5F,H

W.Carlyle Open-Drive Compressors

Installation, Start-Up and Service Instructions

CONTENTS SAFETY CONSIDERATIONS
Page Installation and servicing of air-conditioning equipment can be
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . 1 hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should install, repair, or
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 service air-conditioning equipment.
Step 1 — Prepare for Installation . . . . . . . . . . . . . . . . 2
Untrained personnel can perform basic maintenance functions of
Step 2 — Receive Compressor (Fig. 1-7) . . . . . . . . . 2 cleaning coils and filters and replacing filters. All other operations
Step 3 — Install Unit . . . . . . . . . . . . . . . . . . . . . . . . . 13 should be performed by trained service personnel. When working
Step 4 — Assemble Refrigerant Piping . . . . . . . . . . 13 on air-conditioning equipment, observe precautions in the litera-
Step 5 — Install Multiple Compressors . . . . . . . . . . 14 ture, tags and labels attached to the unit, and other safety precau-
Step 6 — Check Compressor/Motor Alignment . . . 15 tions that may apply.
Step 7 — Assemble Water Piping . . . . . . . . . . . . . . 16 Follow all safety codes, including ANSI (American National Stan-
Step 8 — Prepare Lubrication System . . . . . . . . . . 16 dards Institute) Z223.1. Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher
PREPARE FOR INITIAL START-UP . . . . . . . . . . . . . 16 available for all brazing operations.
Evacuate, Dehydrate and Leak Test . . . . . . . . . . . . 16
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WARNING
Preliminary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Before performing service or maintenance operations on unit,
High and Low-Pressure Switches . . . . . . . . . . . . . . 17 turn off main power switch to unit. Electrical shock could
Check High-Pressure Switch . . . . . . . . . . . . . . . . . . 17 cause personal injury.
Check Low-Pressure Switch . . . . . . . . . . . . . . . . . . 17
Adjust Capacity Control (if required) . . . . . . . . . . . 18 WARNING
Capacity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ELECTRIC SHOCK HAZARD
Compressor Operating Limits . . . . . . . . . . . . . . . . . 22 Do not operate compressor or provide electric power to it un-
SCHEDULED MAINTENANCE . . . . . . . . . . . . . . . . . 27 less the compressor terminal box is installed and the terminal
Check Lubrication System . . . . . . . . . . . . . . . . . . . . 27 box cover is in place and secured.
Check Water-Cooled Heads . . . . . . . . . . . . . . . . . . . 28
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
WARNING
Service Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Do not provide power to unit or turn-on compressor unless
5H120 and 126 Compressor Oil Pump History suction and discharge service valves are open.
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pressure-Relief Valves . . . . . . . . . . . . . . . . . . . . . . . 36 WARNING
Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cylinder Head and Valve Assemblies . . . . . . . . . . . 36 ELECTRIC SHOCK HAZARD
Connecting Rods and Pistons . . . . . . . . . . . . . . . . . 37 Do not remove the compressor terminal box cover until all
electrical sources have been disconnected.
Capacity Control Operation . . . . . . . . . . . . . . . . . . . 38
Capacity Control Inspection and Service . . . . . . . . 40
Crankshaft Inspection and Service . . . . . . . . . . . . . 41 WARNING
Pump-End Main Bearing (Fig. 52) . . . . . . . . . . . . . . 42
CONTENTS UNDER PRESSURE
Center Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 43 Compressor contains oil and refrigerant under pressure. Pres-
Seal-End Main Bearing . . . . . . . . . . . . . . . . . . . . . . . 43 sure must be relieved before installation, servicing or opening
Crankshaft Seal Inspection and Replacement . . . . 44 any connections.
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 47 WARNING
RISK OF PERSONAL INJURY
HOT and COLD surface temperatures can occur during opera-
tion and can result in severe burns of frostbite.

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53050002-01 Printed in U.S.A. Form 5F-H-24SI Rev. A Pg 1 5-2021 Replaces: 5F,H-23SI
 Provide sufficient clearance for removal of compressor cylinder
w
WARNING heads and valve plates. Allow space on the oil pump end for
crankshaft removal as follows:
RISK OF PERSONAL INJURY 5F20, 30, 40, and 60 compressors .................................... 20 in.
Only approved refrigerants and refrigeration oils may be used. 5H40, 41, 46, 60, 61, 66, and 81 compressors ................. 20 in.
w 5H80, 86, 120, and 126 compressors ............................... 30 in.
WARNING PREPARE FOUNDATION
Use nitrogen or inert gas for tightness/pressure testing. DO The 5F and 5H compressors may be fastened to:
NOT USE oxygen or other industrial gases. • A steel base and vibration isolators on floor
w • A steel base and condenser support stand
WARNING • A concrete base
In each case, the foundation must be of sufficient strength for the
System strength/tightness test pressure may not exceed the expected load and should be resistant to vibration.
compressor maximum Proof Test pressure on the tag. Close
shutoff valves to isolate compressor if necessary. Floor Foundations
Locate the unit over joists or beams wherever possible. Weak
w floors in old buildings must be reinforced with steel beams or tim-
WARNING bers to support the heavy compressors or condensing units. Use
care in placing supports to avoid the transmission of objectionable
Charge only with refrigerant that conforms to AHRI Standard vibrations to other areas.
700.
Concrete Foundations
w The foundation weight should be 1 to 2 times the weight of the
CAUTION machinery it is to support in order to absorb vibration. Let the
foundation set for approximately 3 days before installing com-
This compressor shipped without oil. Do not run without add- pressor. Allow for 3/8 - 1/2 in. grout thickness after compressor has
ing required lubricant. been installed.
Heavy aggregate concrete weighs about 150 pounds per cubic
IMPORTANT: Install all safety decals/labels that come foot.
with the compressor. Step 2 — Receive Compressor (Fig. 1-7)
BEFORE UNLOADING
INSTALLATION Check unit nameplates against model and serial numbers recorded
Step 1 — Prepare for Installation in job specifications. Check all items against shipping list, and ex-
amine items carefully for any shipping damage. If damage is found
PREPARE EQUIPMENT ROOM or any major component has torn loose from its anchorage, have
Locate compressor in a well ventilated area. If natural ventilation transportation inspectors examine it before unloading. File claim
is inadequate, provide forced ventilation through ductwork. Check immediately with shipping company for any loss or damage.
applicable code requirements. RIG UNIT CAREFULLY
Check that rigging equipment can safely handle the approximate
equipment weights for compressor units.
Rig and move unit carefully to prevent damage to mounting
brackets, refrigerant piping or connections.

2
 2-1/11' ODF
DISCHARGE
SHUTOFF VALVE

NAMEPLATE

SUCTION DISCHARGE
MANIFOLD COVER
(RENOVEFORSTRAINERAND
2-5/ll'ODF HIGH PRESSURE RELIEF VALVE)
SUCTION
SHUTDFFVALVE

SEAL COVER PLATE

CDNTRDLOIL
STRAINER PLUG
5/11-18' SIGHT GLASS

CAPACITTCONTROL
VALVEl-1/11'

HIGH PRESSURE
SWITCH

LOI PRESSURE OIL PRESSURE

SWITCH REGULATORS/II' RANKCASEHEATERCASING
PIPE CA~ 1/Z' FIT

OIL DRAIN ONTROL OIL

CONNECTIONS/II' PRESSURE 1 /~'

DOWEL HOLE

i--------24.49 ,___ _ _ _ _ _ _ _ 30. 50

[ 622. 0 l [ 774. 7 l
2. 35 ---,1---i--- 12. 56
gif\i-------i [59.7l [319.1]

26. 65
[ 676. 9 l

16. 63
[422. 3]

1. 25 --I 5. 50 7. 75
[ 31. 8] [ 139. 7 l [ 196. 8]
<-----15.50 -----+-- 7.83
[393. 7l [199.0l

29. 00
[ 736. 6 l

9. 00
[ 228.

j
7] L_j NOTE: Dimensions are in inches (mm).

11. 00
[ 279. 4 l

Fig. 1 — 5H40, 46 4-Cylinder Compressors

3
 3-118' ODF
DISCHARGE
SERVICE VALVE

3-118' ODF
SUCTION
SHUTOFF VALVE

SUCTIONMANIFOL
!REMOVE FOR ACCESS
TO SUCTION STRAINER! ACCESS TO HIGH
PRESSURE RELIEF
VALVE
PNEUMATIC
CONTROL CONN
1/4' !PS

CONTROL OIL
STRAINER PLUG
5/8-18'

NAMEPLATE

OIL PRESSURE
OIL DRAIN REGULATORS/8'
CONNECTIONS/8' ONTROL OIL
PRESSURE1/4' RANKCASEHEATERCASING
PIPECAP1/2'FIT

DOIEL HOLE

~----------31.64
~--------27.15 [803 . 81
1689. J]

1 3. 58 --------J t;IL1 --t--~-1-------nsJ\ 1- - - - - - - - - ~ , . . _ : . _ 4 _ 91124.51

0
134u1 _ I

22.62
1574.61
23.69
1601 . 61

8.50
1215 . 91
- - - - - 1 7 . 0 0 - - - - - i - - - - 7 . 77
[431 .81 1197. 41

27.03
1686 . 61

NOTE: Dimensions are in inches (mm).

71
11. 00
1279.41
_J
Fig. 2 — 5H60, 66 6-Cylinder Compressors

4
 SUCTION SHUT-OFF
VALVE3-1fll'

NAMEPLATE

SIGHT GLASS

CAPACITY CONTROL
VALVE1-1/II'

