Carlyle 06T 033 Series User guide

TM
05T / 06T SCREW COMPRESSOR APPLICATION GUIDE

Section 4 — Refrigerant Management
System
4.1 Suction and Interstage Piping.................23
Section 5 — Electrical Specifications
5.1 Thermal Protection................................. 25
5.2 Screw Compressor Motor Protection......26
5.3 Circuit Breaker Tables.............................27
Section 6 — Motor and Discharge
Temperature Control
6.1 Carlyle Electronic Module (CEM).............29
6.2 Discharge Temperature Control.............. 29
6.3 Motor Cooling Control............................29
Section 7 — Subcooler Selection and
Performance Data Adjustment
7.1 Subcooler Selection................................30
7.2 Subcooling Correction............................30
7.3 Superheat Correction............................. 30
7.4 Carlyle Software..................................... 30
Section 8 — 05T Open Drive Application
Information
8.1 General Information................................31
8.2 Compressor Dimensions........................ 31
8.3 Compressor C-Flange............................ 31
8.4 Compressor Coupling............................ 31
8.5 Overall Dimensions.................................31
8.6 Carlyle Electronic Module....................... 36
8.7 Motor Selection......................................36
8.8 Performance Factors..............................37
Section 9 — Start-Up Procedure
9.1 Oil Charging Procedure.......................... 38
9.2 Testing the Control Circuit...................... 38
9.3 Pre-Start-Up Check List.........................38
9.4 Start-Up Worksheet................................39
Section 10 — Accessory
Part Numbers............................................... 40
Appendix A LonCEM — Electronic
Module
Appendix B Original CEM — Electronic
Module
Introduction
Summary of Control Points...............................1
06T Model Number Significance.......................2
Compressor Physical Dimensions.....................2
Section 1 — General Information
1.1 Certification..............................................4
1.2 Screw Compressor Size (Displacement)...4
1.3 Compressor Mounting..............................4
1.4 Oil Type....................................................4
1.5 Ambient Conditions..................................5
1.6 Installation Environment............................5
1.7 Pressure Relief Valve................................5
1.8 Discharge Check Valve............................5
1.9 Compressor Inlet Screens........................5
1.10 Service Valves..........................................5
1.11 Condenser Pressure Control....................5
Section 2 — Operating Specifications
2.1 Operational Envelopes.............................6
2.2 Vapor Temperature Limits........................ 7
2.3 Minimum Oil Pressure Differential.............7
2.4 Operating Speed Ranges.........................7
2.5 Inverters and Refrigerants........................8
2.6 Compressor Cycling................................ 8
2.7 Mechanical Unloading..............................9
2.8 High Discharge Pressure Control.............9
2.9 Low Suction Pressure Cut Out.................9
2.10 Volume Index (Vi) Control....................... 9
2.11 Reverse Rotation Protection....................10
2.12 Mufflers...................................................10
Section 3 — Oil Management System
3.1 Oil Separator...........................................11
3.2 Piping Configuration................................12
3.3 System Oil Charge..................................12
3.4 Oil Level Switch...................................... 12
3.5 Oil Pressure Protection........................... 13
3.6 Oil Solenoids...........................................13
3.7 Oil Cooling Systems................................14
3.8 Oil Cooler Selection.................................16
3.9 Oil Filter...................................................20
3.10 Oil Sump Heaters................................... 20
3.11 Oil Sight Glass........................................20
3.12 Oil System Schematics...........................21
3.13 Oil Line Manifold Selection Table.............22
Contents

This manual is for the application of the Carlyle 06T
semi-hermetic and 05T open drive twin screw com-
pressors. The operational limits, required accessories
and operational guidelines are contained in this man-
ual and must be complied with to stay within the
compressor warranty guidelines.
The Carlyle 06T and 05T screw compressors are
gear-driven twin screw compressors. The gear drive
yields the benefits of light weight and small cubic vol-
ume. One of the key features of the Carlyle screw
compressor is that all the semi-hermetic models have
the same physical dimensions and port locations, as
do all the open drive models.
The compressors range between 15 and 75 nominal
horsepower, and are designed for use in commercial
refrigeration, process cooling, environmental cham-
ber, and air conditioning applications.
The 06T and 05T screw compressors are an addition
to Carlyle’s line of soft compression technology
(rotary and scroll). Soft compression technology
yields the benefits of smooth continuous pumping of
refrigerant with minimal vibration. The potential for
refrigerant leaks is reduced and rack vibration
is minimized. The addition of variable speed drives to
these compressors is an ideal complement for very
tight capacity control over a wide speed range.
Unlike reciprocating compressors, most models
can run up to 70 Hz yielding extra capacity
that may be needed on above design condition days.
This application guide is intended to set the required
guidelines of system design and operation to maxi-
mize the reliability of the Carlyle 06T and 05T twin
screw compressors. For applications outside the
parameters listed in this guide, please contact Carlyle
Application Engineering.
Unless otherwise noted, all information contained in
this application guide applies to both the 06T and
05T models.
Introduction Summary of Control Points
Oil System:
Maximum oil temperature 190°F (88°C)
entering compressor
Minimum oil temperature 80°F (27°C)
entering compressor
Maximum oil pressure 45 Psi (3 Bar) Cut-Out
differential across the 25 Psi (1.6 Bar) Alarm
oil filter
Minimum oil pressure
differential across each
compressor (oil inlet pressure
to suction pressure) 45 Psi (3 Bar) Cut-Out
Motor Cooling Control Per Compressor:
Refer to LonCEM/CEM Control Parameters Chart
and Appendixes A & B.
Discharge Temperature Control Per
Compressor:
Refer to LonCEM/CEM Control Parameters Chart
and Appendixes A & B.
Reverse Rotation Protection Per Compressor:
LonCEM (Carlyle Electric Module) solid-state
electronic module with integral reverse rotation
protection. — or —
Manual Reset Low Discharge Pressure Cut-Out
(1/4" Tubing Conn.) 10" Vacuum (.33 bar)
— or —
Carlyle Approved Line/Load Phase Monitor
(Optional)
Note: One of the above methods of reverse rotation
protection is required.
Head Pressure Control:
Minimum head pressure must be 45 psi (3 bar)
above suction pressure plus expected pressure drop
in the oil system (including the maximum
pressure drop across the oil filter that is designed into
the oil system before a filter change). If the
system is set to cut-out compressors at 45 psid
(3 bar) across the oil filters, then 90 psid (6 bar) plus
any losses in the oil system between the
separator and compressor is the required pressure
differential from suction to discharge.
1

