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Literature and other documents describing the features, benefits and technical characteristics of Carlyle compressors.

. SERVICE GUIDE 06D/06E/06CC COMPRESSORS. WHAT THIS GUIDE CAN DO FOR YOU Carlyle Compressor Company provides this guide to aid the service specialist in proper installation, service, and maintenance of 06D, E, CC compressors. Following the procedures in this guide will extend the life of the system and improve performance. Exploded View — 6-Cylinder 06D Compressor.56 Exploded View — 6-Cylinder 06E Compressor.58 2.10 Torque Guide –– 06D and 06CC (16 to 37 Cfm) Compressors.

SERIAL NUMBER BAR CODE - For Carlyle internal use only. 1.3 — Compressor Serial Number Significance ALL NEW. Documents Similar To Carlyle Service Manual. The popular 020-611 Carlyle Pocket Service Guide has been updated and improved! Order literature P/N: 020-611 in any quantity at $2.50 each. Or view/download the file online.

60 2.11 Torque Guide –– 06E and 06CC (50 to 99 Cfm) Compressors. 61 3.0 COMPRESSOR AND PARTS DATA. 3.20 Service Valve Gaskets (06D, E, CC). 90 3.21 Oil Drain Plug Adapter.91 3.22 Sight Glass Adapters for Oil Equalization.91 3.23 Replacement Sight Glass/Installation Tool.91 3.24 Replacement Motor End Mounting Foot.91 3.25 Gaskets –– Cylinder Head and Valve Plate.92 3.26 Miscellaneous. 1.0 — GENERAL COMPRESSOR AND CUSTOMER INFORMATION 1.1 — Compressor Model Number Significance 06D COMPRESSORS 06DR 3 37 0 D A 36 5 A – (RP). Model = 0, Package = 1 or 9, A = Shipped Without Oil Oil and Refrigeration (06DR, DM) Unloading Variable.

06E COMPRESSORS 06ER 3 99 3 0 A – (RP). Model = 0, Package = 1 or 9, A = Shipped Without Oil Design Variable: New Compressors: 0 = OEM Model 1 = Carrier A/C Model 2 = Old Design Refrigeration Valve Plates 6 = Carrier A/C Model 9 = Cemak Model S = Oil Sensor Block and OPSS Sensor. NOTE: USE OF “Cfm” AS MODEL SIZE DESIGNATION Carlyle uses the “Cfm” designation in the model number to identify the compressor size. The Cfm values are the sixth and seventh digits of the model number.

See example above. Carlyle offers two series of compressors based on body size. UL (Underwriters Labo- ratory) and CSA (Canadian Standards Association). All 60 Hz semi-hermetic Carlyle Compressors are UL and CSA recognized and comply with UL, CSA, and NEC (National Electrical Code) requirements for internal motor protection. SERIAL NUMBER BAR CODE - For Carlyle internal use only. ELECTRICAL CHARACTERISTICS - Are shown for all semi-hermetic compressors. Voltages are shown with respective operating ranges for both 50 and 60 cycle opera- tion.

1.3 — Compressor Serial Number Significance ALL NEW COMPRESSORS Example: S/N 3695J00123 36 95 J 00123 Numerical Sequence Plant Location: J = Syracuse, U = Atlanta Year of Manufacture: 93, 94, 95, etc. Week of Manufacture: 01 thru 52 Begin Jan.1st ALL SERVICE COMPRESSORS Example: S/N 3602UD0123 36 02 U D 0123. Equipment may carry an extended OEM warranty if that warranty has been purchased from the OEM. The OEM issues the extended warranty, not Carlyle or its distributors, and the OEM is responsible for providing the end user with the credit. OEM or the OEM’s local representative. If questions cannot be answered by the OEM or this Service Guide, please contact the Carlyle engineering group.

The following recommended start-up procedure for Carlyle 06D, 06E, and 06CC compressors will help eliminate initial. 2.2 — Recommended Start-Up Procedure Reliability data of Carlyle’s 06D, 06E, and 06CC refrigera- tion compressors indicate that at least half of compressor failures occur during the first two to four months of opera- tion. Carlyle ships most new and service compressors without oil.

The oil level for 06CC size 16 to 37 Cfm compressors and all 06D compressors should be at 1/4 to 3/4 of the sight glass. The oil level for 06CC size 50 to 99 Cfm compressors and all 06E compressors should be at 1/8 to 3/8 of the sight glass. Typically, equaliza- tion lines are 1-1/8 in. (28 mm) in diameter or larger. For 06D compressors, a sight glass in the line is required to determine the system oil level. Parallel systems using three (3) or more 06E compressors require the use of a common motor barrel interconnection line between compressors. Use only Carlyle approved oil appropriate for the refrig- erant being used.

Section 3.6 on pages 69 to 71 list all the approved oils. Section 3.9 on page 72 notes the correct oil. Leak test, evacuate, and dehydrate the system. Charge the system. When initially charging the high side of the system with liquid refrigerant, all service valves should be closed (front seated). This will prevent refrigerant from migrating to the compressor crankcase and into the oil, causing a flooded start. After the compressor has run 10 to 15 minutes and no liquid floodback is evident, completely open suction ser- vice valve.

