section 1 - carrier screw compressor uae | carlyle compressors … · 2019. 11. 10. · 1.3...

1.1 CertificationUL and CSA approvals have been obtained onthe 06T screw compressors with the following refrigerants:

1. R-22 2. R-134a 3. R-404A & R-507

The UL file number is SA4936. CSA file number is LR29937; CSA report number isLR29937-579c.

For UL and CSA approvals it is essential thatonly listed special purpose circuit breakers orFurnas 958 series soild state overload relays be used. (See Section 5.2 and 5.3 for selectiontables). The must trip amp settings should notexceed 140% of the compressor rated loadamps.

Both UL and CSA approvals have been obtained for all voltage combinations listed in Section 5.3. 60 Hz compressors have been listed.

Section 1 — General Information

1.2 Screw Compressor Size(Displacement)06T compressors are available in the followingdisplacement sizes:

60 Hz 50 HzModel ft3/ m3/ ft3/ m3/

No. min min min min06T**033 33 0.93 27.5 .7806T**039 39 1.10 32.5 .9206T**044 44 1.25 36.7 1.0406T**048 48 1.36 40.0 1.1306T**054 54 1.53 45.0 1.2806T**065 65 1.84 54.2 1.5306T**078 78 2.21 65.0 1.8406T**088 88 2.49 73.3 2.0806T**108 N/A N/A 90.0 2.56

Semi-hermetic compressors will be suppliedwith single voltage motors 208/230 volts, 460volts and 575 volts.

1.3 Compressor MountingThe Carlyle 05T/06T screw compressors maybe rigid mounted. However, Carlyle recom-mends the use of isolation mounts (CarlyleP/N KA75KR007, Package No. 06TA660007)for 06T compressors. These rubber mountsisolate the compressor from the system frame-work which helps to reduce noise transmission.

1.4 Oil TypeCarlyle screw compressors are approved for use with the oils in the table below (basedon refrigerant application).

Contact Carlyle Application Engineering foralternate POE oil selections.

See section 9.1 for System oil charging recom-mendations.

R-404A & R-507 R-134a R-22Medium Medium Medium

POE Oil Type Low Temp. Temp. Temp. & A/C Low Temp. Temp.Castrol SW100 * NO YES YES NO YESCPI Solest BVA 120 *† YES YES YES YES YESCPI Solest 170 ** YES YES YES YES** YES**ICI Emkarate RL100S YES YES YES YES YESCastrol E100 * YES YES YES YES YES* UL Certified† For application purposes, Solest 120 oil is considered to be the same viscosity as POE 100 oils. ** Required for R-22 systems without external oil Cooler. R-22 systems with external oil cooler may use POE 100 oils.

1

1.5 Ambient ConditionsThe screw compressor is designed for the following specified ambient temperature ranges:

Non-Operating -40°F To 130°F (-40°C To 54°C)

Start-Up -40°F To 130°F(-40°C To 54°C)

Operating -25°F To 130°F (-32°C To 54°C)

1.6 Installation EnvironmentThe intended installation modes for the screwcompressor are:

Machine Rooms—Enclosed AtmosphereExternal Environment—Sheet Metal EnclosureNOTE: The electrical terminal box is notapproved for external applications.

1.7 Pressure Relief Valve All compressor models contain an automaticreset high pressure relief valve. The pressurerelief valve is located inside the compressor andwill internally vent the compressor discharge to the compressor suction when it relieves. The valve opens at a pressure differential of400 psi (27.6 bar). The relief valve is notfield serviceable.

1.8 Discharge Check Valve All compressor models are supplied with aninternal discharge check valve. This checkvalve prevents the reverse flow of refrigerantthrough the compressor during compressor offcycles. A check valve in the discharge line isnot required for parallel applications. It may berequired for pump down on single compressorsystems.

The discharge check valve is field serviceable.

1.9 Compressor Inlet ScreensFilter screens are applied at all locations whereliquid or gas enters the compressor, i.e., suc-tion, economizer and oil connections.

For systems that operate below -25F (-32c), itis recommended that the suction screen beremoved after 48 hours of system startup asthe viscous oil can damage the screen.

The compressor inlet screens are field serviceable and available through Carlyle distribution.

1.10 Service ValvesSuction and discharge connections will interface with the 2-1/2" bolt pattern servicevalves currently being used on the Carlyle reciprocating compressors. Rotalock® servicevalves are used for the economizer line shutoff. The line sizes are as follows:

Connection SizeConnectionMax. Min.

Suction 1-5/8" 1-1/8"Discharge 1-5/8" 1-1/8"Economizer 7/8" 7/8"

All compressor models are supplied with the 1-5/8"suction and discharge service valves and the 7/8"economizer valve.

All 05T compressors and 06T compressorsbetween 65cfm and 88cfm use a barstock service valve, (06TA680008) which is physicallylarger than the standard service valve(06TA660001) used on all 06T compressorsbetween 33cfm - 54cfm (see compressorphysical dimensions on pages 2 & 3).

1.11 Condenser Pressure Control

Important!Large variations in head pressure will result in very poor oil separation whichmay result in nuisance oil level switch tripping. The condenser pressure must be controlled such that fluctuations aregradual. Carlyle screw compressors must be applied with a minimum of onecondenser fan (preferably variable speed) active at all times and a means of minimumhead pressure control for low ambientoperation. For alternate methods of con-denser control, please contact CarlyleApplication Engineering.

2

2.5 Inverters and RefrigerantsThe Carlyle screw compressor is compatiblewith inverter drives. An inverter drive varies thespeed of a compressor to improve system loadmatching.

VARIABLE SPEED LIMITS For 06TR Low Temp Compressors

Table 1Model Nominal Min. Max.

No. HP Hz Hz06TRC033 15 50 7006TRD039 20 40 7006TRD044 20 35 7006TRE048 25 30 7006TRE054 25 30 7006TRF065 30 25 7006TRG078 35 20 6806TRH088 40 20 6006TRK108 50 20 50

VARIABLE SPEED LIMITS For 06TA A/C & Med. Temp Compressors

Table 2 Model Nom. Min. Max.

No. HP Hz Hz06TAD033 20 50 7006TAE039 25 40 7006TAF044 30 35 7006TAF048 30 30 7006TAG054 35 30 7006TAG065 35 25 7006TAH078 40 20 6806TAK088 50 20 60

Carlyle recommends screw compressors be selected to match the system load at 60 Hz. Overspeeding is a good option during heavy load conditions. Carlyle does not recommend the screw compressor operate at maximum frequency for prolonged periods of time.

Operation above 60 Hz requires adequate motor cooling. Inverters have a tendency to increase the required motor cooling load due toirregular wave forms. When overspeeding, there will be an increased power consumption required to supply the additional capacity. This will also increase the required motor cooling load. It is important that the motor cooling system be capable of handling the increased cooling required for the motor. Oil return, economizer return gas, and the motor cooling valve all assist in cooling the motor. Carlyle recommends applying the largest motor cool-ing valve (Carlyle P/N EF28BZ007) with all screw compressors applied using inverters.

Inverters are an effective tool for efficiently matching system loads with screw compressors. Motor size and motor cooling capabilities must be considered when using an inverter to increase speeds above 60 Hz.Following these guidelines will result inimproved system design and performance.An inverter is capable of changing the compressor’s speed very quickly from fullspeed to minimum speed and vice versa. Compressors should ramp-up to the minimum speed within 15 seconds at start-up. After compressor start, Carlyle recommends that therate of compressor speed change be limited to600 RPM/Min for the 06T semi-hermetic. The rate of compressor speed change for the 05T open drive models is required to be no greater than 500 RPM/MIN.

2.6 Compressor CyclingAlthough compressor cycling is an effectivemeans of capacity control, frequent startingand stopping shortens the compressor life.Carlyle screw compressors should not becycled for capacity control more than sixtimes an hour and should run for at least 5 minutes after each start.

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2.7 Mechanical UnloadingAll Carlyle screw compressors are equippedwith one step of mechanical unloading.Theunloader valve is controlled by a solenoidmounted on the compressor body.The compressor is unloaded when thesolenoid is de-energized and loaded whenthe solenoid is energized. The compressorshould always be started unloaded (for a mini-mum time determined by the control module)which will provide a soft start by partially relieving the compression chamber back tosuction. Unloaded operation reduces the effec-tive capacity by 30% to 62%, depending onthe model and system condition(see tables below).