2
* Standard service valve used on all 33-54 cfm Compressors;
** Larger barstock service valve used on all 65-88 cfm Compressors (shown).
**
*
06T MODEL NUMBER SIGNIFICANCE
COMPRESSOR PHYSICAL DIMENSIONS
FOR REFERENCE ONLY
INCHES
[MILLIMETERS (mm)]

3
COMPRESSOR PHYSICAL DIMENSIONS CONTINUED
**
*
**
*
*
**
* Standard service valve used on all 33-54 cfm Compressors;
** Larger barstock service valve used on all 65-88 cfm Compressors (shown).
**
*

1.1 Certification
UL and CSA approvals have been obtained on
the 06T screw compressors with the
following refrigerants:
1. R-22
2. R-134a
3. R-404A & R-507
The UL file number is SA4936. CSA file
number is LR29937; CSA report number is
LR29937-579c.
For UL and CSA approvals it is essential that
only listed special purpose circuit breakers or
Furnas 958 series soild state overload relays
be used. (See Section 5.2 and 5.3 for selection
tables). The must trip amp settings should not
exceed 140% of the compressor rated load
amps.
Both UL and CSA approvals have been
obtained for all voltage combinations listed
in Section 5.3. 60 Hz compressors have
been listed.
Section 1 — General Information
1.2 Screw Compressor Size
(Displacement)
06T compressors are available in the following
displacement sizes:
60 Hz 50 Hz
Model ft3/m
3/ft 3/m 3/
No. min min min min
06T**033 33 0.93 27.5 .78
06T**039 39 1.10 32.5 .92
06T**044 44 1.25 36.7 1.04
06T**048 48 1.36 40.0 1.13
06T**054 54 1.53 45.0 1.28
06T**065 65 1.84 54.2 1.53
06T**078 78 2.21 65.0 1.84
06T**088 88 2.49 73.3 2.08
06T**108 N/A N/A 90.0 2.56
Semi-hermetic compressors will be supplied
with single voltage motors 208/230 volts, 460
volts and 575 volts.
1.3 Compressor Mounting
The Carlyle 05T/06T screw compressors may
be rigid mounted. However, Carlyle recom-
mends the use of isolation mounts (Carlyle
P/N KA75KR007, Package No. 06TA660007)
for 06T compressors. These rubber mounts
isolate the compressor from the system frame-
work which helps to reduce noise transmission.
1.4 Oil Type
Carlyle screw compressors are approved
for use with the oils in the table below (based
on refrigerant application).
Contact Carlyle Application Engineering for
alternate POE oil selections.
See section 9.1 for System oil charging recom-
mendations.
4
R-404A & R-507 R-134a R-22
Medium Medium Medium
POE Oil Type Low Temp. Temp. Temp. & A/C Low Temp. Temp.
Castrol SW100 * NO YES YES NO YES
CPI Solest BVA 120 *† YES YES YES YES YES
CPI Solest 170 ** YES YES YES YES** YES**
ICI Emkarate RL100S YES YES YES YES YES
Castrol E100 * YES YES YES YES YES
* UL Certified
† For application purposes, Solest 120 oil is considered to be the same viscosity as POE 100 oils.
** Required for R-22 systems without external oil Cooler. R-22 systems with external oil cooler may use POE 100 oils.

5
1.5 Ambient Conditions
The screw compressor is designed for the
following specified ambient temperature ranges:
Non-Operating -40°F To 130°F
(-40°C To 54°C)
Start-Up -40°F To 130°F
(-40°C To 54°C)
Operating -25°F To 130°F
(-32°C To 54°C)
1.6 Installation Environment
The intended installation modes for the screw
compressor are:
Machine Rooms—Enclosed Atmosphere
External Environment—Sheet Metal Enclosure
NOTE: The electrical terminal box is not
approved for external applications.
1.7 Pressure Relief Valve
All compressor models contain an automatic
reset high pressure relief valve. The pressure
relief valve is located inside the compressor and
will internally vent the compressor discharge
to the compressor suction when it relieves.
The valve opens at a pressure differential of
400 psi (27.6 bar). The relief valve is not
field serviceable.
1.8 Discharge Check Valve
All compressor models are supplied with an
internal discharge check valve. This check
valve prevents the reverse flow of refrigerant
through the compressor during compressor off
cycles. A check valve in the discharge line is
not required for parallel applications. It may be
required for pump down on single compressor
systems.
The discharge check valve is field serviceable.
1.9 Compressor Inlet Screens
Filter screens are applied at all locations where
liquid or gas enters the compressor, i.e., suc-
tion, economizer and oil connections.
For systems that operate below -25F (-32c), it
is recommended that the suction screen be
removed after 48 hours of system startup as
the viscous oil can damage the screen.
The compressor inlet screens are field
serviceable and available through Carlyle
distribution.
1.10 Service Valves
Suction and discharge connections will
interface with the 2-1/2" bolt pattern service
valves currently being used on the Carlyle
reciprocating compressors. Rotalock®service
valves are used for the economizer line shut
off. The line sizes are as follows:
Connection Size
Connection Max. Min.
Suction 1-5/8" 1-1/8"
Discharge 1-5/8" 1-1/8"
Economizer 7/8" 7/8"
All compressor models are supplied with the 1-5/8"
suction and discharge service valves and the 7/8"
economizer valve.
All 05T compressors and 06T compressors
between 65cfm and 88cfm use a barstock
service valve, (06TA680008) which is physically
larger than the standard service valve
(06TA660001) used on all 06T compressors
between 33cfm - 54cfm (see compressor
physical dimensions on pages 2 & 3).
1.11 Condenser Pressure Control
Important!
Large variations in head pressure will
result in very poor oil separation which
may result in nuisance oil level switch
tripping. The condenser pressure must
be controlled such that fluctuations are
gradual. Carlyle screw compressors
must be applied with a minimum of one
condenser fan (preferably variable speed)
active at all times and a means of minimum
head pressure control for low ambient
operation. For alternate methods of con-
denser control, please contact Carlyle
Application Engineering.

