Carrier 06E User Manual

Compressors and Condensing Units

Hermetic, Water-Cooled

PRELIMINARY CHECKS

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 condi tioning information.

PLACING THE UNIT

Locate unit on floor in a well ventilated area. Install unit where it will be warmer than condi tioned area. Position it to allow sufficient space for refrigerant and water connections and to seiwice 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 it firmly to foundation.

COMPRESSOR

Remove 4 self-locking bolts from compressor

mounting springs, and reassemble them with

flanged washers and neoprene snubbers as shown in Fig. 1. Flanged washers and neoprene snubbers are shipped in a cloth bag tied to compressor. Tighten

all 4 bolts. Then, loosen each until the flanged washer can be moved sidewise. Check compressor

to see that it floats freely on its mounting springs.»

PIPING CONNECTIONS

Attach water supply and return line to con nections indicated on condensing unit (Fig. 3). Water leaving condenser should not be connected

directly into sewer lines; check local codes.

Attach refrigerant liquid and suction lines to

condensing unit (Fig 3),suction and discharge lines

to compressor unit (Fig. 2) Discharge line muffler

and check valve are factory supplied with 06E com pressor 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 down

stream 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

Table 1 — Physical Data

COMPRESSOR UNIT 06E

1V022JW027

1 6ÔÔ i 640

CONDENSING UNIT 07E OPERATING WEIGHT (Tb) REFRIGERANT COMPRESSOR 66E (06EV,EW)

(07EA,EB,ED):Di50i N265 i N i /5 i N299

Oil Charge, PP33-2(pt) 14 | i9 1 19 I 19 Normal Oil Pressure* Oil Safety Switch Cut-in

High-Pressure Switch

Cutout Range

A022 :3027 ;B033Jp044_

l235{TM0'[T356JT56b '

D2.50 Ie265 Ie275 Ie?99^

Cutout

2 to 5 psi below cut-

300 to 400 psigt

W033

''650^^

R-22, R-502'

13 to 18 psig

9 to 13 psig

W044

320 pspt,

Differential (cutout,

Factory Settings!

cut-in)

Cutout

95 ± 1 5 psi ifixed)

335 ± 6 psig

260 i 6 psig

Cut-In

Low-Pressure Switch

Cutout Range Differential (cutout, cut-in) Factory Settings! Cutout

Low-Side Max Pressure

CONDENSER 69RE

Refrigerant 22

Max Storage Capacity (lb)** Min Operating Charge (lb)

Max Operating Pressure

Refrig erant Side Water Side

. 07E Condensing Unit Data

'Listed pressuies are above operating suction pressure (pressure

diffeieniial between suction and discharge pressures of oil pump)

fAdjustable, but only by authorized personnel and with special

tool

:j Listed settings for R-22 For other refrigerants, reset to

pressures corresponding to saturation temperatures indicated by the listed pressures

**Condenser 80% filled with liquid refrigerant at 104 F

Cut-in

240 t 7 ps:<3

175 3 7'ps>3‘ ■■■

5 to 1 00 psig (adj )

22 ± 8 psi (fixed)

24+4 psig

66 ± 4 psig 245 psig

022

027

139 f

“j'y i

385 PC.Î9

250 psig

043

Î95

Fig. 1 — Compressor Mounting

670

1276

Form 06E, 07E-5SI

L ODF SUCTION VALVE (MAY BE ROTATED 360° AT 90° INTERVALS)

*1 nstall pressure relief device in discharge line

Pressure relief setting is 465 psig

tOverall width includes projection of fuse

holders

M ODF* DISCHARGE VALVE (MAY BE ROTATED 180°

'A~

OVERALL LENGTH (INCLUDES CONTROL BOX OVERHANG)

DIAM KNOCKOUT

DIAM-4 HOLES

06E Hermetic Compressor Unit Dimensions

UNIT 06E mMENMONS A CONNECT Tons On ) u

V022

3-1 1 %

IV«

2-31| OVERALL HEIGHT

W027

3-1IV«

iVa“' IV,

4~VVu

2v; '

iVa

JW0j44_

" 2Va ”■

1 Vs

Fig. 2 —06E Hermetic Compressor Units

UNIT 07E DIMENSIONS (fi

Overall Width

Certified dimension drawings available on request.

