Copeland Scroll ZX Next Gen Condensing Unit
Contents
1. LLI gt NOTES x H dion 1 Dashed line is wired by installer gt LP SW _ 052 2985 00 2 Earth wirings not shown in 2014 12 12 harnesses for clarity 2 50 Sf o 2 LU gt gt 9 za 58 5 db 2 gt 2 2 ATTENTION Unit Must Grounded 5 55268 gt 3 gl gaa x 4 5 T M EH mM ew es 4 6 wr DB A5 4 2 AM 5 1 E WH 250VAC ISA gt WAY cs 2 NEUTRAL DI4 G2D03 c1 D01 Contactor P Lc Low Pressure HP SW Controller P Transformer WIRE COLOR NOTE BU Blue BK Black OG Orange BN Brown RD Red WH White YE Yellow GNYE Yellow Green 24 u99J9 MO 9A 3ANO PUM HM 90 0 9 9 enig na ALON 04 gt ued i i s 10 99 04d T ud 291102900 MS 4 hyhy lololo ng E 4 BR 5 C gt as L2. probe restarts working E13 Voltage sensor 3 error alarm Out of range Related functions are disabled ne probe restarts working 0 probe restarts working NJ 20 120 L21 E22 E23 L23 E24 L24 E25 25 E26 L26 E27 L27 E28 E30 Description Missing phase alarm Missing phase lock Wrong phase sequence lock Imbalanced 3 phase warning Over current alarm Over current lock Compressor running circuit open alarm Compressor running circuit open lock Compressor starting circuit open alarm Compressor starting circuit open lock Low voltage alarm Low voltage lock Over voltage alarm Over voltage lock Compressor internal protec tor open warning No controller power supply alarm Possible Reason Action Electrical Error One or two phases of compressor power supply lost or Voltage sensors do not work 3 ph unit only Missing phase alarm happened frequently Compressor power supply has wrong sequence 3 phase unit only 3 Ph currents are not balanced 3 Ph unit only Compressor current is larger than settings Over current alarm happens fre quently Compressor running circuit open 1 ph unit only Running circuit open alarm happens frequently Compressor starting circuit open 1 ph unit only Compressor starting circuit open alarm happens frequently Voltage is lower than settings or voltage sensors do not w
3. 1 Motor for single fan unit 2 Motors for dual fan unit Contactor Intefnal motor f p otector Z P SW EM 208 LP SW gt a c ch cM A A P gt 2 lt lt 2 gt gt c ea gt gt 0 Ceo NL gt OBZ O Z lt AIO ogo 9 Z c ig lt 9 NA ON S 5 Mi 0 OBA ann oO w PS T J PS PS DIS 6 AI2 AM NEUTRAL 02003 C1 001 x x x o x z m mo al l m Low Pressure Controller P Transformer WIRE COLOR NOTE BU Blue BK Black OG Orange BN Brown RD Red WH White YE Yellow GNYE Yellow Green 26 U99J9 MO 9A 3AN9 84 Ac MO 9A 3A SUUM HM 90 ALON 30103 38IM 11 d 91104409 5 n M FTT TT 1 w w um o o 12 A O 9 9 0 9 2 ty iit Id coq ida lol 25 road TWULNAN Z 1 S M C VN VN ay 5 J0joejo d 00000 24 lt Jojoejuoo j
4. Press SET Display Hr Upload the Program from the Controller to Hot Key Action Phenomenon and Description Inert Hot Key when the controller is ON the uPL message appears followed a by a flashing End label Press 22 Note if display Err it means it fails to upload program to Hot Key Please restart the process Press SET End will stop flashing 4 Turn off the controller and remove Hot Key 11 Download the Program from Hot Key to Controller Step Action Phenomenon and Description Turn offthe controller Insert Hot Key 3 WAY doL message will blink followed by a flashing End label Note if display Err it means it fails to download program to the controller Please restart the process 4 Controller will restart working with the new parameters after 10 seconds Network Wiring Dixell XWEB300D Serial Address e Connect to the ModBUS network using cable with 2 3 shielded wires minimum section 0 5mm2 e g BELDEN8772 e Donotconnect shield to ground Do not connect the Gnd terminal Remember to draw map of the line This will help you to find an error if something is wrong 5485 devices are polarity sensitive Figure 6 Incorrect Network Wiring 12 Termination Resistor for XWEB300D If XWEB300D is placed at the beginning or
5. Probe failure or out of range No ZXD Unit Only E02 Condensing temperature Probe failure or out of range Function fan speed Automatic Reset when the probe failure alarm 40 110 C control is disabled probe restarts working E03 Discharge temperature Probe failure or out of range Function discharge temperature Automatic Reset when the probe failure alarm 40 180 C protection is disabled probe restarts working 204 vapor inlet temperature Probe failure or out of range Function PHE Superheat Control Automatic Reset when the probe failure alarm 40 110 C is disabled ZXL ZXB unit only probe restarts working E05 PHE vapor outlet tempera Probe failure or out of range Function PHE Superheat Control Automatic Reset when the ture probe failure alarm 40 110 C is disabled ZXL ZXB unit only probe restarts working 206 Ambient temperature probe Probe failure or out of range AMINA IA Automatic Reset when the failure alarm 40 110 C 09 Current sensor 1 error alarm Out of range Related functions are disabled nae me probe restarts working E10 Current sensor 2 error alarm Out of range Related functions are disabled RESE Hie probe restarts working E11 Voltage sensor 1 error alarm Out of range Related functions are disabled wash probe restarts working E12 Voltage sensor 2 error alarm Out of range Related functions are disabled ct
