Carlyle 05T User guide

05T 06T
05T / 06T SCREW COMPRESSOR APPLICATION GUIDE

2
General Introduction
Features of Carlyle 05T/06T Compressors . . . . . . 3
Summary of Control Points
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Motor Temperature Control . . . . . . . . . . . . . . . . . . 4
Discharge Temperature Control: . . . . . . . . . . . . . . 4
Reverse Rotation Protection . . . . . . . . . . . . . . . . . 4
Floating Head Pressure . . . . . . . . . . . . . . . . . . . . . 4
1.0 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
2.0 Operating Specifications
2.1 Operational Envelopes. . . . . . . . . . . . . . . . . . . 6
2.2 Vapor Temperature Limits . . . . . . . . . . . . . . . . 7
2.3 Minimum Oil Pressure Differential . . . . . . . . . . 7
2.4 Variable Speed Operation . . . . . . . . . . . . . . . . 7
2.5 Compressor Cycling. . . . . . . . . . . . . . . . . . . . . 7
2.6 Mechanical Unloading . . . . . . . . . . . . . . . . . . . 8
2.7 High Discharge Pressure Control . . . . . . . . . . 8
2.8 Low Suction Pressure Cut Out. . . . . . . . . . . . . 8
2.9 Volume Index (Vi) Control . . . . . . . . . . . . . . . . 8
2.10 Reverse Rotation Protection . . . . . . . . . . . . . 8
2.11 Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.0 Oil Management System
3.1 Oil Separator. . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 Piping Configuration . . . . . . . . . . . . . . . . . . . . .9
3.3 System Oil Charge . . . . . . . . . . . . . . . . . . . . . .9
3.4 Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . .9
3.5 Oil Pressure Protection. . . . . . . . . . . . . . . . . . .9
3.6 Oil Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.7 Discharge Temperature Control . . . . . . . . . . . .9
3.8 Oil Cooler Selection . . . . . . . . . . . . . . . . . . . .11
3.9 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
3.10 Oil Sump Heaters . . . . . . . . . . . . . . . . . . . . .11
3.11 Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . .11
3.12 Oil System Schematics. . . . . . . . . . . . . . . . .12
3.13 Oil Line Manifold Selection Table . . . . . . . . .12
4.0 Refrigerant Management System
4.1 Suction and Interstage Piping. . . . . . . . . . . . .13
5.0 Electrical Protection
5.1 Thermal Protection . . . . . . . . . . . . . . . . . . . . .15
5.2 Overcurrent Protection . . . . . . . . . . . . . . . . . .16
5.3 Allowable Voltage Range . . . . . . . . . . . . . . . .16
6.0 Motor Temperature Control
6.1 Motor Cooling Control. . . . . . . . . . . . . . . . . . .17
7.0 Compressor Selections and
Performance Data
7.1 CARWIN Compressor Selection Software . . .18
7.2 Subcooler Selection . . . . . . . . . . . . . . . . . . . .18
Contents

3
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 manual and must be
complied with to stay within the compressor warranty
guidelines.
Features of Carlyle 05T/06T Compressors
The Carlyle 06T and 05T screw compressors are gear-driven
twin screw compressors. The gear drive yields the benefits
of light weight and footprint. 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 50 nominal horsepower, and are
designed for use in commercial refrigeration, process
cooling, environmental chamber, and air conditioning
applications. Screw compression technology yields the
benefits of smooth continuous pumping of refrigerant with
minimal vibrati on.
The addition of variable speed drives to
these compressors is an ideal complement for very tight
capacity control over a wide speed range. Most models can
run up to 70 Hz yielding extra capacity that can be used to
meet the design day load allowing for a smaller compressor
running at lower speeds during lighter load conditions. This
application guide is intended to set the required guidelines of
system design and operation to maximize 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.
06T MODEL NUMBER NOMENCLATURE
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General Introduction
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4
Oil System:
Maximum oil t emperature entering compressor:
•06T models: 190°F (88°C)
• 05T models: 180°F (82°C)
Minimum oil temperature e ntering compressor:
• 80°F (27°C)
Oil Filter Pressure Drop Protection (discharge pressure mi-
nus oil pressure):
•Cutout: 45 psi (3 Bar)
•Alarm: 25 psi (1.6 Bar)
Minimum oil pressure differential (oil inlet pressure to suction
pressure)
•Cutout: 45 Psi (3 Bar)
(Must be measured for each compressor)
Floating Head Pressure:
Oil pressure at the compressor must be a minimum of
45 psi (3 bar) above suction pressure. To maintain this, the
discharge pressure must be maintained at this 45 psi (3 bar)
plus the pressure drop in the oil filters plus any flow losses
in the oil supply piping.
Motor Temperature Control:
LonCEM protection
— or —
Carlyle recommends liquid injection to mitigate motor tem-
peratures above 180°F (82°C). The compressor must shut-
down with motor temperatures exceed 240°F (116°C).
Discharge Temperature Control:
LonCEM protection or
Carlyle recommends liquid injection to mitigate discharge
temperatures above 205°F (96°C). The compressor must
shutdown with discharge temperatures exceed 230°F
(110°C).
Reverse Rotation Protection:
LonCEM protection or
Manual reset low pressure switch connected to discharge
port and set at 10 inches of vacuum, (0.33 bar). This pres-
sure switch is intended only for commissioning and should
be removed from the system prior to long term operation.
or
Carlyle Approved Line/Load Phase Monitor
1.0 General Information
1.1 Certification
The 06T compressors are UL listed under file number is
SA4936. CSA file number is LR29937; CSA report number
is LR29937-579c. For UL and CSA approvals it is essential
that the overcurrent protection follow the guidelines speci-
fied in Section 5.2 of this guide. Both UL and CSA approvals
have been obtained for all voltage combinations listed in
Section 5.3. 60 Hz compressors have been listed.
1.2 Screw Compressor Size (Displacement)
06T compressors are available in the following
displacement sizes:
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 recommends the use of isola-
tion mounts for 06T compressors. These rubber mounts iso-
late the compressor from the system framework which
helps to reduce noise transmission.
1.4 Oil Type
Carlyle screw compressors are approved for use on
R-448A, R-449A, R-404A, R-507, R-134a, and R-22
with the following oils:
For application purposes the Solest 120 is considered an
equivalent viscosity at the Emkarate RL100E. The Solest
170 is required for R-22 systems without external oil
coolers. R-22 systems with an external oil cooler may use
the POE 100/120 weight oils.
60Hz 50Hz
MODEL NO. ft3/min m3/min ft3/min m3/min
06T—033 33 0.93 27.5 0.78
06T—039 39 1.10 32.5 0.92
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
Oil Manufacturer
Solest 120 CPI
Solest 170 CPI
Emkarate RL100E Lubrizol
Summary of Control Points