ESTIMATED PERCENTAGE UNLOADING BY MODEL

Models ft3/ m3/ Low Med.@ 60 Hz min min Temp. Temp.06T**033 33 0.93 60% 50%06T**039 39 1.10 59% 49%06T**044 44 1.25 58% 48%06T**048 48 1.36 56% 46%06T**054 54 1.53 55% 45%06T**065 65 1.84 50% 40%06T**078 78 2.21 45% 35%06T**088 88 2.49 40% 30%

Models ft3/ m3/ Low Med.@ 50 Hz min min Temp. Temp.06T**033 27.5 0.78 62% 52%06T**039 32.5 0.92 61% 51%06T**044 36.7 1.04 60% 50%06T**048 40.0 1.13 59% 49%06T**054 45.0 1.28 58% 48%06T**065 54.2 1.53 55% 45%06T**078 65.0 1.84 50% 40%06T**088 73.3 2.08 47% 37%06T**108 90.0 2.56 46% -

Unlike reciprocating compressors that shouldnot be run unloaded continuously, the Carlylescrew compressor can be run unloaded con-tinually without affecting the reliability of thecompressor. Other methods of reducing thecompressor capacity are available and must beapproved by Carlyle Application Engineering.

Vi SETTINGS CHART (PSIG)

350

300

250

200

150

100

50

00 5 10 20 25 30 35 40 45 50

Suction Pressure psig (bar)

Dis

char

ge P

ress

ure

psig

(ba

r)

Set at High Vi in this Region (Energized)

15

Set at Low Vi in this Region (De-energized)

(24.1)

(20.7

(17.2)

(13.8

(10.3)

(6.9)

(3.4)

(0)

(0) (.3) (.7) (1.0) (1.4) (1.7) (2.1) (2.4) (2.8) (3.1) (3.4)

2.8 High Discharge Pressure ControlA high pressure cut out must protect the com-pressor from exceeding 350 psig (25.2 bar).The compressor may be brought back on line after the discharge pressure falls below 300 psig (21.4 bar). The maximum pres-sure differential (discharge-suction) is 350 psi.The internal pressure relief valve will open if thepressure differential exceeds 400 psi (+/-3%).

2.9 Low Suction Pressure Cut OutA low suction pressure cut out must protectthe compressor from operating in a vacuum(below 10" hg). Each compressor must be indi-vidually protected with a low pressure switchconnected to the low side access port. Thecompressor may be brought back on line aftera 3 minute delay.

2.10 Volume Index (Vi) ControlAll low temperature models (05TR/06TR) aresupplied with a Vi control valve that allows fortwo Vi settings (see chart below). This dual Viallows for optimum efficiency over a widerange of head pressures. The Vi must be set tolow (solenoid de-energized) during start-up fora minimum of 30 seconds. The Vi may then beset as desired for optimum energy efficiency.The following chart and graph reflect the oper-ational specifications of the Vi control.

The current LonCEM® controller continuouslymonitors the operating pressure ratio and con-trols Vi output accordingly. The older CEMrequires external controls to accomplish thesame task.

System Pressure Ratio Vi SolenoidGreater Than 5:1 High: 4.0 OnLess Than 5:1* Low: 2.8 Off

*Medium/High temperature “TA” compressor modelshave a fixed Vi of 2.8.

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3.1 Oil SeparatorAn oil separator is required on all Carlyle screwcompressor systems. Carlyle offers two sizesof vertical oil separators. Parallel systems (overtwo compressors) require the use of the Carlyle14" (35.6cm) separator, and single and doublecompressor systems require the use of theCarlyle 12" (30.5cm) separator. See the draw-ings below for dimensional information on theoil separators.

Section 3 — Oil Management System

FOR REFERENCE ONLYINCHES

[CENTIMETERS (cm)]

12" (30.5cm) VERTICAL OIL SEPARATORPHYSICAL DIMENSIONS

14" (35.6cm) VERTICAL OIL SEPARATORPHYSICAL DIMENSIONS

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3.7 Oil Cooling Systems Carlyle 06T semi-hermetic screw compressorscan be operated for most applications withoutexternal oil cooling. 05T open drive screw com-pressors require external oil cooling any timethe system discharge temperature may exceed180°F. Carlyle’s Carwin selection software canbe used to estimate the discharge temperaturefor a given application.

When an oil cooler is not required, it also elimi-nates the need for any oil mixing componentsto keep the oil within a designated temperaturerange when the oil is being returned from an aircooled oil cooler during low ambient periods.

Operating without an oil cooler does notchange the lubricant recommendations for R-404A/507. The recommendation is to usePOE 100 or 170 lubricants. For R-22 applica-tions the recommendation for a lubricant isPOE 170, CPI Solest 170, for all R-22 low,medium and high temperature applications.

When an oil cooler is used with R-22, therecommendation is to use POE 100 or 170.

Operating without an oil cooler doesimpact the system's condenser selec-tions. Since the oil cooler removes heatfrom the compressor, additional heat will betransferred to the compressor's heat ofrejection, or condenser load. Current ver-sions of Carlyle's compressor selection pro-gram take this into consideration, allowingselections to be made with or without anexternal oil cooler.

Operating without an oil cooler results in littleor no performance change on higher dis-placement models. The slower rotor speedson smaller CFM models results in a discern-able capacity loss that may require consider-ation. Current versions of Carlyle's compres-sor selection program take this into consid-eration, allowing selections to be made withor without an external oil cooler.

Allowable Application Range Without Oil Coolers

Application: Saturated Suction: Saturated Condensing: Recommended Oils:

R-404A/507 Low Temp. -40 F to 0 F 70 F to 120 F POE 100 or 170

R-404A/507 Medium Temp. 0 F to 50 F 70 F to 130 F POE 100 or 170

R-134a Medium & High Temp. -10 F to 50 F 70 F to 150 F` POE 100 or 170

R-22 Low Temp. -25 F to 0 F 70 F to 120 F POE 170*

R-22 Low Temp. -30 F to -26 F 70 F to 110 F POE 170*

R-22 Medium & High Temp. 0 F to 50 F 70 F to 130 F POE 170*

* If oil cooler used, oil can revert to POE 100

6

The oil cooler does offer some help in keepingthe discharge and motor temperatures withintheir respective limits. To make up for this lostcooling some additional refrigerant injection isrequired. For screw compressors this injectionis by the motor cooling valve or at the rotorinjection port. Because refrigerant injection formotor and discharge cooling flows into thescrew rotor chamber after the suction gas istrapped, compressor capacity is not affectedsignificantly. Under some conditions the motorcooling valve can accommodate this extracooling requirement. For conditions requiringadditional injection, a Sporlan Y-1037 desuper-heating valve, or its equivalent, is recommend-ed. It should be selected to start opening at adischarge temperature of 190 F and be fullyopen at 200 F. The bulb should be located onthe discharge line within 6" of the compressor

discharge service valve. A properly sized sole-noid valve should be located upstream toinsure positive shut-off when the compressor isoff.

The tables presented at the bottom of thispage present desuperheating size and partnumber information for those applicationswhere an oil cooler is not used.

Even when an oil cooler is used, desuperheat-ing may still be required. For R-22 systems, the desuperheating valve is required when the saturated suction temperature is below -25°F (-32°C) and for R-404A/R-507 systems,it is necessary when the saturated suctiontemperature is below -40°F (-32°C). This valveis available through Carlyle (1 ton (3.5Kw); 1.5 ton (5.3Kw); contact Carlyle ApplicationEngineering for valve selection).

DESUPERHEATING VALVE SIZING WITHOUT OIL COOLER

R-22 Added Desuperheating R-404A/507 Added Desuperheating R134a Added DesuperheatingCompressorModel

HPLow Temp. Med/High Temp. Low Temp. Medium Temp. Medium Temp. High Temp.