6. Press SET N7 Enter menu to select PAr parameter or rtC ___2 Press AX or NZ Select rte n01 minute n02 hour Press SET n03 day n04 month n05 year last two digits mmt 2r Press SET Press SET the value will flash for 3 second then move to the next value Refrigerants Step Action Phenomenon and Description um Press SET Enter menu to select PAr parameter or rtC Press SET Confirm selection een NN 19 Evaporating Temperature ZXD Only Step Action Phenomenon and Description pee button for more than 3 seconds the measurement units will flash Modify the number for Target Evaporating Temperature T Press SET to confirm the number will flash 2 seconds wait for about 10 3 Press SET seconds to confirm Alarm Codes Level Descriptions Unit including compressor is running but some data reach unsafe area alarm dry contact will not close reset automatically em Unit including compressor may run not with full functions alarm dry contact will not close reset automatically Warning Lock Unit including compressor stops working alarm dry contact will close manual reset is needed Description Possible Reason Action Hardware error Automatic Reset when the Suction pressure probe 01
7. Te 282 v 4 47 9 zi lt 43 e D 2 WI v 7 2 gt lt N e 7 1 at Ai n a 44 44 EM N Technologies Climate Q LLL uM 72 T 5 e pcm PLN RN A 6 SEMNA wed md med fl Fa ad ad Bk Bd bd Bet F User Manual EMERSON Climate Technologies Copeland Scroll Pioneering Technologies For Best In Class Products Emerson Climate Technologies a business segment of Emerson is the world s leading provider of heating air conditioning and refrigeration solutions for residential industrial and commercial applications The group combines best in class technology with proven engineering design distribution educational and monitoring services to provide customized integrated climate control solutions for customers worldwide Emerson Climate Technologies innovative solutions which include industry leading brands such as Copeland Scroll and White Rodgers improve human comfort safeguard food and protect the environment For more information visit Emerso
8. 121 kg for models under 60 Hz TF7 5 127 kg for models under 60 Hz TF7 14 E o9 ow om om om Weight kg Transport Model ZXBO15BE 7 020 ZXB025BE ZXBO30BE ZXB035BE ZXBOAOBE 7 050 7 6 Weight kg Model Weight kg Model Weight kg 2 s o O o i ww _ ase 1 Electrical Connection Power Supply The ZX condensing unit electrical connection to the power supply must be made by qualified technicians who should refer to the electrical diagrams located inside the electric connection panel The units are designed for below power supply at 10 voltage tolerance The circuit breaker must be switched off before opening the front panel Phase Voltages mu 220 240 401 vs mo Electrical Wiring Before commissioning ensure that neutral wire is connected to the terminal block N furthest to the right After proper connection of the ZX condensing unit the control LED on the power board and control board will light up For more details see wiring diagrams Customers wire size needs to be selected to allow for the maximum operation current of each unit Unit Unit MOC A Unit Unit MOC A Unit Unit ZX020BE TFD ZXLO2OBE TFD ZXDOAOBF TFD 80 mossero 6o ZX040BE TFD ZXLO30BE TFD ZXDO5OBE TFD ZxO5
9. 16 ZX Platform CDU Disclaimer Thank you for purchasing the ZX platform condensing unit from Emerson Climate Technologies ZX platform CDUs are the best in class within the capacity and operating range available in the market ZX CDU is designed to operate reliably and to deliver high operating efficiencies in medium and low temperature refrigeration applications It also provides constant monitoring of the compressor operating conditions and displays the running or fault conditions of the CDU ZX platform CDUs have to be installed by following the industry trade practices for its safe and reliable operation It is assumed that the CDU is selected installed and serviced only by professionals The user manual does not cover good industry practices which are essential ona refrigeration equipment installation No responsibility can be accepted for damage caused by inexperienced or inadequately trained site technicians or improper installation design If in doubt please consult your local sales office quoting unit model and serial number as shown on each unit nameplate In case of any ambiguity the wiring diagram supplied with each unit takes precedence over the diagram in this manual Introduction to ZX Platform CDU ZX medium temperature ZXB medium temperature ZXD digital medium temperature and ZXL low temperature series have been highly successful in the Asian market and enjoys proven success with its energy savings and
10. J T __ L2 un ENP SIOJOWN Z yun Ue JO JOJON 3 LON SYOLOW NVA QNOD HM 5 UJ 6 HM 5 LYOLIOVdV9 E HM JLYOINNWWOO X H 6 ziv m 49 AQ va zt wt E m 2 x 2 B Is T ISNIN UN NOILNALLV 2 it is is fe js EF UMOUS uuedz 00 7862 250 _ 4 lt Aq si PAYSEC d n z SALON ZH09 ADEZ LSv LOT SAL 2 webera Bumm Bursuepuo lt 1 1 2 2 25 ZXIZXL ZXB TFD TF7 Condensing Unit Wiring Diagram TFD 380 420V 50Hz 3Ph TF7 380V 60Hz 3Ph not shown harnesses for clarity 0922262200 3 In 461 units all yellow wires are ATTENTION Unit Must Be Grounded 2014 19 12 replaced by white wires BK 5 CAPACITOR1 en NOTES 1 Dashed line is wired by installer 2 Neutral N and Earth E wirings are V ex ELECTRONIC EXPANSION VALVE Em ee Gt H K COMMUNICATE BK Circuit IT P ELI CAPACITOR2 ji E GY WH R S COND FAN MOTORS NOTE