5/11'
~~~ur:~i:URE

2-4.-49 43.88
[622.01 [111.4.41

18.65
[727.81
27.91
[708.81

50
.(2 91

19 00 8 00
[736 61 [20321

32.00
[812.81

5.5,--t-JI
[139.J] L,,_oo_J NOTE: Dimensions are in inches (mm).

1279 . .(l

Fig. 3 — 5H80, 86 8-Cylinder Compressors

5
 RELIEF VALVE DISCHARGE
PRESSURE
ISCHARGE SHUT-OFF
VALVE~-1/8'

SUCTION SHUT-OFF
VALVE ~-1 f&"

OIL PRESSURE
REGULATORS/8'

SEAL COVER PLATE

DOIEL HOLE
OIL DRAIN
CONNECTIONS/8"

>--------27.15 > - - - - - - - - - - - - - - 46 . 69
C689 . 7 l C1185 . 9 l
1 3 . 58 3. 38 -+---+----------- 35. 63 - - - - - - - - - t - - - - - + - - - ' - - 5 . 90
C344. 9 l [85 . 7l 1904.9] [150 OJ

30. 01
C 762 . 3]

26. 43
C671 . 4 l

.1]

t 8.25
C 209. 5]

- - - - - - - 29. 00 - - - - - - - - - , . - - 9. 57
[736 . 61 [243 . 0l
J

33. 39
[848 . 11

NOTE: Dimensions are in inches (mm).

Fig. 4 — 5H120, 126 12-Cylinder Compressors

6
 SUCTION DISCHARGE
MANIFOLD COVER
!REMOVE FOR STRAINER AND
HIGH PRESSURE RELIEF VALVE>

SEAL COVER PLATE

Oil SAfETY SENSOR SIGHT GLASS

ION BOTH SIDES!

OIL PUMP
!SELF REVERSING)

OIL DRAIN
RANKCASE HEATER CASING
PIPE CAP 1 "/2 FIT

ISCHARGE SHUTOFF DISCHARGE SHUTOFF

VALVE 1 5" /8 ODF VALVE 1 5" /8 ODF

WATER WATER
COOLED HEADS COOLED HEADS

5H41C835 5H41C875
NOTE: Dimensions are in inches (mm).

Fig. 5 — 5H41 Ammonia Model

7
MODEL NO. A B C D
5H41C835D 30.04 [762.95] 28.32 [719.22] 24.49 [621.98] 12.24 [310.96]
5H41C875D 30.04 [762.95] 28.32 [719.26] 27.58 [700.51] 13.81 [350.66]
5H41C895D 27.65 [702.34] 22.18 [563.25] 24.49 [621.98] 12.24 [310.96]
5H41C905D 27.65 [702.33] 22.78 [578.66] 27.58 [700.51] 13.81 [350.66]

'---------c--------"

'-----□

16. 15
1664 . 331

,..__ _ _ _ _ _ _ A _________,

2. 16
[ 54.93]

7. 75
11 96.781 _J
15.5 0 7.56
1393 , 701 1191051

~
.t101

11.00
[279,40]
j NOTE: Dimensions are in inches (mm).

Fig. 5 — 5H41 Ammonia Model (cont)

8
 OIL SAFETY
SENSOR
HIGH PRESSURE PORT
1H" NPT

RANKCASE HEAT ER CASI NG

PIPE CAP 1 "/1 FIT

DOWEL HOLE

DISCHARGE SHUTOFF
DISCHARGE SHUTOFF VALVE 11 '/8 ODF
VALVE 1 1" /8 ODF

SUCTION SHUTOFF
VALVE 1 1" 18 ODF
SUCTION SHUTOFF
VALVE 11'/8 ODF
WATER
COOLED HEADS

CRANKCASE CONNECTIO
1/1" NPT

OIL ACCESSORY PORT/

HI GH PRE SSURE PORT

5H61CB35 5H61CB75

NOTE: Dimensions are in inches (mm).

Fig. 6 — 5H61 Ammonia Model

9
MODEL NO. A B C D E
5H61C835D 30.70 [779.76] 26.51 [673.44] 25.45 [646.39 27.15 [689.72] 27.15 [689.72]
5H61C875D 30.70 [779.76] 26.51 [673.44] 25.45 [646.39 30.33 [770.35] 30.25 [768.32]
5H61C895D 32.81 [833.30] 23.42 [594.88] — 27.15 [689.72] 27.15 [689.72]
5H61C905D 32.81 [833.30] 24.92 [633.06] — 30.33 [770.35] 30.25 [768.32]

,___---E----------i

-----A-----

3.38
185.811

~~LO-l 13.11
1601.44]
B

OJ

11.00
1431.801
_L l. 56
[191.981

L,1.00
1219.401
_J NOTE: Dimensions are in inches (mm).

Fig. 6 — 5H61 Ammonia Model (cont)

10
 SUCTION DI SC HARG E
tiO,IH FOLO COVER
<RE>OVE FOR Sl R!J NEO A>O
HIGH PR ESSUR E REL[Ef VALV[ I

OIL SIFETI
SENSOR
SEH COVER PL!TE

OIL PU •P
<SELF REVERS ING)

OIL DR! !
OIL PR ESS URE RJ\~ ~CASE HE ,!, fE R C.6.SJN-6
RE<i UL ATOR PI PE CAP 1 ' 11 FIT
I EL HOLE

OISCH!RGE SHUTOFF O!SCHARG C SHUTOrr

V• LH 11'/6 OOF VALVE 2 1' /8 oor
SUC TI ON SHU TOFF
SUC 110N SHUTOFF VA LVE 2 I ' 18 OD F
V> LYE 1 S"/8 OOF

W.til[ R
COOLE D HE'D S

0 IL •CC ESSOOY PORr,

HIGH PI ESSUAE PORT

5HBIC835 5H81C875
NOTE: Dimensions are in inches (mm).

Fig. 7 — 5H81 Ammonia Model

11
MODEL NO. A B C D E
5H81C835D 42.72 [1084.99] 31.17 [791.72] 24.49 [622.12] 12.25 [311.06] 30.70 [779.96]
5H81C875D 42.72 [1084.99] 31.17 [791.72] 27.67 [702.73] 13.83 [351.37] 30.70 [779.96]
5H81C895D 41.16 [1045.51] 23.38 [593.93] 24.49 [622.12] 12.25 [311.06] —
5H81C905D 41.16 [1045.51] 23.38 [593.93] 27.67 [702.73] 13.83 [351.37] —
>--------- C _______.,

D --------J

~
131.751
----+--5.'9
1rn . m

i-------------A------------i

B E
18.31
1120 . 131

7. 15 13 . -49
1196.851 13•2 . 6•1

f - - - - - - - - - 2 9 . 00 - - - - - - - - i - 7 . 57
1136.601 1192.401

oj
9.70]
11.00
NOTE: Dimensions are in inches (mm).
1m . ,01

Fig. 7 — 5H81 Ammonia Model (cont)

12
Step 3 — Install Unit Step 4 — Assemble Refrigerant Piping
TO MOUNT MOTOR ON BASE Refrigerant connection sizes are given in Table 1.
The motor fastening set, available as an accessory for all 5F,H COMPRESSOR PIPING
base-mounted compressors, includes motor blocks and shims for • Provide economical line sizes without excessive pressure
motor alignment; cap screws, plate washers and lock washers for drop, but maintain adequate refrigerant velocities, at all ca-
fastening motor to base; taper dowel pins for securing motor posi- pacity steps, to promote oil return.
tion after alignment; and beveled washers for fastening the unit
base to accessory vibration isolators. • Protect the compressor by preventing excessive lubricating
oil from being trapped in the system.
If vibration isolators are used, attach to base (Fig. 8). To avoid dam-
aging the isolators, lift unit from ends when attaching isolators. • Prevent liquid refrigerant from entering the compressor
during operation and shutdown.
With compressor and motor positioned on the base, check the
height of the vibration isolators. Shim between isolators and floor REFRIGERANT DRIER
as required to level compressor base. When level, secure vibration A replaceable-core filter drier is recommended for most systems,
isolators to floor. Check that bevel washer (Fig. 8) is in place. and is essential on all low-temperature systems. Mount the field-
supplied filter drier in the liquid line. Include a shutoff valve to
permit isolation of drier for servicing (Fig. 9).
{20 TAP

fR Install a moisture indicator on downstream side of drier to indicate

f. 1)1HC...U S when drier cartridges need replacing.
~
2

•i

~ .. ·
~
L ':·ti
~r1•·~ 1:
5F

Cll.PSCRE\11
LIQUID LINE
FROM CONO.

V•BRATI ON
ISO L A"iOR

Fig. 8 — Typical Vibration Isolator Mounting Fig. 9 — Refrigerant Filter Drier and
Shutoff Valve Arrangement
Table 1 — Physical Data (HFC Refrigerants)
COMPRESSOR MODEL 5F20 5F30 5F40 5F60 5H40 5H46 5H60 5H66 5H80 5H86 5H120 5H126
Nominal R-134a/R-407C 5 71/2 10 15 25 40 40 50 50 75 75 100
Horsepower R-22 10 15 20 25 40 60 60 75 75 100 125 150
R-507/404A/448A/449A 10 15 20 25 40 60 60 75 75 100 125 150
Number of Cylinders 2 3 4 6 4 4 6 6 8 8 12 12
Bore (in.) 21/2 21/2 21/2 21/2 31/4 31/4 31/4 31/4 31/4 31/4 31/4 31/4
Stroke (in.) 2 2 2 2 23/4 37/16 23/4 37/16 23/4 37/16 23/4 37/16
Displacement Cfm at 1750 Rpm 19.8 29.8 39.8 59.6 92.4 115.5 138.4 173.0 184.7 231.0 276.8 346.0
Ratings in Tons* R-134a/R-407C 5.2 7.8 10.5 15.7 24.7 30.6 37.0 45.9 49.5 61.1 74.0 91.8
R-22 8.5 12.7 16.8 25.3 39.6 49.1 59.4 73.8 79.2 98.2 119.0 145.0
R-507/404A, R-448A/R-449A 8.4 12.6 16.8 25.2 38.5 47.7 57.7 71.6 77.0 95.5 115.5 143.2
Max Speed (rpm) 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750 1750
Min Speed (rpm) For Lubrication 400 400 400 400 400 400 400 400 400 400 400 400
For Unloader Action 600 700 800 900 800 800 900 900 1100 1100 900 900
Net Oil Pressure (psig)† 45 45 45 45 45 45 45 45 45 45 45 45
Oil Charge (pt) 5 51/2 12 13 18 18 21 21 41 41 61 61
Normal Oil Level in Sight Glass C.L. C.L. 3/8Above C.L. 3/8Above C.L. C.L. C.L. C.L. C.L. C.L. C.L. C.L. C.L.
Min Oil Pressure for Unloader Action (psig) 22 28 35 35 35 35 35 35 35 35 35 35
Suction Line ODF (in.) 11/8 15/8 15/8 21/8 25/8 25/8 31/8 31/8 31/8 31/8 41/8 41/8
Discharge Line ODF (in.) 7/8 13/8 13/8 15/8 21/8 21/8 31/8 31/8 31/8 31/8 41/8 41/8
Bare Compressor Weight (lb) 175 215 355 400 610 610 795 795 1115 1115 1580 1580
LEGEND * 40°F saturated suction, 105°F saturated discharge, 15°F superheat,
0°F subcooling.
C.L. — Center Line † Net oil pressure = oil pressure gage reading – suction pressure. The above oil
ODF — Outside Diameter Female (in.) pressure is typical with mineral or alkylbenzene oils. A slight increase in oil pres-
sure may result with the use of Polyolester (POE) oil.

13
FELT FILTERS 5H120 and 126 Compressors include factory-supplied, tapped
Install felt filter supplied with compressor in suction strainer cover plate. On these compressors, use only lower connection for
(Fig. 1-7). Remove filter after 50 hours of operation. If clean, dis- oil equalization (Fig. 10). Connect gas equalizing line to flange
card it; if dirty, clean with kerosene or neutral spirits and insert connection shown. Mating flange for 11/8-in. line is Mueller Part
for another 50 hours of operation. Tag unit to show date that fil- No. A-5151; gasket Part No. is Mueller Part No. A-5152.
ter was cleaned and reinstalled. See Table 2 for information on re- 5F20 and 30 Compressors have no special tapped cover plate. Use
placement filter packages. opening for oil sight glass to attach the 11/8-in. line for gas and oil
equalization (Fig. 11). Accessory Package No. 06DA900072 pro-
Table 2 — Suction (Felt) Filter Packages vides two 1/8-in. line adapters to thread into the sight glass open-
COMPRESSOR FILTER PACKAGE PART NO.
ing. If additional equalization is desired, run a 3/8-in. line to the oil-
filter plug connection (Fig. 1 and 3).
5F40 5F40-A352
5F60 5F60-A352
5H40,46 5H40-A382
5H60,66 5H60-A382
5H80,86 5H80-A382
5H120,126 5H120-A382
Step 5 — Install Multiple Compressors
EQUALIZING LINES
Compressors operating in parallel require interconnecting lines for
oil and gas pressure equalization. Special handhole cover plates, FITTI NG INTO
equipped with tapped holes for equalizing lines, are available as FOR' OIL LEVEL
ASS IFOR 1-1/8"
options for sizes 5F40 and 5F60, as well as for sizes 5H40 through LINIE
86 compressors (Fig. 10). An oil float system is an acceptable al-
ternative to equalizer lines.
OIL LEVE L

Fig. 11 — Equalizer Connections (5F20 and 30)

APPROVED REFRIGERANTS
Compressor models 5F20-5F60 and 5H40-5H126 are approved
,GAS EQUALIZ R for the following refrigerants: R-134a, R-404A, R-507, R-407A,
,cONIIIEClJON
R-407C, R-407F, R-448A, R-449A, and R-22. See Table 1.
1f OD Fl,AINGLFZ
{5H 120- 126 ONLY I Ammonia compressor models 5H41, 5H61, and 5H81 are
approved for R-717. See Tables 3 and 4.

OIL EQUALIZER
cpr·mEcnor-,
1' IPS

Fig. 10 — Special Hand-Hole Cover and Equalizer

Connections (Typical)
Table 3 — 5H Ammonia Compressor Models
5H AMMONIA COMPRESSOR MODELS
UNLOADER HI/LOW
MODEL CAPACITY SERVICE WATER-COOLED OPSS PRESSURE
5H41 5H61 5H81 NOMENCLATURE ELEMENTS
CONTROL VALVES HEADS
INSTALLED SWITCHES
X X X - C835 No
Electric Unloading
X X X - C875 Yes
Yes
X X X - C915 Low Torque Start No Yes
(No Unloading) Yes No
X X X - C925 Yes
X X X - C935 No
(VFD) No Unloading No
X X X - C945 Yes
Example: 5H61-C875 model number is a compressor configured with
Electric Unloading, Service Valves, Water Cooled Heads, and OPSS oil
safety sensor.
VFD compressor models will start fully loaded. VFD range is 30 Hz to
60 Hz.

14
 Table 4 — Physical Data (Ammonia R-717)
COMPRESSOR MODEL AMMONIA 5H41 5H61 5H81
Nominal HP — 25 40 50
Number of Cylinders — 4 6 8
Unloading Cylinders Standard 2 4 5
Suction Service valve Standard 2 1/8" 2 1/8" 2 5/8"
Discharge Service Valve Standard 1 5/8" 2 1/8" 2 1/8"
Oil Pressure Safety Standard Yes
Single High Stage 1275 1275 1275
Maximum Speed (rpm)
Low Stage Booster 1600 1600 1600
Displacement at 1275 rpm 67 101 135
CFM
Displacement at 1600 rpm 85 127 169
For Unloading 800 900 900
Minimum Speed (rpm)
For Lubrication 400 400 400
Recommend Net Oil DP Pressure psid 45 45 45
Recommend Oil Type CAMCO 717-HT Pint 20 24 45
Weight (water cooled heads) lbs 715 965 1340

ATTACH POWER WIRES TO COMPRESSOR MOTOR Control circuit voltage determines relay coil voltage. This voltage
Attach power wires in accordance with motor manufacturer's in- must be specified when ordering relays.
structions and in compliance with NEC and applicable local See Accessory Compressor Crankcase Heater Installation Instruc-
codes. tions for additional information.
CHECK MOTOR ROTATION Table 5 — 5F,H Compressor Crankcase Heater
Package
Before connecting motor to compressor, check direction of motor
rotation. Rotation must be in same direction as that indicated by ELECTRICAL
arrow on compressor pump cover (or on plate attached near COMPRESSOR CHARACTERISTICS PACKAGE NO.
pump-end bearing housing). If direction is not the same, reverse Volts Watts
motor rotation by reversing any 2 power leads to motor. 115 100 -5-F--20---381
5F20,30,40,60
If rotation of oil pump is reversed, reverse direction of pump rota- 230 100 -5-F--20---391
tion arrow as well. At that time make the following adjustments: 115 200 -5-H--40---381
5H40,46,60,66
All 5F Compressors 230 200 -5-H--40---391
Remove 6 cap screws from oil pump cover. Do not damage gas- 115 200 (2) 5H40-381
5H80,86,120,126
ket. Rotate cover 180 degrees and replace. Arrow at top of oil cov- 230 200 (2) 5H40-391
er will indicate new direction of rotation. Table 6 — Crankcase Heater Relay (60 Hz)
5H40 through 86 Compressors
CONTROL CIRCUIT VOLTAGE PART NO.
Drain oil below level of pump-end cover (Fig. 1-7). Remove
pump-end cover to expose oil pump cover in center of main bear- 115 HN61AJ-101
ing housing. Rotate oil pump cover 180 degrees and replace it. Re- 208/230 HN61AJ-108
place pump end cover and reverse external arrow to match new di- Step 6 — Check Compressor/Motor Alignment
rection of rotation. Proper direction can later be checked without
removing pump-end cover. BELT DRIVE
5H120 and 126 Compressors (Beginning SIN 1086J---) See Accessory Belt Drive Package manual for installation and
Supplied with automatically reversing oil pump, eliminating need alignment instructions.
for adjustment. For 5H120 and 126 models built before SIN DIRECT DRIVE
1086J---, follow same adjustment procedure outlined for 5F com-
pressors. Install and align compressor, coupling and motor as described in
w manual for Flexible Couplings for Direct-Drive Units.
CAUTION HOT CHECK AND DOWELING
If the special gasket between oil pump cover and oil pump is To help maintain alignment, and to ensure exact repositioning of
damaged, replace with correct gasket only. Check oil pressure the motor after servicing, the motor and compressor must be dow-
immediately after starting compressor. eled to the base. Install doweling only after motor/compressor
alignment has been hot checked (checked after the compressor
INSTALL CRANKCASE HEATER has warmed up to operating temperature after initial alignment).
