comp carlyle torque.pdf

8/10/2019 COMP CARLYLE TORQUE.pdf

1/125

SERVICE

GUIDE

06D/06E/06CCCOMPRESSORS

www.carlylecompressor.com


2/125

WHAT THIS GUIDE CAN DO FOR YOU

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

This guide uses the terms DANGER, WARNING and CAUTION. These termshave speci c meanings that identify the degree of hazard. Typically in theHVAC industry, these speci c meanings are:

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

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

An Index is provided in the back of this guide.

TO GET MORE HELP

Carlyle Compressor Company sells compressors to Carrier for use in their pack-aged units and to OEMs (Original Equipment Manufacturers) that design and build

nished systems. The system manufacturer is the expert on the system, includingthe application of our compressor. All questions, on either the packaged system orthe compressor in that system, should be rst directed to the local Carrier distributor(for Carrier systems) or the OEM or its local representative (for other units). If thissupport, along with this service guide, cannot resolve your compressor problem,please contact our Carlyle engineering group.

CARLYLE COMPRESSOR THANKS YOUFOR SELECTING OUR EQUIPMENT

Hazards or unsafe practices which COULD result in severe personalinjury or death.

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

CAUTION!

WARNING!

DANGER!

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

Manufacturer reserves the rightto discontinue, or change at any

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


3/125

1

CONTENTS

1.0 GENERAL COMPRESSOR AND CUSTOMERINFORMATION1.1 Compressor Model Number Signi cance ........................................31.2 Nameplate Signi cance ...................................................................61.3 Compressor Serial Number Signi cance .........................................81.4 Carlyle OEM Compressor Warranty ...............................................91.5 Service Billing and Credit .............................................................101.6 Carlyle Compressor Connection Program, Parts and

Stocking Policy .............................................................................10

2.0 START-UP, TROUBLESHOOTING, AND SERVICE 2.1 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 06D and 06CC (16 to 37 Cfm) Compressors .....60 2.11 Torque Guide 06E and 06CC (50 to 99 Cfm) Compressors ....61

3.0 COMPRESSOR AND PARTS DATA 3.1 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 Ef ciency (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 07/08


4/125

2

3.14 Oil Safety Switch ..........................................................................753.15 06CC, E Discharge Gas Cylinder Head Temperature Sensor ........763.16 06D, E Cylinder Head Cooling Fans .............................................773.17 Capacity Control Accessory Packages ...........................................783.18 Capacity Control Coil Packages (06D, E) .....................................803.19 Crankcase Heater Data ...................................................................813.20 Compressor Mounting Data ...........................................................823.21 Compressor Service Valves (06D, E, CC) .....................................823.22 Service Valve Gaskets (06D, E, CC) ..............................................823.23 Oil Drain Plug Adapter ..................................................................833.24 Sight Glass Adapters for Oil Equalization .....................................833.25 Replacement Sight Glass Installation Tool ...............................83

3.26 Replacement Motor End Mounting Foot .......................................833.27 Gaskets Cylinder Head and Valve Plate ....................................843.28 Miscellaneous ................................................................................853.29 Valve Plate Packages, Service Replacement ..................................863.30 Muf er Recommendations .............................................................873.31 Electrical Accessories ....................................................................883.32 Baf e Plate Recommendations ......................................................89

3.33 Interstage Pressure Tables (06CC Compressors Only) ..................89

4.0 ELECTRICAL DATA4.1 06DR 3 Phase Electrical Speci cations ..........................................924.2 06DM, DA 3 Phase Electrical Speci cations ..................................944.3 06DR, DM Single Phase Electrical Speci cations .........................964.4 06ER, EY 3 Phase Electrical Speci cations ...................................98

4.5 06EM, EZ 3 Phase Electrical Speci cations .................................1004.6 06EA, ET 3 Phase Electrical Speci cations .................................1024.7 06CC (16 to 37 Cfm) 3 Phase Electrical Speci cations ...............1044.8 06CC (50 to 99 Cfm) 3 Phase Electrical Speci cations ...............1064.9 06D Compressor Overloads ..........................................................1084.10 Electrical Hook-Up .......................................................................1094.11 Voltage and Current Unbalance .....................................................112

5.0 COMPRESSOR SERVICE WORKSHEETS06D, 06E COMPRESSOR SERVICE WORKSHEET ..................................11406CC COMPRESSOR SERVICE WORKSHEET ..................................115

SERVICE GUIDE INDEX ................................................ 116


5/125

3

1.0 GENERAL COMPRESSOR ANDCUSTOMER INFORMATION

1.1 Compressor Model Number Signi cance06D COMPRESSORS

06DR 3 37 0 D A 36 5 A (RP)**

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

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

8 = 2 Unloaders

Electrical Characteristics (XL Start Only, Unless Noted): New H.E. Models Old Std. Models 31 = 575-3-60 01 = 575-3-60 12 = 208/230-3-60 32 = 208/230-3-60 04 = 200-3-60 13 = 380-3-60 33 = 208/230-1-60 05 = 230-3-60 14 = 200-3-60 (PW) 34 = 220-3-50 06 = 400/460-3-50/60 15 = 230-3-60 (PW) 36 = 400/460-3-50/60 08 = 220-3-50 18 = 220-3-50 (PW)

Electrical Variables: A = With Internal Thermostat and External Overloads C = With Internal Thermostat and Without External Overloads Suction Valve - Variables: Location, Orientation and Mounting Bolts

Compressor Identication Key: 0 = New Compressor 2 = New Compressor

3 = New Compressor 6 = Service Compressor, Remanufactured 7 = Service Compressor, New Manufactured 8 = New Compressor, Special 9 = Service Compressor, Special

Displacement (in Cfm at 1750 rpm)

Motor Size - (Does Not Signify Horsepower)

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

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

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

**Refrigeration Partner

Hot Gas BypassUnloading}Suction Cut-OffUnloading}


6/125

4

06E COMPRESSORS

06ER 3 99 3 0 A (RP)**

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

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

Service Compressors: 2 = New Manufactured (A/C) 4 = Remanufactured (Low Temp.) 6 = Remanufactured (A/C) 7 = Remanufactured (Med Temp.)

