> 5F,H Open-Drive Compressors Installation, Start-Up and Service Instructions CONTENTS Page ‘SAFETY CONSIDERATIONS 1 INSTALLATION 13 Step 1 — Prepare for instailation i + PREPARE EQUIPMENT ROOM Step 2 — Receive Machine 10 + BEFORE UNLOADING. + RIG UNIT CAREFULLY Step 3 — Install Unit 10 + TO MOUNT MOTOR ON BASE + TO MOUNT CARRIER COMPRESSOR UNITS, AND CONDENSER PACKAGES + TO MOUNT COMPRESSOR BASE ON SUPPORT STANDS Step 4 — Assemble Refrigerant Piping ‘and Components 10 + COMPRESSOR DISCHARGE PIPING + REFRIGERANT DRIER + FELT FILTERS ‘Step 5 — install Muttiple Compressors 10 = EQUALIZING LINES ‘Step 6 — Make Electrical Connections 2 IERAL NOTES + ATTACH POWER WIRES TO COMPRESSOR MOTOR + CHECK MOTOR ROTATION + INSTALL CRANKCASE HEATER Step 7 — Check Compressor/Motor Alignment ...... B + BELT DRIVE + DIRECT DRIVE + HOT CHECK AND DOWELING ‘Step 8 — Assemble Water Piping B Step 9 — Prepare Lubrication System 3 + INSTALL OPTIONAL EQUIPMENT + CHECK OIL LEVEL. + RECOMMENDED OILS PREPARE FOR INITIAL START-UP 13 Evacuate, Dehydrate and Leak Test ....2.....13, Refrigerant Charging BUB ‘START-UP 13.16 Preliminary Steps... 2B Start Compressor 4 Check Control Operation 4 Check High-Pressure Switch 4 Check Low-Pressure Switch | 14 Adjust Capacity Control (if required) 4 SCHEDULED MAINTENANCE m9 Check Lubrication System iid Check Water-Cooled Heads 19 SERVICE 19.36 Service Notes : 19 Lubrication System 9 Page Prossure-Reliot Valves 26 Suction Strainer 26 Cylinder Head and Vaive Assembiies 2 Cylinder and Unloader Sleeves 2 ‘Connecting Rods and Pistons 2 Capacity Control Oper % Capacity Control inspection and Service... 31 Crankshaft inspection and Service 32 Pump-End Main Bearing B Center Main Bearing % ‘Seal-End Main Bearing uM Crankshaft Seal Inspection and Replacement u Accessories : 34 ‘TROUBLESHOOTING 37.39 SAFETY CONSIDERATIONS Installation, startup and servicing of this equipment can bbe hazardous due to system pressures, electrical components and equipment location. Only trained, qualified installation and service personnel should install, star-up or service this equipment, ‘When working on this equipment, observe precautions in the literature, tags, stickers and labels attached to the equip: ment and any other safety precautions that apply. + Follow all safety codes + Wear safery glasses and work gloves. + Use care in handling, rigging and setting bulky equipment. PETG Before performing servive or maintenance oper INSTALLATION ‘Step 1 — Prepare for Installation PREPARE EQUIPMENT ROOM — Locate compressor or condensing unit in a well ventilated area. If natural vent lation is inadequate, provide forced ventilation through ductwork. Check applicable code requirements. Provide freeze-up protection for water-cooled condens- rs, water lines and accessories if freezing temperatures can boecur during winter shutdown periods Provide sufficient clearance for removal of compressor cy inder heads and valve plates. Allow space on the oil pump end for crankshaft removal as follows: 5F20, 30, 40, and 60 compressors 20 in, 540, 46, 60, and 66 compressors 20 in, SHR0, 86, 120, and 125 compressors 30 in, (Continued om page 10) ‘anutacturerreseres te Aight to dons, or change at ony ie, spertionsons or Geaigne mfiou note wou Moura oongeane =e Pe ane sing No 830505. Pratedin USA, Fom SEH23S1 Py 1200 Repco SHAS!4 SUCTION SHUTOFF vaLve 2 m7" ODF OL FILLER PLUG GAGE CONNECTON aes ‘ou. PUMP RorETION Beaois Toit Powe’ eaten ‘AL PRESSURE CONNECTION aie CCRANKCASE HEATER CLSING ‘OL ORAN PLUG 5/8"-18: iscHaRgs seuTOrr SERS OE or pessune ME Eager EEttcrion wates SucTION ano oiscHARGE MANIFOLD" coven (Remove HeniaeeeS¥6 suction ‘STRAINER [lL PRESSURE CONNESTION .ow-eRessuae. 588 ‘SeWFRBe EonNECTION fa ips SEAL cover lL, LEVEL Stok eas (iL PRESSURE REGULATOR Fig. 1 — 5F20; 2-Cylinder CompressorDISCHARGE SHUTOFE VALVE, 3a" Ob cage conNecTION vanes HiGh-PReesuRe RETRAIN fave auase SEAL covER SUCTION SHUTORF_vaLVE ing7es oor REMOVE FO ThesesS To SUCTION STRAINER V8" 1S GAGE CONNECTION Ot, FLLER PLU Sree Low: pressure. lL PRESSURE CONNECTION, ‘EON TaOL CONNECTION Sate tates lL pune ROTATION ARROWS ‘IL PRESSURE CONNECTION’ (Gi pina cover varies CL, pRAIN PLUG OHODEN) Sree ceannoase veareR Soy gime ne aonencr BEE SEE on Fig. 2 — 5F30; 3-Cylinder CompressorDISCHARGE SHUTOFF VALVE Pye" oor xe ys" es puewaric tncuconegue CONTROL, : TR COMME on vanes. SUCTION MANIFOLO COVER PLATE (Gemove For access To SUCTION STRAINER) OL PRESSURE REGULATOR CONTROL OL PRESSURE CAPACITY CONTROL. VALVE DOWEL HOLE CcRANKCASE NEATER CASING (Gipe cae vere) SUCTION. SHUTOFF VALVE Poa oF Vs" IPS GAGE CONNECTION Ot FILLER PLUG, Sra eSteerion CONTR Vaties ‘IL, PUMP ROTATION ARROWS (or."Puwe coven PRESSURE. CONNECTION veies DOWEL HOLE: PUMP INTAKE PLUG (MAGNETICIS/8"- ‘OL DRAIN PLUG 8/8" 18 Fig. 3 — 5F40; 4-Cylinder CompressorSUCTION SHUTOFF VALVE 278 OF DISCHARGE SHUTOFF VALVE Tere" OOF ouneerion ares (Above . iow!pressune. va" is pucuuaric SBNTROL CONNECTION (CowTROL CONNECTION LOW PRESSURE CONTROL g egungerion tates LCONTREL OIL PRESSURE CAPACITY CONTROL VALVE SEAL covER DoweL Hole -—————2 os WL. PRESSURE RESALATOR CRANKCASE HEATER CASINGIPPE CAP V/2"FPT) SucTION MANIFOLD ieee Fem sess ro FILLER Pus, See ot. Pum ie CONTROL OL STRANER =, (1, PRESSURE: CONNECTION: vars iL, PUMP ROTATION ARROWS. Coie" Pome cover) [78 1PS (OPENING TO CRANKCASEY ump itaKE PLUG aazGNeETIC) sree OL oRAIN PLUG S7a"-I0 Fig. 4 — 5F60; 6-Cylinder CompressorNAMEPLATE, iL DISCHARGE SHUTOFF VALVE gh: PRessuRe EghTaoL conhecrion wate. Low pressure ‘SONTROL GONNECTION SUCTION GAGE coNECTION fares aes [IL PUMP ROTATION ARROW SUCTION SHUTOFF VALVE: 25/0" 00F e = OIL FILLER PLUG 5/816 Pues cONTROL PRESSURE ERRNEETGet = CONTROL oiL PRES! va" ips (CAPACITY CONTROL VAL OlL LEVEL SIGHT GLASS, PUMP-END COVER fran rue CRANKCASE DRAIN eH GAGE CONNECTION ge-PResguRE CONTROL SUCTION DISCHARGE MAWFOLD COVER ESAS TPS (REMOVE FOR AocESS 0 SUCTION. SF AnD Mae PRESSURE PENING TO GRANCASE (ODEN) va" eS OL PRESSURE REGULATOR ‘OL, PUMP PRESSURE PLusceo OPENINGS Pom INTERCONNECTION {wor STANDARD! SEAL COVER PLATE CCRANKCASE HEATER CASING (hire cap v2FeT) DOWEL HOLE Fig. 5 — 5H40, 46; 4-Cylinder CompressorsGAGE connections aes Se ——— SUCTION SHRTOFF VALVE DiscHagae sHuTore SAVES EE CONNECTION 1/6" IPS. PLUsGED oPeNINaS FoR INTERCONNECTION SEAL COVER PLATE. (nor STANDARO) OIL PRESSURE REGULATOR: CRANKCASE HEATER EASING (PIPE CAP V2" FPTY Access TO MIGH- PRESSURE RELIEF VALVE PNEUMATIC CONTROL, (eouave Pet acres, EaNNEETON TAT : TS SEON staan Low paessue comreot COnNEETION vate MG TO crancase 5 OWL FILLER PLUG po eressune new) > CAPACITY CONTROL. VALVE: CONTROL OL PRESSURE CONTROL OIL STRAINER PLUG" Sree PUMP-END cover OIL LEVEL SOT aL.Ass SHRP Fig. 6 — SH60, 66; 6-Cylinder Compressors__ Nae PATE, HGH PRESSURE. RELIEF VALVE, AO Manito cover BLaTE SEAL COVER PLATE cone Pom ireRcomection (wor'Stanoaeo) (2) CRANKCASE HEATER cASiNes (OL PRESSURE REGULATOR: (iipe cap 2 er SUCTION SHUTOFF VALVE DISCHARGE SHUTOFF vaLve S170" oor Sie" OOF ‘Gage CONNECTIONS varies SuerioN MANIFOLD COVER (henove FoR access 19 ich -PREssuRE coNTROL. SUCTION STRAINER) ESRNECTION Ua Preumaric covTROL, Low pRessure coNTROL ENECTION Ha HS CONNECTION 1a TPS. ‘OPENING TO CRANKCASE, ees CENTER man BEARING Retaiine Senew access cabaciry CONTROL VALVE SeUSTINS Siew on pune RGTETION ARROW (TAG) coNTROL OW, STRAINE ree sae {CONTROL O. PRESSURE ee ee OIL LEVEL SIGHT GLASS. CRANKCASE ORAIN: PUMP-END COVER Fig. 7 — 5H80, 86; 8-Cylinder CompressorsscHaRce service Vasle b6" or SUCTION semvice VALVE sage ua oe acess GAS EOUALIZER CONNECTION sosuerion stannic Qt cous er Ot re oMneetiGR PLUG {AES use FOR LOWPRESSURE tt Une Connestron) capREITY conn. ‘iL PUMP ROTATION ARROW ‘OW ot Pune COVER (1. PUMP pRESsURE Gierone ow FTERY CONTROL OL. PRESSURE. Sohne TION FP CRANKCASE DRAIN PLUG lL PRESSURE Gace suUTORF Save CaF TER GL FIER) FULL, FLOW Hict-PRESSURE ~ Stree ESSURE Sueno ctce conesrion aiscuanse sac EBWTROL cownecTION cH eressune tea ps abBENT oNTROL CONNECTION ———— See Fer at ips aibben See rie? Ot PRESSURE REGULATOR ENTER man geaRine ReTAinive soxew access -— (oven) SEAL COVER PLATE: (2) caanncase wearer (Gasings (oben See rie? (BipE CP 2" eT) Pron ceva. sicur cuss "ON GPPOSITE SOE OF COMPRESSOR) SUCTION MANIFOLO ont BEY Hicr-PRESSURE OL. CONNECTIONProvide space equal to condenser length for tube removal tnd cleaning, Step 2 — Receive Machine (Fig. | through 8) BEFORE UNLOADING — Check unit nameplates a ‘model and serial numbers recorded in job specifications. Chock all items against shipping list, and examine items carefully for any shipping damage. If damage is found or any major component has torn loose from its anchorage, have transportation inspectors examine it before unloading. File claim immediately with shipping company for any loss or damage. RIG UNIT CAREFULLY — Check that rigging equipment ccan safely handle the approximate equipment weights for ‘conrpressors and condensing units. Rig and move unit carefully to prevent damage to mount- ing brackets, refrigerant piping or connections Step 3 — Install Unit TO MOUNT MOTOR ON BASE — The motor fastening set, available as an accessory for all SF,H base-mounted compressors, includes motor blocks and shims for motor alignment; cap screws, plate washers and lock washers for fastening motor to base; taper dowel pins for securing mo- tor position after alignment; and beveled washers for fas- tening the unit base to accessory vibration isolators 1 vibration isolators are used, attach to base (Fig. 9). To, avod damaging the isolators, lift unit from ends when at- tacking isolators, ‘With compressor and motor positioned on the base, check. the height of the vibration isolators, Shim between isolators and floor as required to