Carrier Compressor and Condensing Unit User Manual

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Compressors and Condensing Units

SELF-LOCKING BOLT

SNUBBER FLANGED WASHER

NEOPRENE SNUBBER

COMPRESSOR FOOT

ISOLATION SPRING

Fig. 1 — Compressor Mounting

Installation, Start-Up and

Service Instructions

Hermetic, Water-Cooled

06E,07E

CONTENTS

SAFETY CONSIDERATIONS INSTALLATION

Receive and Inspect Unit Place Unit in Position Check Compressor Mounting Piping Connections Electrical Connections

PRE-START-UP Evacuate, Dehydrate, and Leak Test Oil Charge START-UP Start Compressor Timer Functions

SERVICE Protection Devices Compressor Thermal Protection Capacity Control System Removing, Inspecting and Replacing

Components Lubrication System Cylinder Heads Pressure Relief Valve Suction and Discharge Valve Plate Assembly Terminal Plate Assembly Compressor Running Gear Removal Compressor Running Gear Replacement Motor Removal Motor Replacement Motor Burnout (Clean-Up Procedure) Condenser Maintenance

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INSTALLATION

Receive and Inspect Unit —

damage. File claim with the shipping company if shipment is damaged or parts are missing.

Local water conditions can cause excessive fouling or pitting of condenser tubes. If such conditions are anticipated, a water treatment analysis is recommended. Refer to Carrier System Design Manual, Part 5, for general water conditioning information.

Place Unit in Position —

well-ventilate d area. Instal l unit where i t will be war mer than conditioned area. Position it to allow sufficient space for refrigerant and water connections and to service compressor. Allow space at one end of condenser for tube cleaning or replacement. Place unit so suction and discharge valves can be easily reached and so oil level can be checked.

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

Level unit and bolt firmly to foundation.

Check Compressor Mounting —

sor mounting bolts and remove shipping blocks from under compressor. Ti ghten all 4 bolts on compressor. Loosen each bolt just enough until the flanged washer can be moved sideways with finger pressure. See Fig. 1.

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

Inspect shipment for

Locate unit on floor in a

Loosen compres-

SAFETY CONSIDERATIONS

Installing, starting up, and servicing this equipment can be hazardous due to system pressures, electrical components, and equipment location (roofs, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up, and service this equipment.

When working on the equipment, observe precautions in the literature, tag s, stickers and labels at tached to the equipment, and other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves. Use care when handling, rigging, and setting bulky equipment.

Electrical shock can cause personal injury and even death. Be sure power to equipment is shut off before installing or servicing this equipment. There may be more than one disconnect. Tag disconnect(s) to alert others not to turn power on until work is completed.

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

Book 2244 Tab 1b2a2b3a

PC 802 Catalog No. 530-601 Printed in U.S.A. Form 06/07E-1SI Pg 1 5-01 Replaces: 06E,07E-9SI

Piping Connections —

lines to connections indicated on condensing unit (Fig. 2). Wat er leaving condenser should not be conne cted di rectly into sewer lines; check local codes.

Attach refrigerant liquid and suction lines to condensing unit (Fig. 2); suction and discharge lines to compressor unit (Fig. 3 and 4). Discharge line muffler and check valve are factory supplied with 06E compressor units. Install the muffler as close to shutoff valve as possible and install the check valve in the discharge line close to the muffler, on the downstream side. When soldering or brazing piping to valves, disassemble the valve or wrap it in wet cloth to prevent damage by heat. Allow flexibility in suction line so compressor suction valve may be moved aside for access to suction strainer.

A solenoid valve is necessary for single pumpout control used on 06E and 07E units. Install the valve (field supplied) in the liquid line, just before expansion valve. A filter drier of adequate size should be installed in liquid line between condenser and solenoid valve.

Pressure relief valve located on top of condenser will open to relieve excessive pressure, allowing refrigerant to escape. Most local codes require piping from valve to outdoors.

Refer to Carrier System Design Manual for standard piping techniques.

