Carlyle 06E Instructions and recipes

GENERAL
1. Inspect compressor for shipping damage and file claim with ship-
ping company if damaged or incomplete.
2. Check compressor nameplate for correct model and voltage
designation.
3. Before installation, review all Carlyle compressor application litera-
ture to assure yourself that the proper compressor has been selected
and is being applied in a proper manner. The required application
literature is available through Carlyle.
4. To facilitate customer installation requirements, the following parts
are factory supplied in a separate parts bag located in the compres-
sor terminal box:
PART NUMBER DESCRIPTION QUANTITY
06EA500551 Jumper Bar (2 hole) 3
AT14QA241 Jam Nut 3/8 9
06EA502782 Jumper Bar (3 hole) 1
06EA402632 Tee Valve Assy. 1
574-068 Instruction Sheet 1
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 fittings until factory-
supplied holding charge has been relieved. Exhaust holding charge
pressure through low-pressure connection (shown in Figs. 1 & 2) by
removing the connection cap and depressing the internal disc.
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 termi-
nal 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 psig (1.4 to 2 bar)
charge of dry air. This internal pressure must be relieved before at-
tempting to remove any compressor fitting or part.
Relieve holding charge by removing the cap on the low pressure
connection fitting and depressing the internal disc. See Figs. 1 & 2
for applicable low pressure connection fitting location.
Service Valves
Remove valve pads and attach factory supplied suction and discharge
gaskets and service valves to the compressor. Torque applicable
service valve mounting bolts as noted:
Bolt Size Torque lb-ft (N-m)
5/16 - 18 19 - 23 (25.7 - 31.1)
1/2 - 13 80 - 90 (108 - 122)
5/8 - 11 90 - 120 (122 - 163)
When brazing piping to valve, disassemble valve or wrap in a wet cloth
to prevent heat damage.
Oil
1. Check to see that oil level is 1/8 to 3/8 way up on compressor
sightglass before starting and after 15 to 20 minutes of operation.
Compressors may be shipped with or without an oil charge based on
model. All compressors must contain the specified oil charge prior to
start up as a condition of warranty.
CAUTION: Oil levels on 06E 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 fill connection (see Figs. 1 & 2).To remove
excess oil: Reduce internal crankcase pressure to 2 psig (1.15 bar),
isolate crankcase then loosen the oil drain plug allowing oil to seep
out past the threads of the plug.
CAUTION: With the compressor crankcase under slight pres-
sure, do not remove the oil drain plug as the entire oil charge
could be lost. Do not reuse drained oil or oil that has been
exposed to the atmosphere.
3. 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
For HFC refrigerants use:
Manufacturer Brand Name
ICI EMKARATE RL68H
*Lubrizol Lubrikuhl 2916S
**Mobil Arctic EAL 68
**Castrol SW 68
Castrol E 68
Totaline P903-1701
*Lubrizol ISO 68 also sold under Texaco Capella HFC 68NA brand.
**Medium and high temperature applications only.
ELECTRICAL
General
Consult the wiring diagram located inside the compressor terminal
box cover and Figure A for wiring connection locations.
