Carrier 5F User Manual

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Page 1

5F,H

HEATING A COOLING

Open-Drive Compressors

• Installation, Start-Up and Service Instructions

CONTENTS

Page

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

INSTALLATION

Step 1 — Prepare for Installation

.......................................................

............................

• PREPARE EQUIPMENT ROOM

Step 2 — Receive Machine

.....................................

• BEFORE UNLOADING

• RIG UNIT CAREFULLY

Step 3 — Install Unit

..............................................

• TO MOUNT MOTOR ON BASE

• TO MOUNT CARRIER COMPRESSOR UNITS AND CONDENSER PACKAGES

• TO MOUNT COMPRESSOR BASE ON SUPPORT STANDS

Step 4 — Assemble Refrigerant Piping

and Components.................................................... 10

• COMPRESSOR DISCHARGE PIPING

• REFRIGERANT DRIER

• FELT FILTERS

Step 5 — Install Multiple Compressors

................

• EQUALIZING LINES

Step 6 — Make Electrical Connections

................

• GENERAL NOTES

• ATTACH POWER WIRES TO COMPRESSOR MOTOR

• CHECK MOTOR ROTATION

• INSTALL CRANKCASE HEATER

Step 7 — Check Compressor/Motor

Alignment............................................................ 13

• BELT DRIVE

• DIRECT DRIVE

• HOT CHECK AND DOWELING

Step 8 — Assemble Water Piping Step 9 — Prepare Lubrication System

........................

.................

• INSTALL OPTIONAL EQUIPMENT

• CHECK OIL LEVEL

PREPARE FOR INITIAL START-UP....................... 13

Evacuate, Dehydrate, and Leak Test

...................

Refrigerant Charging ............................................ 13

START-UP............................................................... 13

Preliminary Steps

..................................................

Start Compressor................................................... 14

Check Control Operation

.....................................

Check High-Pressure Switch................................ 14

Check Low-Pressure Switch

...............................

Adjust Capacity Control (if required)................... 14

SCHEDULED MAINTENANCE............................... 17

Check Lubrication System

...................................

Check Water-Cooled Heads.................................. 19

SERVICE INSTRUCTIONS Service Notes

.........................................................

Lubrication System Pressure-Relief Valves

Suction Strainer

.....................................................

Cylinder Head and Valve Assemblies

.....................................

...............................................

..........................................

..................

19 19 19 26 26

Cylinder and Unloader Sleeves............................ 27

Connecting Rods and Pistons Capacity Control Operation

.............................

..................................

28 28

1 1

Capacity Control Inspection and Service Crankshaft Inspection and Service Pump-End Main Bearing

............................................

.........................

Center Main Bearing.................................................... 33

Seal-End Main Bearing

..............................................

Crankshaft Seal Inspection and

Replacement.............................................................. 34

TROUBLESHOOTING

.................................................

SAFETY CONSIDERATIONS

Installation, start-up and servicing of this equipment can be hazardous due to system pressures, electrical components and equipment location.

Only trained, qualified installation and service per

sonnel should install, start-up or service this equipment.

When working on this equipment, observe precautions

in the literature, tags, stickers and labels attached to the

equipment and any other safety precautions that apply.

• Follow all safety codes.

• Wear safety glasses and work gloves.

• Use care in handling, rigging and setting bulky

equipment.

A WARNING

Before performing service or maintenance operations on unit, shut off and tag main power supply to unit. Electrical shock could cause personal injury.

INSTALLATION

Step 1 — Prepare for Installation

PREPARE EQUIPMENT ROOM — Locate compres sor or condensing unit in a well-ventilated area. If natural

ventilation is inadequate, provide forced ventilation

through ductwork. Check applicable code requirements.

Provide freeze-up protection for water-cooled con

densers, water lines and accessories if freezing tempera tures can occur during winter shutdown periods.

Provide sufficient clearance for removal of compressor

cylinder heads and valve plates. Allow space on the oil

pump end for crankshaft removal as follows:

5F20, 30, 40, and 60 compressors...............................20in.

5H40, 46, 60, and 66 compressors

5H80, 86, 120, and 126 compressors

Provide space equal to condenser length for tube

removal and cleaning.

Step 2 — Receive Machine (Fig. 1 through 8)

BEFORE UNLOADING — Check unit nameplates against model and serial numbers recorded in job speci fications. Check all items against shipping list, and examine items carefully for any shipping damage. If damage is found or any major component has torn loose from its anchorage, have transportation inspectors examine it before unloading. File claim immediately with shipping company for any loss or damage.

..............................

..........................

(Continued on page 10.)

______

Page

31 32

33 34

20 in. 30 in.

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

Book

Tab

PC 111

Catalog No 530-526

Printed inUS A Form5F,H-11SI

For replacement Items use Carrier Specllled Parts

Pg 1

2-86 Replaces: 5F,FI-9SI

Page 2

5F,H

HKATtNG A COOLING

OIL FILLER PLUG 5/8"-18

OIL PRESSURE CONNECTION' 1/4" IPS

OIL DRAIN PLUG 5/8"-18

Open-Drive Compressors

SUCTION SHUTOFF VALVE

I- I /8" ODF

GAGE CONNECTION

1/4" IPS

OIL PUMP ROTATION ARROWS

CRANKCASE HEATER CASING (PIPE CAP 1/2" FPT)

PUMP INTAKE PLUG (MAGNETIC)

DISCHARGE SHUTOFF. VALVE-7/8^ ODF

SUCTION AND DISCHARGE MANIFOLD COVER-REMOVE

FOR ACCESS TO SUCTION STRAINER

SEAL COVER

OIL PRESSURE REGULATOR

Fig. 1 — 5F20; 2-Cylinder Compressor

GAGE CONNECTION

1/4" IPS

OIL PRESSURE CONNECTION 5/8" - 18

OIL LEVEL SIGHT GLASS

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

Book 12

PC111 Catalog No 530-526 PrintedinUSA Form 5F,H-11SI Pg2 588 2-86 Replaces: 5F,H-9SI

For replacement Items use Carrier Specified Parts

Page 3

5F,H

HEATING A COOLING

DISCHARGE SHUTOFF VALVE 1-3/8" ODF

GAGE CONNECTION

1/4"-IPS

SEAL COVER

Open-Drive Compressors

OIL PRESSURE REGULATING VALVE

OIL LEVEL SIGHT

GLASS

OIL FILLER PLUG 5/8"-18

OIL PRESSURE CONNECTION 5/8"-18

OIL PRESSURE CONNECTION 1/4" IPS

OIL DRAIN PLUG (HIDDEN) 5/8"- 18

PUMP INTAKE PLUG (MAGNETIC) 5/8 '-18

Fig. 2 — 5F30; 3-Cylinder Compressor

SUCTION SHUTOFF VALVE

1-5/8" ODF (REMOVE FOR ACCESS TO SUCTION STRAINER)

1/4" IPS GAGE CONNECTION

OIL PUMP ROTATION ARROWS

CRANKCASE HEATER CASING (PIPE CAP 1/2" FPT)

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

Book|2 PC 111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg3 2-86 Replaces: 5F,H-9SI

Tab 2a

For replacement Items use Carrier Specitled Parts.

Page 4

5F,H

HEATING A COOLING

DISCHARGE SHUTOFF VALVE 1-3/8" ODF

HIGH-PRESSURE CONTROL CONNECTION

1/4" IPS

SUCTION MANIFOLD COVER PLATE (REMOVE FOR ACCESS TO SUCTION STRAINER)

OIL PRESSURE REGULATOR

SEAL COVER

DOWEL HOLE

Open-Drive Compressors

1/4" IPS GAGE CONNECTION

1/4 IPS PNEUMATIC CONTROL CONNECTION

OIL PUMP PRESSURE

3/8 IPS OPENING TO CRANKCASE

CONTROL OIL PRESSURE

CAPACITY CONTROL VALVE

CRANKCASE HEATER CASING (PIPE CAP 1/2" FPT)

SUCTION SHUTOFF VALVE

1-5/8" ODF

OIL FILLER PLUG 5/8"-18

OIL PRESSURE CONNECTION

1/4" IPS

DOWEL HOLE.

PUMP INTAKE PLUG (MAGNETIC)5/8"-l8

NAMEPLATE

Fig. 3 — 5F40; 4-Cylinder Compressor

1/4" IPS GAGE CONNECTION

OIL PUMP ROTATION ARROWS

OIL DRAIN PLUG 5/8 -18

LOW-PRESSURE CONTROL CONNECTION TO DUAL PRESSURESTAT 1/4" IPS

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

Bool<|2 PC 111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg4 2-86 Replaces: 5F,H-9SI Tab 2a

For replacement items use Carrier Specified Parts.

Page 5

5F,H

HEATING A COOLING

SUCTION SHUTOFF VALVE

2-1/8" ODF

DISCHARGE SHUTOFF VALVE 1-5/8" ODF

HIGH-PRESSURE CONTROL CONNECTION (HIDDEN) 1/4" IPS

LOW-PRESSURE CONTROL CONNECTION 1/4" IPS

SEAL COVER

DOWEL HOLE

Open-Drive Compressors

1/4" IPS PNEUMATIC CONTROL CONNECTION

CONTROL OIL PRESSURE

CAPACITY CONTROL VALVE

OIL PRESSURE REGULATOR

CRANKCASE HEATER CASING{PIPE CAP 1/2" FPT)

SUCTION MANIFOLD (REMOVE FOR ACCESS TO SUCTION STRAINERS)

OIL FILLER PLUG

5/8"-l8

OIL PUMP PRESSURE

CONTROL OIL STRAINER

OIL PRESSURE CONNECTION 1/4" IPS

3/8" IPS (OPENING TO CRANKCASE)

PUMP INTAKE PLUG (MAGNETIC) 5/8"-18

OIL DRAIN PLUG 5/8"-18

Fig. 4 — 5F60; 6-Cylinder Compressor

NAMEPLATE

OIL PUMP ROTATION ARROWS

PRESSURE CONTROL SWITCH STUDS

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

Book|2 PC 111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg5 2-86 Replaces: 5F,H-9SI Tab |2a

For replacement items use Carrier Specified Parts.

Page 6

5F,H

HEATINQ t COOLING

HIGH-PRESSURE CONNECTION 1/4" IPS

SUCTION GAGE CONNECTION

1/4" IPS

SUCTION SHUTOFF VALVE 2-5/8“ OOF

PNEUMATIC CONTROLCONNECTION

1/4" IPS

CAPACITY CONTROL VALVE'

DRAIN PLUG

NAMEPLATE

Open-Drive Compressors

DISCHARGE SHUTOFF VALVE 2-1/8" ODF

LOW PRESSURE CONNECTION 1/4" IPS

OIL PUMP ROTATION ARROW

OIL FILLER PLUG 5/8 -18

CONTROL OIL PRESSURE

OIL LEVEL SIGHT GLASS

CRANKCASE DRAIN

SUCTION DISCHARGE MANIFOLD COVER (REMOVE FOR ACCESS TO SUCTION STRAINER AND HIGH-PRESSURE RELIEF VALVE)

OIL PRESSURE REGULATOR

SEAL COVER PLATE

Fig. 5 — 5H40, 46; 4-Cylinder Compressors

DISCHARGE GAGE CONNECTION 1/4" IPS

HIGH-PRESSURE CONTROL CONNECTION 1/4" IPS

OPENING TO CRANKCASE (HIDDEN)

1/4" IPS

OIL PUMP PRESSURE

PLUGGED OPENINGS FOR INTERCONNECTION (NOT STANDARD)

CRANKCASE HEATER CASING (PIPE CAP 1/2" FPT)

DOWEL HOLE

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

Book|2 PC 111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg6 2-86 Replaces: 5F,H-9SI

Tab |2a

For replacement Items use Carrier Specltled Parts

Page 7

5F,H

.......CO.... Open-Drive Compressors

^ DISCHARGE SHUTOFF " I

'PS 3-1/8 OOF

i ^ . .

......................

J W-

HIGH-PRESSURE CONTROL ’’'i ; CONNECTION 1/4" IPS--------------------------------ig ?■

SEAL COVER PLATE—^ ■- sjfe-^ , (NOT STANDARD)

OIL PRESSURE REGULATORc^SmB .CRANKCASE HEATER

EilllllllllllllllKi^ № «>.

* C ■"

-DOWEL HOLE

PLUGGED OPENINGS

^ FOR INTERCONNECTION

CASING (PIPE CAP 1/2" FPT)

PNEUMATIC CONTROL CONNECTION 1/4" IPS

OPENING TO CRANKCASE 1/4" IPS

OIL PUMP PRESSURE (HIDDEN)

CAPACITY CONTROL VALVE

CONTROL OIL STRAINER PLUG 5/8"-18

PUMP INTAKE PLUG MAGNETIC 5/8"-18

Fig. 6 — 5H60. 66; 6-Cylinder Compressors

CRANKCASE DRAIN

ACCESS TO HIGHPRESSURE RELIEF VALVE

SUCTION MANIFOLD

(REMOVE FOR ACCESS

TO SUCTION STRAINER)

OIL FILLER PLUG 5/8"-18

CONTROL OIL PRESSURE

OIL LEVEL SIGHT GLASS

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

Book I2 PC111 Catalog No 530-526 Printed in U.S A Form5F,H-11Si Pg7 588 2-86 Repiaces: 5F,H-9Si

Tab 2a

For replacement items use Carrier Specified Parts.

