Carlyle 06CC User Manual
Installation
Instructions
06CC
Compound Cooling
Compressor
GENERAL
1. Inspect compressor for shipping damage and file claim
with shipping company if damaged or incomplete.
2. Check compressor nameplate for correct model and
voltage designation.
3. Before installation, review all Carlyle compressor application literature to assure yourself that the proper compressor has been selected and is being applied in a
proper manner. The required application literature is
available through Carlyle.
SAFETY INSTRUCTIONS
DANGER
Failure to follow these instructions will result in severe
personal injury or death.
ELECTRIC SHOCK HAZARD. Do not operate compressor or provide electric power to it unless the compressor
terminal box is installed and the terminal box cover is in
place and secured.
DO NOT provide power to unit or turn on compressor unless suction and discharge service valves are open.
DO NOT remove the compressor terminal box cover until
all electrical sources have been disconnected.
DO NOT USE oxygen or other industrial gases for tightness/pressure testing. Use nitrogen or inert gas.
WARNING
Failure to follow these instructions may result in serious
injury or death.
CONTENTS UNDER PRESSURE. Compressor contains oil and refrigerant under pressure. Pressure must
be relieved before installation, servicing or opening any
connections.
HOT and COLD surface temperatures can occur during
operation and can result in severe burns or frostbite.
USE ONLY approved refrigerants and refrigeration oils.
NEVER EXCEED specified test pressures. System
strength/tightness test pressure may not exceed the
compressor maximum Test pressure on the Nameplate.
Close shutoff valves to isolate compressor if necessary.
CHECK THE REFRIGERANT TYPE. Charge only with
refrigerant that conforms to AHRI Standard 700.
Only qualified, authorized, and appropriately trained HVAC
or refrigeration personnel, should install, commission, and
maintain this equipment.
Use appropriate personal safety equipment where required.
Safety goggles, gloves, protective clothing, safety boots, and
hard hats should be worn where necessary.
OPERATING LIMITS: Refer To Application
Guide
GENERAL INSTALLATION PROCEDURES
Holding Charge
Compressor is factory supplied with a 7 to 20 lb (0.5 to
1.4 bar) charge of dry air or nitrogen. This internal pressure
must be relieved before attempting to remove any compressor fitting or part.
Relieve holding charge by removing the cap on the interstage connection fitting and depressing the internal disc.
See Fig. 1A for applicable interstage pressure connection fitting location.
Service Valves
Remove valve pads and attach factory-supplied suction and
discharge gaskets and service valves to the compressor.
Torque 5/16-in. -18 mounting bolts 20 to 25 lb-ft (27 to
34 Nm) and 1/2-in. -13 mounting bolts 80 to 90 lb-ft (109 to
122 Nm). When brazing piping to valve, wrap the valve in a
wet cloth to prevent heat damage.
Oil
1. Check to see that oil level is 1/4 to 3/4 of the way up on
compressor sight glass before starting and after 15 to
20 minutes of operation. Compressors may be shipped
with or without an oil charge based on model. All compressors must contain the specified oil charge prior to
start-up as a condition of warranty.
2. To add oil: Relieve internal crankcase pressure, isolate
crankcase, and add oil through the oil fill connection
(see Fig. 1A and 1B). To remove excess oil: Reduce internal crankcase pressure to 2 psig (1.15 bar), isolate
crankcase, then loosen the oil drain plug allowing oil to
seep out past the threads of the plug.
CAUTION
With the compressor crankcase under slight pressure, do
not remove the oil drain plug as the entire oil charge
could be lost. Do not reuse drained oil or oil that has
been exposed to the atmosphere.
CAUTION
Do not charge oil through the suction line or through the
compressor suction access fittings. See Fig. 1A for the
recommended oil charging port. Adding oil into the suction side of the compressor can cause damage to the
suction/discharge valves, pistons, and/or connecting
rods.
3. When additional oil or a complete oil change is required, use only the listed Carlyle approved oils.
Manufacturer Brand Name
Totaline 150
Witco Suniso 3GS
IGI Petroleum Ind. Cryol-150
CONNECTION FROM
SUBCOOLING HEAT
EXCHANGER
1/4”-NPT LOW STAGE
PRESSURE TAP (NOT SHOWN)
*BOTTOM OF CYLINDER HEAD HAS A BOSS
AND 1/4” NPT JUST LIKE THE TOP.