A022

6- 5 6- 5 6- 5

C 2-1 IV 3- 0

l-nVs

§027

1 -1 1V 1-1IV

07E Water-Cooled Condensing Unit Dimensions

§033

0044 _UNJT 07E^

6-7V CONNECTIONS (ii

2-1 1V2

3-2 Vs 2-3 Vs

Fig. 3 — 07E Water-Cooled Condensing Units

A022

K iVs IVs L iVs IV« U

B027 B033

2V 2V

0044

2Vs

IVs iVs

Table 2 — Electrical Data (60-Hertz, 3-Phase)

(Circuit Breakers Selected for Units Using R-22)

VOLTS

UNIT

Compr

06 E W033

Cond

07 E B033

VOLTS

UNIT

Compr

06 E

Cond B027

07 E

KW — Maximum Power Input

LRA — Locked Rotor Amps MTA — Must Trip Amps MWA — Minimum Wire Amps Complies with NEC Section

RLA — Rated Load Amps Supply Range — Units are suitable for use on electrical systems

NOTES: 1 Control voltage is 115 v for all units

Nomina 1

Supply Range

V022 W027

W044

A022 B027

D044 Nominal Supply Range

V022 24.8 36 W027 W033 W044

A022 22.6 32

B033 34.0 48 205 66

D044

24.8

33.6 103

37.6

55.1

22.6

31.4

34.0

50.4

KW RLA LRA

33.6

37.6

55.1 76

31.4 43 205

50.4

430-22

where voltage supplied to the unit terminals is not below or above the listed range limits

RLA

1 14

164

72 283

96 107 471 150 159 690 222

70 300

LRA

345 471 144 129 506 160 690

471 134 120 200

150 205 63 56 100 220 71 300

123 45

200

180-229

MTA

114

230 100

460 575 (See Note 5)

414-528

MTA

106

MWA FUSE

102 143

206 350

134 198 350 140

MWA

60 98 88

45 64

95 40 70 27

54 90 60 100 39 164 54

MÀX

AMPS

175 225 250

150 225 96

MAX MAX FUSE

AMPS

150 60 240

150 60 240 84

2 Part-winding start all 200-, 230-volt 06E and 07E units; 460-,

575-volt 06EW044 and 07ED044 units Across-the-line start: all 460-, 575-volt units except 06EW044

and 07ED044.

3. Factory wiring is in compliance with National Electrical Code (NEC) Field wiring must comply with NEC and applicable local codes Maximum incoming wire size to control center terminal block is 250 MCM

4 The 06E compressor unit electrical data shown in the table

does not apply to 06E compressors used as an integral part of other Carrier equipment Refer to the electrical data for the particular application

-> 5 Units for use on 575 volts are available on special order

RLA

92 103 440 144 150 600

85 410 118 106

RLA

29 120 40 37 60 36 164 50 45 80 42

LRA MTA MWA

300 410

r 246

410 600

LRA MTA MWA

176

164

230

207-264

104

128 115 210

134 196

518-660

58 53 90 84 75

37 34 45

129 225 188

120 175

MAX FUSE AMPS

79 125

48 75

150 200

300

175 200 300

FUSE AMPS

125

60 70 80

125

(Continued from page 1.)

suction line so compressor suction valve may be moved aside for access to suction strainer.

A solenoid valve is necessary for single pump

out control used on 06E and 07E units. Install the

valve (field supplied) in the liquid line, just before

the 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 side of con denser 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 REQUIREMENTS

Eield wiring must comply with local and

national codes. See Table 2.

Install a branch circuit fused disconnect of adequate size to handle starting current. The disconnect must be within sight of the unit and readily accessible, in compliance with National Electrical Code (NEC), Section 440—14.

Line power is brought into control center thru indicated opening. Connect line power supply to

terminal block TB1; connect power leads to terminals LI, L2 and L3. Connect control circuit power supply (115 volts) to terminals 1 and 15 on terminal block TB2. Refer to Eig. 4.

Wiring connections for field-supplied equip ment are shown on diagram attached to unit (or in wiring diagram booklet).

Discharge line limit thermostat supplied with

06EV,W compressor units is installed on discharge

line as close to compressor as possible.

1. Place mounting plate on discharge line and solder in place.

Easten the thermostat to plate with screws

supplied. Cover switch with insulation and secure insula

3. tion at each end with straps.

Connect thermostat in series with Ml and M2

4. overloads, between terminals 2 and 4 on termi nal block TB2.

ACCESSORIES

PACKAGE NUMBER

07EA900021 07EA900061

DESCRIPTION

Control Circuit Transformer Gage Panel

1276

REFRIGERANT CHARGING

Evacuate, Dehydrate and Leak Test the entire

refrigerant system by methods described in Carrier Standard Service Techniques Manual, Chapter 1, Sections 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 con denser subcooler coils.

07E Condensing Units - After clear sight glass is obtained, add charge until liquid refrigerant reaches condenser liquid level test cock.

06E Compressor Units — See condenser data for additional charge required to fill subcooler.