Page 8

5F,H

HEATING & COOLING

HIGH-PRESSURE RELIEF VALVE AND MANIFOLD COVER PLATE

SEAL COVER PLATE

OIL PRESSURE REGULATOR

Open-Drive Compressors

NAMEPLATE

plugged openings

FOR interconnection

{NOT STANDARD)

CRANKCASE HEATER CASINGS (PIPE CAP 1/2" FPT)

SUCTION SHUTOFF VALVE 3-1/8“ ODF

SUCTION MANIFOLD COVER (REMOVE FOR ACCESS TO SUCTION STRAINER)

PNEUMATIC CONTROL CONNECTION 1/4" IPS

OPENING TO CRANKCASE 1/4" IPS

CAPACITY CONTROL VALVE ADJUSTING STEM

CONTROL OIL STRAINER PLUG 5/8"-18

OIL FILLER PLUG

CRANKCASE DRAIN

Fig. 7 — 5H80, 86; 8-Cylinder Compressors

DISCHARGE SHUTOFF VALVE 3-1/8" ODF

GAGE CONNECTIONS

1/4" IPS

HIGH-PRESSURE CONTROL CONNECTION 1/4" IPS

LOW-PRESSURE CONTROL CONNECTION 1/4" IPS

CENTER MAIN BEARING RETAINING SCREW ACCESS

OIL PUMP ROTATION ARROW (TAG)

- CONTROL OIL PRESSURE

OIL LEVEL SIGHT GLASS

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

Book|2 PC 111 Catalog No 530-526 PrintedinUSA Form 5F,H-11SI Pg8 588 2-86 Replaces; 5F,H-9SI

Tab T2a

For replacement items use Carrier Specified Parts

Page 9

5F,H

HEATING A COOLING

DISCHARGE SERVICE-

VALVE 4-1/8" ODF

GAS EQUALIZER CONNECTION

OIL EQUALIZER CONNECTION

OIL PUMP PRESSURE (BEFORE OIL FILTER)

FULL FLOW HIGH-PRESSURE OIL FILTER

Open-Drive Compressors

RELIEF VALVE DISCHARGE PRESSURE

SUCTION SERVICE VALVE 4-1/8 "ODF

SUCTION MANIFOLD COVER PLATE (REMOVE FOR ACCESS

TO SUCTION STRAINER)

OIL FILLER PLUG (ALSO USED FOR LOW-PRESSURE OIL LINE CONNECTION)

CAPACITY CONTROL VALVE

OIL PUMP ROTATION ARROW ON OIL PUMP COVER

CONTROL aL PRESSURE CONNECTION 1/4' FPT

CRANKCASE DRAIN PLUG OIL PRESSURE GAGE SHUTOFF

VALVE (AFTER OIL FILTER)

DISCHARGE GAGE CONNECTION 1/4" IPS

OIL PRESSURE REGULATOR

CENTER MAIN BEARING RETAINING SCREW ACCESS

(HIDDEN)

SEAL COVER PLATE

SUCTION MANIFOLD OIL PASSAGES

Fig. 8 — 5H120, 126; 12-Cylinder Compressors

SUCTION GAGE CONNECTION

1/4" IPS

LEVEL SIGHT GLASS

(ON OPPOSITE SIDE OF COMPRESSOR)

HIGH-PRESSURE OIL CONNECTION 1/4“ IPS

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

Book [2 PC 111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg9 2-86 Replaces: 5F,H-9SI Tab 12a For replacement items use Carrier Specified Parts.

Page 10

5F,H

HEATING A COOLING

RIG UNIT CAREFULLY — Check that rigging equip ment can safely handle the approximate equipment weights for compressors and condensing units.

Rig and move unit earefully to prevent damage to

mounting brackets, refrigerant piping or connections.

Step 3 — Install Unit

TO MOUNT MOTOR ON BASE -- The motor fasten ing set supplied with all compressor units (except 5F20, 30, and all OEM models) includes motor blocks and shims for motor alignment; cap screws, plate washers and lock washers for fastening motor to base; taper dowel pins for securing motor position after alignment; and beveled washers for fastening the unit base to accessory vibration isolators.

If vibration isolators are used, attach to base (Fig. 9) To avoid damaging the isolators, lift unit from ends when attaching isolators.

With compressor and motor positioned on the base,

check the height of the vibration isolators. Shim between

isolators and floor as required to level compressor base. When level, secure vibration isolators to floor. Check that beveled washer (Fig. 9) is in place.

Open-Drive Compressors

Remove soldered shipping cap from hot gas inlet. To prevent solder from dripping into inlet pipe while un soldering, rotate condenser until pipe is below horizontal position. Return inlet to upright vertical position.

Tighten lower support straps enough to lift condenser off stands. Place upper straps loosely in position with a strip of protective material between condenser and strap (5F20 and 5F30 units use lower strap only).

TO MOUNT COMPRESSOR BASE ON SUPPORT STANDS — Place compressor base on support stands with 2 extra strips of protective material between top of condenser and base. Bolt base into position with cap screws and lock washers provided.

Step 4 — Assemble Refrigerant Piping and Com ponents — Refrigerant connection sizes are given in

Table 4. COMPRESSOR DISCHARGE PIPING — Refer to

Condensing Unit Piping Installation Instructions for information.

REFRIGERANT DRIER — A replaceable-core filter drier is recommended for most systems, and is essential on all low-temperature systems. Mount the field-supplied filter drier in the liquid line. Include a shutoff valve to permit isolation of drier for servicing (Fig. 10).

Install a moisture indicator on downstream side of

drier to indicate when drier cartridges need replacing.

FELT FILTERS — Install felt filter supplied with com pressor in suction strainer (Fig. 1 through 5). Remove filter after 50 hours of operation. If clean, discard it; if dirty, clean with kerosene or neutral spirits and insert for another 50 hours of operation.

filter was cleaned and reinstalled. Figure 10 and Table 1

give information on replacement filter packages.

Tag unit to show date that

Fig.

Fig. 9 — Typical Vibration Isolator Mounting

TO MOUNT CARRIER COMPRESSOR UNITS AND CONDENSER PACKAGES — Bolt the compressor’s lower support straps loosely to underside of each support stand and place strips of protective material, such as

COMPRESSOR

Fabrica, on straps. Position condenser on stands with hot gas inlet at top of condenser and liquid shutoff valve connection facing compressor end of base. Check that condenser overhangs support stands for same distance on each end.

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

Book|2 PC111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI PglO 2-86 Replaces: 5F,H-9SI

Tab 2a

For replacement Items use Carrier Specified Parts.

10 — Refrigerant Filter Drier and

Shutoff Valve Arrangement

Table 1 — Suction (Felt) Filter Packages

FILTER PACKAGE PART NO.

5F40 5F60 5H40,46 5H60,66 5H80,86 5H120,126

5F40-A352 5F60-A352

5H40-A382 5H60-A382 5H80-A382 5H120-A382

Page 11

5F,H

HEATING A COOLING

Step 5 — Install Multiple Compressors

EQUALIZING LINES — Compressors operating in parallel require interconnecting lines for oil and gas pressure equalization. Special handhole cover plates, equipped with tapped holes for equalizing lines, are avail able as options for sizes 5F40 and 5F60, as well as for sizes 5H40, 46, 60, 66, 80, and 86 eompressors (Fig. 11). An oil float system is an acceptable alternative to

equalizer lines.

5H120 and 126 Compressors include factory-supplied, tapped cover plate. On these compressors, use only lower connection for oil equalization (Fig. 11). Connect

gas equalizing line to flange connection shown. Mat

ing flange for 1-1/8 in. line is Carrier Part No. DK24CA712 (Mueller Part No. A-5151); gasket Part No.

is DK29GA005 (Mueller Part No. A-5152).

GAS EQUALIZER CONNECTION

i4"od flange

(5HI20-I26 ONLY!

Open-Drive Compressors

Step 6 — Make Electrical Connections

GENERAL NOTES

1. Factory wiring complies with National Electrical Code (NEC). Any field modifications or additions must comply with all applicable codes.

2. *For control circuit information, refer to Accessory Control Panel Installation Instructions.

3. If control circuit power is supplied from a separate

source, rather than from a transformer, bring 115-v power through a field-supplied, 15-amp disconnect, in compliance with NEC Section 440-14 (disconnect must be in sight from and readily accessible from unit).

4. Open control-power disconnect only when servicing

unit. Crankcase heaters must remain energized

when unit is not operating.

5. *Factory wiring is for single pumpout control. Do not use pumpout control on equipment used with DX coolers. Wiring label shows field connections used with DX cooler.

6. *Contactor C2 is used with 208-v motors, 25 through 60 hp, and 460-v motors, 50 through 150 hp.

7. *When field interlocks are used, remove jumpers between terminals 3 and 4, and between terminals 7 and 8 on TB2.

♦Refers to compressor units and condensing units only.

OIL EQUALIZER

connection

l" IPS

GAS EQUALIZE

connection

Fig. 11 — Special Handhole Cover and

Equalizer Connections (Typical)

5F20 and 30 Compressors have no special tapped cover plate. Use opening for oil sight glass to attach the I -1 / 8 in. line for gas and oil equalization (Fig. 12). Accessory Package No. 06DA900072 provides two I/8-in. line adapters to thread into the sight glass opening. If addi tional equalization is desired, run a 3/8-in. line to the oilfilter plug connection (Fig. I and 2).

ATTACH POWER WIRES TO COMPRESSOR

MOTOR — Attach power wires in accordance with motor manufacturer’s instructions and in compliance

with NEC and applicable local codes.

CHECK MOTOR ROTATION — Before connecting motor to compressor, check direction of motor rotation.

Rotation must be in same direction as that indicated by arrow on compressor pump cover (or on plate attached near pump-end bearing housing). If direction is not the

same, reverse motor rotation by reversing any 2 power

leads to motor.

If rotation of oil pump is reversed, reverse direction of pump rotation arrow as well. At that time make the following adjustments:

All 5F Compressors and 5H120and 126 Compressors — Remove 6 cap screws from oil pump cover (Fig. 1-4, 8). Do not damage gasket. Rotate cover 180 degrees and replace. Arrow at top of oil cover will indicate new direc tion of rotation.

5F40, 46, 60. 66. 80 and 86 Compressors — Drain oil below level of pump-end dome cover (Fig. 5-7). Remove pump-end cover to expose oil pump cover in center of

main bearing housing. Rotate oil pump cover 180 degrees and replace it. Replace pump-end cover and reverse external arrow to match new direction of rotation. Proper direction can later be checked without removing pumpend cover.

A CAUTION

If the special gasket between oil pump cover and oil pump is damaged, replace with correct gasket only. Check oil pressure immediately after starting

Fig. 12 — Equalizer Connections (5F20 and 5F30)

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

BookI 2 PC 111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pgll 2-86 Replaces: 5F.H-9SI

For replacement items use Carrier Specitled PartsTab 2a

compressor.

Page 12

5F,H

HEATING A COOLING

INSTALL CRANKCASE HEATER — Wire heater to relay or set of normally closed auxiliary contacts on compressor starter to de-energize it when compressor is operating.

Remove rubber plug from crankcase heater casing

(Fig. 1-8), and insert heater element entirely into casing.

Element should fit snugly, not loosely. Wire to comply with applicable electrical codes.

When crankcase heater is installed, system can be operated on single pumpout cycle, unless used with a DX cooler.

Table 2 lists crankcase heater packages. Table 3 shows corresponding relays. Use of 2 heaters on a 5H80 or 5H120 compressor requires only one relay.

Control circuit voltage determines relay coil voltage.

This voltage must be specified when ordering relays.

See Accessory Compressor Crankcase Heater Instal

lation Instructions for additional information.

Table 4 — Physical Data

COMPRESSOR UNIT AND

CONDENSING UNIT REFRIGERANT COMPRESSOR DATA

Maximum Rpm Minimum Rpm Minimum Rpm Capacity

Control

Number of Cylinders

Bore (in.) Stroke (In.)

Compressor Connections (in. O.D.)