Low Temp.SCT Range 70 to 120 F 90 to 120 F 70 to 150 F 70 to 150 F

(21 to 49 C) (32 to 49 C) (21 to 65 C) (21 to 65 C)06TRC033 15 FV-2 N/A FV-1* N/A None None06TRD039 20 FV-3 N/A FV-1-1/2* N/A None None06TRD044 20 FV-3 N/A FV-1-1/2* N/A None None06TRE048 25 FV-3 N/A FV-2* N/A None None06TRE054 25 FV-3 N/A FV-3* N/A None None06TRF065 30 FV-5 N/A FV-3* N/A None None06TRG078 35 FV-5 N/A FV-3* N/A None None06TRH088 40 FV-5 N/A FV-3* N/A None None06TRK108 50 FV-5 N/A FV-3* N/A None None

Med Temp/High TempSCT Range 70 to 130 F 70 to 130 F

(21 to 54 C) (21 to 34 C)06TAD033 20 N/A FV-2** N/A None None None06TAE039 25 N/A FV-3** N/A None None None06TAF044 30 N/A FV-3** N/A None None None06TAF048 30 N/A FV-3** N/A None None None06TAG054 35 N/A FV-3** N/A None None None06TAG065 35 N/A FV-5** N/A None None None06TAH078 40 N/A FV-5** N/A None None None06TAK088 50 N/A FV-5** N/A None None None

LEGEND* Operation with Evap condensers below -25 F SST may not require any additional desuperheating.

Contact Carlyle Applicatioon Engineering for limits.** Operation with Evap condensers above +10F SST may not require any additional desuperheating.

Contact Carlyle Application Engineering for limits.

Note: Valve P/N's shown above are for Sportan Valve Y-1037 series desuperheating valves. A valve with a 190 F temperature setting is required. Alternatedesuperheating valve sizing or manufacturers must be approved by Carlyle Application Engineering.

Sporlan Part No. Carlyle Part No. Qty./Pkg. Weight (Lbs.) SizeFV-1 EA02ZD001 1 2 1 ton

FV-1-1/2 EA02ZD002 1 2 1-1/2 tonFV-2 EA02ZD030 1 2 2 tonFV-3 EA02ZD050 1 2 3 tonFV-5 EA02ZD100 1 2 5 ton

7

3.8 Oil Cooler SelectionAn oil cooler is required on all Carlyle screw com-pressor systems not operating in the range indi-cated in the previous section. This is generally forsystems requiring lower suction temperatures orhigher discharge temperatures. Also, 05T directdrive compressor systems with discharge tem-peratures that may exceed 180 F (82 C) alwaysrequire an oil cooler. The oil cooler must be sizedbased on an oil flow rate of approximately 2 gal-lons per minute (7.6 liters/minute) per compres-sor. (The actual oil flow rate will vary based onpressure ratio of the application. The precise oilcooler load may be obtained from the Carlylecompressor selection software.) The maximum oiltemperature leaving the oil cooler is 170 F (77 C)and the maximum temperature entering the oilcooler is 200 F (93 C) (based on discharge tem-perature control). The oil cooler load is nominally1 ton (3.5 kilowatts) per compressor, but may becalculated with the above data and oil manufac-turer's specifications. In applications whichrequire oil cooling some means of controlling theoil temperature entering the compressor isrequired.

Several possible methods are;• Oil cooler fan cycling based on oil outlet tem-

perature (10F∆T)• Oil cooler bypass via a solenoid valve controlled

off of oil cooler entering temperature• Use of a mixing valve to maintain a constant oil

temperature entering the compressor• Some combination of the three methods listed

above

The oil may be cooled by means of an air cooled,refrigerant cooled, or water cooled oil cooler.Carlyle offers 4 sizes of air cooled oil coolers for

use with the 05T and 06T screw compressor.Following is selection criteria for the various mod-els along with dimensional information.

If using a refrigerant cooled oil cooler, the oilcooling load will need to be subtracted fromeither the compressor's evaporator capacity orthe subcooling capacity. Using compressor suc-tion pressure will led to a reduction in systemcapacity since some of the compressor suctionmass flow will now come from the oil cooler.Using the compressor interstage port for oil cool-ing will not reduce the compressor suctionpumping capacity but will indirectly reduce sys-tem capacity by decreasing the compressor'sability to do liquid subcooling. The additionalmass flow from the oil cooler to the interstage willincrease the interstage pressure. This will preventthe subcooler from achieving the lowest possibleliquid temperature. Both systems require holdback valves to prevent the oil temperature fromdropping below 80 F (27 C).

Also, caution must be taken to ensure that thereturn gas to the compressor is not too hot. Formore information, contact Carlyle ApplicationEngineering.

The oil cooler represents a heat source that maybe used for heat reclaim processes such as hotwater preheat. Since the oil cooler rejects dis-charge heat, the heat rejection from the oil coolercan be subtracted from the heat rejectionrequired by the system condenser. This may leadto a smaller size condenser. Condenser circuitingmay also be used for oil cooling; however, pres-sure drops must be taken into account for mini-mum oil pressure differential to the compressors.A mixing valve is recommended for all oil coolerscircuited through a remote air-cooled condenser.

Oil Cooler Models Available Oil Cooling Capacity @ Ambient Air Temperature95ºF 100ºF 105ºF 110ºFFan Speed 60Hz

(35ºC) (38ºC) (41ºC) (43ºC)32,100 Btu/Hr 30,600 Btu/Hr 29,000 Btu/Hr 27,600 Btu/HrKH51ZZ181 (2 Compressors Max)*(9,405 W/Hr) (8,966 W/Hr) (8,497 W/Hr) (8,087 W/Hr)

69,100 Btu/Hr 65,700 Btu/Hr 62,400 Btu/Hr 59,100 Btu/HrKH51ZZ182 (3 Compressors Max)*(20,246 W/H) (19,250 W/Hr) (18,283 W/Hr) (17,316 W/Hr)

102,600 Btu/Hr 97,700 Btu/Hr 92,800 Btu/Hr 87,900 Btu/HrKH51ZZ183 (4 Compressors Max)*(30,061 W/Hr) (28,626 W/Hr) (27,190 W/Hr) (25,755 W/Hr)


Oil Cooler Models Available Oil Cooling Capacity @ Ambient Air Temperature95ºF 100ºF 105ºF 110ºFFan Speed 50Hz

(35ºC) (38ºC) (41ºC) (43ºC)32,200 Btu/Hr 28,800 Btu/Hr 27,300 Btu/Hr 25,900 Btu/HrKH51ZZ181 (2 Compressors Max)*(9,405 W/Hr) (9,435 W/Hr) (8,438 W/Hr) (7,999 W/Hr)

63,700 Btu/Hr 60,600 Btu/Hr 57,600 Btu/Hr 54,600 Btu/HrKH51ZZ182 (3 Compressors Max)*(18,664 W/H) (17,756 W/Hr) (16,877 W/Hr) (15,998 W/Hr)



*Maximum Number of Compressors Based on Oil Cooler Pressure Drop of Less Than 6 PSID (.41 bar)

8

MODEL # KH51ZZ181FOR REFERENCE ONLYINCHES

[CENTIMETERS (cm)]


[CENTIMETERS (cm)]

MODEL # KH51ZZ182

OIL INLET AT BOTTOM – OIL OUTLET AT TOP; ALL MODELS

Electrical Specifications: All ModelsVoltage: 115/230V 50/60HzAmperage*: 3.2/1.6 Amps Full Load 60Hz

2.8/1.4 Amps Full Load 50Hz*Amperage ratings are per motor

9


[CENTIMETERS (cm)]

MODEL # KH51ZZ183


[CENTIMETERS (cm)]

MODEL # KH51ZZ184

OIL INLET AT BOTTOM – OIL OUTLET AT TOP; ALL MODELS

10

OIL CARTRIDGE FILTER ELEMENT

8.25"

END CAP, 1.75" O.D.

CENTER CORE,PERFORATED

3u FIBERGLASSSUPPORTED

(209.6cm)

(44.5cm)1.75" (44.5cm) O.D. X 1.00" (25.4cm) I.D. W/O–RING GROOVE

1.00"(25.4cm)

1.75"(44.5cm)

O–RING, 0.975" (24.8cm) I.D. X0.210" (5.3cm) CROSS SECT.

