(091)refrigerationsys-scientificfreezer.pdf

FRV40-225-091-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Refrigeration System, Scientific Freezer Model: 90YR16MSD3ND1K9R

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

50-SPNA-1-00031

PUBLISHED BY DIRECTION OF NOAA

FRV40-225-091-010

DESCRIPTION, OPERATION, INSTALLATION AND

MAINTENANCE INSTRUCTIONS

Model: 90YR16MSD3ND1K9R

Halter Marine, Inc.

13085 Seaway Rd.

P.O. Box 3029 Gulfport, MS 39505

PUBLISHED BY DIRECTION OF NOAA

27 SEP 2005

RECORD OF CHANGES

Change No.

Date Title and/or Brief Description Signature of Validating Officer

APPROVAL AND PROCUREMENT RECORD PAGE

APPROVAL DATA FOR: FRV40-225-091-010

TITLE OF MANUAL: Refrigeration System, Scientific Freezer

APPROVAL AUTHORITY: NOAA

Contract Ship Qty Of Building Number Applicability Manuals Yard

50-SPNA-1-00031 FRV40-225 2 EA Halter Marine Inc.

REMARKS:

CERTIFICATION: It is hereby certified that FRV40-225-091-010 to be provided under contract 50-SPNA- 1-00031 has been approved by the approval data shown above.

Date:________________

CHAND, LLC

Mathews, LA 70375

CAGE CODE: 0D5X4

VALIDATION PERFORMANCE

Title of Publication

Contractor Sub-Contractor(If Performing Validation)

Halter Marine Inc.

Contract No. (s) and Purchase Orders, If Applicable

Chapter Section Paragraph Date Check here if Validation Not validated Completed

Contents of this manual have been validated and certified to be applicable to the equipment furnished under the above procurement as specified for Validation.

Name & Authority of Validating Officer: Signature of Validating Officer:

FOREWORD

This manual is intended to clearly and accurately reflect the actual configuration of the installed equipment described for the FRV40-225 Scientific Freezer Refrigeration System. Users are urged to report instances noted wherein the manual does not achieve this objective.

This technical manual provides the instructions necessary to operate, to perform maintenance on and troubleshooting of the Scientific Freezer Refrigeration System. The text is broken down as follows:

Section 1- Introduction

Section 2- Installation and Start-up Instructions

Section 3- Control Circuit Sequence of Operation

Section 4- Unit Performance Summary

Section 5- Unit Configuration Summary

Section 6- Unit Appendix

Section 7- Component Appendix

Section 8- Unit and Major Component Parts List

Section 9- Troubleshooting Guide

Section 10- Ship Loose Items Appendix

TM

O 6 D / E A P P L I C A T I O N G U I D E

TABLE OF CONTENTS

General Information Features of Carlyle 06D/E Compressors 06D/E Model Number Significance 06D/E Compressor Specification Tables

06D/E Refrigeration Compressor Specifications 06D/E Compressor Specifications (60 Hz Units) 06D/E Compressor Specifications (50 Hz Units)

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

1.0 System Design Considerations

1.1 General Application Information

1.2 Compressor Rating Notes

1.3 Refrigerant Piping

1.4 Vibration Isolation

1.5 Refrigerant Migration and Floodback

1.6 Clean and Dry System

1.7 Prevent Excessive Discharge Temperatures

1.8 Compressor Interconnection

1.9 Motor-Compressor Selection

1.10 Outdoor Use

1.11 Code Approvals

2.0 Compressor Lubrication System

2.1 Compressor Lubrication

2.2 The Oil Pump

2.3 Recommended Oils

2.4 06D/E Oil Pressure History

3.0 Capacity Control

3.1 Suction Cut-Off Capacity Control

3.2 Design for Proper Oil Return

3.3 Capacity Control Application Ranges

3.4 Pump-Down Control

3.5 Unloader Differential Setting

3.6 Part Load Performance Factors

3.7 Location and Size of Capacity Control Head Assembly

3.8 Pressure Differential Required to Load Compressor

3.9 Electric Solenoid Capacity Control Operation

3.10 Suction Pressure Capacity Control Operation

3.11 Pressure Actuated Capacity Control Adjustment

3.12 Variable Frequency Drives

4.0 Compressor Features and Accessories

4.1 06D Compressor Motor Protection

4.2 06E Compressor Motor Protection

4.3 Rated Load Amperes (RLA) and

Maximum Continuous Current (MCC)