Installation and
Start-Up Instructions 06E
™

Figure 2
06E 6-Cylinder Compressor 65, 75, 99 Cfm (1.84, 2.12, 2.80 m3/m)
Figure 1
06E 4-Cylinder Compressor 50 Cfm (1.41 m3/m)
TEMPERATURE SENSOR
CYLINDER HEAD
DISCHARGE GAS
DISCHARGE SERVICE VALVE
LOCATION AND LIFTING LUG
NAMEPLATE LOCATION
SUCTION SERVICE VALVE
LOCATION
(ON MOTOR END COVER)
1/4″NPT OIL DRAIN
C’CASE MOTOR COMPARTMENT
6:00 POSITION
C’CASE MOTOR BARREL
BEARING HEAD
(CONTAINS OIL PUMP)
1/4″NPT (2) CONNECTIONS
(1) ABOVE SIGHTGLASS
(1) ABOVE BLANK PLATE
USED FOR:
A) OIL FILL CONNECTION
B) LOW SIDE OIL SAFETY
SWITCH CONNECTION
CRANKCASE HEATER
CONNECTION
OIL LEVEL SIGHTGLASS
INTERCHANGEABLE
WITH BLANK PLATE
7/16″-20 SAE OIL DRAIN
CONNECTION
CRANKCASE OIL SUMP
1/4″NPT OIL PUMP
PRESSURE CONNECTION
OIL PRESSURE ACCESS TEE
TO BE INSTALLED IN THIS CONNECTION
HIGH SIDE CONNECTION OF OIL
PRESSURE SWITCH TO BE CONNECTED
TO FLARED END OF INSTALLED TEE
BLANK PLATE
REMOVE FOR
EQUALIZING LINE
OR OIL FLOAT
CONNECTION
1/4″NPT LOW PRESSURE
CONNECTION
FACTORY SUPPLIED
SCHRADER TYPE FITTING
1/4″NPT HIGH PRESSURE
CONNECTION
CYLINDER HEAD
COOLING FAN
MOUNTING STUDS
(06ER MODELS ONLY)
1/4″NPT HIGH PRESSURE
CONNECTION
CYLINDER HEAD
COOLING FAN
MOUNTING STUDS
(06ER MODELS ONLY)
1/4″NPT LOW PRESSURE
CONNECTION
FACTORY SUPPLIED
SCHRADER TYPE FITTING
BLANK PLATE
REMOVE FOR
EQUALIZING LINE
OR OIL FLOAT
CONNECTION
1/4″NPT OIL PUMP
PRESSURE CONNECTION
OIL PRESSURE ACCESS TEE
TO BE INSTALLED IN THIS CONNECTION
HIGH SIDE CONNECTION OF OIL
PRESSURE SWITCH TO BE CONNECTED
TO FLARED END OF INSTALLED TEE
OIL LEVEL SIGHTGLASS
INTERCHANGEABLE
WITH BLANK PLATE
7/16″-20 SAE OIL DRAIN
CONNECTION
CRANKCASE OIL SUMP
CRANKCASE HEATER
CONNECTION
1/4″NPT (2) CONNECTIONS
(1) ABOVE SIGHTGLASS
(1) ABOVE BLANK PLATE
USED FOR:
A) OIL FILL CONNECTION
B) LOW SIDE OIL SAFETY
SWITCH CONNECTION
BEARING HEAD
(CONTAINS OIL PUMP)
5/8″-18 SAE OIL DRAIN
C’CASE MOTOR COMPARTMENT
6:00 POSITION
C’CASE MOTOR BARREL
NAMEPLATE LOCATION
SUCTION SERVICE VALVE
LOCATION
(ON MOTOR END COVER)
TEMPERATURE SENSOR
CYLINDER HEAD
DISCHARGE GAS
DISCHARGE SERVICE VALVE
AND LIFTING LUG LOCATION

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
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.
Customer supplied wiring to the compressor terminal plate must be
provided with insulated wire terminal connectors and be suitable for
accommodating the 3/8’’ diameter terminal studs.
6-Pin Terminal Plate
3-Lead Across-the-Line (X/L) Start (Fig. 3)
The (3) jumper bars supplied with the compressor are required for
3-Lead XL start only. Jumpers are assembled directly on terminal
studs connecting T1 & T7, T2 & T8 and T3 & T9. 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 termi-
nal studs with the (6) 3/8-16 jam nuts provided with the compressor.
Torque jam nuts to 12 lb-ft (16 n-m) maximum.
6-Lead Part Winding (P/W) Start (Fig. 3)
The 6 power leads are to be assembled and secured to the applicable
terminal studs with the (6) 3/8-6 jam nuts provided with the compres-
sor. Torque jam nuts to 12 lb-ft (16 n-m) maximum.
Note: Jumper bars are not required with 6-Lead X/L or P/W start
applications.
9-Pin Terminal Plate
208/230 V-3-60 or 200 V-3-50 Across-the-Line Start (Fig. 3)
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 flat 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 12 ft-lbs
(16 n-m) maximum.
208/230 V-3-60 or 200 V-3-50 Part Winding Start (Fig. 3)
1. Remove plastic connector block from terminals 4, 5 and 6.
2. Install the flat connector block (non-conducting) on terminals 4,
5 and 6.
3. Re-install 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 12 ft-lbs
(16 n-m) maximum.
460 V-3-60 or 400 V-3-50 Across-the-Line Start (Fig. 3)
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 12 ft-lbs
(16 n-m) maximum.