Attach water supply and return

Electrical Connections

UNBALANCED 3-PHASE SUPPLY VOLTAGE — Never operate a motor where a phase imbalance in supply voltage is greater than 2%. Use the following formula to determine

the % voltage imbalance: % Voltage Imbalance =

100 x

Example: Supply voltage is 240-3-60

max voltage deviation from avg voltage

average voltage

AB = 243 volts BC = 236 volts AC = 238 volts

A verage Voltage =

Determine maximum deviation from average voltage:

(AB) 243 – 239 = 4 volts (BC) 239 – 236 = 3 volts (AC) 239 – 238 = 1 volt

Maximum deviation is 4 volts. Determine % voltage imbalance:

% Voltage Imbalance = 100 x This amount of phase imbalance is satisfactory as it is below

the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately. Allowing the unit to operate with a voltage imbalance in excess of 2% may void the warranty.

POWER SUPPLY — Field wiring must comply with local and national codes. See Table 1.

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

Line power is brought into control center through indicated opening. Connect line power supply to terminal block TB1; connect power leads to terminals L1, L2 and L3. Connect control circuit power supply (115 volts) to terminals 1 and 15 on terminal block TB2. Refer to Fig. 5.

Wiring connections for field-supplied equipment are shown on wiring diagram. See Fig. 5.

ACCESSORIES — Field-installed accessories for the 06E and 07E units are control circuit transformer and gage panel (3 gages). Refer to accessory literature for installation instructions.

243 + 236 + 238

717

239 volts

= 1.7%

239

121 5

34 27

34 26 1 21 5

121 5

34 27

121 5

34 27

/ 9

34 26 1 21 5

/ 2

DIMENSIONS (in.)

/ 9

34 26 1 21 5

/ 2

121 4

34 27

/ 8

121 4

34 27

/ 2

/2 49

208/230 78 49

208/230 66 49

460, 575 66 43

A022

UNIT 07E VOLTS A B C D E F G H I

460, 575 78 43

B027

208/230 78 49

B033

208/230 69

460, 575 78 43

460, 575 69

D044

compressor motor end is 3 ft.

condenser length at either end.

1. Recommended service space for removal of motor at

2. Recommended service space for removal of tube is one

NOTES:

Fig. 2 — 07E Water-Cooled Condensing Units

NOTE: Recommended service space is 3 ft-0 in. at compressor motor end to allow for motor removal.

DIMENSIONS (in.)

06E UNIT VOLTAGE A B C D E F G

V022

W027

W033

W044

208/230 48 460,575 481/ 208/230 50 460,575 501/ 208/230 50 460,575 501/ 208/230 50 460,575 501/

35 367/ 29 367/ 35 367/ 29 367/ 35 367/ 29 367/ 35 367/ 35 367/

11/ 11/ 11/ 11/ 11/ 11/ 11/ 11/

271/

119

26 1 191/

271/

119

26 1 191/

271/

119

26 1 191/ 271/ 271/

119 119

Fig. 3 — 06E Hermetic Compressor Units

Fig. 4 — 06E Compressors

Table 1 — Electrical Data — Compressor Motor With Circuit Breaker

COMPRESSOR MOTOR DATA CIRCUIT BREAKER

Compressor

Part

Number 06E

250

265

275

299

LRA — MHA — MTA — PW — RLA — XL —

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

pressor or water-cooled condensing unit.

NOTES:

1. Compressor MTA and RLA values are maximum figures.

2. LRA values for PW second winding =

3. 3-Pole XL circuit breakers shown, other 3-Pole XL alternates and 6-Pole PW breakers available. Terminal lugs for circuit breakers available in package 06EA660152 (not shown).

Vo lt a ge

(3 Ph - 60 Hz)

208/230

575 45 36 120 72 2.2 XA461 33 38 124 27.1 460 54 44 173 104 1.3 XA424 42 49 175 35.0

208/230

575 57 46 164 98 1.6 XA469 46 53 164 37.9 460 70 56 223 134 1.1 XA426 55 643 210 45.7

208/230

575 65 52 176 106 1.3 XA430 50 58 168 41.4 460 84 68 253 152 0.9 XA425 63 73 210 52.1

208/230

575 94 75 276 165 1.0 XA551 74 85 236 60.7 460 118 95 345 207 0.58 XA550 92 106 295 75.7

LEGEND

Locked Rotor Amps Must Hold Amps Must-Trip Amps Part-Winding (Start) Rated Load Amps Across-the-Line (Start)

Maximum

Must Trip

Amps

Maximum

RLA

108 87 345 207 0.32 HH83XB336 91 104 350 74.3

140 112 446 268 0.27 HH83XC509 110 127 420 90.7

168 135 506 304 0.22 HH83XC539 142 163 507 116.4

236 189 690 414 0.15 HH83XC537 187 215 636 153.6

/2 the LRA – XL value.