Electrical Characteristics (XL and PW Start, Unless Noted): 0 = 208/230-3-60 1 = 575-3-60 3 = 208/230/460-3-50/60 (460v XL Only) 4 = 200-3-60 5 = 230-3-60

6 = 400/460-3-50/60 8 = 230-3-50

9 = 220/380-3-60

Displacement (in Cfm at 1750 rpm)

Motor Size (Does Not Signify Horsepower) 0, 1, 2 = Models With Oil 3, 4, 5 = Models Without Oil 7 = 1 Unloader, Suction Cut-off, Oil-less (ER, EM Only) 8 = Special Order

Compressor Type: STD* REV 06EA 06EF Compressor - A/C Duty No Unloading

06EB 06EJ Compressor - A/C Duty 1-Step Elec. 06EC 06EK Compressor - A/C Duty 2-Step Elec. 06ED 06EL Compressor - A/C Duty 1-Step Press. 06EE 06EN Compressor - A/C Duty 2-Step Press. 06E2 06E6 Compressor - A/C Duty 1-Step Elec. 06E3 06E7 Compressor - A/C Duty 2-Step Elec. 06E4 06E8 Compressor - A/C Duty 1-Step Press. 06E5 06E9 Compressor - A/C Duty 2-Step Press. 06EM - Compressor - Refrig. Duty Med Temp. 06ER - Compressor - Refrig. Duty Low Temp. 06ET - Serv. Compressor A/C Duty Replaces 06E2,3,4,5,6,7,8, and 9.

Compressor has 1 stage of suction cut-off unloading.06EX - Serv. Compressor A/C Duty Replaces 06EA,B,C,D,E,F,J,K,L, and N

Compressor has 1 stage of Bypass unloading. 06EY - Serv. Compressor Refrig. Duty Replaces 06ER 06EZ - Serv. Compressor Refrig. Duty Replaces 06EM

* Standard Center Cylinder Head. Reversed Center Cylinder Head.

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

**Refrigeration Partner

Hot Gas BypassUnloading

Suction Cut-OffUnloading

}}


7/125

5

06CC COMPRESSORS

06CC 6 65 E 201

Design Variable: 101 = Single Pack, W/O Valves, with Oil 102 = Single Pack with Valves & Oil 103 = Single Pack, Service W/O Valves and Term. Box or Oil 201 = Single Pack, W/O Valves or Oil

202 = Single Pack with Valves

Electrical Characteristics: A = 415-3-50, XL and PW B = 415-3-50, XL C = 415-3-50, PW D = 208/230-3-60, XL E = 208/230/400/460-3-50/60 F = 400/460-3-50/60, XL and PW G = 400/460-3-50/60, XL H = 400/460-3-50/60, PW J = 575-3-60, XL and PW K = 230-3-60, PW L = 220-3-50, XL and PW M = 220-3-50, XL N = 220-3-50, PW P = 220/346/380-3-50/60, XL and PW

Displacement (in Cfm at 1750 rpm) (See Note below)

Motor Size: 0 = 14 ft.-lb (5 HP) 5 = 45 ft.-lb (15 HP) 1 = 20 ft.-lb (6.5 HP) 6 = 60 ft.-lb (20 HP) 2 = 24 ft.-lb (7.5 HP) 7 = 75 ft.-lb (25 HP) 3 = 27 ft.-lb (10 HP) 8 = 90 ft.-lb (30 HP) 4 = Not Assigned

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

NOTE: USE OF Cfm AS MODEL SIZE DESIGNATIONCarlyle 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 to37 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 Cfmsizes. The 16 to 37 Cfm compressors use D size bodies. The 50 to 99 Cfm compressors useE size bodies.

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.


8/125

6

1.2 Nameplate Signifcance

Explanation of the above items, starting clockwisefrom upper right:

MODEL NUMBER - Used when selecting and orderinga new compressor. Distributors use the model number

to obtain a proper service replacement. NOTE: Model numbers on some compressors are

identi ed by the symbol M/N located in the upperright hand corner of the nameplate.

UL AND CSA - Single mark indicates that this

compressor meets all the requirements for bothUL (Underwriters Laboratory) and CSA (CanadianStandards Association). All 60 Hz semi-hermeticCarlyle Compressors are UL and CSA recognized andcomply with UL, CSA, and NEC (National ElectricalCode) requirements for internal motor protection.

MOTOR NUMBER - For Carlyle internal use only.


9/125

7

TEST PRESSURES - Each Carlyle 06D/E/CCcompressor is pressure tested at our factory. The LS

pressures are for the low side of the compressor. TheHS 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 toeach compressor. This number, along with the modelnumber and special order number, is normally all thatis needed to obtain information about or order a servicereplacement compressor.

SERIAL NUMBER BAR CODE - For Carlyle internaluse only.

ELECTRICAL CHARACTERISTICS - are shown for

all semi-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.


10/125

8

1.3 Compressor Serial Number Signi cance

ALL NEW COMPRESSORS Example: S/N 3695J00123

36 95 J 00123 Numerical Sequence Plant Location: J = Syracuse, U = Atlanta Year of Manufacture: 93, 94, 95, etc. Week of Manufacture: 01 thru 52 Begin Jan.1st

ALL SERVICE COMPRESSORS

Example: S/N 3602UD0123 36 02 U D 0123

Numerical Sequence Compressor Type: D, E Plant Location: M = Atlanta, P = Phoenix,

U = Atlanta (after 4/2001) Year of Manufacture: 93, 94, 95, etc. Week of Manufacture: 01 thru 52. Begin Jan. 1st

NEW AND SERVICE REPLACEMENTCOMPRESSORS BUILT BETWEEN

NOV. 1968 - OCT. 1978Example: A2J0001

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

M=Dec *An X, A or P in this location indicates service compressor.


