Carrier 06D, 07D Compressors and Condensing Units Service Instructions
Iklan
Iklan
06D,07D
Compressors and Condensing Units
Installation, Start-Up and
Service Instructions
Hermetic, Water-Cooled
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . 1
BEFORE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 1
Check Shipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Unit Location Considerations . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Refrigerant Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
INITIAL START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
To Start Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CHECKING OPERATION. . . . . . . . . . . . . . . . . . . . . . . . .8,9
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High-Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low-Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Time Guard® Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CAPACITY CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . .9,10
Control Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
To Regulate Control Set Point . . . . . . . . . . . . . . . . . . . . 9
Pressure Differential Adjustment. . . . . . . . . . . . . . . . . 9
Capacity Control Pressure . . . . . . . . . . . . . . . . . . . . . . 10
CONDENSER MAINTENANCE . . . . . . . . . . . . . . . . .10,11
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-17
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Testing Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cylinder Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Service Replacement Compressors . . . . . . . . . . . . . 14
Suction and Discharge Valve Plate Assembly . . . 15
Cleaning Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . 16
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Terminal Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . 16
Compressor Running Gear Removal . . . . . . . . . . . . 16
Compressor Running Gear Replacement. . . . . . . . 17
COMPRESSOR MOTOR BURNOUT . . . . . . . . . . . . . . 17
Clean-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . .18,19
SAFETY CONSIDERATIONS
Installing, starting up and servicing this equipment can be hazardous due to system pressures, electrical components and equipment location (roofs, elevated structures, etc.). Only trained, qualified installers and service mechanics should install, start up and service this equipment.
When working on the equipment, observe precautions in the literature, tags, stickers and labels attached to the equipment and any other safety precautions that apply. Follow all safety codes. Wear safety glasses and work gloves. Use care in handling, rigging and setting bulky equipment.
Electrical shock can cause personal injury and even death.
Be sure power to equipment is shut off before installing or servicing this equipment. There may be more than one disconnect. Tag disconnect(s) to alert others not to turn power on until work is completed.
BEFORE INSTALLATION
Check Shipment —
File claim with shipping company if shipment is damaged or incomplete.
Unit Location Considerations —
Locate unit on floor in a well-ventilated area. Position unit to allow sufficient space for refrigerant and water connections and to service compressor. Place unit so suction and discharge valves can be easily reached and oil level checked. Do not install condensing unit where temperature will fall below freezing.
Local water can cause excessive fouling or sealing of condenser tubes. If such conditions are anticipated, a water treatment analysis is recommended. Refer to Carrier System
Design Manual, Part 5, for general water conditioning information.
Make provision in piping layout to drain and vent condenser if system is to be shut down in winter.
INSTALLATION
Mount Unit —
Level unit and bolt firmly to foundation.
Loosen compressor mounting bolts and remove shipping blocks from under compressor. Tighten all 4 bolts on compressor. Next, loosen each bolt until the flanged washer can be moved sideways with finger pressure.
NOTE: Be sure that compressor floats freely on mounting springs.
Piping Connections —
Attach water supply and return lines to connections indicated on condenser unit (Fig. 1). Water leaving condenser should not be connected directly into sewer lines. Check local codes.
Attach refrigerant liquid and suction lines to condensing units (Fig. 1); suction and discharge to compressor unit
(Fig. 2). When soldering or brazing piping to valves, disassemble valve or wrap it in a wet cloth to prevent heat damage.
Allow flexibility in suction line so compressor suction valve may be moved aside for access to suction strainer.
Book 2
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
2 4 4 PC 802 Catalog No. 530-608 Printed in U.S.A.
Form 06/07D-3SI Pg 1 802 7-02 Replaces: 06/07D-2SI
Tab 1b 2a 2b 3a
UNIT 07D
A203
B205
A208
B210
B212
B215
DIMENSIONS (in.)
WIDTH A
30
30
39 9 /
16
51 9 /
16
51 9 /
16
63 13 /
16
NOTES:
1. For standard service practices, such as troubleshooting and refrigerant charging, allow a minimum
2
′-6″ clearance around the unit.
2. Recommended service space for condenser tube removal is one condenser length at either end.
3. For compressor removal, allow a minimum 3
′ wide access aisle to and from the unit.
4. Local codes or jurisdiction may prevail for unit clearances.
WATER CONNECTIONS FOR 07DB215 UNIT ONLY.
Fig. 1 — 07D Condensing Unit Dimensions
2
NOTES:
1. For standard service practices, such as troubleshooting and refrigerant charging, allow a minimum
2
′-6″ clearance around the unit.
2. For compressor removal, allow a minimum 3
′ wide access aisle to and from the unit.
3. Local codes or jurisdiction may prevail for unit clearances.
Fig. 2 — 06D Compressor Unit Dimensions
3
Install a solenoid valve (field supplied) in liquid line directly before expansion valve. Solenoid valve is necessary for single pumpout control used on 06D, 07D units. Refrigerant filter drier and moisture indicator are shipped with 07D condensing units for field installation. Install in liquid line according to manufacturer’s instructions.
Relief valve located on top of condenser (07D units) will open to relieve excessive pressure, allowing refrigerant to escape. Most local codes require piping from safety device to outdoors.
Refer to Carrier System Design Manual, Part 3, for standard piping techniques.
COMPRESSOR UNITS — Connect high- and low-pressure switch capillary tubes from control box to compressor. See
Fig. 2.
Install discharge line muffler (accessory) in discharge line as close to compressor shutoff valve as possible.
Electrical Connections
UNBALANCED 3-PHASE SUPPLY VOLTAGE — Never operate a motor where a phase imbalance in supply voltage
is greater than 2%. Use the following formula to determine the % voltage imbalance:
% Voltage Imbalance =
100 x max voltage deviation from average voltage average voltage
Example: Supply voltage is 230-3-60
AB = 236 volts
BC = 229 volts
AC = 234 volts
Determine maximum deviation from average voltage:
(AB) 236 – 233 = 3 volts
(BC) 233 – 229 = 4 volts
(AC) 234 – 233 = 1 volt
Maximum deviation is 4 volts. Determine % voltage imbalance:
% Voltage Imbalance =100 x
4
233
= 1.7%
This amount of phase imbalance is satisfactory as it is below the maximum allowable of 2%.
IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.
ELECTRICAL DATA NOTES
1. All 06D and 07D units are across-the-line start.
2. Wire sizes are based on TW type copper wire. Maximum wire lengths based on data from Table 1 will result in a
1% voltage drop to compressor. Where up to 3% voltage drop is allowed, the run length can be increased to 3 times the length calculated from data in Table 1.
3. The 06D compressor unit electrical data shown in Table 1 does not apply for 06D compressors used as an integral part of other Carrier equipment. See proper installation book for electrical information.
WIRING — Power supply must correspond with unit nameplate electrical characteristics (units are internally wired at factory for nameplate voltage). Field wiring must comply with local and national codes.
Install a branch circuit fused disconnect of adequate size to handle starting current.