END CAP,

INLET I.D.0.876/0.880

(22.23/22.35)X 0.75 (19.1) DEEP

2 5/16" - 16 UNCTHREADED O-RING

CLOSURE

2.62 O.D.(66.6)

DRAIN1/4"-3000# NPT

HALF COUPLING(PLUGGED)

8.56 ±0.06

(217.4)

10.00 ±0.06

(254.0)

5.25 ±0.06

(133.4)3.25

(82.6)

3.25(82.6)

FILTER HOUSING REPLACEMENT TYPE


[MILLIMETERS (mm)]


[CENTIMETERS (cm)]

11

3.10 Oil Sump HeatersA 500 watt, 120/240 volt silicon rubber flexibleheater is recommended for use on the oil sumpof the 12" (30.5cm) oil separator. Two of theabove 500 watt heaters (connected together) arerecommended for use with the 14" (35.6cm) sep-arator. The heater must be energized during thesystem off cycle if used. This is required in all airconditioning systems and is recommended inrefrigeration systems to keep refrigerant out of theoil sump during compressor off cycles.

3.11 Oil Sight GlassA sight glass is required in the main oil line.The sight glass must be located after the oil filters and just prior to the first compressor on a multiple compressor rack. (See Oil System Schematics, Section 3.12.) Carlyle recommends a sight glass be placed in eachbranch oil line between the compressor and its oil solenoids. The sight glass offers a usefulfeature to help field personnel verify oil is flow-ing when required and not leaking throughwhen the compressor is off.

Carlyle offers a combination oil solenoid/sightglass that can be used for the application (P/NEF23ZZ025). It mounts directly to the oil inlet ofthe compressor. Refer to Figure 2, Appendix Afor details.

15.75”(400mm)

6.0”(152mm)

+/-.0050.050”

(1.27mm)

REF.0.175”

(4.4mm)

FLEXHEATER

NATURALBLACK

RED

NATURALBLACK

RED240 V 120 V

FLEX HEATER WIRING DIAGRAM(TO BE LABELED ON PART)

3.9 Oil FilterCarlyle screw compressors are designed withrolling element bearings to provide exceptionallife. Oil to the bearings must pass through a 3 micron filter which is required on all Carlylescrew compressor systems. The use of filtersin parallel as shown in Section 3.12 (Oil SystemSchematics) is recommended (one filter percompressor may also be used). One filter (bothfilters may be used simultaneously) is used at atime and the pressure drop across the filter ismonitored. This design allows easy mainte-nance of the filter element without shutting thesystem down. The second filter is simplyvalved on while the first filter is changed.

In general, two oil filter housings are piped inparallel with isolation valves located on eitherside of the housings as shown in the schemat-ic in section 3.12. If more than 5 compressorsare fed by the oil system, 3 oil filter elementsshould be piped in parallel to avoid excessivepressure drop through the filter elements.

The LonCEM Module is currently used forcompressor protection for 05T/06T compres-sors. It monitors the difference in pressure inthe oil system from compressor discharge tothe compressor oil inlet with transducers. Thisincludes the pressure drop across the oil filters.See appendix A for settings.

In older systems incorporating the CarlyleElectronic Module (CEM) for compressor pro-tection pressure transducers or a mechanicaldifferential switch can be used to monitor thepressure drop across the oil filters. The settingfor filter alarm or replacement can be at thecustomer's discretion with a maximum value of25 psi (1.7 bar).

Note: Use of the Carlyle 3 micron filter element is required. Use of a non-Carlyle-approved filter element will void compres-sor warranty.

The oil filter(s) must be located after the oil cooler and as close to the compressor(s) aspossible. The oil filter housing is designed for450 psig (31 bar) maximum working pressureand has UL and CSA code approval for use inHVACR systems. Each new oil filter housingcontains one filter element. Additional filterelements should be ordered and suppliedwith each compressor system. Six additionalelements per rack are recommended.


[MILLIMETERS (mm)]

12

OIL SEP.

OIL HEATER

OIL LEVEL SWITCH

OIL L

INE

DISCHARGELINE

LEAD COMPRESSOR

3 MICRON FILTERSP

TO CONDENSER

OIL SOLENOID

SIGHT GLASS

MIXINGVALVE*

P

P

OIL COOLER(IF REQUIRED)

HAND VALVE

PRESSURE SENSOR

OIL SYSTEM SCHEMATICISOMETRIC VIEW

3.12 Oil System Schematics

*

* Note: Other oil temperature control options are available. See section 3.8.

13

3.13 Oil Line Manifold Selection Table

OIL MANIFOLD SIZING FOR PRESSURE DROP

LEGENDLPM - Litres per minutecSt - Centistrokes* If 170 POE oil is used, Carlyle recommends use of the next larger size copper line if pressure drop is greater

than 5.0 psi. This will typically reduce pressure drop to 30% of value shown.NOTES:1. Viscosity of 10 cSt is based on 130 F (54 C) oil with 10% refrigerant dilution.2. Viscosity of 45 cSt is based on 130 F (54 C) oil, no refrigerant dilution or 80 F (27 C) oil

with 10% refrigerant dilution.3. Viscosity of 100 cSt is based on 100 F (38 C) oil, no refrigerant dilution.4. Viscosity of 170 cSt is based on 100 F (38 C) oil, with no refrigerant dilution.

10 Ft Manifold Length

Assumed Delta P (PSI)Number ofCompressors GPM LPM

ManifoldO.D. (in.) at 10 cSt at 45 cSt at 100 cSt at 170 cSt

1 2 7.6 7/8 0.17 0.77 1.72 2.922 4 15.2 7/8 0.34 1.54 3.43 5.833 6 22.8 7/8 0.52 2.31 5.15 8.76*4 8 30.4 1-1/8 0.22 0.97 2.16 3.675 10 38 1-1/8 0.27 1.21 2.69 4.58

20 Ft Manifold LengthAssumed Delta P (PSI)Number of

Compressors GPM LPMManifoldO.D. (in.) at 10 cSt at 45 cSt at 100 cSt at 170 cSt

1 2 7.6 7/8 0.34 1.54 3.43 5.842 4 15.2 1-1/8 0.22 0.97 2.16 3.67*3 6 22.8 1-1/8 0.32 1.46 3.24 5.504 8 30.4 1-1/8 0.43 1.94 4.31 7.335 10 38 1-1/8 0.54 2.43 5.39 9.17*



1 2 7.6 1-1/8 0.15 0.70 1.62 2.75*2 4 15.2 1-1/8 0.32 1.45 3.24 5.503 6 22.8 1-1/8 0.49 2.18 4.85 8.25*4 8 30.4 1-1/8 0.65 2.91 6.47 11.00*5 10 38 1-3/8 0.33 1.49 3.30 5.61



1 2 7.6 1-1/8 0.25 0.91 2.42 3.67*2 4 15.2 1-1/8 0.43 1.94 4.32 7.34*3 6 22.8 1-1/8 0.65 2.91 6.47 11.00*4 8 30.4 1-1/8 0.35 1.50 3.52 5.995 10 38 1-3/8 0.44 1.98 4.40 7.48*

14

5.1 Thermal ProtectionThe compressor motor windings are protected from extreme temperatures by theLonCEM Module and the Carlyle ElectronicModule (CEM) in older systems. All compres-sors are supplied with two 5K NTC (NegativeThermal Coefficient) thermistors in the motorwindings.The module will limit the maximummotor temperature to 240 F (116 C) and is anauto-reset device. Only one 5K sensor is used;the other is a spare. The temperature vs. resis-tance characteristics of the 5K thermistors areshown below. Additionally, the DC voltageacross the thermistors

TEMPERATURE vs. RESISTANCE TABLE

Section 5 — Electrical Specificationsmay be measured at the module while the compres-sor is running and compared to the Temperature vs.DC voltage table. (WARNING: DO NOT MEASURETHE DC VOLTAGE INSIDE THE TERMINALBOX.)

Note that while the resistance of the sensors doesnot change, the measured DC voltage will be differ-ent depending on which protection module is used.

See the "Motor and Discharge Thermistors" table inAppendix A for the conversion when using the newerLonCEM module, and the "Temperature VS. DCVoltage" table in Appendix B for older applicationswith the CEM module.