4.4 06D Compressor MCC Values

4.5 06E Compressor MCC Values

4.6 06D Compressor Contactor Selection

4.7 06D Compressors: Wire Sizing

4.8 06E Compressors: Contactor Selection and Wire Sizing

4.9 Compressor Nameplate Data

5.0 Compressor Features and Accessories

5.1 Safety Relief Valves

5.2 Suction Strainers

5.3 Oil Safety Switch

5.4 Crankcase Heaters

5.5 Mufflers

5.6 Baffle Plates

5.7 Discharge Line Check Valves

5.8 Suction Cut-Off Capacity Control

5.9 Cylinder Head Cooling Fans

5.10 Spring Mounting

5.11 Solid Mounting

5.12 Electrical Terminal Parts

5.13 Conduit Adapter Plates

5.14 SAE Adapter Fitting

5.15 Service Valves

Discharge Valve

Vented Connecting Rods

Automatic Reversible Oil Pump

Oil Drain Connection

Oil Filter Screen Assembly

Oversize Oil Sump

Contoured Pistons

Capacity Control System

Hi-Lift Discharge Valve

Canted Valve Plate

General Information

Features of Carlyle 06D/E Compressors

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.

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06D/E Compressor Specification Tables

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

7/8ODS14.86

14.97

3.75

45°

2.192.19 8.87

10.00

2.01

17.93

3.69

5.52

12.88 6.00

2.91

COMPRESSOR FOOT

MOTOR END AND

PUMP END (TYP.)

= CUSTOMER

SUPPLIED

1.25

.19

3/8-16 x 7/8 LG

CAPSCREW

LOCKWASHER

PLATEWASHER

SPRING CUP

WELD

(TYP.)

.623 DIA. (TYP.).627

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 2

CFM: 8

MODELS: 06DA808

06DM808

UNLOADING AVAIL: NO

STEPS: 0

7/8 ODS

5/8

ODS

16.09

6.87

8.87 10.00

6.94 14.67

15.02

6.27

21.52

18.30

MTG HOLE

4.44

6.00 14.88

COMPRESSOR FOOT

MOTOR END AND

PUMP END (TYP.)

= CUSTOMER

SUPPLIED

1.25

.19

3/8-16 x 7/8 LG

CAPSCREW

LOCKWASHER

PLATEWASHER

SPRING CUP

WELD

(TYP.)

.623 DIA. (TYP.).627

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 4

CFM: 13, 16

MODELS: 06DM313

06DM316

UNLOADING AVAIL.: YES

STEPS: 1

NOTE: ALL DIMENSIONS ARE IN INCHES

Multiple service valve orientations are possible

7/8 ODS

1 1/8

ODS

18.20

10.30

14.67

17.51

7.17

15.95

7.21

8.25

6.94 21.71

13.88 17.30

MTG HOLE

3.43

1.25

CAPSCREW

3/8–16 x 1.50 LG

COMPRESSOR END FOOT MOTOR END FOOT

CAPSCREW

3/8–16 x 7/8 LG

= CUSTOMER

SUPPLIED

PLATEWASHERLOCKWASHER

WELD

(TYP)

.623

.627 DIA.

(TYP.)

.19

1.31

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 4

CFM: 18

MODELS: 06DA818

UNLOADING AVAIL: YES

STEPS: 1

1 5/8 ODS

1 1/8

ODS

11.38

8.21 17.72

8.94

16.09

7.65

MTG HOLE

3.28

6.34

24.01 20.91

12.79

1.25

CAPSCREW

3/8–16 x 1.50 LG

COMPRESSOR END FOOT MOTOR END FOOT

CAPSCREW

3/8–16 x 7/8 LG

= CUSTOMER

SUPPLIED

PLATEWASHERLOCKWASHER

WELD

(TYP)

.623

.627 DIA.

(TYP.)

.19

1.31

SPRING MOUNTING ARRANGEMENT

CYLINDERS: 6

CFM: 28, 37

MODELS: 06DA328

06DA537

06DM337

06DR228

06DR337

UNLOADING AVAIL: YES

STEPS: 2

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

NOTE: 10 Hp, 208/230 v models use 3 overloads.

NOTE: ALL DIMENSIONS ARE IN INCHES

TERMINAL BOX DATA

1 1/8

ODS

1 3/8

ODS

16.35

11.38

8.36

15.51

7.70

4.84

20.88 23.38

MTG HOLE

3.26

12.79

6.34

7.07

1.25

CAPSCREW

3/8–16 x 1.50 LG

COMPRESSOR END FOOT MOTOR END FOOT

CAPSCREW

3/8–16 x 7/8 LG

= CUSTOMER

SUPPLIED

PLATEWASHERLOCKWASHER

WELD

(TYP)

.623

.627 DIA.

(TYP.)

.19

1.31

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 6

CFM: 24

MODELS: 06DA824

06DR724

UNLOADING AVAIL: YES

STEPS: 2

NOTE: ALL DIMENSIONS ARE IN INCHES

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

06D Low Temperature Compressors

7/8ODS14.86

14.97

3.75

45°

2.192.19 8.87

10.00

2.01

17.93

3.69

5.52

12.88 6.00

2.91

COMPRESSOR FOOT

MOTOR END AND

PUMP END (TYP.)

