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Carrier Compressor and Condensing Unit User's Manual
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1. 5 Evacuate and dehydrate compressor A DANGER Do not attempt start up with terminal cover removed Bodily injury or death may result from explosion and or fire if power is supplied to compressor with the terminal cover removed or unsecured See warning label on termi nal cover 6 Place compressor in operation After 2 to 4 hours of operation check compressor oil for discoloration and or acidity If oil shows signs of contamination replace oil charge filter driers and clean suction strainer with solvent 7 Check oil daily for discoloration and acidity If oil stays clean and acid free the system is clean If oil shows signs of contamination change oil filter drier and clean suction strainer If filter drier or suction strainer is dirty or discolored repeat this step until system is clean Condenser Maintenance 07E Units To inspect and clean condenser drain water and remove condenser heads To drain condenser shut off water supply and disconnect inlet and outlet piping Remove drain plugs and vent plug With condenser heads removed inspect tubes for refrigerant leaks Refer to Carrier Standard Service Techniques Manual Chapter 1 Section 1 6 Leak Testing for instructions Clean condenser tubes with nylon brush available from Carrier Service Department Flush water through tubes while cleaning If hard scale has formed clean tubes chemically Do not use brushes that will scrape or scratch tubes
2. FINE MESH RETURN SCREEN Fig 25 Forced Circulation Copyright 2001 Carrier Corporation Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 2 4 4 PC 802 Catalog No 530 601 Printed in U S A Form 06 07E 1SI Pg 20 5 01 Replaces 06E 07E 9SI Tab 1b 2a 2b 3a
3. Relay FU Fuse GND Ground HPS High Pressure Switch LPS Low Pressure Switch NEC National Electrical Code Cor NEMA National Electrical LPS EH Manufacturer s Association 00720 BPS OPS Oil Pressure Switch a POR oes Pumpout Relay HPS LPS OPS LOCATED ON BACK OF BOX TB Terminal Block ON STANDARD UNITS TDR Time Delay Relay INSIDE BOX ON NEMA 4 UNITS TM Timer Motor TR Timer Relay Fig 5 Component Location Li RN REMOVE JUMPER BETWEEN T 204 WHEN de ee Me TB2 NH NN La j on Gn t TB2 OVERLOADS OVERLOADS HPS FIELD M1 AUX THERMOSTAT BLK d Fui p BLK 1 182 BLK CHR BLK armo 115V CONTROL JUMPER 230V CONTROL FUSE BLU TR Terminal Block Connector Unmarked Terminal Marked Terminal Factory Wiring Field Control Wiring To indicate common potential only not to represent wiring Splice zm oO LEGEND AUX Auxiliary M1 Evaporator Fan or C Compressor Contactor Chilled Water Pump C1 Compressor Contactor M2 Cooling Tower Pump XL start and first step of PW start M3 Cooling Tower Fan C2 Compressor Contactor NEC National Electrical Code PW second step OPS Oil Pressure Switch CH Crankcase Heater POR Pumpout Relay CHR Crankcase Heater Relay PW Part Wind CR Control Relay SW Start Stop Reset Switch DTS Discharge Temperature Sensor TB Termin
4. Specified Parts 2 Before compressor is opened the refrigerant must be removed from it by the Pumpdown method a Start compressor close suction shutoff valve and reduce crankcase pressure to 2 psig Bypass low pressurestat with a jumper b Stop compressor and isolate from system by closing discharge shutoff valve c Bleed any residual refrigerant necessary 3 After disassembly clean all parts with solvent Use mineral spirits white gasoline or naphtha 4 Before assembly coat all parts with compressor oil and clean and inspect all gasket surfaces Replace all gaskets with new factory made gaskets See Table 6 for torque values 5 After reassembly evacuate compressor and open suction and discharge valves Restart compressor and adjust refrigerant charge Drain oil if PRESSURE DIFFERENTIAL UNLOADER UNLOADER ADJUSTMENT SCREW UNLOADER VALVE BODY CAPACITY CONTROL VALVE VALVE SPRING CONTROL SET POINT ADJ NUT POPPET VALV OPRET E VALVE a m COVER PLATE BLEED ORIFICE PLATE EE SUCTION PRESSURE DISCHARGE GG DISCHARGE PRESSURE Bere LOADED PRESSURE DIFFERENTIAL SEALING UNLOADER UNLOADER UNLOADER ADJUSTMENT SCREW CAP PISTON HEAD VALVE BODY ASSEMBLY CAPACITY CONTROL VALVE UNLOADER VALVE SPRING COVER PLATE CONTROL SET POINT ADJ NUT POPPET VALVE BLEED ORIFICE Ej SUCTION PRESSURE DISCHARGE DISCHARGE PRESSURE VALVE UNLOADED NOTE Pressure oper
5. Turn adjustment nut clockwise to its bottom stop In this position set point is 86 psig Control set point is then regulated to desired pressure by turning adjustment nut counterclockwise Each full turn decreases set point by approximately 7 2 psi Approximately 12 turns counterclockwise lowers the control set point to 0 psig See Table 5 Table 5 Capacity Control Full Load Capacity noor 100 67 49 s2 UNIT 06E 07E ALL 4 CYLINDER MODELS ALL 6 CYLINDER MODELS NOTE Capacity control valve factory settings for 4 cylinder units are 59 psig control set point cylinder load point 10 psi differential 59 psig cylinder unload point Settings for 6 cylinder units are left cylinder bank control set point is 70 psig differential is 10 psi right cylinder bank control set point is 68 psig differential is 10 psi Pressure Differential Adjustment Turn differential adjust ing screw counterclockwise to its back stop position In this position differential is 6 psi Pressure differential is set by turning adjusting screw clockwise Each full turn increases pressure differential by approximately 0 8 psi Approximately 10 turns increases differential to 16 psi SUCTION CUTOFF UNLOADER OPERATION The ca pacity control valve shown in Fig 9 is the pressure operated type Refer to Fig 10 and the following description for valve operation Loaded When suction pressure rises high enough to over come c