5
1.5 Ambient Conditions
The screw compressor is designed for the following speci-
fied ambient temperature ranges:
1.6 Installation Environment
The intended installation modes for the screw compressor
are: Machine Rooms—Enclosed Atmosphere External En-
vironment—Sheet Metal Enclosure
NOTE: The electrical terminal box is not approved for exter-
nal applications.
1.7 Pressure Relief Valve
All compressor models contain an automatic reset high
pressure relief valve. The pressure relief valve is located in-
side the compressor and will internally relieve the compres-
sor discharge to the compressor suction at a pressure differ-
ential 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 dis-
charge check valve. This check valve prevents the reverse
flow of refrigerant through the compressor during compres-
sor off cycles. A check valve in the discharge line is not re-
quired 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., suction, economizer and oil
connections. For systems that operate below -25°F (-32°C),
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 service-
able and available through Carlyle distribution.
1.10 Service Valves
Suction and discharge connections will interface with the
2-1/2 in. 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:
All 05T compressors and 06T compressors between 65cfm
and 108cfm must use a flange at the discharge connection
with an in-line ball valve for compressor isolation. With the
exception of the 06TA660008 valves (now obsolete), stan-
dard 90-degree compressor isolation valves must not be
used on the discharge of these 65, 78, 88 and 108cfm com-
pressors.
1.11 Condenser Pressure Control
Large fluctuations in head pressure may 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 always be applied with a minimum of one condenser
fan (preferably variable speed) active and a means of mini-
mum head pressure control for low ambient operation.
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)
Connection Connection Size
MAX. MIN.
Suction 1-5/8”1-1/8”
Discharge 1-5/8”1-1/8”
Economizer 7/8”7/8”

