Emerson ZX0200-TFD, ZX0500-TFD, ZX0300-TFD, ZX0400-TFD, ZX0600-TFD User Manual

User Manual

Copeland Scroll

TM

ZX condensing unit for refrigeration applications

About Emerson Climate Technologies

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

mor

e information, visit EmersonClimateAsia.com.

Emerson Climate Technologies is pleased
to offer the ZX platform refrigeration
condensing units (CDU) specifi cally
designed for medium temperature (ZX-MT
& ZXB-MT), digital modulated variable
capacity medium temperature (ZXD) and
low temperature (ZXL-LT) refrigeration.

ZX series CDU has been highly successful in
the Asian market and enjoys proven success
with its energy savings and customer-
friendly electronic features.

Emerson Climate Technologies, With Our Partners,

Will Provide Global Solutions To Improve Human Comfort,

Safeguard Food And Protect The Environment.

Our Vision

Table of Contents

Disclaimer 04

Features and Benefits 04

Nomenclature 05

Bill of Material 05

Physical Layout of the Unit 06

Product Specification

Quali ed Refrigerants And Oils 07

E2 Control Board - Rotary Switch And Dip Switch Setting (ZX-MT, ZXB-MT & ZXL-LT) 08

Defrost Module Function Set 09

Digital Scroll Controller (ZXD) 09

ZX CDU Intelligent Store Solution Module 10

Installation

Condensing Unit Handling 14

Electrical Connection 14

Refrigeration Piping Installation 15

Expansion Valve Selection for Low Ambient Application 16

Location and Fixing 16

Start Up and Operation 17

Diagnostic Initialization Message (ZX-MT, ZXB-MT & ZXL-LT) 17

Diagnostic Messaging - LED Definition (ZX-MT, ZXB-MT & ZXL-LT) 18

Alarm Messaging - Digital Scroll Controller (ZXD) 18

Wiring Diagram 19

Contact Lists 28

4

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 efciencies 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 on a 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 ofce, 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 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 specic 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.

Caution! It is 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 hardware 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 specic needs

• Reduce operational costs and boost the protability at most convenience

Energy Efficiency - Utilizing Copeland Scroll

TM

compressor technology, variable speed fan motor, large capacity condenser

coil and advanced control algorithms, energy consumption is signicantly 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

TM

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 oodback, which can prevent critical damage on the unit.

5

Copeland Scroll Compressor Technology –

High Ef ciency, Ultra Quiet, High Reliability

Intelligent Store Better Decision Making

• Compressor Reverse Rotation

• Compressor Over Current

• Compressor Internal Motor

Protector Trip

• Discharge Gas Over Heat

• High Pressure Cut Out

• Low Pressure Cut Out (only on

MT series)

• Refrigerant Flood Back

• Compressor Minimum Off Time

• Internal Thermal Sensor Failure

• Intelligent Store Solution:

Communication and Retail Store
Monitoring

Intelligent Store

Solution Module

Built-in ZX Platform

Controller

Highest Ef ciency Lower Energy Bills

Reliability

Lower Maintenance Cost

ZXD Family

ZX, ZXB and ZXL Family

Figure 1. ZX Platform CDU Features

Nomenclature

Variable Speed Fan
Motor and High

Ef ciency Fan Blade

Oversized Condenser
Coil for Maximum Heat
Transfer

Bill of Material

CDU Family ZX ZXB ZXL ZXD

BOM 401 451 481 401 451 461 451 461 471 481 450 451 461

Liquid Line Filter Dryer/Sight Glass

            

Oil Separator

          

Accumulator

   

Adjustable LP Switch

         

Fixed LP Switch

     

E2 Controller

         

Digital Scroll Controller

  

Fan Speed Controller

           

Intelligent Store Solution Module

         

Circuit Breaker

            

Sound Jacket

            

Low Ambient Kit

 

Defrost Module ACC ACC ACC ACC



ACC



ACC

Filter Drier ACC

- Capacity modulation to control precise
room temperature and humidity

- With real time monitoring of compressor
operating conditions

Z X L 0 2 0 E - T F D - 4 5 1

Unit Family

Blank = Medium Temp

B = Medium Temp (R134a)