All Units — Stamp type of refrigerant and amount

of charge on unit informative plate

INITIAL START-UP

Crankcase heater should be energized a mini

mum of 24 hours before starting unit.

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-cooled con denser.)

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

Start evaporator fan or chilled water pump.

Start Compressor — Push the control circuit

START-STOP-RESET switch to “Start.” The timer motor starts immediately. Depending on the posi tion 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—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. If the oil level is below the bottom of 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 06E compressor is approximately 1/3 up on sight glass.

là

CONTROL POWER TERMINAL STRIP (TBg)

GROUND SCREW

START-STOP-RESET SWITCH

CONTROL CIRCUIT FUSE(S)

(2 ON 50-Hz UNITS)

CONTROL RELAYS SENSOR MODULE

(SOLID STATE COMPRESSOR MOTOR

PROTECTION)

HIGH PRESSURE SWITCH

LOW PRESSURE SWITCH

TIMER MOTOR (4-FUNCTION TIMER)

MAIN POWER INLET,

MAIN POWER TERMINAL BLOCK (TB|)

EQUIPMENT GROUND

'connection

COMPRESSOR CONTACTOR

OUTLET FOR WIRING TO COMPRESSOR 06E

07E

OIL PRESSURE SAFETY SWITCH

1276

ACCESSORY TRANSFORMER (60-Hz UNITS ONLY)

MAIN POWER CIRCUIT BREAKER

Fig. 4 — Control Center — 06E and 07E

COMPRESSOR CONTACTOR (PART-WIND)

Timer Functions (See Fig. 5 — Tinier Cycle)

1. Switch A (contacts A-Al and A-A2) provides Time Guard® function. Start of compressor is

delayed approximately 5.5 minutes after shut off. The minimum time between starts of compressor is 8 minutes.

2. Switch B (contacts B1 and B—B2) starts compressor and de-energizes the crankcase

heater. These contacts also provide one-second

time delay for part-winding start.

3. Switch E (contacts E—El) provides approxi

mately 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—Dl) bypasses the lowpressure switch (EPS) for 2.5 minutes at start up for winter start control.

(BLACK DENOTES CLOSED CONTACTS)

0 MIN OR

8 MIN

»TT?*

-'E-El-

-xA-

High-Pressure Switch — Check by throttling con

40 SEC +5

2-6 SEC

---

150 SEC

Fig. 5 — Timer Cycle

PROTECTION DEVICES

TIMER POSITION DURING

UNIT OPERATION-

denser water or blocking air flow 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 1.

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 1.

Oil Pressure Switch (OPS) protects against damage

from loss of oil and failure of pressure buildup during start-up. Switch time delay (approximately 35 seconds) is derived from being properly wired to the ambient and voltage insensitive Time Guard timer. If OPS locks out unit, det e rm ine an d c o r r e c t

th e c a u s e (such as loss of compressor oil or flooded

compressor) be f o r e r e s ta r t in g uni t Restart by pushing the control circuit switch on unit control box to “Stop” then to “Reset.” Failure to correct

the cause of the OPS lockout will constitute abuse.

Eq ui p m e n t f a il u r e d u e to a b u s e i s n o t c o v e re d by th e Warr a n t y .

Time Guard Control protects compressor against

short cycling. See Start Compressor.

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.

N ev e r o p e n any s w it c h o r d i sc o n ne c t t h a t w i ll de - e n e rg i z e th e c r a n k c a s e h e a te r u n l e ss u n i t i s be i n g se r v ic e d or is to be s h u t d o w n fo r a

pr o lo ng e d pe r io d Af te r a p r o l o n g e d s h u t d o w n or a se r vi c e jo b , en e r g iz e th e cr a n k c a se he a t e r f o r 2 4 ho u r s b e f o r e s ta r t ing th e co m pre s s o r .

Compressor Motor Protection consists of 3 tem

perature sensors embedded in motor windings and connected to a solid state module in unit control box.

When an overtemperature condition causes module to shut compressor off, push control circuit STOP switch. Investigate cause of compressor shut down and correct. After compressor cools, push control circuit START-RESET switch. Compressor will restart after Time Guard delay period.

SOLID STATE MODULE is checked by applying unit control voltage to terminals T1 and T2 (see label diagram), then checking for continuity across terminals Ml and M2. If no continuity between Ml and M2, check temperature sensor resistance using a volt-ohmmeter. If all sensors check below 95 ohms (180 F) and there is no continuity between module terminals Ml and M2, replace module.