11/125

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 rst.

When a service compressor is used to replace an originalcompressor, the remaining portion of the rst-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 or deter-mination of failure does not void warranty.


12/125

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 Carlyle Compressor Connection Program, Partsand Stocking Policy

The Carlyle Compressor Connection program is afree service created to assist users in locating servicereplacements through our national distribution network.The program supports nding replacement compres-sors for reported installations, ensuring availability atthe designated distributorship closest to the end-users

location. Carlyle Customer Service Representatives can provide assistance in locating the necessary distributor24 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 nished system. The OEM is the expert


13/125

11

on the entire system, including the Carlyle compressor.All system or compressor questions should be directed

rst to the OEM or the OEMs local representative.If questions 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 oodedstart, oodback, 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, pages32 to 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 followin case of motor burnout. Most other internal servicerequires replacement of the compressor.

2.2 Recommended Start-Up Procedure

Reliability data of Carlyles 06D, 06E, and 06CCrefrigeration compressors indicate that at least half ofcompressor failures occur during the rst 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 ooded start,

oodback, and running out of oil. Most of thesefailures 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.


14/125

12

BEFORE START-UP

1. Verify that the compressor nameplate indicates proper 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 speci c oils (mineral, alkylbenzene, or

polyolester [POE]), Carlyle ships most new andservice compressors without oil. The oil level for

06CC 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 beat 1/8 to 3/8 of the sight glass. See Sections 3.6and 3.7, pages 69 to 72 for the proper Carlyleapproved oils for the selected refrigerant. Oil

should be added through the recommended oil llconnection ports on the compressor as identi edin the gures in secton 2.5.Once the compressor system has been running forat least 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.

OPERATING OIL LEVELS

06CC (16 TO 37 CFM) AND 06D

3/4 (MAX)

1/4 (MIN)

06CC (50 TO 99 CFM) AND 06E

3/8 (MAX)

1/8 (MIN)


15/125

13

Do not add excess oil. It is especially important on the06E and 06CC (50 to 99 Cfm) compressors that excessoil not be added to the system. Laboratory tests and eldexperience indicate excessive oil levels can cause blownvalve plate and cylinder head gaskets, increase compres-sor operating temperatures, and cause oil equalization

problems.

NOTE: All 06D compressors and 06CC (16 to 37 Cfm)compressors have one sight glass on the side of the

crankcase. All 06E compressors and 06CC (50 to99 Cfm) compressors have two sight glasses, on the oil pump end of the compressor.

Parallel compressor applications typically use anoil-control oat system consisting of individual oats,a separator and an oil reservoir. When using a oat

system, do not interconnect the oats with an equaliza-tion system without approval from Carlyle applicationengineering. The use of a oat equalization system canresult in system oil control problems.

An oil equalization line can be used instead of a oatsystem, 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 refrig-erant 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 rise

lling the line, and oil control between compressors will be lost. Typically, equalization lines are 1 1/8 in.(28 mm) in diameter or larger. For 06D compressors, 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 interconnectionline is strongly recommended on two (2) 06E

CAUTION!


16/125

14

compressor unit con gurations. This system prevents oilfrom building up in an 06E motor barrel during the offcycle, thereby preventing an oil slug on start-up. The lineis either 1/4 in. (6 mm) or 3/8 in.(8 mm) tubing inter-connecting to ttings located in the bottom of the 06Ecrankcases. To connect to the 06E compressor motor

barrel, tting P/N 5F20-1311 (5/8 in.-18 x 1/4 in. NPT)with AU51YA001 gasket is recommended. Some 50 cfmcompressors have a 1/4 in. NPT connection and do notrequire the 5F20-1311 tting. The motor barrel inter-connection line is in addition to either the crankcase oilequalization line or the oil oats.

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 eldexperience con rm 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 the

correct oil levels.

CAUTION!

Do not charge oil through the suction lineor through the compressor suction access

ttings. See the compressor gures 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!


17/125

15

Use only Carlyle approved oil appropriate for therefrigerant being used. Sections 3.6 and 3.7 on

pages 69-72 list all the approved oils. Section 3.11 on page 73 notes the correct oil pump pressure in relation 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 crankcase

and into the oil, causing a ooded 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 allow

the compressor to run without tripping the low-pressureswitch. This is to prevent damage to the compressor fromany liquid refrigerant oodback.

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.


18/125

16

COMPRESSOR START-UP

1. After circuit breaker and control circuit switches are placed in the ON position and the compressor starts,listen for unusual sounds. If unusual sounds are heard,shut down the compressor, investigate the cause, andcorrect. Possible problems are:

excessive vibration excessive oil liquid slugging low oil

2. After the compressor has run 10 to 15 minutes and noliquid oodback 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 acceptable

limits, 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 lm 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, inspect thecompressor for excessive oil after the defrost cyclehas 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 con gurations by adding only 1 quart


19/125

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 mineral

or alkylbenzene oils, foam in the sight glass normallyindicates either that there is serious liquid refrigerantoodback or that the running gear is hitting the oil due to

a 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 oodback or too much oil in thesystem.

Liquid refrigerant should never be allowed to ood backto the compressor. It may wash out bearings and damagegaskets. If liquid oodback is occurring, adjust theexpansion valve or make other adjustments as necessaryto eliminate this condition.

NOTE: One possible cause of ooding 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!


20/125

18

Fig. 1A Typical 06D, E Operating Limits


21/125

19

Fig. 1B Typical 06CC Operating Limits


22/125

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 testing becausebodily injury or death can result from re and/or

explosion if cover is removed or unsecured beforepower is disconnected and pressure is relieved.Electrical terminal pins may blow out, causinginjury and re.

DANGER!

DANGER!


23/125

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 incompressor. Appropriate service practices should befollowed to properly reclaim refrigerant removed fromthe compressor.