Suction Discharge

Oil Charge* (pt) (See Notes) Normal Oil Pressure* Oil Flow Rate (gpm)

Oil Safety Switch

Cut-in (psig) (See Notes

Cutout (psig) 3 and 4)

High-Pressure Switchf

Cutout Range Differential (psi) Factory Setting (psig)

Low-Pressure Switchf

Cutout Range Differential (psi) Factory Setting (psig)

Low Side Maximum Pressure

CONDENSER DATA

Maximum Refrigerant Storage Capacity** (lb)

Minimum Refrigerant Operating Charge (ib)

Maximum Operating Pressure

Refrigerant Side Water Side

__________

___________

R-12 R-22 R-502

5F20 5F30

600

2'/2

5F40 5F60 5H40 5H46 5H60 5H66 5H80 5H86 5H120

700 800

2'/2

IVs 1%

2'/2

V/e

55 12 13 18 18 21 21 41

1 5_____________I_____________________

5F20f 5F30f 5F40

40 4 50 7 79.4 37 2

38.2 1 8 27

1.9 2.9

46.4 72 8

47.9 75.0 30 140

127 14.5 33.0

13.1 15.0 34.4 38.2

150 psig

900 800 800 900 900 1100

2'/2

2Ve VA

Open-Drive Compressors

Table 2 — 5F,H Compressor Crankcase

COMPRESSOR

5F20,30,40,60

5H40,46,60,66

5H80,86,120,126

Table 3 — Crankcase Heater Relay (60 Hz)

CONTROL CIRCUIT VOLTAGE

208/230

R-12, R-22, R-502

400 (required for proper lubrication)

3Va

2'A

45-55 psig above suction pressure —

150-395 (adjustable) nominal

Cutout, 300 ± 15, Cut-in, 210 ± 10

20 in Hg vac to 60 psig (adjustable)

Cutout, 50 ± 4; Cut-in, 120 ± 6

5F60

09RH-

89 6 154 212 82 0 139 193

84.6 145 199

027

160 37.0 41 0 51 0

1750

3’/4

2'A

3'A 3'A

3_0

15 - 19.5

11 - 15

60-150 (adjustable)

60-90 (adjustable)

245 psig

09RH-

043

37 0 46.0 46 0 71

09RH-

054

263 239 248 223 265 337

47.3 47.3 73 94

385 psig

Heater Package

ELECTRICAL

CHARACTERISTICS

Volts Watts

115 230

115

3'/4

3y,6

3'A 3'A

___________

3'/4

3'A 3'A

09RH-

070

238 282 358 475

216

51 0 78

250 psig

PACKAGE NO.

100 100

200 200

-5-F-20—381

-5-F-20—391

-5-H-40—381

-5-H-40—391

-5-J-40—281

-5-J-40—291

PART NO.

HN61AJ-101 HN61AJ-108

1100 900 900

3'/4

3V,6

3'A 3'A

3'/4

4'/e

4'A

61 61

4.5

09RH-

257

084

09RH-

097

327 432 100 126

91 114

3'/4

3V,6

4'A

09RH-

127

447

118

‘Nominal oil pressures shown in Physical Data table are above suction

pressure, i e , pressure differential between suction pressure and dis

charge pressure of oil pump tSee Table 5 for typical pressure switch settings fShell-and-coil condensers All other 5F,H condensers are shell-and-

tube

‘‘Condenser storage capacity 80% filled with liquid refrigerant at 90 F

NOTES: 1 Oil flow rate is the nominal oil pump capacity 2 The following oil (or equivalents) are specified for use in 5F,H

compressors 5F20 and 30: Witco Chemical Co — Suniso 4GS 5F40-5H126: Witco Chemical Co. — Suniso 3GS

3 Differential switch (oil safety switch) has time delay of 30 to 60 seconds 4 Oil safety switch has manual reset

Texaco, Inc — WF32 Shrieve Chemical Co — Zerol 150 (synthetic)

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

Book 12 PC 111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg12 2-86 Replaces: 5F,H-9SI Tab 12a

For replacement items use Carrier Specified Parts.

Page 13

5F,H

HEATING A COOLING

Step 7 — Check Compressor/Motor Alignment

BELT DRIVE — See Accessory Belt Drive Package manual for installation and alignment instructions.

DIRECT DRIVE — Install and align compressor, coupling and motor as described in manual for Flexible Couplings for Direct-Drive Units.

HOT CHECK AND DOWELING — To help maintain alignment, and to ensure exact repositioning of the motor after servicing, the motor and eompressor must be doweled to tbe base. Install doweling only after

motor!eompressor alignment has been hot checked (checked after the compressor has warmed up to oper ating temperature after initial alignment).

After hot check and while components are still at

Open-Drive Compressors

PREPARE FOR INITIAL START-UP

Evacuate, Dehydrate and Leak Test the entire

refrigerant system as described in Carrier Standard Service Techniques Manual, Chapter 1, Sections 1-6

and 1-7.

LEAK TESTING Preferred Method — Charge the system to 10 psig with

refrigerant. Add dry nitrogen or dry air (DO NOT USE OXYGEN) until system pressure is 150 psig. Check for leaks with a halide or electronic leak detector.

Alternate Method — Charge the system with dry nitrogen or dry air (DO NOT USE OXYGEN) to 40 psig and use soap-bubble test to find large leaks.

operating temperature, drill and ream 2 holes through diagonally-opposite motor and compressor feet and the base. Use a 9/32-in. drill and a no. 6 taper reamer. Secure the motor and compressor to the base with the no. 6 x 2-1/2 in. taper dowel pins provided in the motor fasten

Do not use compressor to build up pressure. Do not

overcharge the system.

A CAUTION

ing set.

Coat the dowels with white lead or other lubricant to prevent rusting, and tap the dowel lightly into position so that 1/16 of taper is left above the motor foot.

Check that all dowels are tight and that they do not

bottom.

Step 8 — Assemble Water Piping — See WaterCooled Condensers Installation Instructions and WaterCooled Heads Installation Instructions for information.

Step 9 — Prepare Lubrication System

INSTALL OPTIONAL EQUIPMENT — Consult local Carrier representative for information on these

accessories.

Refrigerant Charging — Use the sight glass method to charge the system. See Section 1-8 of Carrier Standard Service Techniques Manual, Chapter 1, for details.

Charge the system to a clear sight glass while holding saturated condensing pressure constant at 125 F for air cooled systems or 105 F for water-cooled systems. Add additional refrigerant to fill condenser subcooler coils, if required.

5F,H CONDENSING UNITS ^ After a clear sight glass is obtained, add charge until liquid refrigerant reaches the condenser liquid level test cock.

5F,H COMPRESSOR UNITS — See condenser data for additional charge requirements.

Oil Filter — Oil filter for 5H40 through 5H86 com pressors is available as separate accessory package. Refer to Accessory Oil Filter Package Installation Instructions for installation procedures.

If an accessory oil cooler is also installed (see below), pipe oil filter into system as shown on diagrams in Acces sory Oil Cooler Installation Instructions.

Oil Cooler — Refer to Accessory Oil Cooler Installation Instructions included with this accessory package. Readjust oil-cooler water flow so that it maintains specified oil temperature when compressor has reached operating temperature.

Oil Separator — If oil separator is used in system piping, pipe oil return line to compressor suction line. To mini mize possibility of flooding compressor with oil, oil return line diameter should not exceed 1/4 inch. In addi tion, line should have manual shutoff valve to throttle oil flow as required and to isolate separator for service.

CHECK OIL LEVEL — Check that oil level is visible

at center of compressor sight glass. Compressors that use

optional equipment such as filter, cooler, and oil separator described above will require a greater oil charge than listed in Table 4. Recheck oil level after operating compressor. If unit needs additional oil, use only dehydrated, wax-free, refrigeration-grade oil of suitable viseosity. Table 4 lists oil suitable for use in

reciprocating compressors.

Preliminary Steps

1. Energize crankcase heater for at least 24 hours before starting unit.

2. If control transformer is not used, operate electrical control circuit with main power switch OFF to ensure that field connections have been properly made.

3. Install felt sock filter for the first 50 hours of com pressor operation. Remove and inspect the filter, clean it if required and replace it for another 50 hours. Remove sock when system is clean. (Not applicable for 5F20 and 5F30 units.)

4. Cheek that motor rotates in direction that the arrow on the eompressor oil pump cover indicates. Refer to Installation, Step 5, under Check Motor Rotation.

5. Check that oil fills 1/3 to 1/2 of the compressor sight glass.

6. Open water supply valve to condenser. Open pressure line valve of water-regulating valve (if used). If eompressor unit is equipped with air-cooled con denser, turn on condenser fan.

7. Backseat (open) compressor suction and discharge service valves. Open liquid line valve at receiver.

8. Start evaporator fan or chilled water pump.

START-UP

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

Book 2 Tab

PC111

Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pgi3

For replacement Items use Carrier Specified Parts

2-86

Replaces: 5F,Fi-9SI

Page 14

5F,H

HEATING A COOLING

Start Compressor — Close main power switch supplying current to the compressor motor.

Immediately recheck oil level and check oil pressure.

Pressure should exceed suction pressure by 45-55 psi.

If correct pressure is not reached in 10-12 seconds, stop compressor immediately and check oil pump.

A CAUTION

If any safety device shuts down the compressor, do not reset the control more than once before deter

mining cause of shutdown.

Check Control Operation — Refer to Carrier Standard Service Techniques Manual, Chapter 2, for complete instructions on checking electrical components.

HIGH- AND LOW-PRESSURE SWITCHES — A115F and 5H units except 5F20 and 30 have factory-installed, automatic reset, high- and low-pressure switches. (These

switches are available as accessories for 5F20 and 30

units.) Figure 13 illustrates adjustment procedures for

both switches.

Check High-Pressure Switch — Throttle the con

denser water on water-cooled unit or block the airflow

on air-cooled unit, allowing head pressure to rise grad

ually. Compressor should shut off within 15 psi of cutout

value listed in Table 4. Now reverse procedure; com

pressor should start within 10 psi of cut-in value given.

Check Low-Pressure Switch — Slowly close the

suction service valve; suction pressure will decrease.

Compressor should shut off within 4 psi of cutout value

listed in Table 5. Reverse procedure; compressor should

start within 6 psi of cut-in value given.

Open-Drive Compressors

ROBERTSHAW

A-RANGE ADJUSTMENT SCREW

TOP

B-DIFFERENTIAL ADJ SCREW

RANCO

A-RANGE ADJUSTMENT SCREW

TOP

0'^B-

DIFFERENTIAL ADJ SCREW

Table 5 — Typical Pressure Switch Settings

PRESSURESTAT

REFRIG

ERANT

CONDENSER

Water-Cooled 175 95 16 76 Air-Cooled

Water-Cooled Air-Cooled 325

Water-Cooled 280 200 45

Air-Cooled 325

Hi!

(ps

Cutout Cut-in Cutout Cut-in

225 145 16 76 280 200 36

245 36

245 45

Low

(psig)

96 96

105 105

OIL PRESSURE SAFETY SWITCH — To check, move contact arm at left side of switch forward (Fig. 14). Compressor should stop in approximately 45 seconds.

If compressor continues to run, check the wiring to safety switch. If wiring is correct, switch is faulty and should be replaced.

After completing test, wait 3 minutes; then press

restart button on front of safety switch and restart

compressor.

Check oil level in compressor sight glass after 15-20 minutes of operation. If the oil level is low, add oil by the methods described in Carrier Standard Service Tech niques Manual, Chapter 1, Section 1-11.

If an accessory oil cooler is provided, adjust the water flow as required to maintain a lOOF to 120F crankcase return oil temperature.

Screw A raises or lowers both cutout and cut-in points by a like amount.

Range and Differential scales are on the front of the switch. High Pressure Set cutout point first, with screw A; then set

Low Pressure: Set cut-in point first, with screw A, then set

cut-in point with screw B cutout point with screw B

LOCATION AND ADJUSTMENTS

Fig. 13 — High- and Low-Pressure Switches

For additional information, see Oil Safety Switeh

Accessory Package Installation Instructions.

Adjust Capacity Control (if required) — See

Fig. 17 for unloading sequence.

5F20 AND 5F30 COMPRESSORS ^ Referto Capacity Control Valve Installation Instructions for additional information.

5F40 THROUGH 5H126 COMPRESSORS — Deter mine the refrigerant usage:

If the system is to use R-I2, replace the 11-lb range

adjustment spring (Fig. 15) with the 7-lb spring .supplied

with compressor. A change in 1982 reversed which range

adjusting spring a customer received. The R-22/R-502 spring is now standard with the compressor. See instruc tion tag for spring replacement procedure.

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

Book! 2 PC111 Catalog No 530-526 PrIntedInUSA Form5F,H-11SI Pg14 2-86 Replaces: 5F,H-9SI

Tab 2a

For replacement items use Carrier Specified Parts.

Page 15

5F,H

HEATING A COOLING

CONTACT ARM

HIGH-PRESSURE CONNECTION TO OIL PUMP DISCHARGE

Fig. 14 — Oil Pressure Safety Switch

RESISTANCE

CONNECT IN SERIES WITH CONTROL CIRCUIT

REFER TO UNIT LABEL

WIRING DIAGRAM)

LOW-PRESSURE

CONNECTION

TO CRANKCASE

240 VAC

VAC

Open-Drive Compressors

An external adjusting stem (Fig. 15) sets the control point (suction pressure at which first step of cylinder unloading occurs). The control point is adjustable as follows:

R-22 and R-502 .............................................. 0 to 85psig

R-12................................................................. 0to50psig

One full clockwise turn of adjusting stem will raise the control point approximately 6psig with R-12, or lOpsig with R-22 and R-502.

Control oil pressure is an indication of cylinder loading condition (Table 6). Refer to Fig. 3-8 for location of control oil-pressure gage connection. See Accessory

Unloader Paekage Installation Instructions for addi

tional information.