The other compressors within the system should be started in the same manner. To ensure operating oil levels are within acceptable lim- its, closely observe the oil level in the compressors until the system has stabilized. Ensure defrost cycles are staggered so no more than one third of the system is on defrost at any time. COMPRESSOR OPERATING LIMITS Figures 1A and 1B show the components and typical operat- ing ranges of the Carlyle 06D, E, and 06CC compressors. NOTE: SIGHT GLASS OF ALL 06E COMPRESSORS LOCATED ON PE FACE OF COMPRESSOR. FACTORY INSTALLED OIL PRESSURE SENSOR BLOCK FOR AVAILABLE OIL PRESSURE SAFETY SWITCH (OPSS). FOR MORE INFORMATION SEE SECTION 3.12.

1A — Typical 06D, E Operating Limits. SUCTION VALVE LOCATION MAXIMUM PREFERRED RGT IS 35°F TO 50°F (2°C TO 10°C) 1/4' NPT OIL PUMP PRESSURE CONNECTION SEE PAGE 72 SECTION 3.9 CRANKCASE OIL SUMP 100°F TO 130°F (38°C TO 54°C) MEASURE BELOW CRANKCASE OIL LEVEL, MAXIMUM OIL LEVEL SIGHT GLASS FOR 06CC (16 TO 37 Cfm)- ALLOWABLE 165°F (74°C) 1/4 TO 3/4 SIGHT GLASS (SIGHT GLASS FOR “D”. 2.3 — Troubleshooting Procedure DANGER Before attempting service work on the compressor, the fol- lowing safety precautions must be strictly observed. Failure to follow these instructions could result in serious personal injury or death. See warning label.

Follow recognized safety practices and wear protective goggles. COMPRESSOR ISOLATION If you have determined there is no refrigerant leak around the terminals and the compressor must be replaced, proceed beginning with Step 1: 1. Shut off suction and discharge service valves to isolate compressor and slowly remove all refrigerant in com- pressor. 2.4 — Service Procedures The service section covers replacement of valve plates and gaskets, service to the bearing head assembly containing the oil pump, and a clean-up procedure to follow in case of motor burn out. Most other internal service requires replace- ment of the compressor. DISASSEMBLY 1. Disassemble cylinder heads by removing cylinder head bolts.

Leave at least two bolts partially threaded to pre- vent any problems if refrigerant is accidently left in the compressor under pressure. To separate the cylinder head from the valve plate, pry up between the head and valve plate. Pry up along sides of valve plate to remove valve plate from crankcase. This provides access to suction reed valves (see Fig. Remove suction valves from dowel pins.

On 06D and 06CC (16 to 37 Cfm) compressors, also remove the suction valve positioning springs (see Fig. 3 — Valve Plate Removed (06E Refrigeration Valve Plate Shown) Fig. 4 — Suction Valve and Positioning Springs in Place (06D Shown). They must be reassembled in their original position. Install the suction valve position- ing springs (06CC size 16 to 37 Cfm and 06D compres- sors only) on dowel pins.

Assemble positioning springs with spring ends bearing against cylinder deck (Fig. 4), spring bow upward. Replace cylinder head.

To prevent high to low side leak in center of cylinder head gasket, torque 06D cylinder head cap screws to 30 to 35 ft-lb (40 to 48 Nm), and 06E cylinder head cap screws to 90 to 100 ft-lb (122 to 136 Nm). 06E refrigeration and A/C duty compres- sors (Fig. For 06D, E, CC oil pressure, see page 72, Section 3.9.

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. BEARING HEAD SCREWS (8) Fig.

6 — Removing Pump End Bearing Head (06D Compressor) 1. To disassemble, first remove four (4) cap screws from the bearing head cover plate and remove the oil feed guide vane and spring. Remove the two (2) drive segment cap screws from the end of the crankshaft (see Fig. (see replacement bearing head package listed below). Replacement Bearing Head Compressor Package 06CC, 16 to 37 Cfm, and all 06D 06DA660126 06CC, 50 to 99 Cfm, and all 06E 06EA660157 While bearing head is removed, inspect internal running gear for obvious problems (broken rods or pistons).

To reassemble, bolt the bearing head to the crankcase. Bolt torque:. 06CC, 16 to 37 Cfm, and all 06D: 30 to 35 ft-lb (40 to 48. 06CC, 50 to 99 Cfm, and all 06E: 50 to 60 ft-lb (75 to 81 5.

WARNING Before attempting service work on the compressor, see safety precautions listed in Section 2.3 and on compressor terminal box cover. Also follow any installation instructions provided with the replacement compressor. Failure to fol- low these instructions could result in equipment dam- age or serious personal injury. Evacuate and dehydrate replacement compressor. Ensure oil in compressor is at the proper level. NOTE: Since most new and service compressors are now shipped without oil in the crankcase, you must check to see if there is oil.

