Carrier 07E User Manual

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06E,07E Compressors and Condensing Units

Installation, Start-Upand

Service Instructions

Hermetic, Water-Cooled

CONTENTS

Page

SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6

Receive and Inspect Unit. . . . . . . . . . . . . . . . . . . . . . . . . 1

Place Unit in Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Check Compressor Mounting . . . . . . . . . . . . . . . . . . . . 1

Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,8

Evacuate, Dehydrate, and Leak Test. . . . . . . . . . . . . . 7

Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Start Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Timer Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-18

Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Compressor Thermal Protection . . . . . . . . . . . . . . . . . 9

Capacity Control System . . . . . . . . . . . . . . . . . . . . . . . . . 9

Removing, Inspecting and Replacing

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Cylinder Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Motor Burnout (Clean-UpProcedure). . . . . . . . . . . . 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.

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 disconnect. 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 awell-ventilatedarea. Install unit where it will be warmer than conditioned area. Position it to allow sufficient space for refrigerant 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 compressor 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.

SELF-LOCKING

SNUBBER FLANGED

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

Catalog No. 530-607

Printed in U.S.A.

Form 06/07E-2SI

Pg 1

7-02

Replaces: 06/07E-1SI

Tab

1b

2a

2b

3a

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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 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 condenser 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-PHASESUPPLY 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 =

100 x

max voltage deviation from avg voltage

 

average voltage

Example: Supply voltage is 240-3-60

AB = 243 volts

BC = 236 volts

AC = 238 volts

Average Voltage =

243 + 236 + 238

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 2394 = 1.7%

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-suppliedequipment are shown on wiring diagram. See Fig. 6.

ACCESSORIES — Field-installedaccessories for the 06E and 07E units are control circuit transformer and gage panel (3 gages). Refer to accessory literature for installation instructions.

2

DIMENSIONS (in.)

UNIT 07E

VOLTS

A

B

C

D

E

F

G

H

I

A022

208/230

66

493/4

23/4

34

271/2

1

21

59/16

95/16

460, 575

66

433/4

23/4

34

26

1

21

59/16

95/16

 

B027

208/230

78

493/4

23/4

34

271/2

1

21

59/16

95/16

460, 575

78

433/4

23/4

34

26

1

21

59/16

95/16

 

B033

208/230

78

493/4

23/4

34

271/2

1

21

59/16

95/16

460, 575

78

433/4

23/4

34

26

1

21

59/16

95/16

 

D044

208/230

691/2

493/4

23/4

34

271/2

1

21

41/8

85/8

460, 575

691/2

493/4

23/4

34

271/2

1

21

41/8

85/8

 

NOTES:

1.For standard service practices, such as trouble-

shooting and refrigerant charging, allow a minimum 2′-6″clearance around the unit.

2.Recommended service space for condenser tube removal is one condenser length at either end.

3.For compressor removal, allow a minimum 3′ wide access aisle to and from the unit.

4.Local codes or jurisdiction may prevail for unit clearances.

3

Fig. 2 — 07E Water-CooledCondensing Units

NOTES:

1. For standard service practices, such as troubleshooting and refrigerant charging, allow a minimum 2′-6″clearance around the unit.

2. For compressor removal, allow a minimum 3′ wide access aisle to and from the unit.

3. Local codes or jurisdiction may prevail for unit clearances.

DIMENSIONS (in.)

06E UNIT

VOLTAGE

A

B

C

D

E

F

G

V022

208/230

481/4

35

367/8

11/2

271/2

1

191/2

460,575

481/4

29

367/8

11/2

26

1

191/2

 

W027

208/230

501/4

35

367/8

11/2

271/2

1

191/2

460,575

501/4

29

367/8

11/2

26

1

191/2

 

W033

208/230

501/4

35

367/8

11/2

271/2

1

191/2

460,575

501/4

29

367/8

11/2

26

1

191/2

 

W044

208/230

501/4

35

367/8

11/2

271/2

1

191/2

460,575

501/4

35

367/8

11/2

271/2

1

191/2

 

Fig. 3 — 06E Hermetic Compressor Units

Fig. 4 — 06E Compressors

4

Table 1 — Electrical Data — Compressor Motor With Circuit Breaker

 

 

 

COMPRESSOR MOTOR DATA

 

 

CIRCUIT BREAKER

Compressor

Voltage

 

Maximum

Maximum

 

LRA-PW

Motor

Recommended

 

 

 

 

 

 

Winding

 

 

 

Recommended

Part Number

(3 Ph - 60 Hz)

Hp

Must Trip

RLA

LRA-XL

(first

Resistance

Circuit Breaker

MHA

MTA

LRA

RLA

06E*

 

 

Amps

 

 

winding)

(Ohms)

Part No.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

250

208/230

 