D = Digital Medium Temp

L = Low Temp

1.5 to 7.6 HP

E = Ester Oil

O = Mineral Oil

PFJ = 220V/240V- 1ph- 50 Hz

TFD = 380V/420V- 3ph- 50 Hz

TF5 = 200V/230V- 3ph- 60 Hz

200V/220V - 3ph - 50 Hz

TF7=380 - 3ph - 60 Hz

Bill of Material

Base Model Electrical Code Bill of Material

Note: ACC- Accessory

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

6

Physical Layout of the Unit

The following figures give an introduction to the physical layout of the ZX Platform CDU

ZX-MT, ZXB-MT & ZXL-LT E2 Controller

Scroll Compressor

See Fig. 5 for LED and keypad

ZXD Digital Scroll Controller

Figure 4. Shows the layout of the E2 controller, electrical components, dip switches and rotary switch in the E2 control board.

Figure 2. Identies the Electronic controller assembly on a ZX platform CDU.

Figure 3. Identies other major components layout on a ZX platform CDU.

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

Accumulator

2-Bit Dip Switch

3-Bit Dip Switch

Rotary Switch

E2 Control Board

Power Isolation Switch

E2 Power Board

Compressor Cont

actor

Defrost Module

Intelligent Store
Solution Module

Fuse Holder Electrical Cable connectors

7

Program Mode: browses parameter codes or

increase value

Hot Key Insert : Hot key programming

procedure

INFO Menu: Press and release it to access

INFO Menu

Program Mode: below parameter codes or

decrease value

Maintenance /Clock

Suction pressure
Suction temperature display

Discharge pressure
Condenser temperature display

Enter Alarm

Manual Restart

Setup Menu

ZX ZXB ZXD ZXL

Model

BOM

Model

BOM

Model

BOM

Model

BOM

401 451 ALL ALL ALL

ZXB015E 0.74

ZX0200/E

1.18

1.68 ZXB020E 0.74

ZXL0200/E 1.06

ZX0250/E

1.33

1.83 ZXB025E 0.74

ZXL0250/E 1.06

ZX0300/E

1.33

1.83 ZXB030E 1.36

ZXL0300/E 1.06

ZXB035E 1.36

ZXL0350/E 1.74

ZX0400/E

1.83

2.33 ZXB040E 1.36 ZXD0400/E 1.74

ZXL0400/E 1.74

ZX0500/E

1.83

2.33 ZXB050E 1.89 ZXD0500/E 2.27

ZXL0500/E 1.74

ZXB055E 1.89

ZX0600/E

1.66

2.16 ZXD0600/E 2.27

ZXL0600/E 2.27

ZX0750/E

1.66

2.16 ZXD0750/E 2.27

ZXL0750/E 2.27

ZX0760/E

1.66

2.16

Figure 5. Shows LED and keypad of ZXD digital scroll controller.

Product Specication

For application envelope, envelope varies according to applications and refrigerants. Please refer to ZX platform product
catalogue, product manual, or Copeland

TM

Brand Products Selection Software.

Qualified Refrigerants and Oils

Oils are pre-charged in both compressor and oil separator. Total oil volume (liter) for each unit is shown in the table below:

REFRIGERANT OIL

R404A/R507/R134a

Emkarate RL 32 3MAF

Mobil EAL Artic 22 CC

R22 Suniso 3GS

8

E2 Control Board Dip Switch Setting (ZX-MT, ZXB-MT & ZXL-LT)