= CUSTOMER

SUPPLIED

1.25

.19

3/8-16 x 7/8 LG

CAPSCREW

LOCKWASHER

PLATEWASHER

SPRING CUP

WELD

(TYP.)

.623 DIA. (TYP.).627

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 2

CFM: 9

MODELS: 06DR109

UNLOADING AVAIL: NO

STEPS: 0

14.67

8.87 10.00

6.94

6.00 14.88

18.30 21.52

4.44 MTG HOLE

12.00 21.90

COMPRESSOR FOOT

MOTOR END AND

PUMP END (TYP.)

= CUSTOMER

SUPPLIED

1.25

.19

3/8-16 x 7/8 LG

CAPSCREW

LOCKWASHER

PLATEWASHER

SPRING CUP

WELD

(TYP.)

.623 DIA. (TYP.).627

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 4

CFM: 13, 16

MODELS: 06DR013

06DR316

UNLOADING AVAIL: YES

STEPS: 1

1 5/8 ODS

7/8

ODS

15.95

8.25 6.94

14.67

8.19

16.09

21.09

26.59

23.51

23.89

13.88 18.72

7.21

12.00

MTG HOLE

3.43

7.17

1.25

CAPSCREW

3/8–16 x 1.50 LG

COMPRESSOR END FOOT MOTOR END FOOT

CAPSCREW

3/8–16 x 7/8 LG

= CUSTOMER

SUPPLIED

PLATEWASHERLOCKWASHER

WELD

(TYP)

.623

.627 DIA.

(TYP.)

.19

1.31

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 4

CFM: 18, 20

MODELS: 06DR718

06DR820

UNLOADING AVAIL: YES

STEPS: 1

1 1/8

ODS

1 3/8 ODS

8.36

15.51

20.64

26.14

11.38 7.70

16.35 23.38

24.06 12.00

MTG

HOLE3.267.07

6.34

12.78 4.84

1.25

CAPSCREW

3/8–16 x 1.50 LG

COMPRESSOR END FOOT MOTOR END FOOT

CAPSCREW

3/8–16 x 7/8 LG

= CUSTOMER

SUPPLIED

PLATEWASHERLOCKWASHER

WELD

(TYP)

.623

.627 DIA.

(TYP.)

.19

1.31

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 6

CFM: 24

MODELS: 06DR724

UNLOADING AVAIL: YES

STEPS: 2

NOTE: ALL DIMENSIONS ARE IN INCHES

06D Low Temperature Compressors (cont’d.)

1 5/8

ODS

1 1/8

ODS

20.93

26.43

8.21 17.72

11.38

8.94

16.09

12.00

12.79

MTG

HOLE3.28

7.65

6.34

24.01

20.91

1.25

CAPSCREW

3/8–16 x 1.50 LG

COMPRESSOR END FOOT MOTOR END FOOT

CAPSCREW

3/8–16 x 7/8 LG

= CUSTOMER

SUPPLIED

PLATEWASHERLOCKWASHER

WELD

(TYP)

.623

.627 DIA.

(TYP.)

.19

1.31

SPRING MOUNTING ARRANGEMENT

CYLINDERS: 6

CFM: 28, 37

MODELS: 06DR228

06DR337

UNLOADING AVAIL: YES

STEPS: 2

NOTE: ALL DIMENSIONS ARE IN INCHES

Multiple service valve orientations are possible

NOTE: 10 Hp, 208/230v models use 3 overloads.

06D Low Temperature Compressors (cont’d.)

TERMINAL BOX DATA

06E Medium/High Temperature Compressors*

CYLINDERS: 4

CFM: 50

MODEL: 06EA250

UNLOADING AVAIL: YES

STEPS: 1

CYLINDERS: 6

CFM: 65, 75

MODELS: 06EA275

06EM175

UNLOADING AVAIL: YES

STEPS: 2

CYLINDERS: 6

CFM: 68

MODEL: 06EA265

UNLOADING AVAIL: YES

STEPS: 2

MOUNTING

WASHER

NYLOK CAPSCREW

3/8-16 x 1.75 LONG

1.38

PUMP END FOOT MOTOR END FOOT

SPRING

GUIDE

SNUBBER

SPRING

GUIDE

SPRING

CUP

SNUBBER

NYLOK CAPSCREW

3/8-16 x 2.00 LONG

1.31

.25

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA*All of the compressors pictured on this page use the same terminal box and mounting foot.

MOUNTING

WASHER

NYLOK CAPSCREW

3/8-16 x 1.75 LONG

1.38

PUMP END FOOT MOTOR END FOOT

SPRING

GUIDE

SNUBBER

SPRING

GUIDE

SPRING

CUP

SNUBBER

NYLOK CAPSCREW

3/8-16 x 2.00 LONG

1.31

.25

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 6

CFM: 99

MODELS: 06EA299

06EM199

UNLOADING AVAIL: YES

STEPS: 2

06E Medium/High Temperature Compressors*

*All of the compressors pictured on this page use the same terminal box and mounting foot.

