Carlyle 06CC Compound Cooling Compressor Instruction Manual

06CC Compound Cooling Compressor
50 THRU 99 CFM
Instruction Manual

GENERAL

1. Inspect compressor for shipping damage and fi le claim with shipping company if damaged or incomplete.
2. Check compressor nameplate for correct model and voltage designation.
3. The Carlyle Compound Cooling™ (C3) compressor is a unique design that offers higher capacities and effi ciencies than are possible in single stage compressors. Carlyle’s C3Application Guidelines (Lit. No. 570-869) should be carefully reviewed by the personnel responsible for the design of the units that these compressors will be installed in. It is important that these guidelines are carefully followed to ensure safe and reliable operation.
4. To facilitate customer installation requirements, the following parts are factory supplied in a separate parts bag located in the compressor terminal box:

SAFETY INSTRUCTIONS

WARNING : Failure to follow these instructions could result in serious personal injury.

1. Follow recognized safety procedures and practices.
2. Do not remove any compressor bolts or fi ttings until factory supplied holding charge has been relieved. Exhaust holding charge pressure through mid stage pressure connection (Fig. 2) by removing the connection cap and depressing the internal stem.
3. Do not apply any power to the compressor unless suction and discharge service valves are installed and opened.
4. Do not operate or provide any electrical power to the compressor unless the terminal box cover is in place and secured. Measurement of amps and volts during running conditions must be taken at other points in the power supply.
5. Do not remove terminal box cover until all electrical sources have been disconnected.
6. Follow recommended safety precautions listed on the terminal box cover label before attempting any service work on the compressor.

GENERAL INSTALLATION PROCEDURES

Holding Charge
Compressor is factory supplied with a 5- to 15-pound charge of dry air.
This internal pressure must be relieved before attempting to remove any compressor fi tting or part.
Relieve holding charge by removing the threaded cap on the interstage pressure connection fi tting and depressing the internal schrader-type stem.
See Figure 2 for interstage pressure connection fi tting location.
Service Valves
Remove valve pads and install factory supplied suction and discharge gaskets and service valves to the compressor. Torque applicable service valve mounting bolts as noted:

Oil

1. Check to see that oil level is 1/8 to 3/8 up on compressor sightglass before starting compressor and after 15 to 20 minutes of operation.
   CAUTION : Oil levels on 06CC (50 thru 99 CFM) compressors should not be allowed to go above the center of sightglass. High oil levels require excess power and shorten compressor life.

2. To add oil: Relieve internal crankcase pressure, isolate crankcase, and add oil through the oil fi ll connection. To remove excess oil: Reduce internal crankcase pressure to 2 psig, isolate crankcase, then loosen the oil drain plug allowing oil to seep out past the threads of the plug. See Figures 2 & 3 for connection locations.
   CAUTION : With the compressor crankcase under slight pressure, be careful not to remove the drain plug…the entire oil charge could be lost.
   CAUTION : Do not charge oil through the suction line or through the compressor suction access fi ttings. See Figures 1 & 2 for the recommended oil charging port. Adding oil into the suction side of the compressor can cause damage to the suction/discharge valves, pistons, and/or connecting rods.

3. When additional oil or a complete oil charge is required, use only the listed Carlyle approved oils:
   IGI Petroleum Ind. …………………………………………………… CRYOL-150
   Totaline …………………………………………………………………………….. 150
   Witco …………………………………………………………………….. Suniso 3GS
   Use of oil additives is not allowed without written approval from Carlyle Engineering Department.
   Do not reuse drained oil or oil that has been exposed to the atmosphere.

Electrical
GENERAL
Consult the wiring diagram located inside the compressor terminal box cover and Fig. 1 shown below for wiring connection locations.

TERMINAL BOX

The compressor terminal box is supplied with 2 support plates to mount the connector for the power wiring conduit. Select the one support plate with the opening suitable for the size of the conduit connector to be used and fasten it to the terminal box with the (4) screws provided.
TERMINAL PLATE WIRING FOR 6-PIN TERMINAL
A. The parts listed in item #4 (GENERAL COMMENTS, pg. 1) are supplied in parts bag with the compressor and are used when wiring the terminal plate.
B. Customer wiring to the compressor terminal plate must be provided with insulated wire terminal connectors and be suitable for accommodating the 3/8″ Dia. terminal studs.
C. 3-Lead Across-the-Line (X/L) start:
The (3) jumper bars supplied with the compressors are required for 3-Lead XL start only. Jumpers are assembled directly on terminal studs connecting T1 & T7, T2 & T8 and T3 & T9 as shown in (Fig. 1-A).
The 3 power leads are to be assembled to the applicable terminal stud directly on top of the jumper bar. Secure wire terminals and jumper bars to the terminal studs with the (6) 3/8-16 jam nuts provided with the compressor. Torque jam nuts to 18 lb-ft (24 n-m) maximum.
D. 6-Lead Across-the-Line (X/L) or Part Winding (P/W) start (Fig. 1-B): The 6 power leads are to be assembled and secured to the applicable terminal studs with the (6) 3/8-16 jam nuts provided with the compressor. Torque jam nuts to 18 lb-ft (24 n-m) maximum.
NOTE:
Jumper bars are not required with 6-Lead X/L or P/W start applications.
E. For 9-pin terminals for 208/230V-3-60 or 200V-3-50 “Across-the-Line” start applications, connect the jumper bars as follows (Fig. 1-C):

1. Install (3) 2-hole copper jumper bars connecting terminals 1 to 7, 2 to 6, and 3 to 9.
2. Remove plastic connector block from terminals 4, 5 and 6.
3. Install the fl at connector block (non-conducting) on terminals 4, 5 and 6.
4. Reinstall terminal nuts on terminals 4, 5 and 6 (removed in Step #2).
5. Install the 3-hole copper jumper bar connecting terminals 4, 5 and 6.
6. Connect the line leads to terminals 1, 2 and 3.
7. Install (9) terminal nuts (included in this kit) on terminal studs to secure jumper bar/line connections. Tighten terminal nuts to 18 lb-ft (24 n-m) maximum.

