Carrier 06D User Manual

Compressors and Condensing Units

Installation, Start-Up and

Service Instructions

Hermetic, Water-Cooled

06D,07D

CONTENTS

Page

SAFETY CONSIDERATIONS BEFORE INSTALLATION

Check Shipment Unit Location Considerations

INSTALLATION Mount Unit Piping Connections Electrical Connections Limitations Refrigerant Charging

INITIAL START-UP To St a rt C om p r es s o r

CHECKING OPERATION Oil Charge High-Pressure Switch Low-Pressure Switch Oil Pressure Switch Time Guard® Control

CAPACITY CONTROL Control Set Point To Regulate Control Set Point Pressure Differential Adjustment Capacity Control Pressure

CONDENSER MAINTENANCE SERVICE

Service Notes Testing Oil Pump Cylinder Heads Service Replacement Compressors Suction and Discharge Valve Plate Assembly Cleaning Suction Strainer Motor Replacement Terminal Plate Assembly Compressor Running Gear Removal Compressor Running Gear Replacement

COMPRESSOR MOTOR BURNOUT Clean-Up Procedure

TROUBLESHOOTING

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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 t he equipment and any other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves. Use care in handling, rigging and setting bulky equipment.

Electrical shock can cause persona l 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.

BEFORE INSTALLATION

Check Shipment —

if shipment is damaged or incomplete.

Unit Location Considerations —

floor in a well-v entil ated ar ea. Pos itio n unit t o allow sufficien t space for refrigerant and water connections and to service compressor. Place unit so suction and discharge valves can be easily reached and oil level checked. Do not install condensing unit where temperature will fall below freezing.

Local water can cause excessive fouling or sealing 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.

Make provision in piping layout to drain and vent condenser if system is to be shut down in winter.

File claim with shipping company

Locate unit on

INSTALLATION

Mount Unit —

Loosen compressor mounting bolts and remove shipping blocks from under compressor. Tighten all 4 bolts on compressor. Next, loosen each bolt until the flanged washer can be moved sideways with finger pressure.

NOTE: Be sure that compressor floats freely on mounting springs.

Piping Connections —

lines to connections indicated on condenser unit (Fig. 1). Water leaving condenser should not be connected directly into sewer lines. Check local codes.

Attach refrigerant liquid and suction lines to condensing units (Fig. 1); suction and discharge to compressor unit (Fig. 2). When soldering or brazing piping to valves, disassemble valve or wrap it in a wet cloth to prevent heat damage. Allow flexibility in suction line so compressor suction valve may be moved aside for access to suction strainer.

Level unit and bolt firmly to foundation.

Attach water supply and return

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.

Book 2244 Tab 1b2a2b3a

PC 802 Catalog No. 530-608 Printed in U.S.A. Form 06/07D-3SI Pg 1 802 7-02 Replaces: 06/07D-2SI

DIMENSIONS (in.)

UNIT 07D WIDTH A

A203 B205 A208 B210 B212 B215

39 51 51

30 30

WATER CONNECTIONS FOR 07DB215 UNIT ONLY.

Fig. 1 — 07D Condensing Unit Dimensions

NOTES:

1. For standard service practices, such as troubleshooting 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.

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.

Fig. 2 — 06D Compressor Unit Dimensions

Install a solenoid valve (field supplied) in liquid line directly before expansion valve. Solenoid valve is necessary for single pumpout control used on 06D, 07D units. Refrigerant filter drier and moisture indicator are shipped with 07D condensing units for field installation. Install in liquid line according to manufacturer’s instructions.

Relief valve located on top of condenser (07D units) will open to relieve excessive pressure, allowing refrigerant to escape. Most local codes require piping from safe ty device to outdoors.

Refer to Carrier System Design Manual, Part 3, for standard piping techniques.

COMPRESSOR UNITS — Connect high- and low-pressure switch capillary tubes from control box to compressor. See Fig. 2.

Install discharge line muffler (accessory) in discharge line as close to compressor shutoff valve as possible.

