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Carlyle 5H Installation, Start-Up And Service Instructions Manual

Open-drive compressors
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Installation, Start-Up and Service Instructions
CONTENTS
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Step 1 - Prepare for Installation . . . . . . . . . . . . . . . 2
Step 2 - Receive Compressor . . . . . . . . . . . . . . . . . 3
Step 3 - Install Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Step 7 - Assemble Water Piping . . . . . . . . . . . . . . 25
PREPARE FOR INITIAL START-UP . . . . . . . . . . . . . 26
Evacuate, Dehydrate and Leak Test . . . . . . . . . . . . 26
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Start Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
High and Low-Pressure Switches . . . . . . . . . . . . . . 26
Adjust Capacity Control (if required) . . . . . . . . . . . 27
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 574-603
Page
Printed in U.S.A.
Form 574-603
Open-Drive Compressors
• 5H40-5H86 FACTORY-INSTALLED ELECTRIC
UNLOADING
• 5H120/126 COMPRESSORS
• VALVES

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should install, repair, or
service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of
cleaning coils and filters and replacing filters. All other operations
should be performed by trained service personnel. When working
on air-conditioning equipment, observe precautions in the
literature, tags and labels attached to the unit, and other safety
precautions that may apply.
Follow all safety codes, including ANSI (American National
Standards Institute) Z223.1. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire
extinguisher available for all brazing operations.
It is important to recognize safety information. This is the safety-
alert symbol
. When you see this symbol on the unit and in
instructions or manuals, be alert to the potential for personal
injury.
Understand the signal words DANGER, WARNING, CAUTION,
and NOTE. These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death. WARNING signifies hazards
which could result in personal injury or death. CAUTION is used
to identify unsafe practices, which may result in minor personal
injury or product and property damage. NOTE is used to highlight
suggestions which will result in enhanced installation, reliability,
or operation.
WARNING
Before performing service or maintenance operations on unit,
turn off main power switch to unit. Electrical shock could
cause personal injury.
WARNING
Do not provide power to unit or turn-on compressor unless
suction and discharge service valves are open.
WARNING
CONTENTS UNDER PRESSURE
Compressor contains oil and refrigerant under pressure.
Pressure must be relieved before installation, servicing or
opening any connections.
Pg 1
7-24
5H
Replaces: 5F-H-24SI Rev B

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Summary of Contents for Carlyle 5H

  • Page 1: Table Of Contents

    Open-Drive Compressors Installation, Start-Up and Service Instructions • 5H40-5H86 FACTORY-INSTALLED ELECTRIC CONTENTS UNLOADING Page • 5H120/126 COMPRESSORS • VALVES SAFETY CONSIDERATIONS ....1 SAFETY CONSIDERATIONS INSTALLATION .

  • Page 2: Installation

    5H80, 86, 120, and 126 compressors — 30 in. RISK OF PERSONAL INJURY Only approved refrigerants and refrigeration oils may be used. PREPARE FOUNDATION The 5H compressors may be fastened to: WARNING • A steel base and vibration isolators on the floor •...

