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4

4

AIRFLOW

AIRFLOW

MP

HP

R22

LP

ZX UNIT

4 port Guage Manifold

L

H

Shraeder conn.

Interconnecting

Piping
(Insulated)

LL Solenoid valve

Expansion valve

Evaporator

Note: Remove both
schraeder cores before

evacuation & charging.

Vacuum guage

Clean (new)

refrigerant

Vacuum Pump

Main service connection

size = 3/8"

Suction service hose.
size = 1/4"

Liquid/discharge service hose

size = 1/4"

5000

1500

1000

700

400

300

200

100

50

ATMS

GOOD

MICRONS
VACUUM GAUGE

O
N

O
F
F

S

upc

o

VG-

6

0

10.0 Leak Checking and Evacuation

(See Fig.16 )

27

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Summary of Contents for ZX

Page 1: ...1 ZX OUTDOOR REFRIGERATION CONDENSING UNIT USER MANUAL Emerson Climate Technologies Suzhou Co Ltd ...

Page 2: ...ion Charging 28 10 1 Initial Pressure Testing by vacuum and nitrogen 10 2 Leak Test by refrigerant with nitrogen pressurization 10 3 Evacuation 10 4 Charging and Commissioning 11 0 E2 Control and Operating Features 33 12 0 Operation and Set up of the E2 Unit Controller 35 12 1 Compressor Unit Setting 12 2 Compressor Motor Protection 12 3 Compressor Pressure Protection 12 4 Compressor Discharge Tem...

Page 3: ... Location of the Fixed High and Low Pressure Switches 17 Fig 11 Liquid Injection System 18 Fig 12 3 Dimensional View 19 Fig 13 Physical Dimensions 21 22 Fig 14 Four Port Charging Manifold 23 Fig 15 Electronic Vacuum Gauge 24 Fig 16 Commisioning Hook Up and Essential Equipment 27 Fig 17 Schraeder Valves with and without depressors 28 Fig 18 E2 Unit Controller Board Layout and Major Components 35 Fi...

Page 4: ...o be good refrigeration trade practice applied to this particular product The installation contractor may prefer to use variations to these recommendations however it is to be noted that the methods described in this manual represent the minimum required to avoid any subsequent warranty claims for this equipment or it s component parts These instructions do not cover the fundamentals of good elect...

Page 5: ...gnostics and Communication Features in built into the compact chassis Fig 1 Single Fan Unit ZX 200 ZX 300 ZX 400 2 1 Product Description The application range of the first release is between 15 C to 5C Evaporating Temperature and 27 C and 43 C Ambient without Fan Speed Control This CDU is released with both R22 and R404A Refrigerants The Single Fan units are ZX 200 ZX 300 and ZX 400 2 3 and 4 hp n...

Page 6: ...Speed Control Optional the ZX is one of the Quietest Refrigeration CDU on the market As mentioned in the first paragraph the ZX uses electronics extensively in its Protection Diagnostics and Communication features These features are controlled by the E2 Electronics Control Board The E2 provides Base Control functions related to Temperature Controller Defrost Evaporator Fan control etc Compressor P...

Page 7: ...e E2 Control Board 2 2 Basic and Optional Configuration The ZX is marketed with both a Basic configuration and a Basic plus additional Option Package The Basic ZX CDU consists of a Chassis Condenser Coil and Fan s Electronic Control Board E2 Board Protective Casing a ZX Compressor with a Crankcase Heater Liquid Receiver with Rotalock Valves Liquid Injection Electronic Expansion Valve EXV with Capi...

Page 8: ...Fig 4 The Defrost Module Fig 5 The Diagnostic Module now available without Buzzer 8 ...

Page 9: ...e Voltage Imbalance Protection Loss of Phase Protection Motor Current Overload Built In and therefore External Current Protection not Required Non Adjustable High And Low Pressure Switches Automatic Reset For Nos Of Trips Then Lockout For HP Only And Require Manual Restart Liquid Floodback Protection Measurement of Discharge Superheat To Predict Liquid Floodback Fresh Start Programs To Ensure Safe...

