................................. 66
06CC Service Worksheet .................................................................................. 115
06D 2-Cylinder Compressor, Connection Points ................................................ 44
06D 4-Cylinder Compressor (13 and 16 Cfm), Connection Points ..................... 45
06D 4-Cylinder Compressor (18 and 20 Cfm), Connection Points ..................... 46
06D 6-Cylinder Compressor (24, 25, 28, 37 and 41 Cfm), Connection Points ... 47
06D 6-Cylinder Compressor, Exploded View ...................................................... 56
06D Compressor, Cross-Sectional View ............................................................. 54
06D Compressor Model Numbers ........................................................................ 3
06D Compressor Overloads ............................................................................. 108
06D Compressors — Physical Data ................................................................... 62
06D Compressors — Torque Guide .................................................................... 60
06D, E Service Worksheet ................................................................................ 114
06DM, DA 3 Phase Electrical Specifications ....................................................... 94
06DR 3 Phase Electrical Specifications .............................................................. 92
06DR, DM Single-Phase Electrical Specifications .............................................. 96
06E 4-Cylinder Compressor (50 and old 66 Cfm), Connection Points ................ 48
06E 6-Cylinder Compressor (65, 75, 99 Cfm), Connection Points ..................... 49
06E 6-Cylinder Compressor, Exploded View ...................................................... 58
06E Compressor, Cross-Sectional View ............................................................. 55
06E Compressor Model Numbers ......................................................................... 4
117
06E Compressors — Physical Data .................................................................... 64
06E Compressors — Torque Guide .................................................................... 61
06EA, ET 3 Phase Electrical Specifications ...................................................... 102
06ER, EY 3 Phase Electrical Specifications ....................................................... 98
06EM, EZ 3 Phase Electrical Specifications ..................................................... 100
Additives, Oil ....................................................................................................... 73
Alkylbenzene Oil, Use with CFC, HCFC, and HCFC Blends .............................. 69
Baffle Plates ........................................................................................................ 89
Bearing Head (Oil Pump), Replacement Procedures ......................................... 38
Bearing Head, High Flow Oil Pump .................................................................... 74
Bearing Head, Pump End ................................................................................... 39
Bearing Head, Replacement ............................................................................... 38
Billing and Credit ................................................................................................. 10
Capacity Control Unloading Accessory Packages .............................................. 78
Capacity Control Coil Packages ......................................................................... 80
CFCs, Approved for Use ..................................................................................... 69
Cfm Designation ................................................................................................... 5
Change Out Procedures, Oil & Refrigerant ......................................................... 72
Clean-Up ............................................................................................................. 42
Compressor Isolation .......................................................................................... 21
Compressor Model Number Significance ............................................................. 3
Compressor Mounting Data ................................................................................ 82
Compressor Problems — see “Troubleshooting” ................................................ 20
Compressor Weight ............................................................................................ 63
Compressors without Oil ..................................................................................... 68
Connection Points, 06CC 16 to 37 Cfm Models ........................................... 50, 51
Connection Points, 06CC 50 to 99 Cfm Models ........................................... 52, 53
Connection Points, 06D 2-Cylinder Models ........................................................ 44
Connection Points, 06D 4-Cylinder Models .................................................. 45, 46
Connection Points, 06D 6-Cylinder Models ........................................................ 47
Connection Points, 06E 4-Cylinder Models ........................................................ 48
Connection Points, 06E 6-Cylinder Models ........................................................ 49
Crankcase Heaters ............................................................................................. 81
118
Current Unbalance ............................................................................................ 113
Cycling, Continuous — Typical Causes .............................................................. 23
Cycling, Intermittent — Typical Causes .............................................................. 23
Cylinder Head, Blown ......................................................................................... 23
Cylinder Head Cooling Fans ............................................................................... 77
Cylinder Head Disassembly ................................................................................ 33
Cylinder Head Gasket — Failure Causes ........................................................... 23
Cylinder Head Gaskets ....................................................................................... 84
Cylinder Head Reassembly ................................................................................ 36
Discharge Gas Temperature Sensor ................................................................... 76
Electrical Hookup, 06D Compressors – Barrel Nut Tool ..................................... 85
Electrical Hookup, 06D Compressors ............................................................... 109
Electrical Hookup, 06E Compressors — Across-the-Line Start ........................ 110
Electrical Hookup, 06E Compressors — Part Winding Start ........................... 111
Electrical Specifications ...................................................................................... 92
Electrical, Terminal Box Package ........................................................................ 88
Flooding — Typical Causes ................................................................................ 24
Gasket, Terminal Plate ........................................................................................ 85
Gaskets, Compound Compressor Manifold ........................................................ 84
Gaskets, Cylinder Head and Valve Plates .......................................................... 84
Gasket, Sensor Block ......................................................................................... 85