Adding or charging oil is usu- ally easier prior to installing the compressor. 2.5 — Connection Points, 06D, 06E, and 06CC Compressors LIFTING LUG DISCHARGE VALVE (NEW MODELS ONLY) LOCATION SINGLE PHASE MODELS SUCTION VALVE LOCATED AT MOTOR END 1/4' NPT CONNECTION USED FOR: a) LOW PRESSURE THREE PHASE MODELS CONNECTION SUCTION VALVE. The 13 and 16 Cfm service compressors are made with dual suction ports. 1/8' NPT OIL PRESSURE TAP OLD STYLE 06D BEARING HEAD ASSEMBLY Fig. 9 — 06D 4-Cylinder Compressor (13 to 16 Cfm) Connection Points. 1/8' NPT OIL PRESSURE TAP OLD STYLE 06D BEARING HEAD ASSEMBLY Fig.

10 — 06D 4-Cylinder Compressor (18 to 20 Cfm) Connection Points. 1/8' NPT OIL PRESSURE TAP OLD STYLE 06D BEARING HEAD ASSEMBLY Fig. 11 — 06D 6-Cylinder Compressor (25, 28, 37, and 41 Cfm) Connection Points. DISCHARGE VALVE LOCATION TEMPERATURE SENSOR CYLINDER HEAD LIFTING LUG DISCHARGE GAS (NEW MODELS ONLY) CYLINDER HEAD COOLING FAN MOUNTING STUDS NAMEPLATE LOCATION (06ER MODELS ONLY) CRANKCASE MOTOR BARREL-LEFT SIDE 1/4' NPT HIGH PRESSURE SUCTION VALVE CONNECTION LOCATION (ON MOTOR END COVER) 1/4'. 1/4' NPT HIGH PRESSURE CONNECTION TEMPERATURE SENSOR CYLINDER HEAD DISCHARGE VALVE AND SUCTION VALVE DISCHARGE GAS LIFTING LUG LOCATION LOCATION (ON MOTOR END COVER) CYLINDER HEAD COOLING FAN MOUNTING STUDS (06ER MODELS ONLY) NAMEPLATE LOCATION 1/4' NPT LOW PRESSURE CONNECTION FACTORY SUPPLIED 5/8-18 SAE OIL DRAIN SCHRADER TYPE FITTING. The bolts have no exact metric equivalents. Therefore, to prevent possible cross-threading, loose bolts, or damage to threaded portions of the casing, comparable metric measurements are not included.

14A — 06CC Compressor (16 to 37 Cfm), 06D Body Pump End Connection Points. The bolts have no exact metric equivalents. Therefore, to prevent possible cross-threading, loose bolts, or damage to threaded portions of the casing, comparable metric measurements are not included. 14B — 06CC Compressor (16 to 37 Cfm), 06D Body Motor End Connection Points. 1/4' HIGH STAGE CYLINDER HEAD NAMEPLATE SUCTION VALVE PRESSURE TAP SENSOR (HIGH STAGE LOCATION DISCHARGE TEMP.) TERMINAL 1/4' NPT INTERMEDIATE STAGE PRESSURE CONNECTION FACTORY SUPPLIED SCHRADER TYPE FITTING 1/4' NPT (2) CONNECTIONS (1) ABOVE SIGHT GLASS (1) ABOVE BLANK PLATE USED FOR: A) OIL FILL CONNECTION CRANKCASE HEATER. FROM SUBCOOLING HEAT EXCHANGER OR PORT 3/4-10 UNC C³ SUCTION MANIFOLD TO DESUPERHEAT LOW LIFTING LUG CONN.

(TO LOW STAGE CYLINDERS) STAGE DISCHARGE (LUG NOT SUPPLIED) IF PORT NOT AVAILABLE TAP TUBING HERE IF AVAILABLE USE PORT ON SERVICE 1/4'. 2.10 — Torque Guide - 06D and 06CC (16 to 37 Cfm) Compressors SIZE TORQUE TORQUE THREADS DIAMETER RANGE RANGE USAGE PER INCH (in.) (FT-LB) (NM) 1/16 Pipe 8-12 11-16 Pipe plug crankshaft Pipe 6-10 8-14 Oil return check valve No. 2.11 — Torque Guide - 06E and 06CC (50 to 99 Cfm) Compressors SIZE TORQUE TORQUE THREADS DIAMETER RANGE RANGE USAGE PER INCH (in.) (FT-LB) (NM) 1/16 Pipe 8-12 11-16 Pipe plug crankshaft Pipe 10-12 14-16 Orifice crankcase No. 10 Oil pump drive segment Con-rod cap screw 10-12. 3.4 — 06D, E High Efficiency (H.E.) Compressors High efficiency compressors were phased in between 1985 and 1987.

A high efficiency compressor can be identified as follows: All 06D H.E. Compressors (new or service replacement) have the number “3” in the 11th digit of the model number.