TEMPERATURE RESISTANCE

C F OHMS0 32 16352.41 33.8 15515.22 35.6 147503 37.4 14027.14 39.2 13343.85 41 12697.86 42.8 12086.37 44.6 115088 46.4 10960.89 48.2 10442.610 50 9951.811 51.8 9486.812 53.6 9046.313 55.4 8628.714 57.2 8232.515 59 785716 60.8 7500.617 62.6 7162.318 64.4 6841.319 66.2 6526.420 68 6246.821 69.8 5971.622 71.6 571023 73.4 5461.324 75.2 522525 77 500026 78.8 478627 80.6 4582.428 82.4 4388.529 84.2 4203.930 86 402831 87.8 3860.532 89.6 3700.833 91.4 3548.534 93.2 3403.535 95 3265.136 96.8 3133.137 98.6 3007.1

TEMPERATURE RESISTANCEC F OHMS38 100.4 2886.939 102.2 2772.140 104 2662.441 105.8 2557.842 107.6 2457.743 109.4 2362.144 111.2 2270.845 113 2183.4546 114.8 2099.9347 116.5 2020.0448 118.4 1943.649 120.2 1870.550 122 1800.4951 123.8 1733.4652 125.6 1669.6653 127.4 1607.8154 129.2 1548.9555 131 1492.5456 132.8 1438.4657 134.6 1386.6258 136.4 1336.9359 138.2 1289.2660 140 1243.5361 141.8 1199.762 143.6 1157.5963 145.4 1117.1864 147.2 1078.3765 149 1041.1566 150.8 1005.3867 152.6 971.0368 154.4 938.0269 156.2 906.370 158 875.8171 159.8 846.572 161.6 818.3173 163.4 791.2174 165.2 765.1475 167 740.06

TEMPERATURE RESISTANCEC F OHMS76 168.8 715.9377 170.6 692.6878 172.4 670.3479 174.2 648.8280 176 628.0981 177.8 608.1182 179.6 588.8883 181.4 570.3684 183.2 552.585 185 535.2986 186.8 518.787 188.6 502.788 190.4 487.2889 192.2 474.490 194 458.0691 195.8 444.292 197.6 430.8593 199.4 417.9694 201.2 405.5195 203 393.4996 204.8 381.8997 206.6 370.6998 208.4 359.8799 210.2 349.41

100 212 339.32101 213.8 329.55102 215.6 320.12103 217.4 311104 219.2 302.18105 221 293.65106 222.8 285.41107 224.6 277.43108 226.4 269.72109 228.2 262.26110 230 255.03111 231.8 248.04112 233.6 241.28113 235.4 234.72

TEMPERATURE RESISTANCEC F OHMS

114 237.2 228.38115 239 222.24116 240.8 216.29117 242.6 210.53118 244.4 204.95119 246.2 199.54120 248 194.3121 249.8 189.22122 251.6 184.3123 253.4 178.5124 255.2 174.89125 257 170.41126 258.8 166.06127 260.6 161.83128 262.4 157.74129 264.2 153.77130 266 149.91131 267.8 146.17132 269.6 142.54133 271.4 139.02134 273.2 136.6135 275 132.27136 276.8 129.04137 278.6 125.91138 280.4 122.87139 282.2 119.91140 284 117.04141 285.8 114.25142 287.6 111.54143 289.4 108.9144 291.2 106.34145 293 103.86146 294.8 101.43147 296.6 99.074148 298.4 95.785149 300.2 94.559150 302 92.393

15

5.2 Screw Compressor Motor Protection06T Screw compressors must be applied withproperly sized calibrated circuit breakers orFurnas "958" series solid-state overload relaysto protect the motor against overcurrent faultconditions. Approved selections are shown insection 5.3 for the 06TR and 06TA compres-sors. Use of motor protection devices otherthan those shown in this Application Manualmust be approved by Carlyle ApplicationEngineering. The use of authorized overcurrentprotection is part of the basis of UL recogni-tion. Selection of alternate overcurrent protec-tion without Carlyle's approval will void warran-ty. For proper overcurrent protection, the musttrip setting of the protection device must notexceed the compressor Maximum Must TripAmps shown in the tables. The selected com-pressor overcurrent device must trip in 2 to 6seconds at the LRA value shown for the com-pressor.

The circuit breakers and overload relays select-ed by Carlyle are manually reset and havebeen sized to protect the compressor againstrunning overcurrent, locked rotor, primary andsecondary single phasing. These devices alsooffer the additional advantage of protecting thecompressor against malfunctions of the com-pressor contactor (which may not be possiblewith pilot duty motor protection).

Compressor overcurrent protection devices forpart winding applications must trip the first 3legs in 2 to 6 seconds and the second 3 legsin 1 to 3 seconds. Carlyle recommends a 1 to1.25 second time delay between energizing thefirst and second legs. Consult CarlyleApplication Engineering for part winding circuitbreakers. Part winding circuit breakers arestocked in limited quantities by Carlyle andmay require special order.

ALLOWABLE OPERATING VOLTAGE RANGES

Name Plate Frequency Min. Max.Voltage (Hz) Voltage Voltage208–230 60 187 264

200 50 180 230230 50 198 264460 60 396 528400 50 342 456575 60 495 660400 60 342 460

16

Section 5.3 Circuit Breaker Tables

06T

R –

ELE

CT

RIC

AL

SP

EC

IFIC

AT

ION

SC

OM

PR

ES

SO

R IN

FOR

MA

TIO

NR

EC

OM

ME

ND

ED

OV

ER

CU

RR

EN

T P

RO

TE

CT

ION

CO

MP

RE

SS

OR

MO

DE

LV

OLT

AG

EH

PM

AX

MT

A(S

ee N

ote

#1)

LRA

XL

CIR

CU

IT B

RE

AK

ER

PA

RT

#M

HM

TA

LRA

CA

RLY

LEFU

RN

AS

PA

RT

#(S

ee N

ote

4)M

HM

TA

RLA

(See

Not

e 3)

06TR

C03

3C06

TRC

033B

06TR

C03

3F

575

400/

460

208/

230

1533

.546 90

114

142

286

HH

83XA

460

HH

83XA

463

HH

83XB

626

29 40 78

33.5

46 90

97 150

250

HN

76JZ

015

HN

76JZ

022

HN

76JZ

050

29 40 80

32.5

44.8

89.6

23.2

32 6406

TRD

039C

06TR

D03

9B06

TRD

039F

575

400/

460

208/

230

2039 49 10

4

138

173

348

HH

83XA

461

HH

83XA

424

HH

83XB

625

33 42 91

38 49 104

124

175

350

HN

76JZ

022

HN

76JZ

022

HN

76JZ

050

34 43 92

38.1

48.2

103

27.2

34.4

73.6

06TR

D04

4C06

TRD

044B

06TR

D04

4F

575

400/

460

208/

230

2039 49 10

4

138

173

348

HH

83XA

461

HH

83XA

424

HH

83XB

625

33 42 91

38 49 104

124

175

350

HN

76JZ

022

HN

76JZ

022

HN

76JZ

050

34 43 92

38.1

48.2

103

27.2

34.4

73.6

06TR

E04

8C06

TRE

048B

06TR

E04

8F

575

400/

460

208/

230

2553 64 12

8

172

215

433

HH

83XA

469

HH

83XA

426

HH

83XC

509

46 55 110

53 64 127

164

210

420

HN

76JZ

022

HN

76JZ

033

HN

76JZ

075

44 56 114

49.3

62.7

127.

7

35.2

44.8

91.2

06TR

E05

4C06

TRE

054B

06TR

E05

4F

575

400/

460

208/

230

2553 64 12

8

172

215

433

HH

83XA

469

HH

83XA

426

HH

83XC

509

46 55 110

53 64 127

164

210

420

HN

76JZ

022

HN

76JZ

033

HN

76JZ

075

44 56 114

49.3

62.7

127.

7

35.2

44.8

91.2

06TR

F065

C06

TRF0

65B

06TR

F065

F

575

400/

460

208/

230

3062 76 15

4

219

253

611

HH

83XB

617

HH

83XA

474

HH

83XC

573

54 67 134

61 78 154

219

274

611

HN

76JZ

033

HN

76JZ

033

HN

76JZ

075

55 66 136

61.6

73.9

152.