6
2.1 Operational Envelopes
The following operational envelopes, based on 65°F (18°C)
return gas, show the allowable operating suction and dis-
charge pressure ranges for different refrigerants. Operation
outside of these envelopes requires approval from Carlyle
Application Engineering or warranty is voided. Oil cooling
can be achieved using an oil cooler or with desuperheating
valves (as described in Oil Cooling Systems, Section 3.8).
R-448A, R-449A, R-507 & R-404A APPLICATIONS
R-134a Applications
2.0 Operating Specifications
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7
R-22 APPLICATIONS
2.2 Vapor Temperature Limits
Any application of screw compressors must operate within
the limits defined by the application maps for the various re-
frigerants and applications.
*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). Ap-
plications below this minimum range will require the use of
an external oil pump.
2.4 Variable Speed Operation
The Carlyle screw compressor is compatible with variable
speed drives, the table below shows the allowable speed
range.
Carlyle does not recommend the screw compressor operate
at maximum frequency for prolonged periods of time.
Operation above 60 Hz requires adequate motor cooling.
When overspeeding, there will be an increased power con-
sumption 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 in-
creased cooling required for the motor. Oil return, econo-
mizer return gas, and the motor cooling valve all assist in
cooling the motor. Carlyle recommends applying the largest
motor cooling valve with all screw compressors applied us-
ing inverters.
Compressors should ramp-up to the minimum speed within
15 seconds at start-up. After compressor start, Carlyle rec-
ommends that the rate of compressor speed change be lim-
ited to 600 rpm/min for the 06T semi-hermetic compressors.
The rate of compressor speed change for the 05T open-
drive models is required to be no greater than 500 rpm/min.
*Open Motor Type applies to 05T models only.
2.5 Compressor Cycling
Although compressor cycling is an effective means of ca-
pacity control, frequent starting and stopping shortens the
compressor life. Carlyle screw compressors should not be
stop/start cycled for capacity control more than six times an
hour and should run for at least 5 minutes after each start.
Vapor Temp Min. Max.
Suction 10°F SH*
(6K)
100°F
(38°C)
Economizer Saturated**
Vapor —
Compressor
Model
Nominal
HP
Min.
Hz
Max.
Hz
Open Motor
Type*
06T—033 15 50 70 —
06T—039 20 40 70 —
06T—044 20 35 70 —
06T—048 25 30 70 —
06T—054 25 30 70 —
06T—065 30 25 70 —
06T—078 35 20 68 —
06T—088 40 20 60 —
06T—108 50 20 50 —
05T—033 15 50 140 4-POLE
30 25 70 2-POLE
05T—039 20 40 140 4-POLE
35 20 70 2-POLE
05T—044 20 35 120 4-POLE
40 20 60 2-POLE
05T—048 25 20 70 4-POLE
05T—054 25 20 70 4-POLE
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8
2.6 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 com-
pressor is unloaded when the solenoid is de-energized
and loaded when the solenoid is energized. The compres-
sor should always be started unloaded (for a minimum 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 effective capacity
by 30% to 62%, depending on the model and system condi-
tion (see tables below).
The 05T/06T screw compressors can be run unloaded con-
tinually without affecting the reliability of the compressor.
2.7 High Discharge Pressure Control
A high pressure cut out must protect the compressor from
exceeding 350 psig (25.2 bar). The compressor may be
brought back online after the discharge pressure falls below
300 psig (21.4 bar). The maximum pressure differential
(discharge-suction) is 350 psi. The internal pressure relief
valve will open if the pressure differential exceeds 400 psi
(+/-3%).
2.8 Low Suction Pressure Cut Out
A low suction pressure cut out must protect the compressor
from operating below 10 inches of vacuum pressure. Each
compressor must be individually protected with a low pres-
sure switch connected to the low side access port. The
compressor may be brought back online after a 3 minute
delay.
2.9 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 en-
ergy efficiency. The following table reflects the operational
recommendations for the Vi control. Carlyle also recom-
mends the use of a small deadband at this change-over
point to avoid unnecessary short cycling of the Vi solenoid.
The LonCEM®controller continuously monitors the operat-
ing pressure ratio and controls Vi output accordingly. The
older CEM requires external controls to accomplish the
same task.
2.10 Reverse Rotation Protection
Correct compressor rotation is critical for compressor reli-
ability. The compressor can fail within 2 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 LonCEM protection module uses a pressure sensor to
monitor the discharge pressure change at startup to ensure
proper compressor rotation. The LonCEM module elimi-
nates the need for a mechanical low-pressure switch and
line/load phase monitor. See Appendix A for descriptions of
operation applications for the LonCEM module.
2.11 Mufflers
Screw compressors emit gas pulsations result in radiated
noise from the discharge line and oil separator. The addition
of a muffler is required in all applications to reduce dis-
charge line and oil separator noise levels. The muffler
should be located within 6-inches (15cm) of the compressor
discharge service valve.
ESTIMATED PERCENTAGE UNLOADING
BY MODEL
COMPRESSOR
MODEL
50HZ OPERATION 60HZ OPERATION
06TR
MODELS
06TA
MODELS
06TR
MODELS
06TA
MODELS
06T—033 62% 52% 60% 50%
06T—039 61% 51% 59% 49%
06T—044 60% 50% 58% 48%
06T—048 59% 49% 56% 46%
06T—054 58% 48% 55% 45%
06T—065 55% 45% 50% 40%
06T—078 50% 40% 45% 35%
06T—088 47% 37% 40% 30%
06T—108 45% — — —
Vi Control
(05/06TR only)
Capacity
Control
Compressor
Model
System
Pressure Ratio
Vi
setting
Solenoid
State
06TR >5.0 High:4.0 Energized
<5.0 Low: 2.8 De-energized
06TA All Fixed:
2.8 —
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9
3.1 Oil Separator
An oil separator is required on all Carlyle screw compressor
systems. The screw compressors do not have an oil sump
for storage of the system oil charge. The selection of the oil
separator should consider the desired oil circulation rates as
well as storage of oil for the entire bank of compressors.
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 vortex separators, they
should be piped with a 90° elbow in the discharge line (turn-
ing in the same direction as the vortex) just prior to entering
the oil separator.
Inlet piping to the separator must be sized to maintain
enough 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 maximum
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 oil piping is not recommended for use with 05T/06T
screw compressor applications.
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
manifold, and natural refrigerant piping traps and coating.
3.4 Oil Level Switch
An oil level switch is required and must be located in the bot-
tom 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 com-
pressor control circuits on the rack during cases of low oil
level. The float switch will be normally closed when ade-
quate oil is in the separator or reservoir sump. The oil level
switches are generally pilot duty devices, their electrical
switching capacity should be validated to ensure they are
not overloaded. During transient conditions where signifi-
cant foaming is present in the oil sump, the oil level switch
may rapidly fluctuate causing nuisance tripping. System
controls must be designed to discriminate these nuisance
conditions from real low oil level conditions.
3.5 Oil Pressure Protection
The 05T/06T screw compressors are lubricated using oil fed
from the high pressure side of the system. To ensure ade-
quate lubrication the pressure of the oil feed to each com-
pressor must be a minimum of 45psi (3 bar) above suction
pressure. Care should be taken to avoid large pressure
drops between the oil separator (discharge pressure) and
this oil feed to the compressor (oil pressure). See Section
3.9 for addition details on these pressure drops.
The LonCEM protection module provides comprehensive
oil pressure protection through the use of discharge pres-
sure, oil pressure and suction pressure transducers to mon-
itor operating pressures.
Refer to the LonCEM Installation and Operations Guide for
a complete description of the application and operation of
the LonCEM module.
3.6 Oil Solenoids
A normally closed solenoid is required in the oil feed line to
each compressor, see Section 3.12 for oil system schemat-
ics. To avoid excessive pressure drop, the internal port size
must be 5/16 in. diameter or larger. An oil strainer is re-
quired before each oil solenoid (or as an integral part of the
solenoid). The solenoid will protect the compressor from be-
ing filled with oil from the high pressure oil feed line during
the off cycle. Each solenoid must be properly wired to the
Carlyle LonCEM (per installation instructions) of the com-
pressor it is controlling. The valve must be open during the
on cycle and closed during the off cycle. Manually adjust-
able valves must be checked to ensure the manual opera-
tion stem is completely back seated (ensuring the valve is
closed when the solenoid is de-energized).
Whenever possible use control logic to determine that the
compressor is running before opening the oil solenoid.
3.7 Discharge Temperature Control
The 06T semi-hermetic screw compressors can be operat-
ed for most applications without external oil cooling. 05T
open drive screw compressors require external oil cooling
any time the system discharge temperature may exceed
180°F(82°C). The CARWIN Selection Software can be
used to estimate the discharge temperature for a given ap-
plication. The CARWIN tool allows for selections to be made
with or without an oil cooler.
See Operating Envelopes in Section 2.1 for operating condi-
tions that may require the use of external oil cooling.
An external oil cooler will reduce both the discharge and
motor temperatures within their respective limits, however,
additional refrigerant injection may still be required. For
screw compressors this injection is either by the motor cool-
ing valve and/or at the rotor injection port. Because refriger-
ant injection for motor and discharge cooling flows into the
screw rotor chamber after the suction gas is trapped, com-
pressor capacity is not significantly affected. Under some
conditions the motor cooling valve alone can accommodate
this extra cooling requirement. For conditions requiring addi-
tional discharge temperature cooling, a desuperheating
valve is recommended. It should be selected to start open-
ing at a discharge temperature of 190°F (88°C) and be fully
open at 200°F (93.3°C). The bulb should be located on the
discharge line within 6 inches (15cm) of the compressor dis-
charge service valve. A properly sized solenoid valve should
CAUTION
When testing the control circuit without the compressor
running, the oil line must be valved off so that the com-
pressor will not be filled with oil.
3.0 Oil Management System
w