2. Disconnect all electrical wiring to compressor.3. Unbolt suction and discharge service valves from

compressor.

REMINDER: These valves may be sealing offrefrigerant from the rest of the system. Do not open

these valves without rst determining whether there isrefrigerant in the system.


24/125

22

T r o u

b l e s h o o

t i n g

G u

i d e -

0 6 D

, 0 6 E a n

d 0 6 C C C o m p r e s s o r s


25/125

23


26/125

24


27/125

25


28/125

26


29/125

27


30/125

28


31/125

29


32/125

30


33/125

31

L E G E N D

E P R

- E v a p o r a t o r

P r e s s u r e

R e g u

l a t o r

T X V

- T h e r m o s t a t i c

E x p a n s i o n

V a

l v e


34/125

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 cylinder

head or valve plate gaskets:1. Pump compressor down.

2. Observe suction and discharge pressure equalization.If valves are leaking or a gasket is blown, the

pressure will equalize rapidly.

Maximum allowable discharge pressure drop is 3 psi per minute after initial drop of 10 to 15 psi in rsthalf 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.


35/125

33

DISASSEMBLY

1. Disassemble cylinder heads by removing cylinder head bolts. Leave at least 2 bolts partially threaded to preventany problems if refrigerant is accidentally left in thecompressor under pressure. To separate the cylinder headfrom the valve plate, pry up between the head and valve

plate. When the cylinder head is separated from the compressor body remove the last threaded bolts.

Do not hit the cylinder head to break it free of thevalve plate. This may shear the valve plate dowel pins.Sheared dowel pins usually require that the compres-sor 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 from which

the cap screw was removed.

c. Re-insert cap screw and tighten to break valve plateaway from compressor. (Jack screw method, see Fig.2.) For 06E valve plates, pry against the raised tab to

break valve plate away from the compressor.

CAUTION!


36/125

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 dowel

pins. 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. Individual

parts must not be interchanged. Alignment of highef ciency 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 Efciency Valve Plate Shown)


37/125

35

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

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


38/125

36

REASSEMBLY

1. If reassembling existing components, do not interchangevalves or turn them over. They must be reassembledin their original position. Install the suction valve

positioning 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 of positioning 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)


39/125

37

3. Install new valve plate gasket. Using proper hold-downtorque will prevent leaks.

a. Fiber gaskets can be installed dry or lightly oiled.

Do not soak gaskets in oil. If an oil-soaked gasket isoverheated, it will bind to the metal, making the valve plate and/or the head dif cult 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. Tocon rm the gasket is correct, place it over the cylinder

head and verify all exposed machined surfaces will becovered by the gasket.

a. Line up the gasket with the cylinder head and valve plate.

b. 06E compressor: secure the center rib with a cap 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 06E cyl-inder 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.


40/125

38

7. Certain high compression ratio applications develophigh discharge gas temperatures which may cause thecylinder head and ber 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 ber 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 and

Fig. 7).For 06D, E, CC oil pressure, see page 73, Section 3.11 .

The oil pump assembly is contained in the pump end bearinghead aluminum casting. The pump end main bearing is amachined part of this casting. No insert bearing is required.


41/125

39

1. a. To disassemble, rst remove four (4) cap screws fromthe bearing head cover plate and remove the oil feedguide vane and spring.

b. Remove the two (2) drive segment cap screws fromthe end of the crankshaft (see Fig. 6 and Fig. 7). Thesescrews must be removed before the bearing head canbe removed.

2. Remove the eight (8) cap screws holding the bearing head

assembly to the crankcase. Remove the bearing headassembly by pulling forward.

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


42/125

40

3. Inspect the bearing surfaces for evidence of wear ordamage. If bearing surface is worn or scored, or if theoil pump is defective, the complete bearing head must bereplaced (see replacement bearing head package listed

below).

While bearing head is removed, inspect internal runninggear for obvious problems (broken rods or pistons).

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


43/125

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 in

bearing head could be stripped.


44/125

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 - literature #020-262.

Before attempting service work on the compressor, see safety precautions listed in Section 2.3, pages 20 to 31, and on compressorterminal box cover. Also follow any installation instructions

provided with the replacement compressor. Failur e to followthese instr uctions could r esult in equipment damage or ser iouspersonal injur y.

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 uctuation 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 andremove the 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 all

other connections to damaged compressor. b. Remove damaged compressor and replace with a new

compressor.

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

WARNING!


45/125

43

should be thoroughly cleaned or replaced before connecting toreplacement compressor.

4. Install new liquid line lter-drier. If the system has a suction linelter-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 ush 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 lter-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. CarriersTotal Test Kit is accurate for CFC and HCFC air-conditioningapplications. If used with POE oils, Total Test Kit will indicate acid,

but is not an accurate indicator of moisture.

7. Inspect oil daily for discoloration and acidity. If oil stays clean andacid-free, the system is clean. If oil shows signs of contamination,change oil, change lter-drier, and clean suction strainer. If lter-drier or suction strainer is dirty or discolored, repeat this step untilsystem is cleaned.


46/125

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


47/125

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


48/125

46

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



49/125

47

Fig. 11 06D 6-Cylinder Compressor (24, 25, 28, 37 and41 Cfm) Connection Points



50/125

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 threded portions of thecasing, comparable metric measurements are not included.