level compressor base. When level, secure vibration isolators to floor. Check that bevel washer Gig, 9) isin place fom gat con wee | i SOT HE Fig. 9 ~ Typical Vibration Isolator Mounting ‘TOMOUNT CARRIER COMPRESSOR UNITS AND CON- DENSER PACKAGES — Bolt the compressor's lower sup- por. straps loosely to underside of each support stand and place sips of proiective material (such as Fabrica) on strap. Position condenser on stands with hot gas inlet at top of 693 10 ‘condenser and liquid shutoff valve connection facing com- pressor end of base. Check that condenser overhangs sup. port stands for same distance on each end. Remove soldered shipping cap from hos os inles Ts pre- vent solder from dripping into inlet pipe while unsoldering, rotate condenser until pipe is below horizontal position. Re {um infet 10 upright vertical pos Tighten lower support straps enough to lift condenser off stands, Place upper straps loosely in position with a strip of protective material between condenser and strap (SF20 and '5F30 units use lower strap only. TO MOUNT COMPRESSOR BASE ON SUPPORT STANDS — Place compressor base on support stands with 2 extra strips of protective material between top of con- Genser and base. Bolt base into position with cap screws, and lock washers provided. ‘Step 4 — Assemble Refrigerant Piping and Com- Ponents — Refrigerant connection sizes are Table 1 COMPRESSOR DISCHARGE PIPING — Refer to Condensing Unit Piping Installation Instructions for information. REFRIGERANT DRIER — A replaceable-core filter drier is recommended for most systems, and is essential on all low-temperature systems. Mourt the field-supplied filter drier in the liquid line. Include a shutoft valve to permit isolation of drier for servicing (Fig. 10 Install « moisture indicator on downstream side of drier to indicate when drier cartridges need replaci FELT FILTERS — Install felt iter supplied with compres- sor in suction strainer (Fig. 3 through 8). Remove filter af- ter 50 hours of operation. If clean, discard it; if dirty, clean With Kerosene or neutral spirits and insert for another 50 hours of operation. Tug unit to show date that flier was Cleaned and reinstalled. See Table 2 for information on t- placement filter packages. LIQUID LINE. FROM COND. ‘Shutoff Valve Arrangement Step 5 — Install Multiple Compressors EQUALIZING LINES — Compressors operating in paral- Jel require interconnecting lines for oil and gas pressure equal- ization. Special handhole cover plates, equipped with tapped holes for equalizing lines, are available as options for Sizes SF40 and SF6D, as well as for sizes SH40 through 86 com- pressors (Fig. 11). An oil float system is an acceptable al- temative to equalizer lines.5 5H120 and 126 Compressorsinclude factory-supplied, tapped ‘over plate. On these compressors, use oly lower connec tion for oil equalization (Fig. 11). Connect gas equalizing line to flange connection shown. Mating flange for Ls-in line is Carrier Part No, DK24CA712 (Mueller Part No. A-S151);, ‘gasket Part No. is DX29GAO0SLA (Mueller Part No. A-5152). gas couatizer Soanccrion 1 00 FLANGE (Shi20- 26 ont) ou equauzer GpuneCTION ries gas, cquauizert SRN Fig. 11 — Special Hand-Hole Cover and Equalizer Connections (Typical) Table 1 — Physical Data SF20_and 30 Compressors have no special tapped cover plate. Use opening for oil sight glass to attach the 114- Aine for gas and oil equalization (Fig. 12). Aczessory Pac age No. 061A900072 provides two" Vein. Tine adapters to thread into the sight glass opening. If additional equaliza tion is desired, run a %-in. line t0 the oil-fiter plug con- nection (Fig. 1 and 2) DRIVE AND SEAL END Screw FITTING INTO OPENING FOR OL LEVEL, IGHT GLASS FOR T-1/8" EQUALIZER LINE. on vever Connections (5F20 and 30) Sea a Say wm [ow [wo [oo wm [ wee [ on [ae sara Seon wee a 0 | mo | om | oo wo | 0 | wo | oe ramaomme —Te aya] s Pee sae Slelels ara En aE : a | ds 3 eae CE 35 = wl lala | ape pte Tota aa Sees “ ase Seay ea ee eae seam ia ee “Cutout 150.995 (ata) nominal Sioa Sona EVEL my ne SE 20 cement Se a "pngeason _ eRe cma Tt cee eens fe covwsnsen va sron [on [ow | oe [oom | amt [oar [on [oar [oar [ae ee ec meee wlelalnlelsl#lalelezlele Scones te | cae) eter et ee) eee ee erage ee paper pa ee peed ae peep eae eee seems G2 | 12 | |r 8 | Be | ee | oe | ee | |e | eer onara re = Woes 190 psig L et 250 psig usenet saneseiare ~~ eaee igen Meetmepaenae= “egemrmemimetsame eraser: eesasntes namaste ae Ly wn eas am ee Ree coset asentmnameenstors, Fitter mec re nah ato reyerang tpg 2 GS sshay sich nas manusl rae and Ome dela ot 45 seconds. ESTES EES ES oe. 4 orTable 2 — Suction (Felt) Filter Packages ‘COMPRESSOR FILTER PACKAGE PART Nt SHO SERIES 5re0 Broo nse sH40.48, Bio Ase sHs0.66 SHe0-A362 5H0.86 SHO ASD SH120,126 BHi20-A38 Step 6 — Make Electrical Connections GENERAL NOTES 1, Factory wiring complies with National Electrical Code (NEC), Any field modifications or additions must com- ply with all applicable codes. 2, *For control circuit information, refer to Accessory Con- trol Panel Installation Instruction 3. If control circuit power is supplied from a separate source, rather than from a transformer, bring 115-v power through a field-supplied, 15-amp disconnect, in compliance with NEC Section 440-14 (disconnect must be in sight from ‘and readily accessible from unit, 4. Open control-power disconnect only when servicing unit. ‘Crankease heaters must remain energized when unit is not operating. 5. *Factory wiring is for single pumpout control. Do not use [pumpout control on equipment used with DX coolers. Wir- Ing label shows field connections used with DX cooler. 6. *Contactor C2 is used with 208-v motors, 25 through 60 hp, and 460-v motors, 50 through 150 hp. 7. “When field imerlocks are used, remove jumpers be- ‘ween terminals 3 and 4, and between terminals 7 and 8 on TB2. "Refers to compressor units and condensing units only ATTACH POWER WIRES TO COMPRESSOR MOTOR — ‘Attach power wires in accordance with motor manufactur- F's instructions and in compliance with NEC and appli- ceable local codes. CHECK MOTOR ROTATION — Before connecting motor to compressor, check direction of motor rotation. Rotation ‘must be in same direction as that indicated by arrow on com- pressor pump cover (or on plate attached near pump-end ‘bearing housing). If direction is not the same, reverse motor rotation by reversing any 2 power leads to motor. If rotation of oi pump is reversed, reverse direction of ppump rotation arrow as well, AC that time make the follow- sng adjustments: AILSF Compressors Remove 6 cap screws from oil pump cover (Fig. 1-4). Do not damage gasket. Rotate cover 180 degrees and replace. Arrow at top of oil cover will indicate oT ‘SHO through 86 Compressors— Drain oil below level of ppump-end cover (Fig. 5-7). Remove pump-end cover 10 ex- pose oil pump cover in center of main bearing housing, Ro- late oil pump cover 180 degrees and replace it. Replace pump- ‘end cover and reverse external arrow to match new direction, ‘of rotation, Proper direction can later be checked without removing pump-end cover. 511120 and_126 Compressors(Beginning S/N 10861---) — Supplied with automatically reversing oil pump, eliminating, reed for adjustment. For SH120 and 126 models built before SIN 1086). follow same adjustment procedure outlined for SE compressors. ex Ifthe special gasket between oil pump cover and oil pump is damaged, replace with correct gasket only. Check oil pressure immediately after starting compressor. INSTALL CRANKCASE HEATER — Wire heater to relay or set of normally closed auxiliary contacts on compressor starter to de-energize it when compressor is operating. Remove rubber plug from crankcase heater casing (Fig, 1-8), and insert heater clement entirely into casing. cement should fit snugly, not loosely. Wire to comply with applicable electrical codes, ‘When crankcase heater is installed, system can be oper- ated on single pumpout cycle, unless used with a DX cooler. Table 3 lists crankease heater packages. Table 4 shows corresponding relays. Use of 2 heaters on a SH80 through 126 compressor requires only one relay. Control circuit voltage determines relay coil voltage. This voltage must be specified when ordering relays. See Accessory Compressor Crankease Heater Installation Instructions for additional information Table 3 — 5F.H Compressor Crankcase Heater Package TLESTRIGAT compnesson | CHARACTENSTICS | pacKAGE No. Vor | Watts ‘5F20,30,40,60 20 {20 tis} —200] -SH-«0-87 suaosssoss | io | 00 | shas-a01 115} 200] sra.aar Rc A Table 4 — Crankcase Heater Relay (60 Hz) CONTROL CIRCUTT VOLTAGE PART NO. 5 ENSIAST07 208/730 HNSIAI106Step 7 — Check Compressor/Motor Alignment BELT DRIVE — See Accessory Belt Drive Package manual for installation and alignment instructions. DIRECT DRIVE — Install and align compressor, coupling ‘and motor as described in manual for Flexible Couplings for Direct-Drive Units HOT CHECK AND DOWELING —To help maintain align- ment, and to ensure exact repositioning of the motor alter servicing, the motor and compressor must be doweled to the base. Install doweling only after motor/compressor align- ment has. been hot checked (checked after the com pressor has warmed up to operating temperature after int tial alignment. fier hot check and while components are still at oper- ating temperature, drill and ream 2 holes through diagonally. ‘opposite motor and compressor feet and the base, Use a %o-in. drill aad a no. 6 taper reamer, Secure the motor and. ‘compressor to the base with the no. 6 x 2/-in taper dowel pins provided in the motor fastening set Coat the dowels with white lead or other lubricant to pre- vent rusting, and tap the dowel lightly into position so that “ie of taper is Teft above the motor