108

87

345

207

0.32

HH83XB336

91

104

350

74.3

 

575

20

45

36

120

72

2.2

XA461

33

38

124

27.1

 

 

460

 

54

44

173

104

1.3

XA424

42

49

175

35.0

 

265

208/230

 

140

112

446

268

0.27

HH83XC509

110

127

420

90.7

 

575

25

57

46

164

98

1.6

XA469

46

53

164

37.9

A

 

460

 

70

56

223

134

1.1

XA426

55

643

210

45.7

275

208/230

 

168

135

506

304

0.22

HH83XC539

142

163

507

116.4

 

 

 

575

30

65

52

176

106

1.3

XA430

50

58

168

41.4

 

 

460

 

84

68

253

152

0.9

XA425

63

73

210

52.1

 

299

208/230

 

236

189

690

414

0.15

HH83XC537

187

215

636

153.6

 

575

40

94

75

276

165

1.0

XA551

74

85

236

60.7

 

 

460

 

118

95

345

207

0.58

XA550

92

106

295

75.7

 

LEGEND

LRA

Locked Rotor Amps

MHA — Must Hold Amps

MTA

Must-TripAmps

PW

Part-Winding(Start)

RLA

Rated Load Amps

XL

Across-the-Line(Start)

*Refer to physical data table to match compressor with correct compressor or water-cooledcondensing unit.

NOTES:

1.Compressor MTA and RLA values are maximum figures.

2.LRA values for PW second winding = 1/2 the LRA – XL value.

3.3-PoleXL circuit breakers shown, other3-PoleXL alternates and6-PolePW breakers available. Terminal lugs for circuit breakers available in package 06EA660152 (not shown).

 

LEGEND

C1

Compressor Contactor

C2

Compressor Contactor (PW)

CCB

Compressor Circuit Breaker

CHR

Crankcase Heater Relay

CR

Control Relay

FU

Fuse

GND

Ground

HPS

High-PressureSwitch

LPS

Low-PressureSwitch

NEC

National Electrical Code

NEMA — National Electrical

 

Manufacturer’s Association

OPS

Oil Pressure Switch

POR

Pumpout Relay

TB

Terminal Block

TDR

Time Delay Relay

TM

Timer Motor

TR

Timer Relay

4.Recommended RLA value shown is determined by: circuit breaker must trip value 1.40. Use this recommended (and minimum) RLA value to determine nameplate stamping, minimum contactor sizing, and wire sizing. RECOMMENDED RLA FOR 06E COMPRESSORS EQUALS: MUST-TRIP(MTA) OF

CARLYLE APPROVED OVERCURRENT DEVICE BEING USED 1.40

5.Compressor operating amps at any specific condition can only be determined from a performance curve.

6.Ohm values for resistance are approximate and shown for reference purposes only. Motors from different vendors and motors of different efficiencies can differ up to 15% from data shown.

7.Electrical data for compressor part numbers 06ER, 06EM and 50 Hz models (not shown) are available from Carrier Sales Representative.

Fig. 5 — Component Location

5

 

 

 

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-PressureSwitch

CH

Crankcase Heater

POR

Pumpout Relay

CHR

Crankcase Heater Relay

PW

Part Wind

CR

Control Relay

SW

Start-Stop-ResetSwitch

DTS

Discharge Temperature Sensor

TB

Terminal Block

DX

Direct Expansion

TDR

Time Delay Relay

FU

Fuse

TM

Timer Motor

HPS

High-PressureSwitch

TR

Timer Relay

LLS

Liquid Line Solenoid Valve

XL

Across-the-Line

LPS

Low-PressureSwitch

 

 

Terminal Block Connector

Unmarked Terminal

Marked Terminal

Factory Wiring

Field Control Wiring

To indicate common potential only; not to represent wiring.

Splice

NOTES:

1.Factory wiring is in compliance with NEC. Any field modifications or additions must be in compliance with all applicable codes. Use copper, copper-cladaluminum for field power supply only.

2.Field power supply wiring must be 75 C minimum.

3.Compressor thermally protected. Three-phasemotors are protected against primarysingle-phasingcondition.

4.Pilot duty control must be field supplied. Minimum contact rating must be 25 va.

5.60 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 through a fused disconnect device with a

maximum rating of 15 A to TB2 connections L1 (Hot Side) and L2 (Neutral).

6.Open control circuit disconnect switch for servicing only. Disconnect must remain closed for crankcase heater to operate.

7.A transformer of the following rating may be field supplied for 60 Hz units: 350 va.

8.Transformer must be fused and grounded per applicable codes.

9.If any of the original wiring furnished must be replaced, it must be replaced with 90 C wire or its equivalent.

10.Wiring is shown for single pumpout control. Single pumpout control should not be used on direct-expansion(DX) cooler applications (see lower diagram for wiring when applied with DX cooler).