ZX Model

ZXB Model

ZXL Model

Related Software

Version

300-0043-02 V2.2

With Fan Speed Control

Model

Rotary
Switch

S2 Bit 3

S3 Bit1/

Bit2

ZX0200-TFD 1 OFF ON/ON

ZX0300-TFD 2 OFF ON/ON

ZX0400-TFD 3 OFF ON/ON

ZX0500-TFD 4 OFF ON/ON

ZX0600-TFD 5 OFF ON/ON

ZX0750-TFD 6 OFF ON/ON

ZX0760-TFD 6 OFF ON/ON

ZX0200-PFJ 7 OFF ON/ON

ZX0250-PFJ 8 OFF ON/ON

ZX0300-PFJ 9 OFF ON/ON

ZX0400-PFJ A OFF OFF/OFF

ZX0200-TF5 1 ON ON/ON

ZX0300-TF5 2 ON ON/ON

ZX0400-TF5 3 ON ON/ON

ZX0500-TF5 4 ON OFF/OFF

ZX0600-TF5 5 ON OFF/OFF

ZX0750-TF5 6 ON OFF/OFF

ZX0200-TF7 7 ON ON/ON

ZX0300-TF7 8 ON ON/ON

ZX0400-TF7 9 ON ON/ON

ZX0500-TF7/

ZX0600-TF7

A ON ON/ON

ZX0750-TF7 B ON ON/ON

Related Software

Version

300-0043-03 V2.1

W/O Fan Speed Control

Model

Rotary
Switch

S2 Bit 3

S3 Bit1/

Bit2

ZX0200-TFD 1 OFF ON/ON

ZX0300-TFD 2 OFF ON/ON

ZX0400-TFD 3 OFF ON/ON

ZX0500-TFD 4 OFF ON/ON

ZX0600-TFD 5 OFF ON/ON

ZX0750-TFD 6 OFF ON/ON

ZX0200-PFJ 7 OFF ON/ON

ZX0250-PFJ 8 OFF O

N/ON

ZX0300-PFJ 9 OFF ON/ON

ZX0400-PFJ A OFF OFF/OFF

Related Software

Version

300-0043-00 V2.2

With Fan Speed Control

Model

Rotary
Switch

S2 Bit 3

S3 Bit1/

Bit2

ZXB015E-TFD 1 OFF ON/ON

ZXB020E-TFD 2 OFF ON/ON

ZXB025E-TFD 3 OFF ON/ON

ZXB030E-TFD 4 OFF ON/ON

Related Software

Version

300-0043-00 V2.2

With Fan Speed Control

Model

Rotary
Switch

S2 Bit 3

S3 Bit1/

Bit2

ZXL0200-TFD 1 OFF ON/ON

ZXL0250-TFD 2 OFF ON/ON

ZXL0300-TFD 3 OFF ON/ON

ZXL0350-TFD 4 OFF ON/ON

ZXL0400-TFD 5 OFF ON/ON

ZXL0500-TFD 6 OFF ON/ON

ZXL0600-TFD 7 OFF ON/ON

ZXL0750-TFD 8 OFF ON/ON

ZXL0200-TF5 /

ZXL0250-TF5

1 ON ON/ON

ZXL0300-TF5 2 ON ON/ON

ZXL0350-TF5 3 ON OFF/OFF

ZXL0400-TF5 4 ON OFF/OFF

ZXL0500-TF5 5 ON OFF/OFF

ZXL0600-TF5 6 ON OFF/OFF

ZXL0750-TF5 7 ON OFF/OFF

ZXL0200-TF7 /

ZXL0250-TF7

8 ON ON/ON

ZXL0300-TF7 9 ON ON/ON

ZXL0350-TF7 A ON ON/ON

ZXL0400-TF7 B ON ON/ON

ZXL0500-TF7 C ON ON/ON

ZXL0600-TF7 /

ZXL0750-TF7

D ON ON/ON

Related Software

Version

300-0043-01 V2.0

W/O Fan Speed Control

Model

Rotary
Switch

S2 Bit 3

S3 Bit1/

Bit2

ZXL0200-TFD 1 OFF ON/ON

ZXL0250-TFD 2 OFF ON/ON

ZXL0300-TFD 3 OFF ON/ON

ZXL0350-TFD 4 OFF ON/ON

ZXL0400-TFD 5 OFF ON/ON

ZXL0500-TFD 6 OFF ON/ON

ZXL0600-TFD 7 OFF ON/ON

ZXL0750-TFD 8

OFF ON/ON

Related Software

Version

300-0043-00 V2.2

With Fan Speed Control

Model

Rotary
Switch

S2 Bit 3

S3 Bit1/

Bit2

ZXB035E-TFD 5 OFF ON/ON

ZXB040E-TFD 6 OFF ON/ON

ZXB050E-TFD 7 OFF ON/ON

ZXB055E-TFD 8 OFF ON/ON

9

Digital Scroll Controller (ZXD)

Note: The settings given in the table are pre-set at the factory for new units

Then SEtF (fan speed control set point) will be displayed
automatically.