foot. Cheek thar all dowels are tight and that they do not bottom, Step 8 — Assemble Water Piping — See Water- Cooled Condensers Installation Instructions and Water- Cooled Heads Installation Instructions for information, Step 9 — Prepare Lubrication System INSTALL OPTIONAL EQUIPMENT — Consult local Carrier representative for information on these accessories, OiLEiler — Oi iter for 540 through 86 compressors s avilable a separate acessory package, Refer to Accessory Oil Fier Package Tnsallation insictions for instalation procedures fan ocestory il coolers also stalled (Sc belo), i ci iter into system ss shown on diagrams in Accessor) i Cooler Ins ation Toston. Oil Cooler — Refer to Accessory Oil Cooler Installation In- structions included with this accessory package. Adjust wa- ter flow rate through oil cooler to maintain 100 to 120 F oil temperature returning to compressor. See Scheduled Main- tenance, page 17. Oil Separator — If oil separator is used in system piping, pe oil return line to compressor suction line. To minimize possibility of Hooding compressor with oil, ox! return line diameter should not exceed Y4 inch. In addition, line should have manual shutoff valve to throttle oil flow as required and to isolate separator for service. CHECK OIL LEVEL — Check that oil level is visible at center of compressor sight glass, Compressors that use op- tional equipment such as filter, cooler, and oil separator de~ scribed above will require a greater oil charge than listed in ‘Table 4. Recheck oil level after operating compressor. RECOMMENDED OILS — When acditional ol or a com- plete oil charge is required, use only the Carlyle engineer ing department approved, dehydrated, wax-free refrigeration arade oils noved below IGI Petroleum Specialties, Inc. IGI Petroleum Specialties, Inc. - (Akzo Chemicals, Inc. additive esos eegecees Cryal 150 Cryol 150 with additive Syn-O-Ad (8478) Witco ‘Suniso 3GS Witco iti ambient application, 300 viscosity Suniso 46S B Texaco, Ine... WF32-150, Shrieve Chemical Co. (synthetic) Zerol 150 Mineral oil and synthetic oil have different characteris- tics. One is not necessarily better than the other. Some char- acteristics of the mineral oils have been found to be more favorable for use in some air conditioning and medium tem- perature applications. Approved compressor oils are available from authorized factory parts outlets. The oils recommended are fully com- patible with each other and can be mixed in any proportion, PREPARE FOR INITIAL START-UP Evacuate, Dehydrate and Leak Test the entire re ffigerant system as described in Cartier Standard Service Tech- nigues Manual, Chapter 1, Sections 1-6 and 1-7. LEAK TESTING Preferred Method— Charge the system to 10 psig with re- ffigerant, Add dry nitrogen or dry aie (D0 NOT USE OXYGEN) until system pressure is 150 psig. Cheek for leaks with a halide or electronic leak detector Alternate Method— Charge the system with dry nitrogen or ry air (DO NOT USE OXYGEN) to 40 psig and use soap- bubble test to find large leaks. ‘Do notuse compressor to build up pressure. Do not over- charge the system, Refrigerant Charging — Use the sight glass method to charge the system, See Section 1-8 of Carrier Standard Service Techniques Mamtal, Chapter 1, for details ‘Charge the systom toa clear sight pass while holding satu rated condensing pressure constant at 125 F for at-ooled systems or 103" F for water-cooled systems. Add ditional refrigerant to Gl condenser subcooler coils if required SFH CONDENSING UNITS — After «clear sight glass is obtained, add charge uni liquid refrigerant reaches the con denser liquid level test cock, SF.H COMPRESSOR UNITS — See condenser data for ad ditional charge requirements. START-UP Preliminary Steps L. Energize crankcase heater for at least 24 hours before starting unit, 2, If control transformer is not used, operate electrical con= trol circuit with main power switch OFF to ensure that field connections have been properly made. 3. Install felt sock filter for the first 50 hours of compressor ‘operation. Remove and inspect the filter, clean it if re- 4uited and replace it for another 50 hours, Remove sock ‘when system is clean. (Not applicable for S20 and SF30 units.) 4. Check that motor rotates in direction that the arrow on the compressor oil pump cover indicates. Refer to Instal- lation, Check Motor Rotation section on page 12. Check that oil fills ¥ to % ofthe compressor sight glass. 6. Open water supply valve to condenser: Open pressure line valve of water-regulating valve (if used), If compressor unit is equipped with air-cooled concenser, turn on con- denser fan7. Backseat (open) compressor suction and discharge service valves. Open liquid line valve at receiver. 8, Start evaporator fan or chilled water pump. Start Compressor — Close main power switch sup- plying current to the compressor motor. ‘Immediately recheck oil level and check oil pressure. Pres- sure should exceed suction pressure by 45-55 psi. If correct pressure isnot reached in 10-12 seconds, siop compressor ‘immediately and check oil pump. EX shuts down the compressor, do not reset the control more than once before determining cause of shutdown, Tfany safety de Check Control Operation ~ Refer to Cartier Stan- dard Service Techniques Manual, Chapter 2, for complete instructions on checking electrical Components. HIGH. AND LOW-PRESSURE SWITCHES — All 5F and SH units except SF20 and 30 have factory-instlled, auto- ‘matic reset, high- and low-pressure switches. (These switches are available as accessories for 5F20 and 30 units.) Figure 1S illustrates adjustment procedures for both switches. Check High-Pressure Switch — Throttle the con- denser water on water-cooled unit or block the airflow on air-cooled unit, allowing head pressure to rise gradually. Compressor should shut off within 15 psi of cutout value listed in Table 4. Now reverse procedure; compressor should start within 10 psi of eutin value given. Check Low-Pressure Switch — Slowly close the suction service valve; suction pressure will decrease. Com pressor should shut off within 4 psi of cutout value listed in Table 5, Reverse procedure; compressor should start within 6 psi of cutin value given. Table 5 — Typical Pressure Switch Settings PRESSURESTAT REFRIC- | connenses High om ERANT | CONDENSER | (psig) (sig) Cutout | Cabin | Cutout [cura 2 | Waertooray is | | te Te Rircoied | 228 | as | 16 | 7 | WateeCooted | 260] 200] 35} 96 Kircooied | 825 | 245 | 55 | 98 G02 | Water Cooled | 280 -|~20- | a5 | 05 Aircooled | 323 | 245 | 45 | 108 OIL PRESSURE SAFETY SWITCH — To check, move ‘contact arm at left side of switch forward (Fig. 14). Com- pressor should stop in approximately 45 seconds. If compressor continues to run, check the wiring to safety switch. If wiring is correct, switch is faulty and should be replaced. ‘After completing test, wait 3 minutes; then press restart button on front of safety switch and restart compressor. Check oil level in compressor sight glass after 15-20 min- utes of operation. If the oil level is low, add oil by the ‘methods described in Carrier Standard Service Techniques Manual, Chapter 1, Section 1-11 lo94 If an accessory oil cooler is provided, adjust the water flow as required to maintain a 100 F to 120 F crankcase return oil temperature. ROBERTSHAW [A-RANGE ADJUSTMENT SCREW ew, 'B- DIFFERENTIAL ADS SCREW oP RANCO, [A- RANGE ADJUSTMENT SCREW Top o~ DIFFERENTIAL ADJ SCREW PENN “RANGE ADJUSTMENT SCREW. Ss vor Qo~v+ oirreneniat any senew tow. mien PRESSURE PRESSURE switcH ‘SWITCH ‘SH MOUNTING ARRANGEMENT SHOWN, Serew A raises orlawers both cuout and utin points by alike amount. Range and Diterential scales are on the front of the switch High Pressure: Set cutout point it, wih serow A; then sot cutin point with srew B. Low Pressure: Set cutsin point fist, with screw A; then sot cutout paint wih Serew LOCATION AND ADJUSTMENTS Fig. 13 — High- and Low-Pressure S\ hes For additional information, see Oil Safety Switch Acces- sory Package Installation Instructions, Adjust Capacity Control (if required) 5F20 AND 30 COMPRESSORS — Refer to Capacity Control Valve Installation Instructions for additional information. SF40 AND 60, AND 5H40 THROUGH 126 COMPRES- SORS — Determine the refrigerant usage: >> Hf the system is to use Re12 oF R-134a, replace the 1-Ib range adjustment spring (Fig. 15) with the 7-1b spring sup- plied with compressor. A change in 1982 reversed which Fange-adjusting spring a customer received. The R-22/ R-S02 spring is now standard with the compressor. See in- struction tag for spring replacement procedure.RESISTANCE ‘CONTACT ARAL (aerER TO Unit LaeL ‘Minin o1acRaa) BUTTON sauresaine ae nomsane Fig. 14 — Oil Pressure Safety Switch An external adjusting stem (Fig. 15) sets the control point (suction pressure at which first step of cylinder unloading ‘occurs). The control point is adjustable af follows: R-22 and R-502 0 t0 85 psig Ro12 and R-134a 0 t0 50 psig One full clockwise tum of adjusting stem will raise the control point approximately 6 psig with R-I2 and R-1342, oor 10 psig with R-22 and R-S02, Control oil pressure is an indication of cylinder loading condition (Table 6). Refer to Fig. 3-8 for location of control oil-pressure connection. See Accessory Unloader Package In- sallation Instructions for additional information See Fig. 16 for Capacity Contrel System, and Fig. 17 for unloading sequence. > Table 6 — Control Oil Pressures for Cylinder Loading and Unloading APPROXIMATE compncsson| srer-|__ CONTROL Olt PREC. (pag) Teading Taioading a z 735 730 T 309 202 co 2 398 ed seamso | soo Tao sH40.46, 2 |260 Tt |iso L soso, | 3/230 120 sei201%6 | [200 mcreasing|'0 oecReAsING { Sonenar® XN SBNECTiON ieeneuuaric contaoe panae GRO RoR £5N6E weg Busta VENTED Soa Sonera iE Beran — yp Hii Lif \ TH ewes BESEN BES SF SPRING DETAILS sFea200 =< EB20C2001 (ip spn) (rs Sere) SD tse win sews Ria. Bio, 2, Re. 404A, Fadia, eo, S07: RAGGA. aA “when compressor is recsived, the capacity contol adjusting stom wll be backsoated.