Emerson COPELAND ZX Series User Manual Download

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Thermal Expansion Valve Selection Guide

Selection at 30K Subcooling

R22

R404A

R407A/F

Tevap = -5°C

Tamb = 43°C

50Hz Body -

TIE-HW (802421)

60Hz Body -

TIE-HW (802421)

50Hz Body -

TIE-SW (802460)

60Hz Body -

TIE-SW (802460)

50Hz Body -

TIE-NW (802436)

60Hz Body -

TIE-NW (802436)

ZX Model

Orifice

ZX020BE

TIO-002 (800535) TIO-002 (800535) TIO-002 (800535) TIO-003 (800536) TIO-001 (800534) TIO-002 (800535)

ZX025BE

TIO-002 (800535) TIO-002 (800535) TIO-003 (800536)

TIO-002 (800535)

ZX030BE

TIO-002 (800535) TIO-003 (800536) TIO-003 (800536) TIO-004 (800537) TIO-002 (800535) TIO-003 (800536)

ZX040BE

TIO-003 (800536) TIO-003 (800536) TIO-004 (800537) TIO-004 (800537) TIO-003 (800536) TIO-003 (800536)

ZX050BE

TIO-003 (800536) TIO-004 (800537) TIO-005 (800538) TIO-005 (800538) TIO-004 (800537) TIO-004 (800537)

ZX060BE

TIO-004 (800537) TIO-004 (800537) TIO-005 (800538) TIO-006 (800539) TIO-004 (800537) TIO-004 (800537)

ZX075BE

TIO-004 (800537) TIO-004 (800537) TIO-006 (800539) TIO-006 (800539) TIO-004 (800537) TIO-004 (800537)

ZX076BE

TIO-004 (800537)

TIO-006 (800539)

TIO-004 (800537)

R22

R404A

R407A/F

Tevap = -5°C

Tamb = 43°C

50Hz Body -

TIE-HW (802421)

60Hz Body -

TIE-HW (802421)

50Hz Body -

TIE-SW (802460)

60Hz Body -

TIE-SW (802460)

50Hz Body -

TIE-NW (802436)

60Hz Body -

TIE-NW (802436)

ZXL Model

Orifice

ZXL020BE

TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-001 (800534)

ZXL025BE

TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-001 (800534)

ZXL030BE

TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-002 (800535) TIO-001 (800534) TIO-001 (800534)

ZXL035BE

TIO-001 (800534) TIO-001 (800534) TIO-001 (800534) TIO-002 (800535) TIO-001 (800534) TIO-002 (800535)

ZXL040BE

TIO-001 (800534) TIO-002 (800535) TIO-001 (800534) TIO-003 (800536) TIO-002 (800535) TIO-002 (800535)

ZXL050BE

TIO-002 (800535) TIO-002 (800535) TIO-001 (800534) TIO-003 (800536) TIO-002 (800535) TIO-002 (800535)

ZXL060BE

TIO-002 (800535) TIO-003 (800536) TIO-003 (800536) TIO-003 (800536) TIO-002 (800535) TIO-003 (800536)

ZXL075BE

TIO-002 (800535) TIO-003 (800536) TIO-003 (800536) TIO-003 (800536) TIO-003 (800536) TIO-003 (800536)

R134a

Tevap = -5°C

Tamb = 43°C

50Hz Body -

TIE-MW (802446)

60Hz Body -

TIE-MW (802446)

ZX Model

Orifice

ZX020BE

TIO-002 (800535) TIO-002 (800535)

ZX030BE

TIO-003 (800536) TIO-003 (800536)

ZX040BE

TIO-003 (800536) TIO-004 (800537)

ZX050BE

TIO-004 (800537) TIO-004 (800537)

ZX060BE

TIO-004 (800537) TIO-005 (800538)

ZX075BE

TIO-004 (800537) TIO-005 (800538)

Note: For the ZXD Units, we recommend using Alco Electronic Expansion Valves (EXV). The selection of the EXV will depend on the load
profile on the ZXD Unit. Please contact your local Emerson Climate Technologies office for assistance on selection.

Summary of Contents for COPELAND ZX Series

Page 1: ...ZX Condensing Unit User Manual ZX Condensing Unit UserManual ...

Page 2: ... Condensing Unit 06 Network Wiring 12 Installation Condensing Unit Handling 14 Location and Fixing 15 Refrigeration Piping Installation 16 ZXL Liquid Line Insulation 15 Brazing Recommendations 15 Expansion Valve Selection 17 Electrical Connection 19 Start Up and Operation 20 Controller Initialization Message 22 Alarm Codes 24 Wiring Diagrams 26 System Start Up and Operation Check Sheet 31 Contact ...

