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HVAC System for jack-up drilling unit 2000E-07/08

OPERATION AND MAINTENANCE MANUAL

FOR

REF. SYSTEMS

DOCUMENT NUMBER:
PROJECT NAME: JU2000E-07/08
PROJECT NUMBER:
CLIENT: Dalian Shipbuilding Industry Co., Ltd
CONTRACTOR: Shanghai Cadar International Trading Co., Ltd
CONTRACT NUMBER:

Shanghai Cadar International Trading Co., Ltd

Rm7F/B, 567 ZHONGHUA ROAD. Zip:200010

TEL: 21-63185528 FAX: 21-63185399

E-mail:cadar@online.sh.cn
CONTENTS

1 GENERAL DESCRIPTION
1.1 DESIGN CONDITIONS
2 CONTRAL DIAGRAMS
3 MAINTENANCE SCHEDULES
3.1 CONDENSING UNIT
3.2 AIR COOLERS
4 EQUIPMENT CATALOGUE DATE,SCHEDULES AND DATE SHEETS
4.1 MAJOR EQUIPMENT LIST
4.2 CONTROL VALVE PLATE AND THERMOSTATS
5 SPARE PARTS AND TOOLS
6 DOCUMENT AND MAINTENANCE
Section 1

GENERAL DESCRIPTION
1.1 Designed conditions

1.1.1 Design temperature

Chamber Approx. volume. (m3) Room temp. (℃ ) Cooling type

Freezer room abt.16.38 -25 Unit cooler with

electric defrost

Chiller room abt.16.38 2 Unit cooler

Dry storage abt.24.15 13 Unit cooler

Ex-poof

1.1.2 Highest/ lowest outside air temperature: 45 ~ -20 deg.C

1.1.3 Highest/ lowest outside humidify: 90% R.H ~ 30% R.H

1.1.4 Highest/ lowest sea water temperature: 35 ~ 0 deg.C

1.1.5 Maximum wind velocity (1 min. Mean): 36.01m/s

1.1.6 Volume is inside net volume

1.1.7 Electric power: 480 Volt, 3 Phase, 60 Hz

220 Volt, 1 Phase, 60 Hz


Section 2

CONTROL DIAGRAMS
Section 3

MAINTENANCE SCHEDULES
3.1 CONDENSING UNIT
Component Maintenance Required Interval

Compressor/motor Check oil levels Weekly

Compressor/motor
Check holding down bolts are secure Monthly

Compressor/motor
Check for oil leaks Monthly

Compressor/motor
Check that the unit anti-vibration mounts are free and center Monthly

Compressor/motor Monthly
Check sump heater operation

Compressor/motor 6 Monthly
Check vibration signature and compare with base signature

Compressor/motor 12 Monthly
Examine the interior of motor terminal junction box for moisture and check that all

connections are clean and tight

Compressor/motor 12 Monthly
Remove motor terminal cover and carry out insulation tests between motor poles

and earth

Compressor/motor 12 Monthly
Check compressor efficiency

Weekly
Sight glass (liquid line) Check clear

3 Monthly
Refrigeration system Check entire refrigeration circuit for leads with leak detector (vessel approved

model) and check fittings

Refrigeration system Examine the exterior of the vessel for visible signs of leads and for damage 12 Monthly

Evaporator vessel Remove end caps and clean tubes. Check for corrosion and record findings. 12 Monthly

Condenser Clean the condenser water pipes 3 Monthly


3.2 AIR COOLERS
Component Maintenance Required Interval

Air cooler fan Check for unusual noise and vibrations Monthly

Air cooler fan Check vibration signature and compare with base signature. Monthly

Air cooler fan Check pulleys for security and alignment. 6 Monthly

Air cooler fan Check impeller for accumulation of debris and structural integrity. 6 Monthly

Air cooler fan Check impeller is secure on shaft and shaft is free of end float and journal wear 6 Monthly

Check that lubricant is not leaking from bearing housings. If bearings show signs of
Fan Bearings 6 Monthly
excessive play, replace them.

Air cooler fan motor Check for unusual noise and vibrations Monthly

Air cooler fan motor Check belt tension and for excessive wear. Monthly

Air cooler fan motor Check fixing are secure. Monthly

Air cooler fan motor Check vibration signature against base signature and record. Monthly

Air cooler fan motor Check bearing temperatures for overheating. 6 Monthly
Section 4

EQUIPMENT CATALOGUE DATE,


SCHEDULES AND DATA SHEETS
4.1 MAJOR EQUIPMENT LIST
Item Equipment name Equipment Type Description Tech. data Remark

1 Ref. Cond. unit MPE(F)-7 Package ref. Condensing unit Weight: abt. 380kg

² Condensing unit (two sets2 X100%) Cooling Capacity: 6.1kW

Ø Compressor(carrier) Compressor: reciprocating semi-hermetic type

Refrigerant: R404A

Ø Condenser Voltage: AC480v, 3Ph, 60Hz

Compressor model: 06DR228

Ø Oil separator Capacity control: 33%, 66%, 100%

SST/SDT: -32.9/54.4 ℃

Ø Suction line accumulator Nominal power: 5.75 kW

Condenser type: Air cooled

Cooling air flow: 4500 m3/h

Condenser coil: Cu tube & Cu fins with epoxy coating

2 Air cooler A LUC-15A Air Cooler for freezer (25℃) with automatic defrosting & Cooling capacity: 2.6 kW

dip pan and drain pipe heater Air flow: abt.2 X2700m3/h

Fan motor power: 2 X 0.16kW

Electric defrost power: 2.1kW

Weight: abt. 65kg

3 Air cooler B HUC-8A Air Cooler for chiller Cooling capacity: 2 kW

Air flow: 1700m3/h

Fan motor power: 0.11kW

Weight: abt. 35kg

4 Air cooler C HUC-13A Air Cooler for dry store Cooling capacity: 2.9 kW

Air flow: abt.1700m3/h

Fan motor power: 0.18kW

Weight: abt. 50kg

Explosion-proof: EExd IIB T4(CNEX)


4.2 CONTROL VALVE PLATE AND THERMOSTATS
Item Equipment name Equipment Type Description Tech. data Remark

1 Valve board A Control valve plate for freezer Thermo. Expansion valve: TS2-1.7

Solenoid valve: EVR10

Stop valve: BML10S

BML12s

BML22S

Non-return valve: NRV22S

2 Valve board B Control valve plate for chiller Thermo. Expansion valve: TS2-1.2

Solenoid valve: EVR10

Stop valve: BML10S

BML12s

BML22S

Eva. Press. Regulator valve: KVP22

3 Valve board C Control valve plate for dry store Thermo. Expansion valve: TS2-1.2

Solenoid valve: EVR10

Stop valve: BML10S

BML12s

BML22S

Eva. Press. Regulator valve: KVP22

4 RT7 Thermostats(Danfoss)

5 MR11 Thermostats(Danfoss) MR11 to be premounted on control panel 3sets

6 Dial thermometer(each with capillary tube about 3 m) Range: -40℃~ 40℃ 3sets

7 Flexible connector φ28X450mm 2sets

8 Flexible connector φ16X450mm 2sets

9 Vibration absorber BE120 8 sets

10 Zone generator OZ-1t

11 Elec. Control box Weight: abt. 280 kg


Section 5

SPARE PARTS AND TOOLS


ITEM EQUIPMENT PART DESCRIPTION PART NUMBER QUANTITY

1 Refrigeration Plant Valve plate gasket 05DA500153 3 pcs

2 Refrigeration Plant Cylinder head gasket 05GA502173(center) 1 pc

3 Refrigeration Plant Cylinder head gasket 05GA502223(side) 2 pcs

4 Refrigeration Plant Filter & dryer core D48 1 pc

5 Ref Control panel Contactor LC1-D18M7C 1 pc

6 Ref Control panel Relay CAD-32M7C 1 pc

7 Ref Control panel Pilot lamp XB2-BVM3LC 1 pc

8 Ref Control panel Pilot lamp XB2-BVM1LC 1 pc

9 Ref Control panel Fuse RL98-16 2A 2 pcs


Section 6

DOCUMENT AND MAINTENANCE


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O6D/E APPLICATION GUIDE

TM
TABLE OF CONTENTS
General Information ................................................................................2 4.0 Compressor Features and Accessories .......................................36
Features of Carlyle 06D/E Compressors ............................................................2 4.1 06D Compressor Motor Protection.......................................................36
06D/E Model Number Significance.....................................................................4 4.2 06E Compressor Motor Protection........................................................37
06D/E Compressor Specification Tables............................................................5 4.3 Rated Load Amperes (RLA) and
06D/E Refrigeration Compressor Specifications .......................................5 Maximum Continuous Current (MCC) ................................................41
06D/E Compressor Specifications (60 Hz Units)......................................6 4.4 06D Compressor MCC Values .................................................................42
06D/E Compressor Specifications (50 Hz Units) ......................................7 4.5 06E Compressor MCC Values ................................................................42
06D/E Compressor Specification Drawings .....................................................8 4.6 06D Compressor Contactor Selection..................................................42
06D Medium/High Temperature Compressors..........................................8 4.7 06D Compressors: Wire Sizing ............................................................42
06D Low Temperature Compressors .............................................................11 4.8 06E Compressors: Contactor Selection and Wire Sizing..............43
06E Medium/High Temperature Compressors.........................................14 4.9 Compressor Nameplate Data..................................................................43
06E Low Temperature Compressors.............................................................15
5.0 Compressor Features and Accessories.......................................44
1.0 System Design Considerations.......................................................17
5.1 Safety Relief Valves....................................................................................44
1.1 General Application Information...........................................................17 5.2 Suction Strainers.........................................................................................44
1.2 Compressor Rating Notes .........................................................................17 5.3 Oil Safety Switch.........................................................................................44
1.3 Refrigerant Piping........................................................................................19 5.4 Crankcase Heaters ......................................................................................45
1.4 Vibration Isolation......................................................................................20 5.5 Mufflers ..........................................................................................................45
1.5 Refrigerant Migration and Floodback ................................................20 5.6 Baffle Plates..................................................................................................46
1.6 Clean and Dry System................................................................................21 5.7 Discharge Line Check Valves..................................................................46
1.7 Prevent Excessive Discharge Temperatures......................................21 5.8 Suction Cut-Off Capacity Control .........................................................46
1.8 Compressor Interconnection....................................................................21 5.9 Cylinder Head Cooling Fans....................................................................46
1.9 Motor-Compressor Selection...................................................................24 5.10 Spring Mounting .........................................................................................47
1.10 Outdoor Use ..................................................................................................24 5.11 Solid Mounting.............................................................................................47
1.11 Code Approvals ............................................................................................24 5.12 Electrical Terminal Parts ..........................................................................47
5.13 Conduit Adapter Plates.............................................................................47
2.0 Compressor Lubrication System..................................................25 5.14 SAE Adapter Fitting ...................................................................................47
2.1 Compressor Lubrication ...........................................................................25 5.15 Service Valves...............................................................................................48
2.2 The Oil Pump ................................................................................................27
2.3 Recommended Oils.....................................................................................27
2.4 06D/E Oil Pressure History .....................................................................27

3.0 Capacity Control ..............................................................................29


3.1 Suction Cut-Off Capacity Control .........................................................29
3.2 Design for Proper Oil Return ..................................................................29
3.3 Capacity Control Application Ranges.................................................29
3.4 Pump-Down Control..................................................................................30
3.5 Unloader Differential Setting.................................................................30
3.6 Part Load Performance Factors ..............................................................31
3.7 Location and Size of Capacity Control Head Assembly ...............31
3.8 Pressure Differential Required to Load Compressor .....................32
3.9 Electric Solenoid Capacity Control Operation ..................................32
3.10 Suction Pressure Capacity Control Operation..................................33
3.11 Pressure Actuated Capacity Control Adjustment ..........................34
3.12 Variable Frequency Drives.......................................................................35

1
General Information
Features of Carlyle 06D/E Compressors

Discharge Valve Canted


Valve
Plate
Vented
Connecting Hi-Lift
Rods Discharge
Valve

Capacity
Control
System

Contoured
Pistons
Automatic
Reversible
Oil Pump

Oversize
Oil Sump
Oil Filter
Screen
Oil Drain Assembly
Connection

2
Carlyle 06D/E semi-hermetic compressors are ideally suited for commercial refrigeration, air conditioning, process cooling,
and environmental chambers. They are extremely flexible and may be used with many of the new HFC refrigerants such as
R-507, R-404A, and R-134a, in addition to the conventional refrigerants (R-12, R-22, and R-502). The compressors may be oper-
ated at 50 or 60 hertz and are UL (Underwriters’ Laboratories), CSA (Canadian Standards Association), and ISO 9002 approved.
Many of the prominent features of the 06D/E compressors are listed below.
High Efficiency Valving System
The valving system utilizes low lift valves and high flow ports to reduce valve losses, maximize efficiency, and reduce valve
stress. Carlyle’s valves are made of Swedish steel, the finest material available for this application.
Contoured Pistons and Vented Connecting Rods
The pistons are contoured allowing the suction valves to mate up with the recess in the pistons, resulting in reduced clear-
ances which increases both capacity and efficiency. The connecting rods are also vented to provide premium bearing lubrication
and longer life.
Automatic Reversible High Flow Oil Pump
The positive displacement vane type oil pump is extremely durable and produces a high volume of oil flow. With the new
HFC refrigerants and POE (polyolester) oils (which are more soluble), the 06D/E oil pump will produce oil pressure quickly,
reducing the potential for nuisance oil pressure trips.
Oversize Oil Sump
On start-up, oil level can temporarily drop too low, causing unnecessary wear in other compressor designs because on shut-
down, the oil is diluted by refrigerant. The Carlyle oversize oil sump holds extra oil in crankcase to prevent normal oil migration
from dropping the oil level below the safe lubrication range.
High Efficiency Heavy Duty Motors
These motors have the latest insulation systems which helps to prevent motor burnouts, especially during hot weather
periods, when operating pressures, temperatures, and currents (amps) are high.
Suction Inlet Screen
The suction inlet screen prevents installation scale or abrasives from entering the compressor and shortening the life of the
motor and compressor.
Oversize Suction Gas Passages
The oversize suction gas passages generate less turbulence, lower pressure drops and more efficient motor cooling by suction
gas, thereby producing a cooler motor that has a more economical operation and longer life.
Main Bearings and Running Surface Steel Backed Aluminum or Tin Based Babbitt
Aluminum or tin based babbitt material is used on bearing surfaces to provide greater load carrying ability than other types
of materials and are also less susceptible to damage from overheating or liquid refrigerant.
Crankcase Oil Heater
This optional accessory warms crankcase oil to reduce refrigerant migration which occurs during shutdown periods.
Capacity Control System
Suction cut-off unloading is an option on all four and six cylinder Carlyle 06D/E compressors. Suction cut-off unloading is
an efficient method of capacity control that literally blocks off the suction of two cylinders at a time. This method is not only
efficient, but results in much cooler operating temperatures than hot gas bypass style designs.
ISO 9002 Registration
Carlyle Compressor has ISO 9002 Registration by Underwriters’ Laboratories, Inc. to manufacture 06D/E semi-hermetic recip-
rocating compressors ranging in size from 2 to 40 tons of refrigeration capacity. That means we have a top quality system in
place and will be continually working to improve it. So you can be assured you will always be getting the highest quality com-
pressors with Carlyle.