CAUTI O N: D o no t u s e a ba t te r y p o w e r ed t e s t la m p t o ch e c k s e n so r s E x c e s si v e cu r r e n t ca n ca u s e d a ma g e

If one sensor fails, it can be jumpered out of the circuit with a 75 ohm, or higher, resistor (rated at 2 watts or higher) across the proper sensor terminal and common terminal. If a short to ground in sensor circuit is indicated, replace

compressor motor.

CAPACITY CONTROL SYSTEM

Capacity Control Valve(s) 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 pressure is 10 psi (see Fig. 6).

D o no t us e au t o m a t i c p u m p d o wn c o n tr o l on

06 E , 0 7 E u n i ts e q u i p p ed wi th u n l o a d e r va l v e s . U s e

sing l e p u m p o u t o r s o le n o i d d r o p (mi n im um p r o 

te ct i o n ) c o n tr o l

Capacity Control Valve Adjustments

CONTROL SET POINT (cylinder load point) is

adjustable from 0 psig to 85 psig. Pressure differ ential between cylinder load-up point and cylinder

unload point is adjustable from 6 psi to 22 psi.

PRESSURE DIFFERENTIAL

ADJUSTMENT SCREW

SEALING BYPASS CYLINDER CAP PISTON HEAD

BYPASS PASSAGE

CONTROL SET POINT ADJ NUT

POPPET VALVE' BLEED ORIFICE'

DISCHARGE MANIFOLD

SUCTION PRESSURE

nZH DISCHARGE PRESSURE

DISCHARGE SUCTION VALVE PISTON VALVE

UNLOADED OPERATION

COMMUNICATES WITH SUCTION MANIFOLD

-SUCTION MANIFOLD

l~~~1 DISCHARGE PRESSURE

Fig. 6 — Capacity Control Valve Operation

TO REGULATE CONTROL SET POINT (Refer to Fig. 7) —Turn adjustment nut clockwise to its bottom stop. In this position, set point is 85 psig. Control set point is then regulated to desired pressure by turning adjustment nut counterclock wise. Each full turn decreases set point by 7.5 psig. Approximately 11 1/2 turns counterclockwise will decrease control set point to 0 psig. Table 3 shows the steps of control.

PRESSURE DIFFERENTIAL ADJUSTMENT (Fig. 7) — Turn differential adjusting screw counter clockwise to its back-stop position. In this posi tion, differential is 6 psi. Pressure differential is set by turning adjustment screw clockwise. Each full turn increases differential by 1.5 psi. Approxi mately 10 turns clockwise will increase pressure differential to 22 psi.

LOADED OPERATION

CONTROL

TO PREVENT REFRIGERANT LEAKAGE)

Fig. 7 — Capacity Control Valve

Capacity Control Valve Operation (Fig. 6)

LOADED - When suction pressure is above con

trol point, the poppet valve closes. Discharge gas bleeds into valve chamber, the pressure closes bypass piston and cylinder bank loads up. Dis charge gas pressure forces check valve open, per mitting gas to enter discharge manifold.

UNLOADED — When suction pressure drops below

valve control point, the poppet valve opens. Dis

charge gas bleeds from behind bypass piston to suction manifold. Bypass piston opens, discharge

gas is recirculated back to suction manifold and cylinder bank is unloaded. Reduction in discharge pressure causes check valve to close, isolating cylinder bank from discharge manifold.

CAPACITY CONTROL VALVE

CAP SCREWS

(NONINTERCHANGEABLE WITH FLANGE COVER

CAP SCREWS)

Table 3 — Steps of Control

COMPRESSOR STEPS

06 E

CONDENSING

UNIT 07E

06EV022 07EA022

06EW027 07EB027

06EW033 07EB033

06EW044 07 ED 044

NOTE: Capacity control valve (Fig 7) factory settings for 4-cylinder

units are: 69 psig control set point (cylinder load point), 10 psig differential (59 psig cylinder unload point) Settings for 6-

cylinder units are: left cylinder bank control set point is 70 psig,

differential is 10 psig; right cylinder bank control set point is 68 psig, differential is 10 psig

1 2 3 No. % No. % No. Cyl Cap. Cyl

4 100 2

100

6 100 4 67

Cap. Cyl

2 33

Cop.

Service Replacement Compressors are not equip

ped with capacity control valves. Side bank cylinder head(s) is plugged with spring loaded piston plug assembly(ies). Compressor will run fully loaded with piston plug(s) in place.

Transfer original capacity control valve(s) to

corresponding cylinder bank(s) in replacement compressor (ensures proper valves are used with

correct setting). Install piston plug assembly(ies) into original compressor for sealing purposes.

Three alien head cap screws hold capacity control valve in place (Fig. 8). Remove screws using a “cut down” 3/16-in. alien wrench, and pull valve from cylinder head.