6. V4 EPT OIL FILL PLUG PO 4 E t O AG 03 OIL FILL PLUG 1 4 FPT el SY 5 WIS V4 FPT OIL LEVEL sE SIGHT GLASS Sart GEASS iS CRANKCASE AA CRANKCASE u Au HEATER l ww w wN w Ww al y HEATER EQUALIZING EQUALIZING CONNECTION 5 Ii Ie MTG HOLES PUMP END CONNECTION 5 116 MTG HOLES PUMP END I 38 gt 11 3 82 OIL DRAIN PLUG OIL DRAIN PLUG OIL DRAI 14 EPT PUMP END 4 CYLINDER PUMP END 6 CYLINDER Fig 4 06E Compressors 4 Table 1 Electrical Data Compressor Motor With Circuit Breaker COMPRESSOR MOTOR DATA CIRCUIT BREAKER Maximum Must Trip Maximum RA XL MTA LRA Recommended H RLA RLA mps 208 230 108 87 345 207 0 32 HH83XB336 91 104 350 575 20 45 36 120 72 2 2 XA461 33 38 124 460 54 44 173 104 1 3 XA424 42 49 175 208 230 140 112 446 268 0 27 HH83XC509 110 127 420 575 25 57 46 164 98 1 6 XA469 46 53 164 460 70 56 223 134 11 XA426 55 643 210 208 230 168 135 506 304 0 22 HH83XC539 142 163 507 275 575 30 65 52 176 106 13 XA430 50 58 168 460 84 68 253 152 0 9 XA425 63 73 210 Motor Recommended Winding Tear Resistance MENT Ohms Compressor Part Voltage Number 06E 3 Ph 60 Hz 208 230 236 189 690 414 0 15 HH83XC537 187 215 636 40 94 75 276 165 1 0 XA551 74 85 236 118 95 345 207 0 58 92 XA550 106 295 LEGEND 4 Recommended RLA value shown is determined by circuit LRA Lo
7. can be seen from end bell side 3 Ream out bushing 3 g in drill and drill into stator core until tape is flush with top of bushing Remove drill chips Back off locking pin bushing g of a turn 4 Tap locking pin into position Top of bushing should be approximately 1 16 in above top of pin 5 Peentop of bushing over roll pin 6 Replace washer and acorn nut Motor Burnout Clean Up Procedure When a hermetic motor burns out the stator winding decomposes forming carbon water and acid which contaminate refrigerant systems Remove these contaminants from system to prevent repeat motor failures 1 Close compressor suction and discharge service valves and bleed refrigerant from compressor Save remaining refrigerant in system 17 2 Remove burned motor from compressor and drain com pressor oil Clean crankcase and motor housing with solvent Ensure that all metal particles are wire brushed free and removed On severe burnouts disassemble compressor heads and valve plate assemblies Clean them in same manner as crankcase and motor housing 3 Determine cause of burnout and remedy Check control box for welded starter contacts welded overload contacts or burned out heater elements Check terminal plate for burned or damaged terminals insulation and shorted or grounded terminals 4 Reassemble compressor with new stator and rotor Install new liquid line filter drier and place new oil charge in crankcase
8. the OPS reset button and then push the control circuit switch on the unit control box to OFF and then to ON Table 4 Factory Switch Settings PRESSURE CHANGE AFFECTING SWITCH POSITION psig Open 210 10 290 10 Oil Pressure 6 NOTES Values for the high and low pressure switches based on R 22 For other refrigerants reset to pressure corresponding to satura tion temperatures indicated by the listed pressures 2 Values for oil pressure are above operating suction pressure pressure differential between suction and discharge pressures of oil pump SWITCH TYPE High Pressure Low Pressure TIME GUARD CONTROL The Time Guard control protects against short cycling See Start Compressor CRANKCASE HEATER The crankcase heater prevents absorption of liquid refrigerant by oil in crankcase during brief or extended shutdown periods Source of 115 volt power is the auxiliary control power independent of the main unit power This assures compressor protection even when main unit power disconnect switch is off IMPORTANT Never open any switch or disconnect that will deenergize the crankcase heater unless unit is being serviced or is to be shut down for a prolonged period After a prolonged shutdown or a service job energize the crank case heater for 24 hours before starting the compressor Compressor Thermal Protection A discharge temperature sensor installed in o
9. the control circuit START STOP RESET switch to START The timer motor starts immediately Depending on the position of the timer the compressor start is delayed for 12 seconds to approximately 8 minutes Check oil pressure after compressor has run a few minutes the pressure should be 12 to 18 psi above the suction pressure After about 20 minutes of operation stop the com pressor Allow it to be idle for about 5 minutes then observe the oil level in the sight glass Refer to the Carrier Standard Service Techniques Manual Chapter 1 Section 1 11 for adding oil The proper oil level for the O6E compressor is approximately 1 3 up on sight glass and deenergizes the crankcase heater These contacts also provide one second time delay for part winding start 3 Switch E contacts E 1 provides approximately 40 second bypass of oil pressure switch OPS at start up Compressor will shut off if sufficient oil pressure does not build up 4 Switch D contacts D D1 bypasses the low pressure switch LPS for 2 5 minutes at start up for winter start control BLACK DENOTES CLOSED CONTACTS TIMER POSITION DURING Miren UNIT OPERATION A HMM O MIN 150 sec 5 5 5 MIN A a X1 A ATI a COMPRESSOR STARTS den 12 SEC 2 Sea ae ie DE ES H 2 6 SEC 150 sec 5 5 5 MIN A Fig 7 Timer Cycle SERVICE Protection Devices HIGH PRESSURE SWITCH Check by throttling con den
10. 06E 07E Compressors and Condensing Units Installation Start Up and Service Instructions Hermetic Water Cooled CONTENTS Page SAFETY CONSIDERATIONS 1 INSTALLATION ooo 1 6 Receive and Inspect Unit 1 Place Unit in Position 1 Check Compressor Mounting 1 Piping Connections 005 2 Electrical Connections 2 PRE START UP oooooooococcion cis 7 8 Evacuate Dehydrate and Leak Test 7 Oil Charge ooooocooocccccccrrr eee 7 STARTUP s ee Pee eA POS 8 Start Compressor 0 ee eee eee 8 Timer Functions 00 0 cece eee 8 SERVICE ba peed tae aces 9 18 Protection Devices 0 0c eee 9 Compressor Thermal Protection 9 Capacity Control SysteM 9 Removing Inspecting and Replacing Components ooo 10 Lubrication System usuuuuuuuuuu 13 Cylinder Heads LLuuuuuuuuuuuuuuuue 14 Pressure Relief Valve 14 Suction and Discharge Valve Plate Assembly 14 Terminal Plate Assembly 14 Compressor Running Gear Removal 14 Compressor Running Gear Replacement 15 Motor Removal ssssssess 16 Motor Replacement LLuuuususes 16 Motor Burnout Clean U