SEtC value

Flashing

Or to change set value within 30 seconds

press to memorize new value and Exit, or wait for
30 seconds without pressing any key to memorize value
and exit.

Press for more than 2 seconds

or to change set value within 30 seconds

press to memorize new set value.

SEtC value

Flashing

Time of Defrost Time of Defrost Interval

Rotary

Switch1

Time

(min)

Rotary

Switch2

Time

(hours)

0 0 0 0
1 5 1 1
2 10 2 2
3 15 3 3
4 20 4 4
5 25 5 5
6 30 6 6
7 35 7 7

Defrost Module Function Set

Defrost Duration (in Minutes)

Defrost Interval
(in Hours)

E2 Connector

Manual Defrost
Button

Remote Connector
For Manual Defrost

Figure 6. Defrost Module

The controller has been pre-programmed with a number of parameter values that are set for typical application. Individual
installation requirements, however, may make it necessary to alter parameter settings. The control target of the digital scroll

available compressor capacity. The set-point can be altered using the SEtC parameter. Factory setting SEtC is -6

o

C.

The control target of the fan speed controller is to maintain the average condenser mid-coil temperature and hence the

the SEtF parameter. Factory setting SEtF is 25

o

C. Initial setting of set point for saturated suction temperature.Pre-set value is

located in the SEtC position as shown in the diagram below:

ON

1 2 3

Use setting in the table

For ZX-MT Unit:
OFF: Evaporator ON/OFF logic is same as compressor and this is the factory

default setting
ON: Evaporator fan will be ON for all time irrespective of whether the

compressor is turned ON or OFF

Not applicable for ZX/ZXL/ZXB units

For ZXL-LT & ZXB-MT Units:
OFF: SH target value set at 5K and this is the factory default setting

for R404A, R134A and R22
ON: SH target value set at 10K, for R407F

10

ZX CDU Intelligent Store Solution Module

ZX CDU address is determined using dip switches on the Intelligent Store Solution Module.

Switch numbers 1 to 6 set the slave address. Switch number 7 will set the Baud rate and switch number 8 will set the parity.
The range of allowable addresses is 1 through 63. Refer to Dip Switch Address Settings table below.

Make sure that you are setting the same address, parity and baud rate as in the Dixell XWEB300D. Select “No Parity” and
“9.6Kbps Baud Rate” on the ZX CDU Intelligent Store Solution Module.

Please note the termination JP3 jumper is just used for the devices at beginning or end of the daisy chain – any devices in the
middle of the daisy chain do not need it.

JP3 Termination Jumper ON = Add 150 Ω resistor between A and B

JP3 Termination Jumper Off = Remove 150 Ω resistor between A and B

•No. 1 to 6: Set Slave Address

•No. 7: Set Baud Rate

•No. 8: Set Parity

1 2 3 4 5 6 7 8

Set Address Address

OFF OFF OFF OFF OFF ON - - Address=1

OFF OFF OFF OFF ON OFF - - Address=2

OFF OFF OFF OFF ON ON - - Address=3

OFF OFF OFF ON OFF OFF - - Address=4

OFF OFF OFF ON OFF ON - - Address=5

OFF OFF OFF ON ON OFF - - Address=6

OFF OFF OFF ON ON ON - - Address=7

OFF OFF ON OFF OFF OFF - - Address=8

OFF OFF ON OFF OFF ON - - Address=9

Figure 7. ZX CDU Intelligent Store Solution

Dip Switch Address Settings

Main Board Connector

7-Segment LEDs

Dip Switch

Setting

Reset Button

Message Recall
Button

JP3 Termination Resistor Jumper
ON: Termination Resistor is Enabled
OFF: Termination Resistor is Disabled