Carlyle has approved the following UL listed refrigerants R-404A, R-407A, R-407C, R-407F, R-448A, R-449A, R-450A, R-452A, and R-507 for use in 06D, E, and CC compressors. UL listed R-134a and R-513A are only approved for use in 06D and E compressors. In retrofit applications, a high flow oil pump is required. For HFCs not listed above, please contact Carlyle Engineer- ing for oil recommendations.

FOR CFCs: Carlyle has historically approved the following UL listed refrigerants R-22, R-500, and R-502 for use in 06D, E, and CC compressors. A1/A1 (low flammability/low toxicity). The rat- ing is based on ASHRAE 34 safety standard. Not all A1/A1 refrig- erants are approved for use in Carlyle compressors.

Some of the refrigerants or blends available are either flammable (A1/A2 or A1/A3) and/or toxic (A1/B1 or A1/B3). BETWEEN MAY 1984 AND MARCH 1994 OR BETWEEN S/N 2084J AND 1094J:. For all 06D, E, CC compressors, the oil pressure is 16 to 22 psi (1.1 to 1.5 Bars) BEFORE MAY 1984 OR BEFORE S/N 2084J:. 3.10 — High Flow Oil Pump (Bearing Head) Carlyle introduced a new high flow oil pump to provide improved lubrication with the new HFC refrigerants and POE lubricants. The pump is a durable, automatically reversible, high flow design. The high flow design improves. 3.12 — Oil Pressure Safety Switch Carlyle uses as standard the 120-second time delay oil safety switch, as this time period is preferred for HFC/POE sys- tems.

This is a change from the 45 to 60-second time delay used previously with CFC and HCFC systems. It is not nec- essary to change out the older, shorter time delay switch unless the unit is converted to an HFC/POE system. Electronic Oil Pressure Safety Switch See Bulletin 11T-2 at www.carlylecompressor.com Description: The new Carlyle Oil Pressure Safety Switch (OPSS) is an enhanced means for protecting the compressor from loss of lubrication. The new Carlyle OPSS is an upgrade to the. (not in direct contact with the oil circuit). Screw-in Sensor Electrical Unit (Carlyle Part# 06DA509571) (Carlyle Part# 06DA509570) Oil Pump pressure inlet Coupling Ring Oring (maintains oil pressure DP) Oil Sump Pressure inlet Fig.

Compressor Start: Oil pressure monitoring is activated once the supply voltage is applied to the operating recog- nition signal, which is applied to D1 (violet wire) via an auxiliary contactor or motor contactor (see wiring dia- gram). Following a compressor start, the OPSS allows for a 120 second oil pressure transition delay to allow the compressor to reach steady oil pressures. LED indicator (See LED Status Table). 2.) Oil Sensor Block Installation (06D/E/CC) 1.

Remove cover plate bolts, cover plate and gasket from bearing head. (During reassembly be sure that spring and recess cup are in place and do not re-use factory installed gasket.). Fig.

18 — OPSS Sensor Block Gasket 4. Next, install the sensor block (P/N 06EA507202) over the gasket and the 1/4' NPT O-ring seal fitting as shown. Mount the sensor block to the bearing head using the four 5/16'-18 x 1-1/4' Allen head bolts provided in the kit (Torque to 15-20 ft/lbs). Tighten the sensor's 1' hex nut securely to the sensor block (torque 45-55 ft/lbs). 20 — OPSS Sensor Installed 6. Installation and Wiring for OPSS (06D/E/CC/M). Install the coupling ring end of the OPSS electrical unit to the sensor by hand and secure tightly.

Technical specifications Permitted Temperature -22 F to +194 F Cut-out 9 psig ±1 psig Differential Pressure Reset 13 psig ±1 psig Operating Pressure 435 psig Electronic Unit (BN/BU) Dual Voltage Connection AC 50/60 Hz 115-230V -15/+10% Operating Recognition Connection (D1) Dual Voltage AC 50/60 Hz 115-230V -15/+10% Ambient Temperature Range -22 F to 158 F Delays. The OPSS can be reset in three different ways:. Disconnect the module from the power supply for 5 sec- onds. Push the rest button. Reset by operating recognition signal (D1), violet wire for 5 seconds. Once the module is reset, the compressor is allowed to re- start again after a 120 second time delay. 3.13 — 06CC, E Discharge Gas Cylinder Head Temperature Sensor and 06E Pressure Relief Valve All OEM Carlyle 06EA, EM, ER compressors since 1982 are equipped with a discharge gas temperature sensor.

The sensor is installed in the discharge or center head on all six-cylinder (three-head) models. NOTE: 325 F sensor is no longer available, for service replacement use HN68GA242. Since 1993 all Carrier 06 series air conditioning com- pressors have been made without a sensor. All Carlyle OEM 06 series compressors are equipped with a sensor. Starting in mid-1998 all Carlyle OEM compressors, including 06EA, EM, ER and all 06CC models, are built using the HN68GA242 sensor.