2.1 Operational Envelopes
The following operational envelopes, based on
65°F (18°C) return gas, show the allowable
operating suction and discharge pressure
ranges for R-134a, R-22, and R-507/R-404A.
Operation outside of these envelopes requires
Section 2 — Operating Specifications
6
R-134a APPLICATIONS
Saturated Discharge Temperature deg F (deg C)
120
60
140
0
20
40
80
100
(60)
(49)
(38)
(27)
(16)
(4)
(-7)
(-18)
20
-10 -5 0510 15 25 30 35
(-23) (-21) (-18) (-15) (-12) (-9) (-7) (-4) (-1) (2)
Saturated Suction Temperature deg F (deg C)
160
(71)
40
(4) 45
(7) 50
(10) 55
(13)
Disch Temp Control
Oil Cooling Control
R-22 APPLICATIONS
Saturated Discharge Temperature deg F (deg C)
120
60
140
0
20
40
80
100
(60)
(49)
(38)
(27)
(16)
(4)
(-7)
(-18)
-40 -35 -30 -25 -20 20
-15 -10 -5 0510 15 25 30 35
(-40) (-37) (-34) (-32) (-29) (-26) (-23) (-21) (-18) (-15) (-12) (-9) (-7) (-4) (-1) (2)
Saturated Suction Temperature deg F (deg C)
Disch Temp Control
Oil Cooling Control
Discharge
Temperature
Control and
Oil Cooling
Required
Oil Cooling
Required
40 45 50
No Oil or Discharge
Control
Requirements
(5) (8) (11)
approval from Carlyle Application Engineering
or warranty is voided. Oil cooling can be
achieved through the use of an oil cooler or
with desuperheating valves (as described in
Oil Cooling Systems, Section 3.7)

2.2 Vapor Temperature Limits
Any application of screw compressors must
operate within the limits defined by the appli-
cation maps for the various refrigerants and
applications.
Vapor Temp. Min. Max.
Suction 10°F SH* 100°F
(6°C) (38°C)
Economizer Saturated** Non-
Vapor Economized
*SH = Superheat
**The maximum economizer pressure allowable is
175.3 psig (13.1 bar)
2.3 Minimum Oil Pressure Differential
A minimum pressure differential of 45 psi
(3 bar) is required between suction and oil
pressure (at the compressor). Applications
below this minimum range will require the
use of an external oil pump.
2.4 Operating Speed Ranges
The operating speed range for the screw com-
pressor is as follows for the different size range
compressors.
Model ft3/m
3/ Min. Max.
No. min min Hz Hz
06T**033 33 0.93 50 70
06T**039 39 1.10 40 70
06T**044 44 1.26 35 70
06T**048 48 1.36 30 70
06T**054 54 1.53 30 70
06T**065 65 1.84 25 70
06T**078 78 2.21 20 68
06T**088 88 2.49 20 60
06T**108 90* 2.56* 20 50
* 50 Hz Applications only.
7
R-507-R404AAPPLICATIONS
Saturated Discharge Temperature deg F (deg C)
120
60
140
0
20
40
80
100
(60)
(49)
(38)
(27)
(16)
(4)
(-7)
(-18)
-40 -35 -30 -25 -20 20
-15 -10 -5 0510 15 25 30 35
(-40) (-37) (-34) (-32) (-29) (-26) (-23) (-21) (-18) (-15) (-12) (-9) (-7) (-4) (-1) (2)
Saturated Suction Temperature deg F (deg C)
-45
(-43)
(-46)
-50
Oil Cooling Control
Disch Temp Control
R-507/R404A APPLICATIONS