INTERSTAGE
MANIFOLD
1/2-13 UNC —
LIFTING LUG CONNECTION
(LUG NOT SUPPLIED WITH COMPRESSOR)
1/4” NPT OIL FILL (SUMP)
CONNECTION. ALSO LOW
SIDE OIL SAFETY
SWITCH CONNECTION
1/4-NPT INTERSTAGE
PRESSURE TAP
(INCLUDES SCHRADER
FITTING TO RELIEVE
CRANKCASE PRESSURE)
Fig. 1A — 06CC Compressor, Front View
SUCTION VALVE
LOCATION
1/4” NPT HIGH SIDE
OIL SAFETY SWITCH
CONNECTION
SUCTION MANIFOLD
(TO LOW STAGE
CYLINDERS)
7/16”-20 SAE OIL DRAIN
CONNECTION ADAPTER
PART NO. DE14CA126
Fig. 2 — 5-Pin Plate Assembly
1/4 NPT HIGH STAGE PRESSURE TAP
CYLINDER HEAD
SENSOR (HIGH STAGE
DISCHARGE TEMP.)
(NOT SHOWN)
DISCHARGE
SERVICE
VALVE
HIGH SIDE
CYLINDER
HEAD
OIL LEVEL
SIGHTGLASS
CRANKCASE HEATER (ACCESSORY)
INSERTS INTO HOLE IN BOTTOM COVER
TERMINAL BOX
HIGH STAGE
INLET
NAMEPLATE
DESUPERHEATER
INJECTION LOCATION
Fig. 1B — 06CC Compressor, Rear View
ELECTRICAL
General
Consult the wiring diagram located inside the compressor
terminal box cover and the diagrams shown below associated with the correct terminal plate and overloads for proper
wiring connections.
The compressor will have one of 2 terminal plate configurations: either a 5-pin assembly or a 6-pin assembly. Refer to
Fig. 2 and 3 for details on each arrangement. To determine
which terminal plate arrangement is used, refer to digit 5 of
the nameplate model number and Table 1.
Table 1 — Terminal Plate Arrangement
Identification
PTC — Positive Temperature Coefficient Thermistor
Fig. 3 — 6-Pin Plate Assembly,
Universal Compressors
Each terminal plate assembly may be utilized with or without
overloads. For compressors without overloads, please be
sure adequate protection is supplied for all 3 phases of the
motor in the form of a circuit breaker or similar system. For
compressors with overloads, please refer to Table 2 and
referenced figures to ensure proper connection with the applicable overload system on the compressor.
Table 2 — Overload Systems
TERMINAL PLATE
ARRANGEMENT
5-Pin (Fig. 2)
0, 1, 2 or 3 in Digit 5
6-Pin (Fig. 3)
Any letter A through M
in Digit 5
OVERLOAD SYSTEM OPTIONS
Hybrid
Service
Hybrid
Legacy
Bi-Metal
No Yes (Fig. 6) Yes (Fig. 7)
Yes (Fig. 4) Yes (Fig. 6) Yes (Fig. 7)
DIGIT 5 OF
NAMEPLATE MODEL
NUMBER
TERMINAL
PLATE
ARRANGEMENT
0, 1, 2, or 3 5-Pin 2
Letters A through M 6-Pin Universal 3
FIGURE
2
Hybrid Overload Wiring — 6-Pin Plate Assembly for Universal Compressors
1. Connect one of the 2 control circuit leads to connection
14 located on top of the module. Connect the other
control circuit lead to connection 11 located on top of
the module. Use a fork terminal or stripped and tinned
wire to prevent fraying. See Fig. 4. Torque module connections to 12 lb-in. (1.35 Nm) maximum. Be sure to
connect the discharge gas temperature (DGT) sensor
leads in line with the control circuit connections. See
Overtemperature Protection section for details.
2. Determine module power supply voltage by referring to
the 6th digit in the part number located on the left side
of module (06DANB****). The supply voltages are 115/
230 vac and 24 vac and correlate to digits B and C respectively. Connect two module power leads to module
connections L and N using a fork terminal or stripped
and tinned wire to prevent fraying. Refer to module
front label for further power supply requirements.
Torque module connections to 12 lb-in. (1.35 Nm)
maximum.
3. Route one power lead (L3) through the current transformer (CT) as shown in Fig. 4. See detail in Fig. 5.
4. Once power lead L3 is routed through the CT, make
terminal plate connections as shown in Fig. 4. Refer to
Terminal Plate Wiring section for connection details.
CT
CUSTOMER WIRING
ROUTED THROUGH
THE CT
Fig. 5 — Routing Power Lead through Current
Transformer (CT)
Fig. 4 — Hybrid Overload Wiring
3
SEE DETAIL
IN FIG. 5
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