INSTRUCTIONS

Page 1 of 10

*99TA516174*
*99TA516174* (for RCD use only)
Instruction Sheet Number: 99TA516174

Description: Capacity Control Valves For 06D, 06E Compressors

Author: R.R./T.S. Date: March 27, 2014
Part Number: 06DA660175, 06DA660176 (REPLACES 06EA660135 & 06EA660100)

This control valve package can be used either for hot gas bypass cylinder unloading or suction cutoff
cylinder unloading.

HOT GAS BYPASS APPLICATION:

This type of unloading can be identified by the external physical appearance of the cylinder head (Fig. 1).

For hot gas bypass applications the piston contained in this package must be field assembled to the
control valve. Assemble 06DA508844 threaded stud into the brass body of the capacity control valve and
torque to 5 in-lbs. using a 5/32” allen wrench (this step required only for electrically actuated valve.) Install
5/16 in. lockwasher and piston assembly onto threaded stud. Pull piston assembly away from the brass body
of the capacity control valve, insert ½” wrench onto flats of piston assembly and torque to 84 in-lbs.

SUCTION CUTOFF APPLICATIONS:

Fig. 2 identifies a suction cutoff type cylinder head. For this application, the valve piston contained in this
package is not used and should be discarded.

CAPACITY CONTROL INSTALLATION (HOT GAS BYPASS):

06DX and 06EX service compressors are supplied with one plugged hot gas bypass unloader head and
will operate fully loaded as received.

CAUTION: Screws are not interchangeable between cover plate and control valves.

To change or add a control valve, disconnect power to the unit, valve off and purge pressure from the
compressor. Remove the three Allen head screws holding valve or cover in place. (Fig. 4, 5). CAUTION:
Cover is under spring tension. Remove the control valve or bypass piston plug. Install control valve and
piston in the compressor head per Fig. 5 using new gaskets supplied in package.

ORIENT THE GASKET WITH THE CUTOFF ALIGNED WITH THE GAS PORT AND TORQUE ¼-28
SCREWS TO 12-16 LB.-FT.

SUCTION CUTOFF UNLOADING:

06ET and 06DS service compressors are supplied with one blocked suction cutoff unloader head and will
operate fully loaded as received.

CAUTION: Screws are not interchangeable between coverplate and control valves.

To change or add a control valve, disconnect power to the unit, valve off and purge pressure from the
compressor. Remove the three Allen head screws holding valve or cover in place. (Fig. 4, 5).

Replacement Components Division 6/05 99TA516174.doc

carlyleinstr.dot
 Page 2 of 10
Instruction Sheet Number: 99TA516174

CAUTION: Cover is under spring tension. Remove the control valve or blocking sleeve. Install control
valve (without piston attached) in the compressor cylinder head per Fig. 5 using new gaskets supplied in
package.

ORIENT THE GASKET WITH THE CUTOFF ALIGNED WITH THE GAS PORT AND TORQUE ¼-28
SCREWS TO 12-16 LB.-FT.

ELECTRICALLY OPERATED CONTROL VALVE

Electrically operated control valve is actuated by an electric solenoid which must be the same voltage as
the unit control circuit. NO ADJUSTMENTS TO THE CONTROL VALVE ARE REQUIRED. When the
solenoid is de-energized, the compressor will operate in the loaded condition. When the solenoid is
energized, the compressor will operate in the unloaded condition.

The capacity control valve included in capacity control valve package, part number 06EA660135, must be
used with an unloader solenoid coil. See table below for electrical characteristics and part number.

ELECTRICAL
CHARACTERISTICS PART NUMBER

24-1-50/60 EF19ZZ001
120-1-50/60 EF19ZZ002
208/240-1-50/60 EF19ZZ003
12V DC 06DA401824
24V DC 06DA401834

A solenoid coil anti-rotation pin is supplied in this kit. Press pin into engagement hole adjacent to stem of
control valve. Mount coil to stem taking care to align proper hole (located at bottom side of solenoid coil) with
pin.

NOTE DIFFERENCE IN HEAD DESIGN

HOT GAS BYPASS SUCTION CUTOFF
UNLOADING UNLOADING

FIG. 1 FIG. 2
 Page 3 of 10
Instruction Sheet Number: 99TA516174

PRESSURE TYPE UNLOADER SHOWN

FIGURE 3

CAPACITY CONTROL ADJUSTMENT (PRESSURE TYPE):

Control Set Point (cylinder load point) is adjustable from 0 PSIG to 85 PSIG. Pressure differential
between cylinder load-up point and cylinder unload point is adjustable from 6 PSI to 22 PSI.