Wire heater to relay or set of normally closed auxiliary contacts on After hot check and while components are still at operating tem-
compressor starter to de-energize it when compressor is operating. perature, drill and ream 2 holes through diagonally opposite motor
Remove rubber plug from crankcase heater casing (Fig. 1-7), and and compressor feet and the base. Use a 9/32-in. drill and a no. 6 ta-
insert heater element entirely into casing. Element should fit snug- per reamer. Secure the motor and compressor to the base with the
ly, not loosely. Wire to comply with applicable electrical codes. no. 6 x 21/2-in. taper dowel pins provided in the motor fastening
set.
When crankcase heater is installed, system can be operated on sin-
gle pumpout cycle, unless used with a DX cooler. Coat the dowels with white lead or other lubricant to prevent rust-
ing, and tap the dowel lightly into position so that 1/16 of taper is
Table 5 lists crankcase heater packages. Table 6 shows corre- left above the motor foot.
sponding relays. Use of 2 heaters on a 5H80 through 126 com-
pressor requires only one relay. Check that all dowels are tight and that they do not bottom.

15
Step 7 — Assemble Water Piping 3. Follow the refrigerant and/or oil manufacturer instructions
For compressor’s using water-cooled cylinder heads (WCH), fol- when installing or retrofitting.
lowing the instructions associated in the accessory kits 5H660009, 4. Castrol SW68 (Totaline® P903-1001) is approved for use in
5H660010, and 5H660011 for water-cooled heads and water- Carrier chiller applications as well as Carrier and Carlyle
cooled hose kits. semi-hermetic compressors for air conditioning and medium
Step 8 — Prepare Lubrication System temperature applications. Castrol SW68 (Totaline® P903-
1001) cannot be used in any new low temperature refrig-
INSTALL OPTIONAL EQUIPMENT eration applications using Carlyle OEM semi-hermetic
Consult local Carlyle representative for information on these ac- compressors. Castrol E68 is approved for use in Carlyle
cessories. OEM compressors for low, medium, and high tempera-
Oil Filter ture ranges.
Oil filter for 5H40 through 86 compressors is available as separate 5. All HFC/POE applications require a crankcase heater.
accessory package. Refer to Accessory Oil Filter Package Installa- 6. Moisture must be kept below 50 ppm for POE oils.
tion Instructions for installation procedures.
7. In retrofit applications, a high flow oil pump is required.
If an accessory oil cooler is also installed (see below), pipe oil fil-
ter into system as shown on diagrams in Accessory Oil Cooler In- For HFCs not listed above, please contact Carlyle Engineering for
stallation Instructions. oil recommendations.
Oil Cooler For Ammonia
Refer to Accessory Oil Cooler Installation Instructions included AMMONIA R-717: CAMCO-717-H Oil — 5H41, 5H61, and
with this accessory package. Adjust water flow rate through oil 5H81
cooler to maintain 100 to 120°F oil temperature returning to com- For CFCs
pressor. See Scheduled Maintenance, page 27.
Carlyle has historically approved the following UL listed refriger-
Oil Separator ants R-22, R-500, and R-502 for use in 5F and 5H compressors.
If oil separator is used in system piping, pipe oil return line to The following MINERAL/ALKYLBENZINE are approved oils
compressor suction line. To minimize possibility of flooding com- for CFCs:
pressor with oil, oil return line diameter should not exceed 1/4 inch.
In addition, line should have manual shutoff valve to throttle oil Totaline® .......................................................... P903-2001
flow as required and to isolate separator for service. Witco ...............................................................Suniso 3GS
Shrieve Chemical .............................................. Zerol 150
CHECK OIL LEVEL
Texaco Capella ............................................. WFI-32-150
Check that oil level is visible at center of compressor sight glass.
Compressors that use optional equipment such as filter, cooler, IGI Petroleum Ind ........................................ CRYOL-150
and oil separator described above will require a greater oil charge NOTE: For CFCs not listed above, please contact Carlyle Engi-
than listed in Tables 1 and 4 on pages 13 and 15. Recheck oil neering for oil recommendations.
level after operating compressor.
APPROVED OILS PREPARE FOR INITIAL START-UP
For HFCs Evacuate, Dehydrate and Leak Test
Carlyle has approved the following UL listed refrigerants Evacuate, dehydrate and leak test the entire refrigerant system as
R-134a, R-404A, R-407A, R-407C, R-407F, R-448A, described in Carlyle Standard Service Techniques Manual, Chap-
R-449A, R-450A, R-452A, R-507 and R-513A for use in 5F ter 1, Sections 1-6 and 1-7.
and 5H compressors.
LEAK TESTING
The following POLYOL-ESTER (POE) are approved oils for
HFCs: Preferred Method
Totaline® (see note 5)..............................P903-1001, 1701 Charge the system to 10 psig with refrigerant. Add dry nitro-
gen or dry air (DO NOT USE OXYGEN) until system pres-
Castrol (see Note 5) .....................................................E68 sure is 150 psig. Check for leaks with a halide or electronic
ICI Emkarate ......................................................... RL68H leak detector.
CPI ....................................................................CP-2916S Alternate Method
CPI ..................................................................... Solest 68 Charge the system with dry nitrogen or dry air (DO NOT USE
BP Marine Enersyn ...............................................MP-S68 OXYGEN) to 40 psig and use soap-bubble test to find large leaks.
All POE oils are very hygroscopic (will readily pick up and retain w
mosture from the air) and should be used completely once the con- CAUTION
tainer is opened. It is extremely difficult to reseal the oil container Do not use compressor to build up pressure. Do not over-
effectively enough to prevent moisture absorption, which in turn charge the system.
forms damaging acids.
NOTES:
START-UP
1. The use of any non-approved refrigerant may be dangerous
and may void the warranty. Contact the Carlyle Compressor Preliminary Steps
engineering department before using any refrigerant or oil not 1. Energize crankcase heater for at least 24 hours before starting
listed in this guide as approved for use in a Carlyle semi- unit.
hermitic compresor.
2. If control transformer is not used, operate electrical control
2. Using the wrong type or weight of oil for the refrigerant circuit with main power switch OFF to ensure that field
selected will void the warranty. connections have been properly made.

16
3. Install felt sock filter for the first 50 hours of compressor
operation. Remove and inspect the filter, clean it if required R08EATSHAW
and replace it for another 50 hours. Remove sock when sys- A- RANGE AOJUST'ME~T $CREW
tem is clean. (Not applicable for 5F20 and 5F30 units.)
4. Check that motor rotates in direction that the arrow on the
compressor oil pump cover indicates. Refer to Installation,
ef TOIP

Check Motor Rotation section on page 15. ~ 9 - ,DIFFEREttT iAL AOJ SCREW

5. Check that oil fills 1/3 to 1/2 of the compressor sight glass.
FtANCO
6. Open water supply valve to condenser. Open pressure line
valve of water-regulating valve (if used). If compressor unit is (!]A- RAI\IG1E ADJUST; :N:T SCREW
equipped with air-cooled condenser, tum on condenser fan. 0

7. Backseat (open) compressor suction and discharge service

valves. Open liquid line valve at receiver. 0---ie- OffFE REtfiLAL ADJ SCREW
1

8. Start evaporator fan or chilled water pump.

PENN
Start Compressor A-RANGE ADJIJSTMEINT SCREW
Close main power switch supplying current to the compressor
motor.
Immediately recheck oil level and check oil pressure. Pressure
ef TOP

should exceed suction pressure by 45 to 55 psi. If correct pressure 8 - - 6- DIFFERENTIAL AO.J SCREW
is not reached in 10 to 12 seconds, stop compressor immediately
and check oil pump.

CAUTION
If any safety device shuts down the compressor, do not reset
the control more than once before determining cause of shut-
down.
High and Low-Pressure Switches
LOW -
PRESSURE
0 I-I I GH -
PRESSURE
$W ITCH SWITCH
Some 5F and 5H units except 5F20 and 30 have factory-installed,
automatic reset, high and low-pressure switches. (These switches
are available as accessories for 5F20 and 30 units.) Figure 12 illus-
trates adjustment procedures for both switches.
Check High-Pressure Switch 5H MOUNT1ING ARiRA NGEMEINT SHOWN .
Throttle the condenser water on water-cooled unit or block the air- Fig. 12 — High and Low-Pressure Switches
flow on air-cooled unit, allowing head pressure to rise gradually.
Compressor should shut off within 15 psi of cutout value. Now re- OIL PRESSURE SAFETY SWITCH (OPSS)
verse procedure; compressor should start within 10 psi of cut-in Carlyle has approved the following oil pressure safety switch with
value given. the 5H ammonia compressors. The OPSS will mount directly to
Check Low-Pressure Switch the oil pump bearing end of the compressor. All 5H ammonia
compressors will have the OPSS stainless steel sensor (P/N 5H41-
Slowly close the suction service valve; suction pressure will de- 7602) installed and leak tested at the factory (see Fig. 13). The
crease. Compressor should shut off within 4 psi of cutout value. electronic oil safety switch (P/N 06DA509570) is provided as an
Reverse procedure; compressor should start within 6 psi of cut-in accessory item that is installed by the OEM. The switch must be
value given. properly installed and tested for proper operation as a system pre-
start condition.

MANUAL
RESET
BUTTON

SCREW-IN SENSOR
(P/N – 5H41-7602 FOR AMMONIA,
P/N 06DA509571 FOR NON-AMMONIA)
ELECTRICAL UNIT (P/N - 06DA509570)

Fig. 13 — Oil Pressure Safety Switch

Manual Reset Button
All non-ammonia compressors would apply screw-in sensor
06DA509571 as applicable.

17
The oil safety switch is designed to protect the compressor against Adjust Capacity Control (if required)
the loss of lubrication. The OPSS switch will close the control cir-
cuit at compressor startup and allow 120 second oil pressure 5F20 AND 30 COMPRESSORS
transitional time delay. The switch will open the control circuit Refer to Capacity Control Valve Installation Instructions for addi-
and shut the compressor off when: tional information.
• The oil pump pressure drops to a minimum 9 psig above 5F40 AND 60, AND 5H40 THROUGH 126 COMPRESSORS
the oil sump pressure after 120 seconds, or
• A time-integrated low differential oil pressure (9 psig) be- Determine the refrigerant usage:
tween the oil pump and oil sump pressure that is fluctuat- If the system is to use R-134a, replace the 11-lb range adjustment
ing 60% of the time  to 9 psig over a 5 minute rolling spring (Fig. 15) with the 7-lb spring supplied with compressor. See
window. instruction tag for spring replacement procedure.
• The OPSS will not reset automatically, but must be manual
reset provided the differential pressure between the oil
sump and pump pressure is above 13 psig.
LF PNEUMAT,IC COtffl'lOL
PRESSURE REMOTE IS NOT USED, l i'ilS PORT
TIME
CARLYLE DIFF (psid) ALARM MUST BE VEITTlED.
DELAY VOLTS RESET OONOT PL.UG
P/N CIRCUIT
(sec)
Cut-out Cut-in CAPABLE

06DA509570 I I 120 9-11 12-14 I

115/230 I
Manual I Yes

If Mechanical Oil Switch 5F20-212 is being used

To check, move contact arm at left side of switch forward CAP ~
0
(Fig. 14). Compressor should stop in approximately
45 seconds.
If compressor continues to run, check the wiring to safety EXTEA !!\I.
AOJLISTI G
switch. If wiring is correct, switch is faulty and should be STEM*
replaced.
After completing test, wait 3 minutes; then press restart button
on front of safety switch and restart compressor.
Check oil level in compressor sight glass after 15 to 20 minutes SPRING DETAILS
of operation. If the oil level is low, add oil by the methods de-
scribed in Carlyle Standard Service Techniques Manual, Chapter
1, Section 1-11.
If an accessory oil cooler is provided, adjust the water flow as re-
quired to maintain a 100°F to 120°F crankcase return oil
temperature.
For additional information, see Oil Safety Switch Accessory
Package Installation Instructions.
* When compressor is received, the capacity control adjusting stem
will be backseated. (Compressor will be fully loaded under all condi-
OO IIIT.ACT ARM RESISTA.fl!C£ tions.) Compressor is supplied with 11-lb spring.
Fig. 15 — Capacity Control Valve
Capacity Control
The 5F and 5H compressor line has multiple configurations for
cylinder unloading which are dependent on the compressor model
type. For example the 5F20 and 5F30 models require an external
pressure control valve kit to unload the compressor. For compres-
sor models 5F40 through 5H126, the pressure control valve is in-
ternally installed.
Additionally there are external electric unloading conversion kits
available for all 5FH compressor models, if pressure unloading is
not preferred. These kits consist of 3-way valves, solenoid coils,
and oil line sets that must be installed by the end user (reference
instructions that come with these external unloading kits).
Factory-installed electrical unloading for the 5H40 – 5H126 com-
pressor models are available. A redesign of the oil pump bearing
end-bell incorporates electric unloading solenoid valves and oil
ii !Gtt •?RESSI.U!·E pressure safety control factory installed. An external unloading kit
CO NNECTION. ~
OIL PUMP -
TO•- - - --
LOW- fllRESSUHE is no longer required. The 5H41 – 5H81 ammonia compressors
DISC HARG E 00:NNECTION will be the first production models to utilize installed electrical un-
TO CRAtO<CASE loading technology (see ammonia section). All 5H field compres-
Fig. 14 — Oil Pressure Safety Switch Contact Arm sors, that currently use pressure or external electric unloading, can
be retrofitted with the redesigned electric unloading bearing head.
If cylinder head unloading is not preferred, all 5FH compressor
models can be applied with a VFD for capacity control. The al-
lowable speed range is 400 – 1750 rpm for non-ammonia models.

18
These compressor models will not have cylinder unloading Power elements and valve lifting mechanisms are identical on all
capability. 5F,H compressors. However, when using capacity control, various