ModBus

Connector

XWeb

Connection

E2 Facility

Manager

D0

RS485+ RS485-

D1

RS485- RS485+

11

1 2 3 4 5 6 7 8

Set Address Address

OFF OFF ON OFF ON OFF - - Address=10
OFF OFF ON OFF ON ON - - Address=11
OFF OFF ON ON OFF OFF - - Address=12
OFF OFF ON ON OFF ON - - Address=13
OFF OFF ON ON ON OFF - - Address=14
OFF OFF ON ON ON ON - - Address=15
OFF ON OFF OFF OFF OFF - - Address=16
OFF ON OFF OFF OFF ON - - Address=17
OFF ON OFF OFF ON OFF - - Address=18
OFF ON OFF OFF ON ON - - Address=19
OFF ON OFF ON OFF OFF - - Address=20
OFF ON OFF ON OFF ON - - Address=21
OFF ON OFF ON ON OFF - - Address=22
OFF ON OFF ON ON ON - - Address=23
OFF ON ON OFF OFF OFF - - Address=24
OFF ON ON OFF OFF ON - - Address=25
OFF ON ON OFF ON OFF - - Address=26
OFF ON ON OFF ON ON - - Address=27
OFF ON ON ON OFF OFF - - Address=28
OFF ON ON ON OFF ON - - Address=29
OFF ON ON ON ON OFF - - Address=30
OFF ON ON ON ON ON - - Address=31

ON OFF OFF OFF OFF OFF - - Address=32
ON OFF OFF OFF OFF ON - - Address=33
ON OFF OFF OFF ON OFF - - Address=34
ON OFF OFF OFF ON ON - - Address=35
ON OFF OFF ON OFF OFF - - Address=36
ON OFF OFF ON OFF ON - - Address=37
ON OFF OFF ON ON OFF - - Address=38
ON OFF OFF ON ON ON - - Address=39
ON OFF ON OFF OFF OFF - - Address=40
ON OFF ON OFF OFF ON - - Address=41
ON OFF ON OFF ON OFF - - Address=42
ON OFF ON OFF ON ON - - Address=43
ON OFF ON ON OFF OFF - - Address=44
ON OFF ON ON OFF ON - - Address=45
ON OFF ON ON ON OFF - - Address=46
ON OFF ON ON ON ON - - Address=47
ON ON OFF OFF OFF OFF - - Address=48
ON ON OFF OFF OFF ON - - Address=49
ON ON OFF OFF ON OFF - - Address=50
ON ON OFF OFF ON ON - - Address=51
ON ON OFF ON OFF OFF - - Address=52
ON ON OFF

ON OFF ON - - Addres

s=53
ON ON OFF ON ON OFF - - Address=54
ON ON OFF ON ON ON - - Address=55
ON ON ON OFF OFF OFF - - Address=56
ON ON ON OFF OFF ON - - Address=57

12

1 2 3 4 5 6 7 8

Set Address Address

ON ON ON OFF ON OFF - - Address=58
ON ON ON OFF ON ON - - Address=59
ON ON ON ON OFF OFF - - Address=60
ON ON ON ON OFF ON - - Address=61
ON ON ON ON ON OFF - - Address=62
ON ON ON ON ON ON - - Address=63

Set Baud Rate Baud Rate

- - - - - - ON - 9.6Kbps

- - - - - - - OFF 19.2Kbps
Set Parity Parity

- - - - - - ON - Even Parity

- - - - - - - OFF No Parity

Network Wiring

Dixell XWEB300D Serial Address

Figure 8. Correct Network Wiring

Figure 9. Incorrect Network Wiring

• Connect to the ModBUS network using cable with 2 or 3 shielded wires, 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.

13

Termination Resistor for XWEB300D

ZX CDU Connected to XWEB300D

If XWEB300D is placed at the beginning or 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 the Dixell XWEB300D with the Intelligent Store Solution Module using RS485 ModBUS.

Connect the ZX CDU to the ModBUS network as shown in Figure 9. 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 “D0” of Intelligent Store Solution Module and port “12” of XWEB300D to
port “D1” of Intelligent Store Solution Module for RS485 communication.

Dixell XWEB300D Configuration

XWEB300D is compatible with ZX CDU firmware version 2.1.1 plus patch “Update_CDU-UNITS_(20121203)”.