11. at the end of the line please install its termination resistor by adding a jumper in position 2 JMP2 on the back side of the unit Do not add the jumper if XWEB300D is placed in the middle of the RS485 line ZX CDU Connected to XWEB300D ZX CDU connected to the Dixell XWEB300D with the Intelligent Store Solution Module using RS485 ModBUS Connect the ZX CDU to the ModBUS network as shown in Figure 7 Connect the network cable to the three terminal connector on the XWEB300D port that has been configured as ModBUS port COM 12 13 14 Connect port 13 of XWEB300D to port D0485 of CoreSense and port 12 of XWEB300D to port D1485 of CoreSense for RS485 communication Dixell XWEB Figure 7 XWEB300D Connected to the Intelligent Store Solution Module Dixell XWEB300D Configuration XWEB300D is compatible with ZX CDU if XWEB has the library of ZX controller CoreSense Login into XWEB Goto Information Information e If this is not present follow the steps below Open Dixell website http www dixell com xweb300d xweb500 xweb500d eng then login register required e Go to Support System sw update XWEB300D XWEB500 XWEB500D e Download the upgrade package With your web browser login into XWEB e Goto Information System Update menu Provide the XW5 patch file Once file has been selected wait until the upgrade procedure ends XWEB reboots Verify the installation ended successfully by checking
12. customer friendly electronic features ZX ZXB ZXD and ZXL CDUs have been applied by several well known end users and chain retailers throughout Asia The ZX platform is also gaining wider acceptance in the global market and specific variants have been developed and exported to the USA and to the European and Middle East markets Receiving your unit All units are shipped with a holding charge of dry nitrogen inside at a low but positive pressure Suitable labeling is prominently displayed on both the unit and the packaging Service connectors are provided on the CDU service valve for the convenient checking of the integrity of the holding charge Itis very important to check that this holding pressure exists at the time you receive each unit from us or our authorized representatives Please inform us or our authorized representative if the holding charge is non existent Failure to do so could void the claim for other related system faults at a later period Transit damage is essentially an insurance claim and is not covered under manufacturing defect It is also advisable to inspect the rest of the unit for obvious physical damage and inform us or our authorized representative in case any is discovered ZX Platform Condensing Unit was designed based on three factors demanded by industry users Intelligent Store Solutions A most innovative approach to enterprise facility management Emerson s Intelligent Store architecture integrates hardwar
13. power Since there is a 50 50 chance of connecting power in such a way that causes rotation in the reverse direction it is important to include notices and instructions in appropriate locations on the equipment to ensure proper rotation direction when the system is installed and operated Maximum compressor cycle Maximum permitted starts per hour is 10 Check before starting amp during operation Both valves should be fully opened on the liquid line in order to prevent trapping liquid Check that all valves are fully opened e After starting and operation conditions are stabilized it is recommended to check the oil level in compressor s and see if there is aneed to add oil to ensure a sufficient oil level halfway up the sight glass Controller Initialization Message When the unit is initially powered on the controller will display Step Action Phenomenon and Description Power on controller All LEDs will light up for 3 seconds Firmware version will be displayed for 3 seconds Parameter setting file bin file number identifier will be displayed for 3 seconds Normal display actual suction temperature will be displayed on ZXD unit condensing temperature will be displayed on ZX ZXL ZXB unit Bin Files Number Range Bin Number Range Family After installation and initial power on it is critical to double check the parameters below RTC Real Time Clock Setting Step Action Phenomenon and Description
14. 0BE TFD Zx10358E TFD 7XOGOBE TFD ZXLO40BE TFD 7XDOGOBE TFD ZX075BE TFD ZXLOSOBE TFD ZX076BE TFD ZXLOGOBE TFD PXLUTSBETED ZX02080 TFD ZXDO76BETFD 7X030B0 TFD ZXLO20B0 TFD 60 7XL02580 TFD ZX040BO TFD O ___ 7XLO3OBO TFD ZXD040BO TFD RE 2410358017D oo 200508010 7X076B0 TFD 7XLOGOBO TFD ZXO20BETFS 7XL07580 TFD ZX030BE TFS TETE ZX040BE TF5 7 1025 5 7 007680 ZXOSOBE TF5 7XLO30BE 1F5 7 060 5 7 1035 5 ZX075BE TF5 7 104 5 ZX020B0 TF5 ZXLOSOBE TF5 ZX030B0 TF5 2 1060 5 ZXDO6OBE TF7 16 2 2X040B0 TF5 ZXLO75BE TFS ZX050B0 TF5 ZXLO20BO TF5 ZXDO75BE 1F7 2X06080 TFS 2 102580 5 7 075 0 5 ZXL030B0 TF5 7 004080 7 ZX020BE TF7 ZXL035BO TF5 7 7 7 1040 5 7XDOSOBO TF7 ZX040BE TF7 ZXLOSOBO TFS ZX050BE TF7 1060 0 5 7 1075 0 5 7 7 DDU 2 075 7 2402082107 240258717 ZX020B0 1F7 7XLO3OBE TF7 ZXB015BE TFD ZX030B0 TF7 7X040B0 1F7 7XBO20BE TFD 2505080 Zx06080 7 ETT ZXBO2SBETFD ZXLOGOBE TF7 ZXO20BE PF ZXL020B0 TF7 ZX025BE PF 7 1025 0 ZXB035BE TFD 7 7 10 7 ZX040BE PF 7 1035 7 2 02080 ZXL040B0 TF7 2 025 0 ZXL050B0 TF7 ZX030BO PF ZXLOGOBO TF7 ZXBO60BE TFD 16 2 ZX040BO PF ZXLO75BO TF7 Unit should be powered on at all times except during se
