oer One
tioning 8
у © Division of
Carrier Corporation
Carrier Parkway ® Syracuse NY 13221
Capacity Control Accessory Package
Hot Gas Bypass Type Unloader
Lt CC LC CCAA a ee ee Te a a a a ee eT AAA AA AA ACA ADC
GENERAL
These instructions apply to field installation of
hot gas bypass type unloaders on 06D compressors.
The instructions include package descriptions,
parts lists, step-by-step installation procedures,
control valve setting and adjustment procedures
and an illustrated description of the capacity
control operation.
Pumpdown control is not recommended for
compressors equipped with capacity control.
Crankcase heaters and single pumpout should be
used.
Table 1 — Package Description
PACKAGE VOLTS CONTROL
NUMBER (1-Phase,
50/60 Hz) Type Function
06DA900082 115 Elec | Provides unloading to
06DA900092 208/240 a nonloading cylinder
38AB900171 — Press bank
OGEA900282 208/240 Elec Converts from pressure
OGEA 900292 120 to electric unloading
Table 2 — Parts Lists
PACKAGE NO. O6DA 900082, O6GDA 900092, 38AB900171 .
ITEM DESCRIPTION 1 QTY
1 Capacity control cylinder head complete
i w/control valve (see NOTE) 1
Cap screws 8
2 Valve plate assembly w/check valves and
discharge valves 1
3 Suction valves 2
4 Suction valve springs 2
5 Valve plate gasket 1
6 Cylinder head gasket 1
7 Solenoid coil (Pkg No 06DA900082 and 92) | 1
NOTE: For pressure operated valve, control assembly is complete;
for electric operated valve, solenoid coil (item 7) is loose in package
PACKAGE NO. 06EA900282, 06EA 900292
ITEM DESCRIPTION QTY
1 Solenoid coil and valve assembly . 1
O Carrier Corporation 1981
INSTALLATION
Receive Package — Check package for damage and
missing parts. If any items are damaged or missing
in shipment, file claim immediately with shipping
company.
Complete Head Assembly Replacement — Pressure
and Electric
|. Install discharge and suction pressure service
gages.
2. Start compressor and allow it to run until warm.
Then frontseat suction shut-off valve and let
compressor pump down to approximately 2 psig.
3. Stop compressor and quickly frontseat discharge
shut-off valve. Bleed off remaining refrigerant
from discharge side of compressor.
4. Remove cylinder head holddown screws.
5. Tap cylinder head with wooden or lead mallet
to free gasket.
Г. on Po EE
Xe
Fa
oe а
uo e
npg ee e
o 3 ce se ce
ARSE Dee, NA
6. Free valve plate from dowel pins and cylinder
deck, using discharge valve cap screws. Thread
screws Into tapped holes in valve plate to act
as jack screws.
7, Remove suction valves from dowel pins.
8. Install new suction valves. Be sure that valve
positioning springs have already been placed
over dowel pins. Place springs with ends against
cylinder deck (centers bow upward).
9. Install in order: valve plate gasket, valve plate
assembly, cylinder head gasket and cylinder head.
Before installing valve plate assembly, apply
compressor oil to check valve piston (Fig. 5) and
manually operate check valve several times to be
sure it does not stick or bind.
With valve plate mounted, manually flex the
suction valves to be sure there is no interference
with valve plate gasket. Install cylinder head,
using the long cap screws furnished in accessory
Package {item >.
Installation of pressure operated я valve 1 is now
complete. For electrically operated valve, con-
tinue the installation as follows:
Form 060-151
. . ifn ‘ ‘
10. Place solenoid coil over valve stem and secure
with snap-on retainer.
11. Make necessary wiring connections. When
solenoid coil is energized, cylinder bank
unloads; when coil is de-energized, cylinder
bank loads.
12. Check solenoid valve for proper operation. An
audible click can be heard when valve actuates.
13. Open compressor service valves. Start compres-
sor and allow it to warm up. Operate solenoid
valve several times to be sure it is performing
properly. Suction pressure should rise and
discharge pressure should fall when valve is
energized.
A
DEN a LCL
LA E A
SRE 8 SOLENCIO COL.
Ps e
ee ww ктала он
a a EL
Cet Tt eT NS
GASKET _ S48
12 1 1 SCENE
ata aa
-— CCAA
LPO
+" AC ACACIA
tata taa
“a CI
A PERE aa
Lar Nr
Le Vel ea ae = 2 RCE
NENA
BON
CAPACITY
CONTROL.
VALVE SCDY -
Fig. 1 — 06D Electric Capacity Control Valve
Conversion from Pressure to Electric Unloading
|. Follow Steps 1,2 and 3 under Complete Head
Assembly Replacement.
2. Remove 3 cap screws and remove the pressure
operated control valve.
3. Remove solenoid coil from electric control valve
to gain easier access to hold-down screws.
4. Remove plastic protector from piston. Check
the ring groove — it must be perfectly clean and
free from nicks
5. Gasket (already on valve) must be positioned
correctly on flange.
Align the 2 gasket holes opposite the tab with
2 holes in flange. The elongated gasket hole at
the tab (Fig. 1) should now be over the 3rd
flange hole, which is offset to ensure proper
orientation of valve on cylinder head. Proper
gasket position ensures unobstructed pressure
passages between capacity control valve and
head.
ut
6. Wipe the head cavity walls clean and apply thin
film of compressor oil. Carefully compress
bypass piston ring (Fig. 2) and insert piston into
head cavity. Be sure gasket does not shift. Tab
must be outward as shown in Fig. 1
7. Using the 3 cap screws and washers supplied,
secure control valve body to head. Torque cap
screws to 14 - 16 Ib-ft.