Gaskets, Service Valves ..................................................................................... 82
Gaskets, Leak Testing ......................................................................................... 32
Green Carpet Program ....................................................................................... 10
HCFC Blends, Approved for Use ........................................................................ 70
HCFCs, Approved for Use .................................................................................. 69
Heaters, Crankcase ............................................................................................ 81
Help — Where to Get More .................................................................................. 1
HFCs, Approved for Use ..................................................................................... 71
High Efficiency Compressors, 06D, E ................................................................. 68
Insertion Heaters ................................................................................................. 81
Interstage Pressure Tables (06CC) ..................................................................... 89
Jumper Plate Packages Connection ........................................................... 88, 110
119
Locked Rotor, Cycling On — Typical Causes ..................................................... 27
Low Compressor Capacity .................................................................................. 22
Metric Conversions and Measurements ............................................................... 5
Mineral Oils, To Use With CFC and HCFC Refrigerants ..................................... 69
Model Number .................................................................................................. 3, 6
Motor Burnout ..................................................................................................... 27
Motor Barrel Interconnection ............................................................................... 13
Motor End Mounting Foot ................................................................................... 83
Motor Burnout — Clean-up Procedure ............................................................... 42
Motor Protection Tripping — Typical Causes ...................................................... 26
Mounting Data, Compressor ............................................................................... 82
Mounting Plate, Compressors ............................................................................. 82
Mufflers ............................................................................................................... 87
Nameplate Significance ........................................................................................ 6
OEM ...................................................................................................................... 9
Oil & Refrigerant Change Out Procedures .......................................................... 72
Oil Additives ........................................................................................................ 73
Oil Charge ........................................................................................................... 63
Oil Control — Parallel Compressor Applications ........................................... 13, 28
Oil Control — Motor Barrel Interconnections ...................................................... 13
Oil Drain Plug Adapter ........................................................................................ 83
Oil Level in Sight Glass ....................................................................................... 12
Oil Operating Levels ........................................................................................... 12
Oil Pressure ........................................................................................................ 73
Oil Pressure Problems — Typical Causes .......................................................... 26
Oil Pump – See Bearing Head
Oil Safety Switch ................................................................................................. 75
Oil Viscosity and Pour Points .............................................................................. 72
Oils, Approved for Use ........................................................................................ 69
Operating Limits, Typical — 06CC ...................................................................... 19
Operating Limits, Typical — 06D, E .................................................................... 18
Overloads for 06D Compressors ...................................................................... 108
Overloads – 06CC Compressors (16-37 cfm) ................................................... 104
120
Parallel Compressor Applications, Oil Control .................................................... 28
Parts Identification — 06D Compressor, Exploded View .................................... 56
Parts Identification — 06E Compressor, Exploded View .................................... 58
Physical Data — 06CC Compressors ................................................................. 66
Physical Data — 06D Compressors ................................................................... 62
Physical Data — 06E Compressors .................................................................... 64
Pipe Rattles — Typical Causes ........................................................................... 25
Piston, Suction Valve, and Backer Positions ...................................................... 36
POE Oils, To Use with HFC Refrigerants ............................................................ 71
Pump End Bearing Head .................................................................................... 39
Pre Start-Up Procedures ..................................................................................... 12
Pressure Relief Valve .......................................................................................... 76
Rated Load Amps (RLA) ..................................................................................... 92
Refrigerant and Oil Change-Out Procedures ...................................................... 72
Refrigerants and Oils for 06CC Compressors .................................................... 72
Refrigerants and Oils for 06D, E Compressors ................................................... 69
Relief Valve — 06E & 06CC 50-99 cfm Compressors ........................................ 76
Serial Number ....................................................................................................... 8
Service Billing ..................................................................................................... 10
Service Procedures ............................................................................................. 32
Service Procedures — Bearing Head (Oil Pump) ............................................... 38
Service Procedures — Cylinder Head and Valve Plate Assembly ...................... 32
Service Procedures — Motor Burnout Clean Up ................................................ 42
Service Valve Gaskets ........................................................................................ 82
Service Valves .................................................................................................... 82
Service Worksheet, 06CC ................................................................................. 115
Service Worksheet, 06D, E ............................................................................... 114