Remove same number of piston plugs from replacement compressor as number of unloaders supplied with original compressor. Three alien head cap screws hold piston plug assembly in place. Remove flange cover, gasket, spring, and piston plug (Fig. 9). A tapped hole is provided in piston to allow it to be pulled out. Hole has same thread diameter as cap screws removed above.

Fig. 8 — Removal of Capacity Control Valve

BYPASS PISTON PLUG

SPRING

CAP SCREWS

(NONINTERCHANGEABLE WITH CONTROL VALVE

CAP SCREWS)

GASKET

-FLANGE COVER

Fig. 9 - Removal of Bypass Piston Plug

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 (avail able from Carrier Service Department). Flush water thru tubes while cleaning. If hard scale has formed, clean tubes chemically. Do not use brushes that will scrape or scratch tubes.

For chemical cleaning solution, use inhibited hydrochloric acid solution (Oakite 32). Handle acid cautiously. Clean condenser by gravity or forced circulation (Fig. 10 and 11). For average scale deposits allow acid solution to remain in condenser overnight; for heavy deposits, allow 24 hours. Drain condenser and flush with clean water.

NOTE: Protect condenser from freezing when ambient is below 32 F by draining water from

system or adding antifreeze to water.

Before assembly, coat all parts with compressor

4. oil and clean and inspect all gasket surfaces. Replace all gaskets with new factory-made gaskets. See Table 4 for torque values.

After reassembly, evacuate compressor and

5. open suction and discharge valves. Restart compressor and adjust refrigerant charge.

Legend (Fig. 12)

Fig. 10 — Gravity Circulation

ceOTarcGAt. pcwp sas vemt- 30 OPM AT 35' HEAD

PUMP. • " ^

SUCT:ON

PRl«WS /VAl.VE£\..

, REMCA'E WATER

^ REGULATINC- valve

: ClXSt VENT PIPE ; VALVE WHEN

; PUMP IS : RUMNWG

COiv-CEAiSES

Fig. 11 — Forced Circulation

REMOVING, INSPECTING AND

REPLACING COMPONENTS (Fig. 12)

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.

Start compressor, close suction shutoff

valve, and reduce crankcase pressure to 2 psig. (Jumper low pressurestat.)

Stop compressor and isolate from system by closing discharge shutoff valve.

Bleed any residual refrigerant. Drain oil if necessary.

3. After disassembly, clean all parts with solvent. Use mineral spirits, white gasoline or naptha.

Compressor Motor —

Stator and Rotor

Motor Key

Rotor Plate Washer 31-Pump Rotor

Rotor Lock Washer 32

Rotor Lock Bolt

—

Motor Lock Bushing 34-Pump Vane Spring

7_Roll Pin

Acorn Nut and Gasket

Ring Spacer

—

Junction Box

Terminal Plate Assembly

—

Terminal Bolt Assembly

—

Terminal Bolt Assembly

Cover Plate

Hex Head Screw

Cylinder Head Bolts

—

Connecting Rod and

Piston Assemblies

Compressor Crankcase

Motor End Cover

Cylinder Head —

Center Bank

Cylinder Head — Capacity

21 -

Control Side Bank

Internal Relief Valve

22 -

Crankcase Oil Filter

Screen

- Oil Sight Glass Assembly

Oil Sight Glass 0-Ring

Gasket

Oil Sight Glass Screw

Oil Sight Glass Lock

Washer

Pipe Plug Gasket

(hex head)

Bottom Cover Plate

29 30—Pump End Bearing

Pump Vane

33 Pump Vane Spring

35“Retaining Spring

Oil Feed Guide Vane

38_Oil Pump Drive Segment

Screw, Soc Head

Screw, Soc Head no 10

41-Cover Plate 42-Cover Plate Cap Screw

Oil Relief Piston

Crankshaft

45_Bearing Washer

Piston Ring (Oil and

47__Piston, Piston Pin and

48-Connecting Rod and

49-Valve Plate Package

Valve Plate

51-Discharge Valve Stop 52-Discharge Valve 53_Valve Stop Support

Cap Screw, Valve Stop

55—Suction Valve

Head Package

Guide

Spring

1/4 - 28 X 5/8 in

- 32 X 1/2 in

Compression)

Retaining Ring

Package

Cap Assembly

.........

^53) \ ' V.

(SEE LEGEND PAGE 8)

V-

_________

^ ^

Fig. 12 — 06E Compressor Components

Table 4 — Torque Values

SIZE

THREADS

DIAM

PER IN.

(in.)