• Go to Information → Information

• Check log update for “Update_CDU-UNITS_(20121203)”. If this is not present, follow the steps below.

• Go to Information → System Update menu

• Go to Information → Information for “Update_CDU-UNITS” string

•

Go to Configuration → Devices drop-down menu

• Go to Actions → New

• Enter device name in the Name field (e.g. ZX CDU)

• Select “ZXL-ECT_001” in the Model field

• Enter the ModBUS address in the RS 485 address field

o

Refer to section “Dip Switch Address Settings”

• Click New

• Go to Support → System sw update → XWEB300D XWEB500 XWEB500D

• Download the upgrade package

Login into XWEB

With your web-browser, login into XWEB

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

Log in again and set up the ZX CDU

Open Dixell website http://www.dixell.com/xweb300d-xweb500-xweb500d/eng/, then login (register required)

Figure 10. XWEB300D Connected to the Intelligent Store Solution Module

Dixell

XWEB

Main Control

Board

Intelligent

Store Solution

Module

Shielded

Cable

RS485-

RS485+

RS485-

RS485+

14

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.

Electrical wiring

Before commissioning, ensure that neutral “N” 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. For more details, see wiring
diagram in Appendix.

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.

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.

ZX ZXB ZXD ZXL

Model Weight (kg) Model Weight (kg) Model Weight (kg) Model Weight (kg)

ZX0200/E 76

ZXB015E

79 ZXD0400/E

2

104 ZXL0200/E 79

ZX0250/E 79

ZXB020E

81 ZXD0500/E

3

112 ZXL0250/E 81

ZX0300/E 79

ZXB025E

81 ZXD0600/E

4

114 ZXL0300/E 81

ZX0400/E

1

91

ZXB030E

93 ZXD0750/E

5

122 ZXL0350/E 93

ZX0500/E 108

ZXB035E

93 ZXL0400/E 93

ZX0600/E 112

ZXB040E

106 ZXL0500/E 106

ZX0750/E 118

ZXB050E

116 ZXL0600/E 116

ZX0760/E 121

ZXB055E(TBD)

121 ZXL0750/E 121

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 for models under 60 Hz TF7

5

127 kg for models under 60 Hz TF7

Codes HZ Phase Voltages

PFJ 50 1 220/240

TFD 50 3 380/420

TF7 60 3 380

TF5 60 3 200/230

2 2

1 1

max
300 Kg

Storag e Transport

max
300 Kg

max
300 Kg

Net Weight

Caution!

Unit should be powered on at all times except during service. 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 re­capped 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 e

nters 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 of oil and refrigerant. This is particularly important for the suction line. The suction line should ideally slope
gently towards the unit. Recommendation s

lope is 1/200~1/250. 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 (1/2 inch) 1.20 m

16.0mm (5/8 inch) 1.50 m

22.0mm (7/8 inch) 1.85 m

28.5mm (1 1/8 inch) 2.20 m

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 va

lves,

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.

• Be sure tube fitting inner diameter and 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.

• Use a double tip torch.

OUTSIDE INSIDE UNIT

End of tube

During brazing
protect housing with
damp cloth

During brazing
pull back fire
insulation

16

Location and Fixing

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 of 500 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.

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 e

vent 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.

Dual Fan Unit

4 to 7.6 HP

388

110

580

2-R7.5MM GROOVE

70

70

1242

500300

500

1029

23

172

90

300500

Liquid
Service Valve

Suction
Service Valve

Power
Supply Hole

424

94

352

2 Holes 15mm DIA

Single Fan Unit

2 to 4 HP

840

500

500

300

7070

23

1029

300500

Power
Supply Hole

Suction
Service Valve
Liquid
Service Valve

90

172

424

352

94

388

110

580

2-R7.5MM GROOVE

2 Holes 15mm DIA

Fixing dimensions and distances - Single fan unit

Fixing dimensions and distances - Dual fan unit

17

Start Up and Operation

Diagnostic Initialization Message (ZX-MT, ZXB-MT and ZXL-LT)

When the unit is initially powered on, the diagnostic module will show the following signals.

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 T

orr. 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
not 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. Three­phase compressors will rotate in either direction depending upon the phasing of the 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 ap

propriate 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 & 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.