(Gomproscor wil be ful loaded under a onaiens) Compressor Is supplied wit 110 spring, > Fig. 15 — Capacity Control Valve 15 “Capacity Conta eduction step. ‘To Adjust Control Point 1. Impose an artificial load on the compressor until suction pressure exceeds control point Slowly close suction valve (© lower compressor suctio pressure to control point pressar. 3. When at control point pressure, turn external adjusting stem clockwise until first step of unloading takes place, as indicated by changes in comtrol oil pressure, current draw and sound of compressor Control point is now set. Reopen suction service valve. Compressor will be fully loaded when suction pressure is 3 psig 4 psig with R-22 and R-S02) above control point, ‘and will be fully unloaded when suction pressure is 4 psig (7 psig, with R-22 and R-502) belrw control point. 5F20 AND 30 COMPRESSORS — Two capacity control ppackages are available as accessories. One is. suitable for R-12 or R-134a applications; the other for R-22 and R-502 applications, ‘The adjusting stem (Fig. 15) is shipped in a backseated (fully counterctockwise) position. Compressor will be fully loaded under all conditions. Adjust the capacity control set point by the same 3-step procedure described above for SF40 and 60, and SH40 through 126 compressors. 697He pueuaric CONTROL, FROM COMPRESSOR oft ui gonraos. on ff] on euwe Pressure || Presume SucTION VALVE Lo LIFTER spain Nb Fork" | piston Noma er — Jes sts ELewen Greinner SUEEIES" (Gren ae (SH ONLY) piston Bhan | UaLonoen ONTROL OIL, CAPILLARY fewer BREED Pour @ sresssez @ mae ~ ig PRESSURE! Fig. 16 — 5F,H Capacity Control System (Except 5H120, 126) 5HI20, 126 Fig. 17 — Cylinder Unloading Sequence 16LEFT SIDE 1 — Connection to Ol Cooler (Sioeve Location) 2 — Ol Pump Pressure (Both Locations) Use githor for High Side Oi Pressure Switch Connaction™ 3 — Opening o Crankease (LowSide Ol Pressure Swrich Connection) when using extemal lect capacty contol, ol pressure connee- Yor must be made tte 9. clock poston onthe bearing em The ‘ania plate insted for exomal Unioaing wi block ol pressure {othe 8 dock poston on he pump cove. RIGHT SIDE 1 = frente ce cermin ; oa Steen ere fr eR 15 SRS Fig. 18 — Typical 5H40 through 5H86 Compressor Pump-End Connections SCHEDULED MAINTENANCE SEH compressor and condensing units provide long lite and dependable service when properly operated and regu- larly maintained, Establish a maintenance schedule based on factors such as operating hours, load conditions and water quality. Maintenance schedules listed in this section are of- fered as guides. Modify them as needed to satisfy individual machine requirements, See Fig. T8 for important compres sor service locations, connections, oil cooler sleeve location, Check Lubrication System — Always check com- pressor oil level before starting unit. Ifo is required, record ale and amount added, Refer to Fig. 1-8 for location of oil filter plug, Table 1 and Step 9 show specified types and quan- tities of oil Use of accessory oil separator requires additional oil, Oil level and separator float valve movement during initial com: pressor operation should agree with instructions furnished ‘with the oil separator. OIL FILTER MAINTENANCE — A bleed-type, high: pressure, disposable filter is available as an accessory for SH40. through SH86 compressors (Fig. 19). Replace oil filter after the first 30 hours of operation, or whenever the oil is changed ‘or becoines ditty. Check yearly for clogged filter, icated by a greater than normal difference between oil pressure ahead of filter and after filter (before orifice elbow). When this difference ex- ceeds 5 psig, change filter as follows: 1. Close cil-tine shutoff valves on each side of filter Fig. 19). oil lines at filter connections, filter bracket; remove and replace filter body. Refer to Accessory Oil Filter Instructor information. ‘The full-flow oil filter, on SH120 and SH126 compressors only, contains a replaceable cartridge. Replace the filter car- tsidge after the first 100 hours of compressor operation. Af- {er the initial filter change, check yearly for filler clogging, Ifthe pressure difference across the filter exceeds 5 psig, pump down the compressor and then remove the cartridge. Figure 20 (B) illustrates complete filter assembly (not shown in Fig. 20 {A}. for additionalsau Fig. 19 ~ Oil Filter Accessory Package (sHa0 through S80) CHECK OIL AND SHAFT SEAL TEMPERATURE ~ The normal operating temperature of the oil in the crankease ranges from 100 F to 135 F when fully loaded. Do not per- ‘mit maximum oil temperature to exceed 150 F. Conditions tunder which such excessive temperatures could occur i clude situations where the compressor operates in_a fully ‘unloaded condition for an extended period, because the com pressor would not be able to remove all of the heat gener- ‘ted by compression and friction. In such situations, use an oil cooler to maintain safe operating temperatures. Refer to SF.H Application Data for more information. a opr (mr When crankcase oil temperature falls within the 120 to 135 F range, the shaft seal housing temperature should be approximately 140 to 150 F, Shaft seal housing tempera- tures above 170 F may cause shaft seal to age rapidly, and harden and crack. Therefore: If shaft seal housing temperature exceeds 170 F. STOP. ‘THE COMPRESSOR. DO NOT restart until the cause of overheating has been identified, and the condition corrected, + OIL COOLER USAGE — The accessory oil cooler main- tains safe operating oil temperatures when: 1. Applying long stroke compressors (SH46, 66, 86 and 126). For added reliability, an oil cooler is recom- mended on all long stroke models regardless of operat ing range or type of refrigerant. Additional heat of fric- tion from extended piston travel on Jong stroke models Increases oil temperatures 2. The suction gas becomes highly superheated (Table 7) 3. a. The compression ratio exceeds 5:1 on R-22 systems, b. Application data indicates the need for an oil cooler for R-12, R-134a, and R-S02 systems. The compres- gion tio can Be determined from the following formula: Absolute Discharge Pressure Compression Ratio = = Absolute Suction Pressure eee SS aan Tae) A {(Auto.-Reversing) Ra hr Ae OB Mie a a Wa, Ae Fig. 20 — Oil Pump and Filter Assembly (5H120, 126) 8 (Manual Reversing) 1094 18> Table 7 — Actual Suction Gas ‘Temperature Limits (F), R-12, R-22, R-134a, R-502 ‘SAT. SUGT | 69 eae 50] -40] -20] -20] -10[0 t0 50 “ACTUAL, — [fos fas [as [os] os Suction ° \* - GAS. aps ps ps pes ps] TEMP (F) See Nota 1 NOTES: 1 For continuous operation with F2: Tsar guerra RNEAT(F) 2, 00 not operate unloaders at saturated suction temperatures ‘2° or below OFF hou prior approval ftom Camericarhie Engineering 4. The compressor operates fully unloaded for prolonged periods. Under these conditions, suction gas levels may not suffice to remove the heat of compression and fric~ tion, This condition ean oceur in any application, but is most likely in low-temperature systems or variable- volume applications that use hot-pas bypass to maintain specified conditions under low evaporator load. Refer 10 SF.H Application Data for additional information. Adjust water flow rate through oil cooler to maintain 100 to 120 F oil temperature retuming to compressor. Crank: ‘case temperature must remain below 140 F; shaft seal tem- perature at the seal housing should not exceed 170 F. Tables 8 and 9 list maximum working pressures for oi and water and estimated water flow rates for various oil cooler/compressor combinations. For additional informa- Caner SF.H Specified Parts Ii interchangeabilily, 3. Before servicing compressor, pump down the refriger= ant as follows: Start compressor, close suction service valve, and re- duce crankcase pressure to 2 psig. (Bypass low pres- Surestat with jumper.) . Stop compressor; close discharge service valve to iso- Tate it from system. cc. Recover or reclaim any residual refrigerant. Drain oil if necessary. 4, After disassembly, clean all parts with solvent. Use min. eral spirits, white gasoline or naphtha, 5. Before assembly, coat all parts with compressor oil and clean and inspect all gasket surfaces. Replace all gas- kets with new, factory-made gaskets, and Tightly coat With oil. See Table 10 for torque values. 6. After reassembly, evacuate compressor and open suc- tion ad discharge valves. Restart compressor and ad Just refrigerant charge. for compressor part Lubrication System OL. PUMPS SF compressors. See Fig. 23 and 25, SHI40-86 compressors, See Fig. 24 and 25, 5HI20,126 compressors, with automatically reversing oil pump. See Fig. 20(A), ‘SH120,126 compressors, with manually reversing oil pump. See Fig. 20(8) and 26. 5H120 and 126 Compressor Oil Pump History Reference tion, see Accessory Oil Cooler Installation Instructions. DATE nw rye | FC. | wanuracTuReD ‘aneare Table 8 — Oil Cooler Maximum Tao, Lay | ORO BE | FR OTD wo ATES Working Pressure Reversing | 2° | crating March 1986 | staring Yaess01067 Ranvally | aye, | Satna 1050 na | —Srating A075 ant On 250 psig Feversna | 2%) | ena Waren 986 | "Ending t0ees WATER 750 psig Table 9 — Oil Cooler Estimated ‘Water Flow Rates ‘COMPRESSOR ‘GPa F Tet ‘40-65 12. ‘5H0,86 wes 5H1120,126 ey “Flow rate based on 80 F entering wate. Check Water-Cooled Heads — To prevent oil break- down and sludge formation, the discharge gas temperature rust remain below 275 F. Water-cooled eylinder heads are available as an accessory for this purpose. See Accessory ‘Water-Cooled Head Package Insulation Instutions for ad tional information SERVICE Service and repair of Carrier reciprocating compressors and other refrigeration components should be performed only by fully wained and qualified personnel. Service Notes 1. Compressor components are shown in normal order of removal from compressor (Fig. 21 and 22), 2. For replacement items, use Carrier specified parts. See 19 NOTE: 8 tet, he automatic reversing ol pup cart be naan place ‘tthe alu erent ump or ee vera Tae comple fearing eed ‘Soaonay wan the of pup (acs. 1 manual motchangesble a 9 com Bete ase MANUALLY REVERSING OIL PUMP il Pump Inspection — See Fig. 20B, 23 and 24 for SF and SH manually reversing oil pumps. Also refer to SH120, 126 auto.