06E Low Temperature Compressors*

CYLINDERS: 4

CFM: 50

MODELS: 06ER150

06EM150*

UNLOADING AVAIL: YES

STEPS: 1

*The 06EM150 does not have head fan assembly.

SPRING MOUNTING ARRANGEMENT

TERMINAL BOX DATA

CYLINDERS: 6

CFM: 65, 75, 99

MODELS: 06ER165

06ER175

06ER099

UNLOADING AVAIL: YES

STEPS: 2

*All of the compressors pictured on this page use the same terminal box and mounting foot.

1.1 General Application Information

The 06D and 06E compressors are versatile in their application. Compressors are available for operation in low temperature R-502, medium temperature R-12, and air conditioning R-22 applications. Recent design modifications allow the use of HFC refrigerants R-134a, R-404A, R-407C, and R-507. This guide pro-vides information and recommendations for the suc-cessful application of compressors in HVACR.

Maximum operating conditions of the compressor models are generally defined in the performance curves and will differ with each model. Operating conditions should be controlled so that the discharge gas does not exceed 275˚F (135˚C) at the discharge ser-vice valve and that oil temperature does not exceed 160˚F (71˚C). For HFC/POE applications the maximum recommended discharge temperature is 250˚ F (121˚ C).

1.2 Compressor Rating Notes

Performance for most standard conditions are plotted in tabular data or rating curves. For special requests, contact Carlyle Application Engineering. Carlyle also-provides computer software data that allows system designers access to Carlyle compressor performance with IBM compatible PC computers.

The compressor capacity and power ratings found in the 06D/E refrigeration compressor specification sheets are based on the following conditions:

Compressor ratings are based on nominal voltage, 60 hertz (1750 rpm) operation and 50 hertz (1450 rpm) operation, with 0˚F (0˚C) subcooling.

Note: Some Carlyle air conditioning ratings are at ARI (Air Conditioning & Refrigeration Institution) rating conditions and with 15˚F subcooling. Ratings may be interpolated but not extrapolated.

Liquid subcooling increases system capacity by approximately 1/2 of 1% for each degree Fahrenheit (.5˚C) of subcooling for R-12, R-22, and R-502. With HFC refrigerants R-134a, R-404A, and R-507, the sub-cooling correction is higher and in most cases a cor-rection of 6/10 of 1% for each degree Fahrenheit (.5˚C) can be used. When correcting for subcooling, power input to the compressor motor does not change.

Refrigerant temperatures (suction and condensing) are saturation temperatures corresponding to pres-sures indicated at the compressor service valves.

Actual gas temperatures are higher because of super-heat.

Capacities are based on the actual suction gas tem-peratures to the compressor of 65˚F (18˚C) for refriger-ants 12, 502, 134a, 404A, and 507. Superheating occurs in the evaporator and in the suction line with-in the refrigerated space, or in a liquid-suction heat exchanger so that all the superheat produces useful cooling. Superheating that occurs outside the refriger-ated space is a loss, but is a compressor load. If increases in return gas temperatures are obtained outside of the refrigerated space or if the compressor is operated at a lower return gas temperature than 65˚F (18˚C), a capacity correction is required. Capacity corrections for R-12, 502, 134a, 404A, and 507 for other than rated suction gas temperatures may be obtained from Table 1 (Page 18). Due to the number of the variables involved in correcting for superheat, this table is only an estimate and should be used as a guide for the system designer. For R-22, ratings at 65˚F (18˚C) return gas temperature, the same adjust-ments as noted above with R-502 should apply. For R-22 ratings based on a suction gas superheat of 20˚F (-11˚C), it is assumed that all the superheat is useful and the capacity can be used without adjustment.

1.0 – System Design Considerations

All R-502 capacity ratings, except for the 06DR109 compressor, are based on the use of cylinder head cooling fans at saturated suction temperatures of -20˚F (-29˚C) or below, and -25˚F (-32˚C) or below for R-404A and R-507. All low temperature (-30˚F to 0˚F, -34˚C to -18˚C) R-22 capacity ratings are based on the use of a cylinder head cooling fan. When the com-pressor is operated at higher return gas temperatures (for example 65˚F, 18˚C), the use of an external desu-perheating valve is also required to maintain dis-charge temperatures below 275˚F (135˚C) and 250˚F (121˚C) for HFC/POE applications.

Total heat of rejection (THR) in tons from the com-pressor equals adjusted compressor capacity (in tons) + .285 x kW input (of the compressor motor), or the THR in kilowatts equals the compressor’s capacity in kilowatts + kW input (of the compressor motor). This heat rejection calculation gives the maximum value possible for condenser selection. Because of heat loss-es at the compressor (especially if a cooling fan is moving air across it) and at the discharge line, the actual heat of rejection will be lower.