27 (pipe)

‘/4

X X

No. 6 No. 10 32

18 20

18 (pipe)

18 (pipe) 30-40

18 16 32

TORQUE

RANGE

(Ib-ft)

8-12

Pipe Plug — Crankshaft

20-25 Pipe Plug — Crankcase

8-10

Conn. Rod Cap Screw Junction Box

8-12

Sight Glass

3-5

14-18

14-18 14-18

15-24 15-24

30-40

30-40 25-30

55-65 55-65

90-100 90-120 90-120

90-120 90-120

60-75

Oil Pump Drive Segment Unloader Valve Discharge Valve Stop

Cover Plate — Pump End

Bearing Head

Discharge Service Va!ve(4 cyl) Bottom Plate — Crankcase

Compressor Foot Terminal Block Oil Plug — Pump End Bearing

Head

Terminal Bolts

2-4

Pipe Plug — Junction Box

Motor End Cover

Pump End Bearing Head Cyl inder Head

Discharge Service Valve (6 cyl)

Suction Service Valve (4 cyl) Suction Service Valve (6 cyl)

Rotor Lock — Crankshaft Oi 1 Drain Plug Stator Lock

105

Check Valve Body — Crankcase

1-2

Oil Pump Drive Segment

4-6

Terminal Screw

4-6

USAGE

OIL PRESSURE TAP

^ drive segment

CAP screws

PUMP END BEARING HEAD

OIL FEED GUIDE VANE

AND SPRING

Fig. 13 — Removing Pump End Bearing Head

LUBRICATION SYSTEM

Testing Oil Pump — An oil pressure tap is located

above oil pump cover plate (Fig. 13). Oil pressure should be 12—18 psi above suction pressure.

OIL FILTER SCREEN is accessible thru 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

assembly is contained in the pump end bearing head aluminum casting. (The pump end main bearing is a machined part of this casting — no insert bearing.)

REMOVE bearing head from crankcase and dis

assemble oil pump. Drive segment cap screws must be removed before bearing head can be removed (Fig. 13). Remove pump vane assemblies from both sides of bearing head. Push the pump rotor

out of the bearing head by pushing against the bearing side of the rotor. Check all parts (Fig. 14)

for wear and damage.

REPLACE

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.

1 — Cover Plate 2 — Oil Feed Guide Vane Spring 3 — Oil Feed Guide Vane 4 — Drive Segment 5 — Pump Rotor

6 — Pump End Bearing Head

7 — Pump Vane 8 — Pump Vane Spring

9 — Pump Vane Spring Guide 10 — Retaining Spring 11 — Pump End Main Bearing 12 — Oil Relief Piston

Fig. 14 — Pump End Bearing Head Package

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.

CYLINDER HEADS (Fig. 12)

Disassemble cylinder 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 safety device is

located in center cylinder bank (6-cylinder com pressors, Fig. 15) or under discharge service valve (4-cylinder compressors). The valve relieves refrig erant 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.

Reassemble — Do not interchange valves. Install

suction valves on dowel pins. Place valve plate on

cylinder deck, and reinstall discharge valve assembly. Retorque discharge valve stop cap screws

to 16 Ib-ft. Replace cylinder head. (Be sure tab on cylinder head gasket is lined up with tabs on cylinder head and valve plate.)

Fig. 15 — Pressure Relief Valve Removal

VALVE PLATE

SUCTION VALVE ?

SEATS

(VALVE PLATE)

SUCTION AND DISCHARGE VALVE

PLATE ASSEMBLY (Fig. 12)

Test for leaking discharge valves by pumping

compressor down and obseiving suction and

discharge pressure equalization. If a discharge valve is leaking, their 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 remove valve plate and expose suction valves (Fig. 16). Remove suction valves from dowel pins.

Inspect valves and valve seats for wear and

damage (see Wear Limits, Table 5). Replace valves

if cracked or worn. If valve seats are worn, replace

complete valve plate assembly.

SUCTION VALVES <

Fig. 16 — Valve Plate Removed

TERMINAL PLATE ASSEMBLY

Removal — Disassemble junction box from termi

nal plate, and remove cap screws holding terminal

plate to compressor. Mark all motor leads so they

can be reassembled correctly to terminal plate. Loosen alien head screws holding motor leads to terminal plate (Fig. 17). Remove terminal plate.

Power Lead Terminal Stud — Disassemble only if

leaking refrigerant or if resistance to ground is low. If there is a short to ground, replace complete terminal plate assembly.

DISASSEMBLE (Fig. 18)

1. Unscrew terminal, terminal locknut, and termi nal bolt assembly hex nut.

2. Push terminal bolt thru terminal plate and remove insulating washers.

Inspect for grounds, insulation breakdown, and sufficient life remaining in terminal seal bush ings. It is recommended that disassembled terminal stud assemblies be replaced with new parts.