3

44 52.8

108.

806

TRG

078C

06TR

G07

8B06

TRG

078F

575

400/

460

208/

230

3572 89 18

1

258

323

721

HH

83XB

618

HH

83XA

475

HH

83XC

574

63 74 158

72 89 181

258

323

721

HN

76JZ

033

HN

76JZ

050

HN

76JZ

090

64 78 160

71.7

87.4

179.

2

51.2

62.4

128

06TR

H08

8C06

TRH

088B

06TR

H08

8F

575

400/

460

208/

230

4081 10

120

3

296

370

825

HH

83XB

619

HH

83XA

476

HH

83XC

575

71 88 179

81 101

203

296

370

825

HN

76JZ

050

HN

76JZ

050

HN

76JZ

090

72 90 180

80.6

100.

820

1.6

57.6

72 144

06TR

K10

8B40

0-3-

5050

114

440

HH

83XA

477

100

115

439

HN

76JZ

050

100

112

80

L

EG

EN

DR

LA=

Rat

ed L

oad

Am

psP

W=

Par

t-W

indi

ng S

tart

LRA

=Lo

cked

Rot

or A

mps

MH

=M

ust H

old

Am

psXL

=A

cros

s-th

e-Li

ne S

tart

MTA

=M

ust T

rip A

mps

NO

TES

:1.

C

ompr

esso

r m

ust t

rip a

mps

are

max

imum

fig

ures

. Ove

rcur

rent

pro

tect

ion

mus

t trip

at o

r be

low

this

val

ue.

2.

LRA

val

ue fo

r P

W 2

nd w

indi

ng =

1/2

the

LRA

XL

valu

e.3.

R

ecom

men

ded

RLA

val

ue =

Crt

Brk

mus

t trip

val

ue /

1.4

. Use

this

rec

omm

ende

d R

LA v

alue

to d

eter

min

e m

inim

um c

onta

ctor

siz

ing

and

wiri

ng s

izin

g. S

ee a

lso

deta

il on

Com

pres

sor

Am

pera

geR

atin

gs o

n U

nit R

atin

g P

late

.4.

A

ltern

ate

over

cur

rent

pro

tect

ion

devi

ce w

hich

can

be

used

in p

lace

of c

alib

rate

d ci

rcui

t bre

aker

.5.

C

arly

le 0

6TR

400

-3-5

0 un

its h

ave

the

sam

e ci

rcui

t bre

aker

tabl

e ra

tings

as

460-

3-60

. Ref

er to

460

-3-6

0 da

ta fo

r 50

Hz

info

rmat

ion.

17

06T

A –

ELE

CT

RIC

AL

SP

EC

IFIC

AT

ION

SC

OM

PR

ES

SO

R IN

FOR

MA

TIO

NR

EC

OM

ME

ND

ED

OV

ER

CU

RR

EN

T P

RO

TE

CT

ION

CO

MP

RE

SS

OR

MO

DE

LV

OLT

AG

EH

PM

AX

MT

A(S

ee N

ote

#1)

LRA

XL

CIR

CU

IT B

RE

AK

ER

PA

RT

#M

HM

TA

LRA

CA

RLY

LEFU

RN

AS

PA

RT

#(S

ee N

ote

4)M

HM

TA

RLA

(See

Not

e 3)

06TA

D03

3C06

TAD

033B

06TA

D03

3F

575

400/

460

208/

230

2039 49 10

4

138

173

348

HH

83XA

461

HH

83XA

424

HH

83XB

625

33 42 91

38 49 104

124

175

350

HN

76JZ

022

HN

76JZ

022

HN

76JZ

050

34 43 92

38.1

48.2

103

27.2

34.4

73.6

06TA

E03

9C06

TAE

039B

06TA

E03

9F

575

400/

460

208/

230

2553 64 12

8

172

215

433

HH

83XA

469

HH

83XA

426

HH

83XC

509

46 55 110

53 64 127

164

210

420

HN

76JZ

022

HN

76JZ

033

HN

76JZ

075

44 56 114

49.3

62.7

127.

7

35.2

44.8

91.2

06TA

F044

C06

TAF0

44B

06TA

F044

F

575

400/

460

208/

230

3062 76 16

3

202

253

510

HH

83XA

430

HH

83XA

478

HH

83XC

539

50 67 142

58 76 163

168

274

507

HN

76JZ

033

HN

76JZ

033

HN

76JZ

075

52 65 144

58.2

72.8

161.

3

41.6

5211

5.2

06TA

F048

C06

TAF0

48B

06TA

F048

F

575

400/

460

208/

230

3062 76 16

3

202

253

510

HH

83XA

430

HH

83XA

478

HH

83XC

539

50 67 142

58 76 163

168

274

507

HN

76JZ

033

HN

76JZ

033

HN

76JZ

075

52 65 144

58.2

72.8

161.

3

41.6

5211

5.2

06TA

G05

4C06

TAG

054B

06TA

G05

4F

575

400/

460

208/

230

3578 88 18

2

242

305

610

HH

83XA

453

HH

83XA

547

HH

83XC

532

68 77 158

78 88 182

236

283

590

HN

76JZ

050

HN

76JZ

050

HN

76JZ

090

69 78 162

77.3

87.4

181.

4

55.2

62.4

129.

606

TAG

065C

06TA

G06

5B06

TAG

065F

575

400/

460

208/

230

3572 89 18

1

258

323

721

HH

83XB

618

HH

83XA

475

HH

83XC

574

63 74 158

72 89 181

258

323

721

HN

76JZ

050

HN

76JZ

050

HN

76JZ

090

69 78 161

77.3

87.4

180.

3

55.2

62.4

128.

806

TAH

078C

06TA

H07

8B06

TAH

078F

575

400/

460

208/

230

4081 10

120

3

296

370

825

HH

83XB

619

HH

83XA

476

HH

83XC

575

71 88 179

81 101

203

296

370

825

HN

76JZ

050

HN

76JZ

050

HN

76JZ

090

72 90 180

80.6

100.

820

1.6

57.6

72 144

06TA

K08

8C06

TAK

088B

06TA

K08

8F*

575

400/

460

208/

230

5092 11

423

0

351

440

974

HH

83XB

610

HH

83XA

477

HH

83XC

576

74 100

200

89 115

230

323

439

979

HN

76JZ

050

HN

76JZ

050

HN

76JZ

050*

78 100

100

87.4

112

112

62.4

80 160

LE

GE

ND

RLA

=R

ated

Loa

d A

mps

PW

=P

art-

Win

ding

Sta

rtLR

A=

Lock

ed R

otor

Am

psM

H=

Mus

t Hol

d A

mps

XL=

Acr

oss-

the-

Line

Sta

rtM

TA=

Mus

t Trip

Am

ps*

To u

se F

urna

s ov

erlo

ad w

/06T

AK

088F

2EA

-A00

, com

pres

sor

mus

t be

wire

d fo

r pa

rt-w

indi

ng s

tart

and

2 o

verlo

ads

wire

d in

par

alle

l with

2 co

ntac

tors

. Fur

nas

mus

t hol

d se

ttin

g =

100

. MTA

Set

ting

= 1

12.

NO

TES

:1.

C

ompr

esso

r m

ust t

rip a

mps

are

max

imum

fig

ures

. Ove

rcur

rent

pro

tect

ion

mus

t trip

at o

r be

low

this

val

ue.

2.

LRA

val

ue fo

r P

W 2

nd w

indi

ng =

1/2

the

LRA

XL

valu

e.3.

R

ecom

men

ded

RLA

val

ue =

Crt

Brk

mus

t trip

val

ue /

1.4

. Use

this

rec

omm

ende

d R

LA v

alue

to d

eter

min

e m

inim

um c

onta

ctor

siz

ing

and

wiri

ng s

izin

g. S

ee a

lso

deta

il on

Com

pres

sor

Am

pera

geR

atin

gs o

n U

nit R

atin

g P

late

.4.

A

ltern

ate

over

cur

rent

pro

tect

ion

devi

ce w

hich

can

be

used

in p

lace

of c

alib

rate

d ci

rcui

t bre

aker

.5.