  • Page 3: Step 2 - Receive Compressor

    11, 13,14,16, and 17 for rigging details. Step 3 — Install Unit TO MOUNT MOTOR ON BASE The motor fastening set, available as an accessory for all 5H base-mounted compressors, includes motor blocks and shims for motor alignment; cap screws, plate washers and lock washers for fastening motor to base;...
  • Page 4 Table 4 — Physical Data (HFC Refrigerants) COMPRESSOR MODEL 5H40 5H46 5H60 5H66 5H80 5H86 5H120 5H126 R-134a/R-407C NOMINAL Hp R-22 R-507/404A/448A/449A NUMBER OF CYLINDERS Bore (in.) 3-1/4 3-1/4 3-1/4 3-1/4 3-1/4 3-1/4 3-1/4 3-1/4 Stroke (in.) 2-3/4 3-7/16 2-3/4 3-7/16 2-3/4 3-7/16...
  • Page 5 2-1/8" ODF Discharge Shutoff Valve Name Plate Suction Discharge Manifold Cover (Remove For Strainer And 2-5/8" ODF High Pressure Relief Valve) Suction Shutoff Valve Pneumatic Control Conn. Seal Cover Plate 1"/4 IPS Control Oil Sight Glass Strainer Plug 5/8-18" Capacity Control Valve 1-1/8"...
  • Page 6 3-1/8" ODF Discharge Service Valve 3-1/8" ODF Suction Shutoff Valve Suction Manifold (Remove For Access To Suction Strainer) Access To High Pressure Relief Pneumatic Valve Control Conn. 1/4" IPS Seal Cover Plate Control Oil Sight Strainer Plug Glass 5/8-18" Capacity Control Valve Low Pressure 1-1/8"...
  • Page 7 Discharge Shutoff Valve 3-1/8" Suction Shutoff Valve 3-1/8” Suction Discharge Manifold Cover (Remove For Strainer And High Pressure Name Relief Valve) Plate Suction Manifold Cover (Remove For Access To Suction Strainer) Pneumatic Control Conn. 1/4" IPS Seal Plate Cover Control Oil Strainer Plug 5/8"-18 Sight Glass Capacity Control...
  • Page 8 Relief Valve Discharge Shutoff Discharge Valve 4-1/8" Pressure Suction Shutoff Valve 4-1/8" Full Flow High Oil Pressure Pressure Oil Filter Regulator 5/8" Oil Pump Pressure Seal (Before Oil Filter) Cover Plate Capacity Control Sight Glass Valve 1-1/8" Center Main Bearing Suction Manifold Cover Retaining Screw Access High Pressure...
  • Page 9 NOTE: Dimensions are in inches (mm). Fig. 6 — 5H41 Ammonia Units...
  • Page 10 NOTE: Dimensions are in inches (mm). MODEL NO. 5H41-C835D 30.03 [762.88] 28.32 [719.25] 24.49 [621.98] 12.24 [310.96] 5H41-C875D 30.03 [762.88] 28.32 [719.25] 27.64 [702.09] 13.81 [350.66] 5H41-C895D 27.65 [702.33] 22.70 [563.02] 24.49 [621.98] 12.24 [310.96] 5H41-C905D 27.65 [702.33] 23.20 [589.27] 27.64 [702.09] 13.81 [350.68] Fig.
  • Page 11 CENTER OF GRAVITY WEIGHT (in.) MODEL NO. (lbs) 5H40-C145 13.69 11.13 8.12 694.50 5H40-C155 13.51 11.82 8.14 764.96 5H40-C835 12.76 11.96 8.29 581.66 5H40-C875 12.69 12.67 8.29 649.70 5H40 5H40-C915 12.74 11.94 8.29 578.54 5H40-C925 12.67 12.68 8.29 649.00 5H40-C935 12.73 11.92 8.31...
  • Page 12 Fig. 8 — 5H40/41/46 Unit Rigging and Center of Gravity Diagram, Pump End (5H41 Model Shown)
  • Page 13 NOTE: Dimensions are in inches (mm). Fig. 9 — 5H61 Ammonia Unit...
  • Page 14 NOTE: Dimensions are in inches (mm). MODEL NO. 5H61-C835D 30.70 [779.76] 26.50 [673.44] 25.45 [646.39] 13.58 [344.86] 27.15 [689.72] 5H61-C875D 30.70 [779.76] 26.50 [673.44] 25.45 [646.39] 15.11 [383.80] 30.25 [768.32] 5H61-C895D 32.75 [831.75] 23.42 [663.76] — 13.58 [344.86] 27.15 [689.72] 5H61-C905D 32.75 [831.75] 26.13 [663.70]...
  • Page 15 CENTER OF GRAVITY WEIGHT (in.) MODEL NO. (lbs) 5H60-C145 14.05 11.18 8.44 801.24 5H60-C155 13.91 11.99 8.42 906.93 5H60-C835 13.12 11.88 8.30 688.62 5H60-C875 13.08 12.72 8.30 794.31 5H60 5H60-C915 13.10 11.89 8.30 687.67 5H60-C925 13.06 12.73 8.30 793.37 5H60-C935 13.09 11.89 8.29...
  • Page 16 Fig. 11 — 5H60/61/66 Unit Rigging and Center of Gravity Diagram, Pump End (5H61 Model Shown)
  • Page 17 NOTE: Dimensions are in inches (mm). Fig. 12 — 5H81 Ammonia Unit...
  • Page 18 NOTE: Dimensions are in inches (mm). MODEL NO. 5H81-C835D 42.72 [1084.99] 31.17 [791.72] 24.49 [622.12] 12.25 [311.06] 30.70 [779.96] 5H81-C875D 42.72 [1084.99] 31.17 [791.72] 27.67 [702.73] 13.83 [351.37] 30.70 [779.96] 5H81-C895D 41.16 [1045.51] 23.38 [593.93] 24.49 [622.12] 12.25 [311.06] — 5H81-C905D 41.16 [1045.51] 23.38 [593.93]...
  • Page 19 CENTER OF GRAVITY WEIGHT (in.) MODEL NO. (lbs) 5H80-C145 18.8 10.75 8.27 950.09 5H80-C155 19.24 12.3 8.32 1100.39 5H80-C835 19.42 11.90 8.32 955.60 5H80-C875 19.30 12.9 8.32 1105.97 5H80 5H80-C915 19.42 12.00 8.32 954.80 5H80-C925 19.30 12.90 8.32 1051.08 5H80-C935 19.30 11.90 8.29...
  • Page 20 Fig. 14 — 5H80/81/86 Unit Rigging and Center of Gravity Diagram, Pump End (5H81 Model Shown)
  • Page 21 Discharge Shutoff Valve 4-1/8" Suction Shutoff Valve 4-1/8" Oil Pressure Regulator 5/8" Seal Cover Plate Sight Glass High Pressure Suction Manifold Cover Center Main Bearing Port Plate (Remove For Access Retaining Screw Access To Suction Strainer) Crankcase Heater Casing Low Pressure Port Name Plate Pipe Cap 1/2"...
  • Page 22 5H 121 Amnonia CENTER OF GRAVITY WEIGHT (in.) MODEL NO. (lbs) 5H120-C149 20.5 1077.8 5H120-C149_SV 20.5 1077.8 5H120 5H120-C864 19.5 917.5 5H120-C64_SV 20.5 13.57 1177.8 5H121-C934 21.11 17.03 10.26 1639 5H121-C944 21.25 17.20 10.26 1600 5H121 5H121-C904 21.15 17.36 10.15...
  • Page 23 5H 121 Amnonia Fig. 17 — 5H120/121/126 Unit Rigging and Center of Gravity Diagram, Pump End (5H Model Shown)