10
be located upstream to ensure positive shut-off when the
compressor is off.
The tables presented at the bottom of this page present de-
superheating valve size and part number information for
those applications where an oil cooler is not used.
DESUPERHEATING VALVE SIZING WITHOUT OIL COOLER
* Operation with Evap. condensers below -25°F (-32°C) SST
may not require any additional desuperheating. Contact Carlyle
Application Engineering for limits.
**Operation with Evap. condensers above +10°F (-12°C) SST
may not require any additional desuperheating. Contact Carlyle
Application Engineering for limits.
NOTE: A valve with a 190°F(88°C) temperature setting is
required. Alternate desuperheating valve sizing or manufactur-
ers must be approved by Carlyle Application Engineering.
Compressor
Model
R-448A, R-449A, R-404A &
R-507 R-22 R-134a
Low Temp. Med Temp. Low Temp. Med/High
Temp. Medium Temp. High Temp.
Low Temp.
SCT Range 90°F to 120°F
(32°C to 49°C)
70°F to 120°F
(21°C to
49°C)
70°F to 150°F
(21°C to 65°C)
70°F to 150°F
(21°C to 65°C)
06TRC033 EA02ZD001* EA02ZD030
Not Required Not Required
06TRD039 EA02ZD002* EA02ZD050
06TRD044 EA02ZD002* EA02ZD050
06TRE048 EA02ZD030* EA02ZD050
06TRE054 EA02ZD050* EA02ZD050
06TRF065 EA02ZD050* EA02ZD100
06TRG078 EA02ZD050* EA02ZD100
06TRH088 EA02ZD050* EA02ZD100
06TRK108 EA02ZD050* EA02ZD100
Med Temp/High Temp
SCT Range 70°F to 130°F
(21°C to 34°C)
70°F to 130°F
(21°C to 54°C)
06TAD033
Not Required
EA02ZD030**
Not Required Not Required
06TAE039 EA02ZD050**
06TAF044 EA02ZD050**
06TAF048 EA02ZD050**
06TAG054 EA02ZD050**
06TAG065 EA02ZD100**
06TAH078 EA02ZD100**
06TAK088 EA02ZD100**