LINE POWER — Connect line power to the compressor contactor C. For example, connect L1 to terminal 11, L2 to terminal 12 and L3 to terminal 13. See Fig. 3.
Average Voltage =
236 + 229 + 234
3
= 233 volts
M
A
COMPRESSOR
PART NUMBER
06D*
808
313
818
825
328
537
VOLTAGE
(3 Ph-60 Hz)
575
208/230
460
575
208/230
460
575
208/230
460
575
208/230
460
575
208/230
460
575
208/230
460
HP
3
5
6.5
7.5
10
15
LEGEND
LRA — Locked Rotor Amps
MCC — Maximum Continuous Current
RLA — Rated Load Amps
*Refer to physical data table to match compressor with correct compressor unit or water-cooled condensing unit.
NOTES:
1. RLA (rated load amps) value shown is: MCC
÷ 1.40 = RLA.
2. For minimum contactor sizing, use RLA value determined by:
MCC
÷ 1.40 = RLA.
Table 1 — Compressor Electrical Data
7
17.4
8.7
10.8
27
13.5
17.6
44
22
22.2
55.5
27.8
25
62
31
32
89
40
MCC RLA
5
12.4
6.2
7.7
19.3
9.6
12.6
31.4
15.7
15.9
39.6
19.8
17.9
44.3
22.1
22.9
63.6
28.6
LRA
28.4
71
35.5
40
100
50
64
160
80
79
198
99
91
228
114
96
266
120
MOTOR WINDING
RESISTANCE
(Ohms)
5.0
0.78
3.1
3.3
0.5
2.1
2.6
0.42
1.7
2.0
0.31
1.3
1.7
0.26
1.0
1.2
0.18
0.72
3. For wiring sizing, the RLA value can be determined by: MCC
÷ 1.56 = RLA.
4. Compressor operating amps at any specific conditions can only be determined from a performance curve.
5. RLA values for 06D compressor protected by a calibrated circuit breaker will depend on must-trip value of circuit breaker.
6. Ohm values shown for resistance are approximate and shown for reference only. Motors from different vendors and motors of different efficiencies can differ up to 15% from data shown.
7. Electrical data for compressor part numbers 06DR and
50 Hz models (not shown) are available from Carrier Sales
Representative.
4
AUX — Auxiliary
C — Compressor Contactor
CH
CR
— Crankcase Heater
— Control Relay
DX — Direct Expansion
EQUIP — Equipment
FU — Fuse
GND — Ground
HPS — High-Pressure Switch
IP — Internal Protector
LLS — Liquid Line Solenoid Valve
LPS — Low-Pressure Switch
M3 — Cooling Tower Fan
NEC — National Electrical Code
OL — Overload
OPS — Oil-Pressure Switch
POR — Pumpout Relay
SW — Start-Stop-Reset Switch
LEGEND
TB — Terminal Block
TM — Timer Motor
TR — Timer Relay
Terminal Block Connector
Unmarked Terminal
Marked Terminal
Factory Wiring
Field Control Wiring
To indicate common potential only; not to represent wiring.
Splice
NOTES:
1. Factory wiring is in compliance with NEC. Any field modifications or additions must be in compliance with all applicable codes. Use copper, copper-clad aluminum for field power supply only.
2. Field power supply wiring must be 75 C minimum.
3. Compressor thermally protected. Three-phase motors are protected against primary single-phasing condition.
4. Pilot duty control must be field supplied. Minimum contact rating must be 25 va.
5. 60 Hz units have 120-volt control circuit. 50 Hz units have
230-volt control circuit. A separate source of supply at the correct voltage must be field supplied through a fused disconnect device with a maximum rating of 15 A to TB2 connections
(Hot Side) and L2 (Neutral).
L1
6. Open control circuit disconnect switch for servicing only. Disconnect must remain closed for crankcase heater to operate.
7. A transformer of the following rating may be field supplied for
60 Hz units: 350 va.
8. Transformer must be fused and grounded per applicable codes.
9. If any of the original wiring furnished must be replaced, it must be replaced with 90 C wire or its equivalent.
Fig. 3 — Unit Label Diagram — 06D,07D Units
5
Compressor Unit Connections — Extend power leads from control center (contactor terminals) to compressor terminal box and make connections as shown in Fig. 4.
Terminals 8 and 9 on motor terminal plate are for internal protector connections. As shown in Fig. 4, run a wire from terminal 9 to terminal 6 on TB2 in control center and a wire from terminal 1 on OL2 to terminal 2 on HPS in control center.
Run crankcase heater power wiring into control center.
Connect leads to terminal 5 on pumpout relay and terminal 3 on terminal block TB2. See Fig. 5.
Affix power warning label supplied in the installer’s packet to fused disconnect which energizes crankcase heater (see unit label diagram).
LEGEND
HPS — High-Pressure Switch
OL — Overload Relay
TB — Terminal Block
Factory Wiring
Fig. 4 — Compressor Terminal Diagram
CONTROL WIRING — Control circuit power is 115 volts, energized from an external source or from unit voltage through field-supplied transformer. Transformer size required is 350 va for 60 Hz units. External control power source must be supplied through a 15-amp fused disconnect. Connect control circuit power leads to terminal block TB2, terminals L1 and
L2. Terminal L2 is neutral potential (ground).
Compressor Protection — The 06D and 07D units are factory wired for single-pumpout control. Field addition and wiring of line voltage remote control and liquid line solenoid valve is required. (See unit Fig. 3 and Fig. 6.) Remote control minimum contact rating must be 25 va. Solenoid valve must have a maximum load rating of 50 va holding; 200 va inrush. For applications with cooling tower, air-cooled or evaporative condensers, add necessary auxiliary contacts in line between compressor contactor and terminal A1 on timer. Insert desired interlocks and overloads between terminals 5 and 9 on terminal block TB2.
Control wiring may be modified as shown in Fig. 6 for
automatic pumpdown control; remove low-pressure switch between timer relay and terminal 4 on TB2. Wire low-pressure switch between terminals 9 and 6 on TB2. Add necessary auxiliary contacts between compressor contactor and terminal
A1 on timer. Remove wire between terminal 6 on TB2 and terminal 3 on pumpout relay. Insert required interlocks and overloads between terminals 5 and 9 on TB2.
Limitations —
Do not use automatic pumpdown control on direct expansion cooler applications or when compressors are equipped with pressure-type unloader valves. Pressure unloader valves have built-in high to low passage which allows compressor to cycle with automatic pumpdown.
LEGEND
C — Contactor, Compressor
CH — Crankcase Heater
CR — Control Relay
FU — Fuse
GND — Ground Connection
HPS — High-Pressure Switch
IP — Internal Protector
LPS — Low-Pressure Switch
NEC — National Electrical Code
OL — Overload Relay
OPS — Oil Pressure Switch
POR — Pumpout Relay
SW — Switch
TB — Terminal Block
TM — Timer Motor
TR — Timer Relay
NOTES:
1. Factory wiring is in compliance with NEC. Any field modifications or additions must be in compliance with all applicable codes. Use copper, copper-clad aluminum for field power supply only.