Table 1—Estimated Capacity Multipliers

Unless otherwise specified on the compressor specifi-cation and performance sheets, the 06D and 06E compressors are suitable for continuous operation within the following limits:

Maximum operating conditions of the compressor models are generally defined in the performance curves and differ with each model. Operating conditions should be controlled so that the discharge gas does not exceed 275˚F (135˚C) and oil temperature (in the sump) does not exceed 160˚F (71˚C). For HFC/POE applications the maximum recommended discharge temperature is 250˚F (121˚C). The motors are thermally protected so that unsafe winding tempera-tures are prevented. Oil pressure switches are avail-able for system protection (see Accessories Section 5.3).

Requirements for Proper Compressor Operation Semi-hermetic compressor application requires good system design for proper compressor performance to ensure against compressor damage.

1.3 Refrigerant Piping

Good system piping designs will minimize the possi-bility of lubrication failure, flooded starts, and refrig-erant floodback problems. Refrigerant piping systems must therefore be designed to protect the compressor by:

1. Preventing excessive lubricating oil from being trapped in the system. Refrigerant piping must be sized for proper velocity, especially in suction lines, to return oil under all conditions. If capacity control is utilized, piping must be sized for full and part load conditions. With the increased use of mechanical subcooling in refrigeration conditions, the system designer must also consider the lower refrigerant mass flow that results in systems that are designed to operate with large amounts of subcooling (30˚F to 70˚F, 16˚C to 39˚C). With the new HFC refrigerants, this is especially important in low temperature applications using large amounts of subcooling (for example liquid sub-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-tem without subcooling.

2. Minimizing the loss of lubricating oil from the compressor at all times.

3. Preventing liquid refrigerant from entering the compressor during operation and shut down.

To properly cover the subject of piping design would be too lengthy to treat here, especially since many excel-

LOW TEMPERATURE*

Refrig erant Saturated Suction Saturated Temperature Condensing

Temperature

R-502, -40 to 0°F 70 to 120°F R-404A, R-507 (-40 to -18°C) (21 to 49°C)

R-22 -30 to 0°F 70 to 120°F (-34 to -18°C) (21 to 49°C)

MEDIUM TEMPERATURE

Refrig erant Saturated Suction Saturated Temperature Condensing

Temperature

R-502, -10 to 40°F 70 to 120°F R-404A, R-507 (-23 to 4°C) (21 to 49°C)

R-12* -10 to 40°F 80 to 130°F (-23 to 4°C) (27 to 54°C)

R-134a* -10 to 50°F 70 to 150°F (-23 to 10°C) (21 to 66°C)

R-22* 0 to 50°F 70 to 130°F (-18 to 10°C) (21 to 54°C)

*Minimum operating pressure ratio in these applications is limited to 2.25:1.

*Minimum operating pressure ratio in these applications is limited to 2.25:1.

HIGH TEMPERATURE*

Refrig erant Saturated Suction Saturated Temperature Condensing

Temperature

R-12 0 to 55°F 70 to 150°F (-18 to 13°C) (21 to 66°C)

R-134a 0 to 55°F 70 to 150°F (-18 to 13°C) (21 to 66°C)

R-22 -0 to 50°F 70 to 150°F (-18 to 10°C) (21 to 66°C)

*Minimum operating pressure ratio in these applications is limited to 2.25:1.

lent guides to piping design are presently available. For complete details of good system piping practices, the Carrier System Design Manual (Part 3 Piping Design) is recommended.

1.4 Vibration Isolation

On installations where noise and vibration must be kept to a minimum, it is desirable to use vibration mounts under the compressor unit, even though the compressors may be spring mounted. Proper precau-tions must be taken to prevent the transmission of compressor vibration through the piping system. It is also recommended to design the suction line with sufficient “spring” so the suction service valve can be moved aside for access to the suction strainer. Many systems have been designed with compressors mounted to the bases. In these cases, it is important that the compressors be properly torqued to the base or the compressor may produce a “rattle” or transmit excessive vibration to the base.

For a more complete review of the system vibration and piping recommendations, see Carlyle OEM Bulletin #118.

1.5 Refrigerant Migration and Floodback

Liquid refrigerant, or even excessive amounts of entrained liquid particles in the suction gas, must be kept out of the compressor by proper system design and compressor control. Under running conditions, the presence of liquid refrigerant in the compressor tends to break down the oil film on the cylinder walls, resulting in increased wear to the cylinder walls and 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.

Therefore, special care should be taken to ensure that liquid refrigerant is kept out of the compressor espe-cially in systems where large quantities of refriger-ants are often used. During compressor operation, the expansion valve must be properly adjusted to prevent liquid from entering the compressor.

