Carrier 07D User Manual

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Carrier

06D,07D

Installation Instructions

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Carrier Corporation 1965 Litho in U.S.A.

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07DA501005 6-65 Tab 4 Supersedes 6D21-1045 1-61

06D,07D INSTALLATION

Carrier

PAGE

Inspect the Site Inspect Shipment for Loss and Damage Set the Unit in Place Code Compliance Electrical Requirements Piping and Accessories Leak Test the System Dehydrate the System Check Refrigerant Charge Initial Start-Up Instructions Checking Operations 07DA210,112,215 Electrically Operated Capacity

Control Device Check the Installation

13 15 15 15 15 20 24 24 26 27 27

28 32

SUCTION SHUT-OFF VALVE

DISCHARGE MANIFOLD PRE5SURESTAT CONN.

PUMP END BEARING HEAD

OIL PUMP COVER SUCTION MANIFOLD

PRESSURESTAT CONNECTION

(REMOVE FITTING TO CHECK OIL LEVEL WITH DIPSTICK)

COMPRESSOR NAMEPLATE REGISTER TAG

FUSIBLE UNION

COOLING WATER

CONN

WATER REGULATOR VALVE PRESSURE CONNECTION

LIQUID LINE CONNECTION

liquid line valve

Fig. 1 - Typical 2 Cylinder Water-Cooled Condensing Unit

MOUNTING SPRINGS (REMOVE BOLTS BEFORE STARTING)

CONDENSER NAMEPLATE

(07DA102, Single-Phase Illustrated)

TERMINAL BLOCK

discharge‘shut-off valve

DISCHARGE GAGE CONNECTION

RUN CAPACITOR

CONTROL BOX

DISCHARGE MUFFLER

CONDENSING UNIT NAMEPLATE (USE FOR WARRANTY PURPOSES)

LIQUID LEVEL TEST

COCK

Carrier

INSTALLATION 06D,07D

DISCHARGE GAGE CONN.

SUCTION PRESSURESTAT CONNECTION

SUCTION SHUT-OFF VALVE

SUCTION GAGE CONN.

PUMP END BEARING

HEAD

OIL PUMP COVER

BULL'S EYE

OIL DRAIN PLUG

WATER OUTLET

(COOLING TOWER ONLY)

FUSIBLE UNION

WATER INLET

(COOLING TOWER) WATER INLET AND OUTLET

(CITY WATER)

'LIQUID LINE CONN.

. DISCHARGE MANIFOLD

-WATER REGULATING VALVE PRESSURE CONN

DISCHARGE MUFFLER

TERMINAL BLOCK

COMPRESSOR NAMEPLATE

RUN CAPACITORS

START CAPACITORS

CONTROL BOX

CONDENSING UNIT NAMEPLATE (USE FOR WARRANTY PURPOSES)

REFRIGERANT TAG

MOUNTING SPRINGS (REMOVE BOLTS BEFORE STARTING)

Fig. 2 - Typical 4 Cylinder Water-Cooled Condensing Unit

DISCHARGE GAGE CONN.

DISCHARGE SHUT-OFF VALVE

SUCTION MANIFOLD PRESSURESTAT CONN,

PUMP END BEARING HEAD

OIL PUMP COVER BULL’S EYE OIL DRAIN PLUG PURGE COCK

WATER OUTLET (COOLING TOWER ONLY)

FUSIBLE UNION

WATER INLET (COOLING TOWER) WATER INLET AND OUTLET (CITY WATER

(07DA103, Single-Phase Illustrated)

'LIQUID LINE

CONN.

■WATER REGULATING VALVE PRESSURE CONN.

DISCHARGE MUFFLER

DISCHARGE MANIFOLD PRESSURESTAT CONN.

-TERMINAL BLOCK

REFRIGERANT TAG

CONTROL BOX

SUCTION SHUT-OFF VALVE

COMPRESSOR NAMEPLATE

CONDENSING UNIT NAMEPLATE (USE FOR WARRANTY PURPOSES)

MOUNTING SPRINGS (REMOVE BOLTS BEFORE STARTING)

Fig. 3 - Typical 4 Cylinder Water-Cooled Condensing Unit

(07DA106, Three-Phase Illustrated)

06D,07D INSTALLATION

DISCHARGE GAGE CONN.

DISCHARGE SHUT-OFF VALVE

DISCHARGE MANIFOLD PRESSURESTAT CONN.

PUMP END BEARING HEAD

OIL PUMP COVER BULL'S EYE

WATER INLET AND OUTLET HEADERS

(SEE FIG 18 FOR

PROPER CONNECTIONS)

MOUNTING SPRINGS (REMOVE BOLTS BEFORE STARTING)

LIQUID LEVEL TEST COCK

DISCHARGE MUFFLER

SUCTION MANIFOLD PRESSURESTAT CONN

TERMINAL BLOCK

SUCTION SHUT-OFF VALVE

CONTROL BOX

REFRIGERANT TAG

COMPRESSOR NAMEPLATE

CONDENSING UNIT

NAMEPLATE

OIL FILL PLUG

LIQUID LINE CONN.

' WATER REGULATING VALVE

PRESSURE CONN

Fig. 4 - Typical 6 Cylinder Water-Cooled Condensing Unit

CAPACITY CONTROL SOLENOID VALVES

DISCHARGE SHUT-OFF VALVE

DISCHARGE GAGE CONNECTION

PUMP END BEARING HEAD

OIL PUMP COVER OIL FILL PLUG

BULL'S EYE

OIL DRAIN PLUG

WATER INLET AND OUTLET

HEADERS (SEE FIG. 18 FOR PROPER CONNECTIONS)

(07DA210, Three-Phase Illustrated)

FUSIBLE UNION (HIDDEN)

' LIQUID

LEVEL TEST COCK

MOUNTING SPRINGS (REMOVE BOLTS BEFORE STARTING)

DISCHARGE MUFFLER

LIQUID LINE CONNECTION

WATER REGULATING VALVE PRESSURE CONN

Fig. 5 - Typical 6 Cylinder Water-Cooled Condensing Unit - Capacity Control

(07DA215, Three-Phase Illustrated)

NOTES

1. NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR EITHER DIRECTION OF ROTATION

3. CONTROL BOX DRAWING 06D-20I-EI

4. MUFFLER DRAWING ' 06D- 202-4

LIQUID STRAINER-DRIER CRANKCASE HEATER PKG.

YES NO

UNIT

MODEL

07DAI02

07DA203

NET WEIGHT

(LBS)

181

190

A D E

2'-s|'

4''

2-7 C

3 i

(/)

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 6 - Dimensions for 07DA102 and 07DA203

NOTES'

1. NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR

EITHER DIRECTION OF ROTATION.

3. CONTROL BOX drawing: 06D-20I-EI

4. MUFFLER DRAWING • 06D- 202-4

LIQUID STRAINER-DRIER CRANKCASE HEATER PKG.

YES NO

UNIT

MODEL

---------------------

07DAI03 247 2-9"

07DAI06 2 94

07DA208

NET WEIGHT

(LBS)

330

2'-9|"

3'-3|"

I'-iiir"

2-4 J,

c 0 E

l'-4"

.1 ...n

I-IO

F G H

I'-O"

|J-''

I'-l"

' 8

4|"

5®"

J K L

s'"

5 " 8

7” 8

I-2-L"

r 7"

MPTXFPT

3 "

1 "

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 7 - Dimensions for 07DA103,106 and 208

NOTES

1. NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR EITHER DIRECTION OF ROTATION.

3. CONTROL BOX DRAWING 06D-20I-EI

4. MUFFLER DRAWING 06D-202-4

PRESS. ACTUATED CONTROL VALVE(S) LIQUID STRAINER- DRIER CRANKCASE HEATER PKG.

YES NO

UNIT

MODEL

07DA2I0 WITHOUT

07DB2I0

CAPACITY

CONTROL

WITH

NET WEIGHT

(LBS)

475

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 8 - Dimensions for 07DA210 and 07DB210

NOTES.

1. NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR

EITHER DIRECTION OF ROTATION.

3. CONTROL BOX DRAWING OSD- 201-El

4. MUFFLER DRAWING OSD- 202-4

PRESS. ACTUATED CONTROL VALVEiS) LIQUID STRAINER-DRIEF

CRANKCASE HEATER PKG.

YES_ NO

UNIT

MODEL 07DAII2 07DA2I5

07DBI 12

07DB2I5

CAPACITY

CONTROL

WITHOUT

WITH 590

NET WEIGHT

(LBS)

580

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 9 - Dimensions for 07DA,DB112 and 07DA,DB215

NOTES.

1. NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR

EITHER DIRECTION OF ROTATION.