2. Field power supply wiring must be 75 C minimum.
3. Compressor thermally protected. Three-phase motors are protected against primary single-phasing condition.
4. Pilot duty control must be field supplied. Minimum contact rating must be 25 va.
5. 60 Hz units have 120-volt control circuit. 50 Hz units have 230-volt control circuit. A separate source of supply at the correct voltage must be field supplied thru a fused disconnect device with a max rating of 15 A to TB2 connections L1 (Hot Side) and L2 (Neutral).
6. Open control circuit disconnect switch for servicing only. Disconnect must remain closed for crankcase heater to operate.
7. A transformer of the following rating may be field supplied for 60 Hz units: 350 va.
8. Transformer must be fused and grounded per applicable codes.
9. If any of the original wiring furnished must be replaced, it must be replaced with 90 C wire or its equivalent.
Fig. 5 — 06D/07D Control Box Components and Connections (3-Phase)
6
LEGEND
AUX — Auxiliary
C — Contactor
CR — Control Relay
HPS — High-Pressure Switch
LLS — Liquid Line Solenoid Valve
LPS — Low-Pressure Switch
M3 — Evaporator Fan or Chilled Water Pump
M4 — Cooling Tower Pump, Air-Cooled or
Evaporative Condenser Fan
M5 — Cooling Tower Fan or
Evaporative Condenser Pump
OL — Overload Relay
POR — Pumpout Relay
SW — Switch
TB — Terminal Block
TR — Timer Relay
Factory Wiring
Field Wiring
*Optional.
Fig. 6 — Recommended Field Wiring
7
Refrigerant Charging
When charging, or when removing charge, circulate water through water-cooled condenser(s) and cooler continuously to prevent freezing. Freezing damage is considered abuse and is not covered by Carrier warranty.
EVACUATE, DEHYDRATE AND LEAK TEST — Entire refrigerant system must be evacuated, dehydrated and leak tested by methods described in Carrier Standard Service Techniques
Manual, Chapter 1, Sections 1-6 and 1-7. Use sight glass method to charge system. See Section 1-8 of manual for details.
CHARGE THE SYSTEM — Charge to a clear sight glass while holding saturated condensing pressure constant at 125 F
(air-cooled systems) or 105 F (water-cooled systems). Add additional refrigerant to fill condenser subcooler coils, where applicable, for air-cooled applications.
06D Compressor Units — See condenser data for additional charge required to fill subcooler after clear sight glass is obtained.
INITIAL START-UP
Do not attempt start-up with terminal cover removed.
Bodily injury or death may result from explosion and/or fire if power is supplied to compressor with the terminal cover removed or unsecured. See warning label on terminal cover.
Crankcase heater should be energized a minimum of
24 hours before starting unit. Do not permit crankcase heaters to be deenergized during normal shutdown periods.
Check to see that oil level is 1 /
3
to 2 /
3
up on compressor sight glass.
Open water supply valve and allow water to reach condenser. Open pressure line valve of water regulating valve, if used.
(Turn condenser fan on when the compressor unit is applied with air-cooled condenser.)
Backseat (open) the compressor suction and discharge shutoff valves; open liquid line valve at receiver.
Start evaporator fan or chilled water pump.
To Start Compressor —
Close main power switch, control power switch, and unit ON-OFF switch. Time Guard® control circuit causes a short delay before compressor starts.
Recheck oil level and check oil pressure. See Oil Charge for details.
With unit operating, voltage at compressor terminals must be within limits shown on nameplate. Phases must be balanced within 2% of voltage (refer to Electrical Connections section).
Contact local power company for correction of improper line voltage or phase imbalance. Operation of unit on improper line voltage or with excessive phase imbalance constitutes abuse and is not covered by Carrier Warranty.
NOTE: The 06D, 07D unit safety controls are of the automatic-reset type. If compressor is shut off by a safety control, do not permit control to reset more than once before determining cause of shutdown.
CHECKING OPERATION
Refer to Carrier Standard Service Techniques Manual,
Chapter 2 for complete instructions on checking electrical
components.
Oil Charge (See Tables 2A and 2B) —
Check oil level in compressor sight glass after 15 to 20 minutes of operation. If oil level is low, add oil according to methods described in Carrier Standard Service Techniques Manual,
Chapter 1 (Section 1-11). Add oil through suction manifold connection on 4-cylinder compressors, and oil port on
6-cylinder compressors.
The preferred method for a complete recharge is to 1 /
2
sight glass with compressor shut down.
When additional oil, or a complete charge, is required, use only Carrier-approved compressor oil.
Approved* oils are:
Witco. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Suniso 3GS
Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capella WF-32
*Oils approved for R-12, R-22, R-502 Carrier refrigerants.
For other refrigerants, contact Carrier Factory Sales
Representative.
IMPORTANT: Do not reuse drained oil and do not use oil that has been exposed to atmosphere.
High-Pressure Switch —
Check by throttling condenser water or blocking airflow on air-cooled units, allowing head pressure to rise gradually. Check discharge pressure constantly throughout procedure. Compressor should shut off within 10 psi of values shown in Table 3.
Low-Pressure Switch —
Check by slowly closing suction shutoff valve or by completely closing liquid line shutoff valve. A decrease of suction pressure will follow. Compressor should shut off within 4 psi of values shown in Table 3.
Oil Pressure Switch (OPS) —
The oil pressure switch protects against damage from loss of oil or loss of oil pressure during unit start-up. If the oil pressure differential sensed by the
OPS is 6 psig or less on unit start-up, the switch remains closed and the OPS heater is energized.
The switch time delay is approximately 45 seconds. If after
45 seconds the oil pressure differential sensed by the OPS is less than 11 psig, the heater remains energized. The OPS temperature actuated switch then opens and the compressor is deenergized. If the differential reaches 11 psig, the OPS opens and deenergizes the heater and the system operates normally.
IMPORTANT: If the oil pressure switch causes unit lockout, determine and correct the cause of the lockout (such as loss of compressor oil or flooded compressor) before restarting the unit. Failure to correct the cause of OPS lockout may constitute abuse. Equipment failure due to abuse is not covered by warranty.
To restart the unit, push the OPS reset button and then push the control circuit switch on the unit control box to OFF and then to ON.
Time Guard® Control —
Control provides a delay of approximately 5 minutes before restarting compressor after shutdown for any reason. On starting, the Time Guard control timer causes a delay of 15 seconds after thermostat closes before compressor will start.
8
Table 2A — 06D Physical Data
UNIT 06D
OPERATING WEIGHT (lb)
REFRIGERANT
COMPRESSOR — 06D*
Cylinders
Bore (in.)
Stroke (in.)
Displacement (cfm at 1750 rpm)
Maximum Rpm
Oil Charge (pt)
High Side Maximum Pressure
Low Side Maximum Pressure
CONNECTIONS (in.)
Suction Valve (ODF)
Discharge Valve (ODF)
A8081
180
M808
2
2
1 1 /
4
8
3
7 /
8
5 /
8
*Compressors listed are for R-22 applications. For R-134a and R-507/
404A an 06DR compressor is standard. Factory compressor substitutes may be made. Contact Carrier Sales Representative.