8. Follow Steps 10 thru 13 of Complete Head
Assembly Replacement. Conversion is now
complete.
CONTROL
SET POINT
ADJUSTMENT
| NUT
a LOWER
PRESSURE e HEAD
DIFFERENTIAL Recs
ADJUSTMENT =
go N VALVE BODY
PISTN RING:
TD
BE
BYPASS a
PISTON E
Dr — ORY WY
Mage
La ИА NC NONE
Lea NA
ANSE Ye,
A
' O. Es
- L ль м к] в
ces . a Ls Le
aa KA la. LT
- “ae TT
Te
na
DIFFERENTIAL SCREW
SEALING CAP
(CAP MUST BE REPLACED
TO PREVENT REFRIGERANT LEAKAGE)
Fig. 2 — Pressure Operated Capacity Control Valve
CONTROLS AND VALVE SETTING —
ELECTRIC UNLOADER
Controls for solenoid valve operation must be
field furnished. They may be either temperature
or pressure operated. Valve setting is made on
field-furnished control in accordance with job
requirements.
VALVE SETTINGS — PRESSURE UNLOADER
Valve Adjustment Range — The control set point
(cylinder load point) is adjustable from O psig to
85 psig. The pressure differential between the
cylinder load point and cylinder unload point is
adjustable from 6 psi to 22 psi. Refer to Fig. 3
and 4.
To Regulate Control Set Point — First turn the
adjustment nut (Fig. 2) clockwise to its bottom
stop. In this position, set point is 85 psig.
Now regulate to desired pressure by turning
adjustment nut counterclockwise. Each full turn
decreases set point by 7.5 psig (Fig. 3). Approx-
imately 11% turns counterclockwise will decrease
control set point to 0 psig.
мы 1 7
To Adjust Pressure Differential — Turn differential screw clockwise. Each full turn increases differ-
adjusting screw (Fig. 2) counterclockwise to its ential by 1.6 psi (Fig. 4). Approximately 10 turns
back-stop position. Differential is now 6 psi. clockwise will increase pressure differential to
Now adjust to desired differential by turning 22 psi.
LOAD-UP PRESSURE -PSIG
90
80
70
60
50
40
20
| 2 3 4 5 6 7 8 9 10 li 12
TURNS QUT FROM BOTTOM STOP- COUNTERCLOCKWISE
Fig. 3 — Control Set Point
7
V4 A
у.
A
PA
EI
A
- a. | Ч ВЕ
|| FORWARD STOP
LOAD -UNLOAD DIFFERENTIAL — PSI
20 frien A ! | + JA
O | 2 3 4 5 6 7 8 9 10
TURNS IN FROM BACKSTOP — CLOCKWISE
Fig. 4 — Differential Set Point
CAPACITY CONTROL VALVE OPERATION
NOTE: When electric unloader solenoid is ener-
gized, compressor cylinder bank unloads; when
solenoid is de-energized, cylinder bank loads up.
Loaded Operation — When suction pressure is
above control set point, bleed orifice poppet valve
(Fig. 5) closes. Discharge gas bleeds into valve
chamber, pressure closes bypass piston and
cylinder bank loads up. Discharge gas pressure
I
forces check valve open, allowing gas to enter
discharge manifold.
Unloaded Operation — When suction pressure
drops below control set point differential, poppet
valve opens. Discharge gas bleeds from behind
bypass piston into suction manifold. Bypass piston
opens, discharge gas recirculates back to suction
manifold and cylinder bank unloads. Reduction in
discharge pressure allows check valve to close,
isolating cylinder bank from discharge manifold.
BYPASS
PISTON
PRESSURE DIFFERENTIAL
SEALING
ADJUSTMENT SCREW CAP
CYLINDER
H
EAD
\ rN JT 1
a ALI
= na a Eu ds Е
E a i
о | : —— BYPASS PASSAGE
E DI НН
a
eos ATTE а 8 vo
CONTROL SET css 3 COMMUNICATES WITH
POINT ADJ NUT "e E. Z SUCTION MANIFOLD
Fora EN у,
BLEED ORIFICE “Tu à
POPPET VALVE a SUCTION MANIFOLD
DISCHARGE rors — > LAR
CHECK DISCHARGE SUCTION
VALVE VALVE PISTON VALVE
al SUCTION PRESSURE
EJ DISCHARGE PRESSURE LOADED OPERATION
CYLINDER
HEAD
SEALING BYPASS
CAP PISTON
PRESSURE DIFFERENTIAL
ADJUSTMENT SCREW
— BYPASS PASSAGE
CONTROL. SET
POINT ADJ NUT
BLEED ORIFICE
POPPET VALVE
COMMUNICATES WITH
SUCTION MANIFOLD
SUCTION MANIFOLD
DISCHARGE MANIFOLD
piston SUSTION
DISCHARGE
VALVE
UNLOADED OPERATION
CHECK
A
Fes] SUCTION PRESSURE VALVE
___1 DISCHARGE PRESSURE
Fig. 5 — Capacity Control Valve Operation
(Pressure-Type Hot Gas Bypass Unloader Shown)
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Book:2 |4
Tab |2a|3a
Form 06D-1S1 Supersedes 06D,E-3SI Printed in US A 8-81 PC 111 Catalog No 530—632
">