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

BLANK PLATEREMOVE FOREQUALIZING LINEOR OIL FLOATCONNECTION

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

1/4" NPT HIGHPRESSURECONNECTION

CYLINDER HEADCOOLING FANMOUNTING STUDS(06ER MODELS ONLY)

TEMPERATURE SENSORCYLINDER HEADDISCHARGE GAS

DISCHARGE VALVELOCATION

LIFTING LUG(NEW MODELS ONLY)

NAMEPLATE LOCATIONCRANKCASE MOTORBARREL-LEFT SIDE

SUCTION VALVELOCATION(ON MOTOR END COVER)

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

BEARING HEAD(CONTAINS OIL PUMP)1/4" NPT (2) CONNECTIONS(1) ABOVE SIGHTGLASS(1) ABOVE BLANK PLATE USED FOR:A) OIL FILL CONNECTIONB) LOW SWITCH OIL SAFETY SWITCH CONNECTION

CRANKCASE HEATER(ACCESSORY)INSERTS INTO WELLIN BOTTOM COVER

OIL LEVEL SIGHTGLASS

INTERCHANGEABLEWITH BLANK PLATE

7/16"-20 SAE OIL DRAIN

CONNECTIONCRANKCASE OIL SUMP


51/125

49


Fig. 13 06E 6-Cylinder Compressor (65, 75, 99 Cfm)Connection Points


52/125

50


Fig. 14A 06CC Compressor (16 to 37 Cfm), 06D BodyPump End Connection Points


53/125

51


Fig. 14B 06CC Compressor (16 to 37 Cfm), 06D BodyMotor End Connection Points

IF AVALABLE USEPORT ON SERVICEVALVE TO DESUPERHEATLIQUID INJECTION FITTING

PN 2TA1004


54/125

52


Fig. 15A 06CC Compressor (50 to 99 Cfm), 06E BodyPump End Connection Points


55/125

53


Fig. 15B 06CC Compressor (50 to 99 Cfm), 06E BodyMotor End Connection Points

IF AVAILABLE USEPORT ON SERVICEVALVE TO DESUPERHEATLIQUID INJECTION FITTINGPN 2TA1004


56/125

54

2 . 6

C r o s s -

S e c t

i o n a

l V i e w , 0 6 D S e m

i - H e r m e t

i c C o m p r e s s o r


57/125

55

2 . 7

C r o s s -

S e c t

i o n a

l V i e w

, 0 6 E S e m

i - H e r m e t

i c C o m p r e s s o r


58/125

56

2 . 8

E x p

l o d e d V i e w

6 - C y l i n

d e r

0 6 D C o m p r e s s o r

C o m p l e t e p a r

t s b r e a

k -

d o w n s h o w n

f o r r e

f e r -

e n c e o n

l y .

S o m e p a r t s

m a y

b e p i c t u r e d p r

i o r

t o d e s i g n c h a n g e s a n

d

n o t a l l p a r t s a r e a v a i

l -

a b l e a s r e p l a c e m e n

t s .

L E G E N D

2

T e r m

i n a l

B o x

C o v e r

3

T e r m

i n a l

B o x

4

T e r m

i n a l

P l a t e A s s e m

b l y

9

G r o m m e t

( f o r p o w e r

l e a d s )

1 4

S u c

t i o n

S e r v

i c e

V a l v e

1 5

S u c

t i o n

S e r v

i c e

V a l v e

S e a

l C a p

1 6

S u c

t i o n

S e r v

i c e

V a l v e

G a s

k e t

1 7

S u c

t i o n

S e r v

i c e

V a l v e

B o l

t

1 8

S u c

t i o n

S e r v

i c e

V a l v e

B o l

t W a s

h e r

1 9

D i s c h a r g e

S e r v i c e

V a l v e

2 0

D i s c h a r g e

S e r v i c e

V a l v e

S e a

l C a p

2 1

D i s c h a r g e

S e r v i c e

V a l v e

G a s

k e t

2 2

D i s c h a r g e

S e r v i c e

V a l v e

B o l

t

2 3

D i s c h a r g e

S e r v i c e

V a l v e

B o l

t W a s h e r

2 9

S t a n d a r

d S i d e B a n

k C y l

i n d e r

H e a

d


59/125

57

3 0

C e n

t e r B a n k

C y l

i n d e r

3 1

S t a n d a r

d S i d e B a n

k C y l

i n d e r

H e a

d

G a s

k e t ( U n l o a

d e r

S i d e

B a n

k

H e a

d n o t s h o w n )