-reversing oil pump section, Drain oil below level of pump-end bearing head. Re- move bearing head. Complete end-bell assembly must be Femoved to access bearing head assembly with oil pump on SHA0 through 86 models. Check oil pump rotor for end play. Maximum allowable movement of rotor is 0.0025. If there is excessive end play. reposition oil pump bushing in bearing head as described below. ‘Tur rotor. If there is more than a slight drag, remove pump cover and disassemble oil pump checking’ all parts for wear and damage. Inspect oil pump bushing for scor- ing, Replace bushing if scored. If bearing head is scored, replace complete bearing head and oil pump assembly. Oil Pump Bushing Installation — See Fig. 25 and 26. Po- ion the bushing oil groove at top (running from 12:00 to 6:00) when the bearing head is installed, Press new bushing. into the pump-end bearing head from the inner side of the hhead with the chamfered end entering first 1094Oi] Pump Bushing Position 1, a, $F20-60 and SH40-86. See Fig. 25. Place 0.001-in. Circular field fabricated shim against bushing and in= stall pump. Shim between bushing and oil pump ro- tor. Complete assembly of oil purnp with gasket and bb. SH120,126, See Fig. 26. Place 0.015-in, (Yoein.) shim between port insert and oil pump cover. Complete assembly of oil pump and pump cover without using ump cover gasket. ‘Tap bushing with suitable cylindrical positioning tool to seat it against shim. See typical arrangement shown in Fig. 25. ‘Oil pump assembly must be flush with coverplate surface, but must nor protrude beyond bearing head surface. \ ee LINER HERD 3. a. SF20-60 and SH40-86. See Fig. 25. Disassemble oil pump and remove shim. Reassemble oil pamp. Check Tor binding. b. $HI20,126. Remove oil pump cover and shim. Reassemble pump cover with gasket. Check for binding. 4, Install bearing head on compressor. Line up tang on oil pump rotor shaft with slot in end of crankshaft. Check ‘il pump for proper direction of rotation, 5. Refill compressor oil to proper level. Observe oil pres- ‘sure when starting compressor. Correct ol pressure should be 45-55 psig above suction pressure. oe HEAD GASKET VALVE PLATE PUMP ENO cover [BND coNTROL gron ve seca oven Ae HAND -HOLE COVER . Fone even sie EEE, ; - ow. FULTER SCREEN HaNo-woue Coven "Saker wano-HOLE cover YB PUMP END BEARING WASHER Le 2 pu rater pulip eno Beane ¢@ Getessorm q mead GasKer a ~ NX ° 21 — SH Compressor External ComponentsAUTO. REVERSING OIL. PUMP and on threads of each mounting hole in bearing head Oil Pump Inspection — See Fig. 20(A) for SH120 and 126 Position one of the supplied gaskets over holes in adapter a and assemble the adaper loosely to bearing head en ee eee 3. Be sure there are no nicks of burs 00 oil pum or bores inadapecr and bearing head, Sie cl pump truth adaper 2, Remose bearing head from compressor and ito bearing head bore, allowing enough clearance 3, Remove oil pump and adapter from bearing head to tighten adapter mounting ‘res wi an” Alea @ aeccige eee ie wrench, The clearance bereen al pump housing and Sees Tores te adapter and bearing head's necessriy very Pump Inelation ose, DO NOTUSE FORCE and do not tempt change 1. Using a new gasket, mount bearing head on compres- the clearance. sor. Tighten the 1-13 cap serews t0 80 Tb-ft 2. Put a drop of thread sealing compound (Loctite 601 or equivaient) on each of the Ye-18 adapter mounting screws PISTON RINGS (COMPRESSION TAPERED) Cm rst ane core STON PIN CYLINDER SLEEVE 4 G-——-PisTON PIN Lock RING Gobet cae Voy UNLOADER SPRINGS-=A \ \ ne AY \» 2 CONNECTING ROD CONNECTING ROD BOLTS. a UNLOADER FORK a © _ Ww : @=—«Lasti¢ Lock NuT UNLOADER 7 POWER EL eweinr GP connectine UNLOnDER SLEEVE soo eune UNLOADER GRACKEeT ad” ners enseee connectins assenpueo ONE Sew Nb — Connecting woo seat. ev ’ Seana asnen tenons) CRANKSHAFT ‘seat ‘END THRUST WASHER (STEEL) Fig. 22 — 5H Compressor Internal Components aTable 10 — Torque Values = aa Se eas SEE Bian | THEEADS | ange UsAGE Siam] THREADS | hanes ‘uske ch ee <_ i a 2ST SEE » | om | BE [RS Gers cao [Cease BE care veo [SER we uo Marifoks Cover we | tec Es Bong “T6IS—|Unioader Power Elament Assembly — se2o | ad Gone! Yayo— Pane Sranecase End Bearng Head 2s eee toa [RTS cence Seon fe Ser one omen | mee = ae ene “+ ve | sone | 2 [Ree tow [ode ramen - vont [OEE a ery — 10-12 | ausitary Control Vato Cover — 1822 | pecharge Vatve Guide — inner Seat i ie [amore oe ge ee 24NF | 1520 | Capacity Control Valve — on Pipe 30-35 _| Pipe Plug — Crankshaft Lina 2523_| Capillary Tube Assembly — | rapper aT sae ey Sacer oars | foe coeemnctecney 2B [See Anca Sr eee 2] ee 88 |Sieoraiae aw sea |[petilenar ower toon M1 TENS | as.29 | pump ng Searing Head Assembly tm | same | Sa |Qituerteas “Crease aa #2 eee a [eter core ba [eee 23 jsceheios- sate Es eeerenes tore Hr mecca eis cena ad va ie asa formar ar : sia 2 eeeoeoas «| ane | BS [Raz seeta. es, we | pee | S538 [Petre aat 2 Soe a aces eee sou [pais Ease Sanne ee "60-96 | Suction and Orecharge Mansokd — ee Se aoe BH lager Sao oe es eee 60:78 | oi Byposs Pog — Pump End ‘Grarkcase Oe | Se eee toe |i Rare borg Sump End Beata end me [tine | HOT [Setar nani Gove and sea geeeee ed theron oy [ste eben, cor eee 30:60 _| CanS¥ equator Vane Asser iaing Hee xe wer |aeaes cer omen one} Br pearein ser |e ec ao | ee | Be eR Rae oo ag |e ececr, moe] a2 Nae be 80:96 | Hotow Lock Sctow — Pump End Cover 00 ‘ang Cont Mm Beara Housna , eg [mera Chace aaa 3 [Sosa ae - FETS] Pgs Pag — Runany Con a he Eee Wave Bay mF 50 Ppa ag Ce Pipe 75:20_| Pipe Plug — Pump End Bearing Head a pe = = Ss =o iilegsel ieee ns somes oe | BS [Sas Seow 35 aes tin— 38 [SS ces ww [over | 2 Seer oe See SS aa 12 | special Cap Screw — Auxiiary Wee = Nasco Cot" Eine eas gett bee er oS aera ne or 2‘Table 11 — Wear Limits; 5F,H Compressors rasa SETA cournszon an = a oleae ny | Mowmum Atowstie | rourantee jn) | Matinum Atowabe ax [in oe Mar Min eee Sa "ivan oomeer— 99 2 vee | age we | ome [own | me =eaa se | 288 5 ao e Je ane — ies | 128 % | ems | es | ae Be ie | 255 Ea eel | as 7 Taegoeme ame | rem | ies a : coamewape omg | tas | 8 = |= 7 arte 18S | IBS SB | caw | aoe Ed cae Sa EST cena gaa vee [age | i ‘eases te ee = ot | ogg | Sheree == = wae | oes | Samer mT tay Rone ves | ops oe | om | 2a | oe so ar es | gs.) vas | eas |e Sc sae tg | Bs = = | ats e 2S oem a |e : 2) 8 : Fans Sa ake Tae mB aS : een oo | 3m we leeles |e $e ameer—siet soma agie, | “2 | 238 a Tigers - an | ee 98 Te eo 00) = = a | us a brio naar =) | & 21 |e en a Dae =| = & ‘me | 2 i Babe fee fs Bo comoneonansoint | i | oe Sr | RE | Bn “Gomores 2008 oes sors | c00s 08 ef oe ae | as oR a Sea 85 8 os Se 8 gut | = Se Sa Sa mart ee | 88 = ice Ses ee es = 88 : Bi aha ay ae 7 sa | 0 = cae —y~ = ~ we Sapa Se) sehen = | oe ele 3 EE Oe) |e 05 = | = sos on ie = | ee te = Lim we “Same waar alowance apaies io undersized shat a bear ‘Romaradacured serves Compressors can e bull wih ungrtzed man, bearings ad comacing 04 bearings Carers ths ingen bar 8 oC ents nape R= 010m, B= 020m, C= G30, undoes bows Eelaceert marge er conpresors wih versed sts st Stn wih opr eed “CRANKSHAFT END CLEARANCE fn ee tee ine He a Sub > 1G amen rereans (yup 0 TOR) when cyngor aes Rave ben honed (nace) on SFM ean a 398,BRONZE BEARING WASHER PUMP END GEARING HEAD o1L PUMP ROTOR / OIL PUMP IDLER OWL PUMP COVER GasKET ROTATION ARROW 7 ou. Le - o1L PUMP CovER Sonne oN a “ (MAGNETIC) OL PRESSURE CONNECTION % ce GRANKCASE PRESSURE CONNECTION a6 nw lL PRESSURE CONNECTION ~~ GREMOVE FOR ACCESS TO CONTROL OIL STRAINER} 1094 ig. 23 — SF Oil Pump Assembly Fire tection Ween aie Oedouiet gt puue ot puuP Boron ter 5 pats j a Bren euinses uns, 6 ARO 8 CYUNDER UNS) Fig. 24 — 5H40 through 86 Oil Pump Assemblyeae osm PRLS Recarern Setting Oil Pump Bushing (Typical 5F20 through 60, and SH40 through 86 — 5F40 Bearing Head Shown) REE OUTER GEAR pow nae si wwe oran—— ewan pee ‘SPRING | ip L Yj i “rive ose ot ee ‘F ee Y Fig, 26 — Setting 0 Pump Bushing (Typical 5H120, 126) 4. Hold pump with one hand and rotate it while equally lightenng adapter mounting screws. Proper alignment between pump and bearing head bore is extremely im- portant. THERE MUST BE NO BINDING. 