• After starting and operation conditions are stabilized, it is recommended to check the oil level in compressor(s) and see

if there is a need to add oil to ensure a sufficient oil level (halfway up the sight glass).

(1 second)-

>

- Power On

- Unit Identification Code

- Software Version No.

(3 seconds)-

>

(3 seconds)-

>

“F”-With OD Fan Speed Control; “-”- W/O OD Fan Speed Control

“-” ZX; “L” ZXB & ZXL

LED 2

LED 1

18

Alarm Messaging - Digital Scroll Controller (ZXD)

Alarm Mode Set Points Controller Actions Reset Remarks

dLt

DLT >= dLt after dLd time

delay

- Compressors are turned off

Auto reset when DLT < dLt-dLH

E01L

Low pressure is lower than ELP

(Level 3 Parameter)

- Compressors are turned off

- Fans are unchanged

Auto reset when LP >= ELP(Level 3)

LP

E0L

Mechanical LP

switch opens

- Compressors are turned off

- Fans are unchanged

Auto reset when Number of
activations < PEn in PEi time

LP

Manual reset when Number of

activations >= PEn in PEi time

- Press

key for 3 sec or

- Turn off and on the unit

LP

C-LA

LP < LAL

- Signaling only

Auto reset when LP = LAL + delta (0.3bar)

LP

C-HA

LP >= HAL

- Signaling only

Auto reset when LP = HAL -delta (0.3bar)

LP

E0H

Mechanical HP

switch opens

- Compressors are turned off - Fans are
turned on

Auto reset when Number of activations

< PEn in PEi time

HP

Manual reset when Number of activations

>= PEn in PEi time

- Press

key for 3 sec or - Turn off

and on the unit

HP

F-HA

HP >= HAF

- HFC = yes, compressor are turned off

Auto reset when HAF + delta (0.3bar)

Cond Mid Temp.

P1

Suction Transducer failure or

out of range

- Compressors are activated according
to SPr or PoPr

Auto reset when probe is normal

LP

P2

Condenser Mid Coil Sensor

failure or out of range

- Fans are activated according to FPr

Auto reset when probe is normal

Cond Mid Temp.

P3

Discharge Temp Sensor failure

or out of range

-The functions related to No.3 probe
are disabled

Auto reset when probe is normal

DLT

DLT: Discharge line temperature
LP: Low pressure
HP: High pressure

LED1-Unit Status LED2-Error/Warning Code

Display Warning Signal

Controller
Pause Unit
Automatic

Reset

Controller

Lock Unit

Manual Reset

Display Status Display Error/Warning

Idle (Stop When
Reach To Set-point)

No error/warning

Run

Compressor Phase Error (Wrong Phase Sequence/Loss of
Phase)

Every Protection Action

Every Protec­tion Action

NA

About To Start Compressor Inside Thermal Protector Trip Every Protection Action NA NA

Defrost Compressor Over Current Every Protection Action

<5 times
Protec tion In
1 Hour

6th Protection
In 1 Hour

Stop Due to Error Overheat Every Protection Action

ZX: <3 times
Protection In 1
Hour
ZXL: Every
Protection

ZX: <4th
Protection In 1
Hour
ZXL: NA

Lockout Compressor High Pressure Cut Out Every Protection Action

<5 times
Protection In 1
Hour

6th Protection
In 1 Hour

Compressor Low Pressure Cut Out Every Protection Action

Every
Protection

NA

DLT Thermistors Failure Every Protection Action

<5 times
Protection In 1
Hour

NA

Ambient Temperature Sensor Failure Every Protection Action NA NA

Mid-coil Temperature Sensor Failure Every Protection Action NA NA

PHE Vapor In Temperature Sensor Failure or Over Range Every Protection Action NA NA

PHE Vapor Out Temperature Sensor Failure or Over Range Every Protection Action NA NA

System Liquid Flood Back Warning ~20% Liquid Back NA NA

Notes:

New start, normal start by program and any start request delay
“LP Cutout”signal is not applicable in ZXL condensing unit.
PHE Vapor In/Out temperature sensor is not applicable in ZX medium temperature condensing unit.