REASSEMBLE

1. Refer to Fig. 18 for position of terminal assembly parts (washers are color coded).

2. Tighten terminal bolt assembly hex nut only enough to stop escape of refrigerant gas (max imum recommended torque is 4 Ib-ft). Do not tighten nuts so terminal insulation washers are flush with mounting plate.

ALLEN HEAD SCREWS (T)

Table 5 — Wear Limits — 06E Compressor

FACTORY

COMPRESSOR PART

MOTOR END

Main Bearing Diameter Journal Diameter

PUMP END

Main Bearing Diameter Journal Diameter

CONNECTING ROD

Bearing Diameter

(After Assembly)

Crankpin Diameter

THRUST WASHER

(Thickness)

CYLINDERS

Bore

Piston Diameter Wrist Pin Diameter Con. Rod Wrist Pin ID

Piston Ring End Gap

Piston Ring Side

C learance

VALVE

THICKNESS

END CLEARANCE

""Maximum allowable wear above maximum or below minimum

factory tolerances shown For example difference between main bearing diameter and journal diameter is 0035 in

(1 8760 — 1 8725) per factory tolerances Maximum allowable

difference is 0045 in (0035+ 001)

Suctic

D ischarge

TOL. (in.)

Max

1 .8760

6260

1 7515

2 6885

8755 007

003 0315 0255

0225 031

1 8725

6233

7483

155

2 6817

8748

002

001^

0305

0245*

0215

MAXIMUM

ALLOWABLE

WEAR* (in.)

001"

002*

002

001 001

015

002

010

Fig. 17 — Removing Terminal Plate Assembly

■r--7.7X

TERMINAL BOLT ASSEMBLY

TERMINAL INSULATION WASHER

INSULATION WASHER

■TERMINAL INSULATION BUSHING

-----

TERMINAL SEAL BUSHING

TERMINAL INSULATION WASHERS(GRAY)

TERMINAL INSULATION

WASHER LOCK WASHER

(SPRING)

TERMINAL LOCKNUT

TERMINAL SEAL WASHERS (RED)

TERMINAL INSULATION BUSHING

PLATE WASHER

HEX NUT

■TERMINAL

Fig. 18 — Power Lead Terminal Stud Assembly

MOTOR REMOVAL

Motor End Bell — Remove motor end bell care

fully to prevent damage to the stator. Use three

7/16 — 14x5 in. studs for guides and support. In spect suction strainer in end bell. Clean it with sol vent or replace if broken or corroded.

Rotor — Bend rotor lock washer tab backward and

remove rotor lock bolt. If crankshaft turns, pre venting 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.

19). Replace valve plate assembly and cylinder head (only two bolts required to hold cylinder head in place). Proceed to remove rotor lock bolt, lock washer and plate washer.

Use a jackscrew to remove rotor (Fig. 19). Insert a brass plug into rotor hole to protect end of crankshaft from jackscrew. Support rotor while it is being removed to prevent stator damage. Re move ring spacer between rotor and crankshaft.

Clean rotor thoroughly with solvent. If stator is

to be replaced, a matching rotor must be used.

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. Remove acorn nut and washer. Back out locking pin and bushing. With draw stator (Fig. 20). Axial key positions stator and crankcase. If necessary, heat crankcase motor

housing (not over 20 to 30 F above stator temp).

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

housing. Insert the terminal leads first, guiding

them to terminal plate opening as stator is being

inserted.

Replace ring spacer (Fig. 12) 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 lock washer and plate washer.

CAUTI O N. Do n o t p u s h st a to r in c o m p l e te l y un t i l ro t o r i s i n p l a c e

RUBBER PLUG

JACKSCREW

Fig. 19 — Removing Rotor

VALVE PLATE

STATOR LOCKING ASSEMBLY

^OTOR LOCK BOLT

Push stator into housing until it lines up correctly

with rotor (Fig. 21).

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. 22 and instruc

tions). Connect stator leads to proper terminals on terminal plate. Refasten terminal plate and junc

tion 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 in 12 bolts holding terminal

plate to crankcase at 30—40 Ib-ft.

END

V STATOR

TURN

■ . }■

END

RING

ROTOR CENTER LiNS

ASSEMBLY

LOCKING PIN BOSS

STATOR

WASHER

Fig. 20 — Removing Stator

LOCKING PIN

Fig. 21 — Motor Alignment

REENEC ENOS

MOTOR LOCK BUSHfNG

locking RiN

..........