The cylinder unloading mechanism is powered by a compressor methods are used to activate the power elements.
force-feed lubricating system. This feature assures unloading of all See Table 7 for unloading steps and power requirements at each
controlled cylinders at starting regardless of the position of the step.
capacity control valve, since suction valves will be held in open
position until the lubricating oil pressure reaches its normal oper- CAPACITY CONTROL FOR 5F20 AND 5F30 (FIG. 18)
ating level. Refer to Fig. 16 for cylinder unloading sequence. Major Elements of Control Systems:
An external adjusting stem is provided to set control point and 1. Capacity Control Valve: Function is to raise or lower oil
maintain desired suction pressure. The control point is adjustable pressure from oil pump in response to refrigerant suction
from 0 to 85 psig suction pressure. Differential over the complete pressure.
range at any temperature level is 10.7 psig with Refrigerant 22. A 2. Power Elements: Function is to supply power necessary to
7-lb spring (for use on 5F40 and larger units) is furnished with the operate valve lifting mechanism. It is modulated by the ca-
compressor which, when used, results in an adjustable control pacity control valve.
point from 0 to 50 psig with a 6.8 psig range (see Fig. 17).
3. Valve Lifting Mechanism: Consists of a sleeve and push pin
With this arrangement, suction pressure will not drop below the assembly around each controlled cylinder, designed to hold
control set point minus the differential within range of capacity the suction valve open, or to permit the valve to remain in a
steps since the compressor will unload to balance its capacity with normal operating position depending on its actuation by the
evaporator load. power element.

1
4 1

2 3 3 2 2

5F20 5F30

5H80,86
2 1
1
2 2 4

1 1

3 2
4 3
5F40 3 3 4
5F60

5H120, 5H126
5H120, 5H126
NOTE: The numerals indicate the unloading sequence
and the number of cylinders that unload with each step.

— Cylinders recommended for permanently

5H40,66 5H60,66
0 unloaded operation.

Fig. 16 — Cylinder Unloading Sequence

19
 UNIT REDUCTION
SIZE STEPS
1 U L
2 U U L
5F40
5H40 3 L
5H46 1 U L
2 U U L
3 L
1 U L
2 U L
5F60 3
5H60 U U L
5H66 4 L
5H80 1 U L
5H86 2 U L
3 U U L
4 L
1 U L
2 U L
3 U U L
5H120 4 L
5H126 1 U L
2 U L
3 U U L
4 L
0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0
PSI DIFFERENTIAL
R-134a; 7-LB RANGE ADJUSTMENT SPRING L - LOAD
R-22 & R-507/404A R-448A/R-449A; 11-LB RANGE ADJUSTMENT SPRING U - UNLOAD

Fig. 17 — Operating Sequence of Capacity Reduction Steps

Table 7 — Capacity Control Reduction Steps
CAP. STEPS (% FULL LOAD CAP.)
100 871/2 831/3 75 662/3 621/2 50 371/2 331/3 25
COMPR CONTR % FULL LOAD BHP
MODEL CYL
100 90 86 80 74 71 60 50 45 38
Number Of Active Cylinders
5F20 1 2 — — — — — 1 — — —
5F30* 1 3 — — — 2 — — — — —
5F40 3 4 — — 3 — — 2 — — 1
5F60 4 6 — 5 — 4 — 3 — 2 —
5H40 3 4 — — 3 — — 2 — — 1
5H46 3 4 — — 3 — — 2 — — 1
5H60 4 6 — 5 — 4 — 3 — 2 —
5H66 4 6 — 5 — 4 — 3 — 2 —
5H80 6 8 7 — — — 5 — 3 — 2
5H86 6 8 7 — — — 5 — 3 — 2
5H120 8 12 — 10 — 8 — 6 — 4 —
5H126 8 12 — 10 — 8 — 6 — 4 —
*Two controlled cylinders (to 331/3%) available on request for 5F30.

20
 SUCTION VALVE
FROM COMPRESSOR DISC
ADJUSTING SCREW OIL PUMP
OIL PUMP

' PRESSURE

LIFTING SPRINGS
AND PINS
LIFTING
FORK

CONTROL OIL
PRESSURE

UNLOADER
POWER ELEMENT

CRANKCASE CONNECTION
FOR OIL RETURN AND
OPERATING PRESSURE OIL
DRAIN

t
TO OTHER UNLOADER
0 CONTROL OIL
PRESSURE

POWER ELEMENTS
( SPECIAL ORDER ON 5F3O ONLY) 0 CRANKCASE
PRESSURE

Fig. 18 — Capacity Control — 5F20, 5F30

Principle of Operation of the System elements. Relay is activated by control oil pressure from the
An increase in suction gas pressure, which requires increased capacity control valve.
compressor capacity, causes the needle valve to close. Therefore, 3. Power Element: Supplies power to operate the valve lifting
lubrication oil pressure in power element increases. Increased oil mechanism.
pressure in power element moves the power piston upward and
the suction valve discs are allowed to seat. 4. Valve Lifting Mechanism: Consists of a sleeve and push pin
assembly around each controlled cylinder, designed to hold
Table 8 indicates control oil pressure at which controlled cylinders
start to unload and are completely unloaded. the suction valve open or to permit the valve to remain in a
normal operating position, depending on its actuation by the
Different points of control pressure on 5F30 are obtained by using
springs with different loading rates in the power element. power element.
Principle of Operation of the System
CAPACITY CONTROL FOR 5F40 THROUGH 5H86
A decrease in suction gas pressure, which necessitates a decrease
(FIG. 19) in compressor capacity, causes the range spring to open the capac-
Major Elements of Capacity Control Systems: ity control modulating valve. This allows control oil to relieve
1. Capacity Control Valve: Function is to raise or lower the con- from the hydraulic relay and thus reduces control oil pressure in
trol oil pressure to the hydraulic relay piston in response to the relay. With reduced control oil pressure, the spring in the hy-
refrigerant suction pressure. Increase in suction pressure draulic relay moves a piston and thus lubrication oil from the oil
increases control oil pressure in the hydraulic relay. pump is prevented from flowing to a particular deactivated power
element. This relieves oil pressure from the power element, allow-
2. Hydraulic Relay: Function is to feed lubrication oil from the ing the spring in the power element to move the lifting fork and
oil pump at full pressure in sequence to one or more power unload the cylinder. An increase in suction pressure reverses ac-
tion and loads cylinders.

Table 8 — Initial and Final Unloading Oil Pressures — 5F20, 5F30

START TO UNLOAD COMPLETELY UNLOADED
COMPR NO. OF CONTROLLED CYLINDERS OIL PRESS. (PSI) OIL PRESS. (PSI)
5F20 1 19.8 13.0
1 30.0 20.2
5F30
2 19.8 13.0

21
 FROM COMPRESSOR
OIL PUMP

CONTROL OIL OIL PUMP

PRESSURE PRESSURE

VALVE

UNLOADER
POWER
E,,..L:::E=M=E=N=T~::_, OILl::::::;z=.=::=::=;:'==':c==;"===:I
. DRAIN UNLOADER CYLINDER
SLEEVE SLEEVE
SURGE
CHAMBER
(5H ONLY)

OIL TO OTHER
DRAIN UNLOADER CONTROL OIL
POWER • PRESSURE
CAPILLARY
ELEMENTS
DRILLED
HOLE 0 CRANKCASE
PRESSURE

HYDRAULIC
RELAY 0 OIL PUMP
PRESSURE

Fig. 19 — Capacity Control — 5F40, 60; 5H40, 46, 60, 66, 80 and 86
5H120, 5H126 CAPACITY CONTROL (FIG. 20) Pressurestat settings should be adjusted on the job to meet particu-
This capacity control system is slightly different from the system lar operating conditions for which the compressor(s) have been se-
on 5F40 through 5H86 compressors. Unloaded starting and capac- lected. Directions for setting these pressurestats are in the 5F,H In-
ity reduction is obtained by holding open the suction valves of a stallation Instructions.
number of cylinders. For capacity control purposes, a suction- Permanently Unloaded Cylinders
pressure-actuated capacity control valve pilots a hydraulic relay Operation of an open-drive compressor with its cylinders perma-
that loads or unloads cylinders in pairs. nently unloaded requires field modification. 5F60 through 5H66
Major Difference from the 5F40 through 5H86 Capacity compressors can operate with one cylinder unloaded; 5H80
Control through 5H126 compressors can operate with 2 cylinders unload-
The hydraulic relay design provides a wider pressure differential ed. Compressors are modified by removing the suction valve and
between cylinder cut-in and cutout points. The relay is a small, suction valve springs from the cylinder(s) shown in Fig. 16.
easily removed cartridge rather than an integral part of pump end Compressor Operating Limits
cover.
Operation of ammonia compressors within the limits indicated in
PNEUMATIC COMPENSATION OF COMPRESSOR the published rating tables will result in trouble-free operation pro-
CAPACITY CONTROL viding the following recommendations and limitations are applied.
Adding a control air line to the external pneumatic control connec- For physical data see Table 4; for ratings information see Fig. 21-
tion permits pneumatic resetting of the control point in accordance 24.
with changes in operating conditions. Each pound of change in air
pressure resets the control one pound in the same direction. Thus,
a one-pound rise in air pressure will cause unloading to begin at a
suction pressure one pound higher than the original control point,
etc. Figure 19 shows a typical pneumatic control arrangement. All
components and installation instructions are field supplied.
Control Pressurestats
Dual pressurestats come factory-installed with some 5F,H com-
pressor models. They are often referred to as high- and low-pres-
sure cutouts. Their function is to cut the circuit to the holding coil
of the compressor motor starter when pressure setting limits are
exceeded.
The high pressurestat has an operating range from 50 to 450 psig
with a differential range from 170 to 235 psig (adj). The low pres-
surestat has an operating range from 20 in. Hg to 60 psig and a dif-
ferential range from 60 to 90 psig (adj).

22
ORIFICE
SUCTION VALVE
DISC
CONTROL TO OTHER
OIL UNLOADER
STRAINER POWER
ELEMENTS LIFTER SPRINGS
AND PINS

LIFTING
FORK

RANGE UNLOADER
ADJUSTMENT SLEEVE
SPRING

TRAVELIN G
NUT CYLINDER
UNLOADER SLEEVE
POWER ELEMENT

SURGE
CHAMBER

CAPILLARY

- CON TROL OIL

- PRESSURE
FROM
~---~====="{')--- ~~:~:s~~E
(SUCTION OF
OIL PUMP)
0 CRAN KCAS E
PRESSURE

0 OIL PUMP
PRESSURE

Fig. 20 — Capacity Control — 5H120, 5H126

23
UNLOADER
VALVE

OIL PRESSURE
SAFETY SWITCH
(OPSS) FACTORY
INSTALLED
D

A
B

CAPACITY CONTROL STEPS - AMMONIA

CYLINDER
UNLOADING CAPACITY UNLOADER VALVE UNLOADING
MODEL UNLOADED
CYLINDERS (% of full load) DESIGNATION STEP SEQUENCE
75 A 1 1
5H41 2 of 4 (2 steps)
50 D 2 2
83 A 1 1
67 B 2 2
5H61 4 of 6 (4 steps)
50 D 3 3
33 C 4 4
87 A 1 1
5H81 5 of 8 (3 steps) 63 B 2 2, 2
38 D 3 3, 3

Fig. 21 — Unloader Valve/Cylinder Designation

24
 0 0 0
0 0
0 o O

0 ~~ O

□1
- -~ 0 ~

0 ~ O
O O ~ O

0 0 0 0 0

5H41 5H61

5H81

Fig. 22 — Cylinder Unloading Sequence

25
 OIL DIVERTED FROM THE UNLOADER POWER ELEMENT WILL RESULT IN AN SUCTION VALVE
UPWARD MOTION OF THE LIFTING FORK AND UNLOADER SLEEVE. CAUSING THE DISC.
LIFTER SPRINGS AND PINS TO ENGAGE THE SUCTION VALVE DISC, LIFTING THE DISC
OFF THE VALVE PLATE, THUS UNLOADING THE COMPRESSOR CYLINDER.
LIFTER SPRINGS
AND PINS
LIFTING
UNLOADER SOLENOID VALVE FORK

PISTON

UNLOADER
POWER
COMPRESSOR ELEMENT
CRANKCASE
OIL
DRAIN UNLOADER CYLINDER
OIL SUMP
SLEEVE SLEEVE
SUPPLY OIL FROM
COMPRESSOR OIL PUMP
IS CLOSED OFF WHEN
UNLOADER COIL IS
DE-ENERGIZED.
NET OIL PRESSURE: 45-55 PSID

DE-ENERGIZING THE UNLOADER SOLENOID COIL

WILL UNLOAD THE COMPRESSOR. THE 3-WAY
UNLOADING VALVE WILL DIVERT OIL FROM THE
POWER ELEMENT, DRAINING THE OIL BACK TO
THE COMPRESSOR CRANKCASE, CAUSING THE
CYLINDER TO UNLOAD.

Fig. 23 — Compressor Unloaded

SUCTION VALVE
DISC.

LIFTER SPRINGS
AND PINS
LIFTING
UNLOADER SOLENOID VALVE FORK

PISTON

UNLOADER
POWER
COMPRESSOR ELEMENT
CRANKCASE
OIL
DRAIN UNLOADER CYLINDER
OIL SUMP
SLEEVE SLEEVE
SUPPLY OIL FROM
COMPRESSOR OIL PUMP
IS PORTED TO THE
UNLOADER POWER
ELEMENT WHEN THE
NET OIL PRESSURE: 45-55 PSID
UNLOADER COIL IS
ENERGIZED.

ENERGIZING THE UNLOADER SOLENOID COIL

WILL LOAD THE COMPRESSOR. THE 3-WAY
UNLOADING VALVE WILL DIVERT OIL FROM THE
OIL PUMP TO THE UNLOADER POWER ELEMENT,
CAUSING THE CYLINDER TO LOAD.

Fig. 24 — Compressor Loaded

26
To Adjust Control Point
1. Impose an artificial load on the compressor until suction pres-
sure exceeds control point.
2. Slowly close suction valve to lower compressor suction pres-
sure to control point pressure.
3. When at control point pressure, turn external adjusting stem
clockwise until first step of unloading takes place, as indi-
cated by changes in control oil pressure, current draw and
sound of compressor.
Control point is now set. Reopen suction service valve. Com-
pressor will be fully loaded when suction pressure is 3 psig
(4 psig with R-22) above control point, and will be fully unload-
ed when suction pressure is 4 psig (7 psig with R-22) below con-
trol point.
5F20 AND 30 COMPRESSORS
Two capacity control packages are available as accessories. One is
suitable for R-134a applications; the other for R-22 applications.
The adjusting stem (Fig. 13) is shipped in a backseated (fully
counterclockwise) position. Compressor will be fully loaded un-
der all conditions. Adjust the capacity control setpoint by the same
3-step procedure described above for 5F40 and 60, and 5H40 Fig. 25 — Oil Filter Accessory Package
through 126 compressors. (5H40 through 5H86)
CHECK OIL AND SHAFT SEAL TEMPERATURE
SCHEDULED MAINTENANCE
The normal operating temperature of the oil in the crankcase rang-
5F,H compressor and condensing units provide long life and de- es from 100°F to 135°F when fully loaded. Do not permit maxi-
pendable service when properly operated and regularly main- mum oil temperature to exceed 150°F. Conditions under which
tained. Establish a maintenance schedule based on factors such as such excessive temperatures could occur include situations where
operating hours, load conditions and water quality. Maintenance the compressor operates in a fully unloaded condition for an ex-
schedules listed in this section are offered as guides. Modify them tended period, because the compressor would not be able to re-
as needed to satisfy individual machine requirements. move all of the heat generated by compression and friction. In
such situations, use an oil cooler to maintain safe operating tem-
Check Lubrication System peratures. Refer to 5F,H Application Data for more information.
Always check compressor oil level before starting unit. If oil is re- When crankcase oil temperature falls within the 120 to 135°F
quired, record date and amount added. Refer to Fig. 1-7 for loca- range, the shaft seal housing temperature should be approximately
tion of oil filter plug. Table 1 and Step 8 on page16 show specified 140 to 150°F. Shaft seal housing temperatures above 170°F may
types and quantities of oil. cause shaft seal to age rapidly, and harden and crack. Therefore:
Use of accessory oil separator requires additional oil. Oil level and If shaft seal housing temperature exceeds 170°F, STOP THE