11. 44 600 6o o 670 R 134a R 22 R 507 404A A265 A275 A299 6 6 6 211 46 211 46 211 16 2 23 46 27 8 68 75 99 1750 19 19 19 450 PSIG 245 PSIG 15 8 15 8 21 3 21 8 13 g 15 g Compressors listed are for R 22 applications For R 134a an 06EM compressor is standard offering an O6ER compressor is standard for R 507 404A Factory compressor substitutes may be made Contact Carrier Sales Representative Table 3 07E Physical Data UNIT 07E A022 B027 Boss D044 OPERATING WEIGHT Ib 1090 1200 1250 1410 REFRIGERANT R 134a R 22 R 507 404A COMPRESSOR 06E A250 A265 A275 A299 Cylinders 4 6 6 6 Bore in 211 6 211 46 211 46 211 46 Stroke in 23 16 2 23 46 27 8 Displacement cfm at 1750 rpm 50 68 75 99 Oil Charge pt 14 19 19 19 High Side Maximum Pressure psi 450 Low Side Maximum Pressure psi 245 CONDENSER Shell and Tube t Part Number P701 0840AX P701 0850AX P701 0850AX P701 1065AX 71 3 85 90 85 90 112 70 FEIER 18 67 18 67 23 77 15 1 18 30 18 30 23 30 Min Refrigerant Operating Charge Ib R 507 404A 61 1 73 60 73 60 96 50 15 1 18 30 18 30 23 30 REFRIGERANT CONNECTION in ODF Inlet 21 3 21 3 21 3 25 5 Outlet 13 8 198 198 15 8 WATER CONNECTION in FPT 21 2 21 2 21 2 3 Inlet Outlet LEGEND FPT Female Pipe Thread ODF Outside Diameter Female Refrigerant Storage Capacity Ib Compressor listed is the standard compressor for R 22 air conditioning duty An O6ER c
12. AC 238 volts 243 236 238 Average Voltage 3 _ 717 3 239 volts Determine maximum deviation from average voltage AB 243 239 4 volts BC 239 236 3 volts AC 239 238 1 volt Maximum deviation is 4 volts Determine voltage imbalance Voltage Imbalance 100 x 3 17 This amount of phase imbalance is satisfactory as it is below the maximum allowable 2 IMPORTANT If the supply voltage phase imbalance is more than 2 contact your local electric utility company immediately Allowing the unit to operate with a voltage imbalance in excess of 2 may void the warranty POWER SUPPLY Field wiring must comply with local and national codes See Table 1 Install a branch circuit fused disconnect of adequate size to handle starting current The disconnect must be within sight from the unit and readily accessible in compliance with National Electrical Code NEC Section 440 14 Line power is brought into control center through indicated opening Connect line power supply to terminal block TB1 connect power leads to terminals L1 L2 and L3 Connect control circuit power supply 115 volts to terminals 1 and 15 on terminal block TB2 Refer to Fig 5 Wiring connections for field supplied equipment are shown on wiring diagram See Fig 5 ACCESSORIES Field installed accessories for the 06E and 07E units are control circuit transformer and gage panel 3 gages Refer to accessory litera
13. Because the condenser water circuit is usually an open system the condenser tubes may be subject to contamination by foreign matter Local water conditions may cause excessive fouling or pitting of tubes Condenser tubes therefore should be cleaned at least once a year or more often if the water is contaminated Proper water treatment can minimize tube fouling and pitting If such conditions are anticipated water treatment analysis is recommended Refer to the Carrier System Design Manual Part 5 for general water conditioning information If hard scale has formed clean the tubes chemically Con sult an experienced and reliable water treatment firm in your area for treatment recommendations Clean the condenser by gravity or by forced circulation as shown in Fig 24 and 25 IMPORTANT If the ambient temperature is below 32 F during a shutdown period protect the condenser from freezing by draining the water from the system or by add ing antifreeze to the water FILL CONDENSER WITH CLEANING SOLUTION DO NOT ADD SOLUTION MORE RAPIDLY THAN VENT CAN EXHAUST GASES CAUSED BY CHEMICAL ACTION 3 TO 4 CONDENSER Fig 24 Gravity Circulation 18 CENTRIFUGAL PUMP 1 2 HP CLOSE VENT PIPE 30 GPM AT 35 HEAD GAS VENT gt VALVE WHEN PRIMING PUMP IS GLOBE PUMP CONN GLORE 1 RUNNING SUCTION PUMP SUPPORT 1 PIPE CONDENSER REMOVE WATER REGULATING VALVE
14. NT Use only Carrier approved compressor oil Do not reuse oil that has been drained and do not use oil that has been exposed to atmosphere Approved compressor oils Petroleum Specialties Inc o o o oooooo o Cryol 150 Texaco Ingo Limit Capella WR 32 Witco Chemical Co 2 0 eee eee Suniso 3GS Approved for R 12 R 22 R 502 refrigerants Contact Carrier Factory Sales Representative for other refrigerants TO ADD OIL Close suction shutoff valve and pump down crankcase to 2 psig Low pressure cut out must be bypassed Wait a few minutes and repeat as needed until pressure remains at 2 psig Remove oil fill plug above bull s eye add oil through plug hole and replace plug Run compressor for about 20 min utes and check the oil level TO REMOVE OIL Pump down compressor to 2 psig Loosen the 4 in pipe plug in compressor base and allow the oil to seep out past the threads of the plug The crankcase will be under slight pressure Be careful not to remove the plug the entire oil charge may be lost Table 2 06E Physical Data UNIT 06E OPERATING WEIGHT Ib REFRIGERANT COMPRESSOR 06E A250 Cylinders 4 Bore in 211 46 Stroke in 23 46 Displacement cfm at 1750 rpm 50 Maximum Rpm Oil Charge pt 14 High Side Maximum Pressure psi Low Side Maximum Pressure psi CONNECTIONS in Suction Valve ODF Discharge Valve ODF LEGEND ODF Outside Diameter Female V022 W027 wo33 W0
15. OD PISTON ASSEMBLY Remove cyl inder heads valve plate assemblies crankcase bottom cover plate oil filter screen and connecting rod caps Fig 17 Label caps and rods so they may be reinstalled in same place on crankshaft Push connecting rod and piston assemblies up through cylinder deck Disassemble connecting rods from pistons by removing retaining rings and piston pins Remove oil and compression rings from piston Keep each connecting rod and piston assembly together for proper reassembly Check all parts and crankpins for wear refer to Table 7 for wear limits PRESSURE RELIEF VALVE Fig 14 Pressure Relief Valve Removal VALVE PLATE SECTION VALV BACKER SEATS VALVE PLATE BACKER IS UNDER THE VALVE SUCTION VALVE STOPS CYLINDER DECK PINS Fig 15 Valve Plate Removed TERMINAL PLATE ASSEMBLY ALLEN HEAD SCREWS 1 4 Fig 16 Removing Terminal Plate Assembly CRANKSHAFT CONNECTING 4 RODS AND CAPS OIL DRAIN PLUG MAGNETIC BOTTOM COVER PLATE OIL FILTER SCREEN Fig 17 View with Bottom Cover Plate Removed CRANKSHAFT Remove pump end bearing head and rotor If connecting rod and piston assemblies are still in place remove connecting rod caps and push piston assembly up into cylinder for crankshaft clearance Pull crankshaft out through pump end opening Inspect crankshaft journals for wear and toler