F. For 9-pin terminals for 208/230V-3-60 or 200V-3-50 “Part Winding” start applications, connect the jumper bars as follows (Fig. 1-D):

1. Remove plastic connector block from terminals 4, 5 and 6.
2. Install the fl at connector block (non-conducting) on terminals 4, 5 and 6.
3. Reinstall terminal nuts on terminals 4, 5 and 6 (removed in Step #1).
4. Install the 3-hole copper jumper bar connecting terminals 4, 5 and 6.
5. Connect the line leads to terminals 1, 2, 3, 7, 8 and 9.
6. Install (9) terminal nuts (included in this kit) on terminal studs to secure jumper bar/line connections. Tighten terminal nuts to 18 lb-ft (24 n-m) maximum.

G. For 9-pin terminals for 460V-3-60 or 400V-3-50 “Across-the-Line” start applications, connect the jumper bars as follows (Fig. 1-E):

1. Install (3) 2-hole copper jumper bars connecting terminals 7 to 4, 8 to 5, and 9 to 6.
2. Connect the line leads to terminals 1, 2 and 3.
3. Install (9) terminal nuts (included in this kit) on terminal studs to secure jumper bar/line connections. Tighten terminal nuts to 18 lb-ft (24 n-m) maximum.

OIL PRESSURE SAFETY SWITCH

1. All Carlyle refrigeration-duty 06CC compressors are provided with connections for an oil-safety switch. The use of an oil-safety switch is required as a condition of warranty for 06CC compressors. The oil safety switch can help prevent compressor failures when loss of lubrication or loss of compressor oil charge occur.

2. Normal oil pressure for C3 compressors is 12 to 30 psi above interstage pressure (standard pump). The use of a high fl ow oil pump yields up to 30 psi, depending on model, above interstage pressure. The high fl ow pumps will allow a minimum oil pressure differential switch time delay of 30 seconds and a maximum time delay of 120 seconds. The switch must be manually reset regardless of the style pump being used.

3. The oil-safety switch high side connection is to be attached to the oil pressure access tee which is fi eld installed in the oil pump pressure connection as noted below. The low side connection of the oil-safety switch is connected to the oil sump compartment of the crankcase.
   See compressor pictorials (Figures 2 & 3) for proper locations.

4. The following oil-safety switches have been specifi cally approved by Carlyle:

Carlyle & Carrier
Part No.| Dantoss
Part No.| Time
Delay| Connec-
bons| Pressure Diff| psi)| Volts| Reset| Remote Alarm
Circuit Capability
---|---|---|---|---|---|---|---|---
Cut
In| Cut
Out
634-2008
OR
P529-2130| 60B2101| 45 sec| 1/4″ Male
Flares| 8-11| 4-8| 115/230| Manual| Yes
634-2050
OR
P529-2110| 6082151| 36″ Lg.
Cap. Tube 1/4″ SAE Nuts
Electronic
Oil Switch| N/A| 45 sec
lectrical| Electrical Switch w/o Ext. Tubing| 8-11| 4-6| 115/230| Manual| Yes

OIL PRESSURE ACCESS TEE

1. The oil pressure access tee supplied in separate parts bag with the compressor is to be installed in the oil pump pressure connection located at the 12:00 position immediately above the oil pump cover.
   CAUTION : Aluminum Bearing Head. Torque oil pressure access tee: 20-25 lb-ft.

2. The oil pressure safety switch high-side connection is to be attached to the opened fl ared end of the installed oil pressure access tee. The capped end of this tee contains schrader-type valve which permits access to the oil pressure while the compressor is operating.

MOTOR PROTECTION

Overcurrent Protection — Customer Supplied

1. 06CC compressors are supplied “less” motor overcurrent protection devices. Compressor user must provide properly sized overcurrent motor protection. See application manual and price pages for specifi cations.
2. Carlyle recommends the use of calibrated circuit breakers. Circuit breakers based on X/L start with trip settings selected for proper compressor motor size and voltage are available from Carlyle.

Over Temperature Protection — Factory Supplied

1. A discharge gas thermal sensor is factory installed in the cylinder head on all new 06CC compressors. The temperature of the discharge gas in the high stage cylinder head is monitored by the thermal sensor. If the discharge gas temperature at the sensor exceeds 295° F, the sensor will open the control circuit and shut off the compressor. The (2) sensor wire leads (#16 AWG, stripped back 1/2″), located in the compressor terminal box are to be connected in series in the unit control circuit wiring.
   The discharge temperature sensor operates as an automatic re-set device; however, Carlyle recommends that it be wired in the control circuit in a manual re-set mode. Since the cylinder head sensor would help prevent many of the failures caused by overheating, the best control method would be to determine the cause and correct the reason for overheating when the initial sensor trip occurs.

© 2021 Carrier
Manufacturer reserves the right to discontinue,
or change at any time, specifications or designs
without notice and without incurring obligations.
Catalogue No. 570-850 Rev. A
Printed in U.S.A.
Pg 4 12-21
Replaces: 570-850 12-06

Documents / Resources

| Carlyle 06CC Compound Cooling Compressor [pdf] Instruction Manual
06CC, Compound Cooling Compressor, 06CC Compound Cooling Compressor, Cooling Compressor, Compressor, 50 THRU 99 CFM
---|---

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>