2.5 Inverters and Refrigerants
The Carlyle screw compressor is compatible
with inverter drives. An inverter drive varies the
speed of a compressor to improve system load
matching.
VARIABLE SPEED LIMITS
For 06TR Low Temp Compressors
Table 1
Model Nominal Min. Max.
No. HP Hz Hz
06TRC033 15 50 70
06TRD039 20 40 70
06TRD044 20 35 70
06TRE048 25 30 70
06TRE054 25 30 70
06TRF065 30 25 70
06TRG078 35 20 68
06TRH088 40 20 60
06TRK108 50 20 50
VARIABLE SPEED LIMITS
For 06TA A/C & Med. Temp Compressors
Table 2
Model Nom. Min. Max.
No. HP Hz Hz
06TAD033 20 50 70
06TAE039 25 40 70
06TAF044 30 35 70
06TAF048 30 30 70
06TAG054 35 30 70
06TAG065 35 25 70
06TAH078 40 20 68
06TAK088 50 20 60
Carlyle recommends screw compressors be
selected to match the system load at 60 Hz.
Overspeeding is a good option during heavy
load conditions. Carlyle does not recommend
the screw compressor operate at maximum
frequency for prolonged periods of time.
Operation above 60 Hz requires adequate
motor cooling. Inverters have a tendency to
increase the required motor cooling load due to
irregular wave forms. When overspeeding,
there will be an increased power consumption
required to supply the additional capacity. This
will also increase the required motor cooling
load. It is important that the motor cooling
system be capable of handling the increased
cooling required for the motor. Oil return,
economizer return gas, and the motor cooling
valve all assist in cooling the motor. Carlyle
recommends applying the largest motor cool-
ing valve (Carlyle P/N EF28BZ007) with all
screw compressors applied using inverters.
Inverters are an effective tool for efficiently
matching system loads with screw
compressors. Motor size and motor cooling
capabilities must be considered when using
an inverter to increase speeds above 60 Hz.
Following these guidelines will result in
improved system design and performance.
An inverter is capable of changing the
compressor’s speed very quickly from full
speed to minimum speed and vice versa.
Compressors should ramp-up to the minimum
speed within 15 seconds at start-up. After
compressor start, Carlyle recommends that the
rate of compressor speed change be limited to
600 RPM/Min for the 06T semi-hermetic. The
rate of compressor speed change for the
05T open drive models is required to be
no greater than 500 RPM/MIN.
2.6 Compressor Cycling
Although compressor cycling is an effective
means of capacity control, frequent starting
and stopping shortens the compressor life.
Carlyle screw compressors should not be
cycled for capacity control more than six
times an hour and should run for at least
5 minutes after each start.
8

2.7 Mechanical Unloading
All Carlyle screw compressors are equipped
with one step of mechanical unloading.The
unloader valve is controlled by a solenoid
mounted on the compressor body.
The compressor is unloaded when the
solenoid is de-energized and loaded when
the solenoid is energized. The compressor
should always be started unloaded (for a mini-
mum time determined by the control module)
which will provide a soft start by partially
relieving the compression chamber back to
suction. Unloaded operation reduces the effec-
tive capacity by 30% to 62%, depending on
the model and system condition
(see tables below).
ESTIMATED PERCENTAGE
UNLOADING BY MODEL
Models ft3/m
3/ Low Med.
@ 60 Hz min min Temp. Temp.
06T**033 33 0.93 60% 50%
06T**039 39 1.10 59% 49%
06T**044 44 1.25 58% 48%
06T**048 48 1.36 56% 46%
06T**054 54 1.53 55% 45%
06T**065 65 1.84 50% 40%
06T**078 78 2.21 45% 35%
06T**088 88 2.49 40% 30%
Models ft3/m
3/ Low Med.
@ 50 Hz min min Temp. Temp.
06T**033 27.5 0.78 62% 52%
06T**039 32.5 0.92 61% 51%
06T**044 36.7 1.04 60% 50%
06T**048 40.0 1.13 59% 49%
06T**054 45.0 1.28 58% 48%
06T**065 54.2 1.53 55% 45%
06T**078 65.0 1.84 50% 40%
06T**088 73.3 2.08 47% 37%
06T**108 90.0 2.56 46% -
Unlike reciprocating compressors that should
not be run unloaded continuously, the Carlyle
screw compressor can be run unloaded con-
tinually without affecting the reliability of the
compressor. Other methods of reducing the
compressor capacity are available and must be
approved by Carlyle Application Engineering.
9
Vi SETTINGS CHART (PSIG)
350
300
250
200
150
100
50
00510 2025
30 35 40 45 50
Suction Pressure psig (bar)
Discharge Pressure psig (bar)
Set at High Vi in this Region (Energized)
15
Set at Low Vi in this Region (De-energized)
(24.1)
(20.7
(17.2)
(13.8
(10.3)
(6.9)
(3.4)
(0)
(0) (.3) (.7) (1.0) (1.4) (1.7) (2.1) (2.4) (2.8) (3.1) (3.4)
2.8 High Discharge Pressure Control
A high pressure cut out must protect the com-
pressor from exceeding 350 psig (25.2 bar).
The compressor may be brought back on
line after the discharge pressure falls
below 300 psig (21.4 bar). The maximum pres-
sure differential (discharge-suction) is 350 psi.
The internal pressure relief valve will open if the
pressure differential exceeds 400 psi (+/-3%).
2.9 Low Suction Pressure Cut Out
A low suction pressure cut out must protect
the compressor from operating in a vacuum
(below 10" hg). Each compressor must be indi-
vidually protected with a low pressure switch
connected to the low side access port. The
compressor may be brought back on line after
a 3 minute delay.
2.10 Volume Index (Vi) Control
All low temperature models (05TR/06TR) are
supplied with a Vi control valve that allows for
two Vi settings (see chart below). This dual Vi
allows for optimum efficiency over a wide
range of head pressures. The Vi must be set to
low (solenoid de-energized) during start-up for
a minimum of 30 seconds. The Vi may then be
set as desired for optimum energy efficiency.
The following chart and graph reflect the oper-
ational specifications of the Vi control.
The current LonCEM® controller continuously
monitors the operating pressure ratio and con-
trols Vi output accordingly. The older CEM
requires external controls to accomplish the
same task.
System Pressure Ratio Vi Solenoid
Greater Than 5:1 High: 4.0 On
Less Than 5:1* Low: 2.8 Off
*Medium/High temperature “TA” compressor models
have a fixed Vi of 2.8.