Page 10: ...rt Status Event LED Status D1 D2 D3 D4 D5 Normal Unit OFF Phase U or N missing Normal Power ON Normal Compressor ON Normal Fresh Start Normal Start Normal Defrost ON Fault DLT Overlimit Fault Ambient sensor failure Fault MCT sensor failure Fault DLT Thermistor failure Fault HP Cut Out Fault Compressor Over Current Fault Compressor Incorrect Phase sequence Fault Compressor Voltage Imbalance System ...

Page 11: ...i e To Stop Or Start Defrost A Remote Manual Defrost Button can also be connected to the Defrost Module 2 5 Advantages The key advantages that the ZX CDU has over similar units is that it is extremely affordable and has a very low noise level in comparison to other units on the market To be cost effective and more affordable the ZX CDU has Built In Technology which includes the E2 Board with all t...

Page 12: ...board Required Fan Speed Control Low Sound Level and Lower Energy Consumption Ventilation Easy To Retrofit For Discharge Air Extraction Machine Room Saving Eliminate Wasteful Space Mount The ZX On The Wall The following explains why the ZX is more Energy Efficient Scroll Compressor Large Suction And Discharge Ports Reduces Pressure Losses Incurred In Suction And Discharge Processes Physical Separa...

Page 13: ...allations these are listed below Supermarkets medium to small Coldrooms Convenience Stores Independent Coldrooms Fast Food Chains and Restaurants Small Flake Ice Machines 250 to 750 kg per day 15 deg C evap Process Room Air Cooling 10 deg C room temperatures Water Cooling Applications PHE Tube in Tube evaporators 3 0 ZX Nomenclature 13 ...

Page 14: ...Fig 7 ZX Nomenclature 4 0 Receiving Your ZX Unit All units are shipped with a holding charge of Dry Nitrogen inside at a low but positive pressure 14 ...

Page 15: ...you have checked the holding charge and find that the charge is missing you should immediately inform us or our authorized representative To not do so may void your claim for some other fault later on Transit damage is essentially an insurance matter and not a warranty matter It is also advisable to check the rest of the unit for obvious physical damage and then act in the same manner as described...

Page 16: ...odule Option Electrical Terminal Block Receiver Inlet Valve Receiver Diagnostic Module Option Sight Glass Option Liquid Line Service Valve Suction Line Service Valve Receiver Outlet Valve Filter Drier Option Fig 8 ZX 600 TFD with front panel open to expose the components 16 Fan Bracket Mounting ...

Page 17: ...500mm Dia 3 Blade Propeller Fan Fig 9 Fan and Fan Motor exposed Fan Guard removed Fixed LP Switch Fixed HP Switch Fig 10 Location of the Fixed High and Low Pressure Switches Top Cap Thermistor 17 ...

Page 18: ...Injection Line Electronic Expansion Injection Valve Injection Capillary Tubing Fig 11 A ZX 600 during assembly showing the patented Injection System 18 ...

Page 19: ...Fig 12 3 Dimensional Views of Selected Component Layout not to be used for dimensioning or installation 6 0 Dimensions and Installation Guidelines 19 ...

Page 20: ...el on a solid concrete slab with rubber strips between unit feet and concrete However the ZX has also been designed for mounting on suitable brackets for wall mounting In this case it is not only equally important that the spatial guidelines given above are followed but additional consideration needs to be given for possible air recycling if units are stacked above and below each other Other facto...

Page 21: ...ZX200 300 400 Single Fan Units 21 ...

Page 22: ...ZX500 600 750 Dual Fan Units 22 ...