Fig. 6 — Control Circuit Wiring for 06E/07E Units

6

PRE-START-UP

When charging, or when removing charge, circulate water through water-cooledcondenser 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 tested by methods described in Carrier Standard Service Techniques Manual, Chapter 1, Section 1-6 and 1-7. Use sight glass method to charge system. See Section 1-8 of Service Techniques Manual for details.

Charge the system to a clear sight glass while holding saturated condensing pressure constant at 125 F (air-cooledsystems) or 105 F(water-cooledsystems). Add additional refrigerant to fill condenser subcooler coils forair-cooledapplications.

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 crankcase1/8 to3/8 ofbull’s-eyeduring steady

operation. To add or remove oil, see Carrier Standard Service Techniques Manual, Chapter 1, Refrigerants.

IMPORTANT: 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. . . . . . . . . . . . . . . . . . . . . . Cryol 150 Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capella WR-32Witco Chemical Co.. . . . . . . . . . . . . . . . . . . . . . . . . Suniso 3GS

*Approved for R-12,R-22,R-502refrigerants. Contact Carrier Factory Sales Representative for other refrigerants.

TO ADD OIL — Close suction shutoff valve and pump down crankcase to 2 psig. (Low-pressurecut-outmust be bypassed.) Wait a few minutes and repeat as needed until pressure remains at 2 psig. Remove oil fill plug abovebull’s-eye,add oil through plug hole and replace plug. Run compressor for about 20 minutes and check the oil level.

TO REMOVE OIL — Pump down compressor to 2 psig. Loosen the 1/4-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

V022

 

W027

 

 

W033

 

W044

OPERATING WEIGHT (lb)

600

 

640

 

 

650

 

670

REFRIGERANT

 

 

R-134a,R-22,R-507/404A

 

 

COMPRESSOR — 06E*

A250

 

A265

 

 

A275

 

A299

Cylinders

4

 

6

 

 

6

 

6

Bore (in.)

211/16

 

211/16

 

 

211/16

 

211/16

Stroke (in.)

23/16

 

2

 

 

23/16

 

27/8

Displacement (cfm at 1750 rpm)

50

 

68

 

 

75

 

99

Maximum Rpm

 

 

 

1750

 

 

Oil Charge (pt)

14

 

19

 

 

19

 

19

 

 

 

High Side Maximum Pressure (psi)

 

 

 

450

 

PSIG

 

 

Low Side Maximum Pressure (psi)

 

 

 

245 PSIG

 

 

CONNECTIONS (in.)

 

 

 

 

 

 

 

 

Suction Valve (ODF)

15/8

 

15/8

 

 

21/8

 

21/8

Discharge Valve (ODF)

11/8

 

13/8

 

 

13/8

 

15/8

LEGEND

ODF — Outside Diameter Female

*Compressors listed are for R-22applications. ForR-134aan 06EM compressor is standard offering; an 06ER compressor is standard forR-507/404A.Factory compressor substitutes may be made. Contact Carrier Sales Representative.

7

Table 3 — 07E Physical Data

UNIT 07E

 

A022

 

B027

 

 

B033

 

D044

OPERATING WEIGHT (lb)

 

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.)

 

211/16

 

211/16

 

 

211/16

 

211/16

Stroke (in.)

 

23/16

 

2

 

 

23/16

 

27/8

Displacement (cfm at 1750 rpm)

 

50

 

68

 

 

75

 

99

Maximum Rpm

 

 

 

 

1750

 

 

Oil Charge (pt)

 

14

 

19

 

 

19

 

19

 

 

 

 

High Side Maximum Pressure (psi)

 

 

 

450

 

 

Low Side Maximum Pressure (psi)

 

 

 

245

 

 

CONDENSER (Shell and Tube)† Part Number

P701-0840AX

 

P701-0850AX

 

P701-0850AX

 

P701-1065AX

Refrigerant Storage

R-134a

71.3

 

85.90

 

 

85.90

 

112.70

15.4

 

18.67

 

 

18.67

 

23.77

Capacity (lb)

 

 

 

 

 

R-22

70.4

 

84.80

 

 

84.80

 

111.20

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Min Refrigerant Operating

 

15.1

 

18.30

 

 

18.30

 

23.30

 

61.1

 

73.60

 

 

73.60

 

96.50

Charge (lb)

R-507/404A

 

 

 

 

15.1

 

18.30

 

 

18.30

 

23.30

 

 

 

 

 

 

REFRIGERANT CONNECTION (in. ODF)

 

 

 

 

 

 

 

 

Inlet

 

21/8

 

21/8

 

 

21/8

 

25/8

Outlet

 

13/8

 

13/8

 

 

13/8

 

15/8

WATER CONNECTION (in. FPT)

 

 

 

 

 

 

 

 

 

Inlet/Outlet

 

21/2

 

21/2

 

 

21/2

 

3

LEGEND

FPT — Female Pipe Thread

ODF — Outside Diameter, Female

*Compressor listed is the standard compressor for R-22,air conditioning duty. An 06ER compressor is standard equipment for low temperature(R-507/404A)applications. For medium temperature(R-134a)applications, an 06EM compressor is standard. Factory substitutions may be made. Contact Carrier Sales Representative.