2.11 Reverse Rotation Protection
Correct compressor rotation is critical for com-
pressor reliability. The compressor can fail with-
in 2-6 seconds of start-up if it is not rotating in
the correct direction. Installation of a pressure
gage at the discharge pressure access fitting in
the compressor body (measuring the pressure
upstream of the integral discharge check valve)
is recommended during initial start-up or
whenever the compressor is serviced. The
gage should be monitored to ensure increasing
discharge pressure at start-up.
The new LonCEM protection module (available
midyear 2000) uses a pressure sensor to moni-
tor the discharge pressure change at start-up
to ensure proper compressor rotation. The
LonCEM module eliminates the need for a
mechanical low-pressure switch and line/load
phase monitor. See Appendix A for descrip-
tions of operation applications for the LonCEM
module.
2.12 Mufflers
Screw compressors emit very high frequency
gas pulsations that have the potential to result
in significant discharge line and oil separator
noise. The addition of the Carlyle screw com-
pressor muffler is required in all applications to
reduce discharge line and oil separator noise
levels (Carlyle P/N LM10HH162). The muffler
should be located within 6-in. of the compres-
sor discharge service valve.
10
L3 L2 L1
LS3 LS2 LS1
LOW VOLTAGE
HIGH VOLTAGE
LOAD ENERGIZER
FAULT
INTERROGATION
SECONDS
SYMMETRY
LOCKOUT
MINUTES
L3
L2
L1
FUSE
FUSE
FUSE
C
LS1LS2
LS3
LOAD
CONTROL
VOLTAGE
19-240
VAC/VDC
CHECKS
LOAD
VOLTAGE
CHECKS
SOURCE
VOLTAGE
PHASE MONITOR WIRING DIAGRAM
CONTACTOR
VOLTAGE
ADJUST
FOR REFERENCE ONLY
INCHES
[MILLIMETERS (mm)]
Screw Compressor Muffler
PHASE MONITOR WIRING DIAGRAM

3.1 Oil Separator
An oil separator is required on all Carlyle screw
compressor systems. Carlyle offers two sizes
of vertical oil separators. Parallel systems (over
two compressors) require the use of the Carlyle
14" (35.6cm) separator, and single and double
compressor systems require the use of the
Carlyle 12" (30.5cm) separator. See the draw-
ings below for dimensional information on the
oil separators.
Section 3 — Oil Management System
11
FOR REFERENCE ONLY
INCHES
[CENTIMETERS (cm)]
12" (30.5cm) VERTICAL OIL SEPARATOR
PHYSICAL DIMENSIONS 14" (35.6cm) VERTICAL OIL SEPARATOR
PHYSICAL DIMENSIONS

3.2 Piping Configuration
The inlet piping from the compressor to the
separator should follow a few simple rules:
1. The discharge header should be one
consistent size throughout.
2. Step changes in the line diameter should
be avoided with the exception of the
reducing fittings required to couple to
the oil separator.
To optimize the performance of the separator,
it should be piped with a 90° elbow in the
discharge line just prior to entering the oil
separator as shown below.
Inlet piping to the separator must be sized to
maintain sufficient velocity at the minimum load
condition of the rack. The minimum velocity
should be no less than 20fps (feet per second)
(6.1 mps [meters per second]) and the maxi-
mum velocity should be no more than 75fps
(22.9 mps). Velocities above this limit may
result in excessive pressure drop across the oil
separator.
Steel refrigerant piping should not be used on
screw compressor applications. See section
4.1 for further details.
3.3 System Oil Charge
The system oil charge will vary depending
on the size of the separator used, size of the
oil cooler (where applicable), oil manifolding,
and natural refrigerant piping traps and coat-
ing. The nominal oil charge for a three com-
pressor parallel rack is approximately 10–20
gallons (28.5–57 liters), but may vary
significantly.
The oil charge (i.e. quantity required to fill to
the top sight glass) for the smaller single
compressor oil seperator is approximately
5 gallons, while it is 10 gallons for the larger
separator.
See section 9.1 for the recommended oil
charging procedure.
The screw compressors have no oil sump and
therefore are shipped empty and must not be
charged. For the recommended oil type,
please refer to Section 1.4.
Carlyle recommends operating the system with
the oil level between the top two sight glasses
on the oil separator.
3.4 Oil Level Switch
An oil level switch is required and must be
located in the bottom of the oil separator or
reservoir. The level switch is used to monitor
the oil level and act as a safety in case of low
oil levels. The float switch must be wired to
open all the compressor control circuits
on the rack during cases of low oil level.
The float switch will be normally closed when
adequate oil is in the separator or reservoir
sump. This device is 240v pilot duty and
rated for 20 VA maximum. During transient
conditions, the oil level switch may rapidly
fluctuate causing nuisance tripping. To avoid
this, the level switch may be controlled by the
rack controller with the following logic:
DEFINITIONS:
OIL_LEVEL PROGRAM VARIABLE
OIL_LEVEL =1 OIL LEVEL OK
OIL_LEVEL = 0 OIL LEVEL FAULT
FLOAT PROGRAM COUNTER VARIABLE
LEVEL PROGRAM VARIABLE TO INCREMENT/DECREMENT
COUNTER
LEVEL = 1 OIL LEVEL OK
LEVEL = -1 OIL LEVEL FAULT
PROGRAMMING:
INITIALIZATION BLOCK
FLOAT = 3
PROGRAM BLOCK
READ OIL_LEVEL
LEVEL = 2*(OIL_LEVEL - .5) ~CONVERTS 1 OR 0 TO 1 OR -1
FLOAT = FLOAT + LEVEL
IF (FLOAT = 0) THEN SHUTDOWN COMPRESSOR(S)
IF (FLOAT>3) THEN (FLOAT = 3)
~LIMIT FLOAT TO MAXIMUM OF 3
REPEAT PROGRAM BLOCK EACH 15 SECONDS
This Anti-Cycling algorithm will keep a
running tally of the oil level switch status.
The algorithm reduces the likelihood of
nuisance tripping at low oil level.
Another method to avoid nuisance trips is to
add a 30-second time delay to the oil level
switch control circuit. (After a trip, a 2-minute
time delay may be incorporated before
attempting to restart.)
12
OUTLET
INLET