15. 6 HP Generation PF 220V 240V 50 Hz 380V 420V 50 Hz TF Bill of Material Base Model Electrical Code Bill of Material CDU Family BOM Intelligent Store Solution Module v Note 55 BOM Axx Chassis with door 5xx Chassis without door A I In ni lt gt C a 4 ae Jp Physical Layout of the Unit The following figures give an introduction to the physical layout of the ZX Platform CDU CoreSense Scroll Compressor Adjustable LP Controller Accumulator Oil Separator Optional in MT CDU Liquid Receiver Liquid Sight Glass Moisture Indicator Liquid Filter Drier Suction and Liquid Service Valve Receiver Out Service Valve Compressor Oil Sight Glass Figure 3 Major components of ZX Platform CDU C Q CoreSense Power Isolation Switch Cable Channel Customer Connection Compressor Contactor Terminal Block Transformer Figure 4 CoreSense and Intelligent Store Module Layout Product Specification For application envelope envelope varies according to applications and refrigerants Please refer to ZX platform product catalogue product manual or Copeland Brand Products Selection Software Qualified Refrigerants and Oils Refrigerant Emkarate RL 32 3MAF R448 R449 R407F RAOAA R507 R134a Mobil EAL Ar
16. E Tel 9714 811 8100 Fax 9714 886 5465 Philippines Emerson Climate Technologies 10 F SM Cyber West Avenue EDSA cor West Avenue Barangay Bungad Diliman Quezon City 1105 Philippines Tel 632 689 7200 South Korea Emerson Electric Korea Ltd 3F POBA Gangnam Tower 343 Hakdong ro Gangnam qu Seoul 135 820 Republic of Korea Tel 822 3483 1500 Fax 822 592 7883 Taiwan Emerson Electric Taiwan Co Ltd 3F No 2 DunHua South Road Sec 1 Taipei 105 Taiwan Tel 8862 8161 7688 Fax 8862 8161 7614 Thailand Bangkok Emerson Electric Thailand Ltd 34th Floor Interlink Tower 1858 133 Bangna Trad Bangkok 10260 Thailand Tel 662 716 4700 Fax 662 751 4241 Vietnam Emerson Climate Technologies Vietnam Suite 307 308 123 Truong Dinh St Dist 3 Ho Chi Minh Vietnam Tel 84 908 009 189 S6 0318 00 IT SOLVED
17. agrams D iring W U99J9 MO 9A 3AN9 MOJ 9A 3A SUUM HM pes qu 90 78 3 LON 30103 38IM JawJojsued q gt q SABA 10 08 U09 1 1 2 eqazp voa TWULNAN P LS H cU c ANY V LZ V LZ UL ENP SJOJO N Z e Buis 101 JOJOW J LON SYOLOIN NVA QNOD HM 9 UJ 2 na 7 bLYOLIDVdV9 HM G ipepunous eg ISNW HUN NOILLNALLV vIV GIV _ 9 AQ Re N ya Ee YAONASNVYL AYNSSAYd MOOD GIN YOSNAS 110 HOSN3S 39HVHOSIG IN3I8IAV HOSN3S XINO 231 0 2 JA IVA NOISNVaX3 OINOH LO3 T3 spun UNE peer nn ss 3 yey pue 2 00 9862 290 Eo JejJejsui AQ 1 peuseq a WM SALON ZH09 086 2 1 Y ZHOS 02 7 08 lt GAL un 24 1 G41 dxXZ 23 ZX ZXL Condensing Unit Wiring Diagram PFJ 220 240V 50Hz 1Ph
18. ccordance with today s technical knowledge It is intended for use by persons having the appropriate technical knowledge and skill at their own discretion and risk Our products are designed and adapted for fixed locations For mobile applications failures may occur The suitability for this has to be assured from the plant manufacturer which may include making appropriate tests Note The components listed in this catalogue are not released for use with caustic poisonous or flammable substances Emerson Climate Technologies cannot be held responsible for any damage caused by using these substances Contact Lists Asia Pacific Headquarters Emerson Climate Technologies Suite No 2503 8 25 F Exchange Tower 33 Wang Chiu Road Kowloon Bay Kowloon Hong Kong Tel 852 2866 3108 Fax 852 2520 6227 Australia Emerson Climate Technologies Australia Pty Ltd 356 Chisholm Road Auburn NSW 2144 Australia Tel 612 9795 2800 Fax 612 9738 1699 China Beijing Emerson Climate Technologies Suzhou Co Ltd Beijing Sales Office Room 1017 JianWei Building 66 Nan Lishi Road XiCheng District Beijing PRC Tel 8610 5763 0488 Fax 8610 5763 0499 China Guangzhou Emerson Climate Technologies Suzhou Co Ltd Guangzhou Sales Office 508 509 R amp F Yinglong Plaza No 76 Huangpu Road West Guangzhou PRC Tel 8620 2886 7668 Fax 8620 2886 7622 China Shanghai Emerson Climate Technologies Suzho
19. critical damage on the unit Better Decision Making Intelligent Store Highest Efficiency Lower Energy Bills Reliability Lower Maintenance Cost ZX ZXB and ZXL Family Proprietary electronic algorithms present advantage on diagnose communication and protection purposes They are also fundamental to control fan speed optimizing Energy Performance for Local Seasonal Ambient Temperatures ZXD Family Capacity modulation to control precise room temperature and humidity Variable Speed Fan Motor and High Efficiency Fan Blade Design Features LALA With real time monitoring of High Pressure Cut Out 3 compressor operating conditions Low Pressure Cut Out only on FA Compressor Reverse Rotation MT series Ba Compressor Over Current Refrigerant Flood Back Compressor Internal Motor Compressor Minimum Off Time Protector Trip Internal Thermal Sensor Failure Discharge Gas Over Heat Intelligent Store Solution Over Voltage Communication and Retail Store Under Voltage Monitoring Optimized Condenser Coil for Maximum Heat Transfer Copeland Scroll Compressor Technology High Efficiency Ultra Quiet High Reliability E Figure 1 ZX Platform CDU Features Nomenclature 380 60 Hz Digital Medium Temp R134a Medium Temp Low Temp Ester Oil Mineral Oil B L D TF5 200V 230V 3ph 60 Hz Unit Family Blank Medium Temp 2 0 to 7
