Carlyle 06T 033 Series Application Manual
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Carlyle 06T 033 Series Application Manual

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0 5 T / 0 6 T S C R E W C O M P R E S S O R A P P L I C AT I O N G U I D E
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Summary of Contents for Carlyle 06T 033 Series

  • Page 1 0 5 T / 0 6 T S C R E W C O M P R E S S O R A P P L I C AT I O N G U I D E...

  • Page 2: Table Of Contents

    Compressor Mounting......4 Section 6 — Motor and Discharge Oil Type............4 Temperature Control Ambient Conditions........5 Installation Environment......5 Carlyle Electronic Module (CEM)..... 29 Pressure Relief Valve........5 Discharge Temperature Control....29 Discharge Check Valve......5 Motor Cooling Control......29 Compressor Inlet Screens......5 1.10 Service Valves..........5 Section 7 —...

  • Page 3: Summary Of Control Points

    Introduction Summary of Control Points This manual is for the application of the Carlyle 06T semi-hermetic and 05T open drive twin screw com- Oil System: pressors. The operational limits, required accessories and operational guidelines are contained in this man- Maximum oil temperature 190°F (88°C)

  • Page 4: Model Number Significance

    06T MODEL NUMBER SIGNIFICANCE COMPRESSOR PHYSICAL DIMENSIONS * Standard service valve used on all 33-54 cfm Compressors; ** Larger barstock service valve used on all 65-88 cfm Compressors (shown). FOR REFERENCE ONLY INCHES [MILLIMETERS (mm)]...
  • Page 5 COMPRESSOR PHYSICAL DIMENSIONS CONTINUED * Standard service valve used on all 33-54 cfm Compressors; ** Larger barstock service valve used on all 65-88 cfm Compressors (shown).

  • Page 6: Section 1 - General Information

    Section 5.3. 60 Hz compressors have The Carlyle 05T/06T screw compressors may been listed. be rigid mounted. However, Carlyle recom- mends the use of isolation mounts (Carlyle P/N KA75KR007, Package No. 06TA660007) for 06T compressors. These rubber mounts isolate the compressor from the system frame- work which helps to reduce noise transmission.

  • Page 7: Ambient Conditions

    -40°F To 130°F Suction and discharge connections will (-40°C To 54°C) interface with the 2-1/2" bolt pattern service Start-Up -40°F To 130°F valves currently being used on the Carlyle (-40°C To 54°C) reciprocating compressors. Rotalock ® service Operating -25°F To 130°F valves are used for the economizer line shut (-32°C To 54°C)

  • Page 8: Section 2 - Operating Specifications

    Section 2 — Operating Specifications 2.1 Operational Envelopes approval from Carlyle Application Engineering or warranty is voided. Oil cooling can be The following operational envelopes, based on achieved through the use of an oil cooler or 65°F (18°C) return gas, show the allowable...

  • Page 9: Vapor Temperature Limits

    R-507/R404A APPLICATIONS R-507-R404A APPLICATIONS (60) (49) (38) (27) (16) (-7) (-18) (-40) (-37) (-34) (-32) (-29) (-26) (-23) (-21) (-18) (-15) (-12) (-9) (-7) (-4) (-1) (-46) (-43) Saturated Suction Temperature deg F (deg C) 2.2 Vapor Temperature Limits 2.4 Operating Speed Ranges Any application of screw compressors must The operating speed range for the screw com- operate within the limits defined by the appli-...

  • Page 10: Inverters And Refrigerants

    Oil return, Model Nominal Min. Max. economizer return gas, and the motor cooling valve all assist in cooling the motor. Carlyle 06TRC033 recommends applying the largest motor cool- 06TRD039 ing valve (Carlyle P/N EF28BZ007) with all 06TRD044 screw compressors applied using inverters.

  • Page 11: Mechanical Unloading

    *Medium/High temperature “TA” compressor models have a fixed Vi of 2.8. Unlike reciprocating compressors that should Vi SETTINGS CHART (PSIG) not be run unloaded continuously, the Carlyle screw compressor can be run unloaded con- (24.1) tinually without affecting the reliability of the (20.7...