During compressor shutdown, gravity, thermal action and refrigerant absorption will result in a refrigerant and oil mixture in the compressor crankcase. Gravity flow can be prevented by the use of recommended loops in the piping, but thermal action and the absorption of refrigerant by lubricating oil cannot be prevented by piping design. To minimize the absorp-tion of refrigerant into the oil, the use of crankcase heaters is strongly recommended. Because oil dilution is more critical with HFC refrigerants and POE lubri-cants, Carlyle requires the use of crankcase heaters in these applications. It is important, however, to never energize the crankcase heater while the compressor is running because this may overheat the compressor oil. (See Accessory Section 5.4 for applicable heaters.)

Carlyle’s experience indicates that many compressor failures occur during the first several months of oper-ation. Many of these failures occurred during the ini-tial start-up of the unit, and inspection reports indi-cate flooding was the probable cause of failure in many of these compressor returns.

It is believed that many of these failures could have been avoided by using more care during the initial start-up of the compressors. Refer to the recommend-ed start-up procedure in Carlyle’s Refrigeration Compressor Service Guide (Lit. No. 020-611).

1.6 Clean and Dry System

Clean and dry systems are essential for long compres-sor and motor life, and satisfactory operation. This cannot be over-emphasized. It is even more critical with the introduction of new HFC refrigerants and POE lubricants. The new POE lubricants are excellent cleaning agents that will deposit system contami-nants into the system or compressor filters and screens, causing excessive pressure drop or clogging, if the system is not kept clean.

Liquid line refrigerant filter-driers maintain low moisture content, and in the event of a motor burnout, prevent contamination of the evaporator and other parts of the refrigeration system. These filter-driers should be compatible with the new HFC refrigerants and POE oils if used.

Liquid line moisture indicators are recommended in all systems that use semi-hermetic compressors because they provide a continuous check on the sys-tem’s moisture content. Excessive moisture in combi-nation with a high operating temperature can lead to motor winding breakdown and burnout. When mois-ture is indicated, prompt corrective action, such as changing the filter-drier core or dehydrating the sys-tem, can prevent serious compressor damage.

1.7 Prevent Excessive Discharge Temperatures

The actual discharge gas temperature at the compres-sor discharge service valve must not exceed 275˚F (135˚C). For HFC/POE applications the maximum rec-ommended discharge temperature is 250˚F (121˚C).

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.

1.8 Compressor Interconnection

All 06D and 06E compressors are suitable for inter-connection on common refrigerant circuits. General suction and discharge line piping recommendations are shown in Figures 1 and 2 (Page 22), respectively.

For a complete guide to system piping practices, the Carrier System Design Manual (Part 3 Piping Design) is again recommended.

When only two 06D or 06E compressors of the same size are to be connected in parallel, the oil equaliza-tion can be accomplished with a single oil equaliza-tion line. This line can equalize both oil and gas. This method of equalization is only recommended when there are two compressors of the same size and the oil equalization line is short (2 to 4 feet, .6 to 1.2 meters long). In this case, a single 1-1/8″ line can be used. Since this line equalizes both oil and gas, it is important that it be level to permit the lower half to act as an oil equalizer and the upper half as a gas equalizer.

The 06E compressors have two sightglass connec-tions, either of which may be removed for installation of the equalizer line. A small oil equalization check valve must also be added to those 06E compressors 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 13-16 lb-ft, 1.8-2.2 kg-m) of each compressor (see Figure 3, Page 22). The 06E rotor bolt is accessible by removing the suction strainer from the motor end cover. Installation of the check valve is best accom-plished just prior to mounting the suction service valve.

Figure 3—Rotor Locking Bolt

The 06D compressors have only one sightglass and provision must be made for a sightglass in the oil equalizer line when the 06D compressors are intercon-nected using an oil equalization line. The 06D oil equalizer interconnection package is 06DA900092. The 06D compressors do not utilize or require the check valve in the rotor lock bolt.

When more than two compressors are to be connected in parallel or if 06D/E compressors of different dis-placements are to be connected in parallel, an oil 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 with this recommendation, Carlyle has found that many system manifold piping arrangements can allow excessive oil to drain into the motor compart-ment of “off” 06E compressors. To avoid this poten-tial problem, Carlyle recommends the motor barrels of 06E compressors be equalized as shown in Figures 4 and 5, Page 23. This motor barrel equalization is rec-ommended in addition to either a float system or an oil compartment equalization line. Motor barrel equalization is recommended for 06E compressors only, the 06D compressors do not have this connection.

FIGURE 5 - SUCTION PIPING

RECOMMENDED

Compressor

Compressor

Suction Line

Compressor

Compressor

Compressor

Compressor

Compressor

Compressor

RECOMMENDED

NOT RECOMMENDED

Excessive Liquid Refrigerant Foodback will be Predominantly in Comp No. 2

FIGURE 6 - DISCHARGE PIPING

RECOMMENDED

RECOMMENDED

Cycles

21 43

NOT RECOMMENDED

Run Continuously

Cycles Most Often

Run Continuously

Dead-heading

Figure 1—Suction Piping Figure 2—Discharge Piping

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

Figure 5—Oil Equalization Between Compressor Motor Compartments

Suction Manifold

See compressor modification above (typical)

Header Assy.