H3131
M313
4
2
1
13
A8181 E8251
250 265 325
R-134a, R-22, R-507/404A
A818
4
2
1 7 /
16
18.3
A825
6
2
1 1 /
4
23.9
1750
4.5
5.5
8
450 PSIG
245 PSIG
7
5 /
/
8
8
1 1 /
8
7 /
8
1 3 /
8
7 /
8
E3281
325
A328
6
2
1 15 /
32
28
8
1 3 /
8
7 /
8
E5371
330
A537
6
2
1 15 /
16
37.1
8
1 3 /
8
1 1 /
8
→
NOTE: The 06DE8251 compressor unit with the 06DA825 compressor replaces the 06DE8241 once inventory of the 06DA824 compressor is depleted.
Table 2B — 07D Physical Data
UNIT 07D
OPERATING WEIGHT (lb)
REFRIGERANT
COMPRESSOR — 06D*
Cylinders
Bore (in.)
Stroke (in.)
Displacement (cfm at 1750 rpm)
Maximum Rpm
Oil Charge (pt)
High Side Maximum Pressure
Low Side Maximum Pressure
CONDENSER (Shell and Tube)† Part Number
Refrigerant Storage
Capacity (lb)
R-134a
Min Refrigerant Operating
Charge (lb)
R-22
R-507/404A
A203
270
M808
1
2
2
1
8
3
/
4
B205
395
M313
4
2
1
13
4.5
A208
420
B210
545
R-134a, R-22, R-507/404A
A818
1 7
4
2
/
16
18.3
A825
6
2
1 1 /
4
23.9
1750
5.5
8
450 PSIG
245 PSIG
B212
595
A328
6
2
1 15
28
8
/
32
B215
620
A537
6
2
1 15 /
16
37.1
8
P701-0605CX P701-0607CX P701-0610CX P701-0615CX P701-0620CX P701-0625AX
17.20
2.86
15.90
3.16
24.40
5.00
31.60
7.55
27.40
8.47
39.80
9.18
17.00
2.80
14.70
2.80
15.70
3.10
13.60
3.10
24.10
4.90
20.90
4.90
31.20
7.40
27.10
7.40
27.10
8.30
23.50
8.30
39.30
9.00
34.10
9.00
REFRIGERANT CONNECTION (in. ODF)
Inlet
Outlet
WATER CONNECTION (in. FPT)
Inlet/Outlet
1 5
1 1 /
1
/
8
8
LEGEND
FPT — Female Pipe Thread
ODF — Outside Diameter, Female
*Compressor listed is the standard compressor for R-22, air conditioning duty. An 06DR compressor is standard equipment for low temperature
(R-507/404A) or medium temperature (R-134a) applications. Factory substitutions may be made. Contact Carrier Sales Representative.
1 5
1 1 /
1
/
8
8
→
1 5
1 1 /
1 1
/
/
8
8
4
1 5 /
1
1
1
1 /
/
8
8
4
1 5
1 1 /
1 1
/
/
8
8
4
1 5
1 1 /
2
/
8
8
†The condenser listed is for R-22, air conditioning duty and may change based on the application. Maximum condenser operating pressure:
350 psi refrigerant side, 300 psi water side (“CX” models); 350 psi refrigerant side, 150 psi water side (“AX” models).
NOTE: The 07DB210 with the 06DA825 compressor replaces the
07DB210 with the 06DA824 once the compressor inventory is depleted.
Table 3 — Factory Switch Settings
SWITCH TYPE
High Pressure
Low Pressure
Oil Pressure
PRESSURE CHANGE AFFECTING
SWITCH POSITION
Closed Open
210 (±10) (psig)
70 (±4) (psig)
6 (psid)
290 (±10) (psig)
60 (±4) (psig)
11 (psid)
LEGEND psid — pounds per square inch differential psig — pounds per square inch gage
NOTES:
1. Values for the high- and low-pressure switches based on R-22.
For other refrigerants, reset to pressure corresponding to saturation temperatures indicated by the listed pressures.
2. Values for oil pressure are above operating suction pressure
(pressure differential between suction and discharge pressures of oil pump).
9
CAPACITY CONTROL (Suction Cutoff Type)
Control Set Point (Cylinder Load Point) —
Set point is adjustable from 0 to 86 psig. Pressure differential between cylinder load-up point and cylinder unload point is adjustable from 7 to 19 psi.
To Regulate Control Set Point —
Refer to Fig. 7.
Turn adjustment nut clockwise to its bottom stop (with nut in this position, set point is 86 psig). Control set point is then regulated to desired pressure by turning adjustment nut counterclockwise. Every full turn decreases set point by 7.2 psi.
Approximately 12 turns in counterclockwise direction will decrease control set point to 0 psig. Table 4 shows steps of control for the compressor and condensing unit.
Pressure Differential Adjustment —
Turn differential adjusting screw counterclockwise to its back-stop position (differential in this position is 7 psi). Pressure differential is set by turning adjustment screw clockwise. Every full turn increases differential by 1.2 psi. Approximately 10 turns in clockwise direction will increase pressure differential to 19 psi.
802
PRESSURE
DIFFERENTIAL
ADJUSTMENT
SCREW
BYPASS
PISTON RING
CONTROL
SET POINT
ADJUSTMENT
NUT
POWER
HEAD
VALVE BODY
BYPASS PISTON-USED
WITH HOT GAS BYPASS
TYPE OF UNLOADING ONLY.
NOT REQUIRED WITH
SUCTION CUTOFF TYPE
UNLOADING.
DIFFERENTIAL SCREW
SEALING CAP (CAP MUST
BE REPLACED TO PREVENT
REFRIGERANT LEAKAGE)
Fig. 7 — Capacity Control Valve
(Pressure Type)
Table 4 — Capacity Control Reduction Steps
UNIT 06D,07D
ALL 4 CYLINDER
MODELS
ALL 6 CYLINDER
MODELS
NO. OF
CONTR
CYL
2
4
100
% Full Load Capacity
67 49 32
100
% Full Load kW
73 57 46
Number of Active Cylinders
4 — 2 —
6 4 — 2
Capacity Control Pressure (Fig. 8)
LOADED OPERATION — Pressure-operated control valve is controlled by suction pressure and actuated by discharge pressure. Each valve controls 2 cylinders (one bank). On start-up, controlled cylinders do not load up until differential between suction and discharge pressures is approximately
25 psi.
When suction pressure rises high enough to overcome control set point spring, the diaphragm snaps to the left and relieves pressure against the poppet valve. The drive spring moves the poppet valve to left and it seats in the closed position.
With poppet valve closed, discharge gas is directed into the unloader-piston chamber and pressure builds up against the piston. When pressure against unloader piston is high enough to overcome the unloader valve spring, piston moves valve to the right, opening suction port. Suction gas can now be drawn into the cylinders and the bank is running fully loaded.