3 3

C e n

t e r B a n k

C y l

i n d e r

H e a

d G a s

k e t

3 4

C y l

i n d e r H e a d

C a p

S c r e w

3 5

C y l

i n d e r H e a d

C a p

S c r e w

G a s

k e t

3 6

O i l F i l t e r

S c r e e n

A s s e m

b l y

3 7

O i l S u c

t i o n T u b e

3 8

O i l R e l

i e f V a l v e

A s s e m

b l y

4 0

O i l L e v e

l S i g h t G l a s s

A s s e m

b l y

4 1

O i l L e v e

l S i g h t G l a s s

G a s

k e t

4 4

M o t o r

E n d

C o v e r

4 5

M o t o r

E n d

C o v e r

G a s

k e t

4 6

M o t o r

E n d

C o v e r

C a p

S c r e w

4 7

M o t o r

E n d

C o v e r

C a p

S c r e w

W a s

h e r

4 8

B o t

t o m

C o v e r

P l a t e

4 9

B o t

t o m

P l a t e

G a s

k e t

5 0

B o t

t o m

P l a t e

C a p

S c r e w

5 1

B o t

t o m

P l a t e

C a p

S c r e w

W a s

h e r

5 2

C o m p r e s s o r

F o o

t

5 3

C o m p r e s s o r

F o o

t S c r e w

5 4

C o m p r e s s o r

F o o

t E v e r l o c k w a s

h e r

5 5

S u c

t i o n

S t r a i n e r

A s s e m

b l y

5 6

O i l B y p a s s P

l u g

5 7

O i l R e t u r n C

h e c k

V a l v e

A s s e m

b l y

5 8

P u m p

E n d

B e a r i n g

H e a

d A s s e m

b l y

5 9

B e a r i n g

H e a d

6 0

P u m p

R o t o r

6 4

P u m p

R o t o r

R e t a i n i n g

R i n g

6 6

D r i v e

S e g m e n

t

6 7

O i l F e e

d G u i d e

V a n e

6 8

O i l F e e

d V a n e

S p r

i n g

6 9

C o v e r

P l a t e

7 0

C o v e r

P l a t e C a p

S c r e w

7 1

C o v e r

P l a t e C a p

S c r e w

G a s

k e t

7 2

C o v e r

P l a t e G a s

k e t

7 3

B e a r i n g

H e a

d G a s

k e t

7 4

C a p

S c r e w s

& L o c k w a s h e r s

7 5

C a p

S c r e w s


7 6

C a p

S c r e w s


7 7

C a p

S c r e w s


7 8

B e a r i n g

H e a

d C a p

S c r e w

7 9

B e a r i n g

H e a

d C a p

S c r e w

W a s

h e r

8 0

C r a n k s h a f

t

8 1

T h r u s

t W a s

h e r

8 2

S p i r o

l P i n

8 3

R o t o r

D r i v e

K e y

8 4

R o t o r

W a s

h e r

8 5

R o t o r

L o c k w a s

h e r

8 6

E q u a l

i z e r

T u b e A s s e m

b l y

8 7

P i s t o n

A s s e m

b l y

9 1

O i l R i n g

( N o t

A l l M o d e

l s )

9 2

C o m p r e s s i o n

R i n g

9 3

C o n n e c t

i n g

R o d

& C a p

A s s e m

b l y

9 4

C o n n e c t

i n g

R o d

C a p

S c r e w

9 6

S u c

t i o n

V a l v e

9 7

S u c

t i o n

V a l v e

P o s

i t i o n

i n g

S p r

i n g

9 8

D i s c h a r g e

V a l v e

9 9

D i s c h a r g e

V a l v e

S t o p

1 0 0

V a l v e

P l a t e G a s

k e t

1 0 1

D i s c h a r g e

V a l v e

S t o p C

a p S c r e w

1 0 2

D i s c h a r g e

V a l v e

S t o p L o c

k w a s

h e r

1 0 3

V a l v e

P l a t e D o w e l

1 0 4

O i l D r a

i n P l u g ,

( N e w

D e s

i g n

S A E

F i t t i n g a n

d O - R

i n g )


60/125

58

2 . 9

E x p

l o d e d

V i e w

6 - C y l i n

d e r

0 6 E C o m p r e s s o r

C o m p l e t e p a r t s

b r e a

k -

d o w n s h o w n

f o r r e

f e r -

e n c e o n

l y . S

o m e p a r t s

m a y

b e p i c t u r e

d p r

i o r

t o d e s i g n c h a n g e s a n

d

n o t a l l p a r t s a r e a v a i

l -

a b l e a s r e p l a c e m e n

t s .

L E G E N D

1

C o m p r e s s o r

M o t o r

S t a t o r a n

d R o t o r

2

M o t o r

K e y

3

R o t o r

P l a t e W

a s h e r

4

R o t o r

L o c k W

a s h e r

5

R o t o r

L o c k B o l

t

6

M o t o r

L o c k B u s

h i n g

7

R o l

l P i n

8

A c o r n

N u t a n

d G a s

k e t


61/125

59

1 0

T e r m

i n a l

B o x

A s s e m

b l y

1 2

T e r m

i n a l

P l a t e

A s s e m

b l y

1 4

T e r m

i n a l

B o l t A s s e m

b l y

1 8

C o m p r e s s o r

C r a n k c a s e

1 9

M o t o r

E n d

C o v e r

2 0

C y l

i n d e r H e a d -

C e n

t e r

B a n

k

2 1

C y l

i n d e r H e a d -

S i d e

B a n

k

( U n l o a

d e r H

e a d N o t

S h o w n )

2 2

I n t e r n a l

R e l i e f V a l v e

2 3

C r a n k c a s e

O i l F i l t e r

S c r e e n

2 4

O i l S i g h t G l a s s

A s s e m

b l y

2 5


O R i n g

G a s

k e t

2 6


S c r e w

2 7


L o c k

W a s

h e r

2 8

P i p e

P l u g G

a s k e t ( H e x

H e a

d )

2 9

B o t

t o m

C o v e r

P l a t e

3 0

P u m p

E n d

B e a r i n g

H e a

d A s s e m

b l y

3 1

P u m p

R o t o r

3 2

P u m p

V a n e

3 3

P u m p

V a n e

S p r

i n g

3 4

P u m p

V a n e

S p r

i n g

G u i

d e

3 5

R e t a i n i n g

S p r

i n g

G u i

d e

3 6

O i l F e e

d G u i

d e V a n e

3 7

O i l F e e

d G u i

d e V a n e

S p r

i n g

3 8

O i l P u m p D r i v e

S e g m e n

t

3 9

S c r e w , S

o c H e a

d 1 / 4

2 8 x

5 / 8 - i n

.

4 0

S c r e w , S

o c H e a

d # 1 0

3 2 x

1 / 2 - i n

.

4 1

C o v e r

P l a t e

4 2

C o v e r

P l a t e

C a p

S c r e w

4 3

O i l R e l

i e f P i s t o n

4 4

C r a n k s h a f t

4 5

B e a r i n g

W a s h e r

4 6

P i s t o n

R i n g s

( O i l a n

d C o m p r e s s i o n

)

4 7

P i s t o n ,

P i s t o n

P i n a n

d R

e t a i n i n g

R i n g

A s s e m

b l y

4 8

C o n n e c t

i n g

R o d a n

d C a p

A s s e m

b l y

4 9

V a l v e

P l a t e A s s e m

b l y

5 0

V a l v e

P l a t e

5 1

D i s c h a r g e

V a l v e

S t o p

5 2

D i s c h a r g e

V a l v e

5 3

V a l v e

S t o p

S u p p o r t

5 4

C a p

S c r e w , V

a l v e

S t o p

5 5

S u c

t i o n

V a l v e

( B a c

k e r s

F o r

A / C M o d e l s

N o t

S h o w n

s e e

F i g

. 5 , p

a g e

3 6 )

5 6

C h e c k

V a l v e

( U s e

O n l y w

i t h P a r a l

l e l C o m p r e s s o r

I n s t a l

l a t i o n s

)


62/125

60

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

(CC) - Compound cooling compressors only Torque for jam nut #3 for compressors manufacturedNM - Newton meter (metric torque rating) after 0203J--. For compressors built before thisSAE - Society of Automotive Engineers jumper bar must be under jam nut #3 or Loctite #089*See Fig. 17 page 111, for jam locations. applied to jam nut #2, or use 12 ft. lb.