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 =

100 x

Example: Supply voltage is 230-3-60

A verage Voltage =

max voltage deviation from average voltage

average voltage

AB = 236 volts BC = 229 volts AC = 234 volts

236 + 229 + 234

= 233 volts

Determine maximum deviation from average voltage:

(AB) 236 – 233 = 3 volts (BC) 233 – 229 = 4 volts (AC) 234 – 233 = 1 volt

Maximum deviation is 4 volts. Determine % voltage imbalance:

% Voltage Imbalance =100 x

233

= 1.7%

This amount of phase imbalance is satisfactory as it is below the maximum allowable of 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

ELECTRICAL DATA NOTES

1. All 06D and 07D units are across-the-line start.

2. Wire sizes are based on TW type copper wire. Maximum wire lengths based on data from Table 1 will result in a 1% voltage drop to compressor. Where up to 3% voltage drop is allowed, the run length can be increased to 3 times the length calculated from data in Table 1.

3. The 06D compressor unit electrical data shown in Table 1 does not apply for 06D compressors used as an integral part of other Carrier equipment. See proper installation book for electrical information.

WIRI NG — Power supply must correspond with unit nameplate electrical characteristics (units are internally wired at factory for nameplate voltage). Field wiring must comply with local and national codes.

Install a branch circuit fused disconnect of adequate size to

handle starting current. LIN E POWER — Connect line power to the compressor con-

tactor C. For example, connect L1 to terminal 11, L2 to terminal 12 and L3 to terminal 13. See Fig. 3.

Table 1 — Compressor Electrical Data

COMPRESSOR

PART NUMBER

06D*

808

313

818

825

328

537

LEGEND

LRA — MCC — RLA —

*Refer to physical data table to match compressor with correct com-

pressor unit or water-cooled condensing unit.

NOTES:

1. RLA (rated load amps) value shown is: MCC ÷ 1.40 = RLA.

2. For minimum contactor sizing, use RLA value determined by:

Locked Rotor Amps Maximum Continuous Current Rated Load Amps

MCC ÷ 1.40 = RLA.

VO LTAGE

(3 Ph-60 Hz)

575

208/230 17.4 12.4 71 0.78

460 8.7 6.2 35.5 3.1 575

208/230 27 19.3 100 0.5

460 13.5 9.6 50 2.1 575

208/230 44 31.4 160 0.42

460 22 15.7 80 1.7 575

208/230 55.5 39.6 198 0.31

460 27.8 19.8 99 1.3 575

208/230 62 44.3 228 0.26

460 31 22.1 114 1.0 575

208/230 89 63.6 266 0.18

460 40 28.6 120 0.72

HP MCC RLA LRA

6.5

7.5

MOTOR WINDING

RESISTANCE

(Ohms)

7 5 28.4 5.0

10.8 7.7 40 3.3

17.6 12.6 64 2.6

22.2 15.9 79 2.0

25 17.9 91 1.7

32 22.9 96 1.2

3. For wiring sizing, the RLA value can be determined by: MCC

1.56 = RLA.

4. Compressor operating amps at any specific conditions can only be determined from a performance curve.

5. RLA values for 06D compressor protected by a calibrated circuit breaker will depend on must-trip value of circuit breaker.

6. Ohm values shown for resistance are approximate and shown for reference 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 06DR and 50 Hz models (not shown) are available from Carrier Sales Representative.

AUX — C— CH — CR — DX — EQUIP — FU — GND — HPS — IP — LLS — LPS — M3 — NEC — OL — OPS — POR — SW —

Auxiliary Compressor Contactor Crankcase Heater Control Relay Direct Expansion Equipment Fuse Ground High-Pressure Switch Internal Protector Liquid Line Solenoid Valve Low-Pressure Switch Cooling Tower Fan National Electrical Code Overload Oil-Pressure Switch Pumpout Relay Start-Stop-Reset Switch

LEGEND

TB — TM — TR —

Terminal Block Timer Motor Timer Relay

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-clad aluminum for field power supply only.