3.15 — Capacity Control Accessory Packages (Suction Cut-Off Unloading Type) The following suction cut-off capacity control packages are available to field convert those 06D, 06E compressors with- out unloading. With the exception of the 06D 2-cylinder models, these packages can be added to any new, replace- ment, or existing 06D or 06E compressors. (viewed from P.E. Of compressor): 06D 4-cyl - left hand cylinder deck 06E 4-cyl - right hand cylinder deck 06D, 06E 6-cyl - either cylinder deck (both when appli- cable) 4. Unloader valve gasket part number 06EA501253.

Unloader is not available for 06CC compressors. LOADED OPERATION UNLOADED OPERATION Fig. 22 — Loaded and Unloaded Operation 3.16 — Capacity Control Coil Packages (06D, E) COIL PACKAGE PART NUMBER VOLTAGE EF19ZZ001 24-1-50/60 EF19ZZ002 120-1-50/60 EF19ZZ003 208/240-1-50/60. INSERTION HEATERS: Insert into cast well (hole) in cast iron bottom plate.

Circular clip with barbs secures heater. Used on 06D( )718, 818, and 820 4-cylinder compressors, all 6-cylinder 06D compres- sors, all 06E and all 06CC compressors. Insertion heaters are available in 125 and 180 watt sizes. Valve packages consist of (1) service shut-off valve and required gasket and mounting bolts. NOTE: Sensor valve packages required with Carlyle Sentinel module. Adapter for 06CC Liquid Injection Port PN 2TA1004. 3.20 — Service Valve Gaskets (06D, E, CC).

3.21 — Oil Drain Plug Adapter All new compressors, except for 06D( )808, 109, 013, 313, and 316 models, are built with a 7/16-20 SAE fitting and O-ring as the oil drain plug. Carlyle offers an oil drain adapter, P/N DE14CA126, which replaces the SAE plug. 3.25 — Gaskets - Cylinder Head and Valve Plate GASKET TYPE PART NUMBER 06D COMPRESSORS 1: Cylinder head gaskets a. Side bank, no unloading 05GA502213 b.

Side bank, with unloading (suction cut-off design) 05GA602223 c. Side bank, with unloading (hot gas bypass design) 05GA502183 d. 06E, 06CC (50 to 99 Cfm) 6G45-1082 Sensor Block Gasket COMPRESSOR USAGE GASKET 06D, 06E, 06CC 06DA504473 Electrical Terminal Barrel Nut Tool (Socket tool used for installation for terminal nuts) COMPRESSOR USAGE GASKET All 06D, 06CC (16 to 37 Cfm) P920-0009. Service valve plate kits include: (1) valve plate assembly, (2) suction reed valves, (3) cylinder head gaskets (side, center and suction gas unloading), (1) valve plate gasket; and for 06D compressors there are (2) suc- tion valve position springs. used on all 06E 66 and 99 Cfm compressor models.

used on all 06E compressors with capacity control. considered for use with all 06D 37 and 41 Cfm compressor models. considered for use with all 06D 6-cylinder compressors with capacity control. Fabricated All 06D 4-cyl. (6” x 5”) (15.2 x 12.7 cm) 06DA660150 Fabricated All 06D 6-cyl. And 06CC 16 to 37 Cfm (6” x 8”) (15.2 x 20.3 cm) 06EA660095 Drawn Steel All 06E 4 and 6-cyl.

Compressors and 06CC 50 to 99 Cfm (7” x 7”) (17.8 x 17.8 cm). These baffle plates, sandwiched between two gaskets, are installed between the compressor discharge service valve and the compressor crankcase or cylinder head. For further details, see Carlyle OEM Bulletins No.

BAFFLE COMPRESSOR APPLICATION. † Two overloads in parallel in legs 1 and 3.

Most 06D compressors have internal thermostat installed in motor and wire across terminals 8 and 9 at the terminal block. It trips (opens) control circuit at 221 F (105 C) and resets at 181 F (83 C). 4.10 — 06D and 06CC (16-37 Cfm) Electronic Overcurrent Protection The latest production Carlyle 06D and 06CC (16-37 Cfm) compressors manufactured after August 2015, S/N starting with '3115', include a new electronic overcurrent protection module, that interprets a signal from a PTC triplet (embed- ded in the stator windings) and a current transformer (located in terminal box).

CUSTOMER MODEL NUMBER CHANGES: The 10th digit of the 06D customer model number will indi- cate the rated control voltage of the electronic overcurrent protection module that is applied. Three new customer mod- els will replace each existing 06D model.

Please see the fol- lowing examples of the 06D customer model number changes. MCC value based on the compressor model number. For additional information on the kit and installation, please see 99TA516180A located on the Carlyle Compressor website (www.carlylecompressor.com). ELECTRONIC OVERCURRENT PROTECTION SERVICE REPLACEMENT KIT NUMBER.

06C. M37J. 06DA6606DBND0188 18.8 06C. M37Q. 06DA6606DBND0378 37.8 06D. 013. 132.