3.5 Oil Pressure Protection
Current Carlyle compressor design requires
that oil is fed to the compressor at discharge
pressure. The pressure differential between oil
pressure (discharge pressure-oil pressure drop)
and suction pressure is used to drive oil
through the compressor. There cannot be any
excessive flow restrictions (excessive pressure
drop across oil filters, etc...) in the oil system to
ensure adequate lubrication. There must be
sufficient oil pressure differential between the
oil pressure and the suction pressure to drive
the lubricant through the compressor.
The LonCEM protection module (available mid-
year 2000) provides comprehensive oil pres-
sure protection through the use of discharge
pressure, oil pressure and suction pressure
transducers to monitor operating pressures.
Appendix A contains a complete description of
the application and operation of the LonCEM
module. Refer to the following table for a sum-
mary of LonCEM parameters for alarms (indi-
cate system problems and allow the compre-
sor to continue operating) and cut-outs (caus-
es compressor to shut down and requires
manual reset).
Refer to Appendix B for information regarding
the oil protection system used with the Carlyle
Electronic Module (CEM) prior to midyear
2000.
3.6 Oil Solenoids
A normally closed solenoid is required in the oil
feed line to each compressor, located before
(upstream of) the high side of the Oil Pressure
Differential Switch (OPDS). To avoid exces-
sive pressure drop, the internal port size
must be 5/16" diameter or larger. An oil
strainer is required before each oil solenoid (or
as an integral part of the solenoid). The sole-
noid will protect the compressor from being
filled with oil from the high pressure oil feed line
during the off cycle. Each solenoid must be
properly wired to the Carlyle CEM
(per installation instructions) of the compressor
it is controlling. The valve must be open during
the on cycle and closed during the off cycle.
Manually adjustable valves must be
checked to ensure the manual operation
stem is completely back seated (ensuring
the valve is closed when the solenoid is
de-energized). Carlyle does offer a combina-
tion oil control solenoid valve and sight glass
assembly (EF23ZZ025) which incorporates a
solenoid valve.
Warning!
When testing the control circuit without the
compressor running, the oil line must be valved off
so that the compressor will not be filled with oil.
Whenever possible use control logic to deter-
mine that the compressor is actually running
before opening the oil solenoid. There are
two ways to accomplish this:
1. Make sure the current is greater than zero
and less than the locked rotor amperage
(LRA).
2. Make sure the discharge plenum pressure
is greater than the suction pressure (this
method is ineffective on multiple com-
pressor racks).
13
OIL LEVEL SWITCH DIMENSIONS
FOR REFERENCE ONLY
INCHES
[CENTIMETERS (cm)]
Parameter Explanation Alarm/Cut-Out Reset
Discharge pressure
– oil pressure is
greater than 35 psi
(2.4bar)
Alarm AutoOil system
Pressure
Drop
Discharge pressure
– oil pressure is
greater than 50 psi
(3.4bar)
Cut-Out Manual
Oil Pressure
Differential Oil pressure – suction pressure is
less than 45 psi
(3.0bar) for 90
seconds or more
Cut-Out Manual

3.7 Oil Cooling Systems
Carlyle 06T semi-hermetic screw compressors
can be operated for most applications without
external oil cooling. 05T open drive screw com-
pressors require external oil cooling any time
the system discharge temperature may exceed
180°F. Carlyle’s Carwin selection software can
be used to estimate the discharge temperature
for a given application.
When an oil cooler is not required, it also elimi-
nates the need for any oil mixing components
to keep the oil within a designated temperature
range when the oil is being returned from an air
cooled oil cooler during low ambient periods.
Operating without an oil cooler does not
change the lubricant recommendations for
R-404A/507. The recommendation is to use
POE 100 or 170 lubricants. For R-22 applica-
tions the recommendation for a lubricant is
POE 170, CPI Solest 170, for all R-22 low,
medium and high temperature applications.
14
When an oil cooler is used with R-22, the
recommendation is to use POE 100 or 170.
Operating without an oil cooler does
impact the system's condenser selec-
tions. Since the oil cooler removes heat
from the compressor, additional heat will be
transferred to the compressor's heat of
rejection, or condenser load. Current ver-
sions of Carlyle's compressor selection pro-
gram take this into consideration, allowing
selections to be made with or without an
external oil cooler.
Operating without an oil cooler results in little
or no performance change on higher dis-
placement models. The slower rotor speeds
on smaller CFM models results in a discern-
able capacity loss that may require consider-
ation. Current versions of Carlyle's compres-
sor selection program take this into consid-
eration, allowing selections to be made with
or without an external oil cooler.
Allowable Application Range Without Oil Coolers
Application: Saturated Suction: Saturated Condensing: Recommended Oils:
R-404A/507 Low Temp. -40 F to 0 F 70 F to 120 F POE 100 or 170
R-404A/507 Medium Temp. 0 F to 50 F 70 F to 130 F POE 100 or 170
R-134a Medium & High Temp. -10 F to 50 F 70 F to 150 F` POE 100 or 170
R-22 Low Temp. -25 F to 0 F 70 F to 120 F POE 170*
R-22 Low Temp. -30 F to -26 F 70 F to 110 F POE 170*
R-22 Medium & High Temp. 0 F to 50 F 70 F to 130 F POE 170*
* If oil cooler used, oil can revert to POE 100