Page 3: ...t 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 t...

Page 4: ...k Internal Thermal Sensor Failure Intelligent Store Solution Communication for Retail Store Monitoring Over Voltage Under Voltage Copeland Scroll Compressor Technology High Efficiency Ultra Quiet High Reliability Intelligent Store Highest Efficiency Reliability Better Decision Making Lower Energy Bills Lower Maintenance Cost Nomenclature Bill of Material ZX L 020 B E TFD 451 Unit Family Blank Medi...

Page 5: ...on Terminal Block Figure 2 CoreSense and other components in ZX Platform CDU Figure 3 Major components of ZX Platform CDU Figure 4 CoreSense and Intelligent Store Module Layout CoreSense Scroll Compressor Adjustable LP Controller Accumulator Oil Separator Optional in MT CDU Liquid Receiver Liquid Filter Drier Suction and Liquid Service Valve Receiver Out Service Valve Compressor Oil Sight Glass Li...

Page 6: ...D040BE 1 74 ZXL040BE 1 74 ZX050BE 2 33 ZXD050BE 2 27 ZXL050BE 1 74 ZX060BE 2 16 ZXD060BE 2 27 ZXL060BE 2 27 ZX075BE 2 16 ZXD075BE 2 27 ZXL075BE 2 27 ZX076BE 2 16 Oils are pre charged in both compressor and oil separator Total oil volume liter for each unit is shown in the table below LED Status Description 1 ON Compressor1 is running Flashing Compressor1 is ready to start 2 ON Compressor2 is runni...

Page 7: ...o start a manual defrost or terminate an active defrost Not available at the moment Step Action Phenomenon and Description 1 Power on controller All LEDs will light up for 3 seconds 2 Firmware version will be displayed for 3 seconds 3 Parameter setting file bin file identifier will be displayed for 3 seconds 4 Normal display actual suction temperature will be displayed on ZXD unit condensing tempe...

Page 8: ...r about 10 second to confirm Step Action Phenomenon and Description 1 Press Enter menu to select PAr parameter or rtC 2 Press or Select PAr parameter 3 Press Confirm select and browse Pr1 parameters 4 Press or Browse Pr1 parameters 5 Press View the actual number of the Pr1 parameters 6 Press or Modify the actual number of the Pr1 parameters 7 Press Press SET The number will flash for 3 seconds and...

Page 9: ... or Select PAr parameter 3 Press 4 Press or Browse to t18 parameter 5 Press Enter password 321 6 Press or Browse to parameter E39 Enter desired condensing temperature 7 Press 8 The number will flash for 3 seconds and confirm the modifications will go to the next parameter 9 Press Exit or exit automatically after waiting for 120 seconds Press ...

Page 10: ...mid coil sensor P2P pressure sensor not used P3 discharge line temperature sensor P4 PHE vapor inlet temperature sensor P5 PHE vapor outlet temperature sensor P6 ambient temperature sensor P7 temperature sensor not used SH PHE superheat oPP EXV opening step LLS the status of liquid line solenoid valve Std Condensing temperature setting point Aoo The percentage of the analog output dSo percentage o...

Page 11: ...larm exact timing day 10 Press Display Mon 11 Press Display the alarm exact timing month 12 Press Display yEA 13 Press Display the alarm exact timing year 14 Press Exit or exit automatically after waiting for 15 seconds Step Action Phenomenon and Description 1 Insert Hot Key when the controller is ON 2 Press The uPL message appears followed a by a flashing End label Note if display Err it means it...

Page 12: ...s minimum section 0 5mm2 e g BELDEN8772 Do not connect shield to ground Do not connect the Gnd terminal Remember to draw a map of the line This will help you to find an error if something is wrong RS485 devices are polarity sensitive Figure 6 Correct Network Wiring Figure 7 Incorrect Network Wiring Figure 5 XWEB300D Connected to the Intelligent Store Solution Module Download the Program from Hot K...

Page 13: ... com xweb300d xweb500 xweb500d eng then login register required Go to Support System sw update XWEB300D XWEB500 XWEB500D Download the upgrade package With your web browser login into XWEB Go to 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 into the menu ...