UNLOADED OPERATION — As suction pressure drops below set point, control spring expands, snapping diaphragm to right. This forces poppet valve open and allows gas from discharge manifold to vent through base of control valve to suction side. Loss of full discharge pressure against unloaded piston allows unloader valve spring to move valve left to closed position. The suction port is blocked, isolating the cylinder bank from the suction manifold. The cylinder bank is now unloaded.
CONDENSER MAINTENANCE
To inspect and clean condenser, drain water and remove condenser heads. To drain condenser, shut off water supply and disconnect inlet and outlet piping. Remove drain plugs and vent plug.
With condenser heads removed, inspect tubes for refrigerant leaks. (Refer to Carrier Refrigerant Service Techniques Manual.)
Clean condenser tubes with nylon brush (available from
Carrier Service Department). Flush water through tubes while cleaning. If hard scale has formed, clean tubes chemically. Do not use brushes that will scrape or scratch tubes.
Because the condenser water circuit is usually an open system, the condenser tubes may be subject to contamination by foreign matter. Local water conditions may cause excessive fouling or pitting of tubes. Condenser tubes, therefore, should be cleaned at least once a year or more often if the water is contaminated.
Proper water treatment can minimize tube fouling and pitting. If such conditions are anticipated, water treatment analysis is recommended. Refer to the Carrier System Design
Manual, Part 5, for general water conditioning information.
If hard scale has formed, clean the tubes chemically. Consult an experienced and reliable water-treatment firm in your area for treatment recommendations. Clean the condenser by gravity or by forced circulation as shown in Fig. 9 and 10.
IMPORTANT: If the ambient temperature is below 32 F during a shutdown period; protect the condenser from freezing by draining the water from the system or by adding antifreeze to the water.
10
Fig. 8 — Capacity Control Valve Operation
FILL CONDENSER WITH
CLEANING SOLUTION. DO
NOT ADD SOLUTION
MORE RAPIDLY THAN
VENT CAN EXHAUST
GASES CAUSED BY
CHEMICAL ACTION.
3’ TO 4’
VENT
PIPE
1”
PIPE
5’ APPROX
Fig. 9 — Gravity Circulation
CONDENSER
11
CENTRIFUGAL PUMP 1/2 HP
30 GPM AT 35’ HEAD
PUMP
PRIMING
CONN.
SUCTION
PUMP
SUPPORT
GAS VENT
GLOBE
VALVES
1” PIPE
CLOSE VENT PIPE
VALVE WHEN
PUMP IS
RUNNING
CONDENSER
TANK LEGEND
1 — Oil Pressure Relief Valve 5
REMOVE WATER
— Eccentric Shaft
2 — Piston and Eccentric
Strap Assembly
6 — Eccentric Strap Side
Shield
3 — Motor End Counterweight 7 — Oil Suction Tube
4 — Oil Return Check Valve 8 — Pump End Counterweight
Fig. 11 — Compressor
(Bottom Plate Removed)
SERVICE
Do not remove the compressor terminal box cover until all electrical power is disconnected and pressure is relieved. Terminal pins may blow out causing injuries, death, and/or fire.
Service Notes
1. Where compressor components are shown, they are in normal order of removal from compressor.
2. For replacement items, use Carrier specified parts.
See Carrier 06D Specified Parts list for compressor part interchangeability.
3. Before compressor is opened, the refrigerant must be removed from it by the Pumpdown method.
a. Start compressor, close suction shutoff valve, and reduce crankcase pressure to 2 psig (bypass low pressurestat with jumper).
b. Stop compressor and isolate from system by closing discharge shutoff valve.
c. Bleed any residual refrigerant. Drain oil if necessary.
4. After disassembly, clean all parts with solvent. Use mineral spirits, white gasoline or naphtha.
5. Before assembly, coat all parts with compressor oil and clean and inspect all gasket surfaces. Replace all gaskets with new standard specified gaskets, coated with compressor oil. See Table 5 for typical torque values.
6. After reassembly, evacuate compressor and open suction and discharge valves. Restart compressor and adjust refrigerant charge.
Table 5 — Torque Values
SIZE
DIAM
(in.)
1
1
1
5
3
/
/
16
/
/
8
4
16
/
8
7 /
16
1 /
2
5 /
8
No. 10
1 1 /
2
THREADS
PER IN.
27 (pipe)
20 (pipe)
20 (pipe)
20
28
18
16
14
13
11
32
18 NEF
TORQUE
RANGE
(lb-ft)
USAGE
8-12 Pipe Plug — Crankshaft
6-10
Oil Return Check Valve —
Crankcase
20-25 Pipe Plug — Press. Gage Conn.
10-12 Connecting Rod Capscrew
12-15 Baffle Plate — Crankcase
12-15 Side Shield
12-15 Oil Pump Drive Segment
12-15 Unloader Valve
16-20
Cover Plate — Pump End
Bearing Head
16-20 Terminal Block Cap Screws
20-25 Suction Service Valve
20-25 Discharge Service Valve
30-35 Pump End Bearing Head
30-35 Bottom Plate — Crankcase
30-35 Compressor Foot
30-35 Cylinder Head
30-35 Motor End Cover — Crankcase
55-60 Motor End Cover — Crankcase
80-90 Suction Service Valve
25-30 Crankshaft Spinner Tube
4- 6 Oil Pump Drive Segment
35-45 Oil Level Sight Glass
LEGEND
NEF — National Extra Fine
8
7
Testing Oil Pump —
Observe oil level sight glass. The oil pressure relief valve line is positioned to discharge oil against sight glass. When oil does not discharge from this line, it is an indication of low oil pump pressure.
If oil pump pressure is low, remove and check oil filter screen, oil pressure regulator and oil return check valve.
OIL PRESSURE RELIEF VALVE (Fig. 11) — Unscrew relief valve assembly from motor partition plate, and be sure assembly is not clogged or the plunger is not stuck.
OIL RETURN CHECK VALVE (Fig. 11) — Unscrew check valve from motor partition plate. Be sure flutter valve is not sticking and that it seats tightly.
OIL FILTER SCREEN (Fig. 12) — Screen is accessible through bottom cover plate. Remove and inspect strainer for holes and dirt. Clean it with solvent and replace.
OIL PUMP AND BEARING HEAD (Fig. 12) — The oil pump assembly is contained in the pump end bearing head aluminum casting. The pump end main bearing is a machined part of this casting. An insert bearing is not required.
Remove Bearing Head Assembly from Crankcase — Remove in sequence (refer to Fig. 12 and 13): oil pump cover, oil feed guide retaining spring, oil feed guide, pump drive segment. If damage to the oil pump or main bearing is found, a new pump end bearing head assembly should be installed.
Replace (Refer to Fig. 12 and 13) — For torque values, refer to Table 5. Following steps are used to replace bearing head:
1. Bolt bearing head to crankcase. Place pump drive segment into position and secure to end of crankshaft with cap screws and lock washers that were removed (see
Fig. 13).