15
The oil cooler does offer some help in keeping
the discharge and motor temperatures within
their respective limits. To make up for this lost
cooling some additional refrigerant injection is
required. For screw compressors this injection
is by the motor cooling valve or at the rotor
injection port. Because refrigerant injection for
motor and discharge cooling flows into the
screw rotor chamber after the suction gas is
trapped, compressor capacity is not affected
significantly. Under some conditions the motor
cooling valve can accommodate this extra
cooling requirement. For conditions requiring
additional injection, a Sporlan Y-1037 desuper-
heating valve, or its equivalent, is recommend-
ed. It should be selected to start opening at a
discharge temperature of 190 F and be fully
open at 200 F. The bulb should be located on
the discharge line within 6" of the compressor
discharge service valve. A properly sized sole-
noid valve should be located upstream to
insure positive shut-off when the compressor is
off.
The tables presented at the bottom of this
page present desuperheating size and part
number information for those applications
where an oil cooler is not used.
Even when an oil cooler is used, desuperheat-
ing may still be required. For R-22 systems,
the desuperheating valve is required when
the saturated suction temperature is below
-25°F (-32°C) and for R-404A/R-507 systems,
it is necessary when the saturated suction
temperature is below -40°F (-32°C). This valve
is available through Carlyle (1 ton (3.5Kw);
1.5 ton (5.3Kw); contact Carlyle Application
Engineering for valve selection).
DESUPERHEATING VALVE SIZING WITHOUT OIL COOLER
R-22 Added Desuperheating R-404A/507 Added Desuperheating R134a Added Desuperheating
Compressor
Model HP Low Temp. Med/High Temp. Low Temp. Medium Temp. Medium Temp. High Temp.
Low Temp.
SCT Range 70 to 120 F 90 to 120 F 70 to 150 F 70 to 150 F
(21 to 49 C) (32 to 49 C) (21 to 65 C) (21 to 65 C)
06TRC033 15 FV-2 N/A FV-1* N/A None None
06TRD039 20 FV-3 N/A FV-1-1/2* N/A None None
06TRD044 20 FV-3 N/A FV-1-1/2* N/A None None
06TRE048 25 FV-3 N/A FV-2* N/A None None
06TRE054 25 FV-3 N/A FV-3* N/A None None
06TRF065 30 FV-5 N/A FV-3* N/A None None
06TRG078 35 FV-5 N/A FV-3* N/A None None
06TRH088 40 FV-5 N/A FV-3* N/A None None
06TRK108 50 FV-5 N/A FV-3* N/A None None
Med Temp/High Temp
SCT Range 70 to 130 F 70 to 130 F
(21 to 54 C) (21 to 34 C)
06TAD033 20 N/A FV-2** N/A None None None
06TAE039 25 N/A FV-3** N/A None None None
06TAF044 30 N/A FV-3** N/A None None None
06TAF048 30 N/A FV-3** N/A None None None
06TAG054 35 N/A FV-3** N/A None None None
06TAG065 35 N/A FV-5** N/A None None None
06TAH078 40 N/A FV-5** N/A None None None
06TAK088 50 N/A FV-5** N/A None None None
LEGEND
* Operation with Evap condensers below -25 F SST may not require any additional desuperheating.
Contact Carlyle Applicatioon Engineering for limits.
** Operation with Evap condensers above +10F SST may not require any additional desuperheating.
Contact Carlyle Application Engineering for limits.
Note: Valve P/N's shown above are for Sportan Valve Y-1037 series desuperheating valves. A valve with a 190 F temperature setting is required. Alternate
desuperheating valve sizing or manufacturers must be approved by Carlyle Application Engineering.
Sporlan Part No. Carlyle Part No. Qty./Pkg. Weight (Lbs.) Size
FV-1 EA02ZD001 1 2 1 ton
FV-1-1/2 EA02ZD002 1 2 1-1/2 ton
FV-2 EA02ZD030 1 2 2 ton
FV-3 EA02ZD050 1 2 3 ton
FV-5 EA02ZD100 1 2 5 ton