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

3. Compressor thermally protected. Three-phase motors are protected against primary single-phasing condition.

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

Fig. 3 — Unit Label Diagram — 06D,07D Units

with a maximum rating of 15 A to TB2 connections (Hot Side) and (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.

Compressor Unit Connections

— Extend power leads from control center (contactor terminals) to compressor terminal box and make connections as shown in Fig. 4.

Terminals 8 and 9 on motor terminal plate are for internal protector connections. As shown in Fig. 4, run a wire from terminal 9 to terminal 6 on TB2 in control center and a wire from terminal 1 on OL2 to terminal 2 on HPS in control center.

Run crankcase heater power wiring into control center. Connect leads to terminal 5 on pumpout relay and terminal 3 on terminal block TB2. See Fig. 5.

Affix power warning label supplied in the installer ’s packet to fused disconnect which energizes crankcase heater (see unit label diagram).

LEGEND

HPS — OL — TB —

High-Pressure Switch Overload Relay Terminal Block Factory Wiring

Fig. 4 — Compressor Terminal Diagram

CONT ROL WIRING — Control circuit power is 115 volts, energized from an external source or from unit voltage through field-supplied transformer. Transformer size required is 350 va for 60 Hz units. External control power source must be supplied through a 15-amp fused disconnect. Connect control circuit power leads to terminal block TB2, terminals L1 and L2. Terminal L2 is neutral potential (ground).

Compressor Protection

— The 06D and 07D units are factory wired for single-pumpout control. Field addition and wiring of line voltage remote control and liquid line solenoid valve is required. (See unit Fig. 3 and Fig. 6.) Remote control minimum contact rating must be 25 va. Solenoid valve must have a maximum load rating of 50 va holding; 200 va inrush. For applications with cooling tower, air-cooled or evaporative condensers, add necessary auxiliary contacts in line between compressor contactor and terminal A1 on timer. Insert desired interlocks and overloads between terminals 5 and 9 on terminal block TB2.

Control wiring may be modified as shown in Fig. 6 for automatic pumpdown control; remove low-pressure switch between timer relay and terminal 4 on TB2. Wire low-pressure switch between terminals 9 and 6 on TB2. Add necessary auxiliary contacts between compressor contactor and ter minal A1 on timer. Remove wire between terminal 6 on TB2 and terminal 3 on pumpout relay. Insert required interlocks and overloads between terminals 5 and 9 on TB2.

Limitations —

Do not use automatic pumpdown control on direct expansion cooler applications or when compre ssors are equipped with pressure-type unloader valves. Pressure unloader valves have built-in high to low passage which allows compressor to cycle with automatic pumpdown.

LEGEND

C— CH — CR — FU — GND — HPS — IP — LPS —

NOTES:

1. Factory wiring is in compliance with NEC. Any field modifications or

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

3. Compressor thermally protected. Three-phase motors are protected

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

5. 60 Hz units have 120-volt control circuit. 50 Hz units have 230-volt con-

6. Open control circuit disconnect switch for servicing only. Disconnect

7. A transformer of the following rating may be field supplied for 60 Hz

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

9. If any of the original wiring furnished must be replaced, it must be

Contactor, Compressor Crankcase Heater Control Relay Fuse Ground Connection High-Pressure Switch Internal Protector Low-Pressure Switch

additions must be in compliance with all applicable codes. Use copper, copper-clad aluminum for field power supply only.

against primary single-phasing condition.

be 25 va.

trol circuit. A separate source of supply at the correct voltage must be field supplied thru a fused disconnect device with a max rating of 15 A to TB2 connections (Hot Side) and (Neutral).

must remain closed for crankcase heater to operate.

units: 350 va.

replaced with 90 C wire or its equivalent.

NEC — OL — OPS — POR — SW — TB — TM — TR —

National Electrical Code Overload Relay Oil Pressure Switch Pumpout Relay Switch Terminal Block Timer Motor Timer Relay

Fig. 5 — 06D/07D Control Box Components and Connections (3-Phase)

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