  • Page 12: Reverse Rotation Protection

    2-6 seconds of start-up if it is not rotating in in significant discharge line and oil separator the correct direction. Installation of a pressure noise. The addition of the Carlyle screw com- gage at the discharge pressure access fitting in pressor muffler is required in all applications to...

  • Page 13: Section 3 - Oil Management System

    Section 3 — Oil Management System 3.1 Oil Separator An oil separator is required on all Carlyle screw compressor systems. Carlyle offers two sizes of vertical oil separators. Parallel systems (over two compressors) require the use of the Carlyle 14" (35.6cm) separator, and single and double compressor systems require the use of the Carlyle 12"...

  • Page 14: Piping Configuration

    Section 1.4. 2. Step changes in the line diameter should Carlyle recommends operating the system with be avoided with the exception of the the oil level between the top two sight glasses reducing fittings required to couple to on the oil separator.

  • Page 15: Oil Pressure Protection

    45 psi (3.0bar) for 90 seconds or more Refer to Appendix B for information regarding the oil protection system used with the Carlyle Electronic Module (CEM) prior to midyear 2000. 3.6 Oil Solenoids A normally closed solenoid is required in the oil...

  • Page 16: Oil Cooling Systems

    Since the oil cooler removes heat the system discharge temperature may exceed from the compressor, additional heat will be 180°F. Carlyle’s Carwin selection software can transferred to the compressor's heat of be used to estimate the discharge temperature rejection, or condenser load. Current ver- for a given application.
  • Page 17 Contact Carlyle Application Engineering for limits. Note: Valve P/N's shown above are for Sportan Valve Y-1037 series desuperheating valves. A valve with a 190 F temperature setting is required. Alternate desuperheating valve sizing or manufacturers must be approved by Carlyle Application Engineering. Sporlan Part No.

  • Page 18: Oil Cooler Selection

    3.8 Oil Cooler Selection use with the 05T and 06T screw compressor. Following is selection criteria for the various mod- An oil cooler is required on all Carlyle screw com- els along with dimensional information. pressor systems not operating in the range indi- cated in the previous section.
  • Page 19 MODEL # KH51ZZ181 FOR REFERENCE ONLY INCHES [CENTIMETERS (cm)] OIL INLET AT BOTTOM – OIL OUTLET AT TOP; ALL MODELS Electrical Specifications: All Models Voltage: 115/230V 50/60Hz Amperage*: 3.2/1.6 Amps Full Load 60Hz 2.8/1.4 Amps Full Load 50Hz *Amperage ratings are per motor MODEL # KH51ZZ182 FOR REFERENCE ONLY INCHES...
  • Page 20 MODEL # KH51ZZ183 FOR REFERENCE ONLY INCHES [CENTIMETERS (cm)] OIL INLET AT BOTTOM – OIL OUTLET AT TOP; ALL MODELS MODEL # KH51ZZ184 FOR REFERENCE ONLY INCHES [CENTIMETERS (cm)]...
  • Page 21 OIL CARTRIDGE FILTER ELEMENT 8.25" O–RING, 0.975" (24.8cm) I.D. X (209.6cm) 0.210" (5.3cm) CROSS SECT. 1.75" (44.5cm) 1.00" (25.4cm) END CAP, 1.75" O.D. (44.5cm) END CAP, CENTER CORE, 1.75" (44.5cm) O.D. X 1.00" (25.4cm) PERFORATED I.D. W/O–RING GROOVE 3u FIBERGLASS SUPPORTED FOR REFERENCE ONLY INCHES...

  • Page 22: Oil Filter

    Oil to the bearings must pass through a above 500 watt heaters (connected together) are 3 micron filter which is required on all Carlyle recommended for use with the 14" (35.6cm) sep- screw compressor systems. The use of filters arator.

  • Page 23: Oil System Schematics

    3.12 Oil System Schematics OIL SYSTEM SCHEMATIC ISOMETRIC VIEW TO CONDENSER DISCHARGE LINE OIL SEP. LEAD COMPRESSOR OIL HEATER OIL LEVEL SWITCH 3 MICRON FILTERS OIL COOLER (IF REQUIRED) MIXING VALVE* PRESSURE SENSOR OIL SOLENOID HAND VALVE SIGHT GLASS * Note: Other oil temperature control options are available. See section 3.8.