C

arly

le 0

6TA

400

-3-5

0 un

its h

ave

the

sam

e ci

rcui

t bre

aker

tabl

e ra

tings

as

460-

3-60

. Ref

er to

460

-3-6

0 da

ta fo

r 50

Hz

info

rmat

ion.

18

6.1 Carlyle Electronic Module (CEM)The Carlyle solid-state electronic module(115v-1-50/60 or 240v-1-50/60) is used forprimary control of the compressor contactor,oil and economizer line solenoids, andunloader and Vi coils. It also provides com-pressor thermal safety protection.

Two versions of this module have been used.The original Carlyle Electronic Module (CEM)and the LonCEM Module. Both versions arecovered in detail in Appendix A and AppendixB of this manual.

6.2 Discharge Temperature ControlDischarge temperature control and high tem-perature protection are supplied by the CEM.There are some applications where the dis-charge temperature becomes so hot that it isnecessary to inject liquid directly into the screwrotors. This is accomplished through the use ofa constant temperature desuperheating valve.Refer to section 3.7 for selection and applica-tion of this valve.The desuperheating valve bulbmust be strapped to the discharge line (asclose to the service valve as possible) andinsulated. The valve will maintain a dischargetemperature of 190°F (88°C). A normallyclosed solenoid with an inlet strainer is requiredupstream of the expansion valve.

The liquid feed header must be sized forthe entire desuperheating and motor cool-ing load. Failure to do so can lead to com-pressor overheating during high ambientoperation.

Section 6 — Motor and Discharge Temperature Control6.3 Motor Cooling Control

Motor cooling control and high temperatureprotection are supplied by the LonCEM/CEM.Carlyle 06T screw compressors utilize an econ-omizer cooled motor. Screw compressor tech-nology allows access to intermediate pressurepart way through the compression cycle. TheCarlyle screw compressor uses this intermedi-ate pressure access to pull vapor through asubcooler and over the compressor motor.This process (called an economizer cycle) pro-vides liquid subcooling and motor cooling(reducing the need for liquid injection). Due toboth these processes being done at an inter-mediate pressure versus suction pressure, sig-nificant increases in energy efficiency are real-ized.

A typical economizer arrangement is shownbelow. The flow to the screw compressormotor is governed by an expansion valve thatis set to maintain 10 to 20°F (6 to 11°C) super-heat above intermediate pressure. A liquid linesolenoid is required in front of the expansionvalve and must be normally closed (this valvemust be off when all compressors are off andon when any compressor is on).

2.50(63.5)

0.50(12.7)

NO BENDS WITHIN1.50" OF HEAD

3" (7.62 mm)REINFORCEMENTSPRING

OUTLET

INLET

0.31(7.9)MIN.

1.37(34.8)

0.94(23.9)HEX

0.31(7.9)MIN.

0.3775/0.3805 DIA.(9.588/9.665)TYP. (INLET & OUTLET)EACH CONNECTION

1.33(33.8)

1.69(42.9)

DESUPERHEATING VALVE

1.78(45.2)

3.89(98.8)

(38.1)

TO EVAPORATOR ECONOMIZERMAIN LIQUID

VAPOR OUTTO COMPRESSOR

ECONOMIZER PORT

For parallel applications, an intermediate header is required to distribute economizer gas to each compressor. A solenoid valve isrequired in the feed line to each compressor.This valve must be normally closed and offwhen the compressor is off to eliminate inter-mediate to suction pressure leak back duringany compressor off cycle. This solenoid can be controlled by the CEM.

If an economizer is not used, motor coolingcontrol is still required. Two cooling valvesshould be installed in parallel, feeding the econ-omizer port to eliminate thermal shock. OneEF28BZ005 (1 ton) valve is wired to be on anytime the compressor is on and the LonCEMcontrols one EF28BZ007 (1.5 ton) valve.

Motor barrel insulation is recommended oncompressors with suction temperatures below-15°F (-26°C) to prevent frost build-up andcondensation on the compressor motor barrel.FOR REFERENCE ONLY

INCHES[MILLIMETERS (mm)]

19

7.1 Subcooler SelectionThe use of an economizer is highly recom-mended and provides the high capacities and energy efficiencies shown in the screwcompressor tabular rating tables. The sub-cooling load may be calculated by taking the total compressor mass flow of the rack and multiplying it by the change in enthalpyacross the subcooler (liquid main in minus liquid main out). To estimate the liquid temper-ature leaving the subcooler, take the saturated intermediate temperature (at the design condition) from the performance tables andadd 10°F (5°C). The subcooler should now be sized based on the subcooling load calcu-lated. Carlyle recommends sizing and pipingthe subcooler for parallel flow. Parallel flowthrough the subcooler results in better control of the subcooler TXV (reduces TXV hunting).

7.2 Subcooling CorrectionThe economized performance data supplied isbased on liquid temperature that is 10°F (6°C)above saturated intermediate temperature. Thecapacity may be varied for other than rated liq-uid temperature by either of two methods. Forthe most accurate adjustment, Method #2should be used.

METHOD 1

Vary compressor capacity by 3% for each 10°F (6°C) difference between actual and rated liquid temperature. For example, if theactual liquid temperature was 50°F (10°C) and the rated liquid temperature was 40°F(5°C), divide the rated capacity by 1.03. This method is specifically for R-22.

METHOD 2

Using the mass flow rates published in the rating tables, a thermodynamic correction may be used by calculating the new change in enthalpy across the evaporator and multiply-ing it by the evaporator mass flow rate.

7.3 Superheat CorrectionThe screw compressor tabular data is ratedwith 65°F (18°C) return gas temperature (alluseful superheat) for low and medium temper-ature applications. The suction gas does notpass over the motor, but goes directly to thecompressor rotors. Utilizing R-22 the compres-sor capacity will have no significant change

Section 7 — Subcooler Selection and Performance Data Adjustmentwith lower return gas temperatures based onall useful superheat at the compressor.However, the actual evaporator capacity willincrease with lower return gas temperature due to the higher gas density entering thecompressor which will result in larger com-pressor mass flow rates. Mass flow rates arepublished in the compressor performancetables and may be used to calculate compres-sor performance at any approved operatingcondition. The Carlyle screw compressor suction gas goes directly into the rotors andtherefore does not incur additional (inefficient)suction gas superheating from passing overthe motor. There is a required minimum of 20°F(11°C) discharge superheat. The systemshould sound an alarm if the superheat reaches 20°F (11°C). Long periods of run timewith low discharge superheat will reduce compressor bearing life.

7.4 Carlyle SoftwareThe Carlyle Compressor Selection program“CARWIN” will select compressors, calculatesubcooler load, oil-cooler load, and performsuperheat and subcooling corrections. This software is available through CarlyleCompressor Company, at www.carlylecompressor.com.

The tabular performance data presented in thiscatalog is at 65°F(18.3°C) return gas tempera-ture and SIT+10°F(5.5°C) liquid temperature.Performance at actual operating conditionsmay vary significantly from these rating condi-tions. Our Carwin selection software can beused to estimate the performance at the actualoperating conditions.

For systems that have mechanical subcooling,as with the economizer cycle on our 74mmcompressors, there can be a substantial differ-ence between the performance at the standardrating conditions and the applications actualoperating conditions. These differences aregenerally only significant in low temperatureapplications. For low temperature applications(SST<0°F/4.4°C), compressor performanceshould be based on design liquid temperature(typically maintained at or above 40°F(4.4°C)and the maximum return gas temperatureexpected (typically 25°F-35°F (-3.8°C-1.7°C)for low temperature applications). The evapora-tor refrigeration effect (ERE reported in Carwin)capacity should then be used to size againstthe required load.

20

8.1 General InformationThe 05T compressor is a compact and light-weight open drive screw compressor whichdelivers high capacity for its size. It is very simi-lar to the 06T semi-hermetic screw compres-sor. With the exception of an internal motor,the 05T and 06T are virtually identical. In placeof the internal motor, the open drive is suppliedwith a gear casing and jack shaft to connectan external C-Face motor or other device. Thecompression end of the compressor is identicalto the 06T semi-hermetic screw compressor.