3. CONTROL BOX DRAWING 06D-201-El

4. MUFFLER DRAWING 06D-202-4 CONTROL BOX r

MOUNTING SPRINGS

MUFFLER

CRANKCASE HEATERS

YES NO

MODEL

06DA7I8 210 LBS.

06DA8I8

NET

WEIGHT

225 LBS.

OIL

CHARGE

7 PINTS

SPRING MOUNTING ARRANGEMENT

(TYPICAL)

(/>

Dimensions are approximate. Certified dimension drawings are availabie on request.

Fig. 10 - Dimensions for 06DA718 and 06DA818

NOTES

I NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR EITHER DIRECTION OF ROTATION.

3. CONTROL BOX DRAWING 06D-20I-EI

4. MUFFLER DRAWING 06D-202-4 PRESS. ACTUATED

CONTROL VALVE(S)

CONTROL BOX

MOUNTING SPRINGS MUFFLER CRANKCASE HEATER

YES NO

NET WEIGHT 270 LBS.

OIL CHARGE 10 PTS.

06DA DENOTES NO UNLOADERS

06DE DENOTES 2 STEP PRESSURE

ACTUATED UNLOADING

M/8" DIA. HOLE FOR 3/4“C0NN.. 13/8“ DIA. K.O. FOR I" CONN. 8.

3Æ-I6 X 1 1/2 LG

CAPSCREW

COMPRESSOR END FOOT

LOCKWASHER —

PLATE WASHER

SPRING GUIDE-

JL (NOT FURNISHED)

SPRING MOUNTING ARRANGEMENT

BASE-

(TYPICAL)

3/8 - 16-7/8‘‘LG. CAPSCREW

MOTOR END

FOOT

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 11 - Dimensions for 06DA824 and 06DE824

NOTES

1. NET WEIGHT INCLUDES OIL BUT NOT REFRIG. CHARGE.

2. OIL PUMP IS AUTOMATICALLY REVERSIBLE FOR EITHER DIRECTION OF ROTATION.

3. CONTROL BOX DRAWING OSD-201-El

4. MUFFLER DRAWING OSD-202-4

PRESS. ACTUATED

CONTROL VALVE(S)

CONTROL BOX MOUNTING SPRINGS MUFFLER

CRANKCASE HEATER

YES

MODE L

06D( )337

06 D( Ì537

„ 06DA DENOTES NO UNLOADERS

06DE DENOTES 2 STEP PRESSURE

NET

WEIGHT

285 LBS.

ACTUATED UNLOADING

OIL

CHARGE

10 PINTS

ELECTRICAL

208-3-60 230-3-60 230-3-50 400-3-50

460-3- 60

SPRING MOUNTING ARRANGEMENT

1 3/8" DIA. HOLE FOR 1" CONN, a

1 3/4" DIA. K.O. FOR 1 1/4" CONN. 1 1/8" DIA. HOLE FOR 3-4" CONN., 13/8" DIA K.O. FOR l" CONN. 8

1 3/4" DIA K.O. FOR 1 1/4" CONN.

(TYPICAL)

"E" CONNECTION SIZES

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 12 - Dimensions for 06DA337,06DE337 and 06DA537,06DE537

FIGURE I

n FIGURE H

MUFFLER

PKG.

NO.

6D44-

882

6047-

882

6075-

882

FIG.

NO.

JL 10 IL

1-4"

9|''

DIMENSIONS

c D 5"

4"3"4 4"

DIXH.

COND. CONN.

INLET

MTG.

HORIZ.

VERT

CONN.

INLET

—

I'ODF

^OOM

|-§ODF

|0DF

l-gODF

MODELS

USED

06DA7I8

06DA8I8

06D_824

060—337

060 — 537

Dimensions are approximate. Certified dimension drawings are available on request.

Fig. 13 - Dimensions for 06D Muffler Assembly

Carrier

INSTALLATION 06D,07D

Table 1 - 07D Condensing Unit Data

Condensing Unit A102 A203 A103 A106

Compressor Mo lei

Unit Type

Nominal Tons

Evap Temp Le\ el

No. of Cy 1 inders

Bore ond Stroke (in )

Compr Speed (rpm)

DispI at 1750 Rpm (cfm)

Suet Gas Conn

Disch Gas Conn. (ODF) 5/8 5/8

Liq Line Conn

Refrigerant 12

Optg Ref Charge (lbs)** 2

Cond Storoge Cap

(80% Liquid at 100 F)

Water Conn Inlet 1/2 FPT Cooling Tower

Water Conn City Water

Frangible Discs, M. Fl. 3/8

06DA109

H,M,L

2 X 1-3/8 2 X 1-1/4

1750

(ODF)

Outlet

Outlet 1/2 FPT 1/2 FPT 1/2 FPT

Inlet

1/2 FPT

06DA808

H,M

2 2

1750 1750

8.69 7 96 13.1

7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 1-3/8 1-3/8

1/2

18 18.5 20.5 39.5 35.8 45

1/2 FPT(2) 1/2 FPT(2) 1/2 FPT(2) 1/2 FPT(2) 3/4 FPT (2) 3/4 MPT 3/4 MPT 1 MPT 1 MPT 1 MPT *1-1/2 MPT 2 FPT 2 FPT

1/2 FPT 1/2 FPT 1/2 FPT

1/2 1/2 1/2

2.5

3/8

06DA013 06DA718

WC WC WC

H,M H

4 4 4

1-13/16 X 1-1/4 2 X 1-7/16 2 X 1-7/16 2 X 1-7/16

5/8 7/8 7/8

12 12 22 22 22

2.7 2.0 1.9

3/8 3/8 3/8

5 5

1750

18.3

1/2 FPT

-------------------------

06DA818

1750 1750 1750

18.3 18 3 23.88 37 07 37 07

1/2 1/2 5/8 5/8 5/8

1/2 FPT 1/2 FPT 3/4 FPT 1-1/2 MPT 1-1/2 FPT 1-1/2 FPT

3/4 FPT 1-1/2 MPT 1-1/2 FPT

A .

A208

7-1/2

H,M

7/8 7/8 1-1/8

2 7 3.2 4.3 4.3

3/8

210

06DA724 06DA337 06DA537

10 10

H,M H,M

6 6 6

2 X 1-1/4 2 X 1-15/16

1-1/2 MPT

3/8

WC WC

2 X 1-15/16

1750

12 22

88 88

*1-1/2 FPT(2) *1-1/2 FPT(2)

1-1/2 FPT

3/8 3/8

'^215 B

H,M

1750

1-3/8

1-1/8

*Remove upper header plug for parallel circuiting for cooling tower application (See Fig. 18 )

**Condensing unit minimum operating refrigerant charge

WC — Water-Cooled

INSPECT THE SITE

Preliminary Survey

Before starting the installation, make a survey

to determine the following: SPACE REQUIREMENTS Dimensions for the 07D Condensing Units are

given in Table 2. Allow additional room to re

move the compressor heads and valve plates.

Place the unit so the suction and discharge shut

off valves can be easily reached and the oil

level checked. Install the unit where it will be warmer than the

refrigerated space, to prevent refrigerant from condensing in the compressor crankcase during shutdown. Water-cooled condensing units must be protected against freezing. Make provision in the piping layout to drain and blow out the condenser and water piping if the system is to be shut down in winter.

Table 2 - Condensing Unit Dimensions

Length

Unit

07DÂ102 WC 0 0) 07DA102 WC (Poly 0) 07DA203 WC 0 </.)

(in.)

21-3/8 12 ■ 21-1/2

29-1/16 12 21-1/2

29-1/2 07DA203 WC (Poly 0) 31-3/16 07DA103 WC (1 </.)

07DA103 WC (Poly0) 07DA106 WC (All) 07DA208 WC (All) 07DA210 WC (All) 07DA112 WC (All)

31-3/32 14 22-5/8

32-3/4

33-1/4

39-5/8

39-11/16

46-3/8 17-7/16

07DA215 WC (All) 46-3/8

NOTE: WC - Water-Cooled

Width

(in.)

15-1/2

17-7/16

Height

(in.)