separator float valve movement during initial compressor opera- COMPRESSOR. DO NOT restart until the cause of overheating
tion should agree with instructions furnished with the oil separator. has been identified, and the condition corrected.
OIL FILTER MAINTENANCE OIL COOLER USAGE
A bleed-type, high-pressure, disposable filter is available as an ac- The accessory oil cooler maintains safe operating oil temperatures
cessory for 5H40 through 5H86 compressors (Fig. 25). Replace when:
oil filter after the first 50 hours of operation, or whenever the oil is
changed or becomes dirty. 1. Applying long stroke compressors (5H46, 66, 86 and 126).
For added reliability, an oil cooler is recommended on all
Check yearly for clogged filter, indicated by a greater than normal long stroke models regardless of operating range or type of
difference between oil pressure ahead of filter and after filter (be- refrigerant. Additional heat of friction from extended piston
fore orifice elbow). When this difference exceeds 5 psig, change travel on long stroke models increases oil temperatures.
filter as follows:
2. The suction gas becomes highly superheated.
1. Close oil-line shutoff valves on each side of filter (Fig. 25).
3.
2. Disconnect oil lines at filter connections.
a. The compression ratio exceeds 5:1 on R-22 systems.
3. Loosen filter bracket; remove and replace filter body.
b. Application data indicates the need for an oil cooler for
Refer to Accessory Oil Filter Instructions for additional informa- R-134a systems. The compression ratio can be deter-
tion. mined from the following formula:
The full-flow oil filter, on 5H120 and 5H126 compressors only,
contains a replaceable cartridge. Replace the filter cartridge after Absolute Discharge Pressure
the first 100 hours of compressor operation. After the initial filter Compression Ratio =
Absolute Suction Pressure
change, check yearly for filter clogging. If the pressure difference
across the filter exceeds 5 psig, pump down the compressor and
then remove the cartridge. Figure 26 illustrates complete filter as-
sembly (not shown in Fig. 26).

27
 A
(Auto.-Reve:rslog)
.Ii H A l)

0 1L PRESS, GAGE CON

{ Ftllil;; f lL l . __ Y (; ROt ~LIiii ,flJ ~T _G 51T M

SC
f AR
G
OIL FILTE: DOYER ,114SK
00\l~!R

..,'...,.
l - OIL f!UMP· CQl,',E ~

~ .
,

Sli1R I Iii - R B-
on. L.T'ER !SPRIN,S, (Ma.nual Reversl'rng)

Fig. 26 — Oil Pump and Filter Assembly (5H120, 126)

NOTE: Do not operate unloaders at saturated suction temperatures Table 9 — Oil Cooler Maximum Working Pressure
at or below 0°F without prior approval from Carlyle Engineering.
OIL 250 psig
4. The compressor operates fully unloaded for prolonged peri-
WATER 150 psig
ods. Under these conditions, suction gas levels may not suf-
fice to remove the heat of compression and friction. This Table 10 — Oil Cooler Estimated Water Flow Rates
condition can occur in any application, but is most likely in
COMPRESSOR GPM*
low-temperature systems or variable volume applications that
5F 1/4-1
use hot-gas bypass to maintain specified conditions under
5H4Q-66 1-2
low evaporator load. Refer to 5F,H Application Data for addi-
5H80,86 11/2-3
tional information.
5H120,126 2-4
Adjust water flow rate through oil cooler to maintain 100 to 120°F
*Flow rate based on 80°F entering water.
oil temperature returning to compressor. Crankcase temperature
must remain below 140°F; shaft seal temperature at the seal hous- Check Water-Cooled Heads
ing should not exceed 170°F. To prevent oil breakdown and sludge formation, the discharge gas
Tables 9 and 10 list maximum working pressures for oil and water temperature must remain below 275°F. Water-cooled cylinder
and estimated water flow rates for various oil cooler/compressor heads are available as an accessory for this purpose. See Accesso-
combinations. For additional information, see Accessory Oil ry Water-Cooled Head Package Installation Instructions for addi-
Cooler Installation Instructions. tional information.

28
 SERVICE MANUALLY REVERSING OIL PUMP
Service and repair of reciprocating compressors and other refriger- Oil Pump Inspection
ation components should be performed only by fully trained and See Fig. 26, 29 and 30 for 5F and 5H manually reversing oil
qualified personnel. pumps. Also refer to 5H120, 126 auto-reversing oil pump section.
Service Notes Drain oil below level of pump-end bearing head. Remove bearing
head. Complete end-bell assembly must be removed to access
1. Compressor components are shown in normal order of bearing head assembly with oil pump on 5H40 through 86 mod-
removal from compressor (Fig. 27 and 28). els. Check oil pump rotor for end play. Maximum allowable
2. For replacement items, use Carlyle specified parts. See movement of rotor is 0.0025. If there is excessive end play, reposi-
Carlyle 5F,H Specified Parts list for compressor part inter- tion oil pump bushing in bearing head as described below.
changeability. Tum rotor. If there is more than a slight drag, remove pump cover
3. Before servicing compressor, pump down the refrigerant as and disassemble oil pump checking all parts for wear and damage.
follows: Inspect oil pump bushing for scoring. Replace bushing if scored. If
bearing head is scored, replace complete bearing head and oil
a. Start compressor, close suction service valve, and reduce pump assembly.
crankcase pressure to 2 psig. (Bypass low pressurestat
with jumper.) Oil Pump Bushing Installation
b. Stop compressor; close discharge service valve to isolate See Fig. 31 and 32. Position the bushing oil groove at top (running
it from system. from 12:00 to 6:00) when the bearing head is installed. Press new
bushing into the pump-end bearing head from the inner side of the
c. Recover or reclaim any residual refrigerant. Drain oil if head with the chamfered end entering first.
necessary.
Oil Pump Bushing Position
4. After disassembly, clean all parts with solvent. Use mineral
1.
spirits, white gasoline or naphtha.
a. 5F20-60 and 5840-86. See Fig. 31. Place 0.001-in. cir-
5. Before assembly, coat all parts with compressor oil and clean cular field fabricated shim against bushing and install
and inspect all gasket surfaces. Replace all gaskets with new, pump. Shim between bushing and oil pump rotor. Com-
factory-made gaskets, and lightly coat with oil. See Table 11 plete assembly of oil pump with gasket and cover.
for torque values. b. 5H120,126. See Fig. 32. Place 0.015-in. (1/64-in.) shim
6. After reassembly, evacuate compressor and open suction and between port insert and oil pump cover. Complete
discharge valves. Restart compressor and adjust refrigerant assembly of oil pump and pump cover without using
charge. pump cover gasket.
2. Tap bushing with suitable cylindrical positioning tool to seat
Lubrication System it against shim. See typical arrangement shown in Fig. 31.
OIL PUMPS w
WARNING
5F compressors. See Fig. 29 and 31.
5H40-86 compressors. See Fig. 30 and 31. Oil pump assembly must be flush with coverplate surface, but
must not protrude beyond bearing head surface.
5H120,126 compressors, with automatically reversing oil pump.
See Fig. 26(A).
5H120,126 compressors, with manually reversing oil pump. See 3.
Fig. 26(B) and 32. a. 5F20-60 and 5840-86. See Fig. 31. Disassemble oil
pump and remove shim. Reassemble oil pump. Check
5H120 and 126 Compressor Oil Pump History for binding.
Reference b. 5H120,126. Remove oil pump cover and shim. Reas-
DATE semble pump cover with gasket. Check for binding.
TYPE FIG. SERIAL NO. BREAK
MANUFACTURED 4. Install bearing head on compressor. Line up tang on oil pump
Auto.- 1960 through 1968 and From 0447119 to rotor shaft with slot in end of crankshaft. Check oil pump for
26 A901765 and Starting
Reversing Starting March 1986 1086J01967 proper direction of rotation.
Manually 26 Starting 1969 and Starting A901765 and 5. Refill compressor oil to proper level. Observe oil pressure
Reversing Ending March 1986 Ending 1086J--- when starting compressor. Correct oil pressure should be 45
NOTE: By itself, the automatic reversing oil pump cannot be installed in to 55 psig above suction pressure.
place of the manually reversing oil pump or vice versa. The complete
bearing head assembly with the oil pump (auto. or manual) is inter-
changeable as a complete assembly.

29
 ~C"l'LIIIIOEH £ AO GA.SIC i

'' VALVE PI..Af 1E

PUMP END COVER
PUMP' END AtilO CONTROL
DlSCI-IAR!GE VALVE e A.RING HEAD VALVE ASSEMEl•LY
INNEIR SEAT \/AlVS: PLATE GASK T ASSEMBI.Y
fQMP END
COll'ER GASK f
s ucrmN \/ALVE
OISC

SEAL
SHA T SEAL 8EL LO~S
COVER Pl.ATE ASS•Et.181.Y

....

O•L Fl LTEFl SCREEN

HANO - HOLE
COVE R GASKET

I-IAN(HiOl

Fig. 27 — 5H Compressor External Components

30
AUTO. REVERSING OIL PUMP 2. Put a drop of thread sealing compound (Loctite 601 or equiv-
Oil Pump Inspection alent) on each of the 5/16-18 adapter mounting screws and on
See Fig. 26 for 5H120 and 126 for automatic reversing oil pumps. threads of each mounting hole in bearing head. Position one
of the supplied gaskets over holes in adapter and assemble the
1. Drain oil below level of pump-end bearing head. adapter loosely to bearing head.
2. Remove bearing head from compressor.
3. Be sure there are no nicks or burrs on oil pump or bores in
3. Remove oil pump and adapter from bearing head. adapter and bearing head. Slide oil pump through adapter and
4. Check all parts for wear and damage. into bearing head bore, allowing enough clearance to tighten
Pump Installation adapter mounting screws with an Allen wrench. The clear-
ance between oil pump housing and bores in adapter and
1. Using a new gasket, mount bearing head on compressor.
Tighten the 1/2-13 cap screws to 80 lb-ft. bearing head is necessarily very close. DO NOT USE
FORCE and do not attempt to change the clearance.

cePISTON ~IN GS (COMPRESSION-TAPERED )

0 - - PI ST·ON RING ! OI L )

P I STON PI N
CY LI DER SLEEVE
a ..; PIS TON Plt4 L OCK IUNG

CYLINDER S EEVE
SNAP IR ING
-------0· P l STON

\
' \
\
U L OAOER SPR LNGS--\ \
CON!N"EC TI NG ROD

UNLO·A OE1R PINS

\ \ CONNECT IN G ROD BO LTS
\ \
UNLOADER F ORK
\ Y_-----ELASTIC LOC K NU T

UNLOADER
POWE R EL EM ENT
~
CON NECTING
UNLOA DER SL EEVE ROD BEAR ING
UNLOADER BIR ACKET 1NSE RTS
G,ASKET

_ ( \ - - - 'COtOJECTllltG
ASSEMBLED ~ ROD CAP
P I STON AN D
CONNEC T!N-G

SEALEND
BEARING WASHER
•(BRON ZE)
~ ..

CR'ANKSHAFf
SEA L ENO
TH RUST WAS HER (STEJEU

Fig. 28 — 5H Compressor Internal Components

31
 Table 11 — Torque Values 5H UNITS (cont)
SIZE THREADS RANGE
5F UNITS DIA USAGE
SIZE THREADS RANGE PER IN. (lb-ft)
(in.)
DIA USAGE 16-20 Oil Pump Cover - Pump End Bearing Head
PER IN. (lb-ft)
(in.)
16-20 Capacity Control Valve - Pump End
20-25 Pipe Plug - Pump End Bearing Head Bearing Head
20-25 Pipe Plug - Crankshaft 5/16 18 NC 16-20 Auxiliary
1/4 Pipe Control Valve - Pump End
20-25 Pipe Plug - Suction and Discharge Bearing Head
Manifold Cover 16-20 Manifold Cover Plate - Crankcase
10-15 Unloader Power Element Assembly - 18-24 Oil Pump Adapter (12 cylinder)
Crankcase
18-22 Unloader Power Element - Crankcase
10-15 Unloader Cylinder Cover Plate -
Unloader Cylinder Bracket 18-22 Capacity Control Valve - Pump End Cover
18-22 Discharge
12-15 Discharge Valve Cap Screw - Inner Seat 5/16 Valve Guide Assembly - Valve
24 NF
1/4 28 NF Plate
12-15 Discharge Valve Guide Assembly -
Valve Plate 18-22 Discharge Valve Guide - Inner Seat
18-22 Cylinder Bracket
12-15 Oil Pump Cover - Pump End Bearing
Head 30-35 Pipe Plug - Pump End Bearing Head
3/ Pipe
8
10-12 Auxiliary Control Valve Cover - Valve 30-35 Pipe Plug - Crankshaft
Body
25-29 Capillary Tube Assembly - Pump End
22-25 Connecting Rod Bolt - Locknut 3/8 16 NC Bearing Head
5/16 24 NF
15-20 Capacity Control Valve - Hand-Hole 28 Connecting Rod Bolt (Aluminum Rod)
Cover
35-60 Suction and Discharge Manifold Cover -
3/8 Pipe 30-35 Pipe Plug - Pump End Bearing Head Crankcase
25-29 Cylinder Head - Crankcase 55-60 Discharge Manifold - Cylinder Heads
25-29 Shaft Seal Cover Plate - Crankcases 55-60 Valve Plate - Crankcase
25-29 Bottom Plate - Crankcase 7/16 14 NC 55-60 Cylinder Head - Crankcase
25-29 Suction and Discharge Manifold Cover - 53-60 Hand-Hole Cover - Crankcase
3/8 16 NC Crankcase
55-60 Shaft Seal Cover
25-29 Pump End Bearing Head Assembly -
55-60 Pump
Crankcase End Cover and Pump End Bearing
Head - Crankcase
25-29 Hand-Hole Cover - Crankcase 7/16 20 NF 40-45 Connecting Rod Bolt - Locknut*
25-29 Suction Manifold - Crankcase
35-50 Pipe Plug - Crankcase
3/8 24 NF 45-50 Flywheel Screw - Crankshaft
35-40 Pipe Plug - Pump End Bearing Head
25-30 Oil
7/16 Return Check Valve Assembly - 1/2 Pipe
20 NF
30-35 Pressure
Crankcase Relief Valve - Suction and
Discharge Manifold Cover
80-85 Suction Service Valve - Crankcase
1/2 13 NC 30-35 Pressure Relief Valve - Crankcase
80-85 Discharge Service Valve - Crankcase
80-90 Suction and Discharge Manifold -
5/8 11 NC 120-130 Suction Service Valve - Suction Manifold Crankcase
60-75 Magnetic Plug - Crankcase 1/2 13 NC 80-90 Suction Manifold Cover - Crankcase
60-75 Magnetic Plug - Pump End Bearing 80-90 Pump End Bearing Head - Crankcase
Head
80-90 Oil Filter Housing - Bearing Head
60-75 Oil Bypass Plug - Pump End Bearing
140-150 Suction
5/8 Manifold Cover and Suction
Head 11 NC Manifold - Crankcase
5/8 18 NC 60-75 Modulating Valve Adapter - Pump End
Bearing Head 60-75 Magnetic Plug - Pump End Bearing Head
60-75 Lock Screw - Pump End Bearing Head 60-75 Modulating Valve Adapter - Crankcase
60-75 Oil Bypass Plug - Crankcase
18-22 Oil Regulator Valve Assembly -
Crankcase 60-75 Oil Bypass Plug - Pump End Bearing Head
50-60 Cap-Oil Regulator Valve Assembly 5/8 18NF 60-75 Oil Bypass Plug - Pump End Cover
80-90 Hollow
3/4 10 NC 70-80 Flywheel Locknut Crankshaft Lock Screw - Pump End Cover and
Center Main Bearing Housing
34-45 Sight Glass Clamping Gland - Hand-
11/2 18 NEF Hole Cover 18-22 Oil Pressure Regulator Valve - Crankcase
80-90 Cap-Oil Pressure Regulator Valve
8-10 Auxiliary Control Valve Cover - Valve
No. 6 32 Assembly
Body
5H UNITS 7/8
60-75 Seal Plug - Pump End Bearing Head
14 NF
1/16 Pipe 10-15 Pipe Plug - Auxiliary Control Valve Body 18-22 Oil Pressure Regulator Valve - Crankcase
1/8 3/4 Pipe 45-50 Pipe Plug - Crankcase
Pipe 15-20 Pipe Plug - Pump End Bearing Head
20-25 Pipe Plug - Crankcase 1 Pipe 50-55 Pipe Plug - Crankcase
35-45 Sight