5. When adapter is secure, remove pump assembly and place second gasket on pump housing. Insert two 4-20 mount- ing screws and lock Washers, one on either side of the ‘word TOP on pump end cover, and position gasket on screws, For remaining operations, be sure the word TOP is at the top. 6. Turn pump shaft to align drive tang with slot in end of crankshaft. Holding pump assemby with thumbs on the 2 screws, slide assembly into beiring head until tang ‘engages slot. A slight rotation should align screws with tapped holes in adapter. Start screws to hold alignment and then install balance of screws and lock washers, Torque all screws (14-20) to 8-10 feb. 7. Start compressor and check oil pressure. This oil pump ‘operates in either direction of rotation. The correct i pressure for compressors using this pump is 45 t0 35 psig above suction pressure. OIL PRESSURE REGULATING VALVE (nonadjustable, Fig. 27) is located on the side of compressor adjacent t@ seal housing. Regulator maintains correct oil pressure (Table 6) and ensures satisfactory unloader operation ‘ pf — ou. neducarine asker ou. geoucarine Sasa sae Fig. 27 — Oil Pressure Regulating Valve (Nonadjustabie) Unserew regulator from crankcase: use ein. Allen wrench conall compressors except SH120, which requires in, Allen ‘wrench. Regulator must not be clogged and plunger must not be stuck. Check drillings to reguator for fouling “The nonadjustable oil pressure regulator is interchange- able on al curtent SF compressors except SH120 and 126 models. SHI20 and 126 units have larger, nonadjustable regulators. Early SF.H compressors were equipped with an ‘adjustable-typeoil-pessure regulator. When an adjustable~ type regulating valve needs replacing, use a nonadjustable regulator. OIL RETURN CHECK VALVE (S20 through 60, and SH40 through 86) allows oil to reum fom suction manifold tw crankcase. This normally open valve closes when cerankease pressure becomes higher than suction pressure ig. 28). ‘Two dise-type check valves on SF20 and 30 compressors are located beneath partition between suction manifold and crankease, one on each side of compressor. Remove check vvalves through bottom cover of pamp end of compressor. Leaf-type check valve on 5F40 and 60 and SH40 through 86 compressors is accessible through, and located at top center of, hand-hole cover opening. Remove check valves and check to see that flutter valve or leaf does not stick, and that it seas tightlycecx vauve — ERESQURE RELIEF vaLvE Lene TYPE NOTE: The pressure-elef valve is not pat of the valve plate as- Fig. 28 — Oil Return Check Valves ‘Semi, The valve mounts nthe crankcase in the lof side cyinder {eck (looking at pump end). The vale pale openng outineg, sips ‘ver the prossure-elet valve when assombiod Fig. 30 — Pressure Relief Valve (5F60) ween” poe PRESSURE RELIEF VALVE E NN ( Fig. 29 — Centrifugal Oil Separator impeller =? 7 iiastrOte Cover CENTRIFUGAL OIL. SEPARATOR on SHI20 and 126, mounted on crankshaft (Fig. 29), returns oil to compressor Fig. 31 — Pressure Relief Valve and crankcase. To remove or replace oil separator, sec Crank- Suction Strainer (5H40, 46, 80 and 86) shaft Inspection and Service. OIL FILTER SCREEN (Fig. 21) in compressor crankcase Js accessible through hand-hole cover or bottom plate. Re- 511120 AND 126 COMPRESSORS ate equipped with ex- move and inspect itfor holes, then clean it with solvent and _—_temnal relief valve mounted on bypass line between suction replace Shutoff valve and discharge manifold. To remove valve, #e- move bolts from flanges on either side of valve Pressure-Relief Valves — When pressure differen- : " tial between high- and low-pressure sides exceeds 350 Suction Strainer — To withdraw strainer on SE20 and 435 psi (P00; 400 40 psi). pressure-reliet valve bleeds 40 and SH40 and 46 compressors, remove suetion and dis- refiigerant from high 0 low side. charge manifold cover on seal end of compressor. Check relief valves for evidence of leaking. Change if On SF30 compressor, remove suction service valve. On defective or if valve has ‘ever opened due to excessive E60 and SH60 and 66 compressors, remove suction man- pressure ifold and withdraw 2 strainers. On SH80 and 86 compres- Sors, remove Suction manifold cover SF60 COMPRESSORS — Internal relief valve serews into crankcase and projects up through left cylinder-bank valve Seperate eo ae oem panes ot ete cae ad weplace valve RCTPS SerewUHVEE © ple suction manifold and suction line, Witeaw 2 suction strainers ‘SH40, 46, 80 AND 86 COMPRESSORS — Pressure-telief valve is located on suction and discharge manifold cover (Fig. 31) ‘SH60 AND 66 COMPRESSORS ~ Relief valve is located in wall between suetion and discharge manifolds. Remove discharge manifold for access to relief valve. Use a stan- ‘dard 1/2 in, socket to remove and install the valve. 26Clean strainer with solvent or replace if broken or cor- roded, When replacing suction strainer, do not damage it ‘On SH120 and 126 compressors, positioned manifold cover late must compress strainer bail. If bail is too shor. grasp des and elongate it enough to be compressed by man- ifold cover, Position bail between the 2 bosses on inside of ‘manifold cover to prevent strainer from turning. Ex Ifa felt sock filter is installed, remove and inspect it after 50 hours of operation. Clean filter if required and replace i for another 50 hours. Clean the suction strainer whenever the felt sock is removed. Remove sock when system is clean. (Not applicable for 5F20 and 30 compressors.) Cylinder Head and Valve Assemblies CYLINDER HEAD INSPECTION — Remove cylinder heads and check heads for warping, cracks and damage to gasket surfaces. VALVE INSPECTION (Fig. 32) Disassembly — Remove cylinder head. Loosen cap screws holding discharge valve seat to discharge valve guide, and Cap screws holding valve guide to valve plate. Remove cap Screws holding valve plate to cylinder block. Remove valve plate from cylinder block and discharge valve guide from wale plate. Inspection — Inspect suetion and discharge valve discs and valve seat fr cracks or excessive wear (Table 11). Check {plinder sleeve valve stops for uneven wear. Replace valves if cracked or wor. If valve seats are wor, replace com plete valve plate assembly. If eylinder-sleeve valve stops fe wor, replace sleeve Reassembly.— Pistons mus be below tops of ylinde loves. ‘To position corretly, tum erankshaf or force pistons down 1. Place suction valve springs in valve plate recesses. Large spring coil should be in full contact with bottom of recess. 2. Place suction valve dise on valve springs; press dise into valve plate recess. Slide valve retainer clips into place (Fig. 33). Clips must not cover valve lifter springs or pins. Valve retainer clips SF20-2061 (SF compressors) ‘and SH40-2061 (SH compressors) are field supplied. 3. Bolt valve plate to cylinder block. Remove valve clips, 4, Place discharge valve springs in discharge valve guide spring recesses. 5. Place cischarge valve dise over springs, and fit inner spring in place over valve disc. Hand-tighien bolts hold- ing inner seat to valve guide (valve guide assembly). 6. Place valve guide assembly on valve plate, Tighten all bolts and bend tabs on lock washer and lock plates. Re~ place cylinder head, a ar no pee a SHRRTESMET gu TANER Seat / sucron| aur ae Fig. 32 ~ Suction and Dlscharge Valve Assembly VALVE PLATE SUCTION VALVE Ise ‘SUCTION VALVE RETAINER CLIPS Fig. 33 — Valve Clips in Place Cylinder and Unioader Sleeves DISASSEMBLY (Fig. 34) — Remove cylinder head, sue- tion and discharge valve assembly, and pump-end bearing hhcad. Whenever cylinder sleeve or valve plate is replaced, use a new suetion valve dise. 1. Turn crankshaft until piston is in midposition, 2, Insert a sleeve puller into cylinder and push it down onto top of piston. 3 Tighton ant on top of sleeve puller to expand puller in sleeve, 4, Tum crankshaft, forcing sleeve upward until it can be removed. 5. Remove unloader snap rings (SH compressors only). Dis- assemble uploader sleeve, pins and springs. INSPECTION — Examine bore of sleeve for wear. Check suction valve seats for scratches and wear. Check unloader sleeves, pins and springs for wear and freedom of move- ‘ment (Table 11). REASSEMBLY — When new rings ere being installed in a used cylinder sleeve, break the hard, glazed surface of cyl- inder sleeve to reduce wearing-in period of new rings. Clean sleeves thoroughly afer breaking glareTo reassemble: 1. Rotate crankshaft to position piston at top center. 2. Lubricate piston rings and beveled surface at lower edge of cylinder sleeve, 3. Stagger sing gaps around piston. 4. With turning motion, work sleeve over piston and rings. Compress and align each ring with beveled edge of sleeve eat sleeve in suction manifold partition and cylinder 5: Seat sleeve in sct fold partition and cylinds 6. Rotate sleeve so that any 2 valve lifterpin holes lie equal distances from longitudinal axis of compressor (Fig. 34). Ii this position, lifter pins line up with suction valve springs. Never operate compressor with heads or valve plate removed. Connecting Rods and Pistons REMOVAL — Remove cylinder head, valve plate and hhand-hole cover or bottom plate to gain access to rods and pistons, Remove connecting rod caps (Fig, 22). Label caps and rods so they may be reinstalled in same places on crank: shaft. Remove cylinder sleeve, connecting rod and piston assembly as a unit by pushing assembly up through cylin- der deck. Do not allow piston to come up through top of sleeve during removal process. Remove retaining rings and piston pins to disassemble connecting rods fom pistons. Remove rings. Keep each individual connecting rod and piston assem- bly together to aid reassembly. Check all parts and crank- pin journals for wear (Table 1). INSPECTION AND REPLACEMENT — Attach connect- ing rods to pistons with piston pins and lock in place With retaining rings. Piston pins are Selectively fied for a push fit: reassemble in the piston from which they were re= moved. Place piston pin retaining ings, with gap on side, ‘on piston (Fig. 35). They should be tight enough to inhibit roultion under finger pressure ‘Check Rings 1. Check ring gap by inserting each ring separately in cyl- inder approximately % in. from top. Ring gap should be between 007 and -017 inches. 2. Install compression rings on piston with marked side up (Gee Fig. 35) towatd piston head. Install el sings either side up Stagger ring gaps around piston. 