05T 06T

05T / 06T SCREW COMPRESSOR APPLICATION GUIDE

Contents
General Introduction 3.0 Oil Management System
Features of Carlyle 05T/06T Compressors . . . . . . 3 3.1 Oil Separator. . . . . . . . . . . . . . . . . . . . . . . . . . .9
Summary of Control Points 3.2 Piping Configuration . . . . . . . . . . . . . . . . . . . . .9
Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.3 System Oil Charge . . . . . . . . . . . . . . . . . . . . . .9
Motor Temperature Control . . . . . . . . . . . . . . . . . . 4 3.4 Oil Level Switch . . . . . . . . . . . . . . . . . . . . . . . .9
Discharge Temperature Control: . . . . . . . . . . . . . . 4 3.5 Oil Pressure Protection. . . . . . . . . . . . . . . . . . .9
Reverse Rotation Protection . . . . . . . . . . . . . . . . . 4 3.6 Oil Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . .9
Floating Head Pressure . . . . . . . . . . . . . . . . . . . . . 4 3.7 Discharge Temperature Control . . . . . . . . . . . .9
3.8 Oil Cooler Selection . . . . . . . . . . . . . . . . . . . .11
3.9 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
1.0 General Information 3.10 Oil Sump Heaters . . . . . . . . . . . . . . . . . . . . .11
1.1 Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3.11 Oil Sight Glass . . . . . . . . . . . . . . . . . . . . . . .11
1.2 Screw Compressor Size (Displacement) . . . . . 4 3.12 Oil System Schematics. . . . . . . . . . . . . . . . .12
1.3 Compressor Mounting . . . . . . . . . . . . . . . . . . . 4 3.13 Oil Line Manifold Selection Table . . . . . . . . .12
1.4 Oil Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . 5
4.0 Refrigerant Management System
1.6 Installation Environment. . . . . . . . . . . . . . . . . . 5
4.1 Suction and Interstage Piping. . . . . . . . . . . . .13
1.7 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . 5
1.8 Discharge Check Valve . . . . . . . . . . . . . . . . . . 5
1.9 Compressor Inlet Screens . . . . . . . . . . . . . . . . 5 5.0 Electrical Protection
1.10 Service Valves . . . . . . . . . . . . . . . . . . . . . . . . 5 5.1 Thermal Protection . . . . . . . . . . . . . . . . . . . . .15
1.11 Condenser Pressure Control . . . . . . . . . . . . . 5 5.2 Overcurrent Protection . . . . . . . . . . . . . . . . . .16
5.3 Allowable Voltage Range . . . . . . . . . . . . . . . .16
2.0 Operating Specifications
2.1 Operational Envelopes. . . . . . . . . . . . . . . . . . . 6 6.0 Motor Temperature Control
2.2 Vapor Temperature Limits . . . . . . . . . . . . . . . . 7 6.1 Motor Cooling Control. . . . . . . . . . . . . . . . . . .17
2.3 Minimum Oil Pressure Differential . . . . . . . . . . 7
2.4 Variable Speed Operation . . . . . . . . . . . . . . . . 7 7.0 Compressor Selections and
2.5 Compressor Cycling. . . . . . . . . . . . . . . . . . . . . 7 Performance Data
2.6 Mechanical Unloading . . . . . . . . . . . . . . . . . . . 8 7.1 CARWIN Compressor Selection Software . . .18
2.7 High Discharge Pressure Control . . . . . . . . . . 8 7.2 Subcooler Selection . . . . . . . . . . . . . . . . . . . .18
2.8 Low Suction Pressure Cut Out. . . . . . . . . . . . . 8
2.9 Volume Index (Vi) Control . . . . . . . . . . . . . . . . 8
2.10 Reverse Rotation Protection . . . . . . . . . . . . . 8
2.11 Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2
General Introduction
This manual is for the application of the Carlyle 06T semi- cooling, environmental chamber, and air conditioning
hermetic and 05T open drive twin screw compressors. The applications. Screw compression technology yields the
operational limits, required accessories, and operational benefits of smooth continuous pumping of refrigerant with
guidelines are contained in this manual and must be minimal vibration. The addition of variable speed drives to
complied with to stay within the compressor warranty these compressors is an ideal complement for very tight
guidelines. capacity control over a wide speed range. Most models can
run up to 70 Hz yielding extra capacity that can be used to
Features of Carlyle 05T/06T Compressors meet the design day load allowing for a smaller compressor
The Carlyle 06T and 05T screw compressors are gear-driven running at lower speeds during lighter load conditions. This
twin screw compressors. The gear drive yields the benefits application guide is intended to set the required guidelines of
of light weight and footprint. One of the key features of the system design and operation to maximize the reliability of the
Carlyle screw compressor is that all the semi-hermetic Carlyle 06T and 05T twin screw compressors. For
models have the same physical dimensions and port applications outside the parameters listed in this guide,
locations, as do all the open drive models. The compressors please contact Carlyle Application Engineering. Unless
range between 15 and 50 nominal horsepower, and are otherwise noted, all information contained in this application
designed for use in commercial refrigeration, process guide applies to both the 06T and 05T models.

06T MODEL NUMBER NOMENCLATURE

I PROD UCT SERIE S I

I DIGIT
I MOD EL NO.