16. Plug Crankshaft 1 4 18 pipe 20 25 Pipe Plug Crankcase 1 20 8 10 Conn Rod Cap Screw 4 8 12 Junction Box Sight Glass Oil Pump Drive Segment Unloader Valve Discharge Valve Stop Head Gasket Positioning Screw 15 24 Cover Plate Pump End Bearing 5 46 18 pipe Head 15 24 Discharge Service Valve 4 cyl Bottom Plate Crankcase Compressor Foot Terminal Plate Oil Plug Pump End Bearing Head Terminal Bolts 3 3 18 pipe 30 40 Pipe Plug Junction Box 7 14 55 65 Motor End Cover 16 55 65 Pump End Bearing Head 90 100 Cylinder Head 1 2 13 90 120 Discharge Service Valve 6 cyl 90 120 Suction Service Valve 4 cyl 5j 11 90 120 Suction Service Valve 6 cyl 8 90 120 Rotor Lock Crankshaft 5g Oil Drain Plug Sla Stator Lock No 6 Check Valve Body Crankcase 4 6 Oil Pump Drive Segment No 19 Terminal Screw Lubrication System TESTING OIL PUMP An oil pressure tap is located above oil pump cover plate Fig 12 Oil pressure should be 12 to 18 psi above suction pressure Oil Filter Screen Screen is accessible through bottom cover plate Remove and inspect strainer for holes and dirt Clean it with solvent and replace OIL PUMP AND BEARING HEAD The oil pump assem bly is contained in the pump end bearing head aluminum casting The pump end main bearing is a machined part of this casing no insert bearing Remove Bearing Head Remove bearing head from crank case and d
17. al Block DX Direct Expansion TDR Time Delay Relay FU Fuse TM Timer Motor HPS High Pressure Switch TR Timer Relay LLS Liquid Line Solenoid Valve XL Across the Line LPS Low Pressure Switch NOTES 1 Factory wiring is in compliance with NEC Any field modifications a fF oN or additions must be in compliance with all applicable codes Use copper copper clad aluminum for field power supply only Field power supply wiring must be 75 C minimum Compressor thermally protected Three phase motors are pro tected against primary single phasing condition Pilot duty control must be field supplied Minimum contact rating must be 25 va 60 Hz units have 120 volt control circuit 50 Hz units have 230 volt control circuit A separate source of supply at the correct voltage must be field supplied supply at the through a fused disconnect FIELD THERMOSTAT o oo N 9 device with a EIE ME rating of 15 A to TB2 connections L1 Hot Side and L2 Neutral Open control bieo disconnect switch for servicing only Discon nect must remain closed for crankcase heater to operate A transformer of the following rating may be field supplied for 60 Hz units 350 va Transformer must be fused and grounded per applicable codes If any of the original wiring furnished must be replaced it must be replaced with 90 C wire or its equivalent Wiring is shown for single pumpout control Single pumpout con
18. ances shown in Table 7 Check oil passages and clean if clogged PUMP END MAIN BEARING This bearing is a machined part of the oil pump and bearing head casting Disassemble bearing head If bearing is scored or worn replace the complete bearing head CRANKCASE AND MOTOR END MAIN BEAR INGS These bearings are not field replaceable If bearings are worn or damaged replace compressor Table 7 Wear Limits 06E Compressor FACTORY TOL in 1 8725 MAXIMUM ALLOWABLE WEAR in COMPRESSOR PART MOTOR END Main Bearing Diameter Journal Diameter PUMP END Main Bearing Diameter Journal Diameter CONNECTING ROD Bearing Diameter After Assembly Crankpin Diameter THRUSTWASHER Thickness 1 8760 1 6260 1 6233 1 7515 1 7483 em CYLINDERS Bore 0 002 Piston Diameter 0 002 Wrist Pin Diameter 0 001 Con Rod Wrist Pin ID 0 001 Piston Ring End Gap 0 015 Piston Ring Side Clearance 0 002 VALVE THICKNESS pe press ones roost Maximum allowable wear above maximum or below minimum factory tolerances shown For example difference between main bearing diam eter and journal diameter is 0035 in 1 8760 1 8725 per factory tol erances Maximum allowable difference is 0045 in 0035 001 END CLEARANCE 15 Compressor Running Gear Replacement CRANKSHAFT Be sure compressor end bearing washer is in place on d
19. ated control valve shown A solenoid operated control valve can also be used Fig 10 Suction Cutoff Unloader Operation 11 V0ONXJONADN Stator Compressor Motor Rotor Compressor Motor Motor Key Rotor Plate Washer Rotor Lock Washer Rotor Lock Bolt Motor Lock Bushing Roll Pin Acorn Nut and Gasket Compressor Crankcase Bottom Cover Plate Crankcase Oil Filter Screen Pump End Bearing Head Assembly Motor End Cover Oil Sight Glass Assembly Oil Sight Glass O Ring Gasket 14 15 16 17 18 me aad 27 LEGEND Oil Sight Glass Screw Oil Sight Glass Lock Washer Pipe Plug Hex Head Crankshaft Ring Spacer when required Bearing Washer Connecting Rod and Piston Assembly Connecting Rod and Cap Assembly Piston Piston Pin and Retaining Ring Package Piston Rings Oil and Compression Terminal Plate Assembly Terminal Bolt Assembly Terminal Box Terminal Box Mounting Screw 4 Suction Valve Fig 11 Compressor Components 06E Shown 12 Valve Plate Assembly includes dis charge valves Cylinder Head Gasket Cap Screw Valve Stop Valve Stop Support Discharge Valve Stop Discharge Valve Cylinder Head Capacity control side bank Cylinder Head Center bank Cylinder Head Bolt 8 per head Capacity Control Valve Pressure type shown Table 6 Torque Values SIZE TORQUE DIAM THREADS RANGE in lb ft Wie 27 pipe Pipe