Figure A
Terminal Box Arrangement
Figure 3
Terminal Plate Wiring

Manufacturer reserves the right
to discontinue, or change at any
time, specifications or designs
without notice and without
incurring obligations.
Carlyle Compressor Co. • © Carrier Corporation
P.O. Box 4808, Syracuse, NY 13221
Phone: In US & Puerto Rico 1-800-GO-CARLYLE
In Canada 1-800-258-1123
In Mexico 001-800-462-2759
www.carlylecompressor.com
Lit. No. 574-068
Rev D 12/06
Replaces 06EA501602
OIL PRESSURE SAFETY SWITCH
1. All Carlyle 06E compressors are provided with connections for
an oil safety switch. The use of an oil safety switch can help prevent
compressor failures when loss of lubrication or loss of compressor oil
charge occur. The use of an oil safety switch is required as a condition
of warranty for those 06E compressors which are applied on systems
in which two or more 06E compressors are connected in parallel. On
units in which single 06E compressors are applied, the use of an oil
pressure switch is recommended. See Figs. 1 and 2 for oil safety
switch connections.
2. Normal oil pressure for 06E compressors is 12 to 30 psi (.83 -
2.1 bar) above suction pressure. Select a switch to close the control
circuit (at start-up) at a maximum of 12 psi (.83 bar) and open the
control circuit at a minimum of 5 psi (.35 bar). A time delay of not less
than 30 seconds nor more than 120 seconds is required for start-up
purposes. The switch must also be manually reset when it trips.
3. The oil safety switch high side connection is to be attached to
the oil pressure access tee which is field installed in the oil pump
pressure connection (see Figs. 1 and 2). The low side connection
of the oil safety switch is connected to the oil sump compartment
of the crankcase (above the sight glass). See compressor pictorials
(Figs. 1 and 2) for proper locations.
4. The following oil safety switches have been approved by Carlyle:
Carlyle
Part
No.
Time
Delay Connections
Pressure Diff.
psi (bar) Volts Reset
Remote
Alrm Circ
Capability
Cut
In
Cut
Out
P529-2430
120
sec
1/4″Male
Flares
8-11
(0.55-0.76)
4-8
(0.28-0.55)
115/230
(100/220) Manual Yes
P529-2410
36″Lg. Cap
Tu b e
1/4″SAE
Nuts
Carlyle
Part
No.
Time
Delay Connections
Pressure Diff.
psi (bar) Volts Reset
Remote
Alrm Circ
Capability
Cut
In
Cut
Out
06DA660115 120
sec Electronic 8-11 (0.55-0.76)
4-8
(0.28-0.55)
115/230
(100/220) Manual Yes
OIL PRESSURE ACCESS TEE
1. The oil pressure access tee is supplied in a separate parts bag
with the compressor and is to be installed in the oil pump above the
oil pump cover.
CAUTION: Aluminum Bearing Head, Torque oil pressure access
tee to 20 - 25 ft.-lbs (27 - 33 n-m).
2. The oil pressure safety switch high-side connection is to be
attached to the opened flared end of the installed oil pressure ac-
cess tee. The capped end of this tee contains a schrader type valve
which permits access to the oil pressure while the compressor is
operating.
MOTOR PROTECTION
Overcurrent Protection - Customer Supplied
1. 06E compressors are supplied “less” motor overcurrent protec-
tion devices. Compressor user must provide properly sized over-
current motor protection. See application manual and price pages
for specifications.
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
A discharge gas thermal sensor is factory installed in the cylinder
head on all new 06E 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 its maximum
limit (see 06D/E application guide for limits), the sensor will open the
control circuit and shut off the compressor. The (2) sensor wire leads
(#16 AWG, stripped back 1/2”) (1.27 cm), 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
reset device; however, Carlyle recommends that it be wired in the
control circuit in a manual reset mode (see 06D/E application guide
for wiring diagram). 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 overheat-
ing when the initial sensor trip occurs.
COOLING FANS
Cylinder head cooling fans are recommended for saturated suction
temperature (SST) below 0°F (-18°C) and are required based on
SST as follows:
Refrigerant SST
R-22 <0°F (-18°C)
R-507/404A <-25°F (-32°C)