( 0[GJT S 13 ,1 4 & 15
I 2•0 DIGIT I MODEL I ARIANC E
I 05 I OPE< DR IVE I
l 1r, DIGIT
D,...,.._ _ _ _ _ _ _ _-l
AOO I SHN OA,;;,l.:.
I 06 I SE• I - HE RM I A01 I SO Hi APPLI O H O' Olll I
sn DIG!T DESIGN LEYEL
HORS EPOW[R < PI Ol OTY PE l 11
( HOM!MAU
A s i £ PI OTOTl PE 121

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a 10 DI GIT S 0 OUALlF . L EYEl ( I)

(
6, 7 & 8 [ PILOT1 PIOOUC Tlo«
IS
4TH DIGIT DESIGN VARI ABLE CFM.
0 10
on
I •U COOL ED c o• OEN SING E IS
039
F 30
' WATE R COOl EO CONO E•S IIIG
G Jl
OU
0<8
i
LOW TEMP REFRI GERAT !OII H ,o 9TH DIGIT 1A ll 3 PH• St>
A
VARlA6LE y ; _
J ,s 05 4 POWE R REOUIREMENT S
-- - 06 S
·- ..• ,
·-· ·- so • I • O MOTOR, LOIi SPEE D SEAL

-- --.
"L lS
018
B <iO/SO, <OOIS O XL 4 PW
- w &O
188
096
C SlSIIO , soo,so l L 4 PW
65 0 I J 0/ 50 XL 4 U
'
p JO
108
E 400110 , 346150 XL 4 h'
0 ~O ~OTOR f 108·1 30160, l 00/S0 XL 4 PW
1 ,o MOTOR, HI GH SP[ [ O SEAL

3
Summary of Control Points
Oil System: Motor Temperature Control:
Maximum oil temperature entering compressor: LonCEM protection
• 06T models: 190°F (88°C) — or —
• 05T models: 180°F (82°C) Carlyle recommends liquid injection to mitigate motor tem-
peratures above 180°F (82°C). The compressor must shut-
Minimum oil temperature entering compressor: down with motor temperatures exceed 240°F (116°C).
• 80°F (27°C) Discharge Temperature Control:
LonCEM protection or
Oil Filter Pressure Drop Protection (discharge pressure mi- Carlyle recommends liquid injection to mitigate discharge
nus oil pressure): temperatures above 205°F (96°C). The compressor must
• Cutout: 45 psi (3 Bar) shutdown with discharge temperatures exceed 230°F
• Alarm: 25 psi (1.6 Bar) (110°C).
Reverse Rotation Protection:
Minimum oil pressure differential (oil inlet pressure to suction
pressure) LonCEM protection or
• Cutout: 45 Psi (3 Bar) Manual reset low pressure switch connected to discharge
(Must be measured for each compressor) port and set at 10 inches of vacuum, (0.33 bar). This pres-
sure switch is intended only for commissioning and should
Floating Head Pressure: be removed from the system prior to long term operation.
Oil pressure at the compressor must be a minimum of or
45 psi (3 bar) above suction pressure. To maintain this, the Carlyle Approved Line/Load Phase Monitor
discharge pressure must be maintained at this 45 psi (3 bar)
plus the pressure drop in the oil filters plus any flow losses
in the oil supply piping.

1.0 General Information

1.1 Certification
The 06T compressors are UL listed under file number is Semi-hermetic compressors will be supplied with single
SA4936. CSA file number is LR29937; CSA report number voltage motors 208/230 volts, 460 volts and 575 volts.
is LR29937-579c. For UL and CSA approvals it is essential
that the overcurrent protection follow the guidelines speci- 1.3 Compressor Mounting
fied in Section 5.2 of this guide. Both UL and CSA approvals The Carlyle 05T/06T screw compressors may be rigid
have been obtained for all voltage combinations listed in mounted. However, Carlyle recommends the use of isola-
Section 5.3. 60 Hz compressors have been listed. tion mounts for 06T compressors. These rubber mounts iso-
late the compressor from the system framework which
1.2 Screw Compressor Size (Displacement) helps to reduce noise transmission.
06T compressors are available in the following
displacement sizes: 1.4 Oil Type
Carlyle screw compressors are approved for use on
60Hz 50Hz R-448A, R-449A, R-404A, R-507, R-134a, and R-22
MODEL NO. ft3/min m3/min ft3/min m3/min with the following oils:
06T—033 33 0.93 27.5 0.78 Oil Manufacturer
06T—039 39 1.10 32.5 0.92 Solest 120 CPI
06T—044 44 1.25 36.7 1.04 Solest 170 CPI
06T—048 48 1.36 40.0 1.13 Emkarate RL100E Lubrizol
06T—054 54 1.53 45.0 1.28
06T—065 65 1.84 54.2 1.53 For application purposes the Solest 120 is considered an
equivalent viscosity at the Emkarate RL100E. The Solest
06T—078 78 2.21 65.0 1.84 170 is required for R-22 systems without external oil
06T—088 88 2.49 73.3 2.08 coolers. R-22 systems with an external oil cooler may use
06T—108 N/A N/A 90.0 2.56 the POE 100/120 weight oils.

4
1.5 Ambient Conditions 1.9 Compressor Inlet Screens
The screw compressor is designed for the following speci- Filter screens are applied at all locations where liquid or gas
fied ambient temperature ranges: enters the compressor, i.e., suction, economizer and oil
connections. For systems that operate below -25°F (-32°C),
-40°F To 130°F it is recommended that the suction screen be removed after
Non-Operating (-40°C To 54°C) 48 hours of system startup as the viscous oil can damage
-40°F To 130°F the screen. The compressor inlet screens are field service-
Start-up able and available through Carlyle distribution.
(-40°C To 54°C)
-25°F To 130°F 1.10 Service Valves
Operating (-32°C To 54°C)
Suction and discharge connections will interface with the
1.6 Installation Environment 2-1/2 in. bolt pattern service valves currently being used on
the Carlyle reciprocating compressors. Rotalock® service
The intended installation modes for the screw compressor valves are used for the economizer line shut off. The line
are: Machine Rooms—Enclosed Atmosphere External En- sizes are as follows:
vironment—Sheet Metal Enclosure
NOTE: The electrical terminal box is not approved for exter-
nal applications. Connection Connection Size

1.7 Pressure Relief Valve MAX. MIN.

All compressor models contain an automatic reset high Suction 1-5/8” 1-1/8”
pressure relief valve. The pressure relief valve is located in-
side the compressor and will internally relieve the compres- Discharge 1-5/8” 1-1/8”
sor discharge to the compressor suction at a pressure differ- Economizer 7/ ” 7/ ”
8 8
ential of 400 psi (27.6 bar). The relief valve is not field
serviceable. All 05T compressors and 06T compressors between 65cfm
and 108cfm must use a flange at the discharge connection
1.8 Discharge Check Valve with an in-line ball valve for compressor isolation. With the
All compressor models are supplied with an internal dis- exception of the 06TA660008 valves (now obsolete), stan-
charge check valve. This check valve prevents the reverse dard 90-degree compressor isolation valves must not be
flow of refrigerant through the compressor during compres- used on the discharge of these 65, 78, 88 and 108cfm com-
sor off cycles. A check valve in the discharge line is not re- pressors.
quired for parallel applications. It may be required for pump 1.11 Condenser Pressure Control
down on single compressor systems. The discharge check
valve is field serviceable. Large fluctuations in head pressure may result in very poor
oil separation which may result in nuisance oil level switch
tripping. The condenser pressure must be controlled such
that fluctuations are gradual. Carlyle screw compressors
must always be applied with a minimum of one condenser
fan (preferably variable speed) active and a means of mini-
mum head pressure control for low ambient operation.

5
2.0 Operating Specifications
2.1 Operational Envelopes outside of these envelopes requires approval from Carlyle
Application Engineering or warranty is voided. Oil cooling
The following operational envelopes, based on 65°F (18°C) can be achieved using an oil cooler or with desuperheating
return gas, show the allowable operating suction and dis- valves (as described in Oil Cooling Systems, Section 3.8).
charge pressure ranges for different refrigerants. Operation

R-448A, R-449A, R-507 & R-404A APPLICATIONS

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Saturated Suction Temperature deg F (deg CJ

6
 R-22 APPLICATIONS
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Saturated Suction Temperature deg F (deg C)

2.2 Vapor Temperature Limits Compressors should ramp-up to the minimum speed within
15 seconds at start-up. After compressor start, Carlyle rec-
Any application of screw compressors must operate within ommends that the rate of compressor speed change be lim-
the limits defined by the application maps for the various re- ited to 600 rpm/min for the 06T semi-hermetic compressors.
frigerants and applications. The rate of compressor speed change for the 05T open-
drive models is required to be no greater than 500 rpm/min.
Vapor Temp Min. Max.
10°F SH* 100°F Compressor Nominal Min. Max. Open Motor
Suction (6K) (38°C) Model HP Hz Hz Type*
Saturated** 06T—033 15 50 70 —
Economizer —
Vapor 06T—039 20 40 70 —
*SH = Superheat
**The maximum economizer pressure allowable is 175.3 psig 06T—044 20 35 70 —
(13.1 bar) 06T—048 25 30 70 —
2.3 Minimum Oil Pressure Differential 06T—054 25 30 70 —
06T—065 30 25 70 —
A minimum pressure differential of 45 psi (3 bar) is required
06T—078 35 20 68 —
between suction and oil pressure (at the compressor). Ap-
plications below this minimum range will require the use of 06T—088 40 20 60 —
an external oil pump. 06T—108 50 20 50 —
15 50 140 4-POLE
2.4 Variable Speed Operation 05T—033
30 25 70 2-POLE
The Carlyle screw compressor is compatible with variable 20 40 140 4-POLE
speed drives, the table below shows the allowable speed 05T—039
35 20 70 2-POLE
range.
20 35 120 4-POLE
Carlyle does not recommend the screw compressor operate 05T—044
40 20 60 2-POLE
at maximum frequency for prolonged periods of time.
05T—048 25 20 70 4-POLE
Operation above 60 Hz requires adequate motor cooling.
When overspeeding, there will be an increased power con- 05T—054 25 20 70 4-POLE
sumption required to supply the additional capacity. This will *Open Motor Type applies to 05T models only.
also increase the required motor cooling load. It is important
that the motor cooling system be capable of handling the in-
2.5 Compressor Cycling
creased cooling required for the motor. Oil return, econo- Although compressor cycling is an effective means of ca-
mizer return gas, and the motor cooling valve all assist in pacity control, frequent starting and stopping shortens the
cooling the motor. Carlyle recommends applying the largest compressor life. Carlyle screw compressors should not be
motor cooling valve with all screw compressors applied us- stop/start cycled for capacity control more than six times an
ing inverters. hour and should run for at least 5 minutes after each start.

7
2.6 Mechanical Unloading (discharge-suction) is 350 psi. The internal pressure relief
valve will open if the pressure differential exceeds 400 psi
All Carlyle screw compressors are equipped with one step (+/-3%).
of mechanical unloading. The unloader valve is controlled
by a solenoid mounted on the compressor body. The com- 2.8 Low Suction Pressure Cut Out
pressor is unloaded when the solenoid is de-energized
A low suction pressure cut out must protect the compressor
and loaded when the solenoid is energized. The compres-
from operating below 10 inches of vacuum pressure. Each
sor should always be started unloaded (for a minimum time
compressor must be individually protected with a low pres-
determined by the control module) which will provide a soft
sure switch connected to the low side access port. The
start by partially relieving the compression chamber back to
compressor may be brought back online after a 3 minute
suction. Unloaded operation reduces the effective capacity
delay.
by 30% to 62%, depending on the model and system condi-
tion (see tables below). 2.9 Volume Index (Vi) Control
ESTIMATED PERCENTAGE UNLOADING All low temperature models (05TR/06TR) are supplied with
a Vi control valve that allows for two Vi settings (see chart
BY MODEL below). This dual Vi allows for optimum efficiency over a
~ 50HZ OPERATION T 60HZ OPERATION wide range of head pressures. The Vi must be set to low
COMPRESSOR - (solenoid de-energized) during start-up for a minimum of 30
MODEL 06TR I 06TA 06TR 06TA
- MODELS MODELS MODELS MODELS
- I seconds. The Vi may then be set as desired for optimum en-
ergy efficiency. The following table reflects the operational
06T—033 62% 52% 60% I 50% -
- recommendations for the Vi control. Carlyle also recom-
- 06T—039 61% 51% 59% I 49% - mends the use of a small deadband at this change-over
06T—044 60% 50% 58% I 48% -
-
point to avoid unnecessary short cycling of the Vi solenoid.
06T—048 59% 49% 56% I 46%-
- The LonCEM® controller continuously monitors the operat-
06T—054 58% 48% 55% I 45%
- - ing pressure ratio and controls Vi output accordingly. The
06T—065 55% 45% 50% l 40% older CEM requires external controls to accomplish the
- -
-
06T—078 50% 40% 45% I 35% - same task.
06T—088 47% 37% 40% I 30% -
Compressor System Vi Solenoid
-
06T—108 I 45% I — I — I —
- Model Pressure Ratio setting State
>5.0 High:4.0 Energized
06TR
<5.0 Low: 2.8 De-energized
Capacity Fixed:
06TA All —
Control 2.8

2.10 Reverse Rotation Protection

Correct compressor rotation is critical for compressor reli-
ability. The compressor can fail within 2 seconds of start-up
if it is not rotating in the correct direction. Installation of a
pressure gage at the discharge pressure access fitting in
the compressor body (measuring the pressure upstream of
the integral discharge check valve) is recommended during
initial start-up or whenever the compressor is serviced. The
gage should be monitored to ensure increasing discharge
pressure at start-up.
The LonCEM protection module uses a pressure sensor to
monitor the discharge pressure change at startup to ensure
proper compressor rotation. The LonCEM module elimi-
Vi Control nates the need for a mechanical low-pressure switch and
(05/06TR only) line/load phase monitor. See Appendix A for descriptions of
operation applications for the LonCEM module.
The 05T/06T screw compressors can be run unloaded con- 2.11 Mufflers
tinually without affecting the reliability of the compressor.
Screw compressors emit gas pulsations result in radiated
2.7 High Discharge Pressure Control noise from the discharge line and oil separator. The addition
of a muffler is required in all applications to reduce dis-
A high pressure cut out must protect the compressor from
charge line and oil separator noise levels. The muffler
exceeding 350 psig (25.2 bar). The compressor may be
should be located within 6-inches (15cm) of the compressor
brought back online after the discharge pressure falls below
discharge service valve.
300 psig (21.4 bar). The maximum pressure differential

8
3.0 Oil Management System
3.1 Oil Separator The LonCEM protection module provides comprehensive
oil pressure protection through the use of discharge pres-
An oil separator is required on all Carlyle screw compressor sure, oil pressure and suction pressure transducers to mon-
systems. The screw compressors do not have an oil sump itor operating pressures.
for storage of the system oil charge. The selection of the oil
separator should consider the desired oil circulation rates as Refer to the LonCEM Installation and Operations Guide for
well as storage of oil for the entire bank of compressors. a complete description of the application and operation of
the LonCEM module.
3.2 Piping Configuration
3.6 Oil Solenoids
The inlet piping from the compressor to the separator
should follow a few simple rules: A normally closed solenoid is required in the oil feed line to
each compressor, see Section 3.12 for oil system schemat-
1. The discharge header should be one consistent size ics. To avoid excessive pressure drop, the internal port size
throughout. must be 5/16 in. diameter or larger. An oil strainer is re-
2. Step changes in the line diameter should be avoided quired before each oil solenoid (or as an integral part of the
with the exception of the reducing fittings required to solenoid). The solenoid will protect the compressor from be-
couple to the oil separator. ing filled with oil from the high pressure oil feed line during
To optimize the performance of the vortex separators, they the off cycle. Each solenoid must be properly wired to the
should be piped with a 90° elbow in the discharge line (turn- Carlyle LonCEM (per installation instructions) of the com-
ing in the same direction as the vortex) just prior to entering pressor it is controlling. The valve must be open during the
the oil separator. on cycle and closed during the off cycle. Manually adjust-
able valves must be checked to ensure the manual opera-
Inlet piping to the separator must be sized to maintain
tion stem is completely back seated (ensuring the valve is
enough velocity at the minimum load condition of the rack.
closed when the solenoid is de-energized).
The minimum velocity should be no less than 20fps (feet per
second) (6.1 mps [meters per second]) and the maximum w
velocity should be no more than 75fps (22.9 mps). Velocities CAUTION
above this limit may result in excessive pressure drop
across the oil separator. When testing the control circuit without the compressor
running, the oil line must be valved off so that the com-
Steel oil piping is not recommended for use with 05T/06T pressor will not be filled with oil.
screw compressor applications.
Whenever possible use control logic to determine that the
3.3 System Oil Charge compressor is running before opening the oil solenoid.
The system oil charge will vary depending on the size of the
separator used, size of the oil cooler (where applicable), oil 3.7 Discharge Temperature Control
manifold, and natural refrigerant piping traps and coating. The 06T semi-hermetic screw compressors can be operat-
ed for most applications without external oil cooling. 05T
3.4 Oil Level Switch open drive screw compressors require external oil cooling
An oil level switch is required and must be located in the bot- any time the system discharge temperature may exceed
tom of the oil separator or reservoir. The level switch is used 180°F(82°C). The CARWIN Selection Software can be
to monitor the oil level and act as a safety in case of low oil used to estimate the discharge temperature for a given ap-
levels. The float switch must be wired to open all the com- plication. The CARWIN tool allows for selections to be made
pressor control circuits on the rack during cases of low oil with or without an oil cooler.
level. The float switch will be normally closed when ade- See Operating Envelopes in Section 2.1 for operating condi-
quate oil is in the separator or reservoir sump. The oil level tions that may require the use of external oil cooling.
switches are generally pilot duty devices, their electrical
switching capacity should be validated to ensure they are An external oil cooler will reduce both the discharge and
not overloaded. During transient conditions where signifi- motor temperatures within their respective limits, however,
cant foaming is present in the oil sump, the oil level switch additional refrigerant injection may still be required. For
may rapidly fluctuate causing nuisance tripping. System screw compressors this injection is either by the motor cool-
controls must be designed to discriminate these nuisance ing valve and/or at the rotor injection port. Because refriger-
conditions from real low oil level conditions. ant injection for motor and discharge cooling flows into the
screw rotor chamber after the suction gas is trapped, com-
3.5 Oil Pressure Protection pressor capacity is not significantly affected. Under some
conditions the motor cooling valve alone can accommodate
The 05T/06T screw compressors are lubricated using oil fed this extra cooling requirement. For conditions requiring addi-
from the high pressure side of the system. To ensure ade- tional discharge temperature cooling, a desuperheating
quate lubrication the pressure of the oil feed to each com- valve is recommended. It should be selected to start open-
pressor must be a minimum of 45psi (3 bar) above suction ing at a discharge temperature of 190°F (88°C) and be fully
pressure. Care should be taken to avoid large pressure open at 200°F (93.3°C). The bulb should be located on the
drops between the oil separator (discharge pressure) and discharge line within 6 inches (15cm) of the compressor dis-
this oil feed to the compressor (oil pressure). See Section charge service valve. A properly sized solenoid valve should
3.9 for addition details on these pressure drops.

9
be located upstream to ensure positive shut-off when the The tables presented at the bottom of this page present de-
compressor is off. superheating valve size and part number information for
those applications where an oil cooler is not used.

DESUPERHEATING VALVE SIZING WITHOUT OIL COOLER

R-448A, R-449A, R-404A & R-22 R-134a
Compressor R-507
Model Med/High
Low Temp. Med Temp. Low Temp. Medium Temp. High Temp.
Temp.
Low Temp.
70°F to 120°F
90°F to 120°F 70°F to 150°F 70°F to 150°F
SCT Range (21°C to
(32°C to 49°C) (21°C to 65°C) (21°C to 65°C)
49°C)
06TRC033 EA02ZD001* EA02ZD030
06TRD039 EA02ZD002* EA02ZD050
06TRD044 EA02ZD002* EA02ZD050
06TRE048 EA02ZD030* EA02ZD050
06TRE054 EA02ZD050* EA02ZD050 Not Required Not Required
06TRF065 EA02ZD050* EA02ZD100
06TRG078 EA02ZD050* EA02ZD100
06TRH088 EA02ZD050* EA02ZD100
06TRK108 EA02ZD050* EA02ZD100
Med Temp/High Temp
70°F to 130°F 70°F to 130°F
SCT Range (21°C to 34°C) (21°C to 54°C)
06TAD033 EA02ZD030**
06TAE039 EA02ZD050**
06TAF044 EA02ZD050**
06TAF048 EA02ZD050**
Not Required Not Required Not Required
06TAG054 EA02ZD050**
06TAG065 EA02ZD100**
06TAH078 EA02ZD100**
06TAK088 EA02ZD100**
* Operation with Evap. condensers below -25°F (-32°C) SST NOTE: A valve with a 190°F(88°C) temperature setting is
may not require any additional desuperheating. Contact Carlyle required. Alternate desuperheating valve sizing or manufactur-
Application Engineering for limits. ers must be approved by Carlyle Application Engineering.
**Operation with Evap. condensers above +10°F (-12°C) SST
may not require any additional desuperheating. Contact Carlyle
Application Engineering for limits.

10
Oil Cooling Capacity kBtu/hr kW/hr
Fan Speed 60Hz 50Hz
Ambient Air Temperature 95°F 100°F 105°F 110°F 35°C 38°C 41°C 43°C
Maximum 2
KH51ZZ181 32.1 30.6 29.9 27.6 9.4 9.4 8.4 8.0
compressors
Maximum 3
KH51ZZ182 69.1 65.7 62.4 59.1 18.7 17.8 16.9 16.0
compressors
Maximum 4
KH51KK183 102.6 97.7 92.8 87.9 27.8 26.5 25.2 23.9
compressors
Maximum 5
KH51KK183 134.1 127.7 121.3 114.9 26.2 34.4 32.7 30.1
compressors
*Maximum Number of Compressors Based on Oil Cooler Pressure Drop of Less Than 6 PSID (.41 bar)
3.8 Oil Cooler Selection If more than five compressors are fed by the oil system,
three parallel oil filter elements (2 for operation, 1 for redun-
Oil coolers are required for 06T compressors where the oil dancy) should be used to avoid excessive pressure drop
temperature can exceed 190°F (88°C) and for 05T com- through the filter elements. The oil filter should be located
pressors where it can exceed 180°F (82°C). The CARWIN downstream from any oil coolers, as close to the compres-
selection software should be used to determine operating sors as possible.
conditions where this will occur. For initial reference, the op-
erating envelopes in Section 2.1 may be used as an initial Oil Filter Pressure Drop Protection:
reference. LonCEM protection
The oil cooler should be sized based on an oil flow rate of — or —
approximately 2 gallons per minute (7.6 liters/minute) per Carlyle recommends maximum allowable pressure drop
compressor. However, it should be noted that the actual oil across the oil filters of 45psid (3bar). Compressors should
flow rate will vary based on the specific operating condition. be shutdown above this limit. Carlyle also recommends an
Oil cooler loads may be obtained from the CARWIN selec- alert (shutdown not required) when the pressure drop rises
tion software. With an oil cooler, the maximum oil tempera- above 25psid (~1.5bar).
ture leaving the oil cooler is 170°F (77°C). Systems using
external oil coolers also require controls that prevent the oil 3.10 Oil Sump Heaters
temperature from dropping below 80°F (27°C). The heater must be energized during the system off cycle if
Acceptable means of control are fan cycling or oil cooler by- used. This is required in all air conditioning systems and is
pass or mixing valves. Mixing valves are recommended for recommended in refrigeration systems to keep refrigerant
any oil coolers that are integrated into the system condens- out of the oil sump during compressor off cycles. Carlyle
er coil. For direct expansion oil coolers rejecting heat into typically recommends flexible heaters that are applied on
the refrigeration circuit caution must be taken to ensure that the outside of the oil separator shells. Carlyle recommends
the return gas temperature is within operating guidelines. 500W heaters for shells 12 inches and smaller and 100W
for heaters larger than 12 inches. Direct immersion heaters
3.9 Oil Filter may also be used. Carlyle advises caution with these im-
Carlyle screw compressors are designed with rolling ele- mersion heaters, localized temperatures surrounding the
ment bearings to provide exceptional life. Oil to the bearings heater element should not create issues with the lubricant.
must pass through a 3 micron filter which is required on all
Carlyle screw compressor systems.
3.11 Oil Sight Glass
NOTE: Use of the Carlyle 3 micron filter element is required. A sightglass is required in the main oil line. The sightglass
Use of a non-Carlyle- approved filter element will void com- must be located after the oil filters and just prior to the first
pressor warranty. The use of a second redundant filter in compressor on a multiple compressor rack. To aid service
parallel is recommended to allow for servicing of one filter personnel in verifying oil flow to any given compressor
while the other maintains the operability of the equipment. Carlyle recommends a sightglass be placed in each branch
oil line between the compressor and its oil solenoid.

11
3.12 Oil System Schematics
OIL SYSTEM SCHEMATIC

Discharge Gas
to Condenser

Discharge Header

Oil
Separator
& Sump

Oil
Heater

Level
Switch

Oil Cooler

P P

Hand Valve Oil Filter Hand Valve

Sightglass Sightglass Mixing
Valve

Solenoid Solenoid
Valve Valve

Oil Man ifold Sightglass

3.13 Oil Line Manifold Selection Table

OIL MANIFOLD FOR PRESSURE DROP (FOR POE100 OILS)
Number of Flow Rate Manifold Size at 10 cSt at 45 cSt at 100 cSt at 170 cSt
Compressors
English Pressure Drop (psi) per 10 feet of manifold
1 2 gpm 7
/8 0.17 0.77 1.72 2.92
2 4 gpm 7/
8
0.34 1.54 3.43 5.83*
3 6 gpm 7/
8
0.52 2.31 5.15* 8.76*
4 8 gpm 1/
1- 8 0.22 0.97 2.16 3.67
5 10 gpm 1-1/8 0.27 1.21 2.69 4.58
Metric Pressure Drop (kPa) per 1 meter of manifold
1 7.6 l/min 7/
8
0.38 1.74 3.89 6.60
2 15.2 l/min 7
/8 0.77 3.48 7.76 13.19*
3 22.8 l/min 7/
8
1.18 5.23 11.6*5 19.81*
4 30.4 l/min 1
1- /8 0.50 2.19 4.89 8.30
5 38.0 l/min 1-1/8 0.61 2.74 6.08 10.36
LEGEND 2. Viscosity of 45 cSt is based on 130°F (54°C) oil, no
refrigerant dilution or 80°F (27°C) oil with 10% refrig-
cSt — Centistokes
erant dilution.
* If 170 POE oil is used, Carlyle recommends use of the next 3. Viscosity of 100 cSt is based on 100°F (38°C) oil, no
larger size copper line if pressure drop is greater than 5.0 psi.
This will typically reduce pressure drop to 30% of value shown. refrigerant dilution.
NOTES: 4. Viscosity of 170 cSt is based on 100°F (38°C) oil,
1. Viscosity of 10 cSt is based on 130°F (54°C) oil with with no refrigerant dilution.
10% refrigerant dilution.

12
4.0 Refrigerant Management System
4.1 Suction and Interstage Piping Steel refrigerant piping is not recommended for use with
05T/06T screw compressor applications. The contaminants
The suction and interstage manifolds should be piped in associated with the steel pipe will overload the 3 micron fil-
such a way that liquid cannot gravity drain into any compres- ters used in the oil system increasing the chances of oil re-
sor. Carlyle recommends that the manifold be located below lated compressor failures.
the compressor body. An inverted trap must be used com-
ing off the top of the suction header if it is above the com-
pressor body.

SUCTION AND INTERSTAGE HEADER SCHEMATIC

(HEADER LOCATED ABOVE COMPRESSOR INLET)

45°

1/
8"
gap
(3mm)

NOTE: If suction or interstage piping is to be located above the compressor the recommendations in the figure below also
apply.

SUCTION AND INTERSTAGE HEADER SCHEMATIC

(HEADER LOCATED BELOW COMPRESSOR INLET)

Mechanical subcooling via interstage manifolds are com- to efficiently distribute refrigerant gas to each compressor.
monly applied with parallel 05T/06T rack designs. The gas Interstage headers should be designed similar to suction
exiting the subcooler is used to provide additional motor line manifolds.
cooling in 06T models. This design reduces the amount of
liquid injection required for motor cooling. The manifold acts

13
 INTERSTAGE SCHEMATIC WITH INJECTION TO MOTOR AND ROTORS

Liquid Line
from Condenser

Liquid Injecon Motor Cooling Liquid Injecon Motor Cooling

LRI LRI
to Rotors Injecon Valve to Rotors Injecon Valve
EXV Mechanical
Subcooler

Interstage Header

Isolaon Check Solenoid Isolaon Check Solenoid

Valve Valve Valve Valve Valve Valve
Liquid Line
To Evaporator

A normally closed solenoid valve is required in the inter- Compressors operating with different saturated suction tem-
stage line feeding each compressor on a parallel rack. This peratures can have a significant difference in interstage
valve is required to eliminate interstage to suction pressure pressure. Separate subcoolers are recommended for each
leak back during the off cycle of any compressor. This valve suction temperature group.
must open only when the compressor is in operation.
Check valves are also required in the interstage line feeding
each compressor on a parallel rack as shown. The check
valve must be located upstream of the motor cooling valve
for each compressor and downstream of the solenoid valve.

14
5.0 Electrical Protection
5.1Thermal Protection limit the maximum motor temperature to 240°F (116°C) and
is an automatic reset device. Only one 5K sensor is used;
The compressor motor windings are protected from ex- the other is a spare. The temperature vs. resistance charac-
treme temperatures by the LonCEM module. All compres- teristics of the thermistors are shown below.
sors are supplied with two 5K NTC (Negative Thermal Coef-
ficient) thermistors in the motor windings. The module will

TEMPERATURE VS. RESISTANCE TABLE

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE
°C °F OHMS °C °F OHMS °C °F OHMS °C °F OHMS
0 32.0 16,352.4 38 100.4 886.9 76 168.8 715.93 114 237.2 228.38
1 33.8 15,515.2 39 102.2 2,772.1 77 170.6 692.68 115 239.0 222.24
2 35.6 14,750.0 40 104.0 2,662.4 78 172.4 670.34 116 240.8 216.29
3 37.4 14,027.1 41 105.8 2,557.8 79 174.2 648.82 117 242.6 210.53
4 39.2 13,343.8 42 107.6 2,457.7 80 176.0 628.09 118 244.4 204.95
5 41.0 12,697.8 43 109.4 2,362.1 81 177.8 608.11 119 246.2 199.54
6 42.8 12,086.3 44 111.2 2,270.8 82 179.6 588.88 120 248.0 194.3
7 44.6 11,508.0 45 113.0 2,183.45 83 181.4 570.36 121 249.8 189.22
8 46.4 10,960.8 46 114.8 2,099.93 84 183.2 552.5 122 251.6 184.3
9 48.2 10,442.6 47 116.6 2,020.04 85 185.0 535.29 123 253.4 178.5
10 50.0 9,951.8 48 118.4 1,943.6 86 186..8 518.7 124 255.2 174.89
11 51.8 9,486.8 49 120.2 1,870.5 87 188.6 502.7 125 257.0 170.41
12 53.6 9,046.3 50 122.0 1,800.49 88 190.4 487.28 126 258.8 166.06
13 55.4 8,628.7 51 123.8 1,733.46 89 192.2 474.4 127 260.6 161.83
14 57.2 8,232.5 52 125.6 1,669.66 90 194.0 458.06 128 262.4 157.74
15 59.0 7,857.0 53 127.4 1,607.81 91 195.8 444.2 129 266.0 153.77
16 60.8 7,500.6 54 129.2 1,548.95 92 197.6 430.85 130 267.8 149.91
17 62.6 7,126.3 55 131.0 1,492.54 93 199.4 417.96 131 269.6 146.17
18 64.4 6,841.3 56 132.8 1,438.46 94 201.2 405.51 132 271.4 142.54
19 66.2 6,526.4 57 134.6 1,386.62 95 203.0 393.49 133 273.2 139.02
20 68.0 6,526.8 58 136.4 1,336.93 96 204.8 381.89 134 275.0 136.6
21 69.8 5,971.6 59 138.2 1,289.26 97 206.6 370.69 135 276.8 132.27
22 71.6 5,710.0 60 140.0 1,243.53 98 208.4 359.87 136 278.6 129.04
23 73.4 5,461.3 61 141.8 1,199.7 99 210.2 349.41 137 280.4 125.91
24 75.2 5,225.0 62 143.6 1,157.59 100 212.0 339.32 138 285.8 122.87
25 77.0 5,000.0 63 145.4 1,117.18 101 213.8 329.55 139 287.6 119.91
26 78.8 4,786.0 64 147.2 1,078.37 102 215.6 320.12 140 289.4 117.04
27 80.6 4,582.4 65 149.0 1,041.15 103 217.4 311.0 141 281.2 114.25
28 82.4 4,338.5 66 150.8 1,005.38 104 219.2 302.18 142 287.6 111.54
29 84.2 4,203.9 67 152.6 971.03 105 221.0 293.65 143 289.4 108.9
30 86.0 4,028.0 68 154.4 938.02 106 222.8 285.41 144 291.2 106.34
31 87.8 3,860.5 69 156.2 906.3 107 224.6 277.43 145 293.0 103.86
32 89.6 3,700.8 70 158.0 875.81 108 226.4 269.72 146 294.8 101.43
33 91.4 3,548.5 71 159.8 846.5 109 228.2 262.26 147 296.6 99.074
34 93.2 3,403.5 72 161.6 818.31 110 230.0 255.03 148 298.4 95.785
35 95.0 3,265.1 73 163.4 791.21 111 231.8 248.04 149 300.2 94.559
36 96.8 3,133.1 74 165.2 765.14 112 233.6 241.28 150 302.0 92.393
37 98.6 3,007.1 75 167.0 740.06 113 235.4 234.72

15
5.2 Overcurrent Protection The 06T compressor motor may be protected using a rec-
ognized variable speed drive that meets these compressor
06T screw compressors must be protected with a three- protection requirements. The system designer is responsi-
phase manual-reset type of overcurrent protection. ble to program these requirements appropriately.
The code agency certifications of the 06T compressor is For part wind start applications Carlyle recommends a 1 to
contingent upon the use of appropriate overcurrent protec- 1.25 second time delay between energizing the first and
tion. Properly selected overcurrent devices protect the com- second legs.
pressors against running overcurrent, locked rotor, as well
as primary and secondary single phasing faults. If the end user is not intending on using the full published
operating envelope; the overcurrent protection can be sized
Overcurrent protection must comply with the following: to trip at lower values than the maximum MCC.
• Manual Reset
• The device must trip at or below the maximum MCC 5.3 Allowable Voltage Range
listed for the compressor. Settable devices may re- The allowable voltage variation at the compressor terminals
quire settings that differ from the maximum allowed for the 06T screw compressors is shown in the table below.
current. Consult the manufacturer's documentation
for proper setting of these devices.
Model # Voltage Range
• To minimize nuisance tripping risks, the maximum ra- Digit 9 Nominal Voltage
tio between the must trip and must hold values can- Min Max
not be larger than 1.15 460-3-60 396 528
B
• Locked Rotor Trip Timing: 400-3-50 342 456
a. Across-the-Line Start: Device must trip in 2 to 6 C 575-3-60 495 660
seconds 208/230-3-60 187 264
F
b. Part Wind Start: Device must trip the first three con- 200-3-50 180 230
nected legs in 2 to 6 seconds and the remaining
three connected legs in 1 to 3 seconds

06TR LOW TEMP COMPRESSORS 06TA MED/HIGH TEMP COMPRESSORS

MAXIMUM LOCKED MAXIMUM LOCKED

COMPRESSOR CONTINUOUS ROTOR COMPRESSOR CONTINUOUS ROTOR
HP VOLTAGE HP
MODEL CURRENT CURRENT MODEL CURRENT CURRENT
06TRC033F2EA 15 90 286 06TAD033F2EA 20 104 348
06TRD039F2EA 20 104 348 06TAE038F2EA 25 128 433
06TRD044F2EA 20 104 348 208/230V-3- 06TAF044F2EA 30 163 510
06TRE048F2EA 25 128 433 06TAF048F2EA 30 163 510
60Hz
06TRE054F2EA 25 128 433 06TAG054F2EA 35 182 610
06TRF065F2EA 30 154 611 200V-3-50Hz 06TAG065F2EA 35 181 721
06TRG078F2EA 35 181 721 06TAH078F2EA 40 203 825
06TRH088F2EA 40 203 825 06TAK088F2EA 50 230 974
06TRC033B2EA 15 46 142 06TAD033B2EA 20 49 173
06TRD039B2EA 20 49 173 06TAE038B2EA 25 64 215
06TRD044B2EA 20 49 173 06TAF044B2EA 30 76 253
06TRE048B2EA 25 64 215 06TAF048B2EA 30 76 253
460V-3-60Hz
06TRE054B2EA 25 64 215 06TAG054B2EA 35 88 305
400V-3-50Hz
06TRF065B2EA 30 76 253 06TAG065B2EA 35 89 323
06TRG078B2EA 35 89 323 06TAH078B2EA 40 101 370
06TRH088B2EA 40 101 370 06TAK088B2EA 50 114 440
06TRK108B2EA 50 114 440 — — — —
06TRC033C2EA 15 33.5 114 06TAD033C2EA 20 39 138
06TRD039C2EA 20 39 138 06TAE038C2EA 25 53 172
06TRD044C2EA 20 39 138 06TAF044C2EA 30 62 202
06TRE048C2EA 25 53 172 06TAF048C2EA 30 62 202
575V-3-60Hz
06TRE054C2EA 25 53 172 06TAG054C2EA 35 78 242
06TRF065C2EA 30 62 219 06TAG065C2EA 35 72 258
06TRG078C2EA 35 72 258 06TAH078C2EA 40 81 296
06TRH088C2EA 40 81 296 06TAK088C2EA 50 92 351

16
6.0 Motor Temperature Control
6.1 Motor Cooling Control required to distribute economizer gas to each compressor.
A solenoid valve is required to isolate each compressor
The motors in the 06T compressors are not located in the from this intermediate header when the compressor is not
suction gas stream like other compressors. These motors operating. This solenoid valve can be controlled with the
require cooling to maintain reliable operation. Motor barrel LonCEM module.
insulation is recommended on compressors with suction
temperatures below -15°F (-26°C) to prevent frost build-up When using only liquid injection, the 1-ton liquid injection
on the compressor motor barrel. valve (part # EF28BZ001) must feed liquid refrigerant to the
compressor motor at any time the compressor is in opera-
All motors must have a steady flow of cooling while in oper- tion.
ation to avoid thermal shock to the motor. There are two
methods for providing this cooling; economizer flow from the For both economizer gas cooling and liquid injection, the
mechanical subcooler or liquid injection directly into the mo- motor may require additional cooling when operating under
tor barrel. high loads. A supplemental liquid injection valve (part #
EF28BZ007) should be installed to provide this additional
When using economizer flow, the superheat leaving the me- cooling. This supplement valve can be controlled with the
chanical subcooler should be set in the range of 10 to 20°F LonCEM module.
(6 to 11°C) superheat above saturated intermediate tem-
perature. For parallel applications, an intermediate header is

Liquid Line
from Condenser

Liquid Injecon Liquid Injecon

LRI LRI
to Rotors to Rotors
Primary Supplemental
Motor Cooling Motor Cooling Primary Supplemental
Injecon Valve Injecon Valve Motor Cooling Motor Cooling
Injecon Valve Injecon Valve

Isolaon Isolaon
Valve Valve

Liquid Line
To Evaporator

17
7.0 Compressor Selections and Performance Data
7.1 CARWIN Compressor 7.2 Subcooler Selection
Selection Software The use of mechanical subcoolers are recommended to in-
The performance of the 06T/05T screw compressors can crease both the capacity and operating efficiency of the
be estimated using the CARWIN compressor selection tool. compressors. Subcooler loads can also be estimated using
CARWIN is a web-based application available at CARWIN.
https://carwin.carlylecompressor.com Carlyle recommends sizing and piping the subcooler for
parallel flow. Parallel flow through the subcooler results in
better control of the subcooler by reducing TXV hunting.
NOTES:

19
NOTES:

Manufacturer reserves the right to discontinue, or change CARLYLE COMPRESSOR • © CARRIER CORPORATION 05/2021 Lit. No. 574-030
at any time, specifications or designs and prices without P.O. Box 4808 • Syracuse, New York 13221 (Rev. G 5/21)
www.carlylecompressor.com
notice and without incurring obligations. In U.S. and Puerto Rico: 1-800-GO-CARLYLE (1-800-462-2759)
In Canada: 1-800-258-1123
In Mexico: 001-800-GO-CARLYLE (001-800-462-2759)