20. d tube outer diameter are clean prior to assembly Since both tubes are extended from the condensing unit housing we recommend insulating the housing by using a wet cloth on the copper tubing Recommended brazing materials a copper phosphorous or copper phosphorous silver alloy rod should be used for joining copper to copper whereas to join dissimilar or ferric metals use a silver alloy rod either flux coated or with a separate During brazing pull back fire insulation During brazing protect housing Use a double tip torch with damp cloth 16 Expansion Valve Selection for Low Ambient Application For systems expected to operate in varying ambient conditions namely summer and winter temperatures the expansion valve TXV or EXV sizing should take into consideration the maximum expected saturated condensing temperature at high ambient conditions Summer and the minimum expected saturated condensing temperature set at 25 C during low ambient conditions winter The chosen expansion valve s operating capacities should be well within these limits to ensure satisfactory system performance In the event that different expansion valves come up for the two conditions the valve for low ambient condition should be selected This means that at higher ambient the valve will be oversized However if the valve at the high ambient is selected it may be too small during low ambient condition Location and Fixin
21. e and services to provide retailers a single view into their entire network of facilities and understanding what facilities actually cost to operate and maintain The Intelligent Store architecture transforms data from store equipment and controls into actionable insights Designed to deliver value in both new and existing stores Emerson aims to help the retailers Make better decisions on recourses investment for greatest impact Gain accurate feedback and customized service to your specific needs Reduce operational costs and boost the profitability at most convenience Energy Efficiency Utilizing Copeland Scroll compressor technology variable speed fan motor large capacity condenser coil and advanced control algorithms energy consumption is significantly reduced End users can save more than 20 on annual energy costs rather than using hermetic reciprocating units Reliability Combining the proven reliability of Copeland Scroll compressors with advanced electronics controller and diagnostics equipment reliability is greatly enhanced Fault code alerts and fault code retrieval capabilities provide information to help improve speed and accuracy of system diagnostics Integrated electronics provide protection against over current over heating incorrect phase rotation compressor cycling high pressure resets low pressure cut outs It can also send out a warning message to an operator when there is a liquid floodback which can prevent
22. f oil and refrigerant This is particularly important for the suction line The suction line should ideally slope gently towards the unit Recommendation slope is 1 2007 1 250 P traps double risers and reduced pipe diameters may be required for suction lines where long vertical risers cannot be avoided All pipes should be adequately supported to prevent sagging which can create oil traps The recommended pipe clamp support distance is shown in the table Tube Size Max distance between 2 clamp support 12 7mm 1 2inch 160mm G B inch 220mm 7 8 inch 28 5mm 1 ZXL Liquid Line Insulation ZXL liquid line should be insulated with a 19 mm insulation thickness Temperature could be as low as 15 C Brazing Recommendations Maintain a flow of oxygen free nitrogen through the system at a very low pressure during brazing Nitrogen displaces the air and prevents the formation of copper oxides in the system If copper oxidization is allowed to form the copper oxide material can later be swept through the system and block screens such as those protecting capillary tubes thermal expansion valves and accumulator oil return holes This minimizes any entry of contaminants and moisture Remove the liquid line connection cap Then remove the suction connection cap Open both valves midway Care should be taken to avoid the holding charge from releasing too quickly OUTSIDE INSIDE UNIT Be sure tube fitting inner diameter an
23. g The unit should always be installed in a location that ensures clean air flow It is recommended that a clearance of 300 mm from the wall or the next unit be maintained from the unit s left and rear panels whereas a clearance 01500 mm must be maintained from the unit s right top and front panels seen facing the front of the unit Both service access and airflow have been considered in making these recommendations Where multiple units are to be installed in the same location the contractor needs to consider each individual case carefully There can be many variations of unit quantities and available space and it is not the intention of this manual to go over these Ideally the unit should be mounted on a solid concrete slab with anti vibration pads between unit feet and concrete However the ZX condensing unit has also been designed for wall mounting on suitable brackets Wall mounting brackets are not included Another factor to consider in finding a good installation site is the direction of the prevailing wind For example if the air leaving the condenser faces the prevailing wind the air flow through the condenser can be impeded causing high condensing temperatures ultimately resulting in reducing unit life A baffle is a remedy for this situation 2 HOLES 15MM DIA Power Supply Hole Suction Service Valve Liquid Service Valve 2 R7 5MM GROOVE Single Fan Unit 2 to 4 HP Fi