Page 23: ...ring the evacuation process A Four Port Charging Manifold including 1 A 3 8 hose to vacuum pump 2 All hoses fitted with removable schraeder depressors 3 One compound and one pressure gauge All of this equipment to be leak free accurate and reliable See Fig 14 below Fig 14 Four Port Charging Manifold Clean and new not recycled R22 Refrigerant of sufficient quantity for the refrigerant operating cha...

Page 24: ... is recommended for the ZX R404A units If the recommended oils are not available in your area contact us or our nearest distributor wholesaler for acceptable alternatives Thermometer to measure discharge temperature and suction temperature Electronic Leak detector Electrical Insulation Performance Measuring Gauge 8 0 Electrical Installation 24 ...

Page 25: ...be of refrigeration grade clean dehydrated and remain capped at both ends until installation Even during installation if the system is left for any reasonable period of time say 2 hours pipes should be re capped to prevent moisture and contaminant from entering the system It is advisable to insulate both the suction and liquid interconnecting piping between the ZX unit and the evaporator Usually t...

Page 26: ...e tube when brazing the joint There are many books on good trade practice for refrigeration piping available and as stated earlier in the Disclaimer page of this Manual and it is not our intention to repeat the many variations here but the above can be used as a good practical guide Warning Do not assume that the service connection sizes on the unit at the service valves are in fact the correct si...

Page 27: ...orator Note Remove both schraeder cores before evacuation charging Vacuum guage Clean new refrigerant Vacuum Pump Main service connection size 3 8 Suction service hose size 1 4 Liquid discharge service hose size 1 4 5000 1500 1000 700 400 300 200 100 50 ATMS GOOD MICRONS VACUUM GAUGE O N O F F Supco VG 60 10 0 Leak Checking and Evacuation See Fig 16 27 ...

Page 28: ...ow important to re check all joints within the unit as well as the external joints you have made Remember we are aiming at a high degree of vacuum in the next process so the unit must be leak free first Please refer to Fig 8 for the connection points described below 10 1 Initial Pressure Testing by vacuum and nitrogen Step by Step Use a 4 port gauge manifold with 3 8 hose and connections to the va...

Page 29: ...sound This step is to look for large leaks only Repair leakage if leak is detected Proceed to step 10 2 10 2 Leak Test by refrigerant with nitrogen pressurization Step by Step Release nitrogen from system start vacuum pump and open main pump valve Then evacuate for a second time to 0 85 bar as read on the manifold gauge Break this vacuum with R22 after shutting off the main pump valve and then sto...

Page 30: ...rwise the pump may lose its lubrication oil to the system and contaminate it Therefore the pump must have a Vacuum Breaker fitted to it 1st Time Vacuum Bring system down to 1500 microns and then Break Vacuum to 2 psig with the same refrigerant 2nd Time Vacuum Same as the 1st Time Vacuum 3rd Time Vacuum Leave the pump running while checking the vacuum regularly The target system vacuum is 500 micro...

Page 31: ...eave the crankcase heater off Connect the refrigerant cylinder to main service hose and purge line at the manifold end Then invert the refrigerant cylinder if necessary to ensure only liquid refrigerant can be charged into the system This will be charged through the high pressure side of the manifold and ZX unit liquid service valve The refrigerant cylinder should be weighed at this point to be ab...

Page 32: ...t It is at this point that the normal refrigeration operational checks can be carried out such as checking the liquid line sight glass for violent bubbles and the operating pressures In the event that the system is still short of refrigerant repeat from the last 4 steps onwards 11 0 E2 Control and Operating Features 32 ...

Page 33: ...tomer supplied functions such as Main load controller or Thermostat Evaporator electric defrost heater contactor Evaporator fan contactor Copeland supplied Option Liquid Line Solenoid Valve supplied loose for fitting external to the ZX unit Copeland supplied Option Fan Speed Control This option automatically controls fan speed and is useful where low ambient temperatures are experienced such as mi...