Table 6 — Control Oil Pressures for

Cylinder Loading and Unloading

APPROXIMATE

COMPRESSOR STEP*

5F20 1 19 8 5F30

5F40,60; 1 30.0 5H40,46, 2 60,66,80, 3

86,120,126

1 2

4 20 0

CONTROL OIL PRESS. (psIg)

Loading Unloading

13.0

30 0 198

26.0 160 23 0

20 2 130

19.0 120

9.0

SPRING DETAILS

7-LB SPRING

R-12 USAGE

11-LB SPRING

R-22, R-502

USAGE

‘Capacity control reduction steps

To Adjust Control Point

1. Impose an artificial load on the compressor until suction pressure exceeds control point.

2. Slowly close suction valve to lower compressor suction pressure to eontrol point pressure.

3. When at control point pressure, turn external adjusting stem clockwise until first step of unloading takes place, as indicated by ehanges in control

oil pressure, current draw and sound of compressor.

Control point is now set. Reopen suction service valve.

Compressor will be fully loaded when suction pressure is

3psig (4psig with R-22 and R-502) above control point,

and will be fully unloaded when suction pressure is 4psig

(7 psig with R-22 and R-502) below control point.

5F20 AND 5F30 COMPRESSORS — Two capacity control packages are available as accessories. One is

suitable for R-12 applications; the other for R-22 and R-502 applications.

The adjusting stem (Fig. 15) is shipped in a backseated (fully eounterclockwise) position. Compressor will be fully loaded under all conditions. Adjust the capacity control set point by the same 3-step procedure described above for 5F40 through 5H126 compressors.

*When compressor Is received, the capacity control adjusting

stem will be backseated. (Compressor will be fully loaded under all conditions )

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

Bookl 2 PC111 Catalog No 530-526 PrintedinUSA Form 5F,H-11SI Pg15 2-86 Replaces: 5F.H-9SI

Tab I 2a For replacement items use Carrier Specified Parts

Fig. 15 — Capacity Control Valve

Page 16

5F,H

HEATING A COOLING

Open-Drive Compressors

CONTROL OIL PRESSURE

CRANKCASE PRESSURE

5F20

Fig. 16 — 5F,H Capacity Control System (Except 5H120)

5F30

5H60.66

OIL PUMP PRESSURE

Fig. 17 — Cylinder Unloading Sequence

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

BookI 2 PC111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg16 2-86 Replaces; 5F,H-9SI

Tab 2a

For replacement Items use Carrier Specified Parts.

Page 17

5F,H

HEATING «COOLING

SUCTION SHUTOFF VALVE 3-1/8“ ODF

SUCTION MANIFOLD COVER (REMOVE FOR ACCESS TO

SUCTION STRAINER)

PNEUMATIC CONTROL

CONNECTION 1/4“ IPS

OPENING TO CRANKCASE 1/4" IPS

CAPACITY CONTROL VALVE ADJUSTING STEM

CONTROL OIL STRAINER PLUG 5/8“-18

OIL FILLER PLUG

CRANKCASE DRAIN

Open-Drive Compressors

DISCHARGE SHUTOFF VALVE 3-1/8“ ODF

GAGE CONNECTIONS

1/4“ IPS

HIGH-PRESSURE CONTROL CONNECTION 1/4" IPS

LOW-PRESSURE CONTROL CONNECTION 1/4“ IPS

CENTER MAIN BEARING

RETAINING SCREW ACCESS

OIL PUMP ROTATION ARROW (TAG)

CONTROL OIL PRESSURE

OIL LEVEL SIGHT GLASS

Fig. 18 — 5H80, 86 8- Cylinder Compressor

SCHEDULED MAINTENANCE

for 5H40 through 5H86 eompressors (Fig. 19). Replace oil filter after the first 50 hours of operation, or whenever

5F,H compressor and condensing units provide long life and dependable service when properly operated and regularly maintained. Establish a maintenance schedule based on factors such as operating hours, load eonditions and water quality. Maintenance schedules listed in this section are offered as guides. Modify them as needed to satisfy individual machine requirements.

Check Lubrication System — Always check com pressor oil level before starting unit. If oil is required,

record date and amount added. Refer to Fig. 1-8 for loca tion of oil filter plug. Table 4 shows specified types and quantities of oil.

Use of accessory oil separator requires additional oil. Oil level and separator float valve movement during initial compressor operation should agree with instruc

tions furnished with the oil separator.

the oil is changed or becomes dirty.

Check yearly for clogged filter, indicated by a greater than normal difference between oil pressure ahead of fdter and after filter. When this difference exceeds 5 psig, change filter as follows;

1. Close oil-line shutoff valves on each side of filter (Fig. 19).

2. Disconnect oil lines at filter connections.

3. Loosen filter bracket; remove and replace filter body. Refer to Accessory Oil Filter Instructions for

additional information.

The full-flow oil filter on 5H120 and 5H126 com

pressors contains a replaceable cartridge. Replaee the

filter cartridge after the first 100 hours of compressor operation. After the initial filter change, check yearly for filter clogging. If the pressure difference across the filter exceeds 5 psig, pump down the compressor and then

OIL FILTER MAINTENANCE — A bleed-type, highpressure, disposable filter is available as an accessory

remove the cartridge. Figure 20 illustrates complete

filter assembly.

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

Book|2 PC111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg17 588 2-86 Replaces: 5F.H-9SI

Tab 2a

For replacement items use Carrier Specified Parts

Page 18

5F,H

HEATING A COOLING

SHUTOFF VALVES

PLAIN ELBOW (PART NO DDI0CA052)

OIL FILTER'

HOUSING

-ORIFICE ELBOW (PART NO

DD40CA05I)

Fig. 19 — Oil Filter Accessory Package

(5H40 through 5H86)

CHECK OIL AND SHAFT SEAL TEMPERATURE — The normal operating temperature of the oil in the crankcase ranges from 100 F to 135 F when fully loaded.

Do not permit maximum oil temperature to exceed 150 F. Conditions under which such excessive temperatures could occur include situations where the compressor

Open-Drive Compressors

operates in a fully unloaded condition for an extended period, because the compressor would not be able to

remove all of the heat generated by compression and friction. In such situations, use an oil cooler to maintain safe operating temperatures. Refer to 5F,H Application

Data for more information.

When crankcase oil temperature falls within the 120 to 135 F range, the shaft seal housing temperature should be approximately 140 to 150 F. Shaft seal housing tem peratures above 170 F may cause shaft seal to age rapidly, and harden and crack. Therefore:

If shaft seal housing temperature exceeds 170 F, STOP THE COMPRESSOR. DO NOT restart until the cause of overheating has been identified, and the condition corrected.

OIL COOLER USAGE — The accessory oil cooler maintains safe operating oil temperatures when:

1. The suction gas becomes highly superheated (Table 7).

2. a. The compression ratio exceeds 5:1 on R-22 systems,

b. Application data indicates the need for an oil cooler

for R-12 and R-502 systems. This is especially likely in increased displacement compressors such as the 5H46, 66, 86 and 126. The compression ratio can be determined from the following formula:

Compression _ Absolute Discharge Pressure

Ratio Absolute Suction Pressure

OIL PRESS 6AGE CONN

(BEFORE FILTER )

OIL FILTER HOUSING

OIL FILTER COVER

PUMP END BEARING HEAD

OIL FILL PLUG

CAPACITY CONTROL VALVE ADJUSTING STEM

BUSHING LOC

CONTROL OIL PRESS. GAGE CONN

DRIVE DISC

OUTER GEAR

INNER GEAR

SPRING

OIL PRESS. GAGE CONN (AFTER FILTER)

OIL FILTER

SPRING RETAINER

OIL FILTER SPRING

Fig. 20 — Oil Pump and Filter Assembly (5H120, 126)

COVER GASKET

OIL PUMP COVER

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

Book[2 PC111 Catalog No 530-526 PrIntedInUSA Form5F,H-11SI Pg 18 2-86 Replaces: 5F,H-9SI Tab 2a

For replacement items use Carrier Specified Parts

Page 19

5F,H

HEATING A COOLING

Table 7 — Actual Suction Gas

Temperature Limits (F), R-12, R-22, R-502

SAT. SUCT

TEMP (F)

ACTUAL SUCTION GAS TEMP(F)

NOTES:

1 For continuous operation with R-22

2 Do not operate unloaders at saturated suction temperatures

at or below 0°F without prior approval from Carrier/Carlyle Engineering

R-12 R-502 25 R-22

SAT. SUCT TEMP (F)

-60 -50

— —

-40 to 40 40 to 50

-40

-30 -20 -10

35 45 55 65

35 45 55 65 75

See Note 1

MAX. SUPERHEAT (F)

Oto 50

65 75

3. The compressor operates fully unloaded for prolonged periods. Under these conditions, suction gas levels

may not suffice to remove the heat of compression and friction. This condition can occur in any applica tion, but is most likely in low-temperature systems or variable-volume applications that use hot-gas bypass

to maintain specified conditions under low evaporator

load. Refer to 5F,H Application Data for additional

information.

Adjust water flow through oil cooler to maintain crankcase return oil temperature at 100 to 120 F. Crank case temperature must remain below 140 F; shaft seal temperature at the seal housing should not exceed 170 F.

Tables 8 and 9 list maximum working pressures for oil and water and estimated water flow rates for various oil cooler/compressor combinations. For additional information, see Accessory Oil Cooler Installation

Instructions.

Table 8 — Oil Cooler Maximum Working Pressure

OIL WATER 150 psig

150 psig

Table 9 — Oil Cooler Estimated Water Flow Rates

COMPRESSOR

5F ’/4-1

5H40-66 5H80,86 5H120.126

*Flow rate based on 80 F entering water.

GPM*

1-2

1 '/2 - 3

2-4

Check Water-Cooled Heads — To prevent oil breakdown and sludge formation, the discharge gas temperature must remain below 275 F. Water-cooled cylinder heads are available as an accessory for this purpose. See Accessory Water-Cooled Head Package

Installation Instructions for additional information.

Open-Drive Compressors

SERVICE INSTRUCTIONS

Service and repair of Carrier reciprocating com pressors and other refrigeration components should be performed only by fully trained and qualified personnel.

Service Notes

1. Compressor components are shown in normal order of removal from compressor (Fig. 21 and 22).

2. For replacement items, use Carrier specified parts. See Carrier 5F,H Specified Parts list for compressor

part interchangeability.

3. Before servicing compressor, pump down the refrig erant as follows:

a. Start compressor, close suction service valve,

and reduce crankcase pressure to 2 psig. (Bypass low pressurestat with jumper.)

b. Stop compressor; close discharge service valve to

isolate it from system.

c. Bleed any residual refrigerant. Drain oil if

neeessary.

4. After disassembly, clean all parts with solvent. Use mineral spirits, white gasoline or naphtha.

5. Before assembly, coat all parts with compressor oil and clean and inspect all gasket surfaces. Replace all gaskets with new, factory-made gaskets, and lightly coat with oil. See Table 10 for torque values.

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

Lubrication System

OIL PUMP (For 5H120 and 126 compressors, manu factured in 1969 or later, refer to Gear Rotor Type Oil Pump.)

Drain oil below level of pump-end bearing head.

Remove bearing head. Complete end bell assembly must be removed on 5H40, 46, 60, 66, 80 and 86 models. Check oil-pump rotor for end play. Maximum allowable move ment of rotor is 0.0025 in. (Table 11). If there is excessive end play, reposition oil-pump bushing in bearing head as described below.

Turn rotor; if there is more than a slight drag, remove pump cover and disassemble oil pump. Check all parts (Fig. 20, 23 and 24) for wear and damage. Inspect oilpump bushing for scoring. Replace hushing if scored. If bearing head is scored, replace complete bearing head and oil-pump assembly.

Oil-Pump Bushing Installation — Position bushing oil groove at top when the bearing head is installed.

Machined cireumferential lines mark the lead, or

entering, end of the bushing. Press new bushing into the

pump-end bearing head from the inner side of the head

(Fig. 25 and 26).

Oil Pump Bushing Positioning (Fig. 25 and 26)

1. Place 0.001-in. cireular, field-fabricated shim against bushing and install pump. (Shim between bushing and oil pump rotor.)

(Continued on page 25.)

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

Book

Tab

PC 111

Catalog No 530-526

PrintedinUSA Form5F,H-11SI Pg 19

For replacement items use Carrier Specified Parts

2-86 Replaces: 5F,H-9SI

Page 20

5F,H

HEATING A COOLING

DISCHARGE VALVE

INNER SEAT

HANDHOLE COVER ASSEMBLY

HANDHOLE COVER GASKET

SHAFT SEAL BELLOWS COVER PLATE ASSEMBLY

SEAL

CYLINDER HEAD

CYLINDER HEAD GASKET

VALVE PLATE

VALVE PLATE GASKET

Open-Drive Compressors

PUMP END COVER PUMP END BEARING HEAD

ASSEMBLY

PUMP END BEARING WASHER

AND CONTROL

VALVE ASSEMBLY

OIL FILTER SCREEN

PUMP END BEARING HEAD GASKET

HANDHOLE

COVER GASKET

HANDHOLE COVER'

Fig. 21 — 5H Compressor External Components

OIL FILTER (ACCESSORY)

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

Book 12 PC111 Catalog No 530-526 PrintedInUSA Form5F,H-11SI Pg 20 2-86 Replaces: 5F.H-9SI Tab |2a

For replacement Items use Carrier Specified Parts.