  • Page 24: Oil Line Manifold Selection Table

    LPM - Litres per minute cSt - Centistrokes * If 170 POE oil is used, Carlyle recommends use of the next larger size copper line if pressure drop is greater than 5.0 psi. This will typically reduce pressure drop to 30% of value shown.

  • Page 25: Section 4 - Refrigerant Management System

    The suction and interstage manifold should be below. piped in such a way that liquid cannot gravity drain into any compressor. Carlyle recom- Steel refrigerant piping is not recommended with mends that the manifold be located below the screw compressor applications. The contaminant’s compressor body.
  • Page 26 When any compressor Carlyle also recommends that separate subcoolers be on the rack turns off, its respective interstage used for each different saturated suction tempera- solenoid valve must close and when it turns on its ture group.

  • Page 27: Section 5 - Electrical Specifications

    DC voltage table. (WARNING: DO NOT MEASURE protected from extreme temperatures by the THE DC VOLTAGE INSIDE THE TERMINAL LonCEM Module and the Carlyle Electronic BOX.) Module (CEM) in older systems. All compres- sors are supplied with two 5K NTC (Negative...

  • Page 28: Screw Compressor Motor Protection

    2 to 6 seconds and the second 3 legs 06T Screw compressors must be applied with in 1 to 3 seconds. Carlyle recommends a 1 to properly sized calibrated circuit breakers or 1.25 second time delay between energizing the Furnas "958"...

  • Page 29: Circuit Breaker Tables

    Section 5.3 Circuit Breaker Tables...

  • Page 31: Section 6 - Motor And Discharge Temperature Control

    (115v-1-50/60 or 240v-1-50/60) is used for protection are supplied by the LonCEM/CEM. primary control of the compressor contactor, Carlyle 06T screw compressors utilize an econ- oil and economizer line solenoids, and omizer cooled motor. Screw compressor tech- unloader and Vi coils. It also provides com- nology allows access to intermediate pressure pressor thermal safety protection.

  • Page 32: Section 7 - Subcooler Selection And Performance Data Adjustment

    There is a required minimum of 20°F be sized based on the subcooling load calcu- (11°C) discharge superheat. The system lated. Carlyle recommends sizing and piping should sound an alarm if the superheat the subcooler for parallel flow. Parallel flow reaches 20°F (11°C).

  • Page 33: Section 8 - 05T Open Drive Application Information

    Section 8 — 05T Open Drive Application Information 8.1 General Information 8.2 Compressor Dimensions The 05T compressor is a compact and light- Like the 06T, the 05T models have all the weight open drive screw compressor which same physical dimensions. Please review delivers high capacity for its size.
  • Page 34 Dimensions (Bottom View) 8.3 Compressor C-Flange Several compressor C-Flanges have been designed by Carlyle. The C-Flange bolts to both the compressor and a C-Face motor for easy self aligning (within ± 0.005" [.127mm] TIR) of the coupling. There are three distinct C-Flanges, two for 1750 (1450) RPM motors and one for 3500 (2900) RPM motors.
  • Page 35 +.0005 2X ø.500 X .63 DEEP (295.3) (77.5) ø.0015 11.625" 3.05 45º 4X ø17/32 THRU ø.015 (132.3) 5.21 R5 .39 (136.9) ø12.50" (317.5) 90º (132.3) 5.21 5.00 (127) R .25 (6.4) 1.0" 1.13 3.05 (25.4) (28.7) (77.5) FOR REFERENCE ONLY INCHES [MILLIMETERS (mm)] C-Flange Dimensions (A)
  • Page 36 8.4 Compressor Coupling 8.5 Overall Dimensions A flexible Dodge coupling is used to direct All the 05T compressors have the same exter- couple the compressor to the motor shaft. To nal physical dimensions, therefore the variables properly assemble the C-Flange and coupling that will affect the overall dimensions of the onto the compressor, follow the installation assembly are the motor and C-Flange.
  • Page 37 C-Flange Motor NEMA Package RPM. Frame 1750 254TC 8.25 20.96 5.00 12.70 27.29 69.32 .106 1.42 0TA0929 20 1750 256TC 10.00 25.40 5.00 12.70 27.29 69.32 .106 1.42 1750 284TC 9.50 24.13 5.50 13.97 27.48 69.80 .858 2.18 1.42 1750 286TC 11.00 27.94 5.50 13.97 27.48 69.80...