06DA6606DBNB0174 06D. 013. 232. 06DA6606DBNC0174 17.4 06D. 013. 332. 06DA6606DBND0174.

MODEL NUMBER Control Voltage 110-220V 24V AC 24V DC (Amps) 06D. 313. 136. 06DA6606DBNB0135 06D. 313. 236.

06DA6606DBNC0135 13.5 06D. 313. 336. 06DA6606DBND0135 06D. 313.

137. 06DA6606DBNB0164. MODEL NUMBER Control Voltage 110-220V 24V AC 24V DC (Amps) 06D.

337. 137. 06DA6606DBNB0378 06D. 337. 237.

06DA6606DBNC0378 37.8 06D. 337. 337. 06DA6606DBND0378 06D. 537. 101.

06DA6606DBNB0320. MODEL NUMBER Control Voltage 110-220V 24V AC 24V DC (Amps) 06D. 725. 136. 06DA6606DBNB0220 06D.

725. 236. 06DA6606DBNC0220 22.0 06D. 725. 336.

06DA6606DBND0220 06D. 725. 137. 06DA6606DBNB0266. MODEL NUMBER Control Voltage 110-220V 24V AC 24V DC (Amps) 06D.

820. 131. 06DA6606DBNB0176 06D. 820. 231. 06DA6606DBNC0176 17.6 06D.

820. 331. 06DA6606DBND0176 06D. 820. 132. 06DA6606DBNB0440.

SERVICE RETROFIT KITS (THREE PHASE): The below kits are intended to service Carlyle 06D and 06CC (16-37 Cfm) compressors manufactured BEFORE August 2015, S/N starting with '3115', with the factory installed electromechanical overcurrent protection and a three phase motor. The provided service kits are for RET.

06C. 337Q. 06DA6606DBSB0378 06DA6606DBSC0378 06DA6606DBSD0378 37.8 06D.

013. A13. 06DA6606DBSB0105 06DA6606DBSC0105 06DA6606DBSD0105 10.5 06D. 013. A31.

06DA6606DBSB0070 06DA6606DBSC0070 06DA6606DBSD0070 06D. 013. A32.

06DA6606DBSB0174 06DA6606DBSC0174 06DA6606DBSD0174 17.4. 110-220V 24V AC 24V DC (Amps) 06D. 337.

A13. 06DA6606DBSB0378 06DA6606DBSC0378 06DA6606DBSD0378 37.8 06D.

337. A31. 06DA6606DBSB0250 06DA6606DBSC0250 06DA6606DBSD0250 25.0 06D. 337.

A32. 06DA6606DBSB0620 06DA6606DBSC0620 06DA6606DBSD0620 62.0. 110-220V 24V AC 24V DC (Amps) 06D. 816. A13. 06DA6606DBSB0266 06DA6606DBSC0266 06DA6606DBSD0266 26.6 06D.

816. A31. 06DA6606DBSB0176 06DA6606DBSC0176 06DA6606DBSD0176 17.6 06D. 816. A32. 06DA6606DBSB0440 06DA6606DBSC0440 06DA6606DBSD0440 44.0.

110-220V 24V AC 24V DC (Amps) 06D. 013. A33. 06DA6706DBSB0326 06DA6706DBSC0326 06DA6706DBSD0326 32.6 06D. 109. A03. 06DA6706DBSB0240 06DA6706DBSC0240 06DA6706DBSD0240 24.0 06D.

109. A33. 06DA6706DBSB0240 06DA6706DBSC0240 06DA6706DBSD0240 24.0. Box Packages. 06D & 06CC (17-37 Cfm) COMPRESSORS Single Phase Fig. 23 — Single Phase Electromechanical Overcurrent Protection Three Phase. 3rd overload required on some compressors.

See 4.9 06D compressor overloads. 24 — Three Phase Electromechanical Overcurrent Protection. PIN NOT USED CUSTOMER WIRING SHOWN SOLID Fig. 25 — Electronic Overcurrent Protection (SERVICE ONLY) CUSTOMER WIRING SHOWN SOLID Fig. 26 — Three Phase Electronic Overcurrent Protection (RETROFIT ONLY). CUSTOMER WIRING SHOWN SOLID Fig. 27 — Single Phase Electronic Overcurrent Protection (RETROFIT ONLY).

06E COMPRESSORS (ACROSS-THE-LINE XL START) Fig. 28 — 06E Compressors (Across-the-Line XL Start). 06E COMPRESSORS (PART WINDING START) Fig. 30 — Terminal Post Arrangement, Detail View (06E and 06CC 50 to 99 Cfm) Fig. 29 — 06E Compressors (Part Winding Start). 4.12 — Voltage and Current Unbalance VOLTAGE UNBALANCE (Maximum 2%) Voltage unbalance can cause motors to overheat and fail. Below is the recommended method for determining voltage unbalance.