To regulate Control Set Point (refer to Fig. 6): Turn adjustment nut clockwise to its bottom stop. In this
position, set point is 85 PSIG. Control set point is then regulated to desired pressure by turning adjustment
nut counter-clockwise. Each full turn decreases set point by 7.5 PSIG. Approximately 11-1/2 turns
counterclockwise will decrease set point to 0 PSIG.

Pressure Differential Adjustment (Fig. 6): Turn differential adjusting screw counterclockwise to its back-
stop position. In this position, differential is 6 PSI. Pressure differential is set by turning adjustment screw
clockwise. Each full turn increases differential by 1.5 PSI. Approximately 10 turns clockwise will increase
pressure differential to 22 PSI.

CAPACITY CONTROL VALVE OPERATION:

Capacity Control Valves are of the snap-action type. They are controlled by suction pressure and
actuated by discharge pressure. Electrically actuated solenoid unloaders are available as an accessory.
Each valve controls 2 cylinders. On start-up, controlled cylinders do not load up until differential between
suction and discharge pressure is 19 PSIG.

Do not use automatic pumpdown control on any compressor equipped with unloader valves. Use single
pumpout for solenoid drop (minimum protection) control.

HOT GAS BYPASS UNLOADER OPERATION( Fig. 7):

Loaded Operation * - Capacity control valve is activated by suction pressure. Suction pressure trip point is
set by control set point adjusting nut. This nut controls tension of control set point spring which, when varied,
sets point at which suction pressure overcomes spring, thus determining loading point.

When suction pressure rises high enough to overpower control set point spring, spring compresses and
moves away from poppet valve. This action leaves free space at left of poppet valve. Poppet valve has two
 Page 4 of 10
Instruction Sheet Number: 99TA516174

springs: a centering spring and a drive spring. With no restriction at left of popped valve, drive spring can
overcome centering spring, causing poppet valve to move left and close.

With poppet valve closed, discharge gas from manifold cannot vent into suction side and thus builds up
forcing bypass piston to the right and closed. Pressure then builds up on top of discharge valve, forcing check
valve open which vents discharge gas to discharge manifold.

Unloaded Operation - As suction pressure drops below set point, control set point spring expands and
moves to right. This action forces poppet valve open and allows discharge gas to vent to suction side.
Absence of discharge pressure allows internal springs in bypass piston to move it back to left which unloads
cylinder head.

*When electric solenoid unloader is energized, the compressor cylinder bank unloads; when solenoid
unloader is de-energized, the cylinder bank loads up.

SUCTION CUT-OFF UNLOADER OPERATION (figure 8):

Loaded Operation * - Capacity control valve is activated by suction pressure. Suction pressure trip point is
set by control set point adjusting nut. This nut controls tension of control set point spring which, when varied,
sets point at which suction pressure overcomes spring, thus determining loading point.

When suction pressure rises high enough to overpower control set point spring, spring compresses and
moves away from poppet valve. This action leaves free space at left of poppet valve. Poppet valve has two
springs: a centering spring and a drive spring. With no restriction at left of poppet valve, drive spring can
overcome centering spring, causing poppet valve to move left and close.

With poppet valve closed, discharge gas from manifold cannot vent into suction side, builds pressure back
of the unloader piston and forces the valve body to the right. This opens the suction port allowing the bank of
two cylinders to operate fully loaded.

Unloaded Operation - As suction pressure drops below the set point, the control set point spring expands
and moves to the right. This action forces the poppet valve open and allows discharge gas to vent to suction
side. Absence of discharge pressure on the unloader piston allows the valve spring to move the valve body to
closed position blocking the suction port which unloads the cylinder head.

*When electric solenoid unloader is energized, the compressor cylinder bank unloads; when solenoid
unloader is de-energized, the cylinder bank loads up.

REMOVING, INSPECTING AND REPLACING COMPONENTS:

For instructions regarding inspection of lubricating system, replacing major components such as valve
plates, bearings, pistons, rings, etc. consult your distributor for instruction sheets.
 Page 5 of 10
Instruction Sheet Number: 99TA516174

Figure 4 - Removal of Bypass Piston Plug

Figure 5 - Installation of Capacity Control Valve

(Piston is NOT USED on Suction Cut-Off Unloading)
 Page 6 of 10
Instruction Sheet Number: 99TA516174

Figure 6 - Capacity Control Valve

 Page 7 of 10
Instruction Sheet Number: 99TA516174

Figure 7 - Hot Gas Bypass Unloading Head

 Page 8 of 10
Instruction Sheet Number: 99TA516174

Figure 8 - Suction Cut-off Unloader Head

 Page 9 of 10
Instruction Sheet Number: 99TA516174
 Page 10 of 10
Instruction Sheet Number: 99TA516174