  • Page 38: Carlyle Electronic Module

    Carlyle recommends the use of a high start torque C-Face motor to ensure starting of the compressor. 8.7 Motor Selection The motor starting torque should supply a Please refer to the Carlyle performance minimum 170% of motor full load torque.

  • Page 39: Performance Factors

    The oil cooling requirement will be very similar to the oil cooling requirement for the 06T compressor. Use the calculation from the Carlyle electronic compressor When using an inverter or other variable speed selection program to determine the oil cooling device, it is important to remember that over- requirement.

  • Page 40: Section 9 - Start-Up Procedure

    Oil pressure cut-out must be set at 45 psid (3 bar) with a 45-second time delay. 6. Check the LonCEM or Carlyle Electronic Module and ensure that it is properly wired into the control circuit and compressor.

  • Page 41: Start-Up Worksheet

    7. Check the oil temperature entering the compressor and ensure that it is less than 190°F (88°C). Oil Temperature: 8. Check functionality of the LonCEM/Carlyle Electronic Module: • Disconnect either 5K thermistor from the LonCEM/CEM to verify that the compressor will not start and all solenoid valves stay off.

  • Page 42: Section 10 - Accessory Part Numbers

    Section 10 — Accessory Part Numbers Quantity Per System Quantity Per Compressor Qty. Accessory Part Number Qty. Accessory Part Number Oil Separator Circuit Breaker HH83X . . . Multiple Compressor System Oil Press. Diff. Sw. HK06ZB006† KH31ZZ212 Older Systems HK06ZB001 Single/Two Compressor System Rev.
  • Page 43 APPENDIX A 05T/06T Installation & Application Screw Compressor Module Instructions ® LonCEM Last Updated: 09/20/04...
  • Page 44 Appendix A - Functional Overview Appendix B - Wiring Schematic Appendix C – Sensor Wire Grounding Appendix D - Alarm Summary Appendix E - Converting Sensor Outputs to Engineering Units Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759 Fax: 315-432-3274...
  • Page 45 P251-0090 * Still required, but is included in LonCEM package (see section 2 for complete BoM) ** Was never required but offered as an option for reverse rotation protection. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759...
  • Page 46 DD17GA051 * Parker Part Number: AVC1-4 ** Updated package includes shielded cable for the pressure transducer wiring harness, see Appendix C for proper shielded cable grounding techniques. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759 Fax: 315-432-3274...
  • Page 47 The original pressure transducer wiring harness, which consisted of individual stranded wires, has been replaced with a shielded cable to aid in this effort. See Appendix C for a description of proper shielded cable grounding techniques. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221...
  • Page 48 Cross Fitting Item 6 Discharge Adapter Fitting Figure 1. Suction and Discharge Fittings The same model pressure transducer is used to measure discharge and oil pressure. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759 Fax: 315-432-3274...
  • Page 49 Discharge Temperature The discharge temperature sensor (Item 5) should be strapped to the discharge line as close to the discharge service valve as possible (within 6” or less is optimal). Carlyle recommends using thermoconductive grease to help insure accurate temperature readings.
  • Page 50 Energized whenever the motor temperature limit is exceeded (see Table 2). This output is closed energizing the motor cooling valve and injecting liquid refrigerant into the motor compartment. Liq D Liquid Injection (initialized for Discharge Temperature) Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759...
  • Page 51 The Vi valve is energized (hi Vi) when the compression ratio is above 5:1, and de-energized (low-Vi) when the compression ratio drops below 5:1. The module continuously monitors the operating pressure ratio and Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221...
  • Page 52 A detailed summary of the network variables is included in the “LonCEM Network Interface Notes” document available from Carlyle Application Engineering. Additional information on LonWorks® can be found at www.echelon.com. Following is an overview of the LonWorks®...
  • Page 53 All sensor readings recorded prior to the last compressor alarm • Number of Compressor Cycles • Compressor Run-Time • Cumulative Alarm Trips for each Compressor Alarm Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759 Fax: 315-432-3274...
  • Page 54 If it is lit steady during module operation this indicates that the module software is not functioning properly. This most likely indicates a hardware problem with the module and it should be replaced. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221...
  • Page 55 The module will shut off the pressure ratio drops below 5.1:1 compressor if it detects any failure of an input device (thermistors, pressure transducers) Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759 Fax: 315-432-3274...
  • Page 56 A voltage sensing relay (VSR) (or an equivalent method) should be used to detect if power is lost to the line side of the contactor (i.e. circuit breaker has tripped). Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221...
  • Page 57 * The ground wire is the black wire for the pressure transducer’s and is whatever wire is connected to the ground input (bottom input) for the thermistors. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759...
  • Page 58 If the motor temperature rises above 240F, a shutdown sequence is initiated. Once the motor temperature drops below 200F for 30 continuous seconds All outputs are de-energized (except for alarm) and the appropriate alarm code is flashed. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221...
  • Page 59 A pause is present after each code is flashed out The sensor failure codes (1-1:1-5) are preceded by a long steady lamp to distinguish them from the other alarm codes Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221...
  • Page 60 P r e s s u r e ( P S I G ) P S I G = 1 0 1 . 5 9 * V o u t - 4 7 . 3 3 Carlyle Compressor Div. P O Box 4808...
  • Page 61 293.3 Notes 1. Voltage measured between thermistor input pins on module sensor terminal block. 2. Resistance measured across the Thermistor Leads when not connected to module. Carlyle Compressor Div. P O Box 4808 Syracuse, NY 13221 Phone: 800-462-2759 Fax: 315-432-3274...