20. cked Rotor Amps breaker must trip value 1 40 Use this recommended and MHA Must Hold Amps minimum RLA value to determine nameplate stamping mini MTA Must Trip Amps mum contactor sizing and wire sizing RECOMMENDED RLA PW Part Winding Start FOR 06E COMPRESSORS EQUALS MUST TRIP MTA OF RLA Rated Load Amps CARLYLE APPROVED OVERCURRENT DEVICE BEING XL Across the Line Start USED 1 40 i n 5 Compressor operating amps at any specific condition can only Refer to physical data table to match compressor with correct com be determined from a performance curve pressor or water cooled condensing unit 6 Ohm values for resistance are approximate and shown for ref NOTES erence purposes only Motors from different vendors and 1 Compressor MTA and RLA values are maximum figures motors of different efficiencies can differ up to 1596 from data 2 LRA values for PW second winding 1 2 the LRA XL value 7 El ctrical data for compressor part numbers 06ER O6EM and 3 3 Pole XL circuit breakers shown other 3 Pole XL alternates 50 Hz models not shown are available from Carrier Sales and 6 Pole PW breakers available Terminal lugs for circuit Representative breakers available in package 06EA660152 not shown DISCONNECT PER NE C rr melo Powe TB SUPPLY GND HO LEGEND C1 Compressor Contactor C2 Compressor Contactor PW CCB Compressor Circuit Breaker CHR Crankcase Heater Relay CR Control
21. condensing unit Fig 2 suction and discharge lines to compressor unit Fig 3 and 4 Discharge line muffler and check valve are factory supplied with 06E compressor units Install the muffler as close to shutoff valve as possible and install the check valve in the discharge line close to the muffler on the downstream side When soldering or brazing piping to valves disassemble the valve or wrap it in wet cloth to prevent damage by heat Allow flexibility in suction line so compressor suction valve may be moved aside for access to suction strainer A solenoid valve is necessary for single pumpout control used on 06E and 07E units Install the valve field supplied in the liquid line just before expansion valve A filter drier of adequate size should be installed in liquid line between con denser and solenoid valve Pressure relief valve located on top of condenser will open to relieve excessive pressure allowing refrigerant to escape Most local codes require piping from valve to outdoors Refer to Carrier System Design Manual for standard piping techniques Electrical Connections UNBALANCED 3 PHASE SUPPLY VOLTAGE Never operate a motor where a phase imbalance in supply voltage is greater than 2 Use the following formula to determine the voltage imbalance Voltage Imbalance 100x Max voltage deviation from avg voltage average voltage Example Supply voltage is 240 3 60 A B C AB 243 volts BC 236 volts ES
22. d cylinder head in place Pro ceed to remove rotor lock bolt lock washer and plate washer Use a jackscrew to remove rotor Fig 20 Insert a brass plug into rotor hole to protect end of crankshaft from jack screw Support rotor while it is being removed to prevent stator damage Remove ring spacer between rotor and crankshaft Gf used Clean rotor thoroughly with solvent If stator is to be replaced a matching rotor must be used REMOVE STATOR Fig 21 Stator is a slip fit in motor housing It is held in place by both an axial key and a locking assembly consisting of an acorn nut locking pin motor lock bushing and a washer see Fig 21 Remove acorn nut and washer Back out locking pin and bushing and slide stator out Axial key positions stator and crankcase If necessary heat crankcase motor housing not over 20 to 30 F above stator temperature Check stator for damage to windings and lead wires Use a megohmmeter to check for grounds or shorts between windings Motor Replacement STATOR AND ROTOR Install stator halfway into hous ing Insert the terminal leads first guiding them to terminal plate opening as stator is being inserted Replace ring spacer Fig 11 item 21 on crankshaft Ease rotor onto shaft until it begins to feel snug Insert rotor key and push rotor the remainder of the way on shaft Replace rotor lock bolt with lockwasher and plate washer A CAUTION Do not push stator in completely unt
23. e it will be warmer than conditioned area Position it to allow sufficient space for refrig erant and water connections and to service compressor Allow space at one end of condenser for tube cleaning or replacement Place unit so suction and discharge valves can be easily reached and so oil level can be checked Make provision in piping layout to drain and vent condenser if system is to be shut down in winter Level unit and bolt firmly to foundation Check Compressor Mounting Loosen compres sor mounting bolts and remove shipping blocks from under compressor Tighten all 4 bolts on compressor Loosen each bolt just enough until the flanged washer can be moved sideways with finger pressure See Fig 1 NOTE Be sure that compressor floats freely on mounting springs SNUBBER FLANGED SELF LOCKING BOLT WASHER NEOPRENE SNUBBER COMPRESSOR FOOT ISOLATION SPRING Fig 1 Compressor Mounting Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 2 2 4 4 PC 802 Tab 1b 2a 2b 3a Catalog No 530 601 Printed in U S A Form 06 07E 1SI Pg 1 5 01 Replaces 06E 07E 9SI Piping Connections Attach water supply and return lines to connections indicated on condensing unit Fig 2 Water leaving condenser should not be connected directly into sewer lines check local codes Attach refrigerant liquid and suction lines to
24. emble cyl inder heads by removing cap screws and prying up on side lifting tabs to break heads loose from valve plates Do not hit cylinder heads to break loose Check heads for warping cracks and damage to gasket surfaces When replacing cylinder head torque cap screws 90 to 100 Ib ft prevents high to low side leak in center portion of cylinder head gasket Pressure Relief Valve This internal safety device is located in center cylinder bank 6 cylinder compressors Fig 14 or under discharge service valve 4 cylinder compres sors The valve relieves refrigerant pressure from high to low side at 400 psi pressure differential Check valve for evidence of leaking Change if defective or if valve has ever opened due to excessive pressure Use a standard socket type screwdriver to remove and replace valve Suction and Discharge Valve Plate Assembly TEST Leak test for leaking discharge valves by pumping compressor down and observing suction and discharge pres sure equalization If a discharge valve is leaking pressures will equalize rapidly Maximum allowable discharge pressure drop is 3 psi per minute If there is an indicated loss of capacity and discharge valves check properly remove suction and discharge valve plate assembly and inspect suction valves DISASSEMBLE Remove cylinder head 1 Remove discharge valve assembly cap screws valve stops valve stop supports and valves 2 Pry up on side lifting tab to r