4. Measure side clearance between ring and piston (approx- imately O01 inch). Check rings for fee action. Check Rod Bearing Inserts (Fig. 22) — If bearing inserts ane damaged and crankshaft is not worn, iti only neces- sary f0 replace inserts. Do not file bearing caps. Place the inserts in Connecting rod and connecting rod caps so knobs on inserts fi into notches on rod cap. Lubricate insert bear~ ing and crankpin freely before installing caps. Install cylinder sleeve, connecting rod and piston assem- bly atthe same time. Tirn connecting rod, and install cap so chamfered sides are against radius of crankpin. (Small knobs om rod and caps must be on same side of journal.) ane Webi carter tne Sisecrs BN BSSons! ‘Compression race (SOU) ou. Ins (enreoy _EEITHER SIDE UP << “See Table 11 for piston diameters. Fig. 35 — Piston and Rings Capacity Control Operation ~All SF.H series com- pressors, except SF20 and 30 units, include hydraulic ca- pacity contol unloader systems as standard equipment. (Field- installed accessory unloader packages are available for the 520 and 30.) The unloader system activates and deacti- Yates the compressor's cylinder banks, by permitting suc- tion valves to seat or preventing them from doing so, in response to changing load demands. Capacity control un- loaders can reduce a unit's actual operating capacity by steps down to as litle as 25¢ of its total capacity. Figure 17 shows the sequence and number of eylinders that unload with each step. Capacity control unloader systems consist of 4 major components: L. A capacity control valve, which increases or de. ‘reases control oil pressure tothe hydraulic relay piston proportionally when the suction pressure from the érank- ease rises oF fallssuction. Ls aal ose AnlUSTING SCREW rain ‘Spans NS ‘STRAINER, RB Stce uermg serinas eeLoWs moeRS ty — onto on. = See a EXTERNAL CAPACITY eee Wo Sono at a oy unaoanee STEMS eevee T eer chanacase connection PESTA SUNN rene PRESSURE ou Bans conrnot on. Eo Toothen comcase FaQtSEe comes ae elnewis 6833 ony tees Fig. 36 — Capacity Control (5F20, 5F30) FROM coMPRESSOR Score i Rr ea er hat at NF cearc course on fox. cour ae PONGT Paus CONTROL PRESSURE ff PRESSURE su : INECTION 4 1) 9 eee stance" BR vive Org a ig & ss Hoe — € - =A. il ngron fp . i i — ean conrmo. [gaan Sheawen| ‘CAPACITY CONTRON F a ~~ GSH ONLY He orm puerta ouuen TT] sansa Mee a i saan? wo == mee PRESsune 29 Fig. 37 — Capacity Control Operation (5F40, 60; 5H40, 60, 66, 80 and 86)2. Ahydraulic retay, which (except on the 5F20 and 30) feeds oil to the unloader power elements in sequence. Control oil pressure from the capacity control valve ac- tivates this relay 3. Ahydraulic power element, which supplies the power necessary to Operate the valve-lifting mechanism. It is ‘modulated by the capacity control valve. 4, Avalve-titting mechanism, which consists ofa sleeve, 2 lifting fork and a push-pin assembly around each con- tolled cylinder. The valve-lfting mechanism holds the suction valve open, or permits the valve to remain in normal operating position depending on its actuation by the power element “These components operate in the following manner: 5F20 AND 30 CAPACITY CONTROL OPERATION (ig. 36) (With Optional Unloaders and Control) Loaded Operation — A rise in suction pressure causes nee- dle valve to close. Oil pressure in power element increases ‘8 oll enters capacity control circu from oll pump. Power clement piston is forced upward, pivoting lifting fork down- ward. Lifter pins drop, allowing suction valve to seat and load controlled cylinder. Unloaded Operation — A drop in suction pressure causes needle valve to open. Oil bleeds through valve to crank- PRESSURE: ae Shia SPER case, decreasing oil pressure in power element. As oil pres- sure to power element drops, the piston moves downward, Lifting fork pivots upward, moving lifting pins upward; suc- tion valve rises from its seat and controlled cylinder unloads, 5F40 AND 60, AND 5H40 THROUGH 126 CAPACITY CONTROL OPERATION (Fig. 37 and 38) Loaded Operation — A rise in suction pressure increases pressure against capacity control valve bellows, compress- Ing range adjustment spring. Compression of range adjust- ‘ment spring allows valve spring t0 move push pins and valve needle point toward valve seat. Flow of control oil to erank- ‘case through oil drain is throttled. Control oil pressure rises as oil enters capacity control circuit through orifice from compressor oil pump circuit Increased control oil pressure advances hydraulic relay pis- {on (against spring) Which feeds oil at full pressure to one (or mote controlled cylinder power elements depending on position of control valve. Pump oil pressure in unloader power elements forces piston upward, pivoting the lifting fork(s) downward. Lifter pins drop, aliowing suction valve(s) to seat and Toad eylinder(s), H bse Liter serine SAND PINS. egos Siete weve boNOT PLUS sau Biheor sete ee —L gyawen ie a] Silber alrcase Ser Fig. 38 — Capacity Control (5H120, 5126) 30UNLOADER CYLINDER. spain. BRACKET GASKET RETAINER, GASES’ fBotFom) piston asueR SP OBE beckantty UMLoADER eyLINDER iMiopce freer | | : fo UNLOADER FoRK y me tenis Pin CYLINDER —UNLOALER PISTON UNLOADER —UNLOADER CYLINDER racrer —ercinoer’ ROD” SARE S SINGS” Sve tare Fig. 39 — Unloader Power Element (Typical) Unloaded Operation — A drop in suetion pressure de- creases pressure against control valve bellows. Range ad- justment spring presses against the push pins, compressing the valve Spring, This moves the needle Valve off the seat ‘Control oil bleeds from hydraulic relay and control valve to crankcase, relieving oil pressure on hydraulic pistons. ‘The piston retracts, preventing transmission of pressurized oil to controlled cylinder power elements), and the oil drains to crankcase, As oil pump pressure on power element drops, the piston moves downward. Lifting fork(s) pivot(s) upward, moving lifting pins upward: suction valves rise from their ‘eats and ‘controlled cylinder(s) untoad(s). It should be noted that a ‘minimum of 33 to 35 pounds of oil pressure is required for proper unloader operation, Capacity Control Inspection and Service UNLOADER POWER ELEMENT REMOVAL — Re- ‘move cylinder head, valve plate, connecting rod, piston and cylinder sleeve. Remove Allen head cap screws (2) holding tunloader power element in position Remove power element (Fig. 39) and disassemble. Check all parts for wear or damage, POWER ELEMENT REPLACEMENT ~ Check unloader fork height (Fig. 40) of new or assembled power element. Attach power element to internal suction manifold. Re- place cylinder sleeve piston, connecting rod, valve plate, cylinder head and hand-hole cover. 8 GAH wyn-a Z Fig. 40 — Unloader Fork Height (5F and 5H) 31 EXTERNAL ADJUSTING STEM REMOVAL does not re- ‘quite compressor to be pumped down. Loosen hex nut at valve stem base and remove adjusting stem assembly. REMOVAL OF CAPACITY CONTROL YALVE AND HY__ DRAULIC RELAY — Assembly is located in hand-hole c (Fig. 41) of SF40 and SF6O units: in pump-end cover (Fg. 42) of SH4O through 86 units; and in pump-end bearing head (Fig. 43) of SHI20 and 126 units. Remove capacity control valve and hydraulic relay NOTE: It is not practical to remove hydraulic relay from SH40 through SH86 compressors. Inspect parts for wear, damage or evidence of leaking or sticking A new han-hole cover, pump-end cover or pump-end bear- ing head with control valve assembly and hydraulic relay ‘may be installed. However, capacity contol valve (and hy- NOTE: Bearing pulls can be ordered trough Caro or Totaune Pars Center Main Bearing — Size SH80 through 126 com- pressors have a center main bearing and housing. DISASSEMBLY AND INSPECTION — On SH86, 120 and 126 compressors, disconnect oil line to center main bearing. (SH8O center main bearings are fed through the shaft.) Remove plug on compressor crankeases (Fig. 44). Then remove hollow lock serew beneath the plug (Fig. 45). Next, loosen hollow-cup setserew until center main bearing as sembly can be slid from its support. Remove crankshaft and bearing assembly. Disassemble bearing (Fig. 45) and inspect for proper tol- frances (Table 11). 33 097EA. House sean ‘ovane Pot ‘SHouLBeR Wes. SE DWRECTION oF FULL Tor pare ‘CRANCASE SEARING HOUSING 47 — Seal-End Main Bearing (5F40, 60) [CRANKOASE BEARING HOUSING RECTION Te seer om Tb Fig. 48 — 5H Seal-End Main Bearing REASSEMBLY — Install the new bearing inserts. As- semble bearing housing on crankshaft, bur do not sighten the hhollow-cup setscrews, Install crankshaft, center main bear- ing and housing, and pump-end main bearing assembly. Tighten bolts holding the pump-end main bearing assembly. Rotate crankshaft while tightening setscrew on center main bearing ‘housing. Setscrew should tighten fully without any binding of crankshaft If binding occurs, shim the opposite side of bearing housing, using .00-in. shim stock. Seal-End Main Bearing DISASSEMBLY AND INSPECTION — With crankshaft re moved, use a bearing puller with a shouldering device to remove and install seal-end main bearings (Fig. 47 and 48), Bearing pullers can be ordered through Carrier or Totaline Pas. Inspect bearing and bearing housing for tolerances shown in Table IT REASSEMBLY — Remove any burrs and clean bearing hous- ing before replacing bearing. Lubricate outside of bearing swith heavy grease, ~ 1, Position bearing so chamfered edge enters bearing hous- ing first, oil holes in bearing and housing are aligned (see note below), and bearing relief groove is at top. NOTE: On size 5 120 and 126 compressors oil hole in bearing and housing will not be aligned. 398 34 2. Pull bearing into housing (Fig. 49). Edge of bearing should be Vie-in, below surface of bronze bearing washer 3. Look through oil pressure regulator opening to check oil passage for blockage. 