S~ATCR CORE

Fig. 22 — Stator Locking Assembly

C0'M»R£SS0R

0AST^NG

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 3/8 in. drill bit, 2-1/16 in. from cutting edge.

3. Ream out bushing (3/8 in. drill) and drill into stator core until tape is flush with top of bushing. (Remove drill chips.) Back off locking pin bushing 1/8 of a turn.

CAUTI O N' B e f o r e d r il li n g , b e s u re sta t o r v e n t

ho l e s do no t l in e up wi t h l o ck i n g p i n h o l e . V e n t ho l e s ar e d r i ll e d h o r iz o n t a ll y t h r u s ta t o r , a n d

ca n b e s e e n f r o m e n d b e l l s id e .

4. Tap locking pin into position. (Top of bushing should be approximately 1/16 in. above top of pin.)

5. Peen top of bushing over roll pin.

6. Replace washer and acorn nut.

COMPRESSOR RUNNING GEAR REMOVAL

Connecting Rod and Piston Assembly — Remove

cylinder heads, valve plate assemblies, crankcase bottom cover plate, oil filter screen, and con necting rod caps (Fig. 23.) (Label caps and rods so

they may be reinstalled in same place on crank shaft.) Push connecting rod and piston assemblies

up thru 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 crankpin journals for wear (refer to

Table 5 for wear limits).

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 thm pump end

opening. Inspect crankshaft journals for wear and

tolerances shown in Table 5. Check oil passages

and clean if clogged.

Pump End Main 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 Bearings are not

field replaceable. If bearings are worn or damaged, replace compressor.

CONNECTING

RODS a CAPS "'psTT;-

. 'Cv •

Fig. 23 — Removing Connecting Rod and

Piston Assemblies

COMPRESSOR RUNNING GEAR

REPLACEMENT

Crankshaft — Be sure compressor end bearing

washer is in place on dowel pin. Install crankshaft thru pump end, carefully guiding it thru main bearings. Replace rotor.

Connecting Rod and Piston Assembly (Fig. 12) —

Attach connecting rods to pistons with piston pins,

and lock in place with retaining rings. Place retaining rings with the gap on the side. They should be tight enough so they cannot be rotated

by finger pressure.

RINGS

1. Check ring gap by inserting each ring separately in cylinder approximately 3/8 in. from top. Ring gap should be between .002 in. and .007 in.

2. Install compression ring in top piston groove with side marked “Top” toward piston head. Install oil ring below compression ring with notched end on bottom. Stagger ring gaps around piston.

3. Measure side clearance between ring and piston (Table 5). Check rings for free action.

Install connecting rod and piston assemblies

into cylinders. Place chamfered sides of connecting rods against radius of the crankpins. Install connecting rod caps to matching connecting rods

thru bottom cover plate. Be sure chamfered sides

of caps are against radius of crankpins. Caps are locked in place with nylock cap screws. Use 8—10 Ib-ft torque to tighten cap screws.

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.

CRANKSHAFT

OIL DRAIN PLUG (MAGNETIC)

BOTTOM COVER

PLATE

MOTOR BURNOUT

(Clean-Up Procedure)

When a hermetic motor bums out, the stator

winding decomposes forming carbon, water and

acid which contaminate refrigerant systems. Re

move these contaminates 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.

2. Remove burned motor from compressor, and drain compressor 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. Ascertain cause of burnout and remedy. Check control box for welded starter contacts, welded

overload contacts or burned out heater ele ments. 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.

5. Evacuate and dehydrate compressor.

6. Place compressor in operation. After 2—4 hours

of operation, check compressor oil for discolor

ation 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 filterdrier or suction strainer is dirty or discolored, repeat this step until system is clean.

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

Tabs Form 06E.07E5SI Supersedes 06E,07E-4SI PrintedinUSA 1276 10-75 PC 1 11 Catalog No 530-601

Book

Tab

Carrier 06E User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PRELIMINARY CHECKS

PLACING THE UNIT

PIPING CONNECTIONS

Table 1 — Physical Data

Fig. 3 — 07E Water-Cooled Condensing Units

ELECTRICAL REQUIREMENTS

ACCESSORIES

INITIAL START-UP

CAPACITY CONTROL SYSTEM

Capacity Control Valve Adjustments

Capacity Control Valve Operation (Fig. 6)

CONDENSER MAINTENANCE (07E Units)

Service Notes

LUBRICATION SYSTEM

CYLINDER HEADS (Fig. 12)

TERMINAL PLATE ASSEMBLY

Table 5 — Wear Limits — 06E Compressor

MOTOR REMOVAL

COMPRESSOR RUNNING GEAR REMOVAL