25. emove valve plate and expose suction valves Fig 15 Remove suction valves and backers from dowel pins Inspect valves and valve seats for wear and damage see Wear Limits Table 7 Replace valves if cracked or worn If valve seats are worn replace complete valve plate assembly REASSEMBLE Do not interchange valves Install brack ets and suction valves on dowel pins backer is under the valve see Fig 15 Place valve plate on cylinder deck and reinstall discharge valve assembly Retorque discharge valve stop cap screws to 16 lb ft Replace cylinder head Be sure tab on cylinder head gasket is lined up with tabs on cylinder head and valve plate Terminal Plate Assembly If there is a refrigerant leak between the terminal plate and the compressor remove plate assembly and replace gasket If any terminal is shorted to the terminal plate replace complete plate assembly using a new gasket Do not remove the terminal plate assembly except for the above conditions REMOVAL Remove junction box from terminal plate and remove cap screws holding terminal plate to compressor Mark all motor leads so they can be reassembled correctly to terminal plate Loosen Allen head screws holding motor leads to termi nal plate Fig 16 Remove terminal plate REINSTALL In reverse sequence reinstall making sure motor leads are correct Torque terminal plate cap screws per Table 6 Compressor Running Gear Removal CONNECTING R
26. ide toward the crankpin fillet this is a double check on the connecting rod piston assembly Install caps to matching connecting rods with chamfered sides aligned Caps are secured with Nylock cap screws Tighten with 8 to 10 Ib ft torque TOWARD SUCTION VALVE DOWELS IN CYLINDER DECK RETAINING RING GROOVE BOTH SIDES POSITION RETAINING RING GAP APPROXIMATELY ON THIS CENTERLINE CHAMFER MUST BE ON THIS SIDE Fig 18 Connecting Rod Piston Assembly Turn crankshaft to be sure there is no binding between bearing surfaces and journals Replace oil screen bottom cover plate valve plates and cylinder heads DOWELS IN DOWEL CYLINDER DECK HOLES FOR SUCTION D WEL VALVE AND BACKER HOLES BACKER PLACE AGAINST TOP VIEW OF PISTON EC CYLINDER DECK IN CYLINDER UNDER SUCTION VALVE Fig 19 Piston Suction Valve and Backer Positions Motor Removal MOTOR END BELL Remove motor end bell carefully to prevent damage to the stator Use three 7 16 14 x 5 in studs for guides and support Inspect suction strainer in end bell Clean it with solvent or replace if broken or corroded REMOVE ROTOR Bend rotor lock washer tab backward and remove rotor lock bolt If crankshaft turns preventing lock bolt from being loosened remove a cylinder head and valve plate and place a rubber plug 06R suction plug on top of one piston Fig 20 Replace valve plate assembly and cylinder head only 2 bolts required to hol
27. il rotor is in place 16 Push stator into housing until it lines up correctly with rotor Fig 22 Line up keyways in stator and crankcase and replace stator locking assembly then drive key into keyway and stake over keyway in stator to secure key When a new motor is being installed the stator must be drilled and a new locking pin and motor lock bushing used see Fig 23 and instructions Connect stator leads to proper terminals on terminal plate Refasten terminal plate and junction box to compressor Replace motor end bell using studs for support Remove rubber plug if used from piston head Replace valve plate assembly cylinder head and terminal plate assembly Torque 12 bolts holding terminal plate to crankcase at 30 to 40 Ib ft RUBBER PLUG ROTOR LOCK BOLT Fig 20 Removing Rotor MOTOR LOCK BUSHING WASHER LOCKING PIN Fig 21 Removing Stator STATOR ROTOR CENTER LINE Fig 22 Motor Alignment PEENED ENDS ACORN NUT BUSHING COMPRESSOR CASTING STATOR CORE Fig 23 Stator Locking Assembly Remove 1 Acorn nut and washer 2 Back out locking pin and bushing Replace 1 Screw in locking pin bushing until it rests on stator core 2 Wrap a piece of tape around 3 g in drill bit 21 16 in from cutting edge A CAUTION Before drilling be sure stator vent holes do not line up with locking pin hole Vent holes are drilled horizontally through stator and
28. isassemble oil pump Drive segment cap screws must be removed before bearing head can be removed Fig 12 Remove pump vane assemblies from both sides of the bearing head by pushing against the bearing side of the rotor Check all parts Fig 13 for wear and damage Replace Bearing Head 1 Install the rotor retaining ring in the ring groove of the pump rotor with chamfered edge toward compressor Compress retaining ring and insert pump rotor into bearing head 2 Place the pump vanes pump vane spring with guides and snap rings into the bearing head Compress the springs and force the snap rings into their grooves Insert snap rings with flat side against casting 3 Bolt bearing head to crankcase use 55 to 65 Ib ft torque Bolt drive segment to crankshaft 4 Insert the oil feed guide vane with large diameter inward Place oil feed guide vane spring over small diameter of guide vane 5 Install pump cover plate USAGE Ya 28 3 8 16 13 OIL PRESSURE TAP PUMP END BEARING HEAD DRIVE SEGMENT CAP SCREWS OIL FEED GUIDE VANE M AND SPRING o m COVER PLATE Fig 12 Removing Pump End Bearing Head O o Gio 5 e O O HDD LEGEND 1 Pump End Bearing Head 2 Drive Segment 3 Oil Feed Guide Vane 4 Oil Feed Guide Vane Spring 5 Cover Plate Fig 13 Pump End Bearing Head Assembly Cylinder Heads See Fig 11 Disass