2. Insert oil feed guide with large diameter inward and place guide retainer spring over small diameter of guide.
3. Install gasket and oil pump cover.
6 5
LEGEND
1 — Oil Pressure Relief Valve 5 — Eccentric Shaft
2 — Piston and Eccentric 6 — Eccentric Strap Side
Strap Assembly Shield
3 — Motor End Counterweight 7 — Oil Suction Tube
4 — Oil Return Check Valve 8 — Pump End Counterweight
Fig. 11 — Compressor
(Bottom Plate Removed)
1
2
3
4
12
8 7 6 5 4 3 26 2
9
10
11
12
13
1
24
25
22
23
PHASE BARRIER
POSITIONING
KEY (SEE FIG. 19)
44 43 42
14
41 40 39 16
15 16 17 18
38 37 36
19 20 21
35 34 33 32 31 30
29
28
15 45 46 47 48 49
Fig. 12 — 06D Compressor Components (4-Cylinder with Eccentric Shaft Shown)
27
13
1 — Motor Cover Gasket
2 — Motor End Cover
3 — Discharge Manifold Connection
4 — Valve Plate Gasket
5 — Valve Plate Assembly
6 — Cylinder Head Gasket
7 — Cylinder Head
8 — Cylinder Head Washer and Cap Screw
9 — Suction Manifold Connection*
10 — Suction Valve Positioning Spring
11 — Suction Strainer
12 — Bearing Head Gasket
13 — Oil Pump Inlet Passage
14 — Bearing Head Washer and Cap Screw
15 — Oil Pump Cover
16 — Pump End Bearing Head
TOP
LEGEND FOR FIG. 12
17 — Oil Drain Plug
18 — Crankcase
19 — Bottom Plate Gasket
20 — Bottom Plate
21 — Bottom Plate Washer and Cap Screw
22 — Oil Filter Screen
23 — Oil Return Check Valve
24 — Oil Level Sight Glass
25 — Motor Terminal Plate
26 — Dowel Pins (For Suction Valve
Positioning)
27 — Equalizing Tube and Lock Screw Assembly
28 — Lockwasher
29 — Rotor Lockwasher
30 — Rotor Drive Key
31 — Piston Pin Lock Ring
32 — Piston Pin
33 — Piston
1
2
34 — Oil Ring
35 — Compression Rings
36 — Eccentric Strap
37 — Eccentric Strap Side Shield
38 — Pump End Counterweight
39 — Oil Pump Drive Segment
40 — Drive Segment Cap Screws and Lockwashers
41 — Oil Feed Guide
42 — Oil Feed Guide Retainer Spring
43 — Cover Gasket
44 — Pump Cover Cap Screw and Washer
45 — Counterweight Bolt
46 — Eccentric Strap Side Shield
47 — Motor End Counterweight
48 — Locknut
49 — Eccentric Shaft (or Crankshaft)
*Used to add compressor oil.
Three Allen head cap screws hold capacity control valve in place (Fig. 14). Remove screws using a cut-down 3 /
16
-in. Allen wrench, and pull valve from cylinder head.
Remove same number of piston plugs from replacement compressor as number of unloaders supplied with original compressors. Three Allen head cap screws hold piston plug assembly in place. Remove flange cover, gasket, spring and bypass piston plug (Fig. 15). A tapped hole is provided in piston to allow it to be pulled out. Hole has same thread diameter as cap screws removed above.
3
4
5
8
6
CAPACITY
CONTROL
VALVE
7
LEGEND
1 — Suction Strainer
Assembly
2 — Oil Pump Bearing Head
Assembly
3 — Rotor Retaining Ring
4 — Oil Pump Drive Segment
5 — Oil Pump Rotor
6 — Drive Segment Cap
Screws
7 — Bearing Head Cap
Screws
8 — Oil Pump Inlet Passage
Fig. 13 — Removing Pump End Bearing Head
Cylinder Heads —
Disassemble cylinder heads by removing cap screws and prying up on side between cylinder
head and valve plate to break heads loose from valve plate. Do
not strike cylinder heads to break loose.
Check heads for warping, cracks and damage to gasket surfaces. When replacing cylinder head, torque cap screws
30 to 35 lb-ft to prevent high to low side leak in center portion of cylinder head gasket.
Service Replacement Compressors —
Replacement compressors are not equipped with control valves. One or both side bank cylinder head(s) is plugged with a spring loaded plug piston assembly. Compressor will run fully loaded with piston plug(s) in place.
Transfer original capacity control valve(s) to replacement
compressor (ensures proper valves are used with correct setting). For sealing purposes, install a plug piston assembly into each cylinder head of original compressor from which a control valve was removed.
14
CAP SCREWS
(NONINTERCHANGEABLE
WITH FLANGE COVER
CAP SCREWS)
Fig. 14 — Removal of Capacity Control Valve
BYPASS PISTON PLUG
SPRING
CAP SCREWS
(NONINTERCHANGERABLE
WITH CONTROL VALVE
CAP SCREWS)
TAB
GASKET
GAS PORT
FLANGE COVER
Fig. 15 — Removal of Bypass Piston Plug
Suction and Discharge Valve Plate Assembly
(Fig. 16) —
Test for leaking discharge valves by pumping compressor down and observing suction and discharge pressure equalization. If a discharge valve is leaking, the pressures will equalize rapidly. Maximum allowable discharge pressure drop is 3 psi per minute after an initial drop of 10 to
15 psi in the first half minute.
If there is an indicated loss of capacity and discharge valves check properly, remove suction and discharge valve plate assembly and inspect suction valves.
IMPORTANT: This test procedure is not applicable to compressors equipped with pressure actuated or solenoid unloader valves due to rapid pressure equalization rate.
Check suction and discharge valves by disassembling valve plate (see Fig. 16).
DISASSEMBLY — Remove cylinder head.
1. Remove discharge valve assembly: cap screws, valve stops, valve stop supports and valves.
2. Pry up on side of valve plate, between valve plate and cylinder deck, to remove valve plate and expose suction valves. Remove suction valves and suction valve positioning springs from dowel pins.
Inspect valves and valve seats for wear and damage. See
Table 6. Check cylinder deck valve stops for uneven wear.
Replace valves if cracked or worn. If valve seats are worn, replace complete valve plate assembly. If cylinder deck valve stops are worn, replace compressor.
REASSEMBLY — Do not interchange valves. Install suction valve positioning springs on dowel pins. Assemble positioning springs with spring ends bearing against cylinder deck
(Fig. 17). Springs bow upward. Place suction valves on dowel pins, over positioning springs. Place valve plate on cylinder deck, and reinstall discharge valve plate assembly. Retorque discharge valve stop cap screws to 16 lb-ft. Replace cylinder head. Be sure cylinder head gasket is lined up correctly with cylinder head and valve plate.
CYLINDER HEAD
GASKET
DISCHARGE
VALVE STOP
DISCHARGE VALVE
SCREW AND
LOCK WASHER
VALVE PLATE
GASKET
DISCHARGE
VALVE
VALVE PLATE
VALVE PLATE ASSEMBLY
Fig. 16 — Valve Plate Assembly
DISCHARGE
PORT
HIGH-PRESSURE
CONNECTION
VALVE PLATE
DOWEL PIN
LOW-PRESSURE
CONNECTION
SUCTION VALVE
POSITIONING
SPRING
SUCTION
VALVE
Fig. 17 — Suction Valve and Positioning
Springs in Place
Table 6 — Compressor Wear Limits (Factory Tolerances) (in.)