1/4 Pipe 20-25 Pipe Plug - Pump End Cover Glass Clamping Gland - Hand-Hole
11/2 18 NEF Cover
20-25 Pipe Plug - Crankshaft
No. 6 32 8-10 Auxiliary Control Valve Cover - Valve Body
12-16 Oil Pump Cover - Pump End Bearing
Head LEGEND
8-12 Auxiliary
1/4 Control Valve Cover - Valve
28 NF NC — National Coarse
Body
NEF — National Extra Fine
8-12 Special Cap Screw - Auxiliary Control
Valve Body NF — National Fine
1/
4 20 NC 8-10 Oil Pump - Bearing Head (12 cylinder) *Steel Rod.

32
 Table 12 — Wear Limits; 5F,H Compressors
COMPRESSOR
5F20,30,40,60 5H40,46,60,66,80,86,120,126
COMPRESSOR PART Maximum Maximum
Factory Tolerances (in.) Allowable Factory Tolerances (in.) Allowable
Wear (in.) Wear (in.)*
Max Min Max Min
SEAL END†
Main Bearing Diameter — 5F20, 30 1.6264 1.6250 0.002 2.6264 2.6250 0.001
— 5F40, 60 2.0636 2.0618 0.001 — — —
Journal Diameter — 5F20, 30 1.6240 1.6233 0.003 2.6235 2.6225 0.002
— 5F40, 60 2.061 2.060 0.002 — — —
PUMP END†
Main Bearing Diameter — 5F20, 30 1.6264 1.6250 0.002 2.2530 2.2502 0.001
(Assembled) — 5F40, 60 1.6264 1.6250 0.001 — — —
Journal Diameter 1.6240 1.6233 0.002 2.249 2.248 0.002
CENTER (5H80,86,120,126)†
Main Bearing Diameter — — — 2.6264 2.6250 0.001
Main Bearing Thickness — — — — 0.0942 0.001
Journal Diameter — — — 2.6235 2.6225 0.002
CONNECTING ROD†
Bearing Diameter 1.6255 1.6245 0.002 2.2505 2.2495 0.002
Bearing Thickness — 0.06225 0.001 — 0.06225 0.001
Crankpin Diameter 1.6240 1.6233 0.003 — 2.248 0.002
Seal End Bearing Washer Thickness 0.131 0.129 ** 0.188 0.186 **
Seal End Thrust Washer Thickness 0.157 0.155 ** 0.188 0.186 **
Pump End Bearing Washer Thickness 0.131 0.129 ** 0.188 0.186 **
CYLINDERS
Bore 2.501 2.500 0.003 3.2515 3.2505 0.003
Piston Diameter — Steel, Standard Stroke
— 2.4980 .003 3.2485 3.2480 0.003
— Aluminum, Long Stroke
Body — — — 3.241 3.240 0.003
Ring Groove (OD) — — — 3.235 3.232 0.003
Piston Pin Diameter — 0.7498 0.001 — 0.9998 0.001
Piston Pin Bushing 0.7500 — 0.001 1.000 — 0.001
Piston Ring End Gap (compression and oil)†† .009 0.004 .030†† 0.017 0.007 0.030††
Piston Ring Side Clearance
Compression Side 0.0015 0.0005 0.003 0.0015 0.0005 0.003
Oil Side 0.0012 0.0002 0.0012 0.0002
OIL PUMP
Axial Clearance 0.0015 0.0005 0.0025 0.0015 0.0005 0.0025
Drive Shaft Diameter 0.4361 0.4356 — 0.4361 0.4356 —
Drive Shaft Bushing Diameter (10) 0.4375 — — 0.4375 0.4370 —
Drive Shaft Diameter (5H120 & 126) — — — 0.6250 0.6240 —
Drive Shaft Bushing Diameter (ID — 5H120 & 126) — — — 0.6270 0.6260 —
SUCTION VALVE
Suction Valve Disc (depth of wear below face) — - .005 — — 0.005
Suction Valve Seat — .012 .002 — 0.012 0.002
DISCHARGE VALVE
Discharge Valve Disc (depth of wear below face) — — .005 — — 0.005
Discharge Valve Seat — .012 .002 — 0.012 0.002
* Same wear allowance applies to undersized shafts and bearings.
† Re-manufactured service compressors can be built with under- CRANKSHAFT END CLEARANCE (in.)
sized main bearings and connecting-rod bearings. Compressors with
undersized bearings are identified by the letter A, B, or C stamped on 5F20-5F60 0.011 to 0.035
the compressor nameplate after the model number, and on both ends of 5H40,46 0.010 to 0.036
the crankshaft. 5H60,66 0.011 to 0.037
A = 0.010-in., B = 0.020-in., C = 0.030-in. undersized bearings.
Replacement bearing heads for compressors with undersized 5H80,86 0.014 to 0.042
shafts must be field-modified with proper undersized bearing. 5H120,126 0.014 to 0.044
** Replace thrust and bearing washers when end clearance exceeds
maximum listed: †† Gap dimension increases (by up to 10%) when cylinder bores have
been honed (if necessary) on 5F/H re-manufactured compressors.

33
 8RONZE SEARI NG WAS HER

PUMP !!NO 9EAFH NG H:E AD

OIL PU.M P ROTOR

Oi l PU.MP IDLE R

OIL PUM P COVIEIR GASKET

ROT.i!,.TION ARR•OW

OIL F I LL OI L PUMP COVER

CON N1ECT ION

PUMP IN TAKE PLUG

( MAGNE'. Tl·C),

OIL P RESSURE CO NECTION 0 0

()
CASE PRESSURE CONNECT ION
0 0

OI L Pf!ESSURIE CONN ECTION

(RE:MOVE FOR ACC ESS TO CON T RO L OIL STRA INER l

Fig. 29 — 5F Oil Pump Assembly

,SLEEVE:
LClCATL'ON
~5NI USlNG
·00. COOi.SR

0 f P
OOVe:l.:i

I
OIL PUMP
PRESSLI · E

U . LOAD.ER P-'Q:RTS
(3 ON 4 G DER UNITS;
4 Off 6 ANO fl, C.YLI DER U I
Fig. 30 — 5H40 through 86 Oil Pump Assembly

34
 OIL PRESSURE REGULATING VALVE (nonadjustable,
·OOl"SHIM Fig. 33) is located on the side of compressor adjacent to seal hous-
tl'IEI.D Fll,18 RICATED) ing. Regulator maintains correct oil pressure and ensures satisfac-
tory unloader operation.

OIL REGULATi G GASKET OIL RiE:GULAT ING

VAi.VE BODY VALVE CA,P .

Fig. 33 — Oil Pressure Regulating Valve

(Nonadjustable)
Unscrew regulator from crankcase; use 5/16-in. Allen wrench on
all compressors except 5H120, which requires 1/2-in. Allen
wrench. Regulator must not be clogged and plunger must not be
stuck. Check drillings to regulator for fouling.
Fig. 31 — Setting Oil Pump Bushing The nonadjustable oil pressure regulator is interchangeable on all
(Typical 5F20 through 60, and 5H40 through 86 - 5F40 current 5F,H compressors except 5H120 and 126 models. 5H120
Bearing Head Shown) and 126 units have larger, nonadjustable regulators. Early 5F,H
compressors were equipped with an adjustable-type oil-pressure
regulator. When an adjustable-type regulating valve needs replac-
CflANi<CASE ing, use a nonadjustable regulator.
BUSH ING OIL RETURN CHECK VALVE (5F20 through 60, and 5H40
through 86) allows oil to return from suction manifold to crank-
case. This normally open valve closes when crankcase pressure
becomes higher than suction pressure (Fig. 34).
8EAF!ING Two disc-type check valves on 5F20 and 30 compressors are lo-
cated beneath partition between suction manifold and crankcase,
one on each side of compressor. Remove check valves through
bottom cover or pump end of compressor.
Leaf-type check valve on 5F40 and 60 and 5H40 through 86 com-
DRIVE DISC pressors is accessible through, and located at top center of, hand-
hole cover opening.
OIL ptJ
COVER Remove check valves and check to see that flutter valve or leaf
does not stick, and that it seats tightly.

RiEM:>VE SHIM FOR

1FINAL ASSY

Fig. 32 — Setting Oil Pump Bushing

(Typical 5H120, 126)
4. Hold pump with one hand and rotate it while equally tighten-
ing adapter mounting screws. Proper alignment between
pump and bearing head bore is extremely important. THERE
MUST BE NO BINDING.
5. When adapter is secure, remove pump assembly and place
second gasket on pump housing. Insert two 1/4-20 mounting
screws and lock washers, one on either side of the word TOP
on pump end cover, and position gasket on screws. For L£ AF= TYPE
remaining operations, be sure the word TOP is at the top. Fig. 34 — Oil Return Check Valves
6. Turn pump shaft to align drive tang with slot in end of crank-
shaft. Holding pump assembly with thumbs on the 2 screws,
slide assembly into bearing head until tang engages slot. A
slight rotation should align screws with tapped holes in
adapter. Start screws to hold alignment and then install bal- DOWEL
ance of screws and lock washers. Torque all screws (1/4-20) to KEY
8 to 10 ft-lb.
7. Start compressor and check oil pressure. This oil pump oper-
ates in either direction of rotation. The correct oil pressure for
compressors using this pump is 45 to 55 psig above suction
pressure.

Fig. 35 — Centrifugal Oil Separator Impeller

35
CENTRIFUGAL OIL SEPARATOR on 5H120 and 126, mounted 5H120 AND 126 COMPRESSORS are equipped with external
on crankshaft (Fig. 35), returns oil to compressor crankcase. To re- relief valve mounted on bypass line between suction shutoff valve
move or replace oil separator, see Crankshaft Inspection and Ser- and discharge manifold. To remove valve, remove bolts from
vice. flanges on either side of valve.
OIL FILTER SCREEN (Fig. 27) in compressor crankcase is ac- Suction Strainer
cessible through hand-hole cover or bottom plate. Remove and in-
spect it for holes, then clean it with solvent and replace. To withdraw strainer on 5F20 and 40 and 5H40 and 46 compres-
sors, remove suction and discharge manifold cover on seal end of
Pressure-Relief Valves compressor.
When pressure differential between high and low-pressure sides On 5F30 compressor, remove suction service valve. On 5F60 and
exceeds 350 ± 35 psi (5F60: 400 ± 40 psi), pressure-relief valve 5H60 and 66 compressors, remove suction manifold and with-
bleeds refrigerant from high to low side. draw 2 strainers. On 5H80 and 86 compressors, remove suction
Check relief valves for evidence of leaking. Change if defective or manifold cover.
if valve has ever opened due to excessive pressure. On 5H120 and 126 compressors, remove one suction manifold
plate at a time so as not to disturb position of detachable suction
5F60 COMPRESSORS manifold and suction line. Withdraw 2 suction strainers.
Internal relief valve screws into crankcase and projects up through Clean strainer with solvent or replace if broken or corroded. When
left cylinder-bank valve plate (Fig. 36). Use a standard socket-type replacing suction strainer, do not damage it.
screwdriver to remove and replace valve.
On 5H120 and 126 compressors, positioned manifold cover plate
5H40, 46, 80 AND 86 COMPRESSORS must compress strainer bail. If bail is too short, grasp on sides and
Pressure-relief valve is located on suction and discharge manifold elongate it enough to be compressed by manifold cover. Position
cover (Fig. 37). bail between the 2 bosses on inside of manifold cover to prevent
strainer from turning.
5H60 AND 66 COMPRESSORS
Relief valve is located in wall between suction and discharge man- CAUTION
ifolds. Remove discharge manifold for access to relief valve. Use
a standard 11/2-in. socket to remove and install the valve. If a felt sock filter is installed, remove and inspect it after 50
hours of operation. Clean filter if required and replace it for
another 50 hours. Clean the suction strainer whenever the felt
sock is removed. Remove sock when system is clean. (Not
applicable for 5F20 and 30 compressors.)
Cylinder Head and Valve Assemblies
CYLINDER HEAD INSPECTION
Remove cylinder heads and check heads for warping, cracks and
damage to gasket surfaces.
VALVE INSPECTION (FIG. 38)
Disassembly
Remove cylinder head. Loosen cap screws holding discharge
valve seat to discharge valve guide, and cap screws holding valve
NOTE: The pressure-relief valve is not part of the valve plate assembly. guide to valve plate. Remove cap screws holding valve plate to
The valve mounts in the crankcase in the left side cylinder deck cylinder block. Remove valve plate from cylinder block and dis-
(looking at pump end). The valve plate opening outlined slips over the charge valve guide from valve plate.
pressure-relief valve when assembled.
Inspection
Fig. 36 — Pressure Relief Valve (5F60) Inspect suction and discharge valve discs and valve seats for
cracks or excessive wear (Table 12). Check cylinder-sleeve valve
stops for uneven wear. Replace valves if cracked or worn. If valve
seats are worn, replace complete valve plate assembly. If cylinder-
sleeve valve stops are worn, replace sleeve.
PRESSI\JRE RELIEF VALVE:
Reassembly
Pistons must be below tops of cylinder sleeves. To position cor-
rectly, tum crankshaft or force pistons down.
1. Place suction valve springs in valve plate recesses. Large
spring coil should be in full contact with bottom of recess.
2. Place suction valve disc on valve springs; press disc into
valve plate recess. Slide valve retainer clips into place
(Fig. 39). Clips must not cover valve lifter springs or pins.
SUCTIO AND 0 1$CHAR~ Valve retainer clips 5F20-2061 (5F compressors) and 5H40-
MA Nlfl}U l OOVf:R 2061 (5H compressors) are field supplied.
Fig. 37 — Pressure Relief Valve and Suction Strainer 3. Bolt valve plate to cylinder block. Remove valve clips.
(5H40, 46, 80 and 86) 4. Place discharge valve springs in discharge valve guide spring
recesses.
5. Place discharge valve disc over springs, and fit inner spring in
place over valve disc. Hand-tighten bolts holding inner seat to
valve guide (valve guide assembly).
36
6. Place valve guide assembly on valve plate. Tighten all bolts REASSEMBLY
and bend tabs on lock washer and lock plates. Replace cylin- When new rings are being installed in a used cylinder sleeve,
der head. break the hard, glazed surface of cylinder sleeve to reduce wear-
ing-in period of new rings. Clean sleeves thoroughly after break-
DISCHARGE VALVE
SPffiNG
VALVE L IFT E:R
SPRI G ing glaze.
To reassemble:
Dl<SCHAFlG£
0 1$CHARGE VALVE
GUIOE IN PL ACE 1. Rotate crankshaft to position piston at top center.
VAUIE.
GUI DE 2. Lubricate piston rings and beveled surface at lower edge of
cylinder sleeve.
0ISOHA!RGE
3. Stagger ring gaps around piston.

I =:='O>,
OISCHAIF!ClE VALVE
I EF! SEAT
4. With turning motion, work sleeve over piston and rings.
Compress and align each ring with beveled edge of sleeve.
5. Seat sleeve in suction manifold partition and cylinder deck
recess.
DISCHARGE VALYE
6. Rotate sleeve so that any 2 valve lifter-pin holes lie equal dis-
OIJTEA SEAT tances from longitudinal axis of compressor (Fig. 40). In this
position, lifter pins line up with suction valve springs.
SUCT 10 VALVE
IN Pl.ACE CAUTION
Fig. 38 — Suction and Discharge Valve Assembly
Never operate compressor with heads or valve plate removed.
\/ALVIE PL,i!,TE SUCTIO N VALVE DISC Connecting Rods and Pistons
REMOVAL
Remove cylinder head, valve plate and hand-hole cover or bottom
plate to gain access to rods and pistons.
Remove connecting rod caps (Fig. 28). Label caps and rods so
they may be reinstalled in same places on crankshaft. Remove cyl-
inder sleeve, connecting rod and piston assembly as a unit by
pushing assembly up through cylinder deck. Do not allow piston
to come up through top of sleeve during removal process. Remove
retaining rings and piston pins to disassemble connecting rods
from pistons. Remove rings.
Keep each individual connecting rod and piston assembly together
to aid reassembly. Check all parts and crankpin journals for wear
SUCTION VAi.VE RETAINER Ct.lPS (Table 12).
Fig. 39 — Valve Clips in Place Cylinder and INSPECTION AND REPLACEMENT
Unloader Sleeves
Attach connecting rods to pistons with piston pins and lock in
DISASSEMBLY (FIG. 40) place with retaining rings. Piston pins are selectively fitted for a
Remove cylinder head, suction and discharge valve assembly, and push fit; reassemble in the piston from which they were removed.