  • Page 24: Step 5 - Install Multiple Compressors

    Check oil pressure immediately after starting compressor. Fig. 18 — Special Hand-Hole Cover and Equalizer Connections (Typical) Table 6 — 5H Compressor Crankcase Heater APPROVED REFRIGERANTS Package Compressor models 5H40, 5H46, 5H60, 5H66, 5H80, 5H86,...

  • Page 25: Direct Drive

    Use a 9/32 in. drill and a no. 6 listed in this guide as approved for use in a Carlyle open-drive taper reamer. Secure the motor and compressor to the base with compressor.

  • Page 26: Prepare For Initial Start-Up

    Carlyle has approved the following oil pressure safety switch with Backseat (open) compressor suction and discharge service the 5H ammonia and HFC compressors. The OPSS will mount di- valves. Open liquid line valve at receiver. rectly to the oil pump bearing end of the compressor. 5H41-5H81 ammonia models and 5H40-5H86 HFC models will have the Start evaporator fan or chilled water pump.

  • Page 27: Adjust Capacity Control (If Required)

    - Can be applied with a VFD to operate the compressor speed from 400-1750 rpm. Refer to Tables 1 and 4. If cylinder head unloading is not preferred, all 5H compressor models can be applied with a VFD for capacity control. The allowable speed range is 400 to 1750 rpm for non-ammonia models.

  • Page 28: Pressure Unloading (Capacity Control Operation)

    Power elements and valve lifting mechanisms are identical on all 5H120/126 CAPACITY CONTROL 5H compressors. However, when using capacity control, various methods are used to activate the power elements. This capacity control system is slightly different from the system on 5H40-5H86 compressors.
  • Page 29 Control Oil Stem Traveling Strainer Capacity Control Valve Unloader Power Element Unloader Drain Cylinder Sleeve Sleeve Piston Surge Chamber (5H Only) Control Oil To Other Drain Pressure Capillary Unloader Power Crankcase Drilled Pressure Elements Hole Hydraulic Oil Pump From Crankcase...
  • Page 30 UNIT REDUCTION SIZE STEPS 5H40 5H46 5H60 5H66 5H80 5H86 5H120 5H126 10.0 11.0 PSI Differential R-134a; 7 lb Range Adjustment Spring L — Load U — Unload R-22 & R-507/404A R-448A/R-449A; 11 lb Range Adjustment Spring Fig. 24 — Operating Sequence of Pressure Unloading Capacity Reduction Steps Table 8 —...
  • Page 31 5H40-5H86 FACTORY-INSTALLED ELECTRIC UNLOADING See Fig. 25 for capacity control steps. Unloader Valve Oil Pressure Safety Switch (OPSS) Factory Installed CAPACITY CONTROL STEPS — 5H40-5H86 UNLOADING CAPACITY UNLOADER VALVE MODEL UNLOADING STEPS CYLINDER NO. CYLINDERS (% OF FULL LOAD) DESIGNATION 5H40/46 3 of 4 (3 steps) 5H60/66...
  • Page 32 To Unload, Dump Control Oil Back Into Oil Remove Hydraulic Remove Hydraulic Reservoir through Crankcase and Oil Fill Reservoir through Crankcase and Oil Fill Magnetic Plug Magnetic Plug Relay. Relay. Connection. Connection. (Pump Intake) (Pump Intake) Fig. 26 — 5H 120/126 Bearing Head Assembly...
  • Page 33 This Port Closed From High Side of Oil Pump From Unloader Connections When Unloading Desired, To Unloader Connections. Oil Solenoid Valve Should Allow This Port Pressure Loads This Step When Oil from Unloaders to Dump into Closed Solenoid Valve Allows Flow as Oil Sump.
  • Page 34 Unloader Valve Oil Pressure Safety Switch (OPSS) Factory Installed CAPACITY CONTROL STEPS — AMMONIA CYLINDER UNLOADING CAPACITY UNLOADER VALVE UNLOADING MODEL UNLOADED CYLINDERS (% OF FULL LOAD) DESIGNATION STEP SEQUENCE 5H41 2 of 4 (2 steps) 5H61 4 of 6 (4 steps) 5H81 5 of 8 (3 steps) 2 and 4...
  • Page 35 5H41 5H61 5H81 Fig. 30 — Cylinder Unloading Sequence (Ammonia)
  • Page 36 The lifting fork will pivot upward, causing the lifter spring/pins to lift the suction valve disc off the valve Suction Valve plate to unload the cylinder. Disc. Lifter Springs and Pins Lifting Fork Unloader Solenoid Valve Piston Unloader Power Element Compressor Crankcase Unloader...

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