24. into the menu e Goto Information Information for string Log in again and set up the ZX CDU Go to Configuration gt Devices drop down menu Go to Actions New Enter device name in the Name field e g ZX CDU Select XCM25D in the Model field Enter the ModBUS address in the RS 485 address field Refer to setting of parameter 01 in pr2 level in CoreSense default setting is 1 e Click New 13 Installation Copeland ZX condensing units are delivered with a holding charge of neutral gas The condensing unit should be located in such a place to prevent any dirt plastic bag leaves or papers from covering the condenser and its fins The unit must be installed without restricting the airflow A clogged condenser will increase the condensing temperature thus reduce the cooling capacity and lead to a high pressure switch tripping Clean the condenser fins on a regular basis Condensing Unit Handling Transport and Storage Move ZX ZXB ZXD ZXL unit only with appropriate mechanical or handling equipment according to weight Keep in the upright position Do not stack single boxes on top of each other without pallet in any case Keep the packaging dry at all times Storage Net Weight Model ZX020B0 ZX025B0 ZX030B0 7 04080 7 050 0 ZX060B0 ZX075BO ZX076B0 Notes 100 kg for models under 60 Hz TF5 7 and 50 Hz PFJ 109 kg for models under 60 Hz TF7 117 kg for models under 60 Hz TF7
25. nClimateAsia com Our Vision Emerson Climate Technologies With Our Partners Will Provide Global Solutions To Improve Human Comfort Safequard Food And Protect The Environment M M aaa Emerson Climate Technologies is pleased to offer the ZX platform refrigeration condensing units CDU specifically designed for medium temperature 7 3 8 ZXB MT digital modulated variable capacity medium temperature ZXD and low temperature ZXL LT refrigeration m5 a ZX series has been highly successful in the Asian market and enjoys proven success with its energy savings and customer friendly electronic features wlll N Tl Table of Contents Disclaimer Features and Benefits Nomenclature Bill of Material Physical Layout of the Unit Product Specification Qualified Refrigerants And Oils CoreSense for ZX Platform Condensing Unit Network Wiring Installation Condensing Unit Handling Electrical Connection Refrigeration Piping Installation ZXL Liquid Line Insulation Brazing Recommendations Expansion Valve Selection for Low Ambient Application Location and Fixing Start Up and Operation Controller Initialization Message Alarm Codes Wiring Diagrams Contact Lists 07 12 14 15 16 16
26. nd Par this combination allows the user to go back to previous level Pressed together for 3 seconds allows access to first level of programming mode Pressed together for 3 seconds allows access to EXV manual setting Phenomenon and Description All LEDs will light up for 3 seconds Firmware version will be displayed for 3 seconds Parameter setting file bin file identifier will be displayed for 3 seconds Normal display actual suction temperature will be displayed on ZXD unit condensing temperature will be displayed on ZX ZXL ZXB unit ZXD Unit Setting Point Modification Step Action Phenomenon and Description Press SET gt 3 seconds Press SET button for 3 seconds the measurement units C will flash together Press SET to confirm the number will flash for 2 seconds or wait for about 10 second Press SET to confirm Pr1 parameter 1 level Browse and Modification Step Action Phenomenon and Description m Press SET Enter menu to select PAr parameter or rtC Press SET Confirm select and browse Pr1 parameters Press SET View the actual number of the Pr1 parameters Modify the actual number of the Pr1 parameters Press SET The number will flash for 3 seconds and confirm the modification Will go to the next Pr1 parameter EN Press SET Exit or exit automatically after waiting for 120 seconds Press SET Quick Access Menu Brow
27. ork Low voltage alarm happens fre quently Voltage is higher than settings Over voltage alarm happens fre quently Compress internal protector is open or current sensors do not work Controller lost power supply The compressor will be tripped The compressor will be tripped and the unit will be locked The compressor will be tripped and the unit will be locked The compressor will be tripped The compressor will be tripped and the unit will be locked The compressor will be tripped The compressor will be tripped and the unit will be locked The compressor will be tripped The compressor will be tripped and the unit will be locked The compressor will be tripped The compressor will be tripped and the unit will be locked The compressor will be tripped The compressor will be tripped and the unit will be locked Automatically with time delay Press Start gt 5 sec or manually power off and power on Press Start gt 5 sec or manually power off and power on Automatically with time delay Automatically with time delay Press Start gt 5 sec or manually power off and power on Automatically with time delay Press Start gt 5 sec or manually power off and power on Automatically with time delay Press Start gt 5 sec or manually power off and power on Automatically with time delay Press Start gt 5 sec or manually power off and power on Automatically wi
28. ot only the motor but also the scrolls Temperature builds up very quickly in the scrolls if this is not done Do not charge vapor gas refrigerant into the ZX Scroll unit The suction service valve must not be fully closed at any time while the compressor is running To do so would cause damage to the compressor in the same manner as explained above This valve is provided for ease of connection and for the fitting of service gauges without removing the unit panel It is recommended to charge the ZX unit with refrigerant via its service valves It is recommended to break the vacuum in the system with a partial charge of the refrigerant before starting the system For charge adjustment it is recommended to check the liquid sight glass just before the expansion valve Oil charging procedure Emerson ZX condensing units are supplied only with a compressor oil charge After commissioning the oil level should be checked and topped up if necessary The oil level should be approximately halfway up the sight glass ZXL ZXD units Oil can be charged through the Schraeder valve on suction valve Scroll compressor rotation direction Scroll compressors like several other types of compressors will only compress in one rotational direction The direction of rotation is not an issue with single phase compressors since they will always start and run in the proper direction Three phase compressors will rotate in either direction depending upon the phasing of the
