Carrier Air Compressor Compressor and Condensing Unit User Manual

06E,07E  
Compressors and Condensing Units  
Installation, Start-Up and  
Service Instructions  
Hermetic, Water-Cooled  
CONTENTS  
INSTALLATION  
Page  
SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . . . . . . 1  
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6  
Receive and Inspect Unit. . . . . . . . . . . . . . . . . . . . . . . . . 1  
Place Unit in Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Check Compressor Mounting . . . . . . . . . . . . . . . . . . . . 1  
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7,8  
Evacuate, Dehydrate, and Leak Test. . . . . . . . . . . . . . 7  
Oil Charge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Start Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Timer Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18  
Protection Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
Compressor Thermal Protection . . . . . . . . . . . . . . . . . 9  
Capacity Control System. . . . . . . . . . . . . . . . . . . . . . . . . 9  
Removing, Inspecting and Replacing  
Receive and Inspect Unit — Inspect shipment for  
damage. File claim with the shipping company if shipment is  
damaged or parts are missing.  
Local water conditions can cause excessive fouling or  
pitting 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.  
Place Unit in Position — Locate unit on floor in a  
well-ventilated area. Install unit where it will be warmer than  
conditioned area. Position it to allow sufficient space for refrig-  
erant and water connections and to service compressor. Allow  
space at one end of condenser for tube cleaning or replacement.  
Place unit so suction and discharge valves can be easily  
reached and so oil level can be checked.  
Make provision in piping layout to drain and vent condenser  
if system is to be shut down in winter.  
Level unit and bolt firmly to foundation.  
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
Cylinder Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
Suction and Discharge Valve Plate Assembly . . . 14  
Terminal Plate Assembly . . . . . . . . . . . . . . . . . . . . . . . . 14  
Compressor Running Gear Removal . . . . . . . . . . . . 14  
Compressor Running Gear Replacement. . . . . . . . 15  
Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
Motor Burnout (Clean-Up Procedure). . . . . . . . . . . . 17  
Condenser Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 17  
Check Compressor Mounting — Loosen compres-  
sor mounting bolts and remove shipping blocks from under  
compressor. Tighten all 4 bolts on compressor. Loosen each  
bolt just enough until the flanged washer can be moved  
sideways with finger pressure. See Fig. 1.  
NOTE: Be sure that compressor floats freely on mounting  
springs.  
SELF-LOCKING  
BOLT  
SNUBBER FLANGED  
WASHER  
NEOPRENE  
SNUBBER  
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.  
COMPRESSOR FOOT  
When working on the equipment, observe precautions in the  
literature, tags, stickers and labels attached to the equipment,  
and other safety precautions that apply. Follow all safety codes.  
Wear safety glasses and work gloves. Use care when handling,  
rigging, and setting bulky equipment.  
ISOLATION SPRING  
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 dis-  
connect. Tag disconnect(s) to alert others not to turn power  
on until work is completed.  
Fig. 1 — Compressor Mounting  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 802 Catalog No. 530-601 Printed in U.S.A. Form 06/07E-1SI Pg 1 5-01 Replaces: 06E,07E-9SI  
Book 2  
2
4
4
Tab 1b 2a 2b 3a  
Download from Www.Somanuals.com. All Manuals Search And Download.  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTE: Recommended service space is 3 ft-0 in.  
at compressor motor end to allow for motor  
removal.  
DIMENSIONS (in.)  
06E UNIT  
V022  
VOLTAGE  
208/230  
460,575  
208/230  
460,575  
208/230  
460,575  
208/230  
460,575  
A
B
C
D
E
271/2  
F
1
1
1
1
1
1
1
1
G
481/4  
481/4  
501/4  
501/4  
501/4  
501/4  
501/4  
501/4  
35  
29  
35  
29  
35  
29  
35  
35  
367/8  
367/8  
367/8  
367/8  
367/8  
367/8  
367/8  
367/8  
11/2  
11/2  
11/2  
11/2  
11/2  
11/2  
11/2  
11/2  
191/2  
191/2  
191/2  
191/2  
191/2  
191/2  
191/2  
191/2  
26  
271/2  
26  
W027  
W033  
W044  
271/2  
26  
271/2  
271/2  
Fig. 3 — 06E Hermetic Compressor Units  
Fig. 4 — 06E Compressors  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
Table 1 — Electrical Data — Compressor Motor With Circuit Breaker  
COMPRESSOR MOTOR DATA  
CIRCUIT BREAKER  
Motor  
Winding  
Resistance  
(Ohms)  
Compressor  
Part  
Number 06E  
Maximum  
Maximum  
LRA-PW  
(first  
winding)  
Recommended  
Circuit Breaker MHA MTA LRA  
Part No.  
Voltage  
(3 Ph - 60 Hz)  
Recommended  
RLA  
Hp Must Trip  
Amps  
LRA-XL  
RLA  
208/230  
575  
108  
87  
36  
44  
112  
46  
56  
135  
52  
68  
189  
75  
95  
345  
120  
173  
446  
164  
223  
506  
176  
253  
690  
276  
345  
207  
72  
0.32  
2.2  
HH83XB336  
XA461  
91 104 350  
74.3  
27.1  
35.0  
90.7  
37.9  
45.7  
116.4  
41.4  
52.1  
153.6  
60.7  
75.7  
250  
265  
20  
25  
30  
40  
45  
54  
33  
42  
38 124  
49 175  
460  
104  
1.3  
XA424  
208/230  
575  
460  
208/230  
575  
460  
208/230  
575  
460  
140  
57  
70  
168  
65  
84  
236  
94  
118  
268  
98  
134  
304  
106  
152  
414  
165  
207  
0.27  
1.6  
1.1  
0.22  
1.3  
0.9  
0.15  
1.0  
0.58  
HH83XC509  
XA469  
110 127 420  
46  
53 164  
XA426  
55 643 210  
142 163 507  
A
HH83XC539  
XA430  
275  
50  
63  
58 168  
73 210  
XA425  
HH83XC537  
XA551  
187 215 636  
74 85 236  
92 106 295  
299  
XA550  
LEGEND  
Locked Rotor Amps  
4. Recommended RLA value shown is determined by: circuit  
breaker must trip value ÷ 1.40. Use this recommended (and  
minimum) RLA value to determine nameplate stamping, mini-  
mum contactor sizing, and wire sizing. RECOMMENDED RLA  
FOR 06E COMPRESSORS EQUALS: MUST-TRIP (MTA) OF  
CARLYLE APPROVED OVERCURRENT DEVICE BEING  
USED ÷ 1.40  
LRA  
MHA — Must Hold Amps  
MTA  
PW  
RLA  
XL  
Must-Trip Amps  
Part-Winding (Start)  
Rated Load Amps  
Across-the-Line (Start)  
5. Compressor operating amps at any specific condition can only  
be determined from a performance curve.  