NOTE: Bolt sizes and thread pitch: Compressors are built using English unit bolts. The bolts haveno exact metric equivalents. Therefore, to prevent possible cross-threading, loose bolts, or damage tothreaded portions of the casing, comparable metric measurements are not included.


63/125

61

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

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


64/125

62

3 . 0

C O M P R E S S O R A N D P A R T S D A T A

3 . 1

0 6 D S e r i e s

C o m p r e s s o r s

P h y s i c a l

D a t a

( p a g e 1 o f

2 )

* C y l

i n d e r

h e a d

f a n r e q u

i r e d a t

S S T o f - 2

0 D e g

. F . (

- 2 9 d e g .

C . )

a n d b e l o w f o r

R - 4

0 4 A / R

- 5 0 7 a n

d R

- 5 0 2 .

C y l

i n d e r

h e a d

f a n r e q u

i r e d a t

S S T o f

0 D e g .

F . ( - 1 8 d e g .

C . )

a n d b e l o w f o r

R - 2

2 .

( a ) A p p r o x i m a t e c o n

d e n s

i n g t e m p e r a t u r e r a n g e s

. C H E C K A C T U A L P E R F O R M A N C E D A T A F O R A N Y N E W

A P P L I C A T I O N

E S P E C I A L L Y A T O R N E A R U P P E R O R L O W E R L I M I T : L

. T . =

7 0 t o

1 2 0 D e g

. F . (

2 1 t o

4 9 D e g

. C . ) , M .

T . = 8

0 t o

1 3 0 D e g

. F .

( 2 7 T O 5 4 D e g

. C . )

a n d H

. T . (

R - 2

2 o n

l y )

= 8 0 T O 1 5 0 D e g

. F . (

2 7 t o

6 6 D e g

. C . ) .

( b ) T h e 0 6 D R 1 0 9 s i n g

l e p h a s e c o m p r e s s o r h a s a

3 H P ( 2

. 2 k W ) m o t o r

.

( c ) S e r v i c e c o m p r e s s o r s

h a v e

d u a l

s u c t i o n s e r v i c e v a

l v e

l o c a t i o n s

, o n e o n m o t o r e n

d a n

d o n e n e a r t h e o i

l p u m p .


65/125

63

3 . 1

0 6 D S e r

i e s


P h y s i c a

l D a t a

( p a g e

2 o f

2 )


66/125


67/125

65

3 . 2

0 6 E S e r

i e s


P h y s

i c a l

D a t a

( p a g e

2 o f

2 )


68/125

66

3 . 3

0 6 C C S e r i e s


P h y s i c a

l D a t a ( p a g e

1 o f

2 )

( f ) A p p r o x i m a t e c o n d e n s i n g t e m p e r a t u r e r a n g e s .

C H E C K A C T U A L P E R F O R M A N C E D A T A F O R A N Y N E W

A P P L I C A T I O N

,

E S P E C I A L L Y A T O R N E A R U P P E R O R L O W E R L I M I T : L

. T . =

7 0 t o

1 3 0

D e g

. F . (

2 1 t o

5 5 D e g

. C . ) .

( g ) T o p r o v

i d e a

6 - c y

l i n d e r

b o d y n e e d e d

f o r

C o m p o u n

d C o o

l i n g , t h e n o r m a l

4 - c

y l i n d e r m o d e l

1 6 , 1 8 a n d

5 0 C f m c o m p r e s s o r s a r e

b u i l t u s

i n g t h e

2 4 , 1

8 , a n

d 6 5 C f m 6 - c y

l i n d e r

b o d i e s r e s p e c t i v e l y .

T h e

a c t u a l

C f m r e d u c t i o n

i s a c

h i e v e d

b y m o d

i f y i n g t h e r u n n

i n g g e a r

.

( h ) R 4 0 4 A / R

- 5 0 7 C

A N N O T b e u s e d

i n t h e s m a

l l D b o d y s i z e

C o m p o u n

d C o o

l i n g c o m p r e s s o r s

( 1 6 t o 3

7 C f m ) , m a n u f a c t u r e

d p r

i o r

t o S e r

i a l N o .

2 0 9 9 J

.

( i ) R

- 1 3 4 a a n

d R - 1 2 C A N N O T b e u s e d

i n a n y C

o m p o u n

d C o o

l i n g c o m p r e s s o r .


69/125

67

3 . 3

0 6 C C S e r i e s


P h y s i c a

l D a t a ( p a g e

2 o f

2 )


70/125

68

3.4 06D, E High Ef ciency (H.E.) Compressors

High ef ciency compressors were phased in between1985 and 1987. A high ef ciency compressor can beidenti ed as follows:

All 06D H.E. compressors (new or service replacement)have the number 3 in the 11th digit of the model num -

ber. See page 3 for examples.

The 06E compressor model numbers did not change. Todetermine if a 06E compressor is high ef ciency, check

the serial number. The following serial numbers indicatehigh ef ciency:

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 ef ciency, except for

some D body units without a 3 in the 11th digit of themodel numbers.

NOTE: The 06E H.E. valve plates are identi ed by anelongated ear protruding from the side of the valve plate,in contrast to the standard ef ciency 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 service com-

pressors with no oil in the crankcase due to the introduc-tion of HFC/POE systems. This eliminates the need todrain mineral oil from the crankcase when alkylbenzeneor POE oil is to be used. POE oil is very hygroscopic(will readily pick up and retain moisture


71/125

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 3.6

below for the proper refrigerant oils.