3
06D Compressor Model Number Significance 06E Compressor Model Number Significance

06DR 3 37 0 D A 36 5 A 06ER 3 99 3 0 A

Model = 0, Package = 1 or 9, A = Shipped Without Oil Model = 0, Package = 1 or 9, A = Shipped Without Oil

Suction Cut-Off Unloading Designation for 06DR, DM Compressors: Design Variable:


0 = All Models Except as Noted New Compressors:
5 = No Oil 0 = OEM Model
7 = 1 Unloader Elec. (DR, DM Only) 1 = Carrier A/C Model (New)
6 = Carrier A/C Model (Old)
Electrical Characteristics (XL Start Only, Unless Noted):
New H.E. Models Old Std. Models Service Compressors:
31 = 575-3-60 01 = 575-3-60 2 = New Manufactured (A/C)
32 = 208/230-3-60 04 = 200-3-60 4 = Remanufactured (Low Temp.)
33 = 208/230-1-60 05 = 230-3-60 6 = Remanufactured (A/C)
34 = 220-3-50 06 = 400/460-3-50/60 7 = Remanufactured (Med Temp.)
36 = 400/460-3-50/60 08 = 220-3-50
12 = 208/230-3-60 Electrical Characteristics (XL and PW Start, Unless Noted):
13 = 380-3-60 0 = 208/230-3-60
14 = 200-3-60 (PW) 1 = 575-3-60
15 = 230-3-60 (PW) 3 = 208/230/460-3-50 (460v XL Only)
18 = 220-3-50 (PW) 4 = 200-3-60
5 = 230-3-60
Electrical Variables: 6 = 400/460-3-50/60
A = With Internal Thermostat and External Overloads 8 = 230-3-50
C = With Internal Thermostat and Without External Overloads 9 = 220/380-3-60

Suction Valve - Variables: Displacement (in Cfm at 1750 rpm) (See Note below)
Location, Orientation and Mounting Bolts
Motor Size (Does Not Signify Horsepower)
Compressor Identification Key: 0, 1, 2 = Models With Oil
0 = New Compressor, DR, DM (OEM) or A/C (Carrier) 3, 4, 5 = Models Without Oil
2 = New Compressor, A/C (OEM) 7 = 1 Unloader, Elec. (ER, EM Only)

4
3 = New Compressor, Tyler (Carrier)
6 = Service Compressor, Remanufactured Compressor Type:
7 = Service Compressor, New Manufactured STD* REV†
8 = New Compressor, Special 06EA 06EF New Compressor - A/C Duty No Unloading
9 = Service Compressor, Special 06EB 06EJ New Compressor - A/C Duty 1-Step Elec.
06EC 06EK New Compressor - A/C Duty 2-Step Elec. Old Design
Displacement (in Cfm at 1750 rpm) (See Note below) 06ED 06EL New Compressor - A/C Duty 1-Step Press. Hot Gas Bypass
06EE 06EN New Compressor - A/C Duty 2-Step Press.
} Unloading
Motor Size - No Significance 06E2 06E6 New Compressor - A/C Duty 1-Step Elec. New Design
06E3 06E7 New Compressor - A/C Duty 2-Step Elec. Suction Cut-Off
Compressor Type: 06E4 06E8 New Compressor - A/C Duty 1-Step Press.
} Unloading
06DA = New Compressor - A/C Duty No Unloading 06E5 06E9 New Compressor - A/C Duty 2-Step Press.
06DB = New Compressor - A/C Duty 1-Step Elec. 06EM - New Compressor - Refrig. Duty Med Temp.
06DC = New Compressor - A/C Duty 2-Step Elec. Old Design 06ER - New Compressor - Refrig. Duty Low Temp.
06DD = New Compressor - A/C Duty 1-Step Press. Hot Gas Bypass 06ET - Serv. Compressor A/C Duty Replaces 06E2,3,4,5,6,7,8, and 9
06DE = New Compressor - A/C Duty 2-Step Press. Unloading
} 06EX - Serv. Compressor A/C Duty Replaces 06EA,B,C,D,E,F,J,K,L, and N
06DF = New Compressor - A/C Duty 1-Step Elec. 06EY - Serv. Compressor Refrig. Duty Replaces 06ER
New Design 06EZ - Serv. Compressor Refrig. Duty Replaces 06EM
06DG = New Compressor - A/C Duty 2-Step Elec. Suction Cut-Off
06DH = New Compressor - A/C Duty 1-Step Press. Unloading
}
06DJ = New Compressor - A/C Duty 2-Step Press. * Standard Center Cylinder Head.
06DM = New Compressor Refrig. Duty Medium Temperature † Reversed Center Cylinder Head.
06DR = New Compressor Refrig. Duty Low Temperature
06DM = Service Compressor-Replacement for New 06DA, DM without Unloading NOTE: USE OF “Cfm” AS MODEL SIZE DESIGNATION
06DS = Service Compressor-Replacement for New 06DF,G,H and J with
Suction Cut-Off Unloading Carlyle uses the “Cfm” designation in the model number to identify the compressor size. The Cfm
06DX = Service Compressor-Replacement for New 06DB, C, D, and E with values are the sixth and seventh digits of the model number. See example above.
Hot Gas
Carlyle offers two series of compressors based on body size. The smaller compressors, from 8 to 37
Cfm, are referred to as “D” size units (model number “06D”). The larger compressors, from 50 to
LEGEND 99 Cfm, are referred to as “E” size units (model number “06E”).
A/C – Air Conditioning
OEM – Original Equipment Manufacturer LEGEND
PW – Part Wind A/C – Air Conditioning
XL – Across-The-Line OEM – Original Equipment Manufacturer
PW – Part Wind
XL – Across-The-Line
06D/E Refrigeration Compressor Specifications
06D/E Compressor Specification Tables

5
LEGEND
LRA – Locked Rotor Amps
RLA – Rated Load Amps
06D/E Compressor Specifications (60 Hz Units)

6
06D/E Compressor Specifications (50 Hz Units)

7
06D/E Compressor Specification Drawings
06D Medium/High Temperature Compressors

17.93

2.01 3/8-16 x 7/8 LG


CAPSCREW *
* = CUSTOMER
SUPPLIED
LOCKWASHER *
.19 PLATEWASHER *
SPRING CUP
45°
COMPRESSOR FOOT 1.25 WELD
MOTOR END AND (TYP.)
PUMP END (TYP.)
7
.623 DIA. (TYP.)
14.97 O /8
D .627
S
14.86
3.75 3.69
SPRING MOUNTING ARRANGEMENT

5.52

2.19 2.91
8.87 6.00
10.00 12.88

CYLINDERS: 2
CFM: 8
MODELS: 06DA808
06DM808
UNLOADING AVAIL: NO
STEPS: 0

TERMINAL BOX DATA

14.67 21.52
6.94
3/8-16 x 7/8 LG
MTG HOLE CAPSCREW *
4.44 * = CUSTOMER
SUPPLIED
LOCKWASHER *
.19 PLATEWASHER *
5/8
ODS SPRING CUP
COMPRESSOR FOOT 1.25 WELD
MOTOR END AND (TYP.)
PUMP END (TYP.)
6.87 .623 DIA. (TYP.)
.627
16.09
7/8 ODS
15.02
SPRING MOUNTING ARRANGEMENT

6.27

8.87 6.00
10.00 14.88
18.30

CYLINDERS: 4
CFM: 13, 16
MODELS: 06DM313
06DM316
UNLOADING AVAIL.: YES
STEPS: 1

TERMINAL BOX DATA

NOTE: ALL DIMENSIONS ARE IN INCHES


Multiple service valve orientations are possible

8
06D Medium/High Temperature Compressors (cont’d.)

14.67 21.71
6.94 MTG HOLE CAPSCREW * CAPSCREW *
3.43 3/8–16 x 1.50 LG 3/8–16 x 7/8 LG
* = CUSTOMER
SUPPLIED
LOCKWASHER * PLATEWASHER*
WELD .19
7/8 ODS (TYP)

1.25 1.31
10.30

.623
7.17 .627 DIA.
(TYP.)
17.51 1 1/8
ODS
COMPRESSOR END FOOT MOTOR END FOOT
18.20
15.95
SPRING MOUNTING ARRANGEMENT

7.21

8.25 13.88
17.30

CYLINDERS: 4
CFM: 18
MODELS: 06DA818
UNLOADING AVAIL: YES
STEPS: 1

TERMINAL BOX DATA

24.01
20.91 CAPSCREW * CAPSCREW * * = CUSTOMER
MTG HOLE 3/8–16 x 1.50 LG 3/8–16 x 7/8 LG SUPPLIED
17.72
8.21 3.28 LOCKWASHER * PLATEWASHER*
WELD .19
1 1/8 (TYP)
ODS

1.25 1.31

8.94 .623
7.65
.627 DIA.
(TYP.)
1 5/8 ODS
COMPRESSOR END FOOT MOTOR END FOOT

SPRING MOUNTING ARRANGEMENT


16.09

6.34

11.38 12.79

CYLINDERS: 6
CFM: 28, 37
MODELS: 06DA328
06DA537
06DM337
06DR228
06DR337
UNLOADING AVAIL: YES
STEPS: 2 TERMINAL BOX DATA

NOTE: ALL DIMENSIONS ARE IN INCHES


Multiple service valve orientations are possible NOTE: 10 Hp, 208/230 v models use 3 overloads.
9
06D Medium/High Temperature Compressors (cont’d.)

23.38
20.88 CAPSCREW * CAPSCREW * * = CUSTOMER
16.35 MTG HOLE 3/8–16 x 1.50 LG 3/8–16 x 7/8 LG SUPPLIED
7.70 3.26 LOCKWASHER * PLATEWASHER*
WELD .19
1 1/8
ODS
(TYP)

1.25 1.31

8.36 .623
7.07 .627 DIA.
(TYP.)
1 3/8
ODS
COMPRESSOR END FOOT MOTOR END FOOT

15.51
SPRING MOUNTING ARRANGEMENT

6.34

11.38 12.79 4.84

CYLINDERS: 6
CFM: 24
MODELS: 06DA824
06DR724
UNLOADING AVAIL: YES
STEPS: 2

TERMINAL BOX DATA

NOTE: ALL DIMENSIONS ARE IN INCHES


Multiple service valve orientations are possible

10
06D Low Temperature Compressors

17.93
3/8-16 x 7/8 LG
2.01
CAPSCREW *
* = CUSTOMER
SUPPLIED
LOCKWASHER *
.19 PLATEWASHER *
SPRING CUP

45°
COMPRESSOR FOOT 1.25 WELD
MOTOR END AND (TYP.)
PUMP END (TYP.)
.623 DIA. (TYP.)
7
.627
14.97 O /8
D
S
14.86
3.75 3.69
SPRING MOUNTING ARRANGEMENT

5.52

2.19 2.91
8.87 6.00
10.00 12.88

CYLINDERS: 2
CFM: 9
MODELS: 06DR109
UNLOADING AVAIL: NO
STEPS: 0

TERMINAL BOX DATA

3/8-16 x 7/8 LG
CAPSCREW *
* = CUSTOMER
SUPPLIED
21.90 LOCKWASHER *
12.00 .19 PLATEWASHER *
SPRING CUP
COMPRESSOR FOOT 1.25 WELD
MOTOR END AND (TYP.)
PUMP END (TYP.)
MTG HOLE 4.44 .623 DIA. (TYP.)
.627

SPRING MOUNTING ARRANGEMENT

8.87 6.00
10.00 14.88
6.94 18.30
14.67 21.52

CYLINDERS: 4
CFM: 13, 16
MODELS: 06DR013
06DR316
UNLOADING AVAIL: YES
STEPS: 1

TERMINAL BOX DATA

NOTE: ALL DIMENSIONS ARE IN INCHES


Multiple service valve orientations are possible

11
06D Low Temperature Compressors (cont’d.)

CAPSCREW * CAPSCREW * * = CUSTOMER


3/8–16 x 1.50 LG 3/8–16 x 7/8 LG SUPPLIED
23.89 LOCKWASHER * PLATEWASHER*
12.00
WELD .19
(TYP)

1.25 1.31

.623
7/8
.627 DIA.
(TYP.)
ODS

COMPRESSOR END FOOT MOTOR END FOOT


26.59 MTG HOLE

8.19
7.17
3.43
SPRING MOUNTING ARRANGEMENT
21.09 1 5/8 ODS

15.95
16.09

7.21

8.25 13.88
6.94 18.72
14.67 23.51

CYLINDERS: 4
CFM: 18, 20
MODELS: 06DR718
06DR820
UNLOADING AVAIL: YES
STEPS: 1

TERMINAL BOX DATA

CAPSCREW * CAPSCREW * * = CUSTOMER


3/8–16 x 1.50 LG 3/8–16 x 7/8 LG SUPPLIED
26.14 24.06 LOCKWASHER * PLATEWASHER*
12.00
WELD .19
(TYP)

1.25 1.31
20.64
.623
.627 DIA.
(TYP.)
1 1/8
ODS
COMPRESSOR END FOOT MOTOR END FOOT
8.36
MTG
SPRING MOUNTING ARRANGEMENT
7.07 3.26 HOLE
1 3/8 ODS

15.51

6.34

11.38 12.78 4.84


7.70 23.38
16.35

CYLINDERS: 6
CFM: 24
MODELS: 06DR724
UNLOADING AVAIL: YES
STEPS: 2

TERMINAL BOX DATA

NOTE: ALL DIMENSIONS ARE IN INCHES


Multiple service valve orientations are possible

12
06D Low Temperature Compressors (cont’d.)

CAPSCREW * CAPSCREW * * = CUSTOMER


26.43 3/8–16 x 1.50 LG 3/8–16 x 7/8 LG SUPPLIED
LOCKWASHER * PLATEWASHER*
12.00
WELD .19
(TYP)

20.93 1.25 1.31

.623
1 1/8
.627 DIA.
(TYP.)
ODS

COMPRESSOR END FOOT MOTOR END FOOT

8.94
7.65
MTG
20.91 SPRING MOUNTING ARRANGEMENT
3.28
HOLE
1 5/8
ODS

16.09
6.34

11.38 12.79
8.21 24.01
17.72

CYLINDERS: 6
CFM: 28, 37
MODELS: 06DR228
06DR337
UNLOADING AVAIL: YES
STEPS: 2
TERMINAL BOX DATA
NOTE: 10 Hp, 208/230v models use 3 overloads.

NOTE: ALL DIMENSIONS ARE IN INCHES


Multiple service valve orientations are possible

13
06E Medium/High Temperature Compressors*

CYLINDERS: 4
CFM: 50
MODEL: 06EA250
UNLOADING AVAIL: YES
STEPS: 1

CYLINDERS: 6
CFM: 68
MODEL: 06EA265
UNLOADING AVAIL: YES
STEPS: 2

CYLINDERS: 6
CFM: 65, 75
MODELS: 06EA275
06EM175
UNLOADING AVAIL: YES
STEPS: 2

NYLOK CAPSCREW NYLOK CAPSCREW


3/8-16 x 2.00 LONG MOUNTING 3/8-16 x 1.75 LONG
WASHER
SNUBBER
SNUBBER

SPRING
SPRING 1.31 1.38 CUP
GUIDE
SPRING
GUIDE
.25
PUMP END FOOT MOTOR END FOOT

SPRING MOUNTING ARRANGEMENT

*All of the compressors pictured on this page use the same TERMINAL BOX DATA
terminal box and mounting foot.
NOTE: ALL DIMENSIONS ARE IN INCHES

14
06E Medium/High Temperature Compressors*

NYLOK CAPSCREW NYLOK CAPSCREW


3/8-16 x 2.00 LONG MOUNTING 3/8-16 x 1.75 LONG
WASHER
SNUBBER
SNUBBER

SPRING
SPRING 1.31 1.38 CUP
GUIDE
SPRING
GUIDE
.25
PUMP END FOOT MOTOR END FOOT

SPRING MOUNTING ARRANGEMENT

CYLINDERS: 6
CFM: 99
MODELS: 06EA299
06EM199
UNLOADING AVAIL: YES
STEPS: 2

TERMINAL BOX DATA

*All of the compressors pictured on this page use the same terminal box and mounting foot.
NOTE: ALL DIMENSIONS ARE IN INCHES

15
06E Low Temperature Compressors*

CYLINDERS: 4
CFM: 50
MODELS: 06ER150
06EM150*
UNLOADING AVAIL: YES
STEPS: 1
*The 06EM150 does not have head
fan assembly.

CYLINDERS: 6
CFM: 65, 75, 99
MODELS: 06ER165
06ER175
06ER099
UNLOADING AVAIL: YES
STEPS: 2

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

*All of the compressors pictured on this page use the same terminal box and mounting foot.
NOTE: ALL DIMENSIONS ARE IN INCHES

16
1.0 – System Design Considerations

1.1 General Application Information Liquid subcooling increases system capacity


The 06D and 06E compressors are versatile in their by approximately 1/2 of 1% for each degree Fahrenheit
application. Compressors are available for operation (.5˚C) of subcooling for R-12, R-22, and R-502. With
in low temperature R-502, medium temperature R-12, HFC refrigerants R-134a, R-404A, and R-507, the sub-
and air conditioning R-22 applications. Recent design cooling correction is higher and in most cases a cor-
modifications allow the use of HFC refrigerants rection of 6/10 of 1% for each degree Fahrenheit (.5˚C)
R-134a, R-404A, R-407C, and R-507. This guide pro- can be used. When correcting for subcooling, power
vides information and recommendations for the suc- input to the compressor motor does not change.
cessful application of compressors in HVACR.
Refrigerant temperatures (suction and condensing)
Maximum operating conditions of the compressor are saturation temperatures corresponding to pres-
models are generally defined in the performance sures indicated at the compressor service valves.
curves and will differ with each model. Operating Actual gas temperatures are higher because of super-
conditions should be controlled so that the discharge heat.
gas does not exceed 275˚F (135˚C) at the discharge ser-
vice valve and that oil temperature does not exceed Capacities are based on the actual suction gas tem-
160˚F (71˚C). For HFC/POE applications the maximum peratures to the compressor of 65˚F (18˚C) for refriger-
recommended discharge temperature is 250˚ F ants 12, 502, 134a, 404A, and 507. Superheating
(121˚ C). occurs in the evaporator and in the suction line with-
in the refrigerated space, or in a liquid-suction heat
1.2 Compressor Rating Notes exchanger so that all the superheat produces useful
cooling. Superheating that occurs outside the refriger-
Performance for most standard conditions are plotted
ated space is a loss, but is a compressor load. If
in tabular data or rating curves. For special requests,
increases in return gas temperatures are obtained
contact Carlyle Application Engineering. Carlyle also-
outside of the refrigerated space or if the compressor
provides computer software data that allows system
is operated at a lower return gas temperature than
designers access to Carlyle compressor performance
65˚F (18˚C), a capacity correction is required. Capacity
with IBM compatible PC computers.
corrections for R-12, 502, 134a, 404A, and 507 for
other than rated suction gas temperatures may be
The compressor capacity and power ratings found in
obtained from Table 1 (Page 18). Due to the number of
the 06D/E refrigeration compressor specification
the variables involved in correcting for superheat, this
sheets are based on the following conditions:
table is only an estimate and should be used as a
guide for the system designer. For R-22, ratings at
Compressor ratings are based on nominal voltage, 60 65˚F (18˚C) return gas temperature, the same adjust-
hertz (1750 rpm) operation and 50 hertz (1450 rpm) ments as noted above with R-502 should apply. For
operation, with 0˚F (0˚C) subcooling. R-22 ratings based on a suction gas superheat of 20˚F
(-11˚C), it is assumed that all the superheat is useful
Note: Some Carlyle air conditioning ratings are at ARI and the capacity can be used without adjustment.
(Air Conditioning & Refrigeration Institution) rating
conditions and with 15˚F subcooling. Ratings may be
interpolated but not extrapolated.