*Refer to physical data table to match compressor with correct com-  
pressor or water-cooled condensing unit.  
6. Ohm values for resistance are approximate and shown for ref-  
erence purposes 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 06ER, 06EM and  
50 Hz models (not shown) are available from Carrier Sales  
Representative.  
NOTES:  
1. Compressor MTA and RLA values are maximum figures.  
2. LRA values for PW second winding = / the LRA – XL value.  
3. 3-Pole XL circuit breakers shown, other 3-Pole XL alternates  
and 6-Pole PW breakers available. Terminal lugs for circuit  
breakers available in package 06EA660152 (not shown).  
1
2
LEGEND  
C1  
C2  
Compressor Contactor  
Compressor Contactor (PW)  
CCB — Compressor Circuit Breaker  
CHR — Crankcase Heater Relay  
CR  
FU  
Control Relay  
Fuse  
GND — Ground  
HPS — High-Pressure Switch  
LPS  
Low-Pressure Switch  
NEC — National Electrical Code  
NEMA — National Electrical  
Manufacturer’s Association  
OPS — Oil Pressure Switch  
POR — Pumpout Relay  
TB  
Terminal Block  
TDR — Time Delay Relay  
TM  
TR  
Timer Motor  
Timer Relay  
Fig. 5 — Component Location  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
LEGEND  
AUX  
C
Auxiliary  
M1  
Evaporator Fan or  
Chilled Water Pump  
Cooling Tower Pump  
Cooling Tower Fan  
National Electrical Code  
Oil-Pressure Switch  
Pumpout Relay  
Terminal Block Connector  
Unmarked Terminal  
Marked Terminal  
Compressor Contactor  
Compressor Contactor  
(XL start and first step of PW start)  
Compressor Contactor  
(PW second step)  
C1  
M2  
M3  
C2  
NEC  
OPS  
POR  
PW  
SW  
TB  
CH  
Crankcase Heater  
CHR  
CR  
Crankcase Heater Relay  
Control Relay  
Part Wind  
Factory Wiring  
Start-Stop-Reset Switch  
Terminal Block  
DTS  
DX  
Discharge Temperature Sensor  
Direct Expansion  
Field Control Wiring  
To indicate common potential only;  
not to represent wiring.  
TDR  
TM  
Time Delay Relay  
Timer Motor  
FU  
Fuse  
HPS  
LLS  
LPS  
High-Pressure Switch  
Liquid Line Solenoid Valve  
Low-Pressure Switch  
TR  
Timer Relay  
XL  
Across-the-Line  
Splice  
NOTES:  
device with a maximum rating of 15 A to TB2 connections L1  
(Hot Side) and L2 (Neutral).  
6. Open control circuit disconnect switch for servicing only. Discon-  
nect 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.  
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 pro-  
tected 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 supply at the through a fused disconnect  
10. Wiring is shown for single pumpout control. Single pumpout  
control should not be used on direct-expansion (DX) cooler appli-  
cations (see lower diagram for wiring when applied with DX  
cooler).  
Fig. 6 — Control Circuit Wiring for 06E/07E Units  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
operation. To add or remove oil, see Carrier Standard Service  
Techniques Manual, Chapter 1, Refrigerants.  
PRE-START-UP  
IMPORTANT: Use only Carrier approved compressor oil.  
Do not reuse oil that has been drained and do not use oil  
that has been exposed to atmosphere.  
When charging, or when removing charge, circulate water  
through water-cooled condenser and cooler continuously to  
prevent freezing. Freezing damage is considered abuse and  
is not covered by Carrier warranty.  
Approved compressor oils*:  
Petroleum Specialties, Inc. . . . . . . . . . . . . . . . . . . . . . Cryol 150  
Texaco, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Capella WR-32  
Witco Chemical Co.. . . . . . . . . . . . . . . . . . . . . . . . . Suniso 3GS  
*Approved for R-12, R-22, R-502 refrigerants. Contact Carrier  
Factory Sales Representative for other refrigerants.  
Evacuate, Dehydrate, and Leak Test — The entire  
refrigerant system must be evacuated, dehydrated and leak test-  
ed by methods described in Carrier Standard Service Tech-  
niques Manual, Chapter 1, Section 1-6 and 1-7. Use sight glass  
method to charge system. See Section 1-8 of Service Tech-  
niques Manual for details.  
Charge the system 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 for air-cooled  
applications.  
TO ADD OIL — Close suction shutoff valve and pump down  
crankcase to 2 psig. (Low-pressure cut-out must be bypassed.)  
Wait a few minutes and repeat as needed until pressure remains  
at 2 psig. Remove oil fill plug above bull’s-eye, add oil through  
plug hole and replace plug. Run compressor for about 20 min-  
utes and check the oil level.  
TO REMOVE OIL — Pump down compressor to 2 psig.  
Loosen the 1/4-in. pipe plug in compressor base and allow the  
oil to seep out past the threads of the plug. The crankcase will  
be under slight pressure. Be careful not to remove the plug; the  
entire oil charge may be lost.  
Oil Charge (See Tables 2 and 3) — All units are  
factory charged with oil. If oil is visible in sight glass, start  
compressor. Observe level and add oil, if required, to bring  
1
3
level in crankcase  
/
8
to  
/
8
of bull’s-eye during steady  
Table 2 — 06E Physical Data  
UNIT 06E  
V022  
W027  
W033  
W044  
OPERATING WEIGHT (lb)  
REFRIGERANT  
600  
640  
650  
670  
R-134a, R-22, R-507/404A  
COMPRESSOR — 06E*  
Cylinders  
A250  
A265  
A275  
A299  
4
6
6
6
11  
11  
11  
11  
Bore (in.)  