11
*Maximum Number of Compressors Based on Oil Cooler Pressure Drop of Less Than 6 PSID (.41 bar)
3.8 Oil Cooler Selection
Oil coolers are required for 06T compressors where the oil
temperature can exceed 190°F (88°C) and for 05T com-
pressors where it can exceed 180°F (82°C). The CARWIN
selection software should be used to determine operating
conditions where this will occur. For initial reference, the op-
erating envelopes in Section 2.1 may be used as an initial
reference.
The oil cooler should be sized based on an oil flow rate of
approximately 2 gallons per minute (7.6 liters/minute) per
compressor. However, it should be noted that the actual oil
flow rate will vary based on the specific operating condition.
Oil cooler loads may be obtained from the CARWIN selec-
tion software. With an oil cooler, the maximum oil tempera-
ture leaving the oil cooler is 170°F (77°C). Systems using
external oil coolers also require controls that prevent the oil
temperature from dropping below 80°F (27°C).
Acceptable means of control are fan cycling or oil cooler by-
pass or mixing valves. Mixing valves are recommended for
any oil coolers that are integrated into the system condens-
er coil. For direct expansion oil coolers rejecting heat into
the refrigeration circuit caution must be taken to ensure that
the return gas temperature is within operating guidelines.
3.9 Oil Filter
Carlyle screw compressors are designed with rolling ele-
ment bearings to provide exceptional life. Oil to the bearings
must pass through a 3 micron filter which is required on all
Carlyle screw compressor systems.
NOTE: Use of the Carlyle 3 micron filter element is required.
Use of a non-Carlyle- approved filter element will void com-
pressor warranty. The use of a second redundant filter in
parallel is recommended to allow for servicing of one filter
while the other maintains the operability of the equipment.
If more than five compressors are fed by the oil system,
three parallel oil filter elements (2 for operation, 1 for redun-
dancy) should be used to avoid excessive pressure drop
through the filter elements. The oil filter should be located
downstream from any oil coolers, as close to the compres-
sors as possible.
Oil Filter Pressure Drop Protection:
LonCEM protection
— or —
Carlyle recommends maximum allowable pressure drop
across the oil filters of 45psid (3bar). Compressors should
be shutdown above this limit. Carlyle also recommends an
alert (shutdown not required) when the pressure drop rises
above 25psid (~1.5bar).
3.10 Oil Sump Heaters
The heater must be energized during the system off cycle if
used. This is required in all air conditioning systems and is
recommended in refrigeration systems to keep refrigerant
out of the oil sump during compressor off cycles. Carlyle
typically recommends flexible heaters that are applied on
the outside of the oil separator shells. Carlyle recommends
500W heaters for shells 12 inches and smaller and 100W
for heaters larger than 12 inches. Direct immersion heaters
may also be used. Carlyle advises caution with these im-
mersion heaters, localized temperatures surrounding the
heater element should not create issues with the lubricant.
3.11 Oil Sight Glass
A sightglass is required in the main oil line. The sightglass
must be located after the oil filters and just prior to the first
compressor on a multiple compressor rack. To aid service
personnel in verifying oil flow to any given compressor
Carlyle recommends a sightglass be placed in each branch
oil line between the compressor and its oil solenoid.
Oil Cooling Capacity kBtu/hr kW/hr
Fan Speed 60Hz 50Hz
Ambient Air Temperature 95°F 100°F 105°F 110°F 35°C 38°C 41°C 43°C
KH51ZZ181 Maximum 2
compressors 32.1 30.6 29.9 27.6 9.4 9.4 8.4 8.0
KH51ZZ182 Maximum 3
compressors 69.1 65.7 62.4 59.1 18.7 17.8 16.9 16.0
KH51KK183 Maximum 4
compressors 102.6 97.7 92.8 87.9 27.8 26.5 25.2 23.9
KH51KK183 Maximum 5
compressors 134.1 127.7 121.3 114.9 26.2 34.4 32.7 30.1

12
3.12 Oil System Schematics
OIL SYSTEM SCHEMATIC
3.13 Oil Line Manifold Selection Table
OIL MANIFOLD FOR PRESSURE DROP (FOR POE100 OILS)
LEGEND
* If 170 POE oil is used, Carlyle recommends use of the next
larger size copper line if pressure drop is greater than 5.0 psi.
This will typically reduce pressure drop to 30% of value shown.
NOTES:
1. Viscosity of 10 cSt is based on 130°F (54°C) oil with
10% refrigerant dilution.
2. Viscosity of 45 cSt is based on 130°F (54°C) oil, no
refrigerant dilution or 80°F (27°C) oil with 10% refrig-
erant dilution.
3. Viscosity of 100 cSt is based on 100°F (38°C) oil, no
refrigerant dilution.
4. Viscosity of 170 cSt is based on 100°F (38°C) oil,
with no refrigerant dilution.
Number of
Compressors Flow Rate Manifold Size at 10 cSt at 45 cSt at 100 cSt at 170 cSt
English Pressure Drop (psi) per 10 feet of manifold
12 gpm 7/80.17 0.77 1.72 2.92
24 gpm 7/80.34 1.54 3.43 5.83*
36 gpm 7/80.52 2.31 5.15* 8.76*
48 gpm 1-1/80.22 0.97 2.16 3.67
510 gpm 1-1/80.27 1.21 2.69 4.58
Metric Pressure Drop (kPa) per 1 meter of manifold
17.6 l/min 7/80.38 1.74 3.89 6.60
215.2 l/min 7/80.77 3.48 7.76 13.19*
322.8 l/min 7/81.18 5.23 11.6*5 19.81*
430.4 l/min 1-1/80.50 2.19 4.89 8.30
538.0 l/min 1-1/80.61 2.74 6.08 10.36
Hand Valve Oil Filter Hand Valve
PP
Oil Cooler
Solenoid
Valve
Mixing
Valve
Solenoid
Valve
Oil Man ifold
Sightglass Sightglass
Oi l
Separator
& Su mp
Discharge Header
Oil
Heater
Level
Switch
Discharge Gas
to Condenser
Sightglass
cSt — Centistokes