LRA-XL

LRA-PW

(first

winding)

Motor

Winding

Resistance

(Ohms)

4. Recommended RLA value shown is determined by: circuit breaker must trip value ÷ 1.40. Use this recommended (and minimum) RLA value to determine nameplate stamping, minimum contactor sizing, and wire sizing. RECOMMENDED RLA FOR 06E COMPRESSORS EQUALS: MUST-TRIP (MTA) OF CARLYLE APPROVED OVERCURRENT DEVICE BEING USED ÷ 1.40

5. Compressor operating amps at any specific condition can only be determined from a performance curve.

6. Ohm values for resistance are approximate and shown for reference purposes only. Motors from different vendors and motors of different efficiencies can differ up to 15% from data shown.

7. Electrical data for compressor part numbers 06ER, 06EM and 50 Hz models (not shown) are available from Carrier Sales Representative.

Recommended Circuit Breaker

Part No.

MHA MTA LRA

Recommended

RLA

C1 — C2 — CCB — CHR — CR — FU — GND — HPS — LPS — NEC — NEMA —

OPS — POR — TB — TDR — TM — TR —

LEGEND

Compressor Contactor Compressor Contactor (PW) Compressor Circuit Breaker Crankcase Heater Relay Control Relay Fuse Ground High-Pressure Switch Low-Pressure Switch National Electrical Code National Electrical Manufacturer’s Association Oil Pressure Switch Pumpout Relay Terminal Block Time Delay Relay Timer Motor Timer Relay

Fig. 5 — Component Location

AUX — C— C1 —

C2 —

CH — CHR — CR — DTS — DX — FU — HPS — LLS — LPS —

Auxiliary Compressor Contactor Compressor Contactor (XL start and first step of PW start) Compressor Contactor (PW second step) Crankcase Heater Crankcase Heater Relay Control Relay Discharge Temperature Sensor Direct Expansion Fuse High-Pressure Switch Liquid Line Solenoid Valve Low-Pressure Switch

M1 —

M2 — M3 — NEC — OPS — POR — PW — SW — TB — TDR — TM — TR — XL —

LEGEND

Evaporator Fan or Chilled Water Pump Cooling Tower Pump Cooling Tower Fan National Electrical Code Oil-Pressure Switch Pumpout Relay Par t Wind Start-Stop-Reset Switch Terminal Block Time Delay Relay Timer Motor Timer Relay Across-the-Line

Terminal Block Connector

Unmarked Terminal

Marked Terminal

Factory Wiring

Field Control Wiring To indicate common potential only;

not to represent wiring. Splice

NOTES:

1. Factory wiring is in compliance with NEC. Any field modifications or additions must be in compliance with all applicable codes. Use copper, copper-clad aluminum for field power supply only.

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

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

4. Pilot duty control must be field supplied. Minimum contact rating must be 25 va.

5. 60 Hz units have 120 volt control circuit. 50 Hz units have 230 volt control circuit. A separate source of supply at the correct voltage must be field supplied supply at the through a fused disconnect

Fig. 6 — Control Circuit Wiring for 06E/07E Units

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

6. Open control circuit disconnect switch for servicing only. Disconnect must remain closed for crankcase heater to operate.

7. A transformer of the following rating may be field supplied for 60 Hz units: 350 va.

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

9. If any of the original wiring furnished must be replaced, it must be replaced with 90 C wire or its equivalent.

10. Wiring is shown for single pumpout control. Single pumpout control should not be used on direct-expansion (DX) cooler applications (see lower diagram for wiring when applied with DX cooler).

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