16
3.8 Oil Cooler Selection
An oil cooler is required on all Carlyle screw com-
pressor systems not operating in the range indi-
cated in the previous section. This is generally for
systems requiring lower suction temperatures or
higher discharge temperatures. Also, 05T direct
drive compressor systems with discharge tem-
peratures that may exceed 180 F (82 C) always
require an oil cooler. The oil cooler must be sized
based on an oil flow rate of approximately 2 gal-
lons per minute (7.6 liters/minute) per compres-
sor. (The actual oil flow rate will vary based on
pressure ratio of the application. The precise oil
cooler load may be obtained from the Carlyle
compressor selection software.) The maximum oil
temperature leaving the oil cooler is 170 F (77 C)
and the maximum temperature entering the oil
cooler is 200 F (93 C) (based on discharge tem-
perature control). The oil cooler load is nominally
1 ton (3.5 kilowatts) per compressor, but may be
calculated with the above data and oil manufac-
turer's specifications. In applications which
require oil cooling some means of controlling the
oil temperature entering the compressor is
required.
Several possible methods are;
• Oil cooler fan cycling based on oil outlet tem-
perature (10F∆T)
• Oil cooler bypass via a solenoid valve controlled
off of oil cooler entering temperature
• Use of a mixing valve to maintain a constant oil
temperature entering the compressor
• Some combination of the three methods listed
above
The oil may be cooled by means of an air cooled,
refrigerant cooled, or water cooled oil cooler.
Carlyle offers 4 sizes of air cooled oil coolers for
use with the 05T and 06T screw compressor.
Following is selection criteria for the various mod-
els along with dimensional information.
If using a refrigerant cooled oil cooler, the oil
cooling load will need to be subtracted from
either the compressor's evaporator capacity or
the subcooling capacity. Using compressor suc-
tion pressure will led to a reduction in system
capacity since some of the compressor suction
mass flow will now come from the oil cooler.
Using the compressor interstage port for oil cool-
ing will not reduce the compressor suction
pumping capacity but will indirectly reduce sys-
tem capacity by decreasing the compressor's
ability to do liquid subcooling. The additional
mass flow from the oil cooler to the interstage will
increase the interstage pressure. This will prevent
the subcooler from achieving the lowest possible
liquid temperature. Both systems require hold
back valves to prevent the oil temperature from
dropping below 80 F (27 C).
Also, caution must be taken to ensure that the
return gas to the compressor is not too hot. For
more information, contact Carlyle Application
Engineering.
The oil cooler represents a heat source that may
be used for heat reclaim processes such as hot
water preheat. Since the oil cooler rejects dis-
charge heat, the heat rejection from the oil cooler
can be subtracted from the heat rejection
required by the system condenser. This may lead
to a smaller size condenser. Condenser circuiting
may also be used for oil cooling; however, pres-
sure drops must be taken into account for mini-
mum oil pressure differential to the compressors.
A mixing valve is recommended for all oil coolers
circuited through a remote air-cooled condenser.
Oil Cooler Models Available Oil Cooling Capacity @ Ambient Air Temperature
95ºF 100ºF 105ºF 110ºF
Fan Speed 60Hz (35ºC) (38ºC) (41ºC) (43ºC)
32,100 Btu/Hr 30,600 Btu/Hr 29,000 Btu/Hr 27,600 Btu/Hr
KH51ZZ181 (2 Compressors Max)* (9,405 W/Hr) (8,966 W/Hr) (8,497 W/Hr) (8,087 W/Hr)
69,100 Btu/Hr 65,700 Btu/Hr 62,400 Btu/Hr 59,100 Btu/Hr
KH51ZZ182 (3 Compressors Max)* (20,246 W/H) (19,250 W/Hr) (18,283 W/Hr) (17,316 W/Hr)
102,600 Btu/Hr 97,700 Btu/Hr 92,800 Btu/Hr 87,900 Btu/Hr
KH51ZZ183 (4 Compressors Max)* (30,061 W/Hr) (28,626 W/Hr) (27,190 W/Hr) (25,755 W/Hr)
134,100 Btu/Hr 127,700 Btu/Hr 121,300 Btu/Hr 114,900 Btu/Hr
KH51ZZ184 (5 Compressors Max)* (39,291 W/Hr) (37,416 W/Hr) (35,541 W/Hr) (33,665 W/Hr)
Oil Cooler Models Available Oil Cooling Capacity @ Ambient Air Temperature
95ºF 100ºF 105ºF 110ºF
Fan Speed 50Hz (35ºC) (38ºC) (41ºC) (43ºC)
32,200 Btu/Hr 28,800 Btu/Hr 27,300 Btu/Hr 25,900 Btu/Hr
KH51ZZ181 (2 Compressors Max)* (9,405 W/Hr) (9,435 W/Hr) (8,438 W/Hr) (7,999 W/Hr)
63,700 Btu/Hr 60,600 Btu/Hr 57,600 Btu/Hr 54,600 Btu/Hr
KH51ZZ182 (3 Compressors Max)* (18,664 W/H) (17,756 W/Hr) (16,877 W/Hr) (15,998 W/Hr)
94,900 Btu/Hr 90,400 Btu/Hr 85,900 Btu/Hr 81,400 Btu/Hr
KH51ZZ183 (4 Compressors Max)* (27,805 W/Hr) (26,487 W/Hr) (25,168 W/Hr) (23,850 W/Hr)
123,400 Btu/Hr 117,500 Btu/Hr 111,600 Btu/Hr 105,800 Btu/Hr
KH51ZZ184 (5 Compressors Max)* (26,156 W/Hr) (34,427 W/Hr) (32,699 W/Hr) (30,999 W/Hr)
*Maximum Number of Compressors Based on Oil Cooler Pressure Drop of Less Than 6 PSID (.41 bar)

17
MODEL # KH51ZZ181
FOR REFERENCE ONLY
INCHES
[CENTIMETERS (cm)]
FOR REFERENCE ONLY
INCHES
[CENTIMETERS (cm)]
MODEL # KH51ZZ182
OIL INLET AT BOTTOM – OIL OUTLET AT TOP; ALL MODELS
Electrical Specifications: All Models
Voltage: 115/230V 50/60Hz
Amperage*: 3.2/1.6 Amps Full Load 60Hz
2.8/1.4 Amps Full Load 50Hz
*Amperage ratings are per motor

18
FOR REFERENCE ONLY
INCHES
[CENTIMETERS (cm)]
MODEL # KH51ZZ183
FOR REFERENCE ONLY
INCHES
[CENTIMETERS (cm)]
MODEL # KH51ZZ184
OIL INLET AT BOTTOM – OIL OUTLET AT TOP; ALL MODELS