17
Table 1—Estimated Capacity Multipliers
All R-502 capacity ratings, except for the 06DR109 Total heat of rejection (THR) in tons from the com-
compressor, are based on the use of cylinder head pressor equals adjusted compressor capacity (in tons)
cooling fans at saturated suction temperatures of + .285 x kW input (of the compressor motor), or the
-20˚F (-29˚C) or below, and -25˚F (-32˚C) or below for THR in kilowatts equals the compressor’s capacity in
R-404A and R-507. All low temperature (-30˚F to 0˚F, kilowatts + kW input (of the compressor motor). This
-34˚C to -18˚C) R-22 capacity ratings are based on the heat rejection calculation gives the maximum value
use of a cylinder head cooling fan. When the com- possible for condenser selection. Because of heat loss-
pressor is operated at higher return gas temperatures es at the compressor (especially if a cooling fan is
(for example 65˚F, 18˚C), the use of an external desu- moving air across it) and at the discharge line, the
perheating valve is also required to maintain dis- actual heat of rejection will be lower.
charge temperatures below 275˚F (135˚C) and 250˚F
(121˚C) for HFC/POE applications.

18
Unless otherwise specified on the compressor specifi- conditions should be controlled so that the discharge
cation and performance sheets, the 06D and 06E gas does not exceed 275˚F (135˚C) and oil temperature
compressors are suitable for continuous operation (in the sump) does not exceed 160˚F (71˚C). For
within the following limits: HFC/POE applications the maximum recommended
discharge temperature is 250˚F (121˚C). The motors are
LOW TEMPERATURE* thermally protected so that unsafe winding tempera-
tures are prevented. Oil pressure switches are avail-
Refrigerant Saturated Suction Saturated
Temperature Condensing able for system protection (see Accessories
Temperature Section 5.3).
R-502, -40 to 0°F 70 to 120°F
R-404A, R-507 (-40 to -18°C) (21 to 49°C) Requirements for Proper Compressor Operation
R-22 -30 to 0°F 70 to 120°F
Semi-hermetic compressor application requires good
(-34 to -18°C) (21 to 49°C) system design for proper compressor performance to
ensure against compressor damage.
*Minimum operating pressure ratio in these applications
is limited to 2.25:1.
1.3 Refrigerant Piping
MEDIUM TEMPERATURE
Good system piping designs will minimize the possi-
Refrigerant Saturated Suction Saturated bility of lubrication failure, flooded starts, and refrig-
Temperature Condensing
Temperature
erant floodback problems. Refrigerant piping systems
must therefore be designed to protect the compressor
R-502, -10 to 40°F 70 to 120°F by:
R-404A, R-507 (-23 to 4°C) (21 to 49°C)
1. Preventing excessive lubricating oil from being
R-12* -10 to 40°F 80 to 130°F
(-23 to 4°C) (27 to 54°C) trapped in the system. Refrigerant piping must be
sized for proper velocity, especially in suction
R-134a* -10 to 50°F 70 to 150°F
(-23 to 10°C) (21 to 66°C)
lines, to return oil under all conditions. If capacity
control is utilized, piping must be sized for full and
R-22* 0 to 50°F 70 to 130°F
part load conditions. With the increased use of
(-18 to 10°C) (21 to 54°C)
mechanical subcooling in refrigeration conditions,
*Minimum operating pressure ratio in these applications the system designer must also consider the lower
is limited to 2.25:1.
refrigerant mass flow that results in systems that
HIGH TEMPERATURE* are designed to operate with large amounts of
subcooling (30˚F to 70˚F, 16˚C to 39˚C). With the
Refrigerant Saturated Suction Saturated
Temperature Condensing new HFC refrigerants, this is especially important
Temperature in low temperature applications using large
R-12 0 to 55°F 70 to 150°F
amounts of subcooling (for example liquid sub-
(-18 to 13°C) (21 to 66°C) cooled from 110˚F to 40˚F, 43˚C to 4˚C). This can
result in a 40% reduction in mass flow over a sys-
R-134a 0 to 55°F 70 to 150°F
(-18 to 13°C) (21 to 66°C) tem without subcooling.

R-22 -0 to 50°F 70 to 150°F 2. Minimizing the loss of lubricating oil from the
(-18 to 10°C) (21 to 66°C) compressor at all times.
*Minimum operating pressure ratio in these applications
is limited to 2.25:1. 3. Preventing liquid refrigerant from entering the
compressor during operation and shut down.
Maximum operating conditions of the compressor
models are generally defined in the performance
To properly cover the subject of piping design would be
curves and differ with each model. Operating
too lengthy to treat here, especially since many excel-

19
lent guides to piping design are presently available. For Therefore, special care should be taken to ensure that
complete details of good system piping practices, the liquid refrigerant is kept out of the compressor espe-
Carrier System Design Manual (Part 3 Piping Design) is cially in systems where large quantities of refriger-
recommended. ants are often used. During compressor operation, the
expansion valve must be properly adjusted to prevent
1.4 Vibration Isolation liquid from entering the compressor.
On installations where noise and vibration must be
kept to a minimum, it is desirable to use vibration During compressor shutdown, gravity, thermal action
mounts under the compressor unit, even though the and refrigerant absorption will result in a refrigerant
compressors may be spring mounted. Proper precau- and oil mixture in the compressor crankcase. Gravity
tions must be taken to prevent the transmission of flow can be prevented by the use of recommended
compressor vibration through the piping system. It is loops in the piping, but thermal action and the
also recommended to design the suction line with absorption of refrigerant by lubricating oil cannot be
sufficient “spring” so the suction service valve can be prevented by piping design. To minimize the absorp-
moved aside for access to the suction strainer. Many tion of refrigerant into the oil, the use of crankcase
systems have been designed with compressors heaters is strongly recommended. Because oil dilution
mounted to the bases. In these cases, it is important is more critical with HFC refrigerants and POE lubri-
that the compressors be properly torqued to the base cants, Carlyle requires the use of crankcase heaters in
or the compressor may produce a “rattle” or transmit these applications. It is important, however, to never
excessive vibration to the base. energize the crankcase heater while the compressor is
running because this may overheat the compressor
For a more complete review of the system vibration and oil. (See Accessory Section 5.4 for applicable heaters.)
piping recommendations, see Carlyle OEM Bulletin #118. Carlyle’s experience indicates that many compressor
failures occur during the first several months of oper-
1.5 Refrigerant Migration and Floodback ation. Many of these failures occurred during the ini-
tial start-up of the unit, and inspection reports indi-
Liquid refrigerant, or even excessive amounts of
cate flooding was the probable cause of failure in
entrained liquid particles in the suction gas, must be
many of these compressor returns.
kept out of the compressor by proper system design
It is believed that many of these failures could have
and compressor control. Under running conditions, the
been avoided by using more care during the initial
presence of liquid refrigerant in the compressor tends
start-up of the compressors. Refer to the recommend-
to break down the oil film on the cylinder walls,
ed start-up procedure in Carlyle’s Refrigeration
resulting in increased wear to the cylinder walls and
Compressor Service Guide (Lit. No. 020-611).
piston rings, and possible compressor damage.
Furthermore, excessive liquid in the cylinders causes
hydraulic compression, which can create cylinder pres-
sures as high as 1500 psi (103 bar). This hydraulic
loading can cause suction and discharge valve and
gasket failures to occur while also subjecting the con-
necting rod, piston, and main bearings to excessive
loading. Although laboratory testing of 06D and 06E
compressors has shown that they can withstand sub-
stantial flooded starts and floodback, prolonged
excessive flooding will eventually cause any compres-
sor to fail.

20
1.6 Clean and Dry System 1.8 Compressor Interconnection
Clean and dry systems are essential for long compres- All 06D and 06E compressors are suitable for inter-
sor and motor life, and satisfactory operation. This connection on common refrigerant circuits. General
cannot be over-emphasized. It is even more critical suction and discharge line piping recommendations
with the introduction of new HFC refrigerants and are shown in Figures 1 and 2 (Page 22), respectively.
POE lubricants. The new POE lubricants are excellent For a complete guide to system piping practices, the
cleaning agents that will deposit system contami- Carrier System Design Manual (Part 3 Piping Design)
nants into the system or compressor filters and is again recommended.
screens, causing excessive pressure drop or clogging,
if the system is not kept clean. When only two 06D or 06E compressors of the same
size are to be connected in parallel, the oil equaliza-
Liquid line refrigerant filter-driers maintain low tion can be accomplished with a single oil equaliza-
moisture content, and in the event of a motor tion line. This line can equalize both oil and gas. This
burnout, prevent contamination of the evaporator method of equalization is only recommended when
and other parts of the refrigeration system. These there are two compressors of the same size and the
filter-driers should be compatible with the new HFC oil equalization line is short (2 to 4 feet, .6 to 1.2
refrigerants and POE oils if used. meters long). In this case, a single 1-1/8″ line can be
used. Since this line equalizes both oil and gas, it is
Liquid line moisture indicators are recommended in important that it be level to permit the lower half to
all systems that use semi-hermetic compressors act as an oil equalizer and the upper half as a gas
because they provide a continuous check on the sys- equalizer.
tem’s moisture content. Excessive moisture in combi-
nation with a high operating temperature can lead to The 06E compressors have two sightglass connec-
motor winding breakdown and burnout. When mois- tions, either of which may be removed for installation
ture is indicated, prompt corrective action, such as of the equalizer line. A small oil equalization check
changing the filter-drier core or dehydrating the sys- valve must also be added to those 06E compressors
tem, can prevent serious compressor damage. used in parallel. This check valve is part of the
06EA900101 compressor interconnection package and
must be installed in the rotor locking bolt (torqued to
1.7 Prevent Excessive Discharge Temperatures 13-16 lb-ft, 1.8-2.2 kg-m) of each compressor (see
The actual discharge gas temperature at the compres- Figure 3, Page 22). The 06E rotor bolt is accessible by
sor discharge service valve must not exceed 275˚F removing the suction strainer from the motor end
(135˚C). For HFC/POE applications the maximum rec- cover. Installation of the check valve is best accom-
ommended discharge temperature is 250˚F (121˚C). plished just prior to mounting the suction service
valve.
For a given refrigerant, this discharge temperature
depends upon the compression ratio as well as the
temperature of the superheated suction gas. Since an
increase in either the compression ratio or suction gas
temperature causes the discharge temperature to
increase, both must be kept within allowable limits.

21
Suction Line

Run
Compressor Compressor Compressor Compressor Cycles Continuously

1 2 1 2 1 2 1 2

RECOMMENDED NOT RECOMMENDED


Excessive Liquid Refrigerant Foodback Dead-heading
will be Predominantly in Comp No. 2 RECOMMENDED
NOT RECOMMENDED

Cycles Run
Compressor Compressor Compressor Compressor Most Often Continuously

1 2 1 2 1 2 3 4

RECOMMENDED RECOMMENDED

Figure51—Suction
FIGURE Piping
- SUCTION PIPING Figure 2—Discharge
FIGURE 6 - DISCHARGE Piping
PIPING

control system utilizing an oil separator, oil reservoir,


and floats is recommended. Several manufacturers
supply this type of oil management system. It is
important that floats are properly selected for
Carlyle’s 06D and 06E compressors. For the 06D com-
pressor, a special adapter is required to connect the
float. For the 06E compressor, the float should be able
to control the oil level at 1/8 to 3/8 up the sightglass.

One of Carlyle’s major concerns on multiple 06E com-


pressor applications is to avoid accumulating large
quantities of oil in “off” compressors. To minimize
this potential problem, Carlyle recommends the oil
levels be kept at a 1/8 to 3/8 sightglass level. Even
Figure 3—Rotor Locking Bolt with this recommendation, Carlyle has found that
many system manifold piping arrangements can
The 06D compressors have only one sightglass and
allow excessive oil to drain into the motor compart-
provision must be made for a sightglass in the oil
ment of “off” 06E compressors. To avoid this poten-
equalizer line when the 06D compressors are intercon-
tial problem, Carlyle recommends the motor barrels of
nected using an oil equalization line. The 06D oil
06E compressors be equalized as shown in Figures 4
equalizer interconnection package is 06DA900092. The
and 5, Page 23. This motor barrel equalization is rec-
06D compressors do not utilize or require the check
ommended in addition to either a float system or an
valve in the rotor lock bolt.
oil compartment equalization line. Motor barrel
equalization is recommended for 06E compressors
When more than two compressors are to be connected only, the 06D compressors do not have this
in parallel or if 06D/E compressors of different dis- connection.
placements are to be connected in parallel, an oil

22
Remove existing 5/8-18 SAE
oil plug at location indicated.
Using same capscrew gasket,
assemble adapter (Part No. 5F20-1311)
and angle valve into crankcase as shown.

Figure 4—Compressor Equalization

Suction Manifold

Header Assy.

See compressor modification above Proposed oil equalization line between compressor motor
(typical) compartments (1/4” or 3/8” tubing)

Figure 5—Oil Equalization Between Compressor Motor Compartments

23
1.9 Motor-Compressor Selection 1.10 Outdoor Use
When selecting any compressor, proper allowance All UL recognized 06D and 06E compressors have ter-
should also be made for abnormal conditions that minal enclosures with corrosion protection specified
may result in motor overloading. These conditions that is suitable for outdoor use equipment as a sole
might include high suction temperature during pull- enclosure. The 06D drawn steel terminal boxes used
down or low voltage at compressor motor terminals. on 2 cylinder 06D compressors do not require any
caulking for sole outdoor use, and are UL recognized
During pulldown, the compressor cannot be subjected as “Equal Alternate” to all caulked boxes previously
to loading rates higher than the maximum kW shown used. Drawn steel boxes are available only for units
in the electrical data tables for more than short peri- requiring zero to two overloads.
ods of time. Where an extended pulldown period is
expected, the suction pressure must be limited by 1.11 Code Approvals
some positive means. The 06D/E, 60 hertz compressors are UL recognized
and CSA approved. Both the UL recognition and the
CSA approval are covered in the UL File shown below,
due to harmonized codes between the United States
and Canada. The compressor certification is under UL
984 in the U.S. and under CSA Standard C22.2 No.
140.2-96 in Canada. All 06D/E 50 and 60 hertz com-
pressors manufactured in Syracuse are ISO 9002 reg-
istered. The 06D/E code approvals are shown in the
following files:

UL File# - SA4936
CSA File# - SA4936
ISO 9002 Certificate #A2899

24
2.0 – Compressor Lubrication System

2.1 Compressor Lubrication If the oil level in the sightglass of an 06E compressor
All refrigeration compressors must have adequate is less than one-eighth (1/8) up from the bottom of
lubrication to ensure trouble-free operation and a the glass, this indicates a low oil level. If the oil level
long life. When starting up any new system, some oil is up more than one-half (1/2) from the bottom, this
will be lost to coat the inside of the piping, some oil indicates a high oil level. Therefore, the oil level
will be lodged in low velocity areas of the system, should be 1/8 to 1/2 up the sightglass when the com-
and some will be kept in circulation. This loss must pressor is running for 06E compressors.
be made up by adding oil to the system after the ini-
tial start-up. Very low compressor oil levels can cause Figures 6, 7, and 8 show different oil levels when a
complete loss of lubrication and may result in an single 06E compressor is running. The photos in each
immediate compressor failure if not protected figure show the right and left sightglass of the same
against. compressor (only one sightglass is factory supplied).
If the level is not the same in each glass, consider the
The loss of oil can also be caused by flooded starts or true oil level to be the lower level. The difference in
refrigerant migrating into the oil during an off period levels is due to the rotation of the crankshaft. The
and pulling the oil out of its sump during the sudden crankshaft and running gear are producing the
pressure drop of a start-up. windage required to push the oil down on one side
while raising it on the other. Reversing the direction
While it has always been apparent that very low oil of rotation of the motor will reverse this relationship.
levels can cause compressor damage, it has also
become apparent that excessive oil charges can short-
en the compressor’s life. Oil levels above the center of
the 06E compressor sightglass cause elevated
crankcase and oil temperatures, increased power con-
sumption, and possible valve plate gasket failures.
This problem of excessive oil charges has been main-
ly evident on 06E multiple compressor applications
but does not appear to have caused any difficulties
with the application of 06D compressors.
Figure 6—High Oil Level
The oil level should be observed in the sightglass
The oil level in Figure 6 is at least 7/8 of a sightglass. Note
immediately after the compressor shutdown, while it
the high oil level in the left sightglass, and solid foam in
is still warm. The level observed when the compres-
the right sightglass. Whenever the glass is filled with
sor is not running for a long period may be a mixture
foam, excessive oil is indicated and oil should be removed.
of oil and refrigerant which would not be a true indi-
cation of the oil level when the compressor is
running.