29. ne cylinder head detects an overtemperature condition If the discharge temperature exceeds 295 5 F the sensor contacts open and the compressor shuts down The sensor reset temperature is 235 F minimum See Fig 8 for control circuit connections Capacity Control System CAPACITY CONTROL VALVE Fig 9 Valve is con trolled by suction pressure and actuated by discharge pressure Each valve controls 2 cylinders On start up controlled cylinders do not load up until differential between suction and discharge pressures is approximately 25 psi See Table 5 IMPORTANT Do not use automatic pumpdown control on 06E 07E units equipped with unloader valves Use single pumpout or solenoid drop minimum protection control CAPACITY CONTROL VALVE ADJUSTMENTS Control Set Point Cylinder Load Point Adjustable from 0 to 86 psig Pressure differential between cylinder load up point and cylinder unload point is adjustable from 6 psi to 16 psi AA neo ex s ea ues c1 Q TIMER 2 DTS CONTACTS AB ORN o SES BLU LEGEND C Compressor Contactor CR Control Relay DTS Discharge Temperature Sensor TB Terminal Block Splice in compressor junction box Fig 8 Discharge Temperature Sensor DTS CONTROL SET POINT ADJUSTMENT NUT VALVE BODY SEALING CAP COVERS PRESSURE DIFFERENTIAL ADJUSTMENT SCREW Fig 9 Capacity Control Valve To Regulate Control Set Point
30. ompressor is standard equipment for low temperature R 507 404A applications For medium temperature R 134a applications an O6EM compressor is standard Factory substitutions may be made Contact Carrier Sales Representative TThe condenser listed is for R 22 air conditioning duty and may change based on the application Maximum condenser operating pressure 350 psi refrigerant side 150 psi water side START UP Energize crankcase heater at least 24 hours prior to start up Check to see that oil level is approximately up on the compressor sight glass Open water supply valve and allow water to reach condens 2 Timer Functions See Fig 7 Timer Cycle 1 Switch A contacts A Al and A A2 provides Time Guard function Start of compressor is delayed approxi mately 5 5 minutes after shutoff The minimum time between starts of compressor is 8 minutes Switch B contacts B B1 and B B2 starts compressor er Turn condenser fan on when the compressor unit is applied with air cooled condenser Backseat the compressor suction and discharge shutoff valves open liquid line valve at receiver Start evaporator fan or chilled water pump A DANGER Do not attempt start up with terminal cover removed from compressor Bodily injury or death may result from explosion and or fire 1f power is supplied to compressor with the terminal cover removed or unsecured See warning label on terminal cover Start Compressor Push
31. ontrol set point spring the diaphragm snaps to the left and relieves pressure against the poppet valve The drive spring moves poppet valve to the left and it seats in the closed position See Fig 10 With poppet valve closed discharge gas is directed into the unloader piston chamber and pressure builds up against the piston When pressure against unloader piston is high enough to overcome the unloader valve spring piston moves valve to the right opening suction port Suction gas can now be drawn into the cylinders and the bank is running fully loaded Unloaded As suction pressure drops below set point con trol spring expands snapping diaphragm to right This forces poppet valve open and allows gas from discharge manifold to vent thru base of control valve to suction side Loss of full discharge pressure against unloader piston allows unloader valve spring to move valve left to closed position The suction port is blocked isolating the cylinder bank from the suction manifold The cylinder bank is now unloaded See Fig 10 Service Replacement Compressors These compressors are not equipped with capacity control valves One side bank cylinder head is a bypass unloading type plugged with a spring loaded piston plug assembly As received the compres sor will run fully loaded 10 Replacing Suction Cutoff Unloading Heads When the original compressor is equipped with suction cutoff unloading head s the complete c
32. owel pin Install crankshaft through pump end carefully guiding it through main bearings Replace rotor CONNECTING ROD PISTON ASSEMBLY Fig 18 The assembly of the connecting rod with contoured crown piston must be as shown Note the relationship of the piston crown pattern with the chamfered side of the rod bearing This ensures that the rods in the outer positions on crankpins have the chamfers toward crankpin fillets On 6 cylinder compressors the position of the chamfer of center rod on crankpin has no significance Lock the piston pin in place with retaining rings as shown in Fig 18 The retaining rings should be tight enough that they cannot be rotated by finger pressure Rings 1 Check ring gap by inserting each ring separately in cylin der approximately 3 3 in from top Ring gap should be between 0 002 in and 0 007 inch 2 Install compression ring in top piston groove with either side up no difference Install oil ring below compression ring with notched end on bottom Stagger ring gaps 180 degrees 3 Measure side clearance between ring and piston Table 6 Check rings for free action Installation of Connecting Rod Piston Assembly Insert the connecting rod piston assemblies into cylinders with pistons positioned as shown in Fig 18 and 19 This is necessary so that the suction valve and backer lie properly over the contoured piston crown Be sure that the outer rod on each crankpin has the chamfered s
33. p Procedure 17 Condenser Maintenance 17 SAFETY CONSIDERATIONS Installing starting up and servicing this equipment can be hazardous due to system pressures electrical components and equipment location roofs elevated structures etc Only trained qualified installers and service mechanics should install start up and service this equipment When working on the equipment observe precautions in the literature tags stickers and labels attached to the equipment and other safety precautions that apply Follow all safety codes Wear safety glasses and work gloves Use care when handling rigging and setting bulky equipment A WARNING Electrical shock can cause personal injury and even death Be sure power to equipment is shut off before installing or servicing this equipment There may be more than one dis connect Tag disconnect s to alert others not to turn power on until work is completed INSTALLATION Receive and Inspect Unit Inspect shipment for damage File claim with the shipping company if shipment is damaged or parts are missing Local water conditions can cause excessive fouling or pitting of condenser tubes If such conditions are anticipated a water treatment analysis is recommended Refer to Carrier System Design Manual Part 5 for general water conditioning information Place Unit in Position Locate unit on floor in a well ventilated area Install unit wher