13
4.1 Suction and Interstage Piping
The suction and interstage manifolds should be piped in
such a way that liquid cannot gravity drain into any compres-
sor. Carlyle recommends that the manifold be located below
the compressor body. An inverted trap must be used com-
ing off the top of the suction header if it is above the com-
pressor body.
Steel refrigerant piping is not recommended for use with
05T/06T screw compressor applications. The contaminants
associated with the steel pipe will overload the 3 micron fil-
ters used in the oil system increasing the chances of oil re-
lated compressor failures.
SUCTION AND INTERSTAGE HEADER SCHEMATIC
(HEADER LOCATED ABOVE COMPRESSOR INLET)
NOTE: If suction or interstage piping is to be located above the compressor the recommendations in the figure below also
apply.
SUCTION AND INTERSTAGE HEADER SCHEMATIC
(HEADER LOCATED BELOW COMPRESSOR INLET)
Mechanical subcooling via interstage manifolds are com-
monly applied with parallel 05T/06T rack designs. The gas
exiting the subcooler is used to provide additional motor
cooling in 06T models. This design reduces the amount of
liquid injection required for motor cooling. The manifold acts
to efficiently distribute refrigerant gas to each compressor.
Interstage headers should be designed similar to suction
line manifolds.
45°
1/8"gap
(3mm)
4.0 Refrigerant Management System

14
INTERSTAGE SCHEMATIC WITH INJECTION TO MOTOR AND ROTORS
A normally closed solenoid valve is required in the inter-
stage line feeding each compressor on a parallel rack. This
valve is required to eliminate interstage to suction pressure
leak back during the off cycle of any compressor. This valve
must open only when the compressor is in operation.
Check valves are also required in the interstage line feeding
each compressor on a parallel rack as shown. The check
valve must be located upstream of the motor cooling valve
for each compressor and downstream of the solenoid valve.
Compressors operating with different saturated suction tem-
peratures can have a significant difference in interstage
pressure. Separate subcoolers are recommended for each
suction temperature group.
Solenoid
Valve
Liqui d Line
from Condenser
Chec k
Valve
Isolaon
Valve
EXV Mechanical
Subcooler
Li qui d Line
To Ev aporat or
Solenoid
Valve
Chec k
Valve
Isolaon
Valve
LRI LRI
Liquid Injecon
to Rotors
Liqui d Injecon
to Rotors
Interstage Header
Motor Cooling
Injecon Valve
Motor Cooling
Injecon Valve