25
Another effect which has been noted, especially in
multiple compressor systems, is the increased proba-
bility of blown valve plate gaskets when excessive oil
is in the system. When the system is grossly over-
charged (several gallons too much), the oil levels in
the compressor sumps will only rise 1/2 to 3/4 level in
the sightglass of 06E compressors. The remainder of
the oil will be kept in circulation or will accumulate
somewhere in the system. A likely point is in the suc-
Figure 7—Better Running Oil Level tion manifold (depending on the method of returning
The oil level in Figure 7 is 3/8-1/2 of a sightglass. This oil), and in the compressor motor compartment. This
is an acceptable oil level on a single compressor sys- is especially troublesome in an idle compressor in a
tem, but does not always give a true indication of an multiple compressor system that has an opportunity
excessive oil charge on multiple compressor systems. to accumulate oil in the motor compartment; but
excessive oil in the motor compartment at start-up
will not alone fail gaskets. Some liquid refrigerant
must also be present which will bring enough oil with
it into the cylinders on a start-up to cause gasket fail-
ures. These circumstances have apparently occurred
in a number of installations, and their relationship to
gasket failures has been well confirmed by test.

Figure 8—Preferred Running Oil Level


The oil level in Figure 8 is 1/8-1/4 of a sightglass. The
sightglasses are showing a different level because of
the crankshaft rotation. Note the amount of clear
glass above the levels. These levels will ensure
against the possibility of excessive oil in the system.

26
To check for excessive system oil charges in 06E com- 2.2 The Oil Pump
pressors, it is recommended that the oil levels of the The 06D and 06E oil pump is a positive displacement
compressors in the system be brought down to vane type that produces high volume oil flow at a low
approximately 1/4 of the sightglass. If the system is oil pressure. The compressor utilizes an internal pres-
overcharged, the oil levels will rise to a 1/2 sightglass sure regulator valve to maintain oil pressure at a con-
level within a short time (usually within an hour). stant 12 to 36 psi (.83 to 2.5 bar) above suction
Continue removing oil until the oil level does not rise pressure.
after removal. It is also recommended that the oil lev-
els be kept at this 1/4 level, or between the levels 2.3 Recommended Oils
shown in Figure 8. This is especially true if any com-
When additional oil or a complete oil change is
pressors have experienced any repeated gasket fail-
required, use only the listed Carlyle approved oils. For
ures. To summarize the advantages of keeping the oil
CFC and HCFC refrigerants use:
at this level:
MANUFACTURER BRAND NAME
1. It ensures that excessive oil is not being lodged in Totaline 150
the system. This will eliminate gasket, valve, and
Witco Suniso 3GS
running gear failures.
Shrieve Chemical Zerol 150*
Texaco Ind. WFI-32-150
2. The compressor, oil, and motor run cooler, approxi-
IGI Petroleum Ind. Cryol-150
mately 20˚F (11˚C) or more in many cases.
* Alkyl Benzene Oil.

Use of oil adhesives is not allowed without


written approval from the Carlyle Engineering
Department.

For application with HFC refrigerants R-134a,


R-507, and R-404A, Carlyle recommends an ISO 68
cST viscosity polyolester oil. Shown below are POE-68
oils that are approved for use in Carlyle compressors.
LOW LIMIT HIGH LIMIT

Figure 9—06D Oil Level Limits MANUFACTURER BRAND NAME


Castrol E68
As noted above, the oil level control in 06D compres-
ICI EMKARATE RL68H
sors is less critical than 06E models. Motor barrel
CPI* CP-2916S
equalization is not required and oil level in the com-
pressor sightglass should be controlled between 1/4 CPI Solest 68
and 3/4 of the sightglass (See Figure 9). If the oil level BP Marine Enersyn MP-S68
in the sightglass is less than one-quarter (1/4) up Mobil Artic† EAL 68
from the bottom of the glass, this indicates a low oil Castrol† SW 68
level. If the oil level is up more than three-quarters
*CPI CP-2916S is also sold under BP Marine Enersyn MP-S68.
(3/4) from the bottom, this indicates a high oil level. † Medium temperature applications only.
Again, the oil level should be checked immediately
after the compressor is shut down.

27
2.4 06D/E Oil Pressure History
All current 06D/E compressors are provided with the
connections for an oil safety switch. The 06D/E com-
pressors use the same basic oil pump design, however
recent changes in the oil pressure regulator design
have resulted in slightly different operating oil pres-
sures. Shown below is a brief history of the 06D/E
operating oil pressure.

06D MODELS 06E MODELS


PSI (Bar) PSI (Bar)
Before May 1984 12 to 18 12 to 18
(Prior S/N 2084J....) (.83 to 1.24) (.83 to 1.24)
May 1984 to March 1994 16 to 22 16 to 22
(Between S/N 2084J & 1094J) (1.1 to 1.52) (1.1 to 1.52)
Starting March 1994* 18 to 26 18 to 34
(Starting S/N 1094J....) (1.24 to 1.8) (1.24 to 2.3)

*06D/E refrigeration duty service models started using new high flow oil pumps in June 1994 (starting S/N 2994M (D/E) 5315).

Table 2—Oil Pressure History

28
3.0 – Capacity Control

3.1 Suction Cut-Off Capacity Control temperatures below 120˚F (49˚C) with 1 bank of
Carlyle’s compressor suction cut-off capacity control capacity control. Do not unload more than 1 bank on
system has been approved for R-502, R-404A, and 6-cylinder 06D or 06E compressors in this low tem-
R-507 applications down to -40˚F (-40˚C) suction and perature application.
for R-12, R-134a, and R-22 medium and high tempera-
ture applications, but the system designer must care- Note: In low temperature booster applications see dif-
fully consider certain system design criteria when ferential pressure limits (∆P) (Table 4, Page 31) for
applying this new feature. minimum condensing pressures required to load up.

3.2 Design for Proper Oil Return to Compressor Medium Temperature R-12, R-134a, R-404A,
When the 06D/E compressors are unloaded, the com- R-502, and R-507 Application: 0˚F to 40˚F
pressor and system capacity are reduced by 1/3, 1/2, or (-18˚C to 4˚C) Saturated Suction Temperatures.
2/3 of full load capacity. These capacity reductions
result in the same large percent reduction in refriger- Unloading application limits at saturated condensing
ant flow rates through the system piping. Oil that is temperatures below 130˚F (54˚C): Can unload 1 bank
entrained and carried with refrigerant requires a cer- on any 4-cylinder 06D or 06E compressor. Can unload
tain gas velocity to properly return it back to the com- 1 or 2 banks on any 6-cylinder 06D or 06E
pressor and as this refrigerant flow drops, this may compressor.
not be possible. This is especially true of the sizing of
the suction line where oil return is most critical. Note: With R-134a or R-12 see ∆P limits (Table 4,
Page 31) for loading requirements.
All system piping, but especially the suction line,
must consider both full load and part load capacities Medium Temperature R-22 Applications:
and refrigerant velocities when being sized. For com- 0˚F to 25˚F (-18˚C to -4˚C) Saturated Suction
plete details of good system piping practices, the Temperatures.
Carrier System Design Manual (Part 3 - Piping
Design) or the ASHRAE Manual (Systems Volume) is Unloading application limits at saturated condensing
recommended. temperatures below 130˚F (54˚C): Can unload 1 bank
on any 4 or 6-cylinder 06D or 06E compressor.
To protect the compressor against possible oil return Unloading more than 1 bank on any 6-cylinder 06D or
problems, all 06D and 06E refrigeration duty com- 06E compressor in this medium temperature applica-
pressors applied with capacity control must utilize oil tion is not recommended.
safety switch protection. This requirement may be
waived by Carlyle Application Engineering for certain High Temperature R-22 Applications: 25˚F to
high temperature, single compressor circuit applica- 55˚F (-4˚C to 13˚C) Saturated Suction
tions (contact Carlyle Application Engineering for Temperatures.
approval). Unloading application limits at SCT’s below 145˚F
(63˚C) and maximum superheat of 25˚F (14˚C). Can
3.3 Capacity Control Application Ranges unload 1 bank on any 4-cylinder 06D or 06E compres-
Low temperature R-502, R-404A, and R-507 sor. Can unload 1 or 2 banks on any 6-cylinder 06D or
Application: -40˚F to 0˚F (-40˚C to -18˚C) 06E compressor per Figure 11.
Saturated Suction Temperatures.
Condensing temperature limits:
For all 4-cylinder 06D and 06E compressors -
See Figure 10. All 6-cylinder 06D and 06E
compressors can be unloaded at all condensing

29
SUCTION CUT-OFF UNLOADING OPERATION LIMITS
3.4 Pump-Down Control
For All 4-Cylinder 06D/E Compressors Compressors with suction cut-off unloading have
L.T. – 502, R-404a and 507 Applications
Operated at Half Load inherently greater internal leak paths than compres-
sors without this capacity control feature installed on
140
(60) AD them. Compressors with the electric capacity control
F LO
have been successfully applied with continuous or
CONDENSING TEMP. °F (°C)

H AL
130
(54) automatic pump-down control. To avoid compressor
120
short-cycling, the system designer should avoid contin-
(49) uous pump-down control when the suction pressure
SAFE OPERATIONAL ZONE
110 cut-in and cut-out points are within 30 psi (2.1 bar) of
(43)
each other. Because the pressure actuated unloaders
100 have a small built-in high to low pressure path, short-
(38)
cycling will occur if continuous or automatic pump-
90 down control is applied. D o n o t u s e c o n t i n u o u s
(32)
or automatic pump-down control on any
-40 -30 -20 -10 0 10 20 30
(-40) (-34) (-29) (-23) (-18) (-12) (-7) (-1) c o m p r e s s o r e q u i p p e d w i t h p r e s s u r e a c t u-
SAT. SUCTION TEMP. °F (°C) a t e d c a p a c i t y c o n t r o l . Use single pump-out or
Figure 10—Suction Cut-Off Operation Limits solenoid drop (minimum protection) control.
For 4-Cylinder 06D and 06E Compressors
with R-502, R-404A, R-507 3.5 Unloader Differential Setting
The unloader differential setting is the suction pres-
sure difference at which the controller loads and
SUCTION CUT-OFF UNLOADING OPERATION LIMITS
For: All 4-Cylinder 06D and 06E Compressors unloads the particular cylinder bank. A differential
R-22 High Temperature Applications setting that is too low could cause the unloader
Operated at 1/3 Load (2 Banks Unloaded)
mechanism to short cycle. For example, when an 06D
145
D

or 06E compressor unloads, the suction pressure rises


A

(63)
LO

140
3

because the compressor capacity has decreased by


1/

(60)
one-third or one-half. If the differential setting is too
CONDENSING TEMP. °F (°C)

130
(54) close, this rise in suction pressure may be enough to
load the compressor back-up. For this reason, Carlyle
120
(49) recommends a minimum differential setting of 6 to
SAFE
110 OPERATIONAL
10 psi (.4 to .7 bar). The final setting should be evalu-
(43) ZONE ated for the final application because many variables
100
are involved:
(38)
• Single or multiple compressor application
90 • Low or medium temperature application
(32)
• Unloading 4 or 6 cylinder (1/2 vs. 1/3 load
80
(27)
reduction)
0 10 20 30 40 50 • Refrigerant 12, 22, 502, 507, 404A, or 134a
(-18) (-12) (-7) (-1) (4) (10)
SAT. SUCTION TEMP. °F (°C)

Figure 11—Suction Cut-Off Operation Limits


For 6-Cylinder 06D and 06E Compressors
with R-22

30
3.6 Part Load Performance Factors 3.7 Location and Size of Capacity Control Head
To estimate part load performance of 06D/E compres- Assembly
sors, use Table 3 below. The factors can be applied to The capacity control head assembly cannot be
the full load published Carlyle capacity and power installed and will not function on the center cylinder
data for all refrigerants and conditions. The system head of any 06D or 06E 6-cylinder compressor. This
designer should ensure the conditions are within the is also true of Carlyle’s 2-cylinder 06D models.
safe operating range of the compressor.
Capacity control heads can be installed on either side
The table below shows multiplication factors that bank of any 6-cylinder 06D or 06E compressor.
apply to the compressor ratings when operating with
suction cutoff unloading. A capacity control head can be installed on either side
bank of 4-cylinder 06E compressor.
For example: You have a 6-cylinder 06E compressor
with full load capacity = 100,000 Btu/hr (29.3 kW), Capacity control heads will unload either side bank of
full load power = 10 kW, and full load efficiency = any 4-cylinder 06D compressor but installation on
10 Btu/wHr (COP = 2.92). To calculate the capacity, the side opposite the terminal box is recommended.
power and efficiency at 2/3 load (one bank unloaded) This avoids possible interference between the suction
use the factors from the table as shown: and discharge pressure connections on the compres-
sor and the unloader coil assembly.
2/3 load capacity = .67 x 100,000
= (.67 x 29.3 kW)
The suction cut-off unloader assembly has a cylinder
Btu/Hr = 67,000 Btu/Hr
head which is slightly larger than a plain side cylin-
= (19.63 kW)
der head. This results in a compressor which may be
2/3 load power = .73 x 10 kW unloaded that is slightly wider (approximately 1/2”
= 7.3 kW (1.3 cm) on 06D models and 3/8” (.95 cm) on 06E
2/3 load efficiency = .92 x 10.0 Btu/wHr models) than a compressor without unloading capa-
= (.92 x 2.92) bility.
Energy Efficiency Ratio = 9.2 Btu/wHr
COP = 2.7

MULTIPLICATION FACTOR MULTIPLICATION FACTOR


COMPRESSOR MODEL FOR 1 BANK UNLOADED FOR 2 BANK UNLOADED
CAPACITY POWER EER CAPACITY POWER EER
ALL 4 CYLINDER MODELS .49 .57 .86 - - -
ALL 6 CYLINDER MODELS .67 .73 .92 .32 .46 .70

Table 3—Part Load Performance Multipliers

APPLICATION
SUCTION PRESSURE ∆P REQUIRED-DISCHARGE MINUS
RANGE PSI (BAR) SUCTION PRESSURE PSI (BAR)
06D 06E
L.T. R-502, 404A, 507 10-25 (1.7-2.7) 30 (2.1) 30 (2.1)
M.T. R-502, 404A, 507 30-60 (3.1-5.2) 40 (2.8) 45 (3.1)
M.T. R-12, 134a 10-30 (1.7-3.1) 30 (2.1) 35 (2.4)
M.T. R-22 or H.T. R-22 30-90 (3.1-7.2) 50 (3.5) 55 (3.8)

Table 4—Required Differential Pressure for Unloader Operation


31
3.8 Pressure Differential (∆P) Required to Load 3.9 Electric Solenoid Capacity Control
Compressor Operation
A minimum ∆P between the discharge and suction The electrically operated control valve is actuated by
pressure is required to compress the unloader valve remote signal to the electric solenoid coil. Each valve
spring to load up the cylinder bank. While this differ- controls 2 cylinders (1 bank). No manual adjustments
ential pressure is low, it should be evaluated for cer- to the electric unloader valve are necessary. When the
tain low head pressure applications such as R-12, solenoid is “de-energized,” the passageways in the
R-134a, air conditioning applications or the low stage valve are aligned for “loaded” conditions. When the
of booster applications. The discharge pressure must solenoid is “energized,” the valve passageways are
be higher than the suction pressure in Table 4 aligned for unloading.
(Page 31) for the unloader assembly to load up.
This capacity control valve is controlled by an electric
Suction cut-off unloading is an option for all four and solenoid. When the solenoid is de-energized, the
six cylinder Carlyle 06D/E compressors. The capacity valve loads the cylinder bank (2 cylinders) as shown
control operation and application requirements are in Figure 12.
found in the System Design section (Section 1.0) of
this manual and should be carefully reviewed. When full capacity is desired, an external controller
de-energizes the solenoid coil, allowing the discharge
pressure to build-up behind the unloader piston
assembly. This will compress the unloader valve
spring, opening the unloader suction port. Suction
gas can now be drawn into the cylinders, running the
bank fully loaded.

COIL CLOSE UNLOADER UNLOADER UNLOADER


PORT PISTON HEAD VALVE
ASSEMBLY BODY

SOLENOID
VALVE
ASSY
UNLOADER
VALVE
SPRING

COVER
BLEED PLATE
ORIFICE
VALVE
PLATE

PRESSURE PISTON
SUCTION DISCHARGE SUCTION
MANIFOLD DISCHARGE SUCTION MANIFOLD
DISCHARGE VALVE VALVE

Figure 12—Electric Loaded Operation

32
COIL UNLOADER UNLOADER UNLOADER
PISTON HEAD VALVE
ASSEMBLY BODY

SOLENOID
VALVE
ASSY UNLOADER
VALVE
SPRING

BLEED COVER
ORIFICE PLATE

STRAINER
VALVE
PLATE

PRESSURE
PISTON
SUCTION SUCTION
DISCHARGE
MANIFOLD DISCHARGE SUCTION MANIFOLD
DISCHARGE VALVE VALVE

Figure 13—Electric Unloaded Operation

As reduced capacity is desired an external controller spring moves the poppet valve to the left and it seats
energizes the solenoid coil. This opens the capacity in the closed position.
control valve port, allowing the discharge gas behind
the unloader piston assembly to vent back to the suc- With the poppet valve closed, discharge gas is direct-
tion side as shown in Figure 13. The unloader valve ed into the unloader piston chamber and pressure
spring at this point can move the unloader valve body builds up against the piston. When pressure against
to the left, blocking the unloader suction port. The the unloader piston is high enough to overcome the
cylinder bank is now isolated from the compressor unloader valve spring, the piston moves the valve to
suction manifold, unloading these two cylinders. No the right, opening the suction port. Suction gas can
refrigerant is allowed into the cylinders and no com- now be drawn into the cylinders and the bank is run-
pression takes place. ning fully loaded (as shown in Figure 12A).

3.10 Suction Pressure Capacity Control As suction pressure drops below the set point, the
Operation control spring expands, snapping the diaphragm to
Pressure-operated control valve is controlled by suc- the right. This forces the poppet valve open and
tion pressure and actuated by discharge pressure. allows gas from the discharge manifold to vent
Each valve controls 2 cylinders (one bank). On start- through the base control valve to the suction side.
up, controlled cylinders do not load up until the dif- Loss of full discharge pressure against the unloaded
ferential between suction and discharge pressures is piston allows the unloader valve spring to move the
approximately 25 psi (1.7 bar) for 06D compressors valve left to the closed position. The suction port is
and 35 psi (2.4 bar) for 06E models. blocked, isolating the cylinder bank from the suction
manifold. The cylinder bank is now unloaded (as
When suction pressure rises high enough to overcome shown in Figure 13A).
set point spring, the diaphragm snaps to the left and
relieves pressure against the poppet valve. The drive

33
Figure 12A—Pressure Loaded Operation

Figure 13A—Pressure Unloaded Operation

3.11 Pressure Actuated Capacity Control (7.2) 90 150 PSI (10.4 BAR) SYSTEM DIFFERENTIAL
LOAD UP PRESSURE VS NO. OF TURNS
Adjustment
LOAD — UP PRESSURE PSIG (BAR)

(6.5) 80

Control Set Point - The cylinder load-up point is (5.8) 70

adjustable from 0 psig to 86 psig (1 bar to 6.9 bar). Refer to (5.2) 60


Figure 14. (4.5) 50

(3.8) 40

(3.1) 30
DOTTED LINES INDICATE EXPECTED
(2.4) 20 TOLERANCE EXTREMES UNDER
NORMAL R-22 OPERATING CONDITIONS

(1.7) 10

(1.0) 0
0 1 2 3 4 5 6 7 8 9 10 11 12
TURNS OUT FROM BOTTOM STOP — COUNTERCLOCKWISE

Figure 14—Control Set Point –


Bypass & Suction Cut-Off

34
CONTROL screw clockwise. The number of turns to the desired dif-
SET POINT
ADJUSTMENT
ferential can be determined from the curve. Each full turn
NUT clockwise increases the differential by approximately
0.8 psi (.06 bar). Approximately 5 turns changes the dif-
SEALING CAP
ferential from 6 psi to 10 psi (.41 bar to .69 bar).
(COVERS
PRESSURE
DIFFERENTIAL
ADJUSTMENT
3.12 Variable Frequency Drives
SCREW) Variable Frequency Drives (VFD’s) may be used with
VALVE Carlyle 06D/E refrigeration duty compressors and provide
BODY
optimum capacity control while maximizing the compres-
sor efficiency. Some of Carlyle’s 06D air conditioning mod-
els may require modification of the internal bifurcation
Pressure Actuated Unloader Valve system to operate properly. Contact Carlyle Application
Engineering if this is required. VFD’s, when properly
Turn the adjustment nut clockwise to the bottom stop. In applied, provide very stable suction pressure control and
this position, the cylinder load-up pressure is 86 psig minimize compressor cycling. Additionally, Carlyle recipro-
(6.9 bar). Control set point is regulated to desired pressure cating compressors attain their peak efficiency at approxi-
by turning the adjustment nut counterclockwise. The mately 900 - 1100 rpm. Therefore, the use of VFD’s versus
number of turns can be determined from the curve in simply unloading or cycling compressors will typically
Figure 15. Each full turn counterclockwise decreases the result in significant energy savings. The limitations on
load-up point by approximately 7.2 psi (.5 bar). the allowable speed ranges when using VFD’s are 30 to 60
Approximately 12 turns changes the pressure from 86 psig hertz. Application of Carlyle 06D/E compressors below 30
to 0 psig (6.9 bar to 1 bar). Pressure differential between hertz may result in nuisance oil safety switch trips due to
cylinder load-up point and unload point is adjustable from reduced oil pressure levels. Operation above 60 hertz may
6 psi to 16 psi (.41 bar to 1.1 bar). Refer to Figure 15. result in increased oil circulation rates and compressor
valve failures.

150 PSI (10.4 BAR) SYSTEM DIFFERENTIAL


(1.4) 20 Due to the low discharge gas pulsation frequency
LOAD — UNLOAD DIFFERENTIAL PSI (BAR)

LOAD — UNLOAD DIFF. PRESSURE


VS NO. OF TURNS

(1.2) 18 of reciprocating compressors (typically 30 to 180 hertz),


(1.1) 16 after system start-up the operational frequency band
(1.0) 14 should be swept to identify any high vibration areas due
(.83) 12 to the compressor exciting frequency matching a natural
(.69) 10 frequency of the piping or base. Any frequency bands that
(.55) 8 result in excessive vibration must be programmed to skip
(.41) 6 over.
DOTTED LINES INDICATE EXPECTED
TOLERANCE EXTREMES UNDER
(.28) 4 NORMAL R-22 OPERATING CONDITIONS

(.14) 2 Variable frequency drives should be selected based on the


0 1 2 3 4 5 6 7 8 9 10
maximum kW of the compressor motor shown in
TURNS IN FROM BACKSTOP — CLOCKWISE
Tables 6-9 on Pages 38 and 39.
Figure 15—Differential Set Point
Turn the adjustment screw counterclockwise to the
back-stop. In this position, the differential is 6 psi
(.41 bar). Differential is set by turning the adjustment

35
4.0 – Compressor Features and Accessories

4.1 06D Compressor Motor Protection Primary Motor Protection


The 06D compressors, when purchased with over- Texas Instruments supplementary overloads are nor-
loads installed in the compressor terminal box, are mally supplied with 06D compressors. These relays
protected from motor overcurrent and overtempera- trip at or below the maximum continuous current
ture. The motor is completely protected against locked (MCC) listed in the electrical data tables. These cur-
rotor, running overload, primary and secondary single rent sensitive, pilot duty relays are located inside the
phasing, and loss of refrigerant conditions. These terminal box and will automatically reset after trip-
compressors also comply with UL, CSA, and NEC ping (See Table 5). Load terminals of the overloads
(National Electrical Code) requirements for inherent are 1/4 inch quick connect for ratings of 30 amps and
motor protection. below, and #10 screw terminals for ratings over
30 amps. Control circuit terminals are 1/4 inch quick
connects.

ELECTRICAL DATA ELECTRICAL DATA


COMPRESSOR MAX. COMPRESSOR MAX.
MODEL VOLT HP kW MCC RLA LRA MODEL VOLT HP kW MCC RLA LRA
06DR1090GA31*0 575 4.4 2.8 21.3 06DM8080GA31*0 575 7.0 5.0 28.4
GA32*0 208/230 2 3.1 12.1 8.6 53.3 GA32*0 208/230 17.4 12.4 71.0
GA36*0 460 5.5 3.9 26.3 3 4.1
GA32*0 208/230 17.4 12.4 71.0
06DR0130CA31*0 575 7.0 5.0 28.4 GA36*0 460 8.7 6.2 35.5
CA32*0 208/230 17.4 12.4 71.0 06DM3130CA31*0 575 10.8 7.7 40.0
CA32*0 208/230 3 4.3 17.4 12.4 71.0 CA32*0 208/230 27.0 19.3 100.0
5 6.25
CA36*0 460 8.7 6.2 35.5 CA32*0 208/230 27.0 19.3 100.0
06DR3160CA31*0 575 10.8 7.7 40.0 CA36*0 460 13.5 9.6 50.0
CA32*0 208/230 27.0 19.3 100.0 06DM3160CA31*0 575 10.8 7.7 40.0
CA32*0 208/230 5 6.25 27.0 19.3 100.0 CA32*0 208/230 27.0 19.3 100.0
CA36*0 460 13.5 9.6 50.0 CA32*0 208/230 5 6.25 27.0 19.3 100.0
06DR7180DA31*0 575 10.8 7.7 40.0 CA36*0 460 13.5 9.6 50.0
DA32*0 208/230 27.0 19.3 100.0 06DM3370DA31*0 575 25.0 17.9 91.0
5 6.25
DA32*0 208/230 27.0 19.3 100.0 DA32*0 208/230 10 16.5 62.0 44.3 228.0
DA36*0 460 13.5 9.6 50.0 DA36*0 460 31.0 22.1 114.0
06DR8200DA31*0 575 17.6 12.6 64.0 06DA8182AA31*0 575 17.6 12.6 64.0
DA32*0 208/230 6.5 9.8 44.0 31.4 160.0 AA32*0 208/230 6.5 9.78 44.0 31.4 160.0
DA36*0 460 22.0 15.7 80.0 AA36*0 460 22.0 15.7 80.0
06DR7240DA31*0 575 17.6 12.6 64.0 06DA8242BA31*0 575 22.2 15.9 79.0
DA32*0 208/230 6.5 9.8 44.0 31.4 160.0 BA32*0 208/230 7.5 12.8 55.5 39.6 198.0
DA36*0 460 22.0 15.7 80.0 BA36*0 460 27.8 19.8 99.0
06DR2280DA31*0 575 22.2 15.9 79.0 06DA3282BA31*0 575-3-60 25.0 17.9 91.0
DA32*0 208/230 7.5 12.8 55.5 39.6 198.0 BA32*0 208/230 10 16.5 62.0 44.3 228.0
DA36*0 460 27.8 19.8 99.0 BA36*0 460 31.0 22.1 114.0
06DR3370DA31*0 575 25.0 17.9 91.0 06DA537BA01*0 575 32.0 22.9 96.0
DA32*0 208/230 10 16.5 62.0 44.3 228.0 BA12*0 208/230 15 20.7 89.0 63.6 266.0
DA36*0 460 31.0 22.1 114.0 BA06*0 460 40.0 28.6 120.0

* 0 or 5. * 0 or 5.

ALLOWABLE OPERATING RANGE


NOMINAL VOLTAGE MAXIMUM MINIMUM
208/230 254 187
460 529 414
575 661 518
LEGEND
LRA – Locked Rotor Amps
400 (50Hz) 460 342
MCC – Maximum Continuous Current 200 (50Hz) 230 180
RLA – Rated Load Amps

Table 5—Electrical Specifications

36
In cases where an 06D compressor is applied without 4.2 06E Compressor Motor Protection
the supplementary overloads, the use of approved The 06E compressors must be applied with properly
calibrated circuit breakers is required. These circuit sized calibrated circuit breakers to protect the motor
breakers must trip at or under the maximum continu- against overcurrent fault conditions.
ous current (MCC) level listed in Table 5 on Page 36,
and under the locked rotor conditions within 2 to 6 Primary Motor Protection
seconds. Carlyle-approved circuit breakers can use the
Calibrated circuit breakers must be provided for over-
140% or 156% factor to determine RLA values. When
current protection. Approved circuit breaker selec-
approved circuit breakers are used, the must trip
tions are shown in Tables 6 – 9 (Page 38 and 39) for
ampere value of the circuit breaker becomes the MCC
the 06EA, 06ER and 06EM compressors. Use of cir-
value of the compressor branch circuit. This can be
cuit breakers other than those shown in this
used to determine the new compressor branch circuit
Application Manual, or any other alternate overcur-
RLA value.
rent protection must be approved by Carlyle
Application Engineering. For proper overcurrent pro-
Thermal Protection tection, the must trip setting of the calibrated circuit
Internal thermostats are also supplied with all 06D breaker must not exceed the compressor Maximum
compressors with the only exception being part- Must Trip Amps shown in Tables 6 – 9. The selected
winding start models. These thermostats are embed- compressor overcurrent device must trip in 2 to 6 sec-
ded in the motor windings with contacts rated at onds at the LRA value shown for the compressor.
240VA that open on temperature rise and close on
temperature fall. Due to its small mass and the low The circuit breakers selected by Carlyle are manually
temperature rise rate of the 06D motors, these ther- reset and have been sized to protect the compressor
mostats follow motor temperatures closely and pro- against running overcurrent, locked rotor, primary
vide complete thermal protection. Thermostat con- and secondary single phasing. These circuit breakers
nections are made at terminals #8 and #9 on the also offer the additional advantage of protecting the
compressor terminal block in the terminal box. The compressor against malfunctions of the compressor
thermostats are pilot duty, automatic reset devices. contactor (which may not be possible with pilot duty
motor protection).
Branch Circuit Protection
Branch circuit protection may be obtained by use of Table 9 shows the part winding (PW) 6 pole circuit
time delay fuses as noted in the electrical table or by breakers selected for 208/230 volt, three phase,
circuit breakers selected at 110% to 125% of compres- 60 hertz applications. The selected compressor over-
sor motor overload trip current. current protection device for part winding must trip
the first 3 legs in 2 to 6 seconds and the second 3 legs
in 1 to 3 seconds. Carlyle recommends a 1 to 1.25 sec-
ond time delay between energizing the first and sec-
ond legs. These circuit breakers are stocked in limited
quantities by Carlyle. Other 6 pole, part winding cir-
cuit breakers with different trip settings or for other
voltages are also available but may require special
order.

37
Table 6—Low Temperature – Across the Line Start

Table 7—Medium Temperature – Across the Line Start


* The last two digits of the compressors model number may vary. See page 4. The fifth digit in ( ) of the compressor model number represents models with or without oil. 0,
1, 2 signifies older models with oil; 3, 4, 5 signifies newer models without oil. See page 4.

LEGEND
LRA – Locked Rotor Amps
PW – Part Wind
RLA – Rated Load Amps
XL – Across-the-Line

38
COMPRESSOR MOTOR DATA CIRCUIT BREAKER DATA
MAX. RECOMMENDED
MUST LRA PW CIRCUIT
COMPRESSOR MAX. TRIP MAX. LRA (1ST BREAKER MUST MUST RECOMM.
MODEL* VOLT HP kW AMPS RLA XL WINDING) PART NO. HOLD TRIP LRA RLA

06EA(2/5)50000 208/230 108 87 345 207 HH83XB336/625 91 104 350 74.3


(2/5)50100 575 45 36 120 72 XA461 33 38 124 27.1
20 25.3
(2/5)50600 400/460 54 44 173 104 XA424 42 49 175 35.0
(2/5)50300 208/230/460 108/54 87/44 345/173 207/104 XB338/KA424 91/42 104/49 350/175 74.3/35.0

06EA(2/5)65000 208/230 140 112 446 268 HH83XC509 110 127 420 90.7
(2/5)65100 575 57 46 164 98 XA489 48 53 164 37.8
25 33.6
(2/5)65600 400/460 70 56 223 134 XA426 55 64 210 45.7
(2/5)65300 208/230/460 140/70 112/56 446/223 268/134 XC509/XA426 110/55 127/64 420/210 90.7/45.7

06EA(2/5)75000 208/230 168 135 506 304 HH83XC539 142 163 507 116.4
(2/5)75100 575 65 52 176 106 XA430 50 56 188 41.4
30 39.1
(2/5)75600 400/460 84 68 253 162 XA425 63 73 210 52.1
(2/5)75300 208/230/460 168/64 135/68 608/253 304/152 XC638/XA426 142/63 163/73 507/210 116.4/52.1

06EA(2/5)99000 208/230 236 189 690 414 HH83XC537 187 215 636 153.6
(2/5)99100 575 94 75 276 165 XA551 74 85 236 60.7
40 54.0
(2/5)99600 400/460 118 95 345 207 XA550 92 106 295 75.7
(2/5)99300 208/230/460 236/118 189/95 690/345 414/207 XB537/XA550 187/92 215/106 636/295 153.6/75.7

* The last two digits of the compressors model number may vary. See page 4. The fifth digit in ( ) of the compressor model number represents models with or without oil.
0, 1, 2 signifies older models with oil; 3, 4, 5 signifies newer models without oil. See page 4.