Example: Supply voltage is 240-3-60 AB = 243 volts BC = 236 volts AC = 238 volts 243 + 236 + 238 Average Voltage =. (see the previous section), with a maximum acceptable current unbalance of 10%. 5.0 COMPRESSOR SERVICE WORKSHEETS Carlyle recommends that the Compressor Service Work- sheets (pages 136 and 137) be copied (and enlarged, if pre- ferred) and filled out for each compressor at initial start-up and each time the compressor is serviced.

06D, 06E Compressor Service Worksheet Mechanic: Date: From Compressor Nameplate: Model No.: Serial No.: Motor No.: Voltage: Allow compressor to run for 30 minutes, then obtain the pressures and body temperature at the locations shown below. Check for proper oil return in sight glass. 06CC Compressor Service Worksheet Mechanic: Date: From Compressor Nameplate: Model No.: Serial No.: Motor No.: Voltage: Allow compressor to run for 30 minutes, then obtain the pressures and body temperature at the locations shown below. Check for proper oil return in sight glass. 6.0 — SMART UNLOADING & PWM VALVE The SMART controller is designed to operate the compres- sor cylinder head unloaders or a PWM Valve installed in the compressor's suction line using Pulse Width Modulation (PWM). See Application Guide 574-078 at www.carlylecompres- sor.com 6.1 —. Additionally, a smart unloading cylinder head can be identified by a “horizontal line” stamped on the cylinder head.

Model Family Model Number Change Example 06D semi-hermetic Insert “Y” for 13th digit 06DR3370DA36YA 06E semi-hermetic Insert “Y” for 5th digit 06ERY7530A Compressors applying a PWM Valve installed in the suc- tion line of the compressor will not have a “Y”. SOLENOID COIL P/N 8ADB000688 (240 vac) P/N 8ADB000689 (120 vac) PWM VALVE P/N 8ADB000690 P/N 8ADB000907 Fig. 32 — PWM Valve Installed 6.3 — Smart Controller Inputs/Outputs CONTROLLER INPUT SIGNAL The smart controller (see Fig. 33) receives a 0 to 10 VDC input signal from the system’s rack controller. Every smart controller comes with a 1000 ohm resistor installed. Remove only if installing the Carlyle discharge temperature sensor for discharge temperature control; otherwise do not remove the resistor. Output Fig.

33 — Smart Controller COMPRESSOR CONFIGURATION INPUT The smart controller is configurable for all 06D, 06E, and 06M compressor models by simply adjusting the onboard DIP switches. The DIP switches configure the compressor for Low or Medium/High temperature application and set the compressor’s capacity modulation range profile. The input demand voltage is 8.0 VDC. The Comp/Alarm contactor should be wired into the compressor’s control power circuit if the Carlyle dis- charge temperature sensor is being used to control com- pressor discharge temperature. This will ensure the compressor will shut down if discharge temperature exceeds 295 F or sensor fails.

COIL #1, COIL #2 The unloader solenoid output is a triac output. The triac is rated for 115/208-230 VAC with a maximum continuous rating of 30 VA. The smart controller energizes the unloader solenoid coil in an on/off sequence per the 0 to 10 VDC ana- log input signal received by the smart controller. 33% - 100% Figure 36 06D, 06E 67% - 100% Figure 36 67% - 100% Figure 37 06D, 06E 50% - 100% Figure 37 06D, 06CC, 06M 3, 4, or 6 PWM Valve 20% - 100% Figure 37 3, 4, or 6 None None. 2 stages of Unloading PWM Valve 20-100% 100% 1 stage of Unloading 50-100% No Capacity Modulation 1 stage of Unloading Compressor Monitoring 67-100% and Protection only Position A Position C Position B Position D Fig.

34 — Smart Controller Configuration (DIP Switches) Fig. 4 Cylinder, 1 Stage Unloader Fig. 35 — Smart Controller Configuration (DIP Switches), Compressor Capacity (cont). Carlyle Smart Unloading Module Wiring Schematic Isolation R elay R ack C om pressor Alarm Status Input C ontroller 115 / 230 Vac C ontrol Pow er C om pressor C om pressor C apacity Start /Stop O utput (0-10 Vdc). 24 VAC supply power, discharge temperature sensor failure, discharge tem- perature 295 F, or the input demand voltage is 8.0 VDC.

The COMP contactor should be wired into the compressor’s control power circuit if the Carlyle discharge temperature sensor is being used to control compressor discharge temperature. This will ensure the compressor will shut down if discharge temperature exceeds 295 F or the sensor fails. Isolation R elay R ack C om pressor Alarm Status Input C ontroller 115 / 230 Vac C ontrol Pow er C om pressor C om pressor C apacity Start /Stop O utput (0-10 Vdc) C om pressor 2 am p 120 V C om p Protection D evices M otor. Service Table POSITION A POSITION B POSITION C 06D/E COMPRESSOR 3 AND 6 6 CYLINDER 4 CYLINDER CAPACITY CYLINDER COMPRESSOR COMPRESSOR COMPRESSOR CAPACITY CAPACITY CAPACITY DEMAND MODULATION MODULATION MODULATION PERCENTAGE SIGNAL 33 - 100% 67 - 100% 50 - 100%. 175 F — Cylinder Head Fan OFF Fig.