Page 14: ...ZX020BE 76 ZXD040BE2 104 ZXL020BE 79 ZX025BE 79 ZXD050BE3 112 ZXL025BE 81 ZX030BE 79 ZXD060BE4 114 ZXL030BE 81 ZX040BE1 91 ZXD075BE5 122 ZXL035BE 93 ZX050BE 108 ZXL040BE 93 ZX060BE 112 ZXL050BE 106 ZX075BE 118 ZXL060BE 116 ZX076BE 121 ZXL075BE 121 Net Weight Notes 1 100 kg for models under 60 Hz TF5 7 and 50 Hz PFJ 2 109 kg for models under 60 Hz TF7 3 117 kg for models under 60 Hz TF7 4 121 kg fo...

Page 15: ... 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 ...

Page 16: ...w 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 minim...

Page 17: ...l Orifice Orifice Orifice Orifice Orifice Orifice ZXL020BE TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 001 800534 ZXL025BE TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 001 800534 ZXL030BE TIO 001 800534 TIO 001 800534 TIO 001 800534 TIO 002 800535 TIO 001 800534 TIO 001 800534 ZXL035BE TIO 001 800534 TIO 001 800534 TIO 001 800534...

Page 18: ... at all times except during service Failure to do so can result in component failure Unit Unit MOC A ZX020BE TFD 7 2 ZX030BE TFD 8 6 ZX040BE TFD 11 2 ZX050BE TFD 14 5 ZX060BE TFD 14 8 ZX075BE TFD 16 6 ZX076BE TFD 16 6 ZX020BE TF5 12 1 ZX030BE TF5 16 1 ZX040BE TF5 23 1 ZX050BE TF5 31 7 ZX060BE TF5 30 7 ZX075BE TF5 34 3 ZX020BE TF7 8 0 ZX030BE TF7 10 1 ZX040BE TF7 13 7 ZX050BE TF7 17 2 ZX060BE TF7 1...

Page 19: ...ant and the losses associated with improper evacuation erodes system efficiency as well as costly for the installers A 2 stage vacuum pump along with a micron gauge is recommended in performing evacuation The quality of vacuum is not determined by time a micron gauge must be used since it is the only device that accurately reads the vacuum pressure during the evacuation process REMINDER Do not use...

Page 20: ...e refrigerant cylinder correct orientation and at ambient you should not need to run the compressor at all 6 The compressor can then be started and the unit continued to be charged with liquid refrigerant through the liquid service valve The quantity of charge should always be measured See note 7 Turn off the unit and open the receiver outlet valve which was almost fully closed earlier 8 The syste...

Page 21: ...xit atomically After installation and initial power on it is critical to double check the parameters below RTC Real Time Clock Setting Bin Number Range Family 1 to 200 ZX 301 to 500 ZXL 501 to 600 ZXD 800 to 806 Service Part Step Action Phenomenon and Description 1 Power on controller All LEDs will light up for 3 seconds 2 Firmware version will be displayed for 3 seconds 3 Parameter setting file b...

Page 22: ...tically after waiting for 120 seconds Refrigerants Procedure for converting the unit to R134a in case if it is not specified during ordering Please insert the Jumper at point DI3 after removing the existing LP cutout connection The spare jumper is available in the controller as shown in the below pictures Please note that the ZX condensing units are also provided with adjustable type LP cutout whi...

Page 23: ...n Change the condensing temperature setpoint E39 from 20 C to 35 C for R134a operation as below Step Action Phenomenon and Description 1 Press Enter menu to select PAr parameter or rtC 2 Press or Select PAr parameter 3 Press 4 Press or Browse to parameter E39 5 Press 6 Press or Change the set point from existing 20 C to 35 C 7 Press 8 Press Exit or exit automatically after waiting for 120 seconds ...

Page 24: ...let temperature probe failure alarm Probe failure or out of range 40 110 C Function PHE Superheat Control is disabled ZXL unit only Automatic Reset when the probe restarts working E05 PHE vapor outlet tempera ture probe failure alarm Probe failure or out of range 40 110 C Function PHE Superheat Control is disabled ZXL unit only Automatic Reset when the probe restarts working E06 Ambient temperatur...

Page 25: ...delay L24 Compressor running circuit open lock Running circuit open alarm happens frequently The compressor will be tripped and the unit will be locked Press Start 5 sec or manually power off and power on E25 Compressor starting circuit open alarm Compressor starting circuit open 1 ph unit only The compressor will be tripped Automatically with time delay L25 Compressor starting circuit open lock C...