Table 8—High Temperature – Across-the-Line Start

* The fifth digit in ( ) of the compressor model number represents models with or without oil. 0, 1, 2 signifies older models with oil; 3, 4, 5 signifies newer models without
oil. See page 4.

Table 9—Part Winding

39
Thermal Protection
A discharge gas thermostat is supplied to provide
overtemperature protection. These sensors are sup-
plied with low and medium temperature 06ER and
06EM compressors. The sensor is factory installed
into one cylinder head to sense discharge gas temper-
ature. The sensor will open on temperature rise and
close on temperature fall. The thermostat pilot duty
contacts are rated for a 125 sealed VA and for an
inrush of 1250 VA. They are automatically resetting
and provide complete thermal protection.

Figure 17—Typical Installation of Cylinder Head


Sensor in 4 Cylinder 06E Compressor

Figure 16—Discharge Temperature Sensor


Shown in Figure 16 is the discharge temperature sen-
sor. Figures 17 and 18 show the discharge temperature
sensor installed on a typical 4 and 6-cylinder 06E
compressor. This control device is a temperature
switch that opens on rising temperature and auto-
Figure 18—Typical Installation of Cylinder Head
matically closes with falling temperature.
Sensor in 6 Cylinder 06E Compressor
06ER/EM* 06EA
°F (°C) °F (°C)
OPENS 325° ±8° 295° ±5°
(163° ±4°) (146° ±3°)
CLOSES 250° ±12° 235° Min.
(121° ±7°) (113°) Min.

* Standardized in 1998 on 06EA sensor.

The sensor wire leads located in the compressor ter-


minal box are to be connected in series with the unit
control circuit wiring.

40
This discharge temperature sensor will operate as motor-compressor nameplate and the nameplate of
an automatic reset device. However, because the trip the equipment in which the motor-compressor is
setting is at a high enough value, any trips should used.” The relevant UL Standards also reflect this
be investigated by service personnel. For that rea- position.
son, Carlyle recommends the discharge temperature
thermostat be wired into the control circuit in a The above RLA value is established by the equip-
manual reset mode. While a number of alternate ment manufacturer at their standard rating condi-
wiring arrangements for manual reset are possible, tion or on a calorimeter test with the unit’s com-
one possible alternate is shown in Figure 19. pressor at or near the condition representative of
L1 L2 unit operation. In unitary equipment, that condition
TYPICAL MANUAL RESET CONTROL CIRCUIT
FOR has been defined as the ARI Standard Rating
CYLINDER HEAD SENSOR
Condition for the class of product involved. These
Oil Safety Switch
Heater Circuit products require the tests be run with the complete
unit: compressor, condenser and evaporator. In
Lockout Low High Oil
Relay
R1
Pressure
Control
Pressure
Control
Pressure Safety
Switch
refrigeration systems that are not completely
C defined (i.e., compressor or condensing units that
Compressor
Time Delay
Relay
Contactor
Coil
can be applied with various evaporators), the
Coil
TDR
calorimeter conditions have been arbitrarily selected
Time Delay
Relay
and appear in UL 303 in classes of high, medium or
low suction pressure applications. In these refrigera-
tion applications, UL will allow the equipment man-
Reset
Button
Cylinder Lockout
ufacturer to use the compressor manufacturer’s
Head Relay
Sensor Coil determination of maximum continuous current
R

2
R (MCC) as the basis for calculating minimum RLA
Lockout
Relay values.
Figure 19—Alternate Wiring Diagram
As a compressor manufacturer, Carlyle does not
publish certified RLA values. We publish a maxi-
Branch Circuit Protection mum continuous current value (MCC) which UL cer-
Branch circuit protection may be obtained by use of tifies. This is verified by operating a compressor at a
time delay fuses or by circuit breakers selected at specified condition with a specific refrigerant. The
110% to 125% of compressor motor overload trip voltage is then lowered until the compressor’s pro-
current. tection system trips. The amperage value just before
the point at which the protection trips is considered
4.3 Rated Load Amperes (RLA) and Maximum the MCC value.
Continuous Current (MCC)
Rated Load Amperes or Rated Load Current is Determining RLA From MCC
defined in Paragraph 440.3 of the National The UL standards provide the equipment manufac-
Electrical Code which states: “The rated-load current turer with the option of using a motor-compressor
for a hermetic refrigerant motor-compressor is the Rated Load Amperage established by testing the
current resulting when the motor-compressor is equipment or determining the RLA value based on a
operated at the rated load, rated voltage and rated certain percentage of the MCC value.
frequency of the equipment it serves.” It is also
stated that: “The Rated Load Current in amperes of
the motor-compressor shall be marked by the equip-
ment manufacturer on either or both the

41
The percentage of the MCC value used is a function of selected to match the load, this policy gives the sys-
the type of motor protection device, as outlined in tems manufacturer greater flexibility in selecting and
Paragraph 440.52 of the National Electrical Code. sizing the overcurrent device and the associated elec-
Briefly, the National Electrical Code allows: trical components. Since the overcurrent device can
A separate overload relay that trips in response to vary, there is no single MCC value which Carlyle lists
motor-compressor current and selected to trip at not with UL. Therefore, Carlyle will not be listing any MCC
more than 140% of the marked motor-compressor values with UL on any of the 06E compressors. Carlyle
Rated Load Current. does specify the maximum must trip current which
can be used with the 06E compressors and these val-
A thermal protector or protective system which will
ues are shown on the 06E electrical tables (see
not permit a continuous current in excess of 156%
Pages 38 and 39, Tables 6 – 9).
of the marked Rated Load Current.
A fuse or inverse time circuit breaker response to 4.6 06D Compressor Contactor Selection
motor-compressor current and rated at not more
Because contactors are not tested to determine their
than 125% of the marked motor-compressor
life performance acceptability under the above 156%
Rated Load Current.
rule, Carlyle does not recommend that contactors be
sized to this rule. Carlyle recommends that contactors
4.4 06D Compressor MCC Values be sized to a current determined by dividing the MCC
Carlyle 06D compressors are provided with overcur- by 1.40.
rent and over-temperature protection that comply
with UL and NEC definitions of inherent motor pro- As an example, for the 06DR228, 208/230 volt model,
tection. The overcurrent protection for 06D compres- the minimum contactor sizing amperage equals:
sors is provided by supplementary overloads and
MCC/1.40 = 55.5/1.40 = 39.6 amps.
these compressors have now had MCC values
approved by the appropriate Code organization (UL, It is obvious that using the 140% rule results in more
CSA). The UL Standard allows the MCC testing to be conservative contactor selections, therefore enhanc-
done in five different suction temperature ranges (in ing contactor and compressor reliability.
addition to different refrigerants); from refrigeration
conditions (-40˚F to +10˚F, -40˚C to -12˚C) to normal The RLA value that is stamped on the compressor or
air conditioning evaporator ranges (+32˚F to +53˚F, unit nameplate is left to the system manufacturer’s
0˚C to 12˚C). While changes in suction ranges and discretion. Carlyle does not stamp RLA values on
refrigerants will result in slight changes in MCC val- their compressor nameplates, thus allowing the sys-
ues, Carlyle’s policy is to certify with UL only the tem manufacturer the greatest flexibility in optimiz-
largest MCC value for each individual 06D compres- ing contactor, branch circuit conductor (wire) and dis-
sor. Therefore, there is only one MCC value indepen- connect sizes. In the above example, the 208/230 volt
dent of the suction range or refrigerant used. 06DR228 compressor could be stamped with an RLA
value of 34.6 amperes, providing you meet Carlyle’s
4.5 06E Compressor MCC Values contactor sizing requirements shown above.
On larger 06E compressors, Carlyle requires that the
4.7 06D Compressors: Wire Sizing
system manufacturer utilize an approved and UL rec-
ognized overcurrent device to protect the 06E com- The standard external overloads and internal ther-
pressor against overcurrent conditions. These overcur- mostats currently supplied with all 06D compressors
rent devices may be magnetic overload relays or circuit are considered a combination overcurrent and ther-
breakers where the must trip setting is in effect, the mal protection system which complies with UL and
maximum continuous current at which the compres- NEC definitions of inherent thermal protection.
sor can operate. Since the overcurrent device can be Carlyle compressors that comply with this definition

42
have the statement “Thermally Protected” stamped or operated, and the must trip setting of any circuit
printed on their nameplates. This would allow a sys- breaker or overload relay must be at or below 108
tem manufacturer to use 156 as the specified percent amperes. The 125% rule is used to determine a maxi-
to determine the compressor minimum rated load mum compressor RLA value of 87 (108/1.25). (See
current. The minimum RLA can be computed by Section 4.3 determining RLA from MCC for details.)
dividing the MCC by 156% or 1.56. For the same It is important to note though, that the listed maxi-
06DR228, 208/230 volt model: mum Must Trip Amps and maximum RLA values in
Min. RLA (to meet codes) Tables 6 – 9 on Pages 38 and 39 for 06E compressors
are maximum motor ampere limits. The actual 06E
MCC/1.56 = 55.5/1.56 = 35.6 amps
RLA values can and are likely to be lower depending
on the must trip settings of the overcurrent protection
4.8 06E Compressors: Contactor Selection
system actually used.
and Wire Sizing
On our larger 06E compressors, Carlyle requires that 4.9 Compressor Nameplate Data
the equipment manufacturer utilize an approved and
The compressor nameplate specifies voltage, phase,
UL recognized overcurrent device to protect the 06E
frequency, and locked rotor current. The rated load
compressor. In this case, the must trip setting of the
current shown in our specification charts may vary
overcurrent device is equivalent to the MCC for the
depending on the overcurrent device chosen, and for
compressor.
that reason is not typically printed in the space
shown on the nameplate. If required, the OEM manu-
For the 06E example, an 06ER175, 208/230 volt
facturer can stamp the appropriate value. The locked
model, in combination with a Heinemann calibrated
rotor inrush current for the first step of part-winding
circuit breaker, HH83XB336 was selected. This circuit
start motors is shown in Tables 6 – 9 on Pages 38 and
breaker has a must trip setting of 104 amperes and
39 for the 06E compressors. The 06D compressors are
this ampere value now becomes equivalent to the
currently not available with part-winding start
MCC value for this compressor/protection
motors. The allowable voltage variation at the com-
combination.
pressor terminals for all 06D and 06E compressors is
typically within +- 10 of the nominal nameplate rating
This type of compressor protection combination is
and is shown on Page 36.
classified by UL as an overload relay and, therefore,
the minimum RLA value can be determined by using
the 140% rule. Therefore, the minimum allowable RLA
for this 06ER175, 208/230 volt compressor application
would be 104 divided by 1.40 or 74.3 amperes. This
value would also be the minimum ampere value
Carlyle would allow for contactor and wire sizing.
This RLA value only applies to the 06ER175 compres-
sor protected by the HH83XB336 circuit breaker. If
other circuit breakers or overload protection devices
are used, different MCC and RLA values would result
as dictated by the must trip setting of the protection
device used.

The compressor Must Trip Ampere value shown in


Table 6 (108 amperes for the 06ER175, 208/230-3-60
volt model) is the maximum ampere value at which
the 06ER175 (208/230 volt) compressor motor can be

43
5.0 – Compressor Features and Accessories

5.1 Safety Relief Valves 1. Danfoss: (see Table 10 below)


All 06E compressors are equipped with built-in safety 2. Penn: P45-NCA-82(STD) or 45-NCB-14 with alarm
relief valves that are factory set to relieve from the circuit.
discharge to the suction side of the compressor at a 3. Johnson Controls: P445 (see Table 10 below)
pressure differential of 400 psi (27 bar). On the 4-
cylinder 06E compressor, the relief valve is located
Table 10 below shows the specifications for the Carlyle
below the discharge service valve in the compressor
approved Danfoss Type series oil safety switches that
crankcase. On the 6-cylinder 06E compressors, it is
are currently stocked by Carlyle.
located in the center bank (below the valve plate) of
the crankcase. The 06D compressors do not have a
The oil safety switch is designed to protect the com-
relief valve, since they are only required in compres-
pressor against loss of lubrication. The switch will
sors greater than 50 cfm (1.42 m3/min).
close the control circuit at start-up (within the
120 second time delay), when the compressor operat-
5.2 Suction Strainers
ing oil pressure is at a maximum of 11 psi (.75 bar)
Each 06D and 06E compressor is equipped with a above suction pressure. The switch will open the con-
suction strainer located in the suction manifold of the trol circuit and shut the compressor off when the oil
motor end bell (except on 2-cylinder models where it pressure drops to a minimum of 4 psi (.27 bar) above
is located on the compressor side of the suction ser- suction pressure and remains for the allotted 120 sec-
vice valve. onds. Carlyle’s new higher flow oil pump has been
found to improve lubrication during abuse conditions.
5.3 Oil Safety Switch As a result, for compressors built with the new higher
Carlyle has approved the following oil safety switches flow oil pump (starting S/N1094J...), the allowable
for use with all 06D and 06E compressors: time delay has been increased from 45 to 120 seconds.

Table 10—Oil Safety Switch Specifications

44
The use of an oil safety switch is recommended/required by Carlyle as noted below.

TYPE OF USING 06D USING 06E


SYSTEM COMPRESSORS COMPRESSORS
Single Compressor
without Unloading Recommended Required
Single Compressor
with Unloading Recommended Required
Multiple Compressors
without Unloading Required Required

Multiple Compressors Required Required


with Unloading

5.4 Crankcase Heaters

CRANKCASE HEATER
HEATER PKG. TYPE NUMBER VOLTAGE WATTS USAGE
06DA660091 Strap-on HT33BK300 115 50 06D 2 & 4 Cyl. (Steel Bottom Covers)
06DA660092 Strap-on HT33BK310 230 50 06D 2 & 4 Cyl. (Steel Bottom Covers)
06EA660148 Insertion HT36FZ379 115 180 06D & 06E (4 & 6 Cyl.)
06EA660149 Insertion HT36FZ479 230 180 06D & 06E (4 & 6 Cyl.)
06DA660076 Insertion HT36DL480 480 125 06D & 06E (4 & 6 Cyl.)

5.5 Mufflers

QTY/ WEIGHT CONNECTION SIZES


PACKAGE NO. PKG LBS. (KG) USAGE OUTLET INLET
06DA605594 1 5 (2.3) 06D ( ) 808, 109, 013, 313, 316 5/8" ODM 5/8" ODM
06DA605604 1 5 (2.3) 06D ( ) 718, 818, 820, 724, 824 7/8" ODF 7/8" ODF
06DA605614 1 5 (2.3) 06D ( ) 228, 328, 337, 537 1-1/8" ODF 1-1/8" ODF
06EA500302 1 10 (4.5) 06E ( ) 150, 250 1-3/8" ODF 1 3/8" ODF
LM10HH100 1 6 (2.7) 06E ( ) 165, 265, 175, 275, 099 1-3/8" ODF 1-3/8" ODF
06EA500712 1 7 (3.2) 06E ( ) 199, 299 1-5/8" ODF 1-5/8" ODF

Mufflers can be mounted horizontally or vertically.

Typical Muffler

45
5.6 Baffle Plates
Baffle plates are an effective way to easily reduce gas
pulsation; however, they have several limitations. They
can result in a pressure drop that is too large when the
suction pressure is too far above, or the discharge pres-
sure is too far below, design conditions. Carlyle, there-
fore, recommends applying baffle plates in a manner
that avoids high pressure drops. They are best used in
service applications where occasionally excessive line
vibration is found.

46
5.7 Discharge Line Check Valves 5.9 Cylinder Head Cooling Fans
Under certain conditions a discharge line check valve
is a valuable means for preventing condensed refrig- CYLINDER HEAD COOLING FAN PARTS
erant from migrating into the cylinder heads of an 06D 06E
idle compressor.
Complete fan package 06DR660014 06ER660011

5.8 Suction Cut-Off Capacity Control Replacement motor


HC27GB230 HC27GB230
(208/230-1-60)
Suction cut-off unloading is an option for all four and
six cylinder Carlyle 06D/E compressors. The capacity CFM Air Flow 750 1000
control operation and application requirements are (CMM Air Flow) (21.24) (28.32)
found in the System Design Section (Section 1.0) of
this manual and should be carefully reviewed. Shown
below are the capacity control packages available.

Capacity Control Packages—Suction Cut-Off Unloading

PACKAGE NO. TYPE QTY/PKG USAGE


06DA660089 Electric* 1 All 06D 4 & 6 Cylinder Models
06DA660090 Pressure 1
06EA660138 Electric* 1 All 06E Compressors
06EA660139
* Electric (Alco) coil is NOT included with 06DA660089 & 06EA660138 electric capacity control package – see coil packages below.