2
/
2
/
2
/
2
/
16  
16  
16  
16  
16  
16  
8
3
3
7
Stroke (in.)  
2 /  
2
2 /  
2 /  
Displacement (cfm at 1750 rpm)  
Maximum Rpm  
50  
68  
19  
75  
99  
1750  
Oil Charge (pt)  
14  
19  
19  
High Side Maximum Pressure (psi)  
Low Side Maximum Pressure (psi)  
450 PSIG  
245 PSIG  
CONNECTIONS (in.)  
Suction Valve (ODF)  
Discharge Valve (ODF)  
5
5
1
1
1 /  
1 /  
2 /  
2 /  
8
8
8
8
8
8
8
8
1
3
3
5
1 /  
1 /  
1 /  
1 /  
LEGEND  
ODF — Outside Diameter Female  
*Compressors listed are for R-22 applications. For R-134a an 06EM compressor  
is standard offering; an 06ER compressor is standard for R-507/404A. Factory  
compressor substitutes may be made. Contact Carrier Sales Representative.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
Table 3 — 07E Physical Data  
UNIT 07E  
OPERATING WEIGHT (lb)  
REFRIGERANT  
A022  
1090  
B027  
1200  
B033  
1250  
D044  
1410  
R-134a, R-22, R-507/404A  
COMPRESSOR — 06E*  
Cylinders  
A250  
A265  
A275  
A299  
4
6
6
6
11  
11  
11  
11  
Bore (in.)  
2
/
16  
2
/
2
/
16  
2
/
16  
16  
3
3
7
Stroke (in.)  
2 /  
2
2 /  
2 /  
16  
16  
8
Displacement (cfm at 1750 rpm)  
50  
14  
68  
19  
75  
19  
99  
19  
Oil Charge (pt)  
High Side Maximum Pressure (psi)  
Low Side Maximum Pressure (psi)  
450  
245  
CONDENSER (Shell and Tube)† Part Number  
P701-0840AX P701-0850AX P701-0850AX P701-1065AX  
71.3  
15.4  
70.4  
15.1  
61.1  
15.1  
85.90  
18.67  
84.80  
18.30  
73.60  
18.30  
85.90  
18.67  
84.80  
18.30  
73.60  
18.30  
112.70  
23.77  
111.20  
23.30  
96.50  
23.30  
R-134a  
R-22  
Refrigerant Storage  
Capacity (lb)  
Min Refrigerant Operating  
Charge (lb)  
R-507/404A  
REFRIGERANT CONNECTION (in. ODF)  
1
1
1
5
Inlet  
2 /  
2 /  
2 /  
2 /  
8
8
8
8
8
8
8
8
3
3
3
5
Outlet  
1 /  
1 /  
1 /  
1 /  
WATER CONNECTION (in. FPT)  
Inlet/Outlet  
1
1
1
2 /  
2 /  
2 /  
3
2
2
2
LEGEND  
FPT  
Female Pipe Thread  
ODF — Outside Diameter, Female  
*Compressor listed is the standard compressor for R-22, air conditioning duty. An 06ER compressor is standard equipment  
for low temperature (R-507/404A) applications. For medium temperature (R-134a) applications, an 06EM compressor is  
standard. Factory substitutions may be made. Contact Carrier Sales Representative.  
†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, 150 psi water side.  
START-UP  
Timer Functions (See Fig. 7 — Timer Cycle.)  
1. Switch A (contacts A-A1 and A-A2) provides Time  
Guard® function. Start of compressor is delayed approxi-  
mately 5.5 minutes after shutoff. The minimum time  
between starts of compressor is 8 minutes.  
2. Switch B (contacts B-B1 and B-B2) starts compressor  
and deenergizes the crankcase heater. These contacts also  
provide one-second time delay for part-winding start.  
Energize crankcase heater at least 24 hours prior to start-up.  
1
Check to see that oil level is approximately /3 up on the  
compressor sight glass.  
Open water supply valve and allow water to reach condens-  
er. (Turn condenser fan on when the compressor unit is applied  
with air-cooled condenser.)  
Backseat the compressor suction and discharge shutoff  
valves; open liquid line valve at receiver.  
3. Switch  
E
(contacts E-1) provides approximately  
40-second bypass of oil pressure switch (OPS) at start-up.  
Compressor will shut off if sufficient oil pressure does  
not build up.  
Start evaporator fan or chilled water pump.  
4. Switch D (contacts D-D1) bypasses the low-pressure  
switch (LPS) for 2.5 minutes at start-up for winter start  
control.  
Do not attempt start-up with terminal cover removed from  
compressor. 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.  
Start Compressor — Push the control circuit START-  
STOP-RESET switch to START. The timer motor starts  
immediately. Depending on the position of the timer, the  
compressor start is delayed for 12 seconds to approximately  
8 minutes. Check oil pressure after compressor has run a few  
minutes; the pressure should be 12 to 18 psi above the suction  
pressure. After about 20 minutes of operation, stop the com-  
pressor. Allow it to be idle for about 5 minutes, then observe  
the oil level in the sight glass. Refer to the Carrier Standard  
Service Techniques Manual, Chapter 1, Section 1-11, for  
adding oil. The proper oil level for the 06E compressor is  
approximately 1/3 up on sight glass.  
Fig. 7 — Timer Cycle  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
exceeds 295 ± 5 F, the sensor contacts open and the compressor  
shuts down. The sensor reset temperature is 235 F minimum.  
See Fig. 8 for control circuit connections.  
SERVICE  
Protection Devices  
HIGH-PRESSURE SWITCH — Check by throttling con-  
denser 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 4.  
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 4.  
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.  
See Table 4.  
Capacity Control System  
CAPACITY CONTROL VALVE (Fig. 9) — Valve is con-  
trolled by suction pressure and actuated by discharge pressure.  