pump-end bearing head. Whenever cylinder sleeve or valve plate Place piston pin retaining rings, with gap on side, on piston
is replaced, use a new suction valve disc. (Fig. 41). They should be tight enough to inhibit rotation under
finger pressure.
1. Tum crankshaft until piston is in mid-position.
Check Rings
2. Insert a sleeve puller into cylinder and push it down onto top
of piston. 1. Check ring gap by inserting each ring separately in cylinder
approximately% in. from top. Ring gap should be between
3. Tighten nut on top of sleeve puller to expand puller in sleeve. 0.007 and 0.017 inches.
4. Tum crankshaft, forcing sleeve upward until it can be 2. Install compression rings on piston with marked side up (see
removed. Fig. 41) toward piston head. Install oil rings either side up.
5. Remove unloader snap rings (5H compressors only). Disas- 3. Stagger ring gaps around piston.
semble un1oader sleeve, pins and springs. 4. Measure side clearance between ring and piston (approxi-
INSPECTION mately 0.001 inch). Check rings for free action.
Examine bore of sleeve for wear. Check suction valve seats for Check Rod Bearing Inserts (Fig. 28)
scratches and wear. Check unloader sleeves, pins and springs for If bearing inserts are damaged and crankshaft is not worn, it is
wear and freedom of movement (Table 12). only necessary to replace inserts. Do not file bearing caps. Place
the inserts in connecting rod and connecting rod caps so knobs on
inserts fit into notches on rod cap. Lubricate insert bearing and
crankpin freely before installing caps.
Install cylinder sleeve, connecting rod and piston assembly at the
same time. Turn connecting rod, and install cap so chamfered
sides are against radius of crankpin. (Small knobs on rod and caps
must be on same side of journal.)

37
 Capacity control unloader systems consist of 4 major components:
1. A capacity control valve, which increases or decreases con-
trol oil pressure to the hydraulic relay piston proportionally
when the suction pressure from the crankcase rises or falls.
2. A hydraulic relay, which (except on the 5F20 and 30) feeds
oil to the unloader power elements in sequence. Control oil
pressure from the capacity control valve activates this relay.
3. A hydraulic power element, which supplies the power nec-
essary to operate the valve-lifting mechanism. It is modulated
by the capacity control valve.
4. A valve-lifting mechanism, which consists of a sleeve, a lift-
ing fork and a push-pin assembly around each controlled cyl-
inder. The valve-lifting mechanism holds the suction valve
open, or permits the valve to remain in normal operating posi-
tion depending on its actuation by the power element.
These components operate in the following manner:
Fig. 40 — Position of Cylinder Sleeves 5F20 AND 30 CAPACITY CONTROL OPERATION (FIG. 42)
(WITH OPTIONAL UNLOADERS AND CONTROL)
Loaded Operation
A rise in suction pressure causes needle valve to close. Oil pres-
3,232
3 .325
RI G
sure in power element increases as oil enters capacity control cir-
LANDS l0.0.11' cuit from oil pump. Power element piston is forced upward, pivot-
OIL RING ing lifting fork downward. Lifter pins drop, allowing suction valve
(\IOJfEO) to seat and load controlled cylinder.
Unloaded Operation
900Y11; A drop in suction pressure causes needle valve to open. Oil bleeds
OIL RING through valve to crankcase, decreasing oil pressure in power ele-
(VENT,EO] ment. As oil pressure to power element drops, the piston moves
(STANDARD
STROI< E ONLY) downward. Lifting fork pivots upward, moving lifting pins up-
ward; suction valve rises from its seat and controlled cylinder un-
MA:Rl<ED SIDE UP loads.
5F40 AND 60, AND 5H40 THROUGH 126 CAPACITY
CONTROL OPERATION (FIG. 43 AND 44)
Loaded Operation
COMPRESS ION A ING A rise in suction pressure increases pressure against capacity con-
__j__ NO TA.PER -EITHER SIDE UP trol valve bellows, compressing range adjustment spring. Com-
I pression of range adjustment spring allows valve spring to move
push pins and valve needle point toward valve seat. Flow of con-
trol oil to crankcase through oil drain is throttled.
Control oil pressure rises as oil enters capacity control circuit
through orifice from compressor oil pump circuit. Increased con-
*See Table 11 for piston diameters. trol oil pressure advances hydraulic relay piston (against spring)
Fig. 41 — Piston and Rings which feeds oil at full pressure to one or more controlled cylin-
der power elements depending on position of control valve.
Capacity Control Operation Pump oil pressure in unloader power elements forces piston up-
All 5F,H series compressors, except 5F20 and 30 units, include ward, pivoting the lifting fork(s) downward. Lifter pins drop, al-
hydraulic capacity control unloader systems as standard equip- lowing suction valve(s) to seat and load cylinder(s).
ment. (Field-installed accessory unloader packages are available
for the 5F20 and 30.) The unloader system activates and deacti-
vates the compressor's cylinder banks, by permitting suction
valves to seat or preventing them from doing so, in response to
changing load demands. Capacity control unloaders can reduce a
unit's actual operating capacity by steps down to as little as 25% of
its total capacity. Figures 16 and 22 show the sequence and num-
ber of cylinders that unload with each step.

38
 FROM COMPRESSOR
OILPLIMP --
OIL PUMP
PAESSURE

OONTRO OIL.
PRESSURE--__.,tt - ~ - Utl!LO\I\OEA
Sl.!EEVE

UNLOA0EFI
--1- - CYLINDER
SLl;iEVE:
POWER

i
CRANKCASE CONNECTION
ELEMENT

FOO OIL FIETIJRN ANO

0P5RATING PRESSURE O IL
DRAIN COf'rnRO L OIL
PRESSUl'I
!
TOOIBER
UNLOADER POWEfi
E1-EMENTS ON 5F30 ONLV
O CRANKCASE
~ESSURE

Fig. 42 — Capacity Control (5F20, 5F30)

If PNEt.lMAT~ C0N'lifroL f'ROtll COMPRiE:SSO'R
IS NOT USE(I, THI$ OIL PUMP
PORT MUST BE.V£N TEO
DON9IPLW 00 NTR0L 0 l1L 01 L PUMP
PRESSURC: f>RESS\Jff

VALVE

'
SURG,E
CHAMBER
I ~H ONLY)

OI L TO OTHER
ORION ONLOA!)ER A, CONTROL OIL
CAP ILLARY POWiEFil - PRIESSURE
EL.EMENTS
DRU.L ED
HOLE
A, CR AN KCASE
- PRESSUR.E

---- OIL PUMP

PRESSURE

Fig. 43 — Capacity Control Operation (5F40, 60; 5H40, 60, 66, 80 and 86)

39
 ORIFICE
SUCTION VALVE
DISC
TO OTI-IER
UNLOADER
P-OWE:R
EI..EMENTS UHER SPRI NGS
AN:O P INS

LI FTLNG
FORK

P NEUMATIC
CO . Tf!OL
CON:N ECT'IO

RANGE UN LOADE R
SLEEV1E
Al>JtJSTMEN T
SPRING

TRA\/1::L I G,
NU T CYLlt4O fl
SLEE\/

El< T!ERNAL.
ADJUST ING SURGE
STEM CtlAMi8ER

CONTROL OI L
• PRESSU RE
FROM
CRANKCASII!:
PRESSURE CRA kCA$ £
• PRESSURE
[SIJCTIO N Of'
OIL PUMP)
. PUMP
OIL
• PRf'SSUR

Fig. 44 — Capacity Control (5H120, 5H126)

UN L OADER C'!'L I NO!ER SPR ING UNI.OAOl::R CYLINDER

0 RACKIE:T GJISK E T RE TAI NE R SPR I G GASKET
GASKET I.BOTTOM) PISiON WASH E H [M IOOLEl I TOP }
UNLOADER FOR·K

·. \ _J-.l I .
. L>.-,To~ ~A.
C ru NOE R U 1N LOAOE R p I $fON UN L OA DER UNLOADER
O' -
CYL •ND!ER
o - 'I;,-
. . . - - - --C LEVLS .Pl:N

BRACKET CYI. I DE l'l flO O SPR ING SPR ING COVER PLATE
( INNER] toUTER)
Fig. 45 — Unloader Power Element (Typical)
Unloaded Operation Capacity Control Inspection and Service
A drop in suction pressure decreases pressure against control UNLOADER POWER ELEMENT REMOVAL
valve bellows. Range adjustment spring presses against the push
pins, compressing the valve spring. This moves the needle valve Remove cylinder head, valve plate, connecting rod, piston and
off the seat. cylinder sleeve. Remove Allen head cap screws (2) holding un-
loader power element in position.
Control oil bleeds from hydraulic relay and control valve to
crankcase, relieving oil pressure on hydraulic pistons. The piston Remove power element (Fig. 45) and disassemble. Check all parts
retracts, preventing transmission of pressurized oil to controlled for wear or damage.
cylinder power element(s), and the oil drains to crankcase. POWER ELEMENT REPLACEMENT
As oil pump pressure on power element drops, the piston moves Check unloader fork height (Fig. 46) of new or assembled power
downward. Lifting fork(s) pivot(s) upward, moving lifting pins element.
upward; suction valves rise from their seats and controlled cylin-
der(s) unload(s). It should be noted that a minimum of 33 to 35 Attach power element to internal suction manifold. Replace cylin-
pounds of oil pressure is required for proper unloader operation. der sleeve piston, connecting rod, valve plate, cylinder head and
hand-hole cover.

40
 TO CONTR(JL
OIL PRESS.- -
GAG . COON
CAP ILL.ARY - .
TUBE

(5F) H = ~
2 32
-;'
TO UNLOADER
POWER ELEMENT S

Fig. 46 — Unloader Fork Height (5F and 5H) OSEQU~NCE

~Dl
FROM
s
EXTERNAL ADJUSTING STEM REMOVAL does not require CRA KCASE
compressor to be pumped down. Loosen hex nut at valve stem Fig. 48 — 5H Pump-End Cover and Control Assembly
base and remove adjusting stem assembly. (5H40 through 86)
REMOVAL OF CAPACITY CONTROL VALVE AND OIL PUMP PRESSURE
HYDRAULIC RELAY CAPAC ITY CONTROL VALVE (EIE'FORE FILTERING)

Assembly is located in hand-hole cover (Fig. 47) of 5F40 and

5F60 units; in pump-end cover (Fig. 48) of 5H40 through 86 units; SURGE
and in pump-end bearing head (Fig. 49) of 5H120 and 126 units. CHAMBER ~

Remove capacity control valve and hydraulic relay. PUMP END

NOTE: It is not practical to remove hydraulic relay from 5H40 MAIN
BE.ARING- --
through 5H86 compressors.
Inspect parts for wear, damage or evidence of leaking or sticking. OIL PUMP_. ,
TANG
A new hand-hole cover, pump-end cover or pump-end bearing
head with control valve assembly and hydraulic relay may be in-
stalled. However, capacity control valve (and hydraulic relay on CAPILLA.RY
TO OIL. PUMP
5H120 and 126 units) is available as a separate parts item for in- I TAl<E
stallation on original hand-hole cover, pump-end cover, or pump-
end bearing head. HYDRAULIC
RiELAY PLUG, MAGN ET IC ( PUMP INTAKE )
INSPECT CONTROL OIL STRAINER
Fig. 49 — 5H120 and 126 Pump-End Bearing Head
On 5F compressors, the control oil strainer is located on the side of
the pump-end bearing head (Fig. 29). Strainer is located behind
the control oil pressure gage connection block on the 5H120 and
126 units (Fig. 26) and on pump-end cover (Fig. 48) of all other
5H compressors.
Remove strainer and inspect it for holes and dirt. Clean it with sol-
vent and replace.

£QIJAUZER
LI E

CAPACITY
CONTROL
VAl\lE

Fig. 50 — 5H80 through 126 Center Main Bearing

Housing Setscrew Location
TO, UNLO~ DEIR
POW£R El!EMENT:S
O utU>A
_' DER
_

SEOlENCE
TO UNLOADER
POWER ELEMENTS
Crankshaft Inspection and Service
DISASSEMBLY
Fig. 47 — Compressor Hand-Hole Cover and
Assembly (5F40 and 5F60) Remove cylinder heads, valve plates, connecting rod and piston
assemblies, and pump-end main bearing head.
On 5H80 through 126 units, remove hollow-center main bearing
lock screw located beneath plug (Fig. 50) and loosen hollow-cup
setscrew (Fig. 51) until center main bearing can be slid from its

41
support. On 5H86, 120 and 126 units, disconnect oil line to center All instructions for field grinding apply only to standard stroke
main bearing. Remove crankshaft through pump-end opening. crankshafts.
Normally it is not necessary to remove the oil separator impeller On crankshafts reground locally, hold throw to 1.001 in. for 5F
(Fig. 35) from the 5H120 or 126 shaft. If impeller must be re- compressors and to 1.376 in. on 5H compressors. Stamp A or B on
moved for any reason, however, immerse it in hot water or oil un- crankshaft and pump-end bearing head next to oil pressure gage
til heated to 180°F or more. Remove all traces of water before re- connection.
assembly. Do not heat impellers with torch. To determine maximum and minimum journal diameters for un-
dersized shafts, subtract the amount (in.) that the shaft will be
ground undersize from factory from the tolerances specified in Ta-
ble 11. For example, the factory tolerance for 5H40 seal-end jour-
nal is 2.6225 in. to 2.6235 inches. Tolerance for a crankshaft re-
ground to 0.010 in. undersize should therefore be held between
2.6125 in. and 2.6135 inches.

IMPORTANT: When regrinding the seal-end journal on

5H120 crankshaft, do not grind in the area of the oil separa-
tor impeller. This is not journal area, and must remain intact
or the oil separator impeller will not fit properly.

REASSEMBLY
,BEARI NG I SERTS If 5H120 or 5H126 oil separator has been removed, read impeller
paragraph below before installing crankshaft.
When regrinding crankshaft, remove crankshaft plugs and clean
oil passages as well. Before replacing crankshaft, insert and tight-
en plugs, and reinstall the 5H120 and 126 oil separator impeller:
1. Insert dowel key (Fig. 35) with axis parallel to axis of crank-
shaft. Position key so chamfered edge is toward radius of
crankshaft journal.
2. Immerse oil separator impeller in oil or hot water to heat it to
180°F or more. If water is used, remove all traces before reas-
sembly. Install impeller on crankshaft with dowel key lined
up with impeller keyway. Impeller must fit key snugly.
3. Check that seal-end thrust washer is in place on dowel key in
crankcase.
Insert crankshaft and install pump-end bearing head, connecting
rod and piston assemblies, valve plate and cylinder heads. On
5H80 through 126 units, insert center main bearing setscrew and
lock screw as described under Servicing Center Main Bearing. On
5H86, 120 and 126 units, reconnect oil line to center main bearing.
Pump-End Main Bearing (Fig. 52)
DISASSEMBLY AND INSPECTION
GASKET
~ On 5H40 through 86 units, remove pump-end cover. Remove
PLUG
'
I:) HOLLOW ~CUP
Sa'SCF£W pump-end bearing head on all units. Inspect bearing for tolerances
shown in Table 12. If a pump-end main bearing is worn, remove
bronze bearing washer, and chisel out bearing. Inspect bearing
housing for wear (Table 12) and damage. Remove any burrs.
REASSEMBLY
1. Lubricate outside of new bearing with heavy grease.
Fig. 51 — Center Main Bearing (5H120 and 126)
2. Line up hole in bearing with oil port in housing.
INSPECTION 3. Press bearing into place using a puller shoulder (Table 13 and
Check crankshaft journals for wear and tolerances (Table 12). Re- Fig. 53 and 54) and jack screw or bearing press.
move crankshaft plugs, check oil passages and clean if clogged.
4. Place bearing washer on bearing with notch in washer prop-
Connecting-rod bearing inserts and main bearings are available for erly positioned around dowel pin (Fig. 52).