  • Page 62: Module

    2.0 Carlyle Electronic Module (CEM) Device 3.0 Oil System Schematics 4.0 Refrigerant Management System 1.0 Overview – Original Carlyle Electronic Module (CEM) All systems manufactured after October 1998 and Previous sections of this application manual HFC systems manufactured prior to this date...
  • Page 63 CEM will shut down the compressor. This liquid Module (CEM) injection motor cooling valve (Carlyle P/N EF28BZ007) (used on all models), must be The Carlyle solid-state electronic module added to the economizer line downstream of...
  • Page 64 When a shutdown situation occurs due to a high motor or discharge temperature, 1CR, 2CR, LIQ, Should either 5K thermistor fail (open or short), UNL, and OIL outputs will all open while the ALM the compressor will be shut down with 1CR, 2CR, output will close.
  • Page 65 TEMPERATURE VS. DC VOLTAGE...
  • Page 66 Supplies power to the compressor contactor Whenever a shutdown or fault condition occurs, coil/relay. The output can supply 12 amps at 125 power is supplied to this output and its volts and 7 amps at 250 volts. The module uses corresponding LED lighted.
  • Page 67 3.0 Oil System Schematics Used with Older Carlyle Electronic Module (CEM) Systems OIL SYSTEM SCHEMATIC ISOMETRIC VIEW TO CONDENSER DISCHARGE LINE OIL SEP. LEAD COMPRESSOR OPDS FPDS OIL HEATER LEVEL SWITCH 3 MICRON FILTERS OIL COOLER MIXING VALVE OIL SOLENOID...
  • Page 68 4.0 Refrigerant Management System Used with Older Carlyle Electronic Module (CEM) Systems ECONOMIZER EVAPORATOR CONDENSER LEAD COMPRESSOR RLPS RLPS OIL SEP. DISCHARGE RLPS RLPS HIGH PRESSURE EXPANSION VALVE SWITCH SOLENOID LOW PRESSURE SWITCH CHECK VALVE RLPS REVERSE ROTATION LOW PRESSURE SWITCH...
  • Page 69 Lit. No. 574-030 Manufacturer reserves the right to discontinue, or CARLYLE COMPRESSOR DIVISION • ©CARRIER CORPORATION 2/02 P.O. Box 4808 • Syracuse, New York 13221 (Rev F 09/04) change at any time, specifications or designs and Phone 1-800-532-5031 • Fax 1-315-432-3274 prices without notice and without incurring obligations.

This manual is also suitable for:

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