12 12

21-7/16 21-7/16

14 22-5/8 14 27-7/8

14 27-7/8

31-7/32

32-3/4 32-3/4

06D,07D INSTALLATION

Table 3 - Electrical Data for 06D Compressor Units and

07D Water-Cooled Condensing Units

Carrier

06D 07D

Compressor Condensing

Unit

A808

A718

A818

¿824

*337

¿537

Unit

A102 208/3/60 7.9

A203 208/3/60

A103 208/3/60

A106 208/3/60 19.3

A208 208/3/60 35.0

*210

¿112

¿215

Full

Volt/Phase Load

Cycle (amps)

230/1/60 11.2 230/3/60 460/3/60 3.5 230/3/50 5.8 400/3/50 3.5

230/1/60 15.8 230/3/60 460/3/60 5.2 230/3/50 400/3/50

230/1/60 230/3/60 460/3/60 230/3/50 8.9

400/3/50 5.3

230/1/60 25.0 100.0 35.0 230/3/60 16.8

460/3/60 8.5

230/3/50 400/3/50 8.5

230/3/60 460/3/60 230/3/50 26.2

400/3/50 15.8

208/3/60 36.0 230/3/60

460/3/60 15.8

230/3/50 400/3/50

208/3/60 44.0

230/3/60 39.7 460/3/60 19.9

230/3/50

400/3/50 19.9

208/3/60

230/3/60 44.3

460/3/60 22.2

230/3/50 400/3/50 22.2

208/3/60 55.7

230/3/60 50.0

460/3/60 25.0

230/3/50 41.5

400/3/50 25.0

Locked

Rotor

(amps)

6.8

11.8

10.3

8.6

5.2

12.2

16.1 70.0 22.5 25.0

10.6

5.3 28.8 7.4 9.0

14.0

31.5

15.8

31.5

26.2

15.8

33.0

49.3 191.0 69.0 80.0 15.9 4

37.2 143.0 52.0 60.0 13.2

137.0 48.8 60.0 10.8

124.0

103.0

137.0 48.8 60.0

124.0

103.0 36.7 40.0

170.0 61.5 70.0 14.1

153.0

128.0 46.2 50.0

172.0 62.0 70.0

266.0

240.0

120.0

200.0

115.0

Overload Fusetron

(amps) (amps)

48.5

50.0

43.0 9.5 12.0 2.8

22.5 4.8

35.8

21.5 4.8

63.5

70.0

57.5 14.4

28.8

47.8

27.5 7.2 9.0 3.17

63.5 17.0 20.0 4.1

57.5 14.8 17.5 4.1

47.7 12.4 15.0 3.42

27.5 7.4 9.0 3.42

95.0 27.0 30.0 6.6

86.0 23.5 30.0 6.6

43.0

72.0 19.5 25.0 5.5

41.0

62.0

59.0 22.0 25.0 9.0

62.0

59.0 22.0 25.0 9.0

77.0 27.8 35.0 14.1

74.0 •

86.0

83.0

Trip Size

11.0 12.0 2.8

15.6 17.5

8.0 10.0 2.35

16.5 20.0 3.8

22.0 25.0 3.8

7.2

12.0

11.8 15.0

11.8 15.0 5.5

44.0

22.0

36.7 40.0 9.0

44.0

22.0

55.5 70.0 14.1

27,8

31.0

78.0 90.0 18.9

70.0

35.0 40.0 18.9

58.0

35.0

5.6

17.5 3.8 14 41

9.0 3.8

15.0 3.17

40.0 6.6

50.0 10.8 8

25.0

50.0

25.0

35.0

35.0 13.2

80.0

70.0

40.0

Max

2.8

2.35

4.1

6.6 14 100

10.8

9.0

11.7 11,7

15.9

18.9

15.7

Min

Branch

Circuit Wire Length Old

Size (AWG)

14 14 14 63 14 249 14 14 216

14 32 12 34

14 14 14 143

14 31 12 33 14 35 14 161 14 14 140

10 50 10 32 10 63

12 48 14 87

8 64

12 74

6 8 53

8 64

12 75

6 6

10 107

6 76

10 85

6 57

6 67

4 4 8 131 6 8

Max Wire

(ft)*

Reference

Number

49 29

164

63 53 85

63 6D67

41 63

83 61

115

6D21

6D28

6D40

6D47

6D48

6D68

6D73

6D75

*Wlre sizes are based on minimum wire size needed to

comply with Notional Electric Code for TW Type Wire. Maximum wire length is based on a 1% voltage drop in the

branch circuit. Where up to 3% voltage drop is acceptable, maximum wire lengths can be multiplied by 3.

INSTALLATION 06D,07D

VENTILATION OF MACHINE SPACE Ventilation must be provided to remove heat

from the compressor and allow refrigerant gas to escape in case of a leak.

VIBRATION ISOLATION

Install the unit where the floor is strong enough

to support it. It is not necessary to install it on a special foundation because vibration is ab sorbed by the compressor mounting springs. On critical installations it may be desirable to enclose the unit in an equipment room to pre vent direct transmission of sound to occupied spaces. Place the unit where it will not be dam aged by traffic or flooding. It may be necessary to cage the unit.

NOTE: Remove the compressor hold down bolts to allow the compressor to float freely on the springs.

INSPECT SHIPMENT FOR LOSS AND DAMAGE

Check the shipping list immediately to see if the shipment is complete. Inspect the unit for damage. File a claim with the shipping company

immediately if damaged or lost.

Do not remove the tags until they are read and understood. Save tags, instructions, installation

record card and shipping receipt. The person starting machine may need them for reference.

CODE COMPLIANCE

Install these units in accordance with applicable codes and ordinances. Refer to ASA-B9 1-1953, American Standards Association's "Mechanical Refrigeration Safety Code."

Frangible discs are provided to protect against explosion in cases of extreme heat from an external source.

Before installing the unit, check the electric

service to insure that it is adequate. The volt age at the motor terminals must not vary more than plus or minus 10% of the nameplate volt age during start-up or while running.

Phase unbalance for three-phase units must not exceed 2%. Where unbalance exists, connect the two lines with the higher amperages thru the

switch heater elements.

Table 3 lists the minimum wire sizes for 6D

Water-Cooled Condensing Units.

Figure 14 - 16 are the unit wiring diagrams for the water-cooled condensing units.

Water-Cooled Condensing Unit Control

T ransformers

ELECTRICAL REQUIREMENTS

SET THE UNIT IN PLACE

Set the unit in place. Level the condenser and bolt the unit to the floor. For dimensions be tween hold-down bolt holes, see Fig. 6 - 13.

Control transformers are not furnished with

the 440 condensing units. Recommended trans former sizes are shown in Fig. 16. All 460/3/60 units have 115-volt control circuits. All other units have 230-volt control circuits.

06D,07D INSTALLATION

POWER AND CONTROL CIRCUIT SCHEMATIC

□ -TEKMINAL tLOCK CONNECTION C - CONTACTOR CR-CONTROL RELAY r-FU8E IT-INTERNAL MOTOR THERMOSTAT HP-HI PRESSURESTAT LP-LO PRESSURESTAT HR-H0L0IN6 RELAY

OL-OVERLOAO (OVERCURRENT RELAY) PO-PUMP OUT RELAY

TM’TIMER MOTOR

-----

FACTORY WIRINO

'•"FIELD WIRINO

I. CONTROL MUST BE FIELD SUPPLIED. j

MINIMUM CONTACT RATING MUST BE 25VA.

t. LIQUID LINE SOLENOID VALVE MUST BE

FIELD SUPPLIED. MAXIMUM LOAD'.

«OVA HOLDINOi 200 VA INRUSH.

S A60V AND 57SV UNITS HAVE A II5V

CONTROL CIRCUIT WHICH MUST BE ENERGIZED AT LI AND L2 FROM AN EXTERNAL SOURCE 400V UNITS HAVE A 2SO V CONTROL CIRCUIT WHICH MUST BE ENERGIZED AT LI AND L2 FROM AN EXTERNAL SOURCE. ALL OTHER

UNITS HAVE A 2SOV CONTROL CIRCUIT

WHICH IS ENERGIZED THRU FACTORY WIRING AT LI AND L2

4. A TRANSFORMER OF THE FOLLOWING RATING MUST BE FIELD SUPPLIED FOR 400V, 4S0V AND B7SV UNITS*.

ALL 0TD()|I2, 070U2I5, OSDOSST, 0GD0S37 AND 060()S24 UNITS; ISO VA. ALL OTHER units; 100 VA.

B.OPEN FUSED DISCONNECT SWITCH, ONLY

FOR SERVICING EQUIPMENT. DISCONNECT MUST REMAIN CLOSED IN ORDER FOR THE CRANKCASE HEATER TO OPERATE.

S.290V CONTROL CIRCUIT USES I/4 X

I '/4 SAMP FUSES. IIS V CONTROL CIRCUIT USES 1/4 X 1^/4 10 AMP FUSES,

LEaCND

NOTES

Fig, 14 - Wiring Label 07D Condensing Units, 06D Compressor Units (3-Phase)

INSTALLATION 06D,07D

(irc NOT! t)

I JUNCTION iOX

COMPREttOR

POWER AND CONTROL CIRCUIT SCHEMATIC

□ -TERMINAL BLOCK CONNECTION

C - CONTACTOR CR-CONTROL RELAY F-FUSE

IT-INTERNAL MOTOR THERMOSTAT

HP-HI PRESSURESTAT LP-LO PRESSURESTAT HR-HOLDING RELAY OL-OVERLOAD (OVERCURRENT RELAY) PO-PUMP OUT RELAY TM-TIMER MOTOR

-----

FACTORY WIRING

-----

FIELD WIRING

RC-RUN CAPACITOR

SC-START CAPACITOR

SR-8TARTIN0 RELAY

1. CONTROL MUST BE FIELD SUPPLIED.

MINIMUM CONTACT RATING MUST BE 25VA.

a. LIQUID LINE SOLENOID VALVE MUST BE

FIELD SUPPLIED. MAXIMUM LOAD!