Capacity Control Coil Packages

PACKAGE NO. QTY. VOLTAGE WEIGHT LBS. (KG)


EF19ZE120 1 120-1-50/60 1 (.9)
EF19ZE240 1 208/240-1-50/60 1 (.9)
EF19ZE024 1 24-1-50/60 1 (.9)

47
5.10 Spring Mounting
06D Spring Mounting Package

06E Spring Mounting Package

5.11 Solid Mounting 5.13 Conduit Adapter Plates


All 06D/E compressors may be solid mounted. Carlyle Electrical conduits are mounted to the 06E terminal
offers the 30HR070-1071 solid spacer with four spac- box, by use of an adapter plate. Each compressor is
ers required for each 06D or 06E compressor. The supplied with conduit adapter plates for the appropri-
spacers are 1-1/8” O.D. x 1” high with a 1/2” diameter ate size conduit based on the RLA of the particular
through the hole. compressor. Table 11 shows the conduit plate size pro-
vided with each compressor model.
5.12 Electrical Terminal Parts
Special wire terminations are necessary for use with
the 06E compressors and must be ordered separately
for proper wire size. These crimp type connectors are
available in the following sizes:

TERMINAL PARTS WIRE SIZE


06EA900132 #6
06EA900102 #4
06EA900112 #2
06EA900122 #1/0

Table 11—06E Conduit Sizes Supplied

5.14 SAE Adapter Fitting


PART NO. WEIGHT LBS. (KG) DESCRIPTION USAGE
DE14CA126 1 (0.5) To adapt compressor oil drain plugs from All 06D 4 and 6 cylinder and
SAE fitting to 1/4” NPT 06E compressors

48
5.15 Service Valves

06D - SERVICE SHUT-OFF VALVES


COMPRESSOR SUCTION VALVE ODF (INCHES) DISCHARGE VALVE ODF (INCHES) SELECTION
06DR109 06DA660061 7/8 06DA660060 5/8 Standard
(3ø only)
06DM808 06DA660060 5/8 06DA660061 7/8 Optional
06DR109 06DA660062 7/8 06DA660060 5/8 Standard
(1ø only)
06DM808 06DA660064 1-1/8 06DA660061 7/8 Optional
06DR013
06DA660064 1-1/8 06DA660060 5/8 Standard
06DR316
06DA660062 7/8 06DA660061 7/8 Optional
06DM316
06DA660062 7/8 06DA660060 5/8 Standard
06DM313
06DA660064 1-1/8 06DA660061 7/8 Optional
06DA660065 1-3/8 06DA660061 7/8 Standard
06DR718
06EA660090 1-5/8 06DA660060 5/8 Optional
06DR820
06DA660063 1-1/8 – – Optional
06DA660064 1-1/8 06DA660061 7/8 Standard
06DA818
06DA660062 7/8 06DA660060 5/8 Optional
06DA660065 1-3/8 06DA660062 7/8 Standard
06DR724 06EA660090 1-5/8 06DA660064 1-1/8 Optional
06DA660063 1-1/8 – – Optional
06DA660065 1-3/8 06DA660064 1-1/8 Standard
06DA824
06EA660090 1-5/8 06DA660062 7/8 Optional
06DA328
06DA660063 1-1/8 – – Optional
06EA660090 1-5/8 06DA660062 7/8 Standard
06DR228 06DA660065 1-3/8 06DA660064 1-1/8 Optional
06DA660063 1-1/8 – – Optional
06DR337 06EA660090 1-5/8 06DA660064 1-1/8 Standard
06DM337 06DA660065 1-3/8 06DA660062 7/8 Optional
06DA537 06DA660063 1-1/8 – – Optional

06E - SERVICE SHUT-OFF VALVES


COMPRESSOR SUCTION VALVE ODF (INCHES) DISCHARGE VALVE ODF (INCHES) SELECTION
06ER150 06EA660091 2-1/8 06DA660064 1-1/8 Standard
06EM150 – – 06DA660062 7/8 Optional
06EA660090 1-5/8 06DA660064 1-1/8 Standard
06EA250 06DA660065 1-3/8 06DA660062 7/8 Optional
06DA660063 1-1/8 – – Optional
06ER165
06ER175 06EA660091 2-1/8 06DA660065 1-3/8 Standard
06ER099 – – 06EA660090 1-5/8 Optional
06EM175
– – 06DA660063 1-1/8 Optional
06EA275
06EA660090 1-5/8 06DA660065 1-3/8 Standard
06EA265 06DA660065 1-3/8 06EA660090 1-5/8 Optional
06DA660063 1-1/8 06DA660063 1-1/8 Optional
06EA660091 2-1/8 06EA660090 1-5/8 Standard
06EM199
– – 06DA660065 1-3/8 Optional
06EA299
– – 06DA660063 1-1/8 Optional

49
TM

Manufacturer reserves the right to discontinue, or CARLYLE COMPRESSOR COMPANY • © CARRIER CORPORATION 7/95 Lit. No. 574-069
change at any time, specifications or designs and P.O. Box 4803 • Syracuse, New York 13221 Rev A 8/98
prices without notice and without incurring obligations. In USA & Puerto Rico 1-800-GO-CARLYLE • In Canada 1-800-258-1123 • In Mexico: 95-800-GO-CARLYLE
★★★
★★★

★★★
★★★

★★★

★★★
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ÒÎÊñØ îè íìòî ìðòë ëéòð èìòî ÒÎÊñØ îè ðòîèëè ðòííéç ðòìèîí ðòéðëê
ÒÎÊñØ íë ëîòî êïòè èéòð ïîçòð ÒÎÊñØ íë ðòìíêï ðòëïëð ðòéíêè ïòðéçî

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ÒÎÊñØ ïð íòéð ëòîê éòéê ÒÎÊñØ ïð ðòðîïí ðòðíðé ðòðììç
ÒÎÊñØ ïî ìòìé ëòíï éòëì ïïòï ÒÎÊñØ ïî ðòðîëè ðòðíðì ðòðìíè ðòðêìï
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Refrigeration Controls Catalogue
Catalogue Section 2
Product Bulletin MR10
Issue 09 2001

PRODUCT BULLETIN

MR10 Electronic Controls


for compressor and defrost management

The MR10 range of controllers has been


specifically designed for 'static' or 'ventilated'
refrigeration units working at positive or negative
temperatures. It incorporates all the features
needed by modern units such as compressor and
evaporator fan full management, 'off-cycle' or
'active' defrost control.
Particular emphasis has been given to the cost,
the MR10 offers the basic features for a complete
solution maintaining the cost at a very competitive
level.
Its style has been particularly studied in order to
better suit your machine design. MR14 controller
with defrost and fan management

Features and Benefits


! Attractive Panel mount enclosure Easy and quick installation

! Up to 4 relays in a single package Reduced space

! Up to 16A thermostat output Allows direct control of compressor without the


need for an additional contactor.

! 230Volt power supply models available Reduced installation time

! Accurate and interchangeable IP 68 sensor Accurate control performance


No recalibration needed

! Wide range of sensors with various Possibility to match a wide variety of temperature
enclosures available sensing needs

! SMD technology Higher quality and reliable components

! Keyboard lock Avoids accidental tampering by personnel

© 2001 Johnson Controls, Inc. www.johnsoncontrols.com


Order No. PD-MR10-E Rev. B
General feature
Display Deep freezing
The display has three 7-segment LEDs to display From the front panel, by pressing simultaneously
temperatures from -40°C to +70°C (-40 to 158°F). the + keys it's possible to force the
See Individual LEDs Status table here below. compressor output ON for a pre-set time in order
to start a freezing cycle. This feature is very handy
Sensor input when a loading operation of a cold room or a
This range of controllers uses Johnson Controls display cabinet is performed and there is the need
A99 temperature sensor. Its accuracy is within 0.5°C to bring down the temperature very quickly.
between -15 and 75°C. Its tolerance increases at
temperatures outside this range, as shown below. Alarm management
All devices include a high and low temperature
limit alarm. This alarm is related to the main
setpoint of the thermostat and displays “Hi” or “Lo”
in case of exceeding temperature limits. A delay
can be configured in order to prevent non-
significant events from triggering the alarm
(i.e. door open). The differential of the alarm is
also adjustable. On models with defrost
management, this alarm is disabled during defrost
and for a period after defrost cycle.
Its gas tight packaging makes it the best sensor for Events such as a disconnected or short-circuited
refrigeration applications. For details please refer sensor will be detected, signaled and will results in
to A99 documentation. An offset of the measured a selectable status of the output relay(s).
temperature can be configured for temperature The output cannot only be forced permanently ON
compensation or cable extension. or permanently OFF, but it can also be switched
ON and OFF alternately. This new and innovative
Adjustable setpoint limits function will control the output of the compressor
The setpoint range can be limited in order to avoid according to the average of the last 10 cycles,
“too high” or “too low” setpoint setting of the allowing both energy savings and goods
equipment. The final user cannot set a setpoint preservation.
value exceeding these limits.
Units
Anti short cycle protection Units can be selected from degree Celsius or
Fahrenheit.
In order to protect the compressor against short
cycling all models have a built-in anti short cycle
Output relay rating
protection. This feature determines the minimum
time that must elapse between two start-ups of a Some models feature a 16A thermostat output
compressor. which allows direct control of compressor without
the need for an additional contactor.
Keyboard lock
A sequence of keystrokes allows you to
disable/enable modification of the internal LEDs Status table
parameters. This prevents unauthorised personnel
from making parameter modifications. LED Status Signification
ON compressor ON
Self-testing procedure Blinking deep-freezing cycle active
This feature helps you to check the installation and
configuration of the controller once installed. After ON defrost cycle active
the keystroke sequence + , it will cycle
ON Fan ON
all outputs and flash all LED’s.

2 MR10 Electronic Controls


Dimensions (in mm)
75 68

35 28 35

58

70 75

29

71

Panel cut-out

∅6 50 2000

A99BB-200C Temperature sensor

MR10 Electronic Controls 3


Configuration

1 > 3 sec 1 > 7 sec

2
5 3 > 5 sec

3 4

Set point Parameters System check

> 10 sec

> 5 sec
Keyboard Lock / Unlock Deep freezing

Wiring Instruction Note


These controls are intended to control
WARNING equipment under normal operating conditions.
Where failure or malfunction of the control could
When wiring and servicing make sure that: lead to an abnormal operating condition that
• the electric supply to the actuator is could cause personal injury or damage to the
switched off to avoid possible damage to equipment or other property, other devices (limit
the equipment, personal injury or shock. or safety controls) or systems (alarm or
supervisory systems) intended to warn of or
• you do not touch or attempt to connect or protect against failure or malfunction of the
disconnect wires when electric power is control must be incorporated into and
on. maintained as part of the control system.

4 MR10 Electronic Controls


Compressor control - MR11
This control is specifically designed for the control of refrigeration units operating at positive temperatures.

Description
These controllers are equipped with an SPDT 8(3)A
relay for the compressor control.
Two models are available, either with 12VAC/dc or
230Vac power supply.
Note: A detailed list of available parameters and
their description can be found at the end of
this documentation.

Wiring a) Wiring b)

Selection table:
Item code Enclosure Power supply Shipping weight Wiring diagram
MR11PM12R-1C Panel 75x35 12 Vac/dc 50/60 Hz 230 g a)

MR11PM230-1C Panel 75x35 230 Vac 50/60 Hz 300 g b)

Note: Temperature sensor included in the package

MR10 Electronic Controls 5


Thermostat with “off cycle” defrost control - MR12
This control is specifically designed for the controls of static defrost refrigeration applications operating at
positive temperatures.

Defrost functions Digital input functions


The defrost is initiated and terminated by a timer. All defrost controllers are equipped with a digital
The user sets the interval between successive input performing the following functions:
cycles and its duration.
1. General Alarm
During the defrost cycle, the display can show
\either the last measure before defrost or the 2. Delayed Alarm
setpoint. You can also delay the normal display
3. Door Switch
function after a defrost cycle ends.
Manual defrost is possible by pressing the defrost
key on the keypad.
Note: A detailed list of available parameters and
their description can be found at the end
of this documentation.

Wiring a) Wiring b)

Wiring d)
Wiring c)

Selection table:
Item code Enclosure Power supply Shipping weight Wiring diagram
MR12PM12R-1C Panel 75x35 12 Vac/dc 50/60 Hz 240 g a)

MR12PM12R-A1C Panel 75x35 12 Vac/dc 50/60 Hz 240 g b)

MR12PM230-Z1C Panel 75 x 35 230 Vac 50/60 Hz 240 g c)

MR12PM12H-1C Panel 75 x 35 12 Vac/dc 50/60 Hz 260 g d)

Note: Temperature sensor included in the package

6 MR10 Electronic Controls


Thermostat with active defrost management - MR13
This control is specifically designed for the control of static units working at medium, low temperatures,
requiring active defrost.

This control is equipped with two sensors, one Multifunctional digital input
for the control of the refrigeration unit, the other The digital input (normally closed) can be
sensor manages the evaporator temperature. configured according to the unit requirements.
The functions available are:
Defrost functions
1. General Alarm
The defrost cycle is initiated by a timer and
terminated either by temperature or time, 2. Delayed Alarm
whichever is first fulfilled.
3. Door Switch
The defrost function includes the following
parameters:
• Types of defrost (Hot gas or electrical
heating).
• Interval time to adjust defrost frequency.
• Defrost termination: time or temperature.
• Defrost end temperature.
• Defrost maximum duration time.

You can stop the compressor for an additional


configurable period called dripping time. This will Note: A detailed list of available parameters
allow the evaporator to dry prior to resuming and their description can be found at the
normal operation. end of this documentation
In case of evaporator sensor failure, the defrost
cycle will be terminated by the maximum defrost
duration.
During defrost the display can be configured to
show the last measurement before defrost or the
setpoint.

Wiring a)

Selection table:
Item code Enclosure Power supply Shipping weight Wiring diagram
MR13PM12R-2C Panel 75x35 12 V ac/dc 50/60 Hz 330 g a)

Note: Two Temperature sensors are included in the package

MR10 Electronic Controls 7


Thermostat with defrost and fan management - MR14
This control is specifically designed for the control of ventilated refrigeration applications requiring active
defrost such as hot gas or electrical. This is also suitable for a small plant.

This control is equipped with two sensors, one for Fan management functions
the control of the refrigeration unit, the other With the MR4 models you can choose whether the
sensor manages the evaporator temperature. fan is to be run in parallel with the compressor or
whether it should remain constantly ON. In any
Defrost functions case the fan is switched OFF during defrost.
The defrost cycle is initiated by a timer and After defrost, the fan can resume its work after a
terminated either by temperature or time, preset time or after the evaporator temperature
whichever is first fulfilled. has dropped below an adjustable temperature.
The defrost function includes the following
Digital input functions
parameters:
All defrost controllers are equipped with an
• Types of defrost (Hot gas or electrical additional digital input which can be configured to
heating). perform the following functions:
• Interval time to adjust defrost frequency.
• Defrost termination: time or temperature. 1. General Alarm
• Defrost end temperature. 2. Delayed Alarm
• Defrost maximum duration time.
3. Door Switch
You can stop the compressor for an additional
configurable period called dripping time. This will
allow the evaporator to dry prior to resuming
normal operation.
In case of evaporator sensor failure, the defrost
cycle will be terminated by the maximum defrost
duration.
During defrost the display can be configured to Note: A detailed list of available parameters and
show the last measurement before defrost or the their description can be found at the end
setpoint. of this documentation.

Wiring a) Wiring b)

Selection table :
Item code Enclosure Power supply Shipping weight Wiring diagram
MR14PM12R-A2C Panel 75x35 12 V ac/dc 50/60 Hz 330 g a)

MR14PM12R-2C Panel 75x35 12 V ac/dc 50/60 Hz 330 g b)

Note: Two temperature sensors are included in the package

8 MR10 Electronic Controls


Description of each parameter
Setpoint: Ad Alarm differential
is defined as the relay cut OFF. Useful to avoid alarm oscillation.
For example:
Hy Hysteresis Setpoint = 4ºC
This is the difference between the Max. temperature alarm = 6 K
temperature at which the compressor Alarm differential = 2 K
output is switched OFF and the In this case, when the cold room
temperature at which the output is temperature exceeds 4+6 = 10ºC for a
switched ON. This is an absolute value, time greater than parameter 9 the alarm is
related to the setpoint. activated; when temperature drops below
4+6-2 = 8ºC the alarm is reset.
Hysteresis Example:
Cooling Setpoint = 4ºC. At Alarm time delay
Differential = 2 K. Delay between the detection of the
The compressor is switched temperature alarm and the activation of
ON when the temperature the alarm sequences. This is useful to
goes over 6ºC, and is turned prevent temporary conditions from causing
OFF when the temperature an alarm. Furthermore, the controller
decreases to 4ºC. automatically ignores the temperature
Cooling Setpoint
T °C alarm condition in the following cases:
- for 20 minutes after the power-ON
- during defrost and for 20 minutes after
LL/HL Lower & Higher setpoint limit the defrost-end.
The setpoint value cannot be adjusted
outside the limits defined by these dF Defrost function
parameters, to avoid improper setpoint Select the type of your installation and the
setting by the user.
way defrost is performed:
0 = Electrical defrost (Compressor OFF)
CC Anti short cycle protection 1 = Hot gas defrost (Compressor ON).
This parameter prevents the compressor
from being turned ON / OFF too often. dE Defrost end function
The value that you set is the minimum Select the defrost termination type:
time between two subsequent switches 0 = timer based set with parameter dd
ON of the output. 1 = temperature based set with param. dt.
Note: in any case the defrost ends after
Cooling demand the time set through parameter dd.