Each valve controls 2 cylinders. On start-up, controlled  
cylinders do not load up until differential between suction and  
discharge pressures is approximately 25 psi. See Table 5.  
IMPORTANT: Do not use automatic pumpdown control  
on 06E,07E units equipped with unloader valves. Use  
single pumpout or solenoid drop (minimum protection)  
control.  
CAPACITY CONTROL VALVE ADJUSTMENTS  
Control Set Point (Cylinder Load Point) — Adjustable from  
0 to 86 psig. Pressure differential between cylinder load-up  
point and cylinder unload point is adjustable from 6 psi  
to 16 psi.  
CR  
4
6
C1  
C1 C2  
DTS  
C2  
RED  
C2  
YEL  
BLU  
B2  
TIMER  
CONTACTS  
ORN  
BLU  
B
IMPORTANT: If the oil pressure switch causes unit lock-  
out, 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.  
TB2  
6
B1  
LEGEND  
C
Compressor Contactor  
Control Relay  
CR  
DTS — Discharge Temperature Sensor  
TB  
Terminal Block  
Splice (in compressor junction box)  
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.  
Fig. 8 — Discharge Temperature Sensor (DTS)  
Table 4 — Factory Switch Settings  
PRESSURE CHANGE AFFECTING  
SWITCH POSITION (psig)  
SWITCH TYPE  
Closed  
210 ( 10)  
70 ( 4)  
6
Open  
290 ( 10)  
60 ( 4)  
11  
CONTROL  
SET POINT  
ADJUSTMENT  
NUT  
High Pressure  
Low Pressure  
Oil Pressure  
NOTES:  
1. Values for the high- and low-pressure switches based on R-22.  
For other refrigerants, reset to pressure corresponding to satura-  
tion 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).  
TIME GUARD® CONTROL — The Time Guard control  
protects against short cycling. See Start Compressor.  
VALVE BODY  
CRANKCASE HEATER — The crankcase heater prevents  
absorption of liquid refrigerant by oil in crankcase during brief  
or extended shutdown periods. Source of 115-volt power is the  
auxiliary control power, independent of the main unit power.  
This assures compressor protection even when main unit  
power disconnect switch is off.  
IMPORTANT: Never open any switch or disconnect that  
will deenergize the crankcase heater unless unit is being  
serviced or is to be shut down for a prolonged period. After  
a prolonged shutdown or a service job, energize the crank-  
case heater for 24 hours before starting the compressor.  
SEALING CAP  
(COVERS PRESSURE DIFFERENTIAL  
ADJUSTMENT SCREW)  
Compressor Thermal Protection — A discharge  
temperature sensor, installed in one cylinder head, detects an  
overtemperature condition. If the discharge temperature  
Fig. 9 — Capacity Control Valve  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
To Regulate Control Set Point  
Turn adjustment nut  
Replacing Suction Cutoff Unloading Heads — When the  
original compressor is equipped with suction cutoff unloading  
head(s), the complete cylinder head and control valve assem-  
blies must be transferred to the service (replacement) compres-  
sor. See Fig. 10 for typical suction cutoff installation. Where  
one step of unloading is required, remove the bypass-type  
unloader head and valve plate assembly from replacement  
compressor (cylinder head next to terminal box). Remove  
check valve from the valve plate. Using new gaskets, reinstall  
the valve plate assembly and install the suction cutoff head  
from the original compressor. Torque the cylinder head  
holddown bolts to 90 to 100 lb-ft. For 6-cylinder 2-step suction  
cutoff unloading, transfer the second unloading head and  
control valve from the original compressor to the replacement  
compressor, using the valve plate assembly from the replace-  
ment compressor. Use new gaskets.  
clockwise to its bottom stop. In this position, set point is  
86 psig. Control set point is then regulated to desired pressure  
by turning adjustment nut counterclockwise. Each full turn  
decreases set point by approximately 7.2 psi. Approximately  
12 turns counterclockwise lowers the control set point to  
0 psig. See Table 5.  
Table 5 — Capacity Control  
% Full Load Capacity  
100  
67  
% Full Load kW  
73 57  
49  
32  
NO. OF  
CONTR  
CYL  
UNIT 06E,07E  
100  
46  
Number of Active Cylinders  
ALL 4 CYLINDER  
MODELS  
ALL 6 CYLINDER  
MODELS  
2
4
4
6
2
Be sure the new cylinder head gasket is the one shown in  
Fig. 11, Item 33, when installing suction cutoff unloader head.  
4
2
Install parts removed from replacement compressor on  
original compressor and seal all openings to prevent  
contamination.  
NOTE: Capacity control valve factory settings for 4-cylinder units  
are: 59 psig control set point (cylinder load point), 10 psi differential  
(59 psig cylinder unload point). Settings for 6-cylinder units are: left  
cylinder bank control set point is 70 psig, differential is 10 psi; right  
cylinder bank control set point is 68 psig, differential is 10 psi.  
Removing, Inspecting and Replacing  
Components (Fig. 11)  
Pressure Differential Adjustment — Turn differential adjust-  
ing screw counterclockwise to its back-stop position. In this  
position, differential is 6 psi. Pressure differential is set by  
turning adjusting screw clockwise. Each full turn increases  
pressure differential by approximately 0.8 psi. Approximately  
10 turns increases differential to 16 psi.  
SUCTION CUTOFF UNLOADER OPERATION — The ca-  
pacity control valve shown in Fig. 9 is the pressure operated  
type. Refer to Fig. 10 and the following description for valve  
operation.  
Loaded — When suction pressure rises high enough to over-  
come control set point spring, the diaphragm snaps to the left  
and relieves pressure against the poppet valve. The drive spring  
moves poppet valve to the left and it seats in the closed  
position. See Fig. 10.  
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. All compressors have interchangeable valve plate assem-  
blies, unloader valves and oil pump bearing head  
assemblies. For replacement items use Carrier Specified  
Parts.  
2. 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 a jumper.)  
b. Stop compressor and isolate from system by  
closing discharge shutoff valve.  