Page 21

5F,H

KEATING A COOLING

CYLINDER SLEEVE

SNAP RING

UNLOADER SPRINGS-»^ %

UNLOADER PINS

UNLOADER FORK

% \ V ^

Open-Drive Compressors

PISTON RINGS { COMPRESSION - TAPERED )

igll.. Ill

PISTON RING (OIL)

PISTON PIN

PISTON

PISTON RING (OIL)

CONNECTING ROD

----

PISTON PIN LOCK RING

CONNECTING ROD BOLTS

ELASTIC LOCK NUT

UNLOADER POWER ELEMENT

UNLOADER BRACKET GASKET

SEAL END BEARING WASHER (BRONZE)

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

ASSEMBLED PISTON AND CONNECTING ROD

CRANKSHAFT

SEAL END THRUST WASHER (STEEL)

Fig. 22 — 5H Compressor Internal Components

CONNECTING ROD BEARING INSERTS

CONNECTING ROD CAP

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

Book 2

Tab 2a

PC 111

Catalog No 530-526 PrintedinUSA Form5F,H-11SI

For replacement Items use C arr ier Specltied Parts.

Pg 21

2-86

Replaces: 5F,H-9SI

Page 22

5F,H

HEATING A COOLING

SIZE

THREADS

DIAU

(in.)

1V2

18 NEF

No. 6

'/4

'/4 28 NF

TORQUE

PER IN.

Pipe

28 NF

24 NF

Pipe

16 NC

24 NF 45-50

20 NF

13 NC

11 NC

18 NC

10 NC

Pipe

Pipe 15-20

Pipe

RANGE

(Ib-ll)

20-25 20-25

20-25

10-15

12-15

10-12 22-25

15-20 30-35

25-29 25-29 25-29

25-29

25-29 25-29

25-29

25-30 80-85

80-85

120-130

60-75 60-75

60-75

60-75 60-75

18-22 50-60

70-80 34-45

8-10

10-15

20-25 20-25 20-25

12-16

8-12

Table 10 — Torque Values

USAGE

Pipe Plug — Pump End Bearing Head Pipe Plug — Crankshaft Pipe Plug — Suction and Discharge

Manifold Cover

Unloader Power Element Assembly —

Crankcase

Unloader Cylinder Cover Plate —

Unloader Cylinder Bracket

Discharge Valve Cap Screw —

Inner Seat

Discharge Valve Guide Assembly —

Valve Plate

Oil Pump Cover — Pump End

Bearing Head

Auxiliary Control Valve Cover —

Valve Body

Connecting Rod Bolt — Locknut Capacity Control Valve —

Hand Hole Cover

Pipe Plug — Pump End Bearing Head Cylinder Head — Crankcase

Shaft Seal Cover Plate — Crankcase Bottom Plate — Crankcase Suction and Discharge Manifold

Cover — Crankcase

Pump End Bearing Head Assembly —

Crankcase

Hand Hole Cover — Crankcase Suction Manifold — Crankcase

Flywheel Screw — Crankshaft Oil Return Check Valve Assembly —

Crankcase

Suction Service Valve — Crankcase Discharge Service Valve — Crankcase

Suction Service Valve —

Suction Manifold

Magnetic Plug — Crankcase Magnetic Plug — Pump End

Bearing Head

Oil Bypass Plug — Pump End

Bearing Head

Modulating Valve Adapter —

Pump End Bearing Head

Lock Screw — Pump End Bearing Head Oil Relief Valve Assembly — Crankcase Cap-Oil Relief Valve Assembly

Flywheel Locknut — Crankshaft Sight Glass Clamping Gland —

Hand Hole Cover

Auxiliary Control Valve Cover —

Valve Body

5H UNITS

Pipe Plug — Auxiliary Control

Valve Body Pipe Plug — Pump End Bearing Head Pipe Plug — Crankcase

Pipe Plug — Pump End Cover Pipe Plug — Crankshaft

Oil Pump Cover — Pump End

Bearing Head

Auxiliary Control Valve Cover —

Valve Body

Special Cap Screw — Auxiliary

Control Valve Body

Open-Drive Compressors

5H UNITS (cont)

SIZE

THREADS

DIAM

'-ÍB

(In.)

PER IN.

18 NC

24 NF

Vb 16 NC

14 NC

20 NF 40-45 Connecting Rod Bolt — Locknut*

'/2 Pipe

13 NC

Vb 11 NC 140-150

Va 18 NF

V» 14 NF V4

1V2 18 NEF 35-45

No. 6 32 8-10

NC — National Coarse

NEF — National Extra Fine NF — National Fine

•Steel Rod

TORQUE

RANGE

(Ib-fl)

Oil Pump Cover — Pump End

16-20

16-20 16-20

18-22 18-22

18-22

Pipe

Pipe 45-50 Pipe Plug — Crankcase Pipe 50-55 Pipe Plug — Crankcase

30-35 30-35

25-29

35-60 55-60

55-60 55-60 53-60 55-60

55-60

35-40 35-40

30-35 30-35

80-90 80-90

60-75 60-75

60-75 60-75 60-75 80-90 45-55

80-90 60-75

55-65

Bearing Head

Capacity Control Valve — Pump

End Bearing Head

Auxiliary Control Valve — Pump

End Bearing Head

Manifold Cover Plate — Crankcase Unloader Power Element — Crankcase

Capacity Control Valve — Pump End Cover

Discharge Valve Guide Assembly —

Valve Plate

Discharge Valve Guide — Inner Seat

Cylinder Bracket Pipe Plug — Pump End Bearing Head

Pipe Plug — Crankshaft

Capillary Tube Assembly — Pump

End Bearing Head

Connecting Rod Bolt (Aluminum Rod)

Suction and Discharge Manifold Cover

— Crankcase

Discharge Manifold — Cylinder Heads

Valve Plate — Crankcase

Cylinder Head — Crankcase Hand Hole Cover — Crankcase

Shaft Seal Cover

Pump End Cover and Pump End

Bearing Head — Crankcase

Pipe Plug — Crankcase Pipe Plug — Pump End Bearing Head Pressure Relief Valve — Suction and

Discharge Manifold Cover

Pressure Relief Valve — Crankcase Suction and Discharge Manifold —

Crankcase

Suction Manifold Cover — Crankcase Suction Manifold Cover and Suction

Manifold — Crankcase

Magnetic Plug — Pump End

Bearing Head Modulating Valve Adapter — Crankcase Oil Bypass Plug — Crankcase Oil Bypass Plug — Pump End

Bearing Head

Oil Bypass Plug — Pump End Cover

Hoi low Lock Screw — Pump End Cover

and Center Main Bearing Housing

Oil Pressure Relief Valve — Orankcase

Cap-Oil Pressure Relief Valve Assembly

Seal Plug — Pump End Bearing Head Oil Pressure Relief Valve — Orankcase

Sight Glass Clamping Gland —

Hand Hole Cover Auxiliary Control Valve Cover —

Valve Body

USAGE

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

Book [2 PC111 Catalog No 530-526 PrintedinUSA Form 5F,FI-11 SI Pg22 489 2-86 Replaces: 5F,Fi-9SI Tab 12a For replacement items use Carrier Specified Parts.

Page 23

5F,H

HEATING A COOLING

COMPRESSOR PART

SEAL END

Main Bearing Diameter — 5F20, 30

Journai Diameter — 5F20, 30

PUMP END

Main Bearing Diameter — 5F20, 30

(Assembieid) — 5F40, 60

Journal Diameter

CENTER (5H80,86,120,126)

Main Bearing Diameter Main Bearing Thickness Journal Diameter

CONNECTING ROD

Bearing Diameter Bearing Thickness Crankpin Diameter Seal End Bearing Washer Thickness Seal End Thrust Washer Thickness Pump End Bearing Washer Thickness

CYLINDERS

Bore Piston Diameter —Steel, Standard Stroke

Piston Pin Diameter

Piston Pin Bushing Piston Ring End Gap (compression and oil) Piston Ring Side Clearance

Compression Side Oil Side

OIL PUMPt

Axial Clearance

Drive Shaft Diameter

Drive Shaft Bushing Diameter (10) Drive Shaft Diameter (5H120 & 126) Drive Shaft Bushing Diameter

(ID — 5H120 & 126)

SUCTION VALVE

Suction Valve Disc

(depth of wear below face)

Suction Valve Seat

DISCHARGE VALVE

Discharge Valve Disc

(depth of wear below face)

Discharge Valve Seat

— Aluminum, Long Stroke

— 5F40, 60

Body Ring Groove (OD)

Open-Drive Compressors

Table 11 — Wear Limits; 5F,H Compressors

COMPRESSOR

5F20,30,40,60

Factory

Tolerances (in.)

Max

1 6264

2 0636

1 6240 1 6233

2 061 2 060

1 6264 1 6264 1.6250 001 —

1 6240

— — — — —

1 6255

—

1 6240 1 6233

131 .129

157 155

131 129

2 501 2.500

—

— — —

—

7500

009

0015 0005 0012 0002

0015

4361 4356

4375

— — — 6250

Min

1 6250

2.0618

1.6250 1 6233

—

1 6245

06225

2.4980

7498

—

004 .030

.0005

— —

— 012

—

012 .002

Maximum Allowable Wear (in.)

002 .001 .003 .002

002 2 2530 .002

— 2 6264

—

002 2.2505

001

003

* * *

003 3 2515 003

—

001

003 0015

0025 0015

—

002

005

5H40,46,60,66,80,86,120,126

Factory

Tolerances (in.)

Max

2 6278

— —

2 6235

—

Min

2 6250 2 6225

—

2 2502

—

2 249

2 6235

— 06225 — 2 248

188 188 188

3 2485

3 241

3 235

— .9998

1.000 .017

0012

4361

.4375

6270

—

2 248

2 6250

.0942

2 6225

2.2495

186 186 186

3 2505 3 2480

3 240 3 232

—

007 030

0005 0002

0005 4356 4370

.6240 —

6260

012

Maximum Allowable Wear (in.)

001

—

002

—

001

—

002

001 001

002

.001

002

003 003

003 003 001 001

003

0025

— —

005 002

•Replace thrust and bearing washers when end clearance exceeds maximum listed

CRANKSHAFT END CLEARANCE (In.)

5F20-5F60 5H40,46 5H60,66 5H 80,86

5H120,126

011 to 035 010 to 036 011 to 037 014 to 042 014 to 044

tReturn assemblies for factory exchange

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

Book 2 PC 111 Tab 2a

Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg 23

For replacement items use Carrier Specified Parts.

2-86

Replaces: 5F,H-9SI

Page 24

5F,H

HEATING A COOLING

OIL FILL CONNECTION

Open-Drive Compressors

BRONZE BEARING WASHER

PUMP END BEARING HEAD

OIL PUMP ROTOR

OIL PUMP IDLER

OIL PUMP COVER GASKET

ROTATION ARROW

OIL PUMP COVER

PUMP INTAKE PLUG ( MAGNETIC)

OIL PRESSURE CONNECTION

CRANKCASE PRESSURE CONNECTION

OIL PRESSURE CONNECTION

(REMOVE FOR ACCESS TO CONTROL OIL STRAINER)

Fig. 23 — 5F Oil Pump Assembly

PORT FOR INSERTING BEARING HEAD SLEEVE WHEN USING OIL COOLER ACCESSORY. (SEE ACCESSORY OIL COOLER INSTALLATION INSTRUCTIONS)

OIL PUMP ROTOR

(Hii

ACCESSORY OIL FILTER CONNECTION

Fig. 24 — 5H40-5H86 Oil Pump Assembly

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

Book 12 PC 111 Catalog No 530-526 PrIntedinUSA Form5F,H-11SI Pg 24 2-86 Replaces: 5F.H-9SI

Tab 2a

For replacement Items use Carrier Specified Parts

Page 25

5F,H

HKATING ft COOLING

Fig. 25 — Setting Oil Pump Bushing

(Typical 5F20 through 5H86 —

5H40 Bearing Head Shown)

Open-Drive Compressors

6. Install bearing head on compressor. Line up tang on oil-pump rotor shaft with slot in end of crankshaft.

Check oil pump for proper direction of rotation.

1. Refill compressor oil to proper level.

Observe oil pressure when starting compressor. If correct pressure (Table 4) is not reached in 8 to 12 seconds, stop compressor and recheck oil pump.

GEAR ROTOR TYPE OIL PUMP (Models 5H120 and

126 manufactured from 1969 on) — Remove bearing head and oil-pump cover (Fig. 20). Disassemble oil pump. Check all parts for wear and damage. Inspect bushing for scoring. Replace hushing if scored. If bearing head is scored, replace complete bearing head and oil-pump assembly.

Install New Oil-Pump Bushing — Reinstall oil pump into

bearing head with 1 / 64-in. shim between port insert and

oil-pump cover. Install oil-pump cover without gasket for this operation. Press new bushing into bearing head from

inner side so that the bushing oil groove is at the top

when the bearing head is installed (similar to Fig. 26).

Machined circumferential lines mark the lead, or enter ing, end of the bushing. Press on bushing until port insert bottoms against the 1/64-in. shim. Remove pump cover

and shim. Reinstall pump cover with gasket and install assembled bearing head on compressor. Check oil pump

for proper direction of rotation.