Comp. output dt Defrost termination temperature


Used only when parameter dE = 1.
Anti cycle timer When the evaporator temperature reaches
this value, the defrost automatically ends.
Co Deep freezing time
di Defrost interval time
This is the time for which the compressor
This is the time between two subsequent
is forced ON when pressing the deep
defrost cycles. This timer will initiate every
freezing cycle key from the faceplate.
defrost cycle.
AH High temperature alarm
dd Maximum defrost duration
High temperature alarm value relative to
The defrost cycle will stop after this time,
setpoint.
even if the defrost end temperature has
E.g. If your set point is at 4ºC and AH = 5K
not been reached.
the alarm will be triggered at 9ºC.
dC Dripping time
AL Low temperature alarm
After defrost is terminated, the compressor
Low temperature alarm value relative to
is stopped to allow the evaporator to drip.
setpoint.
E.g. If your set point is at 4ºC and AL = 3K
below setpoint, it will be triggered at 1ºC.

MR10 Electronic Controls 9


dU First defrost cycle after power-on FF Fan operating function
This parameter allows to delay a defrost 0 = fan runs in parallel to the compressor
cycle, after power-up. This will prevent a 1 = fan is always ON
cycle from occurring before the cold room Note: in both cases, the fan is switched
has reached its operation temperature. OFF during the defrost cycle.
This function is disabled when set to "OF".
Fd Fan start-up delay after defrost end and
dP Display during defrost power up
You can select what to display during the This parameter is a safety function, the fan
defrost cycle. This is meant to avoid is activated after this time even if the
misleading users during the defrost cycle. temperature set through parameter (Fr)
0 = last measured value before defrost has not been reached.
cycle
1 = setpoint Fr Fan start temperature after defrost end
and power up
dr Delay displayed temperature after defrost Evaporator sensor temperature at which
During defrost cycles the ambient tempe- the fan is switched ON, after defrost cycle,
rature is not displayed (see parameter dp).
Note: in any case the fan is switched ON
The actual temperature returns to display
after the time set through parameter (Fd).
when its value reaches the setpoint value
or, in any case, after the time defined by
SF Thermostat operating function when
this parameter.
sensor failure
iF Digital input function This defines the cycle of the thermostat
output in case of failure
The digital input (normally closed) can be
0 = Compressor ON
configured according to the plant
1 = Compressor OFF
requirements:
2 = Automatic
0 = the DI is not connected
In the automatic mode, the controller will
1 = General Alarm: If the contact stays
calculate the average time the compressor
open (On) for longer than parameter id
was ON for the last 10 cycles, and the
then:
compressor will run accordingly. If a deep
• all outputs are de-energised;
freezing cycle or a defrost cycle occurred,
• an alarm message (A1) is displayed; they will not be taken into account nor will
• the alarm output is energised the first cycle afterwards.
(if present).
The alarm condition automatically resets So Offset thermostat sensor
as soon as the contact closes back.
2 = Delayed Alarm: If the contact stays This value is added to or subtracted from
open (On) for longer than parameter id the measured value to compensate for
then: possible field measurement offset errors.
• an alarm message (A2) is displayed; To compensate for extra long copper
cabling use the following formula:
• the alarm output is energised
(if present). 5 × length
C om p ens ation = − K
All other functions continue as usual, the 1 000 × area
, where
alarm condition resets as soon as the
length = length of the cable in meters
contact closes back.
area = section of the cable in square
3 = Door Switch: As soon as the contact
millimetres and compensate for the
opens (On) the fan is switched off
calculated value
(if applicable) and if it stays open for
longer than parameter id then:
Un Temperature units
• an alarm message (A3) is displayed;
• the alarm output is energised 0 = Celsius degrees,
(if present). 1 = Fahrenheit degrees.
High and low alarms are disabled. The
condition automatically resets as soon as PU Display updating time delay
the contact closes back. The temperature value display of the MR
will be refreshed with this defined period.
id Digital input time delay It will not affect the control performance.
Time between the detection of the digital
input opening and the enabling of the
function selected through parameter (iF).

10 MR10 Electronic Controls


Parameters
Parameter Setting Range Default MR11 MR12 MR13 MR14
Temperature control parameters
Hy Hysteresis (HY) 1 to 9 K 2 • • • •

LL Lower setpoint limit (LL) -40°C to higher limit -40 • • • •

HL Higher setpoint limit (HL) lower limit to 70°C 70 • • • •

CC Anti short cycling (CC) 0 to 9 min 2 • • • •

Co Deep freezing time (Co) 0 to 99 min 60 • • • •

Alarm parameters
AH High. temperature alarm 0 to 50°C related to setpoint 10 • • • •

AL Low temperature alarm -50 to 0°C related to setpoint -10 • • • •

Ad Alarm differential 1 to 9 K 1 • • • •

At Alarm time delay 0 to 99 min 30 • • • •

Defrost parameters
dF Defrost function 0 = Electric heater 0 • •
1 = Hot gas
dE Defrost end function 0= by time 1 • •
1= by temperature
dt Defrost termination temp 0 to 20°C 7 • •

di Defrost interval time 0 to 99 hours 6 • • •

dd Max. defrost duration 0 to 99 min 40 • • •

dC Dripping time 0 to 99 min 5 • • •

dU First defrost after power on OFF, 0 to 99 min OF • • •

dP Display during defrost 0 = Last value before defrost 0 • • •


1 = Set point
dr Delay displayed temp after 1 to 99 min 20 • • •
defrost
Digital input parameters
iF Digital input function 0= not connected 0 • • •
1= High Level Al.
2= Delayed Alarm
3= door switch
id Digital input time delay 0 to 99 min 5 • • •

Fan control parameters


FF Fan operating function 0 = Parallel with compressor 0 •
1 = Continuous
Always OFF during defrost
Fd Fan start-up delay after defrost 0 to 99 min. 5 •
end and power up
Fr Fan start-up temperature after -30 to +5 °C -5 •
defrost end and power up

MR10 Electronic Controls 11


Parameter Setting Range Default MR11 MR12 MR13 MR14
Other parameters
SF Thermostat operating function 0 = Always ON 2 • • • •
if sensor failure 1 = Always OFF
2 = Automatic
So Sensor offset -20 to +20 k 0 • • • •

Un Temperature units 0 = °C 0 • • • •
1 = °F
PU Display updating time 1 to 99 sec 1 • • • •

Accessories
Item Code Description
TR230/12-1 Transformer 230 / 12,3 VA

A99BB-200C Sensor, cable length: 2m

Alarm and Fault Codes


Error Codes and Status
Error Code (Codes will flash on the display) System Status
F1 Open or shorted room temperature sensor Alarm output energised (if present)
Compressor output in function of param. SF
Cycle power to reset
F2 Open or shorted evaporator temperature sensor Alarm output energised (if present)
Defrost end only by time
Fan managed in parallel to compressor
Automatic reset
A1 Digital input open for longer than param. id and iF = 1 Alarm output energised (if present)
All other outputs go OFF
Automatic reset
A2 Digital input open for longer than param. id and iF = 2 Alarm output energised (if present)
Automatic reset
A3 Digital input open for longer than param. id and iF = 3 Alarm output energised (if present)
Automatic reset
HI Calculated case temperature has reached or exceeded Alarm output energised (if present)
(Setpoint + AH) Automatic reset
LO Calculated case temperature has reached or fallen below Alarm output energised (if present)
(Setpoint + AL) Compressor output OFF
Automatic reset
EE Program failure Replace controller

Repair and replacement


Field repair is not possible. In case of defective or improperly functioning control, please check with your
nearest supplier. When contacting the supplier for replacement, you should state the type-model number
of the control. This number can be found on the data plate.

12 MR10 Electronic Controls


MR1/4 13

Specifications
Product MR10 Electronic Controls
Power Requirements 12 VAC/dc ±10%, 50/60 Hz Not all power supplies are available in every version.
230 VAC ±10%, 50/60 Hz Please refer to selection tables.
Power Consumption 2 VA
Protection Class Panel Front plate IP 54
mount Rear IP 20
Ambient Operating -10° to +55°C (14° to 131°F)
Conditions 10 to 95 % RH (non condensing)
Ambient Storage -30° to +80°C (-22° to +176°F)
Conditions 0 to 95 % RH (non condensing)
Range -40 to +70°C
Accuracy & Precision ± 1°C
Sensor cable 2 meters
Output ratings (250 VAC) Compressor Alarm Defrost Fan
MR11PM12R-1C SPDT 8(3)A
MR11PM230-1C SPDT 8(3)A
MR12PM12R-A1C SPDT 8(3)A SPST 8(3)A
MR12PM12R-1C SPDT 8(3)A
MR12PM230-Z1C SPDT 8(3)A
MR12PM12H-1C SPDT 16(12)A
MR13PM12R-2C SPST 8(3)A SPST 8(3)A
MR14PM12R-2C (*) SPST 8(3)A SPST 8(3)A SPST 8(3)A
MR14PM12R-A2C (*) SPST 8(3)A SPST 8(3)A SPST 8(3)A SPST 8(3)A
(*) Max. current on common = 20 Amps
Dimensions (H x W x D) Panel mount 35 x 75 x 68 (1.38” x 2.95” x 2.68”)
Compliance 73/23 EEC directive: EN 60730
89/336 EEC directive: EN 50081-1, EN 50082-2

The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond
these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from
misapplication or misuse of its products. This document is subject to change without prior notice.

Johnson Controls International, Inc.


Headquarters: Milwaukee, WI, USA
European Headquarters: Westendhof 8, 45143 Essen, Germany
European Factories: Lomagna (Italy), Leeuwarden (The Netherlands) and Essen (Germany)
Branch Offices: Principal European Cities.
This document is subject to change

MR10 Electronic Controls 13


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Data sheet Thermostats, differential thermostats
type RT

Introduction

An RT thermostat is fitted with a single-pole The RT series also includes differential


changeover switch. thermostats, thermostats for neutral zone
The position of the contacts depends on the regulation, and special thermostats with
bulb temperature and the set scale value. gold-plated contact surface for PLC applica-
The RT series includes thermostats for general tions.
applications within industrial and marine
refrigeration.

Features Waterproof versions, enclosure IP 66 Suitable for alternating and direct current

Wide regulating range Interchangeable contact system

Wide range of units for industrial and marine Special versions for PLC applications
applications

Technical data Cable connection Permissible ambient temperature


Pg 13.5. Cable diameter 6 14 mm. 50 +70 C for thermostat housing.

Enclosure Switches
IP 66 to IEC 529, except for versions with ext. See "Ordering switches".
reset which are to IP 54.

Danfoss A/S, 09 - 1999 RD.5E.A2.02 1


Datasheet Thermostats, differential thermostats, type RT

Approvals

DEMKO, Denmark
Lloyd’s Reg. of Shipping, UK
Germanischer Lloyd, Germany
Canadian Standards Association, Canada 1)
Det norske Veritas, Norway
Bureau Veritas, France
Polski Rejestr Statków, Poland
RINA, Registro Italiano Navale, Italy
RMRS Russian Maritime Register of Shipping
NKK, Japan
Korean Register of Shipping, Korea
EN 60730-2-1 to 9
CE mark according to RN 60947-4, -5
1) Special versions supplied from Danfoss, Canada.

Overview
50 0 +50 +100 +150 +200 +250 +300 C Range
Type
C
60 -25 RT 10
Vapour-charged with remote bulb 45 15 RT 9
(bulb coldest) 30 0 RT 13
25 +15 RT 3
25 +15 RT 2, 7
20 +12 RT 8
5 +10 RT 12
5 +30 RT 14
Adsorption-charged with remote bulb +5 +22 RT 23
(bulb warmest or coldest) +8 +32 RT 15
+15 +34 RT 24
+15 +45 RT 140
+25 +90 RT 101, 102
Partial charge with remote bulb (bulb warmest) +70 +150 RT 107
50 15 RT 17
Vapour-charged with coiled capillary tube sensor 30 0 RT 11
(room thermostats) 5 +30 RT 4
Adsorption-charged with coiled capillary tube sensor (room thermostats) 25 +15 RT 34
20 +12 RT 8L
Adsorption-charged dead zone thermostats with remote bulb 5 +30 RT 14L
(bulb warmest or coldest) +15 +45 RT 140L
Vapour-charged dead zone thermostat (room thermostat) 0 +38 RT 16L
Adsorption-charged differential thermostats with remote bulb (bulb warmest or coldest) 30 +40 RT 270

50 0 +50 +100 +150 +200 +250 +300 C

2 RD.5E.A2.02 Danfoss A/S, 09 - 1999


Datasheet Thermostats, differential thermostats, type RT

Ordering Thermostats
Differential t Max. Capillary
Bulb Regulation Lowest Highest bulb tube
Charge Type range temp. temp. Reset temp. length Code no.
type
setting setting
C K K C m
Vapour 1) RT 10 A 60 25 1.7 7.0 1.0 3.0 Aut. 150 2 017-5077
RT 9 A 45 15 2.2 10.0 1.0 4.5 Aut. 150 2 017-5066
RT 3 A 25 +15 2.8 10.0 1.0 4.0 Aut. 150 2 017-5014
RT 17 B 50 15 2.2 7.0 1.5 5.0 Aut. 100 017-51017
RT 11 B 30 0 1.5 6.0 1.0 3.0 Aut. 66 017-5083
RT 4 B 5 +30 1.5 7.0 1.2 4.0 Aut. 75 017-5036
017-50374)
RT 13 A 30 0 1.5 6.0 1.0 3.0 Aut. 150 2 017-5097
Adsorp- RT 2 A 25 +15 5.0 18.0 6.0 20.0 Aut. 150 2 017-5008
tion 2) RT 8 A 20 +12 1.5 7.0 1.5 7.0 Aut. 145 2 017-5063
RT 12 A 5 +10 1.0 3.5 1.0 3.0 Aut. 65 2 017-5089
RT 23 A +5 +22 1.1 3.5 1.0 3.0 Aut. 85 2 017-5278
RT 15 A +8 +32 1.6 8.0 1.6 8.0 Aut. 150 2 017-5115
RT 24 A +15 +34 1.4 4.0 1.4 3.5 Aut. 105 2 017-5285
RT 140 C +15 +45 1.8 8.0 2.5 11.0 Aut. 240 2 017-5236
RT 102 D +25 +90 2.4 10.0 3.5 20.0 Aut. 300 2 017-5147
RT 34 B 25 +15 2.0 10.0 2.0 12.0 Aut. 100 017-5118
RT 7 A 25 +15 2.0 10.0 2.5 14.0 Aut. 150 2 017-5053
RT 14 A 5 +30 2.0 8.0 2.0 10.0 Aut. 150 2 017-5099
RT 101 A +25 +90 2.4 10.0 3.5 20.0 Aut. 300 2 017-5003
Partial 3) RT 107 A +70 +150 6.0 25.0 1.8 8.0 Aut. 215 2 017-5135
1) The sensor must be located colder than thermostat housing and capillary tube. 2) The sensor can be located warmer
or colder than thermostat housing. 3) The sensor must be located warmer than thermostat housing and capillary tube.
4) With built-in heating coil reduces the thermal differential.

Thermostats with adjustable dead zone


Dead zone NZ Max. Capillary
Bulb Regulation Differen- Lowest Highest bulb tube
Charge Type range tial temp. temp. temp. length Code no.
type
setting setting
C K K K C m
Vapour RT 16L B 0 +38 1.5 / 0.7 1.5 5.0 0.7 1.9 100 017L0024
Adsorp- RT 8L A 20 +12 1.5 1.5 4.4 1.5 4.9 145 2 017L0030
tion RT 14L A 5 +30 1.5 1.5 5.0 1.5 5.0 150 2 017L0034
RT 140L C +15 +45 1.8 / 2.0 1.8 4.5 2.0 5.0 240 2 017L0031
RT 101L A +25 +90 2.5 / 3.5 2.5 7.0 3.5 12.5 300 2 017L0062

Differential thermostat
Operating Max. Capillary
Bulb Regulating
Charge Type range for Dead zone NZ bulb tube Code no.
type range
LT bulb temp. length
C C K C m
Adsorption RT 270 2 A 0 15 30 40 2 65 2 5 017D0031

Type of bulb / sensor


A B C D 2 A

Cylindrical Room sensor Duct sensor Capillary Differential


remote sensor tube sensor thermostat

Special versions When ordering, please state


RT can be supplied with special switches. 1. Type
See next page. 2. Code no. of standard unit
3. Code no. of special switch

Danfoss A/S, 09 - 1999 RD.5E.A2.02 3