Page 34: ...e three phase motor Motor Current Overload Protection is provided also via the E2 eliminating the need for external current protection for the compressor motor Fixed Low and High Pressure Switches These are non adjustable protection devices to prevent the compressor operating outside of its safe evaporating and condensing pressure range s Reset is automatic for a set number of trips then the unit ...

Page 35: ...sor Selector Rotary Switch not to be tampered by User Digital Switching Power Supply High Voltage Output 3 Phase Protection Module Power and Thermostat Input Fig 18 E2 Unit Controller Board Layout and Major Components Please refer to Fig 9 together with the ZX Wiring Diagram for the connection points in Addendum 17 2 at the end of this Manual 35 ...

Page 36: ...main phase supply lines to the compressor compressor via the contactor are routed through the Current Abnormality Coils 12 3 Compressor Pressure Protection 12 3 1 High Pressure A sensor is registered by the E2 The sensing device is a non adjustable low voltage pressure switch that will open in event of an abnormally high discharge pressure above 2 8Mpa The unit will stop and then restart automatic...

Page 37: ...0 volt AC input ON OFF signal such as the switching action of a normal commercial thermostat and relays a similar action as an output to the compressor contactor refer to the wiring diagram in the Addendum section in the case of thermostat controlled system If the system is controlled by Low Pressure Cut Out for a Multiple Evaporator system and or Pump Down system the E2 accepts signal directly fr...

Page 38: ...istor type sensors are again supplied by Copeland and connected to the E2 board when the Condenser Fan Speed of the condenser fans and is usually applicable where low ambient low condensing temperatures are likely to adversely effect refrigeration performance 38 ...

Page 39: ...VA inrush 12 6 2 Defrost Heater Contactor Coil An ON OFF output connection is provided on the E2 board for direct connection of a customer supplied contactor coil for convenience when the Defrost Option is included Terminals are male spade type Coil voltage rating should be 220VAC and current ratings 30VA hold and 330VA inrush 12 6 3 Indoor Fan Contactor Coil An ON OFF output connection is also pr...

Page 40: ... LED s in various combinations The module Fig 19 is located on the left hand side of the electrical mounting panel The LED s can be viewed by simply removing the front compressor compartment cover Buzzer now sold separately Remote Buzzer Connection Dialer Connection LED s D1 to D5 10 Pin Communication Connector to E2 Board Fig 20 Diagnostic Module details Fig 6 is repeated overleaf for ease of ref...

Page 41: ...ve Copeland should be consulted for compatibility between the customer s buzzer and the E2 board if buzzers other than the option sold by Copeland are to be used Dialer This provision is for the customer to be able to receive a common fault signal any of those listed above at a remote location through the normal telephone network The E2 communicates with a Dialer to supplied by Copeland in future ...

Page 42: ...ately Refer to Fig 20 where the main components have been identified Defrost Interval Defrost Duration Switch Manual Defrost Button Remote Manual Defrost Button Connector 8 Pin Communication Connector to E2 Board Fig 21 Defrost Module details The two rotary switches SW1 SW2 are for setting the defrost interval between defrosts and defrost duration respectively The table below Fig 21 conveys the va...

Page 43: ...Fig 23 Diagnostic Module and Defrost Module connected to the E2 Unit Controller 43 ...

Page 44: ... no exception except the vibration levels from the compliant scroll technology is less severe than units employing reciprocating compressors Because of this the ZX can be mounted on simple less expensive rubber strips Over time however and also due to temperature extremes within the unit housing electrical terminations can come loosened It is suggested that the main electromechanical terminations ...

Page 45: ... are used Note The E2 Board casing must not be removed and the E2 Board tampered with unless absolutely necessary Routine Leak Testing All joints with in the system should be leak checked during each site service time If you find the oil imprint around the joints or in the ground near the joints there may be a leak in the joint All joints within the system should be leak tested once per year This ...