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 — As suction pressure drops below set point, con-  
trol spring expands, snapping diaphragm to right. This forces  
poppet valve open and allows gas from discharge manifold to  
vent thru base of control valve to suction side. Loss of full  
discharge pressure against unloader 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. See Fig. 10.  
c. Bleed any residual refrigerant. Drain oil if  
necessary.  
3. After disassembly, clean all parts with solvent. Use  
mineral spirits, white gasoline or naphtha.  
4. Before assembly, coat all parts with compressor oil and  
clean and inspect all gasket surfaces. Replace all gaskets  
with new factory-made gaskets. See Table 6 for torque  
values.  
5. After reassembly, evacuate compressor and open suction  
and discharge valves. Restart compressor and adjust  
refrigerant charge.  
Service Replacement Compressors — These compressors are  
not equipped with capacity control valves. One side-bank  
cylinder head is a bypass unloading type, plugged with a  
spring-loaded piston plug assembly. As received, the compres-  
sor will run fully loaded.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTE: Pressure-operated control valve shown. A solenoid-operated control valve can also be used.  
Fig. 10 — Suction Cutoff Unloader Operation  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
7
8
9
18  
15 16 17  
14  
3
4
19  
10  
20  
21  
23  
22  
5
6
1
2
31  
32  
33  
26  
25  
31  
31  
34  
35  
32  
33  
36  
37  
24  
32  
38  
38  
39  
40  
41  
41  
29  
30  
28  
27  
11  
12  
13  
LEGEND  
17 — Oil Sight Glass Screw  
32 — Valve Plate Assembly (includes dis-  
charge valves)  
33 — Cylinder Head Gasket  
34 — Cap Screw, Valve Stop  
35 — Valve Stop Support  
36 — Discharge Valve Stop  
37 — Discharge Valve  
38 — Cylinder Head (Capacity control,  
side bank)  
39 — Cylinder Head (Center bank)  
40 — Cylinder Head Bolt (8 per head)  
41 — Capacity Control Valve (Pressure  
type shown)  
1
2
3
4
5
6
7
8
9
Stator (Compressor Motor)  
Rotor (Compressor Motor)  
Motor Key  
18 — Oil Sight Glass Lock Washer  
19 — Pipe Plug (Hex Head)  
20 — Crankshaft  
Rotor Plate Washer  
Rotor Lock Washer  
Rotor Lock Bolt  
21 — Ring Spacer (when required)  
22 — Bearing Washer  
23 — Connecting Rod and Piston Assembly  
24 — Connecting Rod and Cap Assembly  
25 — Piston, Piston Pin and Retaining Ring  
Package  
26 — Piston Rings (Oil and Compression)  
27 — Terminal Plate Assembly  
28 — Terminal Bolt Assembly  
29 — Terminal Box  
30 — Terminal Box Mounting Screw (4)  
31 — Suction Valve  
Motor Lock Bushing  
Roll Pin  
Acorn Nut and Gasket  
10 — Compressor Crankcase  
11 — Bottom Cover Plate  
12 — Crankcase Oil Filter Screen  
13 — Pump End Bearing Head Assembly  
14 — Motor End Cover  
15 — Oil Sight Glass Assembly  
16 — Oil Sight Glass O-Ring Gasket  
Fig. 11 — Compressor Components (06E Shown)  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Table 6 — Torque Values  
REMOVE 8 CAP  
SCREWS  
SIZE  
DIAM  
(in.)  
TORQUE  
RANGE  
(lb-ft)  
THREADS  
PER IN.  
USAGE  
1
/
/
27 (pipe)  
18 (pipe)  
8-12  
Pipe Plug Crankshaft  
16  
1
20-25 Pipe Plug Crankcase  
4
8-10  
8-12  
3-5  
Conn. Rod Cap Screw  
Junction Box  
Sight Glass  
1
1
/
20  
4
14-18 Oil Pump Drive Segment  
14-18 Unloader Valve  
14-18 Discharge Valve Stop  
12-15 Head Gasket Positioning Screw  
/
28  
4
OIL  
Cover Plate Pump End Bearing  
15-24  
PRESSURE  
TAP  
5
/
18 (pipe)  
16  
Head  
16  
15-24 Discharge Service Valve (4 cyl)  
PUMP END  
30-40 Bottom Plate Crankcase  
30-40 Compressor Foot  
BEARING HEAD  
3
/
/
30-40 Terminal Plate  
DRIVE SEGMENT  
CAP SCREWS  
8
25-30 Oil Plug Pump End Bearing Head  
OIL FEED GUIDE VANE  
AND SPRING  
2-4  
Terminal Bolts  
3
18 (pipe)  
14  
30-40 Pipe Plug Junction Box  
8
55-65 Motor End Cover  
7
/
16  
55-65 Pump End Bearing Head  
COVER  
PLATE  
90-100 Cylinder Head  
90-120 Discharge Service Valve (6 cyl)  
90-120 Suction Service Valve (4 cyl)  
1
/
13  
11  
2
Fig. 12 — Removing Pump End Bearing Head  
90-120 Suction Service Valve (6 cyl)  
90-120 Rotor Lock Crankshaft  
5
/
8
5
3
/
/
18  
16  
32  
60-75 Oil Drain Plug  
8
4
105  
1-2  
Stator Lock  
No. 6  
Check Valve Body Crankcase  
4-6  
4-6  
Oil Pump Drive Segment  
Terminal Screw  
No. 10  
32  
Lubrication System  
TESTING OIL PUMP — An oil pressure tap is located above  
oil pump cover plate (Fig. 12). Oil pressure should be 12 to  
18 psi above suction pressure.  
Oil Filter Screen — 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 — The oil pump assem-  
bly is contained in the pump end bearing head aluminum  
casting. (The pump end main bearing is a machined part of this  
casing — no insert bearing.)  
1
2
Remove Bearing Head — Remove bearing head from crank-  
case and disassemble oil pump. Drive segment cap screws  
must be removed before bearing head can be removed  
(Fig. 12). Remove pump vane assemblies from both sides of  
the bearing head by pushing against the bearing side of the  
rotor. Check all parts (Fig. 13) for wear and damage.  