29. rvice Failure to do so can result in component failure 15 Refrigeration Piping Installation All interconnecting pipes should be of refrigeration grade clean dehydrated and must remain capped at both ends until installation Even during installation if the system is left for any reasonable period of time say two hours pipes should be re capped to prevent moisture and contaminants from entering the system Do not assume that the service connection sizes on the unit at the service valves are the correct size to run your interconnecting refrigeration pipes The service valve sizes have been selected for convenience of installation and in some cases larger units these may be considered too small However for the very short pipe run within our units these service connection sizes are adequate All interconnecting pipes should be sized to satisfy the duty required Usually the suction line is insulated but the liquid line is not However the liquid line can pick up additional heat from the ambient and adversely affect the sub cooling desirable for the liquid refrigerant before it enters the expansion valve The pipe should be sized to ensure optimum performance and good oil return The sizing must also take into account the full capacity range through which this particular unit will need to operate Pipe runs should be kept as short as possible using the minimum number of directional changes Use large radius bends and avoid trapping o
30. se Sensors Status and Actual Values Step Action Phenomenon and Description Enter quick access menu will display P1P Press Up Down to view other sensors Press SET View the actual value of P1P Press SET Change to next Sensor code Press SET Exit or exit automatically after waiting for 60 seconds suction pressure sensor only for ZXD unit temperature mid coil sensor pressure sensor not used discharge line temperature sensor PHE vapor inlet temperature sensor PHE vapor outlet temperature sensor ambient temperature sensor temperature sensor not used PHE superheat EXV opening step the status of liquid line solenoid valve Condensing temperature setting point The percentage of the analog output percentage of the PWM output driving the valve of the Digital Scroll compressor min cold room temperature may not be available max cold room temperature may not be available Time menu Sensor Code and Values Descriptions noP mean that the sensor does not exist Err means that the sensor fails out of range disconnected or does not configure correctly Access Alarm Code Maximum of 50 record Step Action Phenomenon and Description T PSI did Exit or exit automatically after waiting for 15 seconds 10 Exact Timing of the Alarm Step Action Phenomenon and Description
31. ssor will be tripped The compressor will be tripped The compressor will be tripped and the unit will be locked E48 Less injection warning Less refrigerant charge or leakage The related functions will be disabled The compressor will not work EXV will not work The compressor will tripped and the unit will be locked Automatically when HP switch closes Press Start gt 5 sec or manually power off and power on Automatically when LP switch closes and time delay Automatically when discharge temperature is lower than set tings and time delay Press Start gt 5 sec or manually power off and power on Automatically when condens ing temperature is lower than settings Automatically when EXV is not at full open Automatically when PHE super heat is smaller than settings Automatically when the differ ence of discharge temperature and condensing temperature is higher than settings and time delay Automatically when finish time configuration Automatically when the commu nication recovers Automatically when the probes are configured correctly Automatically when the digital inputs are configured correctly Manually power off and power on after the compressor configura tion is right Automatically when injection probe is configured correctly Hold start button for 5s or manual power off and on alarm will disappear when the com munication between MCU and EEPROM is success i