• OVA HOLDING^ 200 VA INRUSH.

•«OPEN FUSED DISCONNECT SWITCH, ONLY FOR SERVICING EQUIPMENT. DISCONNECT MUST REMAIN CLOSED IN ORDER FOR

THE CRANKCASE HEATER TO OPERATE.

0 CONTROL CIRCUIT IS 230V AND USES

*/4 X I '/4, S AMP FUSES

LEGEND

NOTES

CRANKCASE

HEATER

-AA/VW

i O-

• Al

Sl^

“tÍmer”

-0

VIEW

070ASOOOS3

Fig. 15 - Wiring Label 07D and 06D Units (1-Phase)

06D,07D INSTALLATION

POWER WIRING

SINGLE PHASE

FACTOR> WIRING IS IN ACCORDANCE WITH THE NATIONAL ELECTRICAL CODE ANY FIELD MODIFICATIONS OR ADDITIONS MUST BE IN COMPLIANCE WITH ALL APPLICABLE CODES A6C VOLT UNITS HAVE 115 VOLT CONTROL CIRCUIT ENERGIZED FROM EXTERNAL SOURCE AOO VOLT UNITS HAVE 250 VOLT CONTROL CIRCUIT ENERGIZED FROM EXTERNAL SOURCE ALL OTHER UNITS HAVE 230 VOLT CONTROL CIRCUIT ENERGIZED THRU FACTORY WIRING AT L» AND L2 CONTROL CIRCUIT POWER REQUIREMENTS! ALL 07D( ) 112 8215 8 06D( )337,5378824 WITH 400V 8 460V DRAW 150 VA ALL OTHER UNITS REQUIRE lOOVA WHEN CONTROL TRANSFORMERS ARE REQUIRED THEY SHOULD BE SIZED ACCORDINGLY THESE RATINGS APPLY TO DEVICES SHOWN ON CONTROL DIAGRAM, IF ADDITIONAL ARE USED. TRANSFORMER SIZE MUST BE INCREASED PROPORTIONATELY CONTROL CIRCUIT FUSES ARE 11/4" X 1/4" DIA CERAMIC TUBE RATED AT -5 AMPS FOR 208 8 230V0LTS AND lOAMPS FOR 115 VOLTS DO NOT SUBSTITUTE OVERLOAD RELAYS OF A HIGHER RATING THAN

ORIGINALLY SUPPLIED. IF A CONTROL VOLTAGE POWER SUPPLY HAVING A GROUNDED SUPPLY LEG IS USED, THE GROUNDED CONDUCTOR MUST BE CONNECTED TO TERMINAL 3 AND F2 BYPASSED.

OPEN DISCONNECT ONLY WHEN SERVICING EQUIPMENT CRANKCASE

HEATER MUST REMAIN ENERGIZED WHEN EQUIPMENT IS SHUT DOWN WIRING SHOWN IS FOR WATER-COOLED CONDENSING UNITS WITH CONTROL BOX MOUNTED. COMPRESSOR UNITS ARE SHIPPED WITH CONTROL BOX SEPARATE AND PIELD MUST SUPPLY INTERCONNECTING WIRING WHERE NECESSARY WOrning-DlSCONNECT ALL CIRCUITS BEFORE SERVICING THIS

ONE OVERLOAD ON SINGLE PHASE. TWO ON THREE PHASE TIMER MOTOR (TM) CAM ROTATES AT 1/5 RPM WHEN TM IS ENERGIZED TO PROVIDE 15 SEC. TIMING WITH SWITCHES (N A-A2, B-B2, POSITION AND AMIN. 45 SEC, IN A-AI. B-BI, POSITION. COMPLETE TIME GUARD CONTROL PROVIDES 15 SEC ADVANCE START FOR CONDENSER AUXlUARIES AND PREVENTS COMPRESSOR RESTARTING IN LESS THAN 5 MIN AFTER STOPPING

EQUIPMENT

Fig. 16 - Field Wiring for 06D, 07D Units

LEGEND

HR HOLDING RELAY CR CONTROL RELAY

► C COMPRESSOR

M3 EVAPORATOR FAN OR

CHILLED WATER PUMP

M4 COOLING TOWER PUMP.AIR

COOLED OR EVAPORATIVE CONDENSER FAN

M5 COOLING TOWER FAN OR

EVAPORATIVE CONDENSER PUMP

OL OVERLOAD SV LIQUID LINE SOLENOID VALVE

SR STARTING RELAY

US UNLOADER SOLENOID

POR PUMP OUT RELAY

TM TIMER MOTOR

TERMINALS

Q MAIN TERMINAL STRIP

^ COMPRESSOR

MODEL

NUMBERS

070A102 07DA203

07DA103 060A7I8 A.B.C.D.E.F 07DA106 A.B. C.D, E, F 06DA6t8 A. C.D, E.F 07DA208

06D( )824 A, C. D. E. F

07D( )2I0 A. C.D. E, F 06D( )337 A. C.D,E.F

07D( )l 12 06 Di )537 A, C.D, E.F 07D( )2I5 A. C,D.e,F

A = 208/3/60 B • 230/1/60

C • 230/3/60

STANDARD

ELECTRICAL‘S

C HARACTERISTICS

A.B.C.D.E.F A.B.C. D, E.F A.B.C.D, E.F

A. C.D. E.F

A. C.D.E.F

D« 460/3/60 E» 230/3/50

F- 400/3/50

INSTALLATION 06D,07D

[33 SINGLE PUMP OUT CONTROL WITH CITY WATER

1 FI Pel =* CONTROL '

T'STAT t ,

---------------

------------

--------

' дих

____________

AUX

.CONTACT SV t

^Z]

-INSERT SAFETY INTERLOCK

HERE (WHEN USED)

Q^single pump out control with:

tSEE NOTE 3

I I COOLING TOWER I 1 EVAPORATIVE

□ COOLING TOWER FAN ^ ^roRATiVE

I 1 AIR COOLED CONDENSER CONDENSER

-------

PUMP

syt

o-p—4^

LOW PRESS '

CUTOUT

•^OPTIONAL t SEE NOTE3

NOTES:

1 REMOVE WIRE FROM C TO LOW PRESSURE CUTOUT

AND ADD NECESSARY AUXILIARY CONTACTS

2 REMOVE WIRE FROM FI TO Щ AND INSERT DESIRED

INTERLOCKS AND OL'S

3 FIELD SUPPLIED T'STAT MUST HAVE MIN. CONTACT RATING

OF 25VA FIELD SUPPLIED SV MAX LOAD 60VA HOLDING;

200 VA INRUSH.________________________________________________

CONDUIT TO COMPRESSOR TERMINAL BOX ARRANGEMENT

Г“ " ■

a и

---

1 Г“

MOTOR TERM BOX

3 PHASE - 6 CYLINDER

ilfyXP)’

¿2 -] T|

03 OL 4СЯ-------------------

•O i T Tj

“^2 1 T,

05 OL 40

--------------------

i COMPRESSOR

TERMINAL BOX ‘

I I PUMP DOWN CONTROL WITH CITY WATER

(SEE NOTES NO I THRU 6 BELOW)

.CONTROL T'STAT +

CONTACT SY»

I I PUMP DOWN CONTROL WITH.

I I COOLING TOWER [~~3 EVAPORATIVE CONDENSER

I ~1 COOLING TOWER FAN | ~| EVAPORATIVE CONDENSER I 1 AIR COOLED CONDENSER

PUMP

l''l

CONTACT ®V T

M5 P

--------

[T]

|з

¿ *o—яй^—4-i>—

»OPTIONAL T SEE NOTE 6

NOTES FOR PUMP DOWN CONTROL DIAGRAMS:

1 REMOVE LOW PRESSURE CUTOUT BETWEEN C 8 Al AND CONNECT C TO Al

WITH ANY DESIRED INTERLOCKS

2 WIRE LOW PRESSURE SWITCH BETWEEN TERMINALS fil a [F].

3 REMOVE CONNECTION BETWEEN a CR NORMALLY OPEN CONTACT A DO NOT USE PUMP DOWN CONTROL METHODS FOR COMPRESSORS LJUIPPED

WITH CAPACITY CONTROL USE SINGLE PUMP OUT CONTROL.