3
4
Replace Bearing Head  
1. Install the rotor retaining ring in the ring groove of the  
pump rotor with chamfered edge toward compressor.  
Compress retaining ring, and insert pump rotor into  
bearing head.  
5
2. Place the pump vanes, pump vane spring with guides, and  
snap rings into the bearing head. Compress the springs  
and force the snap rings into their grooves. (Insert snap  
rings with flat side against casting.)  
3. Bolt bearing head to crankcase (use 55 to 65 lb-ft torque).  
Bolt drive segment to crankshaft.  
4. Insert the oil feed guide vane with large diameter inward.  
Place oil feed guide vane spring over small diameter of  
guide vane.  
LEGEND  
1
2
3
4
5
Pump End Bearing Head  
Drive Segment  
Oil Feed Guide Vane  
Oil Feed Guide Vane Spring  
Cover Plate  
Fig. 13 — Pump End Bearing Head Assembly  
5. Install pump cover plate.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Keep each connecting rod and piston assembly together for  
proper reassembly. Check all parts and crankpins for wear  
(refer to Table 7 for wear limits).  
Cylinder Heads (See Fig. 11) — Disassemble cyl-  
inder heads by removing cap screws, and prying up on side  
lifting tabs to break heads loose from valve plates. Do not hit  
cylinder heads to break loose.  
Check heads for warping, cracks and damage to gasket  
surfaces. When replacing cylinder head, torque cap screws  
90 to 100 lb-ft (prevents high to low side leak in center portion  
of cylinder head gasket).  
Pressure Relief Valve — This internal safety device is  
located in center cylinder bank (6-cylinder compressors,  
Fig. 14) or under discharge service valve (4-cylinder compres-  
sors). The valve relieves refrigerant pressure from high to low  
side at 400 psi pressure differential. Check valve for evidence  
of leaking. Change if defective or if valve has ever opened due  
to excessive pressure. Use a standard socket-type screwdriver  
to remove and replace valve.  
Suction and Discharge Valve Plate Assembly  
TEST — Leak test for leaking discharge valves by pumping  
compressor down and observing suction and discharge pres-  
sure equalization. If a discharge valve is leaking, pressures will  
equalize rapidly. Maximum allowable discharge pressure drop  
is 3 psi per minute.  
PRESSURE RELIEF VALVE  
If there is an indicated loss of capacity and discharge valves  
check properly, remove suction and discharge valve plate  
assembly and inspect suction valves.  
Fig. 14 — Pressure Relief Valve Removal  
DISASSEMBLE — Remove cylinder head.  
VALVE PLATE  
TAB  
1. Remove discharge valve assembly: cap screws, valve  
stops, valve stop supports and valves.  
2. Pry up on side lifting tab to remove valve plate and  
expose suction valves (Fig. 15). Remove suction valves  
and backers from dowel pins.  
Inspect valves and valve seats for wear and damage (see  
Wear Limits, Table 7). Replace valves if cracked or worn. If  
valve seats are worn, replace complete valve plate assembly.  
REASSEMBLE — Do not interchange valves. Install brack-  
ets and suction valves on dowel pins (backer is under the valve;  
see Fig. 15). Place valve plate on cylinder deck and reinstall  
discharge valve assembly. Retorque discharge valve stop cap  
screws to 16 lb-ft. Replace cylinder head. (Be sure tab on  
cylinder head gasket is lined up with tabs on cylinder head and  
valve plate.)  
SUCTION  
VALVE  
BACKER  
SECTION VALVE  
SEATS  
(VALVE PLATE)  
SUCTION VALVES  
TAB  
(BACKER IS  
UNDER THE  
VALVE)  
SUCTION VALVE STOPS  
(CYLINDER DECK)  
DOWEL  
PINS  
Terminal Plate Assembly — If there is a refrigerant  
leak between the terminal plate and the compressor, remove  
plate assembly and replace gasket.  
Fig. 15 — Valve Plate Removed  
If any terminal is shorted to the terminal plate, replace  
complete plate assembly, using a new gasket.  
Do not remove the terminal plate assembly except for the  
above conditions.  
TERMINAL  
PLATE  
ASSEMBLY  
REMOVAL — Remove junction box from terminal plate, and  
remove cap screws holding terminal plate to compressor. Mark  
all motor leads so they can be reassembled correctly to terminal  
plate. Loosen Allen head screws holding motor leads to termi-  
nal plate (Fig. 16). Remove terminal plate.  
REINSTALL — In reverse sequence, reinstall making sure  
motor leads are correct. Torque terminal plate cap screws per  
Table 6.  
Compressor Running Gear Removal  
CONNECTING ROD/PISTON ASSEMBLY — Remove cyl-  
inder heads, valve plate assemblies, crankcase bottom cover  
plate, oil filter screen, and connecting rod caps (Fig. 17). Label  
caps and rods so they may be reinstalled in same place on  
crankshaft. Push connecting rod and piston assemblies up  
through cylinder deck. Disassemble connecting rods from  
pistons by removing retaining rings and piston pins. Remove  
oil and compression rings from piston.  
ALLEN HEAD  
SCREWS (1/4)  
Fig. 16 — Removing Terminal Plate Assembly  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Compressor Running Gear Replacement  
CRANKSHAFT — Be sure compressor end bearing washer is  
in place on dowel pin. Install crankshaft through pump end,  
carefully guiding it through main bearings. Replace rotor.  
CRANKSHAFT  
CONNECTING ROD/PISTON ASSEMBLY (Fig. 18) — The  
assembly of the connecting rod with contoured-crown piston  
must be as shown. Note the relationship of the piston crown  
pattern with the chamfered side of the rod bearing. This ensures  
that the rods in the outer positions on crankpins have the  
chamfers toward crankpin fillets. On 6-cylinder compressors,  
the position of the chamfer of center rod on crankpin has no  
significance.  
CONNECTING  
RODS AND  
CAPS  
OIL DRAIN  
PLUG  
(MAGNETIC)  
Lock the piston pin in place with retaining rings as shown in  
Fig. 18.  
The retaining rings should be tight enough that they cannot  
be rotated by finger pressure.  