COMPRESSOR PART
COMPRESSOR MODEL
06DM808 06DM313 06DA818 06DA825†
MOTOR END
Main Bearing Diameter
Journal Diameter
PUMP END
Main Bearing Diameter
Journal Diameter
CRANKPIN DIAMETER
THROW
THRUSTWASHER
Max
Min
Max
Min
Min
Max
Min
Max
Min
Max
Max
Min
1.3755
1.3735
1.2500
1.2460
2.2030
1.0000
—
—
—
2.2035
—
1.3735
1.4374
1.4344
1.3745
1.3735
2.2030
1.2500
1.246
ECCENTRIC DIAMETER
CONN. ROD DIAMETER
PISTON PIN BEARING
CYLINDERS
Bore
Piston Diameter
Piston Pin Diameter
Piston Pin Bearing
Piston Ring Gap
Max
Min
Min
—
1.3755
0.6878
Piston Ring Side Clearance
Max
Min
Max
Min
*Maximum allowable wear above maximum or below minimum factory tolerances shown. For example: difference between pump end main bearing diameter and journal diameter is .001 in. (1.3745 – 1.3735) per factory tolerances. Maximum allowable difference is .004 in. (.002 + .002).
†Tolerance for the 06DA825 same as 06DA824.
2.0005
1.996
0.6873
Press Fit
0.0130
0.0050
0.0020
0.0010
2.2035
—
06DA328 06DA537
1.6240
1.6233
1.3735
—
0.1570
0.1550
1.9396
—
1.3755
—
MAX* ALLOW
WEAR
0.002
0.002
0.002
0.002
0.0025
—
—
0.025
0.025
0.002
0.002
0.001
0.002
0.002
0.001
—
0.025
0.025
0.002
0.002
15
Cleaning Suction Strainer
1. Pump down compressor.
2. Remove motor end cover and screws holding disc type strainer (Fig. 18) to cover.
3. Clean strainer with solvent or replace if broken or corroded.
4. Replace strainer and motor end cover. Purge or evacuate compressor before starting.
Motor Replacement —
Stator and rotor are not field replaceable. Stator is a press fit into motor housing. If compressor motor is damaged, replace compressor.
Terminal Plate Assembly —
The terminal plate assembly is shown in Fig. 19. Do not disassemble for any reason except to replace the phase barrier, which may become damaged.
If refrigerant leakage or a ground short occurs, the entire terminal plate assembly must be replaced.
If it becomes necessary to remove the phase barrier, proceed as follows:
1. Loosen and remove all terminal nuts.
2. Remove lock washers and wire terminals.
3. Loosen and disengage the center screw. (Do not try to remove the screw.)
4. Lift the phase barrier off the terminal screws (the spacers and the center screw are removed with the phase barrier).
IMPORTANT: Do not disturb the jam nuts on which the phase barrier rests.
Procedure for reassembling the phase barrier:
1. Place phase barrier over the terminal screws. Be sure po- sitioning key is in the recess in the terminal plate before proceeding further.
2. Place the spacers and wire terminals on the terminal screws.
3. Place the lock washers and terminal nuts over the wire terminals and tighten to specified torque (18 to 30 lb-in.).
4. Install the center screw through the phase barrier and tighten to the specified torque (15 to 25 lb-in.).
NOTE: The design allows for clearance between the center screw head and the phase barrier. Thus, the torque limit may be reached before the screw head contacts the phase barrier.
This condition is acceptable.
Compressor Running Gear Removal
1. Remove pump end bearing head.
2. Remove motor end cover carefully to prevent damage to stator. Support cover and lift off horizontally until it clears windings.
3. Remove bottom cover plate.
4. Remove equalizer tube assembly from motor end of crankshaft (or eccentric shaft). If shaft turns, preventing tube assembly from being loosened, block shaft with a piece of wood.
5. Remove rotor using a jackbolt. Insert a brass plug into rotor hole to protect end of crankshaft from jackbolt.
Support rotor while it is being removed to prevent stator damage.
6. Remove connection rod caps from compressors using connecting rods and crankshafts. Label caps and rods so they may be reinstalled in same plate on crankshaft.
STRAINER SCREWS & WASHERS
SUCTION STRAINER
MOTOR END COVER
VALVE GASKET
VALVE CAP
SCREW
SUCTION SERVICE VALVE
Fig. 18 — Motor End Cover Assembly
BARRIER POSITIONING KEY (THIS SIDE IS
ADJACENT TO THE CYLINDER HEAD)
PHASE BARRIER
NO TERMINAL IN
THIS SECTION
TERMINAL NUMBERS ON
THIS SURFACE
TERMINAL
NUT(TYP)
BLACK JAM NUTS
ON TERMINALS 8 & 9;
BRASS JAM NUTS ON
TERMINALS 1, 2 AND 3
SPACER
(TYP)
CENTRAL SCREW (THREADS
INTO TERMINAL PLATE)
LOCK WASHER
(TYP)
ACROSS-THE-LINE APPLICATION (5 TERMINALS)
Fig. 19 — Terminal Plate Assembly
7. Remove bolts holding counterweights and eccentric strap side shields to eccentric shaft. Remove eccentric strap side shields. Remove pump end counterweight through pump end bearing head opening. Motor end counterweight will remain on eccentric shaft until shaft is removed.
8. Pull eccentric shaft or crankshaft out through pump end opening. Guide eccentric straps from eccentric shaft during removal process. Rotate shaft and tap it lightly to prevent straps from jamming.
9. Remove eccentric straps or connecting rods and pistons through bottom cover plate opening.
10. Disassemble connecting rods or eccentric straps from pistons by removing lock ring(s) and piston pins. Remove oil and compression rings from piston. Keep each piston assembly together for proper reassembly.
Check all parts for wear and tolerances shown in Table 6.
Check crankshaft (eccentric shaft) oil passages and clean if clogged.
16
PUMP END MAIN BEARING — This bearing is a machined part of the new aluminum oil pump and bearing head casting. Disassemble bearing head. If bearing is scored or worn, replace complete bearing head.
CRANKCASE AND MOTOR END MAIN BEAR-
INGS — These bearings are not field replaceable. If bearings are worn or damaged, replace compressor.
Compressor Running Gear Replacement
carefully guiding it through main bearings. Replace rotor.
Attach equalizer tube assembly to motor end of shaft.
Eccentric shafts must be installed after piston assemblies.
Place motor end counterweight on shaft before inserting shaft into compressor. See Piston Assembly Replacement.
PISTON ASSEMBLY — Attach connecting rods or eccentric straps to pistons with piston pins and lock in place with piston pin lock rings. Place lock rings with gap on the side.
They should be tight enough so they cannot be rotated by finger pressure.