5 INSERT SAFETY INTERLOCKS HERE IWHEN USED) 6 FIELD SUPPLIED T'STAT MUST HAVE MIN. CONTACT RATING OF 25VA FIELD

SUPPLIED SV MAX LOAD 60 VA HOLDING ; 200 VA INRUSH

I I ELECTRIC UNLOADER CONTROL FOR COMPRESSORS FIELD EQUIPPED

WITH ELECTRIC CYLINDER UNLOADERS (TWO SHOWN)

PRESSURESTATS OR THERMOSTATS NOT FACTORY FURNISHED

----------

ч:(^Ръ—

-B

MOTOR TERM BOX

a Ш

a в

OÎ

_____J_____

03 OL

-----

3 PHASE-2 0 4 CYLINDER

SINGLE PHASE

~05-

OL !C

40r

____1 COMPRESSOR

TERMINAL BOX

COMPRESSOR

TERMINAL BOX

CYLINDER

UNITS

CYLINDER

UNITS

USED ON SINGLE

PHASE UNITS ONLY

APPROXIMATE COMPONENT LOCATION IN CONTROL BOX

SIDE VIEW

Fig. 16 - Field Wiring for 06D, 07D Units (Confd)

OCDCTCCl IBCCTAT .

—В ^

TERMINAL STRIP

------

(I PHASE

ONLY)

I HOLDING

TM KR

’'ш

FRONT VIEW WITH COVER

REMOVED

RELAY

^AIN Ì

TERMINA®

STRIP I

06D,07D INSTALLATION

PIPING AND ACCESSORIES

Elimination of Pipe Vibration

The liquid and suction lines are usually of soft copper tubing. To absorb vibration, loop or sweep tbe liquid and suction lines near the unit. Fasten the tubing to walls or supports, using vibration isolation type bangers as shown in Fig. 17. Keep uninsulated lines away from hot water or steam lines. Follow the piping prac tices in Carrier System Design Manual, Part 3.

minute period has elapsed. On normal starts, the control will operate 15 seconds before start ing the compressor.

The heart of the control is the cycle timer. The cam on the cycle timer completes one revolu tion in five minutes. Whenever the compressor is stopped the timer motor will automatically run until the cam lever is operated, which in turn actuates the necessary switches. When this sequence is completed, the cycle timer is pre pared to start the unit.

Table 4 shows the normal operating sequence of the timer circuit. This table can be helpful in diagnosing electrical problems.

Operation of the control circuit is generally the same on all voltage units. However, wiring se

quences for the individual controls may vary, such as overloads and safety devices.

The following is a general description of the operating sequence of the control circuit. Refer to the schematic wiring diagrams as a guide.

The functions of this control accessory are:

Fig. 17 - Refrigerant Line Hangers

Time Guard Control Operation

CONTROL CIRCUIT This unit is equipped with controls which pro

vide automatic reset overload protection, time delay in starting, and controlled cycling under any cycling condition. Following shutdown of the compressor for any reason (i.e., opening, of the thermostat, functioning of a protective device, power failure), the control permits re

starting of the compressor only after a five

1. To limit restart cycling of the compressor, under any circumstance, to a minimum of five minute intervals after stopping.

2. To allow time to run during normal "off periods, thus utilizing this time as part of the five minute timing interval described above in No. 1.

3. To provide a 15 second delay on each com pressor start before the compressor motor starter is energized; to allow auxiliaries such as condenser pump, condenser fan, chilled water pump, etc. to be in operation before the compressor starts. This feature will pre

vent nuisance cutouts due to momentary ac tion of the high pressure switch or chilled water flow switch during start-up.

INSTALLATION 06D,07D

Table 4 - Recyling Control Circuit Normal Operation Chart

Unit at Rest

Control Timer Relay

Coil 230 DE EN Contacts N.O. Contacts N.C.

Cycle Timer

Motor Cam Up Contacts A—A2 230 Contacts A—A] Contacts B—B2 230 Contacts B —B|

Compressor Line DE

Accessories Legend: EN - Energized CL

CL — Contacts Closed OP

DE — De-energized

*Accessories will continue to run if high or low pressurestat shuts off compressor.

Voltage

230 230

230 DE

230 OP OP

230

Ready to Start

OP CL

Thermostat Closes

Instantaneous thru

15 Seconds

CL OP

EN Up CL

DE EN

Contacts Closed and in Service Contacts Open

Thermostat or Safety Device

Normal

Run

EN DE DE CL OP CL

Do wn

OP CL CL OP OP CL CL CL OP

EN EN

Opens —Instant

Thru 4-3/4 Min

OP OP

Down

DE* DE

Unit Ready

to Restart

DE Up CL OP

1. starting Sequence (Assuming evaporator in terlocks and all operating safety controls

frigerant pressure rises and low-pressure switch closes.

are in closed position) Time: 0 Min 0 Sec - Timer switch plunger

is up at beginning edge of cam node and contacts are in positions A-A2 and B-B2, as shown.*

Control thermostat closes, energizing liq uid line solenoid valve (SV) and pump-out relay (FOR), FOR N.O. contacts close. Re-

Condenser auxiliaries, such as condenser water pump, tower fan, etc., start and their auxiliary starter contacts close. Timer re

lay (TR) is energized thru timer switch con

tacts A-A2, closing TR N.O. contacts and

opening TR N.C. contacts. Timer motor (TM) is energized thru timer switch contacts B-B2 and starts running.

* This is the position always reached by the cam each time after the compressor has stopped

and the timer motor has completed its 4 min and 45 sec timing run.

Starting Sequence of Time Guard Control (Single Pump-Out Arrangement Shown)

06D,07D INSTALLATION

Carrier

■ L|

EVAPORATOR

---

SAFETY DEVICE

CONTACTS,N.C.

INTERLOCK

CONTACTS,N.O.

----

LOW

PRESS.

SWITCH

CONTROL

THERMOSTAT

---------

*^^-0

------

M" AUX

CONTACTS,N.OT

CONTACTS,N.O.

J/_

POR

CONTACTS,N.C.

2. Operating Condition Time: 0 Min 15 Sec

Timer switch plunger has dropped off the cam node and the contacts have switched to positions A-Ai and B-Bi. Timer motor stops running since TR N.C. contacts are open.

Operating Condition of Time Guard Control (Single Pump-Out Arrangement Shown)

CONTACTS, N.O.

4^—

---------

TIMER MOTOR CAM 1/5 RPM, 15 SEC CAM NODE

Timer relay (TR) remains energized thru TR N.O. contacts, which are now closed.

Compressor motor starter is energized thru timer switch contacts A-Ai and compressor

starts. Compressor continues to run unless

circuit is broken by action of control ther

mostat or safety devices.

CONO AUX

PUMPOUT RELAY

LIQ SOL VALVE

COND AUX

AUX CONTACTS,NO.

—#—

OFF

O O-

TIMER RELAY

■Ö

COMPRESSOR

TIMER MOTOR

—Cj-O—<•

HIGH

PRESS..

SWITCH

CONTACTS, N.C.

3. Stopping Sequence Time: Any time after 15 seconds

Timer switch plunger is still in position of having just dropped off the cam node, since timer motor has not been running, and switch contacts are in position A-Ai and B-Bi.

Thermostat opens when cooling load is sat isfied. Liquid solenoid valve (SV) is de

energized and closes. Pumpout relay (POR) is de-energized, and its contacts open. The

timer relay (TR) and compressor continue

to operate thru compressor starter auxiliary contacts ”M" until system pumps down and low-pressure switch opens. Then compres-

Stopping Sequence of Time Guard Control (Single Pump-Out Arrangement Shown)

TIMER MOTOR CAM 1/5 RPM, 15 SEC CAM NODE

sor and condenser auxiliaries stop and relay TR is de-energized. TR N.C. contacts close and timer motor (TM) is energized thru switch contacts B-Bi and starts to run.

The TM timer will switch again to position A-A2 and B-B2 after 4 min 45 sec elapse.

Thus, at least 4 min 45 sec must elapse after a shutdown before the compressor can begin its restart sequence, if the cooling thermo

stat is closed. A total of 5 min will elapse before the compressor can restart. Each compressor restart is preceded by 15 sec operation of the condensing equipment.

This reverts to conditions at time 0 min 0 sec.

INSTALLATION 06D,07D

Shut-Off Valves

The suction and discharge shut-off valves are of the backseating type and have gage ports. Frontseating the valve closes the refrigerant line and opens the gage port to the pressure in the compressor.

Backseating the valve shuts off pressure to the gage port. To attach a gage or charging line to the gage port, backseat the valve to prevent es cape of refrigerant.

U se a square ratchet or box-end wrench to open or

close a valve. Do not use pliers or an adjustable wrench. They are likely to round the valve stem.

Do not use excessive force to turn the stem. If it turns hard, loosen the packing gland nut. If the valve sticks on its seat, a sharp rap on the wrench will usually break it loose.

Crankcase Heater

The crankcase heater is an internal cartridge-

type heater that is inserted in a blind hole in

the compressor bottom cover. It does not come in direct contact with the oil. The heater draws 75 watts and is held in the hole by a clip. In sure that the crankcase is held tightly in place

by the clip.

The heater is approved for wet locations. The crankcase heater should be energized at

least 12 hours before start-up to insure that the refrigerant is out of the oil.

Liquid Line Strainer-Drier

Install the liquid line strainer-drier in the liquid refrigerant line. The drier should be installed

between the sight glass and the solenoid valve.

Flare Connections

Using too much force in tightening flare nuts will damage the copper flare. Repeated tighten

ing will harden the copper. To soften copper

tubing, heat it to a dull red and allow it to cool.

Soldering and Brazing Piping to Valves

Disassemble the valve or wrap it in wet cloth

to prevent damage by heat.

Water Regulating Valves (Water-Cooled Units Only)

Install the water regulating valve with the cap illary down and the arrow on the valve body in the direction of water flow.

1. Backseat the liquid line shut-off valve.

2. Connect the capillary of the water regulating valve to the 1 /4 inch flare connection on the liquid line shut-off valve.

3. Open the shut-off valve one turn from the backseated position. This allows refrigerant pressure to reach the water regulating valve and still leave the refrigerant line open.

NOTE: The water regulating valves for R-12 and R-22 are not interchangeable.

Liquid Line Solenoid Valve (Field Supplied)

The puipose of this valve is to prevent dam age to the compressor which would result from flooding of the crankcase with refrigerant during

shutdown and to provide the pumpdown control

feature. Install this valve in the liquid refrig

erant line directly ahead of the expansion valve.

It must be installed in the vertical position and

wired as shown in the wiring diagrams.

Liquid Line Sight Glass

Install the liquid line sight glass between the liquid line solenoid and expansion valve. Locate the sight glass so that it is convenient to place a light behind the glass when observing the liq uid for proper charge.

Condenser Water Connections

When city water is used for condensing, the condenser circuits are normally connected in series.

When cooling tower water is used for condens ing, the condenser circuits are normally con

nected in parallel. (See Fig. 18 for correct

connections.)

IMPORTANT: In the case of the 07DA210,

112, 215 WC Condensers, a plug in the upper header must be removed to provide parallel circuiting for cooling tower application. This plug is accessible by removing the upper header cap and unscrewing the Allen pipe plug. (See Fig. 18 for proper wrench sizes.)

06D,07D INSTALLATION

COOLING TOWER OR

CITY WATER

Carrier

The Halide Leak Detector

The halide leak detector in Fig. 19 consists of a burner, needle valve, suction tube, and a chim ney with a copper reaction plate. Some torches use alcohol and others propane as fuel.

To use the leak detector:

1. Adjust the flame so the top of the flame cone is level with or slightly above the chimney.

Place the end of the suction tube at the point

to be tested. The tube pulls in a sample of air to the burner where the refrigerant is decomposed by reaction with the copper plate.

3. Observe color of the flame. Small leaks give a greenish tint and large ones a vivid blue.

COOLING TOWER

Fig. 18 - Water-Cooled Condensing Units

Condenser Water Connections

LEAK TEST THE SYSTEM

CITY WATER

1. Charge the system to 40 psi with dry nitrogen or carbon dioxide. Check all joints for large leaks with soap solution.

2. Release the pressure and charge to 10 psi with refrigerant.

3. Add dry nitrogen or carbon dioxide until the pressure is 150 psi.

4. Check for leaks with a halide leak detector.

5. Repair leaks and purge system.

SUCTION FEELER TUBE

Fig. 19 - Halide Leak Detector

PRECAUTIONS: Do not use the compres sor to build up pressure. If used to com

press air, overheating and damage may

result.

DO NOT USE OXYGEN TO BUILD UP PRES SURE. Use a refrigerant or a dry stable gas

such as nitrogen or carbon dioxide instead.

DEHYDRATE THE SYSTEM

Preparation

Moisture in the system causes oil sludge and

corrosion. It is likely to freeze up the expansion

valve of a low temperature system. The best means of dehydration is evacuation with a pump especially built for this purpose.

INSTALLATION 06D,07D

Before dehydrating a system make the following preparations:

1. Obtain a pump that will produce a vacuum of

0.2 in. Hg absolute. Do not use the compres sor as a vacuum pump. It is not designed for such use and may be seriously damaged.

2. Pressure test the system to be sure it is free of leaks.

3. Obtain a vacuum indicator similar to that shown in Fig. 20 (available from Robinair Manufacturing Corporation, Edgerton, Ohio).

4. Keep the ambient temperature above 60 F to speed the evaporation of moisture.

TO COMPRESSOR

TO VACUUM PUMP SHUT-OFF VALVE

water in the tube. The temperature is related to the absolute pressure in the tube. Table 5

gives the absolute pressures corresponding to various temperatures.

Table 5 - Vapor Pressures of Water

Temp F Observed on

Vacuum Indicator

70 60 0.522 55 0 436 50 0 363 45 0.300 40

35 32 0.180

NOTE: To determine the vacuum in inches of mercury,

subtract the absolute pressure from the barometer reading.

Absolute Pressure

Inches of Mercury

0.739

0.248 0 204

Handle the vacuum indicator with care. It must be vacuum tight to give a true reading. The top seal of the indicator is not designed to support a long run of connecting tubes. Faster the tubes to supports to prevent damage.

Fig. 20 - Vacuum Indicator

Description and Use of the Vacuum Indicator

The vacuum indicator consists of a wet-bulb thermometer in an insulated glass tube con taining distilled water. Part of the tube is ex posed so the thermometer can be read and the water level checked. When the vacuum indicator

is connected to the vacuum pump suction line, the thermometer reads the temperature of the

Use only distilled water in the indicator. Be

sure the wick is clean. Oil or dirt on the wick

causes erroneous readings.

To prevent loss of oil from the vacuum pump

and contamination of the indicator:

1. Install a shut-off valve in the suction line at the vacuum pump.

2. Install a shut-off valve in the suction line at the vacuum indicator (Fig. 20).

3. When shutting off the pump, close the indica tor valve and the pump valve, and turn off the pump in that sequence.

Procedure for Dehydrating the System

1. Connect the pump and vacuum indicator to the system. Put a "jumper" line between the high and low side so that the pump will draw a vacuum on all portions of the system. Open the compressor shut-off valves. Start the pump.

2. Open the indicator connection shut-off valve occasionally and take a reading. Keep the

06D,07D INSTALLATION

Fig. 21 - Dehydration Pull-Down Curve

Carrier

valve open at least three minutes for each reading. (Keep the valve closed at all other times to decrease the amount of water the

pump must handle and hasten dehydration.)

When the pressure in the system drops to a value corresponding to the vapor pressure of the water in the indicator, the temperature will start to drop. In the example shown in Fig. 21, the ambient temperature and the

temperature of the water in the indicator is 60 F. Starting at 60 F and 0 time, the temperature of the water in the indicator remains at 60 F until the pressure in the system is pulled down to the pressure cor responding to the saturation temperature of the water (60 F). At this point the moisture in the system will start to boil. The tem

perature drops slowly until the free mois

ture is removed, and then more rapidly until the absorbed moisture is removed (35 F). Dehydration is nearly completed at this point,

provided the ambient temperature remains

at 60 F or higher. If the ambient temperature were lower than 60 F, ice might form before moisture removal is complete.

3. Continue the dehydrating operation until the vacuum indicator shows a reading of 35 F which corresponds to a pressure of 0.204 in. Hg absolute. This may take several hours. It may be advantageous to run the pump all night.

4. With the pump still running, open the system at a point farthest from the pump and admit air thru a drier. Close system and repeat Steps 2 and 3. Vapor in the system is thus greatly diluted and almost completely re moved by double dehydration.

5. After evacuation, turn off the pump suction valve and break the vacuum by admitting refrigerant.

6. Disconnect the pump and vacuum indicator.

CHECK REFRIGERANT CHARGE

After the system has been evacuated and dehy drated, charge refrigerant in gas form into the low side as follows:

1. Backseat the suction and discharge shut-off valves. Install a gage in the discharge gage port and turn the valve one turn from the backseat position to allow pressure to reach the gage.

2. Connect a refrigerant drum thru a drier and tee connection with a compound gage, to the suction gage port. Purge air from the lines and tighten the connections.

3. Turn the suction shut-off valve a couple turns from the backseat position and open the re frigerant drum valve. Keep the refrigerant drum in an upright position to prevent liquid refrigerant from entering the compressor.

4. Start the compressor. See "INITIAL START UP INSTRUCTIONS."

5. Check the refrigerant charge frequently while charging, by observing the liquid line sight glass. The refrigerant charge is sufficient when flashing (bubbles) disappears. An al ternate method of checking the charge is to

INSTALLATION 06D,07D

crack open the liquid test cock. The charge is sufficient if a mixture of liquid and vapor comes from the test cock.

The sight glass method of checking the re frigerant charge is more reliable, and should

be used whenever possible.

6. When the system is sufficiently charged, close the valve to the refrigerant cylinder, back

seat the suction shut-off valve, disconnect the charging line, plug the gage ports, and recap the valve stems. If the pressure in the cylinder drops to the level of the suction pressure, all refrigerant can be drawn from the cylinder by frontseating the suction shut off valve and pulling a vacuum on the cylinder.

CAUTION: Be careful not to overcharge the sys tem, Overcharging results in:

1. Higher discharge pressure due to excess liq uid in the condenser. With water-cooled units this means higher cooling water consumption.

2. Possible compressor damage,

3. Higher power consumption,

4. Increased flooding of refrigerant to the com

pressor during off-cycle if the expansion

valve is leaky.

To charge the system thru the liquid line, refer to the Service Section of the Product Informa tion Book.

3. Open the compressor discharge and suction shut-off valves,

4. Open the liquid line valve at the receiver.

5. Open pressure line valve of the water reg ulating valve.

6. Close the main power switch supplying cur rent to the compressor starter,

7. Check the oil pressure. (See "Lubrication.")

8. Adjust the water regulating valve.

9. Check control settings.

10. Recheck the oil level in the crankcase.

11. Cap all valves tightly.

CHECKING OPERATIONS

When starting a newly Installed compressor, be on the alert for any sign of trouble. Always in stall suction and discharge pressure gages. The water regulating valve on water-cooled units may need adjustment.

Dual Pressurestat

A dual pressurestatis connected to both the high

side and low side to protect the compressor. Settings are preset at the factory for use with R-12 or R-22 as shown by the values in Table 6.

INITIAL START-UP INSTRUCTIONS

The compressor should be started up only by a refrigeration mechanic who is familiar with accepted operation practices for refrigeration systems. Detailed instructions for checking and adjusting the components will be found under

"CHECKING OPERATIONS." Proceed as follows:

Water-Cooled Units

1, Check to see that the proper oil level appears

in the compressor sight glass, (A dipstick must be used with two cylinder compres sors.) See "Lubrication" under "CHECK ING OPERATIONS,"

2, Open the main water supply valve and allow

water to reach the condenser.

Table 6 - Factory Pressurestat Settings (Psig)

High Pressure

Unit

07D Units 280 200

U6U Units 370 290

Cutout

Cut-in Cutout Cut-in

Low Pressure

36 67 36 67

The 07D condensing unit high pressurestat cut

out point is adjustable from 230-340 psig with

a fixed differential. The 06D compressor unit

high pressurestat cutout point is adjustable from

230-400 psig with a fixed differential. The low pressurestat on all units have an adjustable cut out from 20" vacuum to 70 psig and an adjust able differential from 13-50psi. All adjustments are made thru the back of the control box.

Check the high-pressure cutout by throttling the condenser water on water-cooled units, or

06D,07D INSTALLATION

blocking the air flow on air-cooled units, allow ing the head pressure to rise gradually. The cutout and cut-in pressures should be within

10- to 15-pounds of the values shown in Table 6. If they are not, the pressurestat should be re placed or adjusted if it is an adjustable type. Check the low-pressure cutout by closing the

suction shut-off valve or by closing the liquid line shut-off valve to allow the compressor to pump down. The cut-in and cutout points may be adjusted if necessary.

Lubrication

A properly adjusted compressor should run with

the crankcase warm to the touch. Check oil level frequently to see that a sufficient amount of oil

remains in the crankcase. Check the oil pres

sure by looking thru the crankcase sight glass

at the oil pressure relief valve, (For 2 cylinder

compressors, see Fig, 22.) If oil is discharged

from the relief valve, pressure is adequate.

To check the oil charge on 2 cylinder 6D com

pressors, proceed as follows;

1. Pump down the compressor, turn off power and close the shut-off valves.

2. Remove the suction manifold pressurestat connection and half-union coupling.

3. Insert a dipstick in the hole and measure the oil charge.

Below is a sketch of a simple dipstick that may be used on 2 cylinder 6D compressors.

Table 7 - Factory Oil Charge (Pts)

Compressor Oil Charge

06DA109 06DA808 3-1/2 06DA013 06DA718 7 06DA518 7 06DA724 10 06DA337 06DA537

3-1/2

10 10

ADDING OIL

1. Pump down the compressor to 2-psi gage; stop the compressor and close shut-off valves.

2. Add oil thru the low-side pressurestat con nection or the oil fill plug on 6 cylinder compressors.

NOTE: Be sure to connect the low-side equipment and to size the piping, so oil will return to the compressor under all operating conditions.

Water Valve Adjustment (Water-Cooled Units Only)

Adjust the water regulating valve to the most

economical head pressure for the locality. Nor

mally this is between 120- and 140-psi for R-12 and between 200- and 230-psi for R-22,

Factory Oil Charge

The unit compressors are shipped with the oil charges of PP33-2 oil shown in Table 7. Do not assume that the charge is sufficient. Run the^ unit for 15- to 20-minutes until conditions have*

leveled off. Stop the compressor without pump

ing down and immediately check the oil level.

The oil level must be 1/3 to 2/3 of the way up on the sight glass. If the oil level is low, add oil.

PRESSURESTAT BOSS TO END OF STICK

-------

MIN OIL LEVEL- 4^/16

NORMAL OIL LEVEL-3k4M AX OIL LEVEL - 3 ^''16 —

Fig. 22 - Oil Level Measurement 2 Cylinder

Compressors

07DA210,112,215 ELECTRICALLY OPERATED

CAPACITY CONTROL DEVICE

The Capacity Control Device is a cylinder head bypass type, solenoid operated. Energizing the

control solenoid unloads a complete cylinder

bank and de-energizing the solenoid loads a

complete cylinder bank.

Controls to operate the solenoid valve are not furnished with the 07DA210,112,215 condensing

units. They must be field furnished and may be either temperature or pressure operated as per job requirements.

Solenoid Valve Electrical Characteristics

208/220 volts 1 (/> 60 cycle 10 4 VA holding 41 6 VA inrush

220 volts 1 0 50 cycle 10 4 VA holding 41.6 VA inrush

115 volts 1 0 60 cycle 10.4 VA holding 41.6 VA inrush

INSTALLATION 06D,07D

The control solenoids will be field wired to the

condensing unit control box (Fig. 16). All wiring must comply with local codes.

3. REFRIGERANT PRESSURE WILL BE BLED TO THE SUCTION MANIFOLD THROUGH THE OPENED GAS BYPASS PORT. A RE

DUCTION IN PRESSURE ON THE VALVE PISTON WILL TAKE WITH THE SOLENOID VALVE ENERGIZED THE SOLENOID VALVE STEM WILL OPEN THE GAS BYPASS PORT.

PRESSURE FROM THE DISCHARGE MANIFOLD PASSES THROUGH THE STRAINER AND BLEED ORIFICE TO THE BACK OF THE PISTON BYPASS VALVE. UNLESS BLED AWAY, THIS PRESSURE WOULD TEND TO CLOSE THE PISTON AGAINST THE PISTON SPRING PRESSURE.

PLACE BECAUSE THE RATE OF BLEED THROUGH THE GAS BYPASS

PORT IS GREATER THAN THE RATE OF BLEED THROUGH THE

BLEED ORIFICE.

DISCHARGE PRESSURE IN THE DlSCHARGE MANIFOLD WlLL CLOSE THE DISCHARGE PISTON CHECK VALVE ISOLATING THE COMPRESSOR DISCHARGE MANIFOLD FROM THE INDIVIDUAL CYLINDER BANK MANIFOLD.

Figures 23 and 24 explain the operating sequence of the 07DA210,112,215CapacityControlDevice.

WHEN THE PRESSURE BEHIND THE PISTON HAS BEEN REDUCED SUFFICIENTLY, THE VALVE

SPRING WILL FORCE THE VALVE PISTON BACK. OPENING THE GAS BYPASS FROM THE DIS CHARGE MANIFOLD TO THE

SUCTION MANIFOLD.