15
5.1Thermal Protection
The compressor motor windings are protected from ex-
treme temperatures by the LonCEM module. All compres-
sors are supplied with two 5K NTC (Negative Thermal Coef-
ficient) thermistors in the motor windings. The module will
limit the maximum motor temperature to 240°F (116°C) and
is an automatic reset device. Only one 5K sensor is used;
the other is a spare. The temperature vs. resistance charac-
teristics of the thermistors are shown below.
TEMPERATURE VS. RESISTANCE TABLE
TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE
°C°F OHMS °C°F OHMS °C°F OHMS °C°F OHMS
032.0 16,352.4 38 100.4 886.9 76 168.8 715.93 114 237.2 228.38
133.8 15,515.2 39 102.2 2,772.1 77 170.6 692.68 115 239.0 222.24
235.6 14,750.0 40 104.0 2,662.4 78 172.4 670.34 116 240.8 216.29
337.4 14,027.1 41 105.8 2,557.8 79 174.2 648.82 117 242.6 210.53
439.2 13,343.8 42 107.6 2,457.7 80 176.0 628.09 118 244.4 204.95
541.0 12,697.8 43 109.4 2,362.1 81 177.8 608.11 119 246.2 199.54
642.8 12,086.3 44 111.2 2,270.8 82 179.6 588.88 120 248.0 194.3
744.6 11,508.0 45 113.0 2,183.45 83 181.4 570.36 121 249.8 189.22
846.4 10,960.8 46 114.8 2,099.93 84 183.2 552.5 122 251.6 184.3
948.2 10,442.6 47 116.6 2,020.04 85 185.0 535.29 123 253.4 178.5
10 50.0 9,951.8 48 118.4 1,943.6 86 186..8 518.7 124 255.2 174.89
11 51.8 9,486.8 49 120.2 1,870.5 87 188.6 502.7 125 257.0 170.41
12 53.6 9,046.3 50 122.0 1,800.49 88 190.4 487.28 126 258.8 166.06
13 55.4 8,628.7 51 123.8 1,733.46 89 192.2 474.4 127 260.6 161.83
14 57.2 8,232.5 52 125.6 1,669.66 90 194.0 458.06 128 262.4 157.74
15 59.0 7,857.0 53 127.4 1,607.81 91 195.8 444.2 129 266.0 153.77
16 60.8 7,500.6 54 129.2 1,548.95 92 197.6 430.85 130 267.8 149.91
17 62.6 7,126.3 55 131.0 1,492.54 93 199.4 417.96 131 269.6 146.17
18 64.4 6,841.3 56 132.8 1,438.46 94 201.2 405.51 132 271.4 142.54
19 66.2 6,526.4 57 134.6 1,386.62 95 203.0 393.49 133 273.2 139.02
20 68.0 6,526.8 58 136.4 1,336.93 96 204.8 381.89 134 275.0 136.6
21 69.8 5,971.6 59 138.2 1,289.26 97 206.6 370.69 135 276.8 132.27
22 71.6 5,710.0 60 140.0 1,243.53 98 208.4 359.87 136 278.6 129.04
23 73.4 5,461.3 61 141.8 1,199.7 99 210.2 349.41 137 280.4 125.91
24 75.2 5,225.0 62 143.6 1,157.59 100 212.0 339.32 138 285.8 122.87
25 77.0 5,000.0 63 145.4 1,117.18 101 213.8 329.55 139 287.6 119.91
26 78.8 4,786.0 64 147.2 1,078.37 102 215.6 320.12 140 289.4 117.04
27 80.6 4,582.4 65 149.0 1,041.15 103 217.4 311.0 141 281.2 114.25
28 82.4 4,338.5 66 150.8 1,005.38 104 219.2 302.18 142 287.6 111.54
29 84.2 4,203.9 67 152.6 971.03 105 221.0 293.65 143 289.4 108.9
30 86.0 4,028.0 68 154.4 938.02 106 222.8 285.41 144 291.2 106.34
31 87.8 3,860.5 69 156.2 906.3 107 224.6 277.43 145 293.0 103.86
32 89.6 3,700.8 70 158.0 875.81 108 226.4 269.72 146 294.8 101.43
33 91.4 3,548.5 71 159.8 846.5 109 228.2 262.26 147 296.6 99.074
34 93.2 3,403.5 72 161.6 818.31 110 230.0 255.03 148 298.4 95.785
35 95.0 3,265.1 73 163.4 791.21 111 231.8 248.04 149 300.2 94.559
36 96.8 3,133.1 74 165.2 765.14 112 233.6 241.28 150 302.0 92.393
37 98.6 3,007.1 75 167.0 740.06 113 235.4 234.72
5.0 Electrical Protection

16
5.2 Overcurrent Protection
06T screw compressors must be protected with a three-
phase manual-reset type of overcurrent protection.
The code agency certifications of the 06T compressor is
contingent upon the use of appropriate overcurrent protec-
tion. Properly selected overcurrent devices protect the com-
pressors against running overcurrent, locked rotor, as well
as primary and secondary single phasing faults.
Overcurrent protection must comply with the following:
•Manual Reset
•The device must trip at or below the maximum MCC
listed for the compressor. Settable devices may re-
quire settings that differ from the maximum allowed
current. Consult the manufacturer's documentation
for proper setting of these devices.
•To minimize nuisance tripping risks, the maximum ra-
tio between the must trip and must hold values can-
not be larger than 1.15
•Locked Rotor Trip Timing:
a. Across-the-Line Start: Device must trip in 2 to 6
seconds
b. Part Wind Start: Device must trip the first three con-
nected legs in 2 to 6 seconds and the remaining
three connected legs in 1 to 3 seconds
The 06T compressor motor may be protected using a rec-
ognized variable speed drive that meets these compressor
protection requirements. The system designer is responsi-
ble to program these requirements appropriately.
For part wind start applications Carlyle recommends a 1 to
1.25 second time delay between energizing the first and
second legs.
If the end user is not intending on using the full published
operating envelope; the overcurrent protection can be sized
to trip at lower values than the maximum MCC.
5.3 Allowable Voltage Range
The allowable voltage variation at the compressor terminals
for the 06T screw compressors is shown in the table below.
Model #
Digit 9 Nominal Voltage Voltage Range
Min Max
B460-3-60 396 528
400-3-50 342 456
C575-3-60 495 660
F208/230-3-60 187 264
200-3-50 180 230
06TR LOW TEMP COMPRESSORS 06TA MED/HIGH TEMP COMPRESSORS
COMPRESSOR
MODEL HP
MAXIMUM
CONTINUOUS
CURRENT
LOCKED
ROTOR
CURRENT
VOLTAGE COMPRESSOR
MODEL HP
MAXIMUM
CONTINUOUS
CURRENT
LOCKED
ROTOR
CURRENT
06TRC033F2EA 15 90 286
208/230V-3-
60Hz
200V-3-50Hz
06TAD033F2EA 20 104 348
06TRD039F2EA 20 104 348 06TAE038F2EA 25 128 433
06TRD044F2EA 20 104 348 06TAF044F2EA 30 163 510
06TRE048F2EA 25 128 433 06TAF048F2EA 30 163 510
06TRE054F2EA 25 128 433 06TAG054F2EA 35 182 610
06TRF065F2EA 30 154 611 06TAG065F2EA 35 181 721
06TRG078F2EA 35 181 721 06TAH078F2EA 40 203 825
06TRH088F2EA 40 203 825 06TAK088F2EA 50 230 974
06TRC033B2EA 15 46 142
460V-3-60Hz
400V-3-50Hz
06TAD033B2EA 20 49 173
06TRD039B2EA 20 49 173 06TAE038B2EA 25 64 215
06TRD044B2EA 20 49 173 06TAF044B2EA 30 76 253
06TRE048B2EA 25 64 215 06TAF048B2EA 30 76 253
06TRE054B2EA 25 64 215 06TAG054B2EA 35 88 305
06TRF065B2EA 30 76 253 06TAG065B2EA 35 89 323
06TRG078B2EA35 89 323 06TAH078B2EA 40 101 370
06TRH088B2EA 40 101 370 06TAK088B2EA 50 114 440
06TRK108B2EA 50 114 440 —— — —
06TRC033C2EA 15 33.5 114
575V-3-60Hz
06TAD033C2EA 20 39 138
06TRD039C2EA 20 39 138 06TAE038C2EA 25 53 172
06TRD044C2EA 20 39 138 06TAF044C2EA 30 62 202
06TRE048C2EA 25 53 172 06TAF048C2EA 30 62 202
06TRE054C2EA 25 53 172 06TAG054C2EA 35 78 242
06TRF065C2EA 30 62 219 06TAG065C2EA 35 72 258
06TRG078C2EA 35 72 258 06TAH078C2EA 40 81 296
06TRH088C2EA 40 81 296 06TAK088C2EA 50 92 351