Fig. 26 — Setting Oil Pump Bushing

(Typical 5H120, 126)

2. Complete assembly of oil pump.

A WARNING

Oil pump assembly must be flush with coverplate surface, but must not protrude beyond bearing head surface.

3. Tap bushing with a cylindrical positioning tool to seat it against shim (Fig. 25 and 26).

4. Disassemble oil pump and remove shim.

5. Reassemble oil pump; check for binding.

OIL PRESSURE REGULATING VALVE (nonadjust-

able, Fig. 27) is located on the side of compressor adjacent

to seal housing. Regulator maintains correct oil pressure (Table 6) and ensures satisfactory unloader operation.

OIL REGULATING VALVE BODY

GASKET

OIL REGULATING VALVE CAP

Fig. 27 — Oil Pressure Regulating Valve

(Nonadjustable)

Unscrew regulator from crankcase; use 5/ 16-in. Allen

wrench on all compressors except 5H120, which requires

1/2-in. Allen wrench. Regulator must not be clogged and plunger must not be stuck. Check drillings to regulator for fouling.

The nonadjustable oil pressure regulator is inter

changeable on all current 5F,H compressors except

5 H120 and 5 H126 models. 5 H120 and 5 H126 units have larger, nonadjustable regulators. Early 5F,H com pressors were equipped with an adjustable-type oilpressure regulator. When an adjustable-type regulating valve needs replacing, use a

nonadjustable regulator.

OIL RETURN CHECK VALVE (5F20 through 5H86) allows oil to return from suction manifold to crankcase. This normally open valve closes when crankcase pressure

becomes higher than suction pressure (Fig. 28).

Two disc-type check valves on 5F20 and 5F30 com pressors are located beneath partition between suction manifold and crankcase, one on each side of compressor.

Remove check valves through bottom cover or pump

end of eompressor.

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

Book|2 PC 111 Catalog No 530-526 PrIntedInUSA Form5F,H-11SI Pg 25 2-86 Replaces: 5F.H-9SI

Tab 2a

For replacement items use Carrier Specified Parts.

Page 26

5F,H

HEATING A COOLING

Leaf-type check valve on 5F40 and 60 and 5H40, 46, 60, 66, 80, and 86 compressors is accessible through, and located at top center of, handhole cover opening.

Remove check valves and check to see that flutter

valve or leaf does not stick, and that it seats tightly.

CHECK VALVE

LEAF TYPE

Fig. 28 — Oil Return Check Valves

Open-Drive Compressors

¡^‘'^PRESSURE RELIEF VALVE

(SEE NOTE)

NOTE: The pressure-relief valve is not part of the valve plate assembly The valve mounts in the crankcase in the left side cylinder deck (looking at pump end). The valve plate opening outlined, slips over the pressure-relief valve when assembled

Fig. 30 — Pressure Relief Valve (5F60)

DISCHARGE MANIFOLD

PRESSURE RELIEF VALVE

OIL SEPARATOR

IMPELLER

Centrifugal Oil Separator Impeller

CENTRIFUGAL OIL SEPARATOR on 5HI20 and

126, mounted on crankshaft (Fig. 29), returns oil to compressor crankcase. To remove or replace oil separator, see Crankshaft Inspection and Service.

OIL FILTER SCREEN (Fig. 21) in compressor crank case is accessible through handhole cover or bottom plate. Remove and inspect it for holes, then clean it with solvent and replace.

Pressure-Relief Valves — When pressure differ

ential between high- and low-pressure sides exceeds 350

± 35 psi (5F60: 400 ± 40 psi), pressure-relief valve bleeds

refrigerant from high to low side.

Check relief valves for evidence of leaking. Change if defective or if valve has ever opened due to excessive pressure.

5F60 COMPRESSORS — Internal relief valve screws into crankcase and projects up through left cylinderbank valve plate (Fig. 30). Use a standard socket-type screwdriver to remove and replace valve.

IP*

SUCTION AND DISCHARGE MANIFOLD COVER

Fig. 31 — Pressure Relief Valve and

Suction Strainer (5H40, 46, 80, 86)

5H40, 46, 80 AND 86 COMPRESSORS — Pressurerelief valve is located on suction and discharge manifold cover (Fig. 31).

5H60 AND 5H66 COMPRESSORS — Relief valve is located in wall between suction and discharge manifolds. Remove discharge manifold for access to relief valve. Use a standard 1-1/2in. socket to remove and install the valve.

5H120 AND 5H126 COMPRESSORS are equipped with external relief valve mounted on bypass line between suction shutoff valve and discharge manifold. To remove valve, remove bolts from flanges on either side of valve.

Suction Strainer — To withdraw strainer on 5F20

and 40 and 5H40 and 46 compressors, remove suction and discharge manifold cover on seal end of compressor.

On 5F30 compressor, remove suction service valve. On 5F60 and 5H60 and 66 compressors, remove suction manifold and withdraw 2 strainers. On 5H80 and 86 compressors, remove suction manifold cover.

On 5H120 and 126 compressors, remove one suction manifold plate at a time so as not to disturb position of

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

Book|2 PC111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg 26 2-86 Replaces: 5F,H-9SI

Tab 12a replacement Items use Carrier Specified Parts.

Page 27

5F,H

HEATING A COOLING

detachable suction manifold and suction line. Withdraw 2 suction strainers.

Clean strainer with solvent or replace if broken or corroded. When replacing suction strainer, do not damage it.

On 5H120 and 126 compressors, positioned manifold cover plate must compress strainer bail. If bail is too short, grasp on sides and elongate it enough to be com pressed by manifold cover. Position bail between the 2 bosses on inside of manifold cover to prevent strainer from turning.

A CAUTION

If a felt sock filter is installed, remove and inspect it

after 50 hours of operation. Clean filter if required and replace it for another 50 hours. Clean the suction strainer whenever the felt sock is removed. Remove sock when system is clean. (Not applicable for 5F20 and 30 compressors.)

Cylinder Head and Valve Assemblies

CYLINDER HEAD INSPECTION — Remove cylinder heads and check heads for warping, cracks and damage to gasket surfaces.

VALVE INSPECTION (Fig. 32)

Disassembly — Remove cylinder head. Loosen cap screws holding discharge valve seat to discharge valve

guide, and cap screws holding valve guide to valve plate.

Remove cap screws holding valve plate to cylinder block. Remove valve plate from cylinder block and discharge valve guide from valve plate.

Inspeetion — Inspect suction and discharge valve discs and valve seats for craeks or excessive wear (Table 11). Check cylinder-sleeve valve stops for uneven wear.

Replace valves if cracked or worn. If valve seats are worn, replace complete valve plate assembly. If cylinder-sleeve valve stops are worn, replace sleeve.

Reassembly — Pistons must be below tops of cylinder sleeves. To position correctly, turn crankshaft or force pistons down.

1. Place suetion valve springs in valve plate recesses. Large spring coil should be in full contact

with bottom of recess.

2. Place suction valve disc on valve springs; press disc into valve plate recess. Slide valve retainer elips into place (Fig. 33). Clips must not cover valve lifter springs or pins. Valve retainer clips 5F20-2061 (5F compressors) and 5H40-2061 (5H eompressors) are field supplied.

3. Bolt valve plate to cylinder block. Remove valve elips.

4. Place discharge valve springs in diseharge valve guide spring recesses.

5. Place diseharge valve dise over springs, and fit inner spring in place over valve disc. Hand-tighten bolts holding inner seat to valve guide (valve guide assembly).

6. Place valve guide assembly on valve plate. Tighten all bolts and bend tabs on lock washer and lock plates.

Replace cylinder head.

Open-Drive Compressors

DISCHARGE VALVE

SPRING

DISCHARGE VALVE

INNER SEAT

DISCHARGE VALVE

OUTER SEAT

Fig. 32 — Suction and Discharge Valve Assembly

VALVE PLATE

SUCTION VALVE RETAINER CLIPS

Fig. 33 — Valve Clips in Place

Cylinder and Unloader Sleeves

DISASSEMBLY (Fig. 35) — Remove cylinder head, suction and discharge valve assembly, and pump-end bearing head. Whenever cylinder sleeve or valve plate is replaced, use a new suction valve disc.

1. Turn crankshaft until piston is in midposition.

2. Insert a sleeve puller into cylinder and push it down

onto top of piston.

3. Tighten nut on top of sleeve puller to expand puller

in sleeve.

4. Turn crankshaft, forcing sleeve upward until it can

be removed.

5. Remove unloader snap rings (5H eompressors only). Disassemble unloader sleeve, pins and springs.

INSPECTION — Examine bore of sleeve for wear. Check suction valve seats for scratches and wear. Check unloader sleeves, pins and springs for wear and freedom of movement (Table 11).

REASSEMBLY — When new rings are being installed in a used cylinder sleeve, break the hard, glazed surfaee of eylinder sleeve to reduce wearing-in period of new

rings. Clean sleeves thoroughly after breaking glaze.

VALVE LIFTER

SPRING-

SUCTION VALVE

IN PLACE

SUCTION VALVE DISC

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

BookI 2 PC111 Catalog No 530-526 Printed in U.S A. Form5F,H-11SI Pg 27 2-86 Repiaces: 5F,H-9SI Tab I 2a For replacement items use Carrier Specified Parts.

Page 28

5F,H

HEATING A COOLING

To reassemble:

1. Rotate crankshaft to position piston at top center.

2. Lubricate piston rings and beveled surface at lower edge of cylinder sleeve.

3. Stagger ring gaps around piston.

4. With turning motion, work sleeve over piston and rings. Compress and align each ring with beveled edge of sleeve.

5. Seat sleeve in suetion manifold partition and cylinder deck recess.

6. Rotate sleeve so that any 2 valve lifter-pin holes lie equal distances from longitudinal axis of compressor (Fig. 35). In this position, lifter pins line up with suction valve springs.

Connecting Rods and Pistons

REMOVAL — Remove cylinder head, valve plate and handhole cover or bottom plate to gain access to rods and pistons.

Remove connecting rod caps (Fig. 22). Label caps and

rods so they may be reinstalled in same places on crank

shaft. Remove cylinder sleeve, connecting rod and piston assembly as a unit by pushing assembly up through cylinder deck. Do not allow piston to come up through top of sleeve during removal process. Remove retaining rings and piston pins to disassemble connecting rods from pistons. Remove rings.

Keep each individual connecting rod and piston assembly together to aid reassembly. Check all parts and crankpin journals for wear (Table 11).

INSPECTION AND REPLACEMENT Attach con necting rods to pistons with piston pins and lock in place with retaining rings. Piston pins are selectively fitted for

a push fit; reassemble in the piston from which they

were removed. Place piston pin retaining rings, with gap on side, on piston (Fig. 34). They should be tight

enough to inhibit rotation under finger pressure.

Check Rings

1. Check ring gap by inserting each ring separately in cylinder approximately 3/8in. from top. Ring gap

should be between .007 and .017 inches.

2. Install compression rings on piston with side marked- top toward piston head. Install oil rings either side up.

3. Stagger ring gaps around piston.

4. Measure side clearance between ring and piston

(approximately .001 inch). Check rings for free action.

Check Rod Bearing Inserts (Fig. 22) — If bearing inserts are damaged and crankshaft is not worn, it is only

necessary to replace inserts. Do not file bearing caps. Place the inserts in connecting rod and connecting rod

caps so knobs on inserts fit into notches on rod cap.

Lubricate insert bearing and crankpin freely before installing caps.

Install cylinder sleeve, eonnecting rod and piston

assembly at the same time. Turn connecting rod, and

Open-Drive Compressors

install cap so chamfered sides are against radius of crankpin. (Small knobs on rod and caps must be on same

'See Table 11 for piston diameters.

Fig. 34 — Aluminum Long-Stroke Piston Details

CAP SCREWS AND WASHERS

Fig. 35 — Position of Cylinder Sleeves

Capacity Control Operation — All 5F,H series

compressors, except 5F20 and 30 units, include hydraulic capacity control unloader systems as standard equip ment. (Field-installed accessory unloader packages are available for the 5F20 and 30.) The unloader system activates and deactivates the compressor’s cylinder banks, by permitting suction valves to seat or preventing them from doing so, in response to changing load de mands. Capacity control unloaders can reduce a unit’s actual operating capacity by steps down to as little as 25%

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

Book 2

Tab

PC111 Catalog No 530-526 PrintedinUSA Form5F.H-11SI Pg 28 2-86 Replaces: 5F.H-9SI

For replacement items use Carrier Specified Parts

Page 29

5F,H

HEATING A COOLING

of its total capacity. Figure 17 shows the sequence and number of cylinders that unload with each step.

Capacity control unloader systems consist of 4 major

components:

Open-Drive Compressors

1. A capacity control valve, which increases or

decreases control oil pressure to the hydraulic relay piston proportionally when the suction pressure from the crankcase rises or falls.

SUCTION VALVE

IF PNEUMATIC CONTROL IS NOT USED. THIS

PORT MUST BE VENTED

FROM CRANKCASE PRESSURE

Fig. 36 — Capacity Control (5F20, 5F30)

FROM COMPRESSOR OIL PUMP,

SUCTION VALVE

DISC -

CONTROL OIL

PRESSURE

CRANKCASE PRESSURE

OIL PUMP PRESSURE

Fig. 37 — Capacity Control Operation (5F40. 60; 5H40, 60. 66, 80 and 86)

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

Book 2 Tab

PC 111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg 29 2-86 Replaces: 5F,H-9SI

For replacement items use Carrier Specified Parts

Page 30

5F,H

HEATING A COOLING

2. A hydraulic relay, which (except on the 5F20 and 30)

feeds oil to the unloader power elements in sequence. Control oil pressure from the capacity control valve activates this relay.

3. A hydraulic power element, which supplies the

power necessary to operate the valve-lifting mechanism. It is modulated by the capacity control valve.

4. A valve-lifting mechanism, whieh consists of a

sleeve, a lifting fork and a push-pin assembly around each controlled cylinder. The valve-lifting mechanism

holds the suction valve open, or permits the valve to remain in normal operating position depending on its

actuation by the power element.

These components operate in the following manner:

5F20 AND 30 CAPACITY CONTROL OPERATION (Fig. 36) (With Optional Unloaders and Control)

Loaded Operation — A rise in suction pressure causes needle valve to close. Oil pressure in power element increases as oil enters capacity control circuit from oil pump. Power element piston is forced upward, pivoting lifting fork downward. Lifter pins drop, allowing suction valve to seat and load controlled cylinder.

Open-Drive Compressors

Unloaded Operation — A drop in suction pressure causes needle valve to open. Oil bleeds through valve to crank

case, decreasing oil pressure in power element. As oil

pressure to power element drops, the piston moves downward. Lifting fork pivots upward, moving lifting pins upward; suction valve rises from its seat and con trolled eylinder unloads.

5F40 THROUGH 5H126 CAPACITY CONTROL OPERATION (Fig. 37 and 38)

Loaded Operation— A rise in suction pressure increases

pressure against capacity control valve bellows, com pressing range adjustment spring. Compression of range adjustment spring allows valve spring to move push pins and valve needle point toward valve seat. Flow of control oil to crankcase through oil drain is throttled.

Control oil pressure rises as oil enters capacity control

circuit through orifice from compressor oil pump circuit.

Increased control oil pressure advances hydraulic relay piston (against spring) which feeds oil at full pressure to one or more controlled cylinder power elements depend ing on position of control valve.

Pump oil pressure in unloader power elements forces piston upward, pivoting the lifting fork(s) downward. Lifter pins drop, allowing suction valve(s) to seat and load cylinder(s).

TRAVELING NUT

CONTROL OIL PRESSURE

CRANKCASE PRESSURE

OIL PUMP PRESSURE

Fig. 38 — Capacity Control (5H120, 5H126)

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

Book|2 PC111 Catalog No 530-526 Printed In U S A Form5F,H-11SI Pg 30 2-86 Replaces: 5F,H-9SI

Tab 2a

For replacement items use Carrier Specified Parts.

Page 31

5F,H

HEATING A COOLING

UNLOADER CYLINDER

BRACKET GASKET

GASKET (BOTTOM)

PISTON WASHER

SPRING RETAINER

Fig. 39 — Unloader Power Element (Typical)

Unloaded Operation — A drop in suction pressure decreases pressure against control valve bellows. Range adjustment spring presses against the push pins, com pressing the valve spring. This moves the needle valve off the seat.

Control oil bleeds from hydraulic relay and control valve to crankcase, relieving oil pressure on hydraulic piston. The piston retracts, preventing transmission of pressurized oil to controlled cylinder power element(s),

and the oil drains to crankcase.

As oil pump pressure on power element drops, the

piston moves downward. Lifting fork(s) pivot(s) upward,

moving lifting pins upward; suction valves rise from

their seats and controlled cylinder(s) unload(s). It should be noted that a minimum of 33 to 35 pounds of oil pres sure is required for proper unloader operation.

Capacity Control Inspection and Service

UNLOADER POWER ELEMENT REMOVAL

Remove cylinder head, valve plate, connecting rod, piston and cylinder sleeve. Remove Allen head cap screws (2) holding unloader power element in position.

Remove power element (Fig. 39) and disassemble.

Check all parts for wear or damage.

POWER ELEMENT REPLACEMENT Check un loader fork height (Fig. 40) of new or assembled power element.

Attach power element to internal suction manifold.

Replace cylinder sleeve piston, connecting rod, valve plate, cylinder head and handhole cover.

Open-Drive Compressors

UNLOADER CYLINDER SPRING GASKET (MIDDLE) (TOP)

UNLOADER SPRING (OUTER)

CYLINDER COVER PLATE

EXTERNAL ADJUSTING STEM REMOVAL does not require compressor to be pumped down. Loosen hex nut at valve stem base and remove adjusting stem assembly.

REMOVAL OF CAPACITY CONTROL VALVE AND HYDRAULIC RELAY — Assembly is located in handhole cover (Fig. 41) of 5F40 and 5F60 units; in pump-end cover (Fig. 42) of 5H40, 46, 60, 66, 80, and 86 units; and in pump-end bearing head (Fig. 43) of 5H120 and 126 units.

Remove capacity control valve and hydraulic relay.

NOTE; It is not practical to remove hydraulic relay from

5H40 through 5H86 compressors.

Inspect parts for wear, damage or evidence of leaking

or sticking.

A new handhole cover, pump-end cover or pump-end

bearing head with control valve assembly and hydraulic

relay may be installed. However, capacity control valve (and hydraulic relay on 5H120 and 126 units) is available as a separate parts item for installation on original handhole cover, pump-end cover, or pump-end bearing head.

INSPECT CONTROL OIL STRAINER — On 5F com pressors, the control oil strainer is located on the side of the pump-end bearing head (Fig. 23). Strainer is located behind the control oil pressure gage connection block on the 5H120 and 126 units (Fig. 20) and on pumpend cover (Fig. 42) of all other 5H compressors.

Remove strainer and inspect it for holes and dirt. Clean

it with solvent and replace.

UNLOADER FORK

CLEVIS PIN

TO CONTROL PRESSURE GAGE CONN.

TO UNLOADER

POWER ELEMENTS

- 0 - 0

Fig. 40 — Unloader Fork Height (5F and 5H)

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

Book 2 Tab

PC111 Catalog No 530-526 Printed in U S A Form 5F.H-11 SI

For replacement Items use Carrier Specified Parts.

Fig. 41 — Compressor Handhole Cover and

Assembly (5F40 and 5F60)

UNLOADER

Pg 31

SEQUENCE

TO UNLOADER POWER ELEMENTS

2-86 Replaces: 5F,H-9SI

Page 32

5F,H

HEATING A COOLING

CAPACITY CONTROL VALVE

SURGE DRUM

TO UNLOADER L

POWER ELEMENTS

^ UNLOADER ^ IvJSEQUENCE

---------ro UNLOADER

POWER ELEMENTS

NOTE Dotted lines indicate piping behind surge drum

Fig. 42 — 5H Pump-End Cover and Control

Assembly (5H40, 46, 60, 66, 80, 86)

CAPACITY CONTROL VALVE

OIL PUMP PRESSURE (BEFORE FILTERING)

tf* HYDRAULIC

V RELAY

(AUXILIARY

CONTROL VALVE )

FROM COMPR

OIL PUMP (CONTROL OIL STRAINER)

Open-Drive Compressors

Crankshaft Inspection and Service

DISASSEMBLY — Remove cylinder heads, valve plates, connecting rod and piston assemblies, and pump-

end main bearing head.

On 5H80, 86, 120 and 126 units, remove hollow-center main bearing lock screw located beneath plug (Fig. 44) and loosen hollow-cup setscrew (Fig. 45) until center

main bearing can be slid from its support. On 5H86, 120

and 126 units, disconnect oil line to center main bearing.

Remove crankshaft through pump-end opening.

Normally it is not necessary to remove the oil separator impeller (Fig. 29) from the 5H120 or 126 shaft. If impeller must be removed for any reason, however, immerse it in

CAPILLARY TO OIL PUMP INTAKE

HYDRAULIC RELAY

Fig. 43 — 5H120 and 5H126 Pump-End

' i^vOl^-OIL PUMP PRESSURE

unloader SEQUENCE

PLUG, MAGNETIC (PUMP INTAKE)

Bearing Head

(AFTER FILTERING)

ACCESS PLUG

BEARING INSERTS

GASKET

PLUG-;C|^

Fig. 44 — 5H80, 86,120,126 Center Main Bearing

Housing Setscrew Location

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

Book Tab

2 2a

PC111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg 32

For replacement items use Carrier Specified Parts

Fig. 45 — Center Main Bearing

(5H120 and 5H126)

2-86 Replaces: 5F,H-9SI

Page 33

5F,H

HEATING A COOLING

hot water or oil until heated to 180F or more. Remove

all traces of water before reassembly. Do not heat

impellers with torch.

INSPECTION — Check crankshaft journals for wear and tolerances (Table 11). Remove crankshaft plugs, check oil passages and clean if clogged.

Connecting-rod bearing inserts and main bearings are

available for crankshafts reground from .010-in. or

.020-in. undersize. A worn crankshaft suitable for

regrinding to above tolerances can be exchanged for a factory-reground crankshaft and bearings. Factory-

reground crankshafts are stamped on both ends with an

A (.010-in. undersized) or B (.020-in. undersized).

IMPORTANT; Do NOT regrind crankshafts for

5H46, 66, 86, and 126 compressors in the field.

Replace shafts with scored journals.

All instructions for field grinding apply only to

standard-stroke crankshafts.

On crankshafts reground locally, hold throw to

1.001 in. for 5F compressors and to 1.376 in. on 5H com pressors. Stamp A or B on crankshaft and pump-end bearing head next to oil pressure gage connection.

To determine maximum and minimum journal diameters for undersized shafts, subtract the amount (in.) that the shaft will be ground undersize from factory from the tolerances specified in Table 11. For example, the factory tolerance for 5H40 seal-end journal is 2.6225 in. to 2.6235 inches. Tolerance for a crankshaft reground to .010 in. undersize should therefore be held between

2.6125 in. and 2.6135 inches.

Open-Drive Compressors

Pump-End Main Bearing (Fig. 46)

DISASSEMBLY AND INSPECTION — On 5H40, 46, 60, 66, 80 and 86 units, remove pump-end cover. Remove pump-end bearing head on all units. Inspect bearing for tolerances shown in Table 11. If a pump-end main bear ing is worn, remove bronze bearing washer, and chisel out bearing. Inspect bearing housing for wear (Table 11) and

damage. Remove any burrs.

REASSEMBLY

1. Lubricate outside of new bearing with heavy grease.

2. Line up hole in bearing with oil port in housing.

3. Press bearing into place using a puller shoulder (Table 12and Fig.47 and 48) andjack screw or bearing press.

Place bearing washer on bearing with notch in washer

4. properly positioned around dowel pin (Fig. 46).

IMPORTANT: When regrinding the seal-end

journal on 5H120 crankshaft, do not grind in the

area of the oil separator impeller. This is not journal area, and must remain intact or the oil separator

impeller will not fit properly.

REASSEMBLY — If 5H120 or 5H126 oil separator has

been removed, read impeller paragraph below before installing crankshaft.

When regrinding crankshaft, remove crankshaft plugs and clean oil passages as well. Before replacing crank shaft, insert and tighten plugs, and reinstall the 5H120 and 126 oil separator impeller:

1. Insert dowel key (Fig. 29) with axis parallel to axis of crankshaft. Position key so chamfered edge is

toward radius of crankshaft journal.

2. Immerse oil separator impeller in oil or hot water to heat it to 180 F or more. If water is used, remove all traces before reassembly. Install impeller on crank shaft with dowel key lined up with impeller keyway. Impeller must fit key snugly.

3. Check that seal-end thrust washer is in place on dowel key in crankcase.

Insert crankshaft and install pump-end bearing head,

connecting rod and piston assemblies, valve plate and

cylinder heads. On 5H80, 86, 120 and 126 units, insert

center main bearing setscrew and lock screw as described under Servicing Center Main Bearing. On 5H86, 120 and

126 units, reconnect oil line to center main bearing.

Fig. 46 — Pump-End Main Bearing Position

Table 12 — Main Bearing Puller Sizes

COMPRESSOR 5F20, 5F30

5F40, 5F60

5H40,46,60,66, 80,86,120,126

NOTES.

1. Bearing pullers are available from the Robin Air Mfg Co, Montpelier, Ohio

2. Side of puller marked B is for undersized bearings.

PULLER SIZE

5F20 5F40

5H40

Center Main Bearing — Size 5H80 through 5H126 compressors have a center main bearing and housing.

DISASSEMBLY AND INSPECTION — On 5H86, 120 and 126 compressors, disconnect oil line to center main bearing. (5H80 center main bearings are fed through the shaft.)

Remove plug on compressor crankcase (Fig. 44).

Then remove hollow lock screw beneath the plug (Fig.

45). Next, loosen hollow-cup setscrew until center main

bearing assembly can be slid from its support. Remove

crankshaft and bearing assembly.

Disassemble bearing (Fig. 45) and inspect for proper

tolerances (Table 11).

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

Book|2 PC 111 Catalog No 530-526 PrintedinUSA Form5F.H-11SI Pg 33 2-86 Replaces; 5F.H-9SI Tab 2a

For replacement Items use Carrier Specified Parts.

Page 34

5F,H

HEATING A COOLING

•SEAL HOUSING

BEARING

PULLER

SHOULDER

DIRECTION OF PULL

CRANKCASE BEARING HOUSING

Fig. 47 — Seal-End Main Bearing (5F40, 60)

HOUSING PILOT

TOP PLATE

Open-Drive Compressors

1. Position bearing so chamfered edge enters bearing housing first, oil holes in bearing and housing are aligned, and bearing relief groove is at top.

2. Pull bearing into housing (Fig. 49). Edge of bearing should be 1/32-in. below surface of bronze bearing washer.

Look through oil pressure regulator opening to

3. check oil passage for blockage.

Blow out oil groove in bearing housing and oil lines

(if any) to it.

REASSEMBLY — Install the new bearing inserts. Assemble bearing housing on crankshaft, hut do not

tighten the hollow-cup setscrew. Install crankshaft, center main bearing and housing, and pump-end main bearing assembly. Tighten bolts holding the pump-end bearing assembly. Rotate crankshaft while tightening setscrew on center main bearing housing. Setscrew should tighten fully without any binding of crankshaft. If bind ing occurs, shim the opposite side of bearing housing, using .001-in. shim stock.

Seal-End Main Bearing

DISASSEMBLY AND INSPECTION — With crank shaft removed, use a bearing puller with a shouldering device to remove and install seal-end main bearings (Fig. 47 and 48). Bearing pullers and sleeve pullers are available from the Robin Air Manufacturing Company,

Montpelier, Ohio.

Inspect bearing and bearing housing for tolerances

shown in Table 11. REASSEMBLY — Remove any burrs and clean bearing

housing before replacing bearing. Lubricate outside of bearing with heavy grease.

Fig. 49 — Seal-End Main Bearing Positioning

Crankshaft Seal Inspection and Replacement

— The crankshaft seal in all current 5F,H compressors is a rotating, bellows-type seal. This seal is the service replacement for all earlier seal assemblies. Figure 50 shows Types I and II of this design (5F20 through 5H126 compressors).

IMPORTANT; Do not attempt to repair or replace seal components. Replace complete seal assembly with current rotating-bellows-type assembly. Do not disassemble bellows assembly of service replace ment seal.

BEFORE INSTALLING SEAL

1. Pump-end bearing head must be in place for proper positioning of seal on crankshaft.

2. Be sure shaft extension and edges of keyway are free of sharp edges and nicks. Also, shaft must be clean and

free of rust. Polish shaft with crocus cloth.

3. Check seal assembly for proper bellows placement and cleanliness.

4. Apply compressor oil to seal assembly and crank

shaft, completely saturating bellows and carbon ring.

INSTALLATION — Refer to Fig. 51 for procedure.

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

Book [2 PC 111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg 34 2-86 Replaces: 5F,H-9SI

Tab 12a For replacement Items use Carrier Specified Parts.

Page 35

5F,H

HCATINQ A COOLING

COVER PLATE GASKET'

BELLOWS ASSEMBLY

COVER PLATE WITH INTEGRAL SEAL SEAT^

A — 5F20, 30 (Type I)

FELT WIPER

COVER PLATE GASKET

Open-Drive Compressors

COVER PLATE GASKET'

CARBON RING SEAL NOSE

COVER PLATE WITH INTEGRAL SEAL SEAT

B — 5F40-5H86* (Type I) — Typical

*5F40 and 60 — 1.5" diameter; 5H40 through 86 — 2.0" diameter.

CARBON RING SEAL NOSE

COVER PLATE WITH INTEGRAL SEAL SEAT

C — 5H120, 126 (Type II)

Fig. 50 — Service Replacement Seals

Table 13 — Accessory Literature

ACCESSORY

Condensing Unit Piping Accessory Control Panel Accessory Compressor Crankcase Heater Accessory Belt Drive Package

Flexible Couplings for Direct-Drive Units

Water-Cooled Condensers Installation Accessory Water-Cooled Heads Package Accessory Oil Filter Package Accessory Oil Cooler Accessory Oil Safety Switch Package Capacity Control Valve Accessory Unloader Package

*See your Carrier Distributor for current form number.

LITERATURE

AVAILABLE

Instructions*

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

Book Tab

PC111 Catalog No 530-526 Printed in U S A. Form5F,H-11SI

For replacement items use Carrier Specified Parts.

Pg 35

2-86

Replaces: 5F,H-9SI

Page 36

5F,H

HIATINO A COOLINO

Step 1 — Lubricate the shaft and the neoprene bellows where it comes in contact with the shaft. Slide the seal assembly, as it is shipped from the factory, onto the shaft until the neoprene just starts to grasp the shaft.

Open-Drive Compressors

Step 2 — Holding the sleeve and spring assem

bly, pull forward on the seal nose assembly at the

same time, turning it so that the lugs on the driv-.

ing band are out of the slots in the retainer shell and rest on the surface of the retainer shell as shown by the pencil.

Step 3 — Using the seal cover plate, push the seal assembly into its proper location on theshaft.

DO NOT use cover plate bolts to push seal into position. The spring guide should be tight against the shaft shoulder as shown by the pencil. Re

move the cover plate, being careful not to damage the carbon washer. GRASP THE SEAL NOSE ASSEMBLY AND TURN IT UNTIL THE LUGS ON THE DRIVING BAND DROP BACK INTO

Step 4 — Lubricate the carbon seal washer and seal seat. Reinstall the seal cover plate, drawing the bolts down evenly to prevent damage to the carbon seal nose. This view shows the lugs of the driving band properly positioned in the center of the slots in the seal retainer shell. This is the

correct position during operation. This prevents the seal from being used as a thrust washer under all operating conditions.

THE SLOTS IN THE RETAINER SHELL.

NOTE The seal may leak slightly immediately after installation, but a short period of operation will correct the condition.

Fig. 51 — Installation of Sleeve-Type Rotary Seal

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

Bookl2 PC 111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Pg 36 2-86 Replaces: 5F,H-9SI

Tab 12a

For replacement Items use Carrier Specified Parts.

Page 37

5F,H

HEATING A COOLING

TROUBLE/SYMPTOM

PROBABLE CAUSE

Compressor will not start. Power off.

Thermostat set too high. Reset thermostat. Thermal overload switch open. Oil safety switch open. Dirty contacts. Loose electrical connections or faulty

wiring. Compressor motor burned out. Liquid line solenoid valve closed.

Evaporator fan off. Evaporative condenser or cooling tower

fan or pump not operating.

Compressor cycles intermittently.

Low-pressure switch erratic in operation.

Low refrigerant charge. Capacity control setting incorrect. Thermostat differential too narrow. Suction valve closed or throttled.

Compressor cycles on high pressurestat.

Tubing to pressurestat restricted.

Faulty pressurestat.

Refrigerant overcharge.

Insufficient condenser water flow or

clogged condenser.

Discharge service valve not fully open. Air in system. Condenser water pump off.

High discharge pressure.

Condenser inlet water temperature too

high.

Insufficient water flow through condenser.

Plugged or scaled condenser tubes.

Discharge service valve partially closed.

Refrigerant overcharge. Air in system.

Low discharge pressure.

Excessive water flow through condenser.

Suction service valve partially closed.

Leaky compressor suction valves.

Worn piston rings.

Flooding

Defective or improperly set expansion

valve.

Low suction pressure.

Low refrigerant charge.

Excessive superheat.

System noises.

Loose or misaligned coupling.

Insufficient clearance between piston and

valve plate.

Motor or compressor bearing worn. Replace bearings. Loose or misaligned belts.

Loose holddown bolts. Tighten bolts.

Open-Drive Compressors

TROUBLESHOOTING

REMEDY

Check main switch, fuse and wiring.

Reset switch. Reset switch. Clean all control contacts.

Tighten connections; check wiring and

rewire. Check and replace If defective. Check for burned-out holding coil.

Replace if defective. Check fuses, overload. Restart. Check fuses, overloads and controls.

Restart. Check for clogged tubing to switch.

Check switch setting. Add refrigerant. Reset. Reset. Open up valve. Check and clean tubing.

Repair or replace. Remove excess refrigerant. Adjust water regulating valve to con

denser. Clean condenser. Open valve.

Purge air. Check pump and start.

Increase water quantity by adjusting water

regulating valve. Use colder water.

Readjust water regulating valve. Increase size of water supply main to condenser.

Clean tubes. Open valve.

Remove excess refrigerant.

Purge air. Adjust water regulating valve. Open valve.

Examine valve discs and valve seats.

Replace if worn.

Replace.

Reset to 5 F -10 F superheat. Valve opera tion must be stable (no hunting).

Add refrigerant.

Reset expansion valves.

Check alignment and tightness.

Replace defective parts.

Check alignment and tension. (Belt slack should be at top.)

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

Book 2 PC111 Catalog No 530-526 PrintedinUSA Form5F,H-11SI Tab

For replacement items use Carrier Specified Parts.

Pg 37

2-86

Replaces: 5F,H-9SI

Page 38

5F,H

HEATING A COOLING

TROUBLE/SYMPTOM

System noises, (cont)

Compressor will not unload.

Compressor will not load.

Rapid unloader cycling.

Low oil pressure.

Open-Drive Compressors

TROUBLESHOOTING (cont)

PROBABLE CAUSE

Unit foundation improperly isolated.

Improper support or isolation of piping.

Slugging from refrigerant feedback. Check expansion valve setting. Check

Hydraulic knock from excessive oil in circulation.

Defective valve lifter mechanism (noise

level varies with unloading).

Piping vibration. Support pipes as required. Check pipe

No muffler in discharge line or improperly

located. Hissing (insufficient flow through expan

sion valves, orclogged liquid line strainer).

Capacity control valve not operating. Repair. Unloader element sticking. Repair. Hydraulic relay sticking. Replace control cover assembly. Plugged pressure line to power element. Clean line.

External adjusting stem damaged. Low oil pressure (below 35 psi). Check oil charge, switch settings. Capacity control valve stuck open. Repair or replace. Unloader element sticking.

Plugged or broken pressure line to power element.

External adjusting stem damaged. Control oil strainer blocked. Clean or replace. Control valve bellows leaking. Remove thread protector and leak test.

Pipe plug in pneumatic connection.

Foaming in crankcase ^rom refrigerant flooding.

Hydraulic relay sticking.

Excessive fluctuation in suction pressure

from oversized expansion valve.

Partially plugged control oil strainer. Clean or replace strainer.

Low oil pressure. See Trouble/Symptom — low oil pressure.

Low oil charge. Add oil.

Faulty oil gage. Check and replace.

Defective oil pressure regulator.

Clogged oil suction strainer. Clean strainer.

Broken oil pump tang.

REMEDY

Isolate foundation. Use correct piping techniques and support

piping with suitable hangers.

thermal bulb looseness and correct

location. See Carrier System Design Manual, Part 3 for standard piping

techniques.

Remove excess oil. Check expansion valve for floodback.

Replace sticking filter pins. Check un loader fork for alignment. Check power element for sticking piston. Check for oil leakage at tube connection to power element. Check amount of valve pin lift above valve seat (0.33 in. for 5F; 0.125 in. for 5H).

connections.

Install muffler. Move muffler closer to

compressor. Add refrigerant. Clean strainer

Replace.

Repair. Clean or repair.

Replace.

Replace valve body if bellows leaks.

Remove pipe plug.

Check expansion valve and piping.

Replace control cover assembly. Resize expansion valve.

Repair or replace.

Replace pump assembly.

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

Book! 2 PC111 Catalog No 530-526 PrintedinUSA Form 5F,H-11SI Pg 38 2-86 Replaces: 5F,H-9SI

Tab 2a

For replacement Hems use Carrier Specified Parts.

Page 39

5F,H

HEATING A COOLING

Open-Drive Compressors

TROUBLESHOOTING (cont)

TROUBLE/SYMPTOM

Low oil pressure, (cont)

Cold compressor.

Low crankcase oil level. Oil return check valve stuck closed. Cylinders and crankcase

sweating.

High crankcase temperature (should be 150 F to 160 F max. at seal housing).

PROBABLE CAUSE REMEDY

Clogged oil line. Worn oil pump. Worn compressor bearings. Liquid carryover from evaporator.

Refrigerant floodback.

Liquid line strainer clogged. Excessive superheat.

Compression ratio too high.

Discharge temperature over 275 F. Leaking suction or discharge valves.

Remove obstruction. Replace pump assembly. Replace. Check refrigerant charge and expansion

valves. Repair or replace check valve. Check refrigerant charge and expansion

valves. Clean strainer. Reset expansion valves. Recheck design. Check unit application. Replace valves.

. BookI 2 PC 111 Catalog No 530-526 Printed inUS A Form5F,H-11SI Pg 39 2-86 Replaces: 5F,H-9SI

Tab 2a

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

For replacement items use Carrier Specified Parts

Page 40

5F,H

HEATING & COOLING

Open-Drive Compressors

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

Book

Tab

PC 111

Catalog No 530-526 Printed in U S A Form 5F,H-11SI

For replacement items use Carrier Specified Parts

Pg 40 489 2-86 Replaces: 5F,H-9SI