The compressor is designed for operation atboth 1750 rpm at 60 Hz (1450 rpm @ 50 Hz)and 3500 rpm at 60 Hz (2900 rpm @ 50 Hz).With the exception of electrical information and motor cooling requirements of the 06Tcompressor, all the information in this applica-tion guide also applies to the 05T models. Anexternal oil cooler is required on all applicationswhere the discharge temperature is above 170 F. The model numbering system, however,is slightly different. The cross reference can befound in the table below.

06T 05T RPM Ft3/min m3/minModel # Model # 60Hz (50Hz) @ 60Hz @ 50Hz

06T**033 05TRQ033 1750 (1450) 33 .7806T**039 05TRQ039 " 39 .9206T**044 05TRQ044 " 44 1.0406T**048 05TRQ048 " 48 1.1306T**054 05TRQ054 " 54 1.2806T**065 05TRQ033 3500 (2900) 65 1.5306T**078 05TRQ039 " 78 1.8406T**088 05TRQ044 " 88 2.08

Model Number Cross Reference

The 05T compressor has been designed fordirect drive duty and should not be used in abelt drive application.

Section 8 — 05T Open Drive Application Information8.2 Compressor Dimensions

Like the 06T, the 05T models have all the same physical dimensions. Please reviewdimensional drawings for external dimensionalinformation on the compressor.

(15.0mm).59"

(145.3mm)5.72"

(384.3mm)15.13"

(558.9mm)22.00"

Dimensions (Top View)

(148.1mm)5.83"

(ø15mm)ø.59"

(2X ø15mm)ø.59"

(70.3mm)2.77"

(54.2mm)2.13"

(359.4mm)14.15"

(32.0mm)1.26"

(300.0mm)11.81"

(134.0mm)5.28"

(101.8mm)4.00"

LIFTING BRACKET

Dimensions (Side View)


[MILLIMETERS (mm)]


[MILLIMETERS (mm)]

21

8.3 Compressor C-FlangeSeveral compressor C-Flanges have beendesigned by Carlyle. The C-Flange bolts toboth the compressor and a C-Face motor foreasy self aligning (within ± 0.005" [.127mm]TIR) of the coupling. There are three distinct C-Flanges, two for 1750 (1450) RPM motorsand one for 3500 (2900) RPM motors. The C-Flange selections can be found in the follow-ing table.

C-FlangeMotor Speed Package Dimensions

Selection Required15Hp (254TC)

20Hp (256TC) 1750 rpm @ 60Hz C-flange0TA0929 drawing A

25Hp (284TC) 1450 rpm @ 50Hz

30Hp (286TC)

40Hp (324TC) 1750 rpm @ 60Hz C-flange0TA0930 drawing B

50Hp (326TC) 1450 rpm @ 50Hz

30Hp (286TSC)

40Hp (324TSC) 3500 rpm @ 60Hz C-flange0TA0931 drawing C

50Hp (326TSC) 2900 rpm @ 50Hz

60Hp (364TSC)

75Hp (365TSC)

Please review C-Flange dimension drawings for all dimensional information on the C-Flanges.

(129.1mm)5.08"

(164.1mm)6.46"

(52.9mm)2.08"

(308.4mm)12.14"

(150.5mm)5.92"

(97.0mm)3.82"

(121.0mm)4.76"

(211.2mm)8.31"

Dimensions (Bottom View)


[MILLIMETERS (mm)]

22

B

-B-

-C- -A-

11.625"

1.0"

-Z-

5.00

SC Zø.0015 S

-D-

2X ø.500 X .63 DEEP

+.0005

0

1.13

D

DD2

D1

S DCø.015 M

4X ø17/32 THRU

B

R .25

ø12.50"90º

R5 .39

45º3.05

5.21

5.21

3.05

(77.5)

(132.3)

(132.3)

(77.5) (28.7)

(6.4)

(127)

(136.9)

(295.3)

(25.4)

(317.5)

(266.7)

B

S DCØ.015 M

4X Ø17/32 THRU

S

-D-C ZØ.0015 S

2X Ø.500 X .63 DEEP+.0005 0

-B-

-C- -A-

10.750"

1.0"

5.00

1.13

D

DD2

D1

Ø .539 X 90° CSKB

B

R . 25

ø10.50"90º

45º3.05

R5 .39

3.05

5.21

5.21(132.3)

(77.5)

(132.3)

(77.5) (28.7)

(6.4)

(127)

(136.9)

(273.1)

(25.4)

B

S DCØ.015 M

4X Ø17/32 THRU

S

-D-

C ZØ.0015 S

2X Ø.500 X .63 DEEP+.0005 0

-B-

-C- -A-

9.875"

1.0"

5.00

1.13

D

DD2

D1

R5 .39

R .25

-Z-

Ø12.50"

45º

90º

3.05

5.21

5.21

3.05(77.5)

(132.3)

(132.3)

(77.5) (28.7)

(6.4)

(25.4)

(317.5)

(250.8)

C-Flange Dimensions (A)

C-Flange Dimensions (B)

C-Flange Dimensions (C)


[MILLIMETERS (mm)]


[MILLIMETERS (mm)]


[MILLIMETERS (mm)]

23

8.4 Compressor CouplingA flexible Dodge coupling is used to directcouple the compressor to the motor shaft. Toproperly assemble the C-Flange and couplingonto the compressor, follow the installationinstructions for C-Flange and coupling suppliedwith the C-Flange packages.

The required coupling for each different motorsize can be found in the following table. Thecoupling dimensions can be found in the figurebelow.

MotorShaft Coupling

Motor Speed Dia. PackageSelection (Inch) Required

15Hp (254TC) 1750 rpm @ 60Hz1-5/8 8TA0868B

20Hp (256TC) 1450 rpm @ 50Hz

25Hp (284TC) 1750 rpm @ 60Hz1-7/8 8TA0869B

30Hp (286TC) 1450 rpm @ 50Hz

40Hp (324TC) 1750 rpm @ 60Hz2-1/8 8TA0870B

50Hp (326TC) 1450 rpm @ 50Hz

3500 rpm @ 60Hz30Hp (286TSC) 1-5/8 8TA0868B

2900 rpm @ 50Hz

40Hp (324TSC)

50Hp (326TSC) 3500 rpm @ 60Hz1-7/8 8TA0869B

60Hp (364TSC) 2900 rpm @ 50Hz

75Hp (365TSC)

Table 8-3

8.5 Overall DimensionsAll the 05T compressors have the same exter-nal physical dimensions, therefore the variablesthat will affect the overall dimensions of theassembly are the motor and C-Flange. Thedimensional drawing shown in the 05T dimen-sion drawing supplies the assembly dimen-sions with the different C-Flanges and motors.

Coupling Dimensions

(112.8 mm)4.44"

(138.4 mm)5.45"


[MILLIMETERS (mm)]

24

C-Flange Motor NEMA A B C D EPackage HP RPM. Frame in. cm. in. cm. in. cm. in. cm. in. cm.

15 1750 254TC 8.25 20.96 5.00 12.70 27.29 69.32 .106 .28 .56 1.42

0TA0929 20 1750 256TC 10.00 25.40 5.00 12.70 27.29 69.32 .106 .28 .56 1.42

25 1750 284TC 9.50 24.13 5.50 13.97 27.48 69.80 .858 2.18 .56 1.42

30 1750 286TC 11.00 27.94 5.50 13.97 27.48 69.80 .858 2.18 .56 1.42

0TA0930 40 1750 324TC 10.50 26.67 6.25 15.88 28.86 73.30 1.86 4.72 .69 1.75

50 1750 326TC 12.00 30.48 6.25 15.88 28.86 73.30 1.86 4.72 .69 1.75

30 3500 286TSC 11.00 27.94 5.50 13.97 26.42 67.11 .858 2.18 .56 1.42

40 3500 324TSC 10.50 26.67 6.25 15.88 27.11 68.86 1.86 4.72 .69 1.75

0TA0931 50 3500 326TSC 12.00 30.48 6.25 15.88 27.11 68.86 1.86 4.72 .69 1.75

60 3500 364TSC 11.25 28.58 7.00 17.78 27.73 70.43 2.86 7.26 .69 1.75

75 3500 365TSC 12.25 31.12 7.00 17.78 27.73 70.43 2.86 7.26 .69 1.75

05T Dimensions


[MILLIMETERS (mm)]

25

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