4, Blow out oil groove in bearing housing and oil lines (if any) to it ‘SEAL END Man SEARING Fetsne ioe owe gear Rae ane on. eRoove Sith BER “Stool washer on S#120 and 126 models Fig. 49 — Seal-End Main Bearing Positioning Crankshaft Seal Inspection and Replacement — The crankshaft seal in all current SEH compressors is a rotating, bellows-type seal. This seal is the service replace- ‘ment for all earlier seal assemblies. Figure 50 shows Types. Land IT of this design (5F20 through 60 and SH40 through 5H26 compressors) IMPORTANT. Do not attempt to repair orreplace seal components. Replace complete seal assembly with cur- rent rotating-bellows-type assembly. Do not disas- semble bellows assembly of service replacement seal. BEFORE INSTALLING SEAL |. Pump-end bearing head must be in place for proper po- sitioning of seal on crankshaft 2. Be sure shaft extension and edges of keyway are free of sharp edges and nicks. Also, shaft must be clean and free of rust. Polish shaft with crocus cloth 3. Check seal assembly for proper bellows placement and cleanliness. 4. Apply compressor oil to seal assembly and crankshaft, ‘completely saturating bellows and carboa ring INSTALLATION — Refer to Fig. 51 for procedure. ‘Accessories — For accessory installation literature, r- ferto Table 13,coves muare wire ‘coveR PLATE GasKer a Seat wose cagpoN ae beL.ows Estate Sete COVER PLATE WITH INTEORAL SEAL SEAT Feur wire, 'B — SF40, 60 AND SH40 THROUGH 86° (Type !) — Typical “F540 and 60 — 1.5" diameter; SH40 trough 86 — 20" ameter, A — 5F20, 30 (Type I) coven PLAT sk © — 5H120, 126 (Type I) Fig. 50 — Service Replacement Seals Table 13 — Accessory Literature LITERATURE, —— ‘AVAILABLE “Condensing Unit Piping, ecescory Gonttot Bare. Accessory Compressor Crankcase Heater rt Belt Brive Package Flexible Couplings for Direct Drive Units ‘Waler-Cooled Condensers Instaaen Recessory Water-Cooled Heads Package Accessory Qi itr Package Iesructions ‘Accessory Ol Sefty Switch Package Cépacity Control Valve Ketossory Unioader Packa ‘Accessory Muffler Package "See your Carr Distrbutor for current form numbers.‘Step 1 — Lubricate the shaft and the neoprene bel- lows where it comes in contact with the shaft. Slide the seal assembly, as itis shipped from the factory, gnio the shaft unt the neoprens just stats to grasp the shaf Step 3 — Using the seal cover plate, push the seal assembly into its proper location on the shaft. DO NOT use cover plate bolts to push seal into position. ‘The spring guide should be tight against the shaft shoulder as shown by the pencil. Remove the cover plate, being careful not to damage the carbon washer. GRASP THE SEAL NOSE ASSEMBLY AND TURN ITUNTIL THE LUGS ONTHE DRIVING BAND DROP BACK INTO THE SLOTS INTHE RETAINER SHELL. Step 2 — Holding the sieeve and spring assembly, pull forward on the seal nose assembly at the same time, turing it so that the lugs on the driving band are Out of the slots in the remainer shell and rest On the surtace ofthe retainer shell as shown by the pencil. (This does not apply to the 5H120 Type I Seal Lugs are permanently fixed.) ug 1N ceNTER orator ‘Step 4 — Lubricate the carbon seal washer and seal seal, Reinstall the seal cover plate, drawing the bolts down evenly to prevent damage to the carbon seal nose. This view shows the lugs of the driving band properly positioned in the center of the slots in the Seal retainer shell. Nis is the correct position during ‘operation. This prevents the seal from being used as a thrust washer under all operating conditions. NOTE: The seal may leak slightly immediately after installaton, but a short period of operation will corect the conston. Fig, 51 — Installation of Sleeve-Type Rotary Seal 097TROUBLESHOOTING TROUBLE/SYMPTOM PROBABLE CAUSE REMEDY ‘Compressor will not start Power off Check main switch, fuse and wiring ‘Thermostat set 100 high. Reset thermostat. Oil safety switch ope Thermal overload switch open. Reset switch. Reset switc Dirty contac. Clean all control contacts. Loose electi:cal connections or Tighten connections: check wiring and fauity wiring rewire. Sompressor motor burned out. Liquid line solenoid vaive closed. Check and replace if defective. ‘Check for burned-out holding coi. Replace if defective. Evaporator fan off Check fuses, overload. Restart Evaporative condenser or cooling tower fan or pump not operating. ‘Check fuses, overloads and controls, Restart, Compressor cycles Low-pressure switch erratic in ‘Check for clogged tubing to switch, intermittently ‘operation. Check switch setting, Low refrigerant charge. ‘Add refrigerant Capacity control setting incorrect, Reset. ‘Thermostat differential too narrow. Reset. ‘Suction valve closed or throttled. ‘Open up valve. ‘Compressor cycles on high pressurestat Faulty pressurestat. | Tubing to pressurestat restricted. ‘Check and clean tubing. Repair or replace. Refrigerant overcharge. Remove excess refrigerant. Insufficient condenser water flow or clogged condenser. ‘Adjust water regulating valve to condenser. Clean condenser. Discharge service valve not fully open. ‘Open valve. ‘cin system. Condenser water pump off Purge air. ‘Check pump and start High fischarge pressure Condenser inlet water temperature too high. Increase water quantity by adjusting water regulating valve. Use colder water. Insufficient water flow through condenser. Readjust water regulating valve, n- crease size of water supply main fo ‘condenser, Plugged or scaled condenser tubes. | Clean tubes. ~ Discharge service valve partaly closed. | Open valve. Retigerant overcharge. Remove excess refrigerant Air in system. urge air ‘Tow discharge pressure | Excessive water flow through condenser. | Adjust water regulating valve ‘Suction service valve partially closed. | Open vaive: Leaky compressor suction valves. [ Worn piston rings. Examine valve discs and vaive seats. Replace if worn, Replace. Flooding Defective or improperly set expansion valve. Reset to 5 F - 10 F superheat. Valve ‘operation must be stable (no hunting). Low suction pressure ‘System noises: Low refrigerant charge. ‘Add refrigerant, Excessive superheat. Loose or misaligned coupling. Reset expansion valves. Check alignment and tightness. Insufficient clearance between piston and valve plate. Replace defective parts. ‘Motor or compressor bearing worn, Replace bearings. Loose oF misaligned belts. Check alignment and tension. (Belt slack should be at top.) Loose holddown bolts. Tighten bolts. 31TROUBLESHOOTING (cont) TROUBLE/SYMPTOM PROBABLE CAUSE REMEDY ‘System noise (cont) Unit foundation improperly isolated. Isolate foundation. Improper support or isolation of piping, Use correct piping techniques and suppor piping with suitable hangers. ‘lugging from refrigerant feedback. circulation, Hydraulic knock from excessive oll in| Remove excess oil. Check expansion ‘Check expansion valve setting. Check thermal bulb looseness and correct. location. See Carrier System Design Manual, Part 3 for standard piping techniques. valve for floodback. Defective valve lifter mechanism (noise level varies with unloading). Replace sticking fiter pins. Check un- loader fork for alignment. Check power ‘element for sticking piston. Check for off leakage al tube connection to power element. Check amount of valve pin it above valve seat (0.33 in. for SF; 0.125 in. for 5H). Piping vibration. ‘Support pipes are required. Check pipe connections. No muffier in discharge line or improperty located. Install muffler. Move muffler closer to compressor. Hissing (insufficient flow through expan- sion valves, or clogged liquid line strainer). ‘Add refrigerant. Clean strainer. ‘Compressor will Capacity control valve not operating. | Repair. an Unioader element sticking. Repair. Hydraulic relay sticking Replace control cover assemby. Plugged pressure line to power element. | Clean line. External adjusting stem damaged. Replace. Compressor Low oil pressure (below 35 psig). Check oil charge, switch settings. not load ‘Capacity control valve stuck open Repair or replace. Unloader element sticking. Repair. Plugged or broken pressure line to power element. Clean or repair. External adjusting stem damaged. Replace. Control oil strainer blocked. (Clean or replace. ‘Control vaive bellows leaking, Remove thread protector and leak test. Replace valve body if bellows leaks. Pipe plug in pneumatic connection. Foaming in crankcase from refrig flooding: Remove pipe plug. __ Check expansion valve and pising Hydraulic relay sticking. Replace control cover assembly Rapid unloader cycling Excessive fluctuation in suction pressure from oversized expansion valve, Partially plugged control oi strainer. Resize expansion valve. Clean or replace strainer. Low oil pressure. ‘See Trouble/Symptom — low oll pressure. Low oil pressure Low oil charge. ‘Add oil Faulty ol gage. ‘Check and replace. Defective oll pressure regulator. Repair or replace. Broken oil pump tang. [ Clogged oil suction strainer, | Clean strainer. Replace pump assembly. 38TROUBLESHOOTING (cont) ‘TROUBLEISYMPTOM. PROBABLE CAUSE Remedy Low oil pressure (cont) Cold compressor ‘Clogged oil line. ‘Wom oil pump. Remove obstruction. _ Replace pump assembly. Check refriger: Replat ‘charge ar expansion valves. Low crankcase oil level (Oil retum check valve stuck closed Repair or replace check valve. Cylinders and crankcase sweating Refrigerant floodback. Check refrigerant charge and expansion valves. High crankcase temperature (should be 150 F to 160 F Max. at seal housing) Liquid line strainer clogged. (Clean strainer Excessive superheat. Reset expansion valves. ‘Compression ratio too high. Recheck design. scharge temperature over 275 F. Leaking suction or discharge valves. ‘Check unit application. Replace valves. 39Conia 1990 Caer Corporation Spectteations or dears without notice an wuvout neurirg colgatons; Book PCA Calang No S30505 PradMUSA. FamSeH 20S Ppa). 08” 120). Fepacee SEH 11S1