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

1.9 Motor-Compressor Selection

When selecting any compressor, proper allowance should also be made for abnormal conditions that may result in motor overloading. These conditions might include high suction temperature during pull-down or low voltage at compressor motor terminals.

During pulldown, the compressor cannot be subjected to loading rates higher than the maximum kW shown in the electrical data tables for more than short peri-ods of time. Where an extended pulldown period is expected, the suction pressure must be limited by some positive means.

1.10 Outdoor Use

All UL recognized 06D and 06E compressors have ter-minal enclosures with corrosion protection specified that is suitable for outdoor use equipment as a sole enclosure. The 06D drawn steel terminal boxes used on 2 cylinder 06D compressors do not require any caulking for sole outdoor use, and are UL recognized as “Equal Alternate” to all caulked boxes previously used. Drawn steel boxes are available only for units requiring zero to two overloads.

1.11 Code Approvals

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

2.1 Compressor Lubrication

All refrigeration compressors must have adequate lubrication to ensure trouble-free operation and a long life. When starting up any new system, some oil will be lost to coat the inside of the piping, some oil will be lodged in low velocity areas of the system, and some will be kept in circulation. This loss must be made up by adding oil to the system after the ini-tial start-up. Very low compressor oil levels can cause complete loss of lubrication and may result in an immediate compressor failure if not protected against.

The loss of oil can also be caused by flooded starts or refrigerant migrating into the oil during an off period and pulling the oil out of its sump during the sudden pressure drop of a start-up.

While it has always been apparent that very low oil 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.

The oil level should be observed in the sightglass immediately after the compressor shutdown, while it is still warm. The level observed when the compres-sor is not running for a long period may be a mixture of oil and refrigerant which would not be a true indi-cation of the oil level when the compressor is running.

If the oil level in the sightglass of an 06E compressor is less than one-eighth (1/8) up from the bottom of the glass, this indicates a low oil level. If the oil level is up more than one-half (1/2) from the bottom, this indicates a high oil level. Therefore, the oil level should be 1/8 to 1/2 up the sightglass when the com-pressor is running for 06E compressors.

Figures 6, 7, and 8 show different oil levels when a single 06E compressor is running. The photos in each figure show the right and left sightglass of the same compressor (only one sightglass is factory supplied).

If the level is not the same in each glass, consider the true oil level to be the lower level. The difference in levels is due to the rotation of the crankshaft. The crankshaft and running gear are producing the windage required to push the oil down on one side while raising it on the other. Reversing the direction of rotation of the motor will reverse this relationship.

Figure 6—High Oil Level

The oil level in Figure 6 is at least 7/8 of a sightglass. Note the high oil level in the left sightglass, and solid foam in the right sightglass. Whenever the glass is filled with foam, excessive oil is indicated and oil should be removed.

2.0 – Compressor Lubrication System

Figure 7—Better Running Oil Level

The oil level in Figure 7 is 3/8-1/2 of a sightglass. This is an acceptable oil level on a single compressor sys-tem, but does not always give a true indication of an excessive oil charge on multiple compressor systems.

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.

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-tion manifold (depending on the method of returning oil), and in the compressor motor compartment. This is especially troublesome in an idle compressor in a multiple compressor system that has an opportunity 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.

To check for excessive system oil charges in 06E com-pressors, it is recommended that the oil levels of the compressors in the system be brought down to approximately 1/4 of the sightglass. If the system is overcharged, the oil levels will rise to a 1/2 sightglass level within a short time (usually within an hour).

Continue removing oil until the oil level does not rise after removal. It is also recommended that the oil lev-els be kept at this 1/4 level, or between the levels shown in Figure 8. This is especially true if any com-pressors have experienced any repeated gasket fail-ures. To summarize the advantages of keeping the oil at this level:

1. It ensures that excessive oil is not being lodged in the system. This will eliminate gasket, valve, and running gear failures.

2. The compressor, oil, and motor run cooler, approxi-mately 20˚F (11˚C) or more in many cases.

Figure 9—06D Oil Level Limits

As noted above, the oil level control in 06D compres-sors is less critical than 06E models. Motor barrel equalization is not required and oil level in the com-pressor sightglass should be controlled between 1/4 and 3/4 of the sightglass (See Figure 9). If the oil level in the sightglass is less than one-quarter (1/4) up from the bottom of the glass, this indicates a low oil level. If the oil level is up more than three-quarters (3/4) from the bottom, this indicates a high oil level.

Again, the oil level should be checked immediately after the compressor is shut down.

2.2 The Oil Pump

The 06D and 06E oil pump is a positive displacement vane type that produces high volume oil flow at a low oil pressure. The compressor utilizes an internal pres-sure regulator valve to maintain oil pressure at a con-stant 12 to 36 psi (.83 to 2.5 bar) above suction pressure.