-CYLINDER DISCHARGE VALVE

-VALVE PLATE

THE UNLOADED CYLINDER BANK

WILL CONTINUE TO OPERATE

FULLY UNLOADED UNTIL THE

SOLENOID VALVE CONTROL DE

VICE IS DE-ENERGIZED AND

THE GAS BYPASS PORT IS

CLOSED.

Fig. 23 - D7DA210,112,215 Compressor with Cylinder Head Unloading - Cylinder Bank Unloaded

2. WITH THE SOLENOID VALVE DE ENERGIZED THE SOLENOID VALVE STEM WILL CLOSE THE GAS BYPASS PORT

1. DISCHARGE PRESSURE

BLEEDS FROM THE DIS CHARGE MANIFOLD THROUGH THE STRAINER AND BLEED ORIFICE TO THE SOLENOID VALVE STEM CHAMBER AND THE BACK OF THE PISTON BYPASS VALVE.

Dl SCHARGE VALVE MANIFOLD

h. CYLINDER DISCHARGE PRES

SURE WILL FORCE OPEN THE DISCHARGE PISTON CHECK

VALVE ASSEMBLY. REFRIG

ERANT GAS WlLL PASS INTO THE COMPRESSOR DISCHARGE MANIFOLD.

3. REFRIGERANT PRESSURE WILL OVERCOME THE BYPASS VALVE SPRING TENSION AND FORCE THE PISTON FORWARD CLOSING THE GAS BYPASS FROM THE DISCHARGE MANIFOLD TO THE SUCTION MANIFOLD.

CYLINDER DISCHARGE VALVE

-VALVE PLATE .CYLINDER SUCTION

VALVE

5. THE LOADED CYLINDER BANK WILL CONTINUE TO OPERATE FULLY LOADED UNTIL THE SOLENOID VALVE CONTROL DEVICE

IS ENERGIZED AND THE GAS BYPASS PORT IS OPENED,

Fig. 24 - 07DA210,! 12,215 Compressor with Cylinder Head Unloading - Cylinder Bank Loaded

06D,07D INSTALLATION

TURN CLOCKWISE TO INCREASE ACTUATING PRESSURE} COUNTERCLOCKWISE TO DECREASE

LOADING POINT MAY BE SET

ANYWHERE FROM 0-PSIG

TO 85-PSIG MAX.

Carrier

DIFFERENTIAL ADJUSTMENT REMOVE SEALING CAP AND

TURN CLOCKWISE TO INCREASE

DIFFERENTIAL j

COUNTERCLOCKWISE TO DECREASE. ONE TURN = 2-PSI REPLACE AND TIGHTEN

SEALING CAP.

DIFFERENTIAL MAY BE ADJUSTED FROM 6-PSI MIN. TO 22-PSI MAX.

(A) UNLOADED OPERATION

(B) LOADED OPERATION

Fig. 25 - Pressure Actuated Capacity Control System - 06D Compressors

Carrier

INSTALLATION 06D,07D

Pressure Operated Capacity Control Valve Operation

This valve is self-contained in that no wiring or external controls such as pressurestats or thermostats are needed as on the solenoid ca

pacity control valve.

This valve is interchangeable with the sole noid capacity control valve now used on the

6D compressors.

It is also interchangeable between the 06D and 06E compressors.

This valve is a self-actuated cylinder head by pass type which is suction pressure operated. The valve operation is such that the controlled cylinders will not load up until a differential of 25 psi between suction and discharge pres sure is established.

There can be a control valve in each side bank

of the six cylinder compressors. Each of the

control valves will load or unload two cylinders

in a single bank of the compressor by allowing

the discharge gas to bypass to the suction side thru the bypass port. The unloaded cylinders then operate thru no pressure differential, thus consuming very little power.

the compressor upon shutdown within 50 psi dif ferential very quickly so that on start-up the compressor will have very little head pressure to start against. There is a possibility of short

cycling on pumpdown because of a short equal

ization time. Therefore, we recommend single

pumpout or liquid line solenoid drop with crank

case heaters. The control load up or set point (Fig. 26) is ad

justable from -40 F (0-psig) to +50 F (85-psig) and is set in the field for individual job require ments. The set point adjustment is made by turning clockwise to increase the control pres sure (load up) and counterclockwise to decrease the control pressure point.

SET POINT ADJUSTMENT

When the suction pressure drops due to decrease in load, the poppet valve will snap open, as shown in Fig. 25A. The discharge gas behind the piston will now bleed out to the suction manifold, re ducing the pressure behind the bypass piston and allowing the bypass piston spring to pull the pis ton back against the valve body. The bypass pis ton port will then open allowing discharge gas to recirculate back to the suction manifold.

When the suction pressure is above the valve set point, the poppet valve will be closed, as shown in Fig. 25B. Discharge gas will now bleed

into the valve chamber. The pressure will then

overcome the bypass valve spring tension and force the piston forward, sealing the bypass port. The two cylinders controlled by this valve will now run fully loaded.

The check valve in the valve plate will close when the cylinder bank is unloaded, isolating the individual cylinder bank from the discharge man ifold. When the bank loads up, the discharge gas pressure will force open the check valve, allow ing the gas to pass into the discharge manifold.

Pumpdown control is NOT recommended when using these valves because of a bleed in the differential chamber. This device will equalize

DIFFERENTIAL ADJUSTMENT

BYPASS PISTON RING

DIFFERENTIAL SCREW SEALING CAP

Fig. 26 - Capacity Control Valve

To Adjust - The set point head should be turned clockwise down to the bottom stop. The coun terclockwise turns can be determined by using the curve in Fig. 27. If the desired load up point

is known, the number of turns can be picked off the curve.

The differential adjustment (Fig. 26) will vary the pressure difference between the cut-in and cutout point from 6- to 22-psi. This differential adjustment is made by removing the sealing cap and turning the inside screw clockwise to increase the differential and counterclockwise to decrease the differential.

06D,07D INSTALLATION

I 2 3 4 5 6 7 8 9 10 II 12

TURNS OUT FROM BOTTOM STOP-COUNTERCLOCKWISE

Fig. 27 - Control Set Point

234 56789 10

TURNS IN FROM BACKSTOP - CLOCKWISE

Fig. 28 - Differential Set Point

To Adjust - The differential screw should be turned counterclockwise out to the back stop. If the desired differential is known, the number of turns can be determined from Fig, 28.

CHECK THE INSTALLATION

After the unit has been checked for leaks, put into operation, and all adjustments made, check the following:

1. Make sure the shipping bolts have been re moved from the compressor.

07DA501005

2. See that the shut-off valves are backseated.

3, Tighten all shut-off valve packing nuts and

replace the caps.

4, Pick up all tools and clean up around the unit.

5. Make sure there is adequate air circulation around the unit.

6. Instruct customer in the operation of the unit.

6-65

Carrier 07D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

CONTENTS

INSPECT SHIPMENT FOR LOSS AND DAMAGE

CODE COMPLIANCE

ELECTRICAL REQUIREMENTS

SET THE UNIT IN PLACE

POWER AND CONTROL CIRCUIT SCHEMATIC

Fig, 14 - Wiring Label 07D Condensing Units, 06D Compressor Units (3-Phase)

Fig. 16 - Field Wiring for 06D, 07D Units

Fig. 16 - Field Wiring for 06D, 07D Units (Confd)

PIPING AND ACCESSORIES

Elimination of Pipe Vibration

Time Guard Control Operation

Starting Sequence of Time Guard Control (Single Pump-Out Arrangement Shown)

Operating Condition of Time Guard Control (Single Pump-Out Arrangement Shown)

Stopping Sequence of Time Guard Control (Single Pump-Out Arrangement Shown)

Shut-Off Valves

Crankcase Heater

Liquid Line Strainer-Drier

Flare Connections

Soldering and Brazing Piping to Valves

Water Regulating Valves (Water-Cooled Units Only)

Liquid Line Solenoid Valve (Field Supplied)

Liquid Line Sight Glass

Condenser Water Connections

The Halide Leak Detector

LEAK TEST THE SYSTEM

Description and Use of the Vacuum Indicator

Procedure for Dehydrating the System

CHECK REFRIGERANT CHARGE

CHECKING OPERATIONS

Dual Pressurestat

INITIAL START-UP INSTRUCTIONS

Water-Cooled Units

Lubrication

Water Valve Adjustment (Water-Cooled Units Only)

Factory Oil Charge

Solenoid Valve Electrical Characteristics

Fig. 24 - 07DA210,! 12,215 Compressor with Cylinder Head Unloading - Cylinder Bank Loaded

(B) LOADED OPERATION

Fig. 25 - Pressure Actuated Capacity Control System - 06D Compressors

Pressure Operated Capacity Control Valve Operation

CHECK THE INSTALLATION