crankshafts reground from 0.010-in., 0.020-in., or 0.030-in. under-
sized. Factory-reground crankshafts are stamped on both ends
with an A (0.010-in. undersized), B (0.020-in. undersized), or C
(0.030-in. undersized).

IMPORTANT: Do NOTE regrind crankshafts for 5H46, 66,

86, and 126 compressors in the field. Replace shafts with
scored journals.

42
 PUMP END MAH• BEARING

PUMP E!NU BEARING HOUSING

Fig. 52 — Pump-End Main Bearing Position
Fig. 54 — 5H Seal-End Main Bearing
Table 13 — Main Bearing Puller Sizes
REASSEMBLY
COMPRESSOR PULLER SIZE
Install the new bearing inserts. Assemble bearing housing on
5F20, 5F30 5F20 crankshaft, but do not tighten the hollow-cup setscrews. Install
5F40,5F60 5F40 crankshaft, center main bearing and housing, and pump-end main
5H40, 46, 60, 66, 80,86, 120,126 5H140 bearing assembly. Tighten bolts holding the pump-end main bear-
NOTE: Bearing pullers can be ordered through Carlyle or Totaline ing assembly. Rotate crankshaft while tightening setscrew on cen-
Parts. ter main bearing housing. Setscrew should tighten fully without
any binding of crankshaft. If binding occurs, shim the opposite
Center Main Bearing side of bearing housing, using 0.001-in. shim stock.
Size 5H80 through 126 compressors have a center main bearing
and housing. Seal-End Main Bearing
DISASSEMBLY AND INSPECTION DISASSEMBLY AND INSPECTION
On 5H86, 120 and 126 compressors, disconnect oil line to center With crankshaft removed, use a bearing puller with a
main bearing. (5H80 center main bearings are fed through the shouldering device to remove and install seal-end main
shaft.). bearings (Fig. 53 and 54). Bearing pullers can be ordered
through Carlyle or Totaline Parts.
Remove plug on compressor crankcases (Fig. 50). Then remove
hollow lock screw beneath the plug (Fig. 51). Next, loosen hol- Inspect bearing and bearing housing for tolerances shown in
low-cup setscrew until center main bearing assembly can be slid Table 12.
from its support. Remove crankshaft and bearing assembly. REASSEMBLY
Disassemble bearing (Fig. 51) and inspect for proper tolerances Remove any burrs and clean bearing housing before replacing
(Table 12). bearing. Lubricate outside of bearing with heavy grease.
1. Position bearing so chamfered edge enters bearing housing
BEAIRI G first, oil holes in bearing and housing are aligned (see note
i:u..l.ER below), and bearing relief groove is at top.
THMT
Sl'tOiJI.Dl:R
WASHER NOTE: On size 5H 120 and 126 compressors oil hole in bear-
ing and housing will not be aligned.
2. Pull bearing into housing (Fig. 55). Edge of bearing should be
1/32-in. below surface of bronze bearing washer.

3. Look through oil pressure regulator opening to check oil pas-

sage for blockage.
4. Blow out oil groove in bearing housing and oil lines (if any)
Fig. 53 — Seal-End Main Bearing (5F40, 60) to it.

43
 2. Be sure shaft extension and edges of keyway are free of sharp
edges and nicks. Also, shaft must be clean and free of rust.
Polish shaft with crocus cloth.
3. Check seal assembly for proper bellows placement and clean-
liness.
4. Apply compressor oil to seal assembly and crankshaft, com-
Oil. GROOVE pletely saturating bellows and carbon ring.
INSTALLATION
Refer to Fig. 57 for procedure.
Accessories
For accessory installation literature, refer to Table 14.
DOWEL Pit Table 14 — Accessory Literature
LITERATURE
*Steel washer on 5H120 and 126 models. ACCESSORY AVAILABLE
Fig. 55 — Seal-End Main Bearing Positioning Condensing Unit Piping
Accessory Control Panel
Crankshaft Seal Inspection and Replacement Accessory Compressor Crankcase Heater
The crankshaft seal in all current 5F,H compressors is a rotat- Accessory Belt Drive Package
ing, bellows-type seal. This seal is the service replacement Flexible Couplings for Direct-Drive Units
for all earlier seal assemblies. Figure 56 shows Types I and II Water-Cooled Condensers
of this design (5F20 through 60 and 5H40 through 5H126 Accessory Water-Cooled Heads Package Installation
compressors). Instructions*
Accessory Oil Filter Package
Accessory Oil Cooler
IMPORTANT: Do not attempt to repair or replace seal Accessory Oil Safety Switch Package
components. Replace complete seal assembly with current Capacity Control Valve
rotating-bellows-type assembly. Do not disassemble bel- Accessory Unloader Package
lows assembly of service replacement seal. Accessory Muffler Package
*See your Carlyle Distributor for current form numbers.
BEFORE INSTALLING SEAL
1. Pump-end bearing head must be in place for proper position-
ing of seal on crankshaft.

44
 OOV£R Pl.ATE WITH COVEil' P AT ,GJISl<E T
I TEGR41. $E"AI.. SEAT ~

CO\/Efi: PLATE GASl<ET

CMOON NG
$D.L NOSE

CARSON RING
SEAL NOSE

BEL L.OWS
ASSEMBLY

\
COVl;R PLATE WITH INTEQRAJLSEAL SEAT

B - 5F40, 60 AND 5Hi40 THROUGH oo· (Type ) - Typical

•F540 and 60 - 1.5" diameter: SH40 lhtough 86 - 2.0" d'arneter.
A - 5F20, 30 ,(Type I)

CARBON RING
SEAL . 0$€

COVER PL ATE WITl:i l ~GR SEAL. SEAT

C - 5H120, 126 (Type II)

Fig. 56 — Service Replacement Seals

45
 Step 1 - Lubricate the shaft and the neoprene bellows where it comes in contact with the shaft. Slide the seal assembly,
as it is shipped from the factory, onto the shaft until the neoprene just starts to grasp the shaft.
Step 1 - Lubricate the shaft and the neoprene bel-
lows where it cornes in contact wi1h the shaft. Slide
theStep
seal2 -assembly,
Holding the assleeve and spring
it is shipped assembly,
from pull forward on the seal nose assembly at the same time, turning it so
the factory,
that
ontothethelugs on until
shaft the driving band arejust
the neoprene out starts
of the to
slots in the retainer shell and rest on the surface of the retainer shell as
grasp
shown by the pencil. (This does not apply to the 5H120 Type II seal.Lugs are permanently fixed.)
the shaft.

Step 3 - Using the seal cover plate, push the seal assembly into its proper
Step locationthe
2 - Hofding on the shaft.and
sleeve DOspring
NOT use cover
assembly,
plate bolts to push seal into position. The spring guide should be tight against the
pun forward on shaft shoulder
the seal noseasassembly
shown byat
thethe
pencil.
same
Remove the cover plate, being careful not to damage the carbon washer. GRASPitTHE
time, turning SEAL
so that theNOSE
lugs on ASSEMBLY
the drivingAND
band
TURN IT UNTIL THE LUGS ON THE DRIVING BAND DROPBACK are out of INTO THEinSLOTS
the slots IN THEshell
the rernainer RETAINER
and rest
SHELL. on the surface of the retainer shell as shown by the
pencil. (This does not apply to the 5H120 Type II seal.
Lugs are permanently fixed.)
Step 4- Lubricate the carbon seal washer and seal seat. Reinstall the seal cover plate, drawing the bolts down evenly to
prevent damage to the carbon seal nose. This view shoes the lugs of the driving band properly positioned m the center of
the slots in the seal retainer shell. This is the correct position during operation. This prevents the seal from being used as a
thrust washer under all operating conditions.
NOTE: The seal may leak slightly immediately after installation, but a short period of operation will correct the condi-
tion.

Step 3 - !Jsin~ the seal cover plate, push the seal

assembly into ,ts proper location on the shaft. DO
NOT use cover plat-e bolts to push seal into position.
The spring guide should be tight ag,aiost the shaft Step 4 - Lubricate the carbon seal washer and seal
shoulde~as shown by the pencil. Remove the oover seat Reinstall the seal cover plate, drawing the bolts
plate, bemg careful not to damage the carbon washer. down evenly to prevent damage to the carbon seal
GRASP THE SEAL NOSE ASSEMBLY AND TURN nose. This view shows the lugs of the driving band
ITUNTIL THE LUGS ON THE DRIVING BAND DROP properly positioned in the center of the slots in the
BACK INTO THE SLOTS IN THE RETAINER SHELL seal retainer shell. This is the correct position during
operation. This prevents the seal from bein9! used as
a thrust washer under all operating condltions.

NOTE: The seal may leak slightly immediately alter irtSl:allalion, but a short period of opetalion will correct lhe coodltlon.

Fig. 57 — Installation of Sleeve-Type Rotary Seal

46
 TROUBLESHOOTING
TROUBLE/SYMPTOM PROBABLE CAUSE REMEDY
Power off. Check main switch, fuse and wiring.
Thermostat set too high. Reset thermostat.
Thermal overload switch open. Reset switch.
Oil safety switch open. Reset switch.
Dirty contacts. Clean all control contacts.
Compressor will not start Loose electrical connections or faulty wiring. Tighten connections; check wiring and rewire.
Compressor motor burned out. Check and replace if defective.
Liquid line solenoid valve closed. Check for burned-out holding coil. Replace if defective.
Evaporator fan off. Check fuses, overload. Restart.
Evaporative condenser or cooling tower fan or pump Check fuses, overloads and controls. Restart.
not operating.
Check for clogged tubing to switch. Check switch
Low-pressure switch erratic in operation. setting.
Low refrigerant charge. Add refrigerant.
Compressor cycles intermittently Capacity control setting incorrect. Reset.
Thermostat differential too narrow. Reset.
Suction valve closed or throttled. Open up valve.
Tubing to pressurestat restricted. Check and clean tubing.
Faulty pressurestat. Repair or replace.
Refrigerant overcharge. Remove excess refrigerant.
Compressor cycles on high Insufficient condenser water flow or clogged Adjust water regulating valve to condenser. Clean
pressurestat condenser. condenser.
Discharge service valve not fully open. Open valve.
Air in system. Purge air.
Condenser water pump off. Check pump and start.
Increase water quantity by adjusting water regulating
Condenser inlet water temperature too high. valve. Use colder water.
Readjust water regulating valve. Increase size of water
Insufficient water flow through condenser. supply main to condenser.
High discharge pressure Plugged or scaled condenser tubes. Clean tubes.
Discharge service valve partially closed. Open valve.
Refrigerant overcharge. Remove excess refrigerant.
Air in system. Purge air.
Excessive water flow through condenser. Adjust water regulating valve.
Suction service valve partially closed. Open valve.
Low discharge pressure
Leaky compressor suction valves. Examine valve discs and valve seats. Replace if worn.
Worn piston rings. Replace.
Reset to 5°F - 10°F superheat. Valve operation must
Flooding Defective or improperly set expansion valve. be stable (no hunting).
Low refrigerant charge. Add refrigerant.
Low suction pressure
Excessive superheat. Reset expansion valves.
Loose or misaligned coupling. Check alignment and tightness.
Insufficient clearance between piston and valve plate. Replace defective parts.
Motor or compressor bearing worn. Replace bearings.
Check alignment and tension. (Belt slack should be at
Loose or misaligned belts. top.)
Loose holddown bolts. Tighten bolts.
Unit foundation improperly isolated. Isolate foundation.
Use correct piping techniques and support piping with
Improper support or isolation of piping. suitable hangers.
Check expansion valve setting. Check thermal bulb
Slugging from refrigerant feedback. looseness and correct location. See Carlyle System
System noises Design Manual, Part 3 for standard piping techniques.
Remove excess oil. Check expansion valve for
Hydraulic knock from excessive oil in circulation. floodback.
Replace sticking filter pins. Check unloader fork for
alignment. Check power element for sticking piston.
Defective valve lifter mechanism (noise level varies Check for oil leakage at tube connection to power
with unloading). element. Check amount of valve pin lift above valve
seat (0.33 in. for 5F; 0.125 in. for 5H).
Piping vibration. Support pipes are required. Check pipe connections.
No muffler in discharge line or improperly located. Install muffler. Move muffler closer to compressor.
Hissing (insufficient flow through expansion valves, or Add refrigerant. Clean strainer.
clogged liquid line strainer).

47
 TROUBLESHOOTING (CONT)
TROUBLE/SYMPTOM PROBABLE CAUSE REMEDY
Capacity control valve not operating. Repair.
Unloader element sticking. Repair.
Compressor will not unload Hydraulic relay sticking. Replace control cover assembly.
Plugged pressure line to power element. Clean line.
External adjusting stem damaged. Replace.
Low oil pressure (below 35 psig). Check oil charge, switch settings.
Capacity control valve stuck open. Repair or replace.
Unloader element sticking. Repair.
Plugged or broken pressure line to power element. Clean or repair.
External adjusting stem damaged. Replace.
Compressor will not load Control oil strainer blocked. Clean or replace.
Remove thread protector and leak test.
Control valve bellows leaking.
Replace valve body if bellows leaks.
Pipe plug in pneumatic connection. Remove pipe plug.
Foaming in crankcase from refrigerant flooding. Check expansion valve and piping.
Hydraulic relay sticking. Replace control cover assembly.
Excessive fluctuation in suction pressure from Resize expansion valve.
oversized expansion valve.
Rapid unloader cycling Partially plugged control oil strainer. Clean or replace strainer.
Low oil pressure. See Trouble/Symptom - low oil pressure.
Low oil charge. Add oil.
Faulty oil gage. Check and replace.
Defective oil pressure regulator. Repair or replace.
Clogged oil suction strainer. Clean strainer.
Low oil pressure
Broken oil pump tang. Replace pump assembly.
Clogged oil line. Remove obstruction.
Worn oil pump. Replace pump assembly.
Worn compressor bearings. Replace.
Cold compressor Liquid carryover from evaporator. Check refrigerant charge and expansion valves.
Low crankcase oil level Oil return check valve stuck closed. Repair or replace check valve.
Cylinders and crankcase Refrigerant floodback. Check refrigerant charge and expansion valves.
sweating
Liquid line strainer clogged. Clean strainer.
High crankcase temperature Excessive superheat. Reset expansion valves.
(should be 150°F to 160°F max. at Compression ratio too high. Recheck design.
seal housing) Discharge temperature over 275°F. Check unit application.
Leaking suction or discharge valves. Replace valves.

© 2021 Carrier

Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
Catalog No. 04-53050002-01 Printed in U.S.A. Form 5F-H-24SI Rev. A Pg 48 5-2021 Replaces: 5F,H-23SI