2.3 Recommended Oils

When additional oil or a complete oil change is required, use only the listed Carlyle approved oils. For CFC and HCFC refrigerants use:

MANUFACTURER BRAND NAME

Totaline 150

Witco Suniso 3GS

Shrieve Chemical Zerol 150*

Texaco Ind. WFI-32-150

IGI Petroleum Ind. Cryol-150

* 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.

MANUFACTURER BRAND NAME

Castrol E68

ICI EMKARATE RL68H

CPI* CP-2916S

CPI Solest 68

BP Marine Enersyn MP-S68

Mobil Artic† EAL 68 Castrol† SW 68

*CPI CP-2916S is also sold under BP Marine Enersyn MP-S68.

† Medium temperature applications only.

LOW LIMIT HIGH LIMIT

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.

Table 2—Oil Pressure History

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 Mar ch 1994 16 to 22 16 to 22 (Between S/N 2084J & 1094J) (1.1 to 1.52) (1.1 to 1.52)

Star ting Mar ch 1994* 18 to 26 18 to 34 (Star ting 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).

3.1 Suction Cut-Off Capacity Control

Carlyle’s compressor suction cut-off capacity control system has been approved for R-502, R-404A, and R-507 applications down to -40˚F (-40˚C) suction and for R-12, R-134a, and R-22 medium and high tempera-ture applications, but the system designer must care-fully consider certain system design criteria when applying this new feature.

3.2 Design for Proper Oil Return to Compressor

When the 06D/E compressors are unloaded, the com-pressor and system capacity are reduced by 1/3, 1/2, or 2/3 of full load capacity. These capacity reductions result in the same large percent reduction in refriger-ant flow rates through the system piping. Oil that is entrained and carried with refrigerant requires a cer-tain gas velocity to properly return it back to the com-pressor and as this refrigerant flow drops, this may not be possible. This is especially true of the sizing of the suction line where oil return is most critical.

All system piping, but especially the suction line, must consider both full load and part load capacities and refrigerant velocities when being sized. For com-plete details of good system piping practices, the Carrier System Design Manual (Part 3 - Piping Design) or the ASHRAE Manual (Systems Volume) is recommended.

To protect the compressor against possible oil return problems, all 06D and 06E refrigeration duty com-pressors applied with capacity control must utilize oil safety switch protection. This requirement may be waived by Carlyle Application Engineering for certain high temperature, single compressor circuit applica-tions (contact Carlyle Application Engineering for approval).

3.3 Capacity Control Application Ranges

Low temperature R-502, R-404A, and R-507 Application: -40˚F to 0˚F (-40˚C to -18˚C) 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 temperatures below 120˚F (49˚C) with 1 bank of capacity control. Do not unload more than 1 bank on 6-cylinder 06D or 06E compressors in this low tem-perature application.

Note: In low temperature booster applications see dif-ferential pressure limits (∆P) (Table 4, Page 31) for minimum condensing pressures required to load up.

Medium Temperature R-12, R-134a, R-404A, R-502, and R-507 Application: 0˚F to 40˚F (-18˚C to 4˚C) Saturated Suction Temperatures.

Unloading application limits at saturated condensing temperatures below 130˚F (54˚C): Can unload 1 bank on any 4-cylinder 06D or 06E compressor. Can unload 1 or 2 banks on any 6-cylinder 06D or 06E compressor.

Note: With R-134a or R-12 see ∆P limits (Table 4, Page 31) for loading requirements.

Medium Temperature R-22 Applications:

0˚F to 25˚F (-18˚C to -4˚C) Saturated Suction Temperatures.

Unloading application limits at saturated condensing temperatures below 130˚F (54˚C): Can unload 1 bank on any 4 or 6-cylinder 06D or 06E compressor.

Unloading more than 1 bank on any 6-cylinder 06D or 06E compressor in this medium temperature applica-tion is not recommended.

High Temperature R-22 Applications: 25˚F to 55˚F (-4˚C to 13˚C) Saturated Suction Temperatures.

Unloading application limits at SCT’s below 145˚F (63˚C) and maximum superheat of 25˚F (14˚C). Can unload 1 bank on any 4-cylinder 06D or 06E compres-sor. Can unload 1 or 2 banks on any 6-cylinder 06D or 06E compressor per Figure 11.

3.0 – Capacity Control

Figure 10—Suction Cut-Off Operation Limits For 4-Cylinder 06D and 06E Compressors with R-502, R-404A, R-507

Figure 11—Suction Cut-Off Operation Limits For 6-Cylinder 06D and 06E Compressors with R-22

3.4 Pump-Down Control

Compressors with suction cut-off unloading have inherently greater internal leak paths than compres-sors without this capacity control feature installed on them. Compressors with the electric capacity control have been successfully applied with continuous or automatic pump-down control.