38 — Discharge Temperatures 6.7 — PWM Valve The Carlyle pulse width modulation (PWM) valve is a robust high cycle capacity control valve designed to modu- late and control compressor capacity from 20% to 100% of. PWM control signal from the smart controller (see Func- tional Overview on page 138). The Carlyle PWM valve (Fig. 39) is designed to work spe- cifically with the Carlyle 06D, 06CC, and 06M compressor models for all low, medium, and high temperature applica- tions. tubing run leading to the inlet of the compressor's suc- tion service valve.

The PWM valve must be mounted in a horizontal posi- tion so the solenoid coil valve stem is in the vertical position. Mounting in any other direction or imposing a tilt angle may result in valve malfunction.

Use Carlyle solenoid coil 8ADB000688 or 8ADB000689. These coils have been qualified and life-cycle tested with the PWM valve.

The use of any other coil is not approved by Carlyle. The PWM valve solenoid coil should wire back to the Smart Control, Coil #1 position as shown in electrical schematic Fig. NOTE: If the PWM valve fails in the close position, the compressor suction line will isolate and the compressor will pulldown into a continuous vacuum. It is recommended that a pressure transducer be installed to the body of the compressor for monitoring crankcase pressure by the system controller and should be set up to trip the compressor off if in a vacuum for more then 120 seconds. SERVICE TABLE Use this service table to verify that the PWM valve is modu- lating correctly per the applied voltage signal to the smart controller.

SMART 06D, 06CC, 06M CONTROLLER COMPRESSOR VALVE CAPACITY Demand Signal Input (vdc) Percentage Solenoid Coil Energized. 06D 4-Cylinder Compressor (13 and 16 Cfm), Connection Points.45 06D 4-Cylinder Compressor (18 and 20 Cfm), Connection Points.46 06D 6-Cylinder Compressor (25, 28, 37 and 41 Cfm), Connection Points.47 06D 6-Cylinder Compressor, Exploded View. 56 06D Compressor, Cross-Sectional View. Cylinder Head Gaskets.92 Cylinder Head Reassembly.36 Discharge Gas Temperature Sensor.84 Electrical Hookup, 06D & 06CC (17-37 Cfm) Compressors.129 Electrical Hookup, 06E Compressors — Across-the-Line Start. 132 Electrical Hookup, 06E Compressors — Part Winding Start.133 Electrical Schematic, Compressors with 1 Unloading Head or PWM Valve. Operating Limits, Typical — 06D, E.18 Overcurrent Protection for 06D Compressors.115 Parallel Compressor Applications, Oil Control.

Serial Numbers Nero

28 Parts Identification — 06D Compressor, Exploded View.56 Parts Identification — 06E Compressor, Exploded View.58 Physical Data — 06CC Compressors.66 Physical Data —. Terminal Plate Jumper Bars, 06E 06CC (50 to 99 Cfm).96 Terminal Posts.133 Torque Guide — 06D and 06CC (16 to 37 Cfm) Compressors.60 Torque Guide — 06E and 06CC (50 to 99 Cfm) Compressors.61 Troubleshooting. Troubleshooting — Cannot Pull Down.22 Troubleshooting — Compressor Isolation Procedures.21 Troubleshooting — Cycling, Continuous.23 Troubleshooting — Cycling, Intermittent. 23 Troubleshooting — Cylinder Head Gasket.23 Troubleshooting — Desuperheater Connection Hot, 06CC.

31 Troubleshooting — Discharge Temperature Sensor. 26 Troubleshooting —. COMPLIMENTS OF: Carlyle service replacement compressors, parts, and support are available through a wide distribution network. Customer Service Representatives can provide assistance in locating your nearest distributor. CANADA MEXICO 800-Go-Carlyle 800-668-7905 01 800 171 11 11 (800-462-2759) www.

Totaline.c www.totalinecom.mx/ www.Totaline.com.

Provide model numbers for all their compressor parts. Model numbers are used when selecting and ordering a new compressor. It helps distributors in finding the right compressor part by using the model number to obtain a proper service replacement.

Carlyle Compressor Serial Number Breakdown

Carlyle Compressor parts distributors and parts dealers offer a wide range of parts to meet your needs. The extensive Carlyle compressor parts breakdown parts list include spare parts for your compressors like Valves, Crankshaft Heaters, Protection Modules, Oil Pumps, Valves Plates, Gaskets, Mounting Springs, Crankcase Heater Casing, Heater Casing and Adaptor Gasket, Center Bearing, Crankcase Heater Relay, Machine Screw, Cylinder Head, Suction Strainer Gasket, Cylinder Sleeve Snap Ring, Oil Suction Tube Gasket, Internal Relief Valve, Regulator Valve Gasket, Shaft Seal Package, and Pump-Cover Gasket.