Page 46: ...043 0071 00 AMBIENT SENSOR 043 0072 00 MID COIL SENSOR ZX15KC TFD 52 4 ZX COMPRESSOR FOR ZX 200 ZX21KC TFD 52 4 ZX COMPRESSOR FOR ZX 300 ZX30KC TFD 52 4 ZX COMPRESSOR FOR ZX 400 ZX38KC TFD 52 4 ZX COMPRESSOR FOR ZX 500 ZX45KC TFD 52 4 ZX COMPRESSOR FOR ZX 600 ZX51KC TFD 52 4 ZX COMPRESSOR FOR ZX 750 018 0057 00 CRANKCASE HEATER 028 8436 02 TUBE CAPILLARY FOR ZX300 028 8436 03 TUBE CAPILLARY FOR ZX...

Page 47: ...89 00 COVER PANEL FRONT RIGHT FOR ZX200 300 400 024 0247 00 FAN GUARD 005 7193 00 COVER HANDLE 005 7193 01 HAND GRIP 032 0592 00 HOLDER FOR SENSOR 066 0349 00 CONDENSOR ZX 200 066 0344 00 CONDENSOR ZX 500 600 066 0350 00 CONDENSOR ZX 750 010 7006 01 VALVE SERVICE 7 8 023 1001 01 COIL EXV ZX500 600 750 085 7044 01 FIXED SETTING HIGH PRESSURE SWITCH ZX 500 600 750 085 7045 01 FIXED SETTING LOW PRESS...

Page 48: ...the core of the issues much quicker These are CDU related conditions that can also give the technician some idea about the condition of the system by using some basic refrigeration troubleshooting tables but not limited to these as below with a basic gauge manifold D S 48 Possible Causes Effects ischarge Pressure Low Refrigerant Shortage Dirty Evaporator Iced up Evaporator Low Superheat Setting at...

Page 49: ...ow Restriction at the Filter Drier Low High Low High High Low Low Evaporator Airflow Low Low Low Low High Low Blocked or Dirty Condensor Coil High High High Low Low High TXV with lost bulb charge Low Low Low High High Low High Evaporator Airflow High High High High Low High Dragging or Seizing Compressor Low High High High High High Electrical Phase Imbalance Low High High High High Low Non Conden...

Page 50: ...0 100 100 200 200 200 Fan Diameter mm 500 500 500 500 500 500 Fan Speed r min 790 790 790 790 790 790 4 Norminal Input kW 1 56 2 13 3 12 3 64 4 5 4 83 4 Norminal Input hp 2 3 4 5 6 7 5 Receiver 80 Capacity at 32 degC kg 7 6 7 6 7 6 7 6 7 6 7 6 Oil Type Whitco LP 200Whitco LP 200Whitco LP 200Whitco LP 200Whitco LP 200 Whitco LP 200 Oil Charge Litre 1 1 1 1 85 1 85 1 65 1 65 Suction in OD 3 4 3 4 3 ...

Page 51: ...Addendum 17 2 ZX Wiring Diagram 51 ...

Page 52: ...Addendum 17 3 Capacity kW at 50Hz for Refrigerant R22 52 ...

Page 53: ...3 8 13 9 62 11 16 38 4 72 6 01 7 42 8 93 10 48 43 4 09 5 37 6 78 8 27 9 80 ZX500 27 7 48 9 19 10 96 12 82 14 82 32 7 10 8 72 10 45 12 30 14 36 38 6 55 8 07 9 74 11 61 13 71 43 5 71 7 14 8 77 10 65 12 81 ZX600 27 8 50 10 41 12 49 14 72 17 80 32 7 71 9 63 11 71 13 94 16 30 38 6 42 8 42 10 57 12 85 15 26 43 7 15 9 40 11 78 14 26 ZX750 27 10 03 12 37 14 91 17 73 20 89 32 9 45 11 64 14 12 16 96 20 21 3...

Page 54: ...54 ...

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