BOTTOM  
COVER  
PLATE  
Rings  
1. Check ring gap by inserting each ring separately in cylin-  
3
der approximately /8 in. from top. Ring gap should be  
OIL FILTER  
SCREEN  
between 0.002 in. and 0.007 inch.  
2. Install compression ring in top piston groove with either  
side up (no difference). Install oil ring below compression  
ring with notched end on bottom. Stagger ring gaps  
180 degrees.  
Fig. 17 — View with Bottom Cover Plate Removed  
3. Measure side clearance between ring and piston  
(Table 6). Check rings for free action.  
Installation of Connecting Rod/Piston Assembly — Insert the  
connecting rod/piston assemblies into cylinders with pistons  
positioned as shown in Fig. 18 and 19.  
CRANKSHAFT — Remove pump end bearing head and  
rotor. If connecting rod and piston assemblies are still in place.  
remove connecting rod caps and push piston assembly up into  
cylinder for crankshaft clearance. Pull crankshaft out through  
pump end opening. Inspect crankshaft journals for wear and  
tolerances shown in Table 7. Check oil passages and clean if  
clogged.  
This is necessary so that the suction valve and backer lie  
properly over the contoured piston crown.  
PUMP END MAIN BEARING — This bearing is a machined  
part of the oil pump and bearing head casting. Disassemble  
bearing head. If bearing is scored or worn, replace the complete  
bearing head.  
CRANKCASE AND MOTOR END MAIN BEAR-  
INGS — These bearings are not field replaceable. If bearings  
are worn or damaged, replace compressor.  
Be sure that the outer rod on each crankpin has the  
chamfered side toward the crankpin fillet (this is a double  
check on the connecting rod/piston assembly).  
Install caps to matching connecting rods with chamfered  
sides aligned. Caps are secured with Nylock cap screws.  
Tighten with 8 to 10 lb-ft torque.  
TOWARD SUCTION VALVE  
DOWELS IN CYLINDER DECK  
Table 7 — Wear Limits — 06E Compressor  
FACTORY TOL.  
(in.)  
MAXIMUM  
ALLOWABLE  
WEAR* (in.)  
COMPRESSOR PART  
Max  
Min  
MOTOR END  
Main Bearing Diameter  
Journal Diameter  
1.8760  
1.8725  
0.001*  
0.001*  
PUMP END  
Main Bearing Diameter  
Journal Diameter  
1.6260  
1.6233  
CONNECTING ROD  
Bearing Diameter  
(After Assembly)  
Crankpin Diameter  
THRUSTWASHER  
(Thickness)  
1.7515  
0.002*  
1.7483  
0.155  
RETAINING  
RING GROOVE  
(BOTH SIDES)  
CYLINDERS  
POSITION RETAINING  
RING GAP APPROXIMATELY  
ON THIS CENTERLINE  
Bore  
2.6885  
0.002  
0.002  
0.001  
0.001  
0.015  
0.002  
Piston Diameter  
Wrist Pin Diameter  
Con. Rod Wrist Pin ID  
Piston Ring End Gap  
Piston Ring Side Clearance  
2.6817  
0.8748  
0.8755  
0.007  
0.003  
0.002  
0.001  
VALVE  
Suction  
0.0315 0.0305  
0.0255 0.0245  
0.0225 0.0215  
0.002  
THICKNESS  
Discharge  
0.002  
0.010  
END CLEARANCE  
0.031  
CHAMFER MUST  
BE ON THIS SIDE  
*Maximum allowable wear above maximum or below minimum factory  
tolerances shown. For example: difference between main bearing diam-  
eter and journal diameter is .0035 in. (1.8760 1.8725) per factory tol-  
erances. Maximum allowable difference is .0045 in. (.0035 + .001).  
Fig. 18 — Connecting Rod/Piston Assembly  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Turn crankshaft to be sure there is no binding between  
bearing surfaces and journals. Replace oil screen, bottom cover  
plate, valve plates and cylinder heads.  
Push stator into housing until it lines up correctly with rotor  
(Fig. 22).  
Line up keyways in stator and crankcase and replace stator  
locking assembly, then drive key into keyway and stake over  
keyway in stator to secure key. When a new motor is being  
installed, the stator must be drilled and a new locking pin and  
motor lock bushing used (see Fig. 23 and instructions).  
Connect stator leads to proper terminals on terminal plate.  
Refasten terminal plate and junction box to compressor.  
Replace motor end bell using studs for support. Remove rubber  
plug (if used) from piston head. Replace valve plate assembly,  
cylinder head, and terminal plate assembly. Torque 12 bolts  
holding terminal plate to crankcase at 30 to 40 lb-ft.  
DOWELS IN  
CYLINDER DECK  
FOR SUCTION  
DOWEL  
HOLES  
VALVE AND BACKER  
DOWEL  
HOLES  
VALVE PLATE  
BACKER  
PLACE AGAINST  
CYLINDER DECK,  
UNDER SUCTION VALVE  
TOP VIEW OF PISTON  
IN CYLINDER  
SUCTION  
VALVE  
RUBBER PLUG  
Fig. 19 — Piston, Suction Valve and  
Backer Positions  
Motor Removal  
MOTOR END BELL — Remove motor end bell carefully to  
prevent damage to the stator. Use three 7/16 - 14- x 5-in. studs  
for guides and support. Inspect suction strainer in end bell.  
Clean it with solvent or replace if broken or corroded.  
REMOVE ROTOR — Bend rotor lock washer tab backward  
and remove rotor lock bolt. If crankshaft turns, preventing lock  
bolt from being loosened, remove a cylinder head and valve  
plate and place a rubber plug (06R suction plug) on top of one  
piston (Fig. 20). Replace valve plate assembly and cylinder  
head (only 2 bolts required to hold cylinder head in place). Pro-  
ceed to remove rotor lock bolt, lock washer and plate washer.  
STATOR LOCKING  
ASSEMBLY  
STATOR  
ROTOR  
Use a jackscrew to remove rotor (Fig. 20). Insert a brass  
plug into rotor hole to protect end of crankshaft from jack-  
screw. Support rotor while it is being removed to prevent stator  
damage. Remove ring spacer between rotor and crankshaft  
(if used).  