†The 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 1/3 up on the compressor sight glass.

Open water supply valve and allow water to reach condenser. (Turn condenser fan on when the compressor unit is applied with air-cooledcondenser.)

Backseat the compressor suction and discharge shutoff valves; open liquid line valve at receiver.

Start evaporator fan or chilled water pump.

Do not attempt start-upwith terminal cover removed from compressor. 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 terminal cover.

Start Compressor — Push the control circuit START-STOP-RESETswitch 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 compressor. 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, Section1-11,for adding oil. The proper oil level for the 06E compressor is approximately1/3 up on sight glass.

Timer Functions (See Fig. 7 — Timer Cycle.)

1.Switch A (contacts A-A1andA-A2)provides Time Guard® function. Start of compressor is delayed approximately 5.5 minutes after shutoff. The minimum time between starts of compressor is 8 minutes.

2.Switch B (contacts B-B1andB-B2)starts compressor and deenergizes the crankcase heater. These contacts also provideone-secondtime delay forpart-windingstart.

3.Switch E (contacts E-E1)provides approximately40-secondbypass of oil pressure switch (OPS) atstart-up.Compressor will shut off if sufficient oil pressure does not build up.

4.Switch D (contacts D-D1)bypasses thelow-pressureswitch (LPS) for 2.5 minutes atstart-upfor winter start control.

Fig. 7 — Timer Cycle

8

SERVICE

Protection Devices

HIGH-PRESSURESWITCH — Check by throttling condenser water or blocking airflow onair-cooledunits, 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-PRESSURESWITCH — 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 unitstart-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 lockout, 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 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 TYPE

SWITCH POSITION (psig)

 

 

Closed

Open

High Pressure

210

(±10)

290

(±10)

Low Pressure

70

(±4)

60

(±4)

Oil Pressure

 

6

11

NOTES:

1.Values for the highand low-pressureswitches based onR-22.For other refrigerants, reset to pressure corresponding to saturation 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).

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-voltpower 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 crankcase heater for 24 hours before starting the compressor.

Compressor Thermal Protection — A discharge temperature sensor, installed in one 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 controlled 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 cylinderload-uppoint and cylinder unload point is adjustable from 6 psi to 16 psi.

 

 

CR

 

 

 

 

 

4

6

RED

C1 C2 C2

YEL

C2 C1

 

BLU

 

 

 

 

 

TIMER

B2

 

 

DTS

 

 

B

ORN

 

 

BLU

 

CONTACTS

 

 

 

 

 

 

 

 

 

 

B1

 

 

 

TB2

6

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

9

To Regulate Control Set Point — 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

 

NO. OF

100

 

67

 

49

 

32

UNIT 06E,07E

CONTR

 

% Full Load kW

 

CYL

 

 

 

 

 

 

 

 

100

 

73

 

57

 

46

 

 

 

 

 

 

 

 

 

Number of Active Cylinders

ALL 4 CYLINDER

2

 

4

 

 

2

 

MODELS

 

 

 

 

 

 

 

 

 

 

 

 

 

ALL 6 CYLINDER

4

 

6

 

4

 

 

2

MODELS

 

 

 

 

 

 

 

 

 

 

 

 

 

NOTE: Capacity control valve factory settings for 4-cylinderunits are: 59 psig control set point (cylinder load point), 10 psi differential (59 psig cylinder unload point). Settings for6-cylinderunits 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 adjusting screw counterclockwise to itsback-stopposition. 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 capacity 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 overcome control 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-pistonchamber 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, control 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. Oneside-bankcylinder head is a bypass unloading type, plugged with aspring-loadedpiston plug assembly. As received, the compressor will run fully loaded.

Replacing Suction Cutoff Unloading Heads — When the original compressor is equipped with suction cutoff unloading head(s), the complete cylinder head and control valve assemblies must be transferred to the service (replacement) compressor. See Fig. 10 for typical suction cutoff installation. Where one step of unloading is required, remove thebypass-typeunloader 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 100lb-ft.For6-cylinder2-stepsuction 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 replacement 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)

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 assemblies, unloader valves and oil pump bearing head assemblies. For replacement items use Carrier 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. Drain oil if 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-madegaskets. See Table 6 for torque values.

5.After reassembly, evacuate compressor and open suction and discharge valves. Restart compressor and adjust refrigerant charge.

10