Page 26: ...or leakage No Automatically when PHE super heat is smaller than settings E50 High side liquid back warning Suction liquid back or injection too much No Automatically when the differ ence of discharge temperature and condensing temperature is higher than settings and time delay Misc Error E80 RTC warning The time is configured for the new controller No Automatically when finish time configuration E...

Page 27: ...BK E BU YE BU YE RD WIRE COLOR NOTE BU Blue BK Black OG Orange BN Brown RD Red WH White YE Yellow GNYE Yellow Green NOTES 1 Dashed line is wired by installer 2 Neutral N and Earth E wirings are not shown in harnesses for clarity 3 In 461 units all yellow wires are replaced by white wires GNYE Transformer 1 L1 3 L2 5 L3 A1 2 T1 4 T2 6 T3 A2 Contactor BU YE RD F3 4A 250V F2 4A 250V N N BK R TO1 TO2 ...

Page 28: ...ue BK Black OG Orange BN Brown RD Red WH White YE Yellow GNYE Yellow Green NOTES 1 Dashed line is wired by installer 2 Earth E wirings are not shown in harnesses for clarity GNYE Transformer 1 L1 3 L2 5 L3 A1 2 T1 4 T2 6 T3 A2 Contactor BU YE RD F3 4A 250V F2 4A 250V N BK R TO1 TO2 DI1 DO4 C2 DO5 DO1 C1 DO2 DO3 T1 T2 ELECTRONIC EXPANSION VALVE H K EV G COMMUNICATE VNR DI3 AI7 AI6 SENSOR AMBIENT AI...

Page 29: ...U YE RD YE RD BK BK BK OG BK BN RD OG BK WH BU OG BU YE RD BK E BU YE BU YE RD WIRE COLOR NOTE BU Blue BK Black OG Orange BN Brown RD Red WH White YE Yellow GNYE Yellow Green NOTES 1 Dashed line is wired by installer 2 Earth E wirings are not shown in harnesses for clarity GNYE Transformer 1 L1 3 L2 5 L3 A1 2 T1 4 T2 6 T3 A2 Contactor BU YE RD F3 4A 250V F2 4A 250V BK R TO1 TO2 DI1 DO4 C2 DO5 DO1 ...

Page 30: ...U OG BU YE RD BK E BU YE BU YE RD WIRE COLOR NOTE BU Blue BK Black OG Orange BN Brown RD Red WH White YE Yellow GNYE Yellow Green NOTES 1 Dashed line is wired by installer 2 Neutral N and Earth E wirings are not shown in harnesses for clarity 3 In 461 units all yellow wires are replaced by white wires GNYE Transformer 1 L1 3 L2 5 L3 A1 2 T1 4 T2 6 T3 A2 Contactor BU YE RD F3 4A 250V F2 4A 250V N N...

Page 31: ...BK E BU YE BU YE RD WIRE COLOR NOTE BU Blue BK Black OG Orange BN Brown RD Red WH White YE Yellow GY Gray GNYE Yellow Green NOTES 1 Dashed line is wired by installer 2 Earth E wirings are not shown in harnesses for clarity GNYE Transformer 1 L1 3 L2 5 L3 A1 2 T1 4 T2 6 T3 A2 Contactor BU YE RD F3 4A 250V F2 4A 250V N N BK R TO1 TO2 DI1 DO4 C2 DO5 DO1 C1 DO2 DO3 T1 T2 ELECTRONIC EXPANSION VALVE H K...

Page 32: ...nd Vibration Comments System Operation COMP Voltage V COMP Current A Suction Pressure PSIG Bar Liquid Line Pressure PSIG Bar COMP Suction Temp C COMP Disch Temp C Liquid Line Temp C Compressor SH K Subcooling K Adjustable LP Setpoint PSIG Design Operating Temp C Actual Room Case Temp C Condenser Fins To TXV from Evap COMPRESSOR SUPERHEAT 10 20K _________ SUCTION LINE TEMP T1 ________ c Compressor ...

Page 33: ...tests which Emerson Climate Technologies believes to be reliable and which are in accordance 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 p...

Page 34: ...rates Jebel Ali Free Zone P O Box 26382 Dubai United Arab Emirates Toll Free 8000 441 3428 Tel 971 4 8118100 Fax 971 4 8865465 Saudi Arabia P O Box 34332 3620 Building 7874 Unit 1 67th Street 2nd Industrial City Dammam Saudi Arabia Toll Free 8008 443 426 Tel 966 3 8147560 Fax 966 3 8147570 South Africa 11 Quark Crescent Linbro Business Park Sandton 2065 South Africa Toll Free 0800 980 371 Tel 27 1...

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