JACKSCREW  
Clean rotor thoroughly with solvent. If stator is to be  
replaced, a matching rotor must be used.  
ROTOR LOCK BOLT  
REMOVE STATOR (Fig. 21) — Stator is a slip fit in motor  
housing. It is held in place by both an axial key and a locking  
assembly consisting of an acorn nut, locking pin, motor lock  
bushing and a washer (see Fig. 21). Remove acorn nut and  
washer. Back out locking pin and bushing and slide stator out.  
Axial key positions stator and crankcase. If necessary, heat  
crankcase motor housing (not over 20 to 30 F above stator  
temperature).  
Fig. 20 — Removing Rotor  
LOCKING PIN BOSS  
STATOR  
Check stator for damage to windings and lead wires. Use a  
megohmmeter to check for grounds or shorts between  
windings.  
Motor Replacement  
STATOR AND ROTOR — Install stator halfway into hous-  
ing. Insert the terminal leads first, guiding them to terminal  
plate opening as stator is being inserted.  
Replace ring spacer (Fig. 11, item 21) on crankshaft. Ease  
rotor onto shaft until it begins to feel snug. Insert rotor key, and  
push rotor the remainder of the way on shaft. Replace rotor  
lock bolt with lockwasher and plate washer.  
KEY  
ACORN  
MOTOR LOCK  
NUT  
BUSHING  
LOCKING PIN  
WASHER  
Do not push stator in completely until rotor is in place.  
Fig. 21 — Removing Stator  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
2. Remove burned motor from compressor, and drain com-  
pressor oil. Clean crankcase and motor housing with  
solvent. Ensure that all metal particles are wire-brushed  
free and removed.  
END  
TURN  
STATOR  
On severe burnouts, disassemble compressor heads and  
valve plate assemblies. Clean them in same manner as  
crankcase and motor housing.  
3. Determine cause of burnout and remedy. Check control  
box for welded starter contacts, welded overload contacts  
or burned out heater elements. Check terminal plate for  
burned or damaged terminals, insulation, and shorted or  
grounded terminals.  
END  
RING  
ROTOR  
4. Reassemble compressor with new stator and rotor. Install  
new liquid line filter drier, and place new oil charge in  
crankcase.  
ROTOR CENTER LINE  
Fig. 22 — Motor Alignment  
5. Evacuate and dehydrate compressor.  
PEENED ENDS  
ACORN NUT  
BUSHING  
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 termi-  
nal cover.  
LOCKING PIN  
WASHER  
6. Place compressor in operation. After 2 to 4 hours of  
operation, check compressor oil for discoloration and/or  
acidity. If oil shows signs of contamination, replace oil  
charge, filter driers, and clean suction strainer with  
solvent.  
COMPRESSOR  
CASTING  
2 1/16"  
7. Check oil daily for discoloration and acidity. If oil stays  
clean and acid-free, the system is clean. If oil shows signs  
of contamination, change oil, filter drier, and clean  
suction strainer. If filter drier or suction strainer is dirty or  
discolored, repeat this step until system is clean.  
STATOR CORE  
3/8"  
Fig. 23 — Stator Locking Assembly  
Condenser Maintenance (07E Units) — 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 Standard Service Techniques Manual,  
Chapter 1, Section 1-6, Leak Testing, for instructions.)  
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.  
Remove  
1. Acorn nut and washer.  
2. Back out locking pin and bushing.  
Replace  
1. Screw in locking pin bushing until it rests on stator core.  
2. Wrap a piece of tape around 3/8-in. drill bit, 21/16 in. from  
cutting edge.  
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.  
Before drilling, be sure stator vent holes do not line up with  
locking pin hole. Vent holes are drilled horizontally  
through stator, and can be seen from end bell side.  
3. Ream out bushing (3/8-in. drill) and drill into stator core  
until tape is flush with top of bushing. (Remove drill  
chips.) Back off locking pin bushing 1/8 of a turn.  
4. Tap locking pin into position. (Top of bushing should be  
approximately 1/16 in. above top of pin.)  
5. Peen top of bushing over roll pin.  
6. Replace washer and acorn nut.  
If hard scale has formed, clean the tubes chemically. Con-  
sult 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. 24 and 25.  
Motor Burnout (Clean-Up Procedure) — When 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.  
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 add-  
ing antifreeze to the water.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
CENTRIFUGAL PUMP 1/2 HP  
CLOSE VENT PIPE  
VALVE WHEN  
PUMP IS  
FILL CONDENSER WITH  
CLEANING SOLUTION. DO  
NOT ADD SOLUTION  
MORE RAPIDLY THAN  
VENT CAN EXHAUST  
GASES CAUSED BY  
GAS VENT  
30 GPM AT 35HEAD  
PRIMING  
CONN.  
GLOBE  
VALVES  
RUNNING  
PUMP  
SUCTION  
CHEMICAL ACTION.  
PUMP  
SUPPORT  
1PIPE  
1”  
PIPE  
CONDENSER  
VENT  
PIPE  
5APPROX  
TANK  
REMOVE WATER  
REGULATING VALVE  
3TO 4’  
RETURN  
FINE MESH  
SCREEN  
CONDENSER  
Fig. 25 — Forced Circulation  
Fig. 24 — Gravity Circulation  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Copyright 2001 Carrier Corporation  
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.  
PC 802 Catalog No. 530-601 Printed in U.S.A. Form 06/07E-1SI Pg 20 5-01 Replaces: 06E,07E-9SI  
Book 2  
2
4
4
Tab 1b 2a 2b 3a  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Belkin Network Card F5U104 User Manual
Belkin Network Card Network Adapror User Manual
Belkin Server F1DP116SEA User Manual
Black Decker Cordless Saw 90537965 User Manual
Blomberg Refrigerator BRFB1800SS User Manual
Bowflex Treadmill TC5300 User Manual
Breville Kitchen Utensil BRC600XL User Manual
Bryant Furnace 394C User Manual
Canon CRT Television LV 7565F User Manual
Canon Printer 2163B002 User Manual