32. th time delay Press Start gt 5 sec or manually power off and power on The compressor will be tripped 21 Description High pressure switch alarm High pressure switch lock Low pressure switch alarm High discharge temperature alarm Higher discharge tempera ture lock High condensing tempera ture alarm EXV Full open warning High side liquid back warning E80 RTC warning RTF warning E81 Probe configuration error alarm Digital inputs configuration error alarm Compressor configuration error alarm Injection probe configura tion error alarm EEPROM R W error lock 22 Possible Reason Action Refrigeration system error High pressure switch is open High pressure switch alarm happens frequently Low pressure switch is open Discharge temperature is higher than settings High discharge temperature alarm happens frequently Condensing temperature is higher than settings Less refrigerant charge or leakage Suction liquid back or injection too much The time is configured for the new controller Communication error between MCU and unit clock The same probes are configured The same digital inputs are config ured Digital compressor and solenoid valve configuration does not match EXV and injection configuration do not match write read error into EEPROM The compressor will be tripped The compressor will be tripped and the unit will be locked The compre
33. tic 22CC Oils are pre charged in both compressor and oil separator Total oil volume liter for each unit is shown in the table below _2 020 148 168 2 020 074 106 ZX025BO 133 43 ZXBO25BE 074 106 ZXO30BO 133 183 2 136 106 NEM E I E LESE _2 1 66 216 7 ZXD060BO E 227 ZXLO60BO E 227 2 075 0 4 16 216 1 2XD075B E 227 2X1075B E 227 ZX076B80 E 2 66 26 CoreSense for ZX Platform Condensing Unit LED IE Status Description Status Description ee amamen Condensing fan is running HB An alarm is occurring B Digital compressor is unloading ON Liquid line solenoid valve on Keyboard Descriptions Single Button Display target set point In programming mode select a parameter or confirm an operation Hold for 5 seconds to reset any lockouts if the current state of the controller allows for it to be reset Enter the fast access menu In programming mode browse the parameter codes or increases the displayed value In programming mode it browses the parameter codes or decreases the displayed value Enter the service and alarm menu Hold for 3 seconds to start a manual defrost or terminate an active defrost Defrost Not available at the moment Pressed together to exit programming mode or menu under rtC a
34. u Co Ltd Shanghai Sales Office 1801 Building B New CaoHeJing International Business Center 391Guiping Rd Shanghai PRC Tel 8621 3418 3968 EmersonClimateAsia com Asia 02 A01 10 R01 Issued 10 2015 GSCAA055 India Mumbai Emerson Climate Technologies India Ltd Delphi B Wing 601 602 6th Floor Central Avenue Hiranandani Business Park Powai Mumbai 400076 Tel 9122 6786 0793 Fax 9122 6662 0500 India PUNE Emerson Climate Technologies India Ltd Plot No 23 Rajiv Gandhi Infotech Park Phase Il Hinjewadi Pune 411 057 Maharashtra India Tel 9120 4200 2000 Fax 9120 4200 2099 Indonesia PT Emerson Indonesia BSD Taman Tekno 8 Jl Tekno Widya Blok H10 No 2 amp 3 Tangerang Selatan 15314 Indonesia Tel 6221 2666244 Fax 6221 2666245 Japan Emerson Japan Ltd Shin yokohama Tosho Building No 3 9 5 Shin Yokohama Kohoku ku Yokohama 222 0033 Japan Tel 8145 475 6371 Fax 8145 475 3565 Malaysia Emerson Electric Malaysia Sdn Bhd Level M2 Blk A Menara 5 Jalan Yong Shook Lin 46050 Petaling Jaya Selangor Malaysia Tel 603 7949 9222 Fax 603 7949 9333 Emerson and Copeland Scroll are trademarks of Emerson Electric Co or one of its affiliated companies 2015 Emerson Climate Technologies Inc All rights reserved EMERSON CONSIDER Middle East amp Africa Emerson Climate Technologies PO Box 26382 Jebel Ali Free Zone South Dubai UA
35. un UL ENP SJOJO N Z 104 JOJON ALON SHOLOINN NV QNOD 49014 LHOLIIOVdVO LU J HM LIV civ ely viv SIV LIV m 49 ZHOS 0 08 GAL 41 841 8 2 1 2 2 NU NEU m xX I m H E ISN HUN NOILN3LIV o 518 508 m 8 o gt 9 5 Pki E 22 0 5102 9 m lt lt lt lt m m Aue SesseuJeu 00 020 2S0 5 a 2 ul uMOUs 3 2 E IP i S peuseqr ie eae 4 gt Dad 27 Notes 23 Notes 29 Notes 30 General Information Technical data are correct at the time of printing Updates may occur and should you need confirmation of a specific value please contact Emerson Climate Technologies stating clearly the information required Emerson Climate Technologies cannot be held responsible for errors in capacities dimensions etc stated herein Products specifications and data in this literature are subject to change without notice The information given herein is based on data and tests which Emerson Climate Technologies believes to be reliable and which are in a
36. xing dimensions and distances Single fan unit 2 HOLES 15MM DIA Power Supply Hole Suction Service Valve Liquid Service Valve Dual Fan Unit 4 to 7 6 HP Fixing dimensions and distances Dual fan unit 17 Start Up Operation Before commissioning ensure that all valves on the condensing unit are fully opened Evacuation The evacuation procedure is based upon achieving an actual system vacuum standard and is not time dependent Before the installation is put into commission it has to be evacuated with a vacuum pump Proper evacuation reduces residual moisture to 50ppm The installation of adequately sized access valves at the furthest point from the compressor in the suction and liquid lines is advisable To achieve undisturbed operation the compressor valves are closed and the system is evacuated down to 0 3 mbar 0 225 Torr Pressure must be measured using a vacuum pressure Torr gauge on the access valves and not on the vacuum pump this serves to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the pump Charging Procedure Refrigerant charging procedure The scroll compressor design requires system charging as quickly as possible with liquid refrigerant into the liquid line This will avoid running the compressor under conditions where there is insufficient suction gas Sufficient suction gas is available to cool n
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