3.6 Refrigerants and Oils for 06D, E Compressors The introduction of HFC/POE systems has led to

confusion as to what refrigerants and oils are 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 foravailable oils:

The following MINERAL/ALKYLBENZINE are approved oilsfor CFCs and HCFCs:

NOTE: Carlyle does not recommend the use of POE oil with R-22. Totaline ............................... P903-2001 Witco ................................. Suniso 3GS Shrieve Chemical ................. Zerol 150

Texaco Capella ................. WFI-32-150 IGI Petroleum Ind .......... CRYOL -150

FOR CFCs AND HCFCs: Carlyle has approved the use of R-12, R-500, R-502,

and R-22. Selected OEMs of ultra low temperatureequipment are approved to use R-13 and R-503 (contactCarlyle Engineering for correct oil).

* Do not use in lowtemperature applications.


72/125

70

FOR HCFC BLENDS: Carlyles engineering efforts were directed toward

testing the new HFC refrigerants, not the interimHCFC blends. Carlyle provides tentative approvals ofthe following blends based on tests by the refrigerantmanufacturer and feedback from eld 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 retro tapplication the amount of mineral oil cannot exceed25% when mixed with alkylbenzene. Carlyle does not

recommend the use of POE lubricants with HCFCblends.

A number of HCFC blends are not approved.Some may create a hazar dous situation. Carlylerequires all refrigerants used in our compressors

to be A1/A1 (low ammability/low toxicity). Therating is based on ASHRAE 34 safety standard. Not all A1/A1 refrigerants are approved for use inCarlyle compressors. Some of the refrigerants or

blends available are either ammable (A1/A2 or A1/A3) and/or toxic (A1/B1 or A1/B3). Some A1/A1refrigerants can change ratings if contaminated. Any

replacement refrigerant must operate with the same pressure levels and temperature ranges as the CFC orHCFC being replaced. Do not use any refr iger antnot speci cally approved in this guide unlessyou have obtained approval from the CarlyleCompressor engineering department.

WARNING!


73/125

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

All POE oils are very hygroscopic (will readily pick upand retain moisture from the air) and should be usedcompletely once the container is opened. It is extremelydif cult to reseal the oil container effectively enough to

prevent moisture absorption, which in turn forms damag-ing acids.

NOTES:1. The use of any non-approved refrigerant may be

dangerous and will void the warranty.2. Using the wrong type or weight of oil for the

refrigerant selected will void the warranty.3. Follow the refrigerant and/or oil manufacturer

instructions when installing or retro tting.4. Contact the Carlyle Compressor engineering

department before using any refrigerant or oil notlisted in this guide as approved for use in a Carlyle

semi-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 temperatur e refr igeration

applications using Carlyle OEM semi-hermeticcompressors. Castrol E68 is approved for use inCarlyle OEM compressors for low, medium, andhigh temperatur e r anges.

6. All HFC/POE applications require a crankcase heater.7. Moisture must be kept below 50 ppm for POE oils.8. In retro t applications, a high ow oil pump is

required


74/125

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 retro t compressor valveplate(Part No. 06CY660-002) kit. See Section 3.6 on page69 for further information about refrigerants and oils.

See Section 3.6 on pages 69 & 71 for the correct oil foreach refrigerant. Contact Carlyle Engineering for correct

oil for R-23 and R-508A (SUVA 95).3.8 Oil and Refrigerant Change-Out Procedures

To change from a CFC or HCFC to either an HFC or anHCFC blend, follow the refrigerant and oil manufacturerinstallation procedures. Select a Carlyle approved

refrigerant and appropriate oil as noted in Sections 3.6and 3.7 above. System cleanliness is extremely important. To ensure a trouble-free change out, CarlyleEngineering has made speci c guidelines available. Westrongly recommend a copy of our guidelines be request-ed and procedures carefully followed to avoid problems.

3.9 Oil Viscosity and Pour Points

The viscosity of oils used in Carlyle reciprocatingcompressors is ISO 68 (centistoke) for all POE oils and150 Saybolt Seconds Universal (150 SSU or 150 SUS) orISO 32 for mineral and alkylbenzene oils. Using oil witha different viscosity without approval from the CarlyleEngineering Department will void the warranty.

The oils listed in Sections 3.6 and 3.7 and the viscos-ity listed above can be used down to -40 F (-40 C). Ifyour system runs at a lower temperature, please contactCarlyle Engineering for an oil recommendation.


75/125

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 ow oil pump and changed oil pressure speci ca -tions due to changes in lubricants and refrigerants. The

following data notes the proper oil pressure range basedon the compressors 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 new pump 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 16 to 22 psi (1.1 to 1.5 Bars)

BEFORE MAY 1984 OR BEFORE S/N 2084J:

For all 06D/E compressors, the oil pressure is 12 to 18 psi (0.8 to 1.2 Bars)

For more information about the high ow oil pump, seeSection 3.12.


76/125

74

3.12 High Flow Oil Pump (Bearing Head)

Carlyle introduced a new high ow oil pump to provideimproved lubrication with the new HFC refrigerantsand POE lubricants. The pump is a durable, automati-cally reversible, high ow design. The high ow designimproves lubrication, especially with the new HFC/POEcombination, and provides improved lubrication in thecase of a ooded start. This oil pump is standard on allnew and service compressors. See Section 3.11 abovefor details on oil pressure. For service replacement, au-thorized service locations will have the new high ow oil

pump only. See Section 3.13 below.3.13 Replacement Oil Pump/Pump End Bearing Package

The oil pump and pump end bearing are an integral partcalled the pump end bearing head. If either the oil pumpor the bearing requires replacement, order part as noted

below:

NOTE: The above pump end bearing head packages include a bearing headwith thehigh side oil safety switch connection. This pump is recommended for all CFC, HCFCand HFC refrigeration applications.


77/125

comp carlyle torque.pdf

Documents