Sight Glass Adapters — Oil Equalization ............................................................ 83
Sight Glass, Oil Level .......................................................................................... 12
Sight Glass Replacement — Installation Tool ..................................................... 83
Special Order Number .......................................................................................... 7
Start-Up — Before Starting ................................................................................. 12
Start-Up — Recommended Procedures ............................................................. 11
Start-Up, Compressor ......................................................................................... 16
121
Start-Up, Troubleshooting and Service ............................................................... 10
Start-Up, Will Not Start ........................................................................................ 22
Strap-On Heaters ................................................................................................ 81
Suction Cut-Off Control ....................................................................................... 78
Suction Valve ...................................................................................................... 36
Technical Assistance, OEM ................................................................................. 10
Technical Assistance, To Get ................................................................................ 1
Terminal Box Package ........................................................................................ 88
Terminal Lug Package ........................................................................................ 88
Terminal Plate Gasket ......................................................................................... 85
Terminal Plate Jumper Bars, 06E ....................................................................... 88
Terminal Posts .................................................................................................. 111
Torque Guide — All 06D and 16 to 37 Cfm 06CC ............................................... 60
Torque Guide — 06E and 06CC (50 to 99 Cfm) Compressors ........................... 61
Troubleshooting ................................................................................................... 20
Troubleshooting — 06CC Desuperheater Connection Hot ................................. 31
Troubleshooting — 06CC Discharge Pressure = Intermediate Pressure ........... 31
Troubleshooting — 06CC Economizer Connection Hot ...................................... 31
Troubleshooting — 06CC High Midstage Pressure ............................................ 31
Troubleshooting — 06CC Intermediate Pressure = Discharge Pressure ........... 31
Troubleshooting — 06CC Low Midstage Pressure ............................................. 31
Troubleshooting — Cannot Pull Down ................................................................ 22
Troubleshooting — Compressor Isolation Procedures ....................................... 21
Troubleshooting — Cycling, Continuous ............................................................. 23
Troubleshooting — Cycling, Intermittent ............................................................. 23
Troubleshooting — Cylinder Head Gasket .......................................................... 23
Troubleshooting — Desuperheater Connection Hot, 06CC ................................ 31
Troubleshooting — Discharge Temperature Sensor ........................................... 26
Troubleshooting — Economizer Connection Hot, 06CC ..................................... 31
Troubleshooting — Flooding ............................................................................... 24
Troubleshooting — Locked Rotor, Cycling On .................................................... 27
Troubleshooting — Low Discharge Pressure ..................................................... 24
Troubleshooting — High Midstage Pressure, 06CC ........................................... 31
Troubleshooting — Low Midstage Pressure, 06CC ............................................ 31
122
Troubleshooting — Low On Capacity ................................................................. 22
Troubleshooting — Low or No Oil Pressure ....................................................... 26
Troubleshooting — Low Suction Pressure .......................................................... 24
Troubleshooting — Motor Burnout ...................................................................... 27
Troubleshooting — Motor Protection Tripping .................................................... 26
Troubleshooting — No Oil Pressure ................................................................... 26
Troubleshooting — Noisy Compressor ............................................................... 25
Troubleshooting — Oil Safety Switch Tripping .................................................... 30
Troubleshooting — Parallel Systems .................................................................. 28
Troubleshooting — Pipe Rattle ........................................................................... 25
Troubleshooting — Running Hot ......................................................................... 29
Troubleshooting — Sight Glass, Low or Empty .................................................. 30
Troubleshooting — Starting Problems ................................................................ 22
Troubleshooting — Valve Plates .......................................................................... 23
Troubleshooting — Will Not Start ........................................................................ 22
Troubleshooting Guide ........................................................................................ 22
Unloading — Capacity Control ............................................................................ 78
Valve Plate Gaskets ............................................................................................ 84
Valve Plate Gaskets, Blown ................................................................................ 23
Valve Plate Disassembly ..................................................................................... 33
Valve Plate Packages ......................................................................................... 86
Valve Plates — Failure Causes .......................................................................... 23
Valve Plates — Replacement Procedures .......................................................... 32
Valve Plates — Leak Testing ............................................................................... 32
Voltage Unbalance ............................................................................................ 112
Warranty ................................................................................................................ 9
Weight, Compressor ........................................................................................... 63
SERVICE GUIDE
06D/06E/06CCCOMPRESSORS
COMPLIMENTS OF:
CARLYLE COMPRESSOR DIVISION • © CARRIER CORPORATION 7/98P.O. Box 4808 • Syracuse New York 13221www.carlylecompressor.comIn U.S., Puerto Rico: 1-800-GO-CARLYLE (1-800-462-2759)In Canada: 1-800-258-1123In Mexico: 001-800-GO CARLYLE (001-800-462-2759)
Manufacturer reserves the right to discontinue or change at any time, specificationsor designs and prices without notice and without incurring obligations.
Rev 1/06 Lit No: 020-611 www.carlylecompressor.com
G#4322Cover020-611/21st 01/23/2006 8:08 AM Page 1