RINGS
1. Check ring gap by inserting each ring separately in cylinder, approximately 3 /
8
in. from top. Ring gap should be between .013 and .005 inch.
2. Install compression rings in top piston grooves with side marked “Top” toward piston head. Install oil ring below compression ring with notched end on bottom. Stagger ring gaps around piston.
3. Measure side clearance between ring and piston
(Table 6). Check for free action.
PISTON ASSEMBLY REPLACEMENT
Compressors Using Crankshafts — Install connecting rod and piston assemblies into cylinders. Place chamfered sides of connecting rods against radius of crankpins. Install connecting rod caps to matching connecting rods through bottom of crankcase. Be sure chamfered sides of caps are against radius of crankpins. Caps are locked in place with cap screws. Use 8 to
10 lb-ft to tighten cap screws.
Compressors Using Eccentric Shafts — Install eccentric strap and piston assemblies into cylinders. Install eccentric shaft through pump end, carefully guiding it through eccentric straps and main bearings. Install pump end counterweight to eccentric shaft and replace eccentric strap side shields.
Turn crankshaft or eccentric shaft to be sure there is no binding between bearing surfaces and journals. Replace oil screen, bottom cover plate, valve plates and cylinder heads.
COMPRESSOR MOTOR BURNOUT
Do not attempt start-up with terminal cover removed.
Bodily injury or death may result from explosion and/or fire if power is supplied to compressor with the terminal cover removed or unsecured. See warning label on terminal cover.
Clean-Up Procedure —
If a hermetic motor burns out, the stator winding decomposes, forming carbon, water and acid which contaminate refrigerant systems. Remove these contaminants from system to prevent repeat motor failures.
1. Close compressor suction and discharge service valves, and bleed refrigerant from compressor. Save remaining refrigerant in system.
2. Check control box for welded contactor contacts, welded overload contacts or burned out heater elements. Check terminal plate for burned or damaged terminals, insulation, and shorted or grounded terminals. Repair or replace where necessary.
3. Remove suction and discharge shutoff valve bolts and all other connections to damaged compressor. Remove damaged compressor and replace with new compressor.
Replace liquid line filter drier with a drier of one size larger.
4. Purge new compressor. Triple-evacuate, using the following procedure: a. Evacuate to 5000 microns.
b. Break vacuum with system refrigerant. Pressurize to 15 psig. Wait 20 minutes to remove moisture.
c. Re-evacuate to 5000 microns.
d. Repeat Step b.
e. Evacuate to 1000 microns or below if possible.
5. Place compressor in operation. After 2 to 4 hours of operation, check compressor oil for signs of discoloration and/or acidity. If oil shows signs of contamination, replace oil charge, filter driers, and clean suction strainer with solvent. Repeat this procedure until oil stays clean and acid free for 48 hours of operation.
17
TROUBLESHOOTING
Read Safety Considerations on page 1 before proceeding with troubleshooting.
PROBLEM
Compressor does not run.
Compressor cycles on low-pressure control.
Compressor cycles on high-pressure control.
Insufficient capacity.
Unit operates long or continuously.
CAUSE
Main power line open.
Safety thermostat tripped.
REMEDY
Replace fuse or reset circuit breaker.
Reset thermostat.
Condenser water pump not running — power off.
Restart.
Pump binding.
Free pump.
Incorrect wiring.
Motor burned out.
Rewire.
Replace.
Control stuck open.
Loose terminal connection.
Improperly wired controls.
Low line voltage.
Compressor motor defective.
Seized compressor.
Low-pressure control erratic in action.
Suction shutoff valve partially closed.
Low refrigerant charge.
Plugged suction strainer.
Defective TXV.
High-pressure control erratic in action.
Replace control.
Check connections.
Check wiring and rewire.
Check line voltage — determine location of voltage drop.
Check motor winding for open or short.
Replace compressor if necessary.
Replace compressor.
Raise differential setting, check capillary for pinches, replace control.
Open valve.
Add refrigerant.
Clean strainer.
Discharge valve partially closed.
Air in system.
Condenser scaled (or airflow restricted).
Receiver not properly vented, refrigerant backs up into evap condenser.
Replace.
Check capillary tube for pinches. Set control as required.
Open valve.
Purge.
Clean condenser.
Repipe as required.
Start pump or fans.
Condenser water pump or fans not operating.
Refrigerant overcharge.
Low refrigerant charge.
Control set too high.
Expansion valve plugged.
Inefficient compressor.
Expansion valve setting too high.
Iced or dirty evaporator.
Evaporator too small.
Condensing unit too small.
Expansion valve too small.
Restricted or small gas lines.
Low refrigerant charge.
Control contacts fused.
Air in system.
Partially plugged or plugged expansion valve or strainer.
Defective insulation.
Service load.
Inefficient compressor.
Condenser scaled.
Restricted evaporator air.
Purge.
Add refrigerant.
Reset control.
Clean or replace.
Check valves and pistons.
Lower setting.
Defrost or clean.
Add surface or replace.
Add unit or replace.
Raise suction pressure with larger valve.
Clear restriction or increase line size.
Add refrigerant.
Replace control.
Purge.
Clean or replace.
Replace or repair.
Keep doors and windows closed.
Check valves.
Clean condenser.
Defrost coil, clean filters and ductwork.
LEGEND
TXV — Thermostatic Expansion Valve
18
PROBLEM
System noises.
Compressor loses oil.
Frosted suction line.
Hot liquid line.
Frosted liquid line.
Frosted expansion valve.
LEGEND
TXV — Thermostatic Expansion Valve
CAUSE
Piping vibration.
Expansion valve hissing.
Compressor noisy.
Insufficient compressor oil.
Leak in system.
Plugged or stuck compressor oil return check valve.
Oil trapping in line.
Crankcase heaters not energized during shutdown.
Expansion valve admitting excess refrigerant.
Shortage of refrigerant.
Receiver shutoff valve partially closed or restricted.
Restricted catchall.
Restricted strainer drier.
Ice plugging TXV orifice.
Moisture indicated by increase in suction pressure.
Plugged TXV strainer.
REMEDY
Support piping as required, check for loose pipe connectors.
Add refrigerant, check for plugged liquid line strainer.
Check valve plates for valve noise, replace compressor (worn bearings), check for loose compressor holddown bolts.
Add oil.
Repair leak.
Repair or replace.
Check piping for oil traps.
Replace heaters.
Adjust expansion valve.
Repair leak and recharge.
Open valve or remove restriction.
Replace.
Replace.
Apply hot wet cloth to TXV.
Install drier.
Clean strainer or replace TXV.
19
Copyright 2002 Carrier Corporation
Book 2
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
2 4 4 PC 802 Catalog No. 530-608 Printed in U.S.A.
Form 06/07D-3SI Pg 20 802 7-02 Replaces: 06/07D-2SI
Tab 1b 2a 2b 3a
Unduh
Tautan publik diperbarui
Tautan publik ke obrolan Anda telah diperbarui. You may view and manage your chat links after registration here.
Tautan publik dokumen
Iklan