17
6.1 Motor Cooling Control
The motors in the 06T compressors are not located in the
suction gas stream like other compressors. These motors
require cooling to maintain reliable operation. Motor barrel
insulation is recommended on compressors with suction
temperatures below -15°F (-26°C) to prevent frost build-up
on the compressor motor barrel.
All motors must have a steady flow of cooling while in oper-
ation to avoid thermal shock to the motor. There are two
methods for providing this cooling; economizer flow from the
mechanical subcooler or liquid injection directly into the mo-
tor barrel.
When using economizer flow, the superheat leaving the me-
chanical subcooler should be set in the range of 10 to 20°F
(6 to 11°C) superheat above saturated intermediate tem-
perature. For parallel applications, an intermediate header is
required to distribute economizer gas to each compressor.
A solenoid valve is required to isolate each compressor
from this intermediate header when the compressor is not
operating. This solenoid valve can be controlled with the
LonCEM module.
When using only liquid injection, the 1-ton liquid injection
valve (part # EF28BZ001) must feed liquid refrigerant to the
compressor motor at any time the compressor is in opera-
tion.
For both economizer gas cooling and liquid injection, the
motor may require additional cooling when operating under
high loads. A supplemental liquid injection valve (part #
EF28BZ007) should be installed to provide this additional
cooling. This supplement valve can be controlled with the
LonCEM module.
Isolaon
Valve
Isolaon
Valve
LRI LRI
Liquid Injecon
to Rotors
Liqui d Injecon
to Rotors
Primary
Motor Cooling
Injecon Valve
Supplemental
Motor Cooling
Injecon Valve
Primary
Moto r Cooli ng
Injecon Valve
Supplemental
Motor Cooling
Injecon Valve
Liquid Line
from Condenser
Liquid Line
To Evaporator
6.0 Motor Temperature Control

7.0 Compressor Selections and Performance Data
7.1 CARWIN Compressor
Selection Software
The performance of the 06T/05T screw compressors can
be estimated using the CARWIN compressor selection tool.
CARWIN is a web-based application available at
https://carwin.carlylecompressor.com
7.2 Subcooler Selection
The use of mechanical subcoolers are recommended to in-
crease both the capacity and operating efficiency of the
compressors. Subcooler loads can also be estimated using
CARWIN.
Carlyle recommends sizing and piping the subcooler for
parallel flow. Parallel flow through the subcooler results in
better control of the subcooler by reducing TXV hunting.

19
NOTES:

CARLYLE COMPRESSOR • © CARRIER CORPORATION 05/2021
P.O. Box 4808 • Syracuse, New York 13221
www.carlylecompressor.com
In U.S. and Puerto Rico: 1-800-GO-CARLYLE (1-800-462-2759)
In Canada: 1-800-258-1123
In Mexico: 001-800-GO-CARLYLE (001-800-462-2759)
Manufacturer reserves the right to discontinue, or change
at any time, specifications or designs and prices without
notice and without incurring obligations.
Lit. No. 574-030
(Rev. G 5/21)
NOTES: