Carlyle 06ZFC2T3AA06013

The Carlyle 06Z screw compressor family consists of variable frequency drive, twin screw, oil-injected helical rotor compressors. This manual specifically covers the 06ZC, ZF, and ZJ frame model sizes, which are designed for Medium/High Temperature applications qualified with R-134a, R-1234ze, or R-513A refrigerants.

Key features of these compressors include:

Variable Vi valve: Optimizes compressor efficiency.
Integrated discharge muffler: Reduces discharge gas pulsation and resonance, leading to reduced refrigerant line vibration and a quieter refrigeration system.
Wide variable speed range: Maximizes compressor capacity.
Standard 2-pole induction motors: For improved compressor efficiency.
Internal relief device: Designed to relieve pressure from the high side to the low side of the compressor when the pressure differential exceeds a specified threshold (e.g., 27.6 bar or 400 psid for R-134a, R-1234ze, or R-513A).
Suction and economizer screens: Incorporated as standard features to increase compressor reliability.
Capacity Control: All 06Z screw compressors are VFD capable and do not use a slide valve unloading system. Capacity can be continuously varied down to 22% of the economized compressor's full load capacity for air-cooled applications.
Vi Control: All 06Z models include a Vi control valve that maintains optimum compressor efficiency. The Vi control valve setting is variable and actuated by the Carlyle PCM module, which continuously monitors operating pressures and controls the Vi output accordingly.

Important Technical Specifications

Refrigerants and Lubricants:

Approved Refrigerants: R-134a, R-1234ze, or R-513A.
Approved Lubricants (for R-134a, R-513A): Carrier Material Spec PP47-13, PP47-14, PP47-32, or PP47-34, Viscosity Grade ISO 220.
Approved Lubricants (for R-1234ze): Carrier Material Spec PP47-38, Viscosity Grade ISO 220.
Assembly Grease: Parker Super-O-Lube (Carrier Part Number 19XL680001) for O-ring retention.
Terminal Pin Dielectric Grease: Carlyle P/N 06TT660050 to reduce condensation effects on terminal pins.

Operating Limits and Controls:

Non-Operating Ambient Temperature: -40°F to 176°F (-40°C to 80°C).
Operating Ambient Temperature: -31°F to 131°F (-35°C to 55°C).
Discharge Gas Temperature: Minimum 20°F (11°C) superheat, Maximum 210°F (99°C).
Economizer Gas Temperature: Saturated liquid, Maximum 9°F (5°C) superheat.
Suction Gas Temperature: Saturated vapor, Maximum 10°F superheat (best for low discharge temperatures).
Oil Supply at Compressor Temperature: Refer to Fig. 6 in the manual, Maximum 210°F (99°C).
Motor Windings Temperature: No limit for minimum, Maximum 275°F (135°C).
Oil Pressure Requirements: POIL > [0.7 x (PDISCHARGE - PSUCTION) + PSUCTION] and POIL > [PSUCTION + 1.0 bar] 75 seconds after start.
Oil Filter Differential Pressure: Compressor operation must stop if differential pressure exceeds 30 psid.
Compressor Start Cycles: Maximum 6 starts per hour, with a 10-minute minimum time delay before restarting.
Economizer Refrigerant Mass Flow: Cannot exceed 30% of the suction mass flow.

Compressor Design Pressures (Gage Pressures):

Hydrostatic Strength (Burst) Test Pressure:
- Discharge: 1520 psig (10.5 MPa)
- Economizer: 820 psig (5.7 MPa)
- Suction: 440 psig (3 MPa)
Proof Test Pressure:
- Discharge: 405 psig (2.8 MPa)
- Economizer: 130 psig (0.9 MPa)
- Suction: 61 psig (0.4 MPa)
Maximum Operating Pressure (R-134a):
- Discharge: 304 psig (2.1 MPa)
- Economizer: 130 psig (0.9 MPa)
- Suction: 61 psig (0.4 MPa)
Maximum Operating Pressure (R-1234ze):
- Discharge: 228 psig (1.6 MPa)
- Economizer: 94 psig (0.7 MPa)
- Suction: 42 psig (0.3 MPa)
Leak Test Pressure:
- Discharge: 305 psig (2.1 MPa)
- Economizer: N/A
- Suction: 88 psig (0.6 MPa)
UL 60335-2-34 Design Pressure:
- Discharge: 186 psig (1.3 MPa)
- Economizer: N/A
- Suction: 88 psig (0.6 MPa)
UL 60335-2-34 Design Pressure (R-513A):
- Discharge: 136 psig (0.9 MPa)
- Economizer: N/A
- Suction: 61 psig (0.4 MPa)

Motor Voltage Range (25-100 Hz):

460V (Nominal): 396V (Min) - 506V (Max)
380V (Nominal): 342V (Min) - 418V (Max)
200V (Nominal): 180V (Min) - 220V (Max)

Compressor Weights and Dimensions (Without Electrical Box and Oil Separator):

06ZC: 1717 lb (779 kg), Height 'H' 21 in. (539 mm), Width 'W' 20 in. (507 mm), Length 'L' 50 in. (1259 mm).
06ZF: 2199 lb (998 kg), Height 'H' 23 in. (571 mm), Width 'W' 21 in. (531 mm), Length 'L' 56 in. (1413 mm).
06ZJ: 2893 lb (1312 kg), Height 'H' 24 in. (606 mm), Width 'W' 22 in. (564 mm), Length 'L' 62 in. (1584 mm).

Usage Features

VFD Application: The 06Z series compressors are specifically designed for Variable Frequency Drive (VFD) applications, enabling continuous capacity variation.
PCM Controller: The Carlyle PCM (Compressor Protection Module, P/N 6BSB000929) is recommended for safety control functionality, including discharge temperature monitoring, oil level monitoring, and oil flow-rate/supply monitoring. It can be configured for Vi Piston Control and Compressor Protection, Vi Piston only, or Compressor protection only.
Liquid Injection: Carlyle requires some form of liquid injection to control/reduce motor and discharge gas temperatures. This can be achieved through motor cooling valves (inject liquid into the suction line) or de-superheating valves (inject liquid at the economizer line or port).
Oil Separator: A dedicated, performance-matched oil separator is required for each variable screw compressor. The combined oil capacity of the oil separator sump, oil reservoir, and oil cooler should meet specified values (Table 4 in the manual).
Oil Heater: Recommended for air-cooled models, especially when refrigerant may collect in the compressor. It should operate when the compressor is OFF to minimize refrigerant migration to the oil sump and maintain oil temperature above outdoor ambient.
Oil Level Safety Switch: An oil level safety switch must be installed in the oil separator sump or reservoir to interrupt compressor operation if oil levels fall below adequate levels.
Oil Filter: Provisions for isolating the oil filter with shutoff valves are recommended for easy element replacement without removing or isolating the unit's charge. The filter must have a Beta Ratio greater than or equal to 200 for 5-micron particles (β(5)≥ 200).
Reverse Rotation Protection: Critical for reliability. The system must detect and stop reverse rotation within 1 second of compressor start-up. A temporary low-pressure switch on the high-pressure port is recommended during initial run tests and service replacements to verify rotation direction.
Suction Pressure Transients: The compressor should not operate with suction pressure less than 0 psig (vacuum) for more than 1 minute after a "cold" start to prevent catastrophic damage.
Liquid Line Solenoid/Economizer: A liquid line solenoid valve is required to shut off liquid flow to the compressor during OFF cycles and allows for additional capacity reduction during low load conditions.

Maintenance Features

Discharge Check Valve: Field serviceable by removing the oil separator or discharge line.
Oil Filter Replacement: The oil filter supply tubing design should include valves to allow for isolation and replacement of the filter without removing the system refrigerant charge. An alarm should signal when pressure drop across the filter exceeds 40 psid, indicating replacement is needed.
PCM Controller Diagnostics: The PCM provides LED fault status indications for various conditions, including oil level, oil flow, motor cooling, discharge temperature, transducer sensor, and temperature thermistor failures. It also provides an LED alarm output signal to the System Controller when a compressor fault condition arises.
PCM Interface: The PCM can be connected to a laptop via a USB-L interface cable (Carlyle Part# USB-L) for configuration using Virtual BACView software, monitoring compressor parameters, and troubleshooting.
Motor Windings Thermistor: Two NTC type thermistors (S1 and S2) are embedded in the motor windings for temperature monitoring. A spare thermistor is supplied for replacement if a primary one fails.
Terminal Pin Coating: Terminal pins should be coated with dielectric grease (Carlyle P/N 06TT660050) to reduce condensation effects.
Storage: Compressors should preferably be stored indoors, shielded from weather, though outdoor storage is permissible within a temperature range of 40°F to 176°F (40°C to 80°C).