34. ser water or blocking airflow on air cooled units allowing head pressure to rise gradually Check discharge pressure constantly throughout procedure Compressor should shut off within 10 psi of values shown in Table 4 LOW PRESSURE SWITCH Check by slowly closing suction shutoff valve or by completely closing liquid line shutoff valve A decrease of suction pressure will follow Compressor should shut off within 4 psi of values shown in Table 4 OIL PRESSURE SWITCH OPS The oil pressure switch protects against damage from loss of oil or loss of oil pressure during unit start up If the oil pressure differential sensed by the OPS is 6 psig or less on unit start up the switch remains closed and the OPS heater is energized The switch time delay is approximately 45 seconds If after 45 seconds the oil pressure differential sensed by the OPS is less than 11 psig the heater remains energized The OPS temperature actuated switch then opens and the compressor is deenergized If the differential reaches 11 psig the OPS opens and deenergizes the heater and the system operates normally See Table 4 IMPORTANT If the oil pressure switch causes unit lock out determine and correct the cause of the lockout such as loss of compressor oil or flooded compressor before restarting the unit Failure to correct the cause of OPS lockout may constitute abuse Equipment failure due to abuse is not covered by warranty To restart the unit push
35. trol should not be used on direct expansion DX cooler appli cations see lower diagram for wiring when applied with DX cooler LLS W AM or TB2 Cis REMOVE JUMPER FIELD CONNECTION WHEN APPLIED WITH DX COOLER Fig 6 Control Circuit Wiring for 06E 07E Units PRE START UP A CAUTION When charging or when removing charge circulate water through water cooled condenser and cooler continuously to prevent freezing Freezing damage is considered abuse and is not covered by Carrier warranty Evacuate Dehydrate and Leak Test The entire refrigerant system must be evacuated dehydrated and leak test ed by methods described in Carrier Standard Service Tech niques Manual Chapter 1 Section 1 6 and 1 7 Use sight glass method to charge system See Section 1 8 of Service Tech niques Manual for details Charge the system to a clear sight glass while holding saturated condensing pressure constant at 125 F air cooled systems or 105 F water cooled systems Add additional refrigerant to fill condenser subcooler coils for air cooled applications Oil Charge See Tables 2 and 3 All units are factory charged with oil If oil is visible in sight glass start compressor Observe level and add oil if required to bring level in crankcase g to 3 g of bull s eye during steady operation To add or remove oil see Carrier Standard Service Techniques Manual Chapter 1 Refrigerants IMPORTA
36. ture for installa tion instructions syun Buisuepuo pajo0 191emM 320 Z 14 adis 31ISOddO NO NOLLO3NNOO 1NVH39IHJ3H GINOM I31NI LATLNO YAlVM NOILONS pue Jeuye 1e y Bua jesuepuoo euo SI eqni jo je ouJa1 JO eoeds eoi es pepueuiuiooeH z Y SI pue 10jou 10sseJdujoo ye JOJOW JO peaowa JO eoeds eones pepueuluooeH SALON me ft ne ve we 7 eo sso ans az i pice ve ee 6e neo oeeo es iz i ee ve e kv ez seso o e iz esr sz exec e ez he a sis ma Ws re i es ve e e 99 suo zm 4 9 al 3 a 9 8 v Suo xom ul SNOISN3INIG NOTE Recommended service space is 3 ft 0 in at compressor motor end to allow for motor removal DISCHARGE VALVE E SUCTION VALVE DIMENSIONS in 06E UNIT VolT aGE a JB C D E JF G 191 2 n 191 m 191 191 m 191 191 E 208 230 1977 460 575 191 2 Fig 3 06E Hermetic Compressor Units HIGH PRESSURE HIGH PRESSURE CONNECTION CONNECTION 14 F P T VA F P T FEN BN LOW PRESSUR Yl 47618 LOW PRESSURE NOT A FIELD ON ONE AEG Y BL CONNECTION CONNECTION VA EPT VERT NOT AFIELD AER O B SS oa CONNECTION jj MAT Ea gy f INE CRANKCASE Q 6 wo CONNECTION OIL PRESSURE CRANKCASE ata gt CONNEC CONNECTION CRANKGAS I nr OIL PRESSURE PT V4 RT CONNECTION bid nml CONNECTION V4 EPT o 2 O
37. ylinder head and control valve assem blies must be transferred to the service replacement compres sor See Fig 10 for typical suction cutoff installation Where one step of unloading is required remove the bypass type unloader head and valve plate assembly from replacement compressor cylinder head next to terminal box Remove check valve from the valve plate Using new gaskets reinstall the valve plate assembly and install the suction cutoff head from the original compressor Torque the cylinder head holddown bolts to 90 to 100 Ib ft For 6 cylinder 2 step suction cutoff unloading transfer the second unloading head and control valve from the original compressor to the replacement compressor using the valve plate assembly from the replace ment compressor Use new gaskets Be sure the new cylinder head gasket is the one shown in Fig 11 Item 33 when installing suction cutoff unloader head Install parts removed from replacement compressor on original compressor and seal all openings to prevent contamination Removing Inspecting and Replacing Components Fig 11 A DANGER Do not remove the compressor terminal box cover until all electrical power is disconnected and pressure is relieved Terminal pins may blow out causing injuries death and or fire SERVICE NOTES 1 All compressors have interchangeable valve plate assem blies unloader valves and oil pump bearing head assemblies For replacement items use Carrier
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