1

2

3

2

1

3

3

Diagnostic Messaging - LED Definition (ZX-MT, ZXB-MT and ZXL-LT)

19

ZX/ZXL Condensing Unit Wiring Diagram

PFJ: 220V-50 Hz -1Ph

ATTENTION: Unit MUST be grounded!

20

ZX/ZXL/ZXB Condensing Unit Wiring Diagram For BOM 481

TFD - 380/420V - 50Hz - 3Ph

TF7 - 380V - 60Hz - 3Ph

21

ZX/ZXL Condensing Unit Wiring Diagram

TFD: 380/420V - 50Hz - 3Ph

TF7: 380V - 60Hz - 3Ph

22

ZX/ZXL Condensing Unit Wiring Diagram

TF5: 220/230V - 50Hz/60Hz - 3Ph

23

ZXD Condensing Unit Wiring Diagram

(With Fan Speed Control Function)

R22 TFD: 380V/420V - 50Hz - 3Ph

ATTENT

ION: Unit MUST be grounded!

24

ZXD Condensing Unit Wiring Diagram

(With Fan Speed Control Function)

R22 TF7: 380V-60Hz-3Ph

11

13 15

12 N N

Terminal

Block

T1

L1

Aux 21N/C

22N/C

A1

A2

Blue

Blue

Red

Blue

Red

Contactor

Red

T2L2T3

L3

Yellow

Yellow

Circuit

Breaker

"I"

U
V
W

1
3 5

2 4 6

Fuse

(2A/250V)

Transformer

Output:

12VAC

COMP'R

1 2

Crankcase Heater

T1(U)

T2(V)

T3(W)

Internal motor

protector

E

Black

ATTENTION:Unit MUST be grounded!

Notes:

1. Dashed line " " is wired by installer.

2.

The connector-jumper(#16 & #17) must be

removed when the cold start connection is

necessary

.

Capacitor1

Black

E

M1

White

White

E

M2

Black

Capacitor2

White

White

Red

Black

N

N

Black

21 22

+ -

+ -

23 24

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Compressor DLT

Sensor

COND. Mid

Coil Temp.

Sensor

Pressure

Transducer

HP Switch

25 26

- +

27 28

- +

PWM Valve

LP Switch

Out

0~10V

4~20mA

Hot KeY / TTL

HP i2F

Pb3Pb1Pb2

LP
Id3 Id1

1 3

10 12

22
23
24

15 16

14

Brown

8

109

6

7

3 5

4

Input:

230VAC

Blue

Blue

Digital Scroll Controller

Fan Speed Controller

White

2

1

N N

ALARM LIGHT

Blue

16

17

Inj.Solenoid

Valve

Cold Start

Connection

Case Temp

Thermostat

Or

Liquid Line

Switch

25

ZXD Condensing Unit Wiring Diagram

(With Fan Speed Control Function)

R404A TF7: 380V-60Hz-3Ph

11

13 15
12 N N

Terminal

Block

T1

L1

Aux 21N/C

22N/C

A1

A2

Blue

Blue

Red

Blue

Red

Contactor

Red

T2L2T3

L3

Yellow

Yellow

Circuit

Breaker

"I"

U

V

W

1

3 5

2 4 6

Fuse

(2A/250V)

Transformer

Output:

12VAC

COMP'R

1 2

Crankcase Heater

T1(U)

T2(V)

T3(W)

Internal motor

protector

E

Black

ATTENTION:Unit MUST be grounded!

Notes:

1. Dashed line " " is wired by installer.

2.

The connector-jumper(#16 & #17) must be

removed when the cold start connection is

necessary

.

Capacitor1

Black

E

M1

White

White

E

M2

Black

Capacitor2

White

White

Red

Black

N

N

Black

21 22

+ - + -

23 24

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

Compressor DLT

Sensor

COND. Mid

Coil Temp.

Sensor

Pressure

Transducer

HP Switch

25 26

- +

27 28

- +

PWM Valve

LP Switch

Out

0~10V

4~20mA

Hot KeY / TTL

HP i2F

Pb3Pb1Pb2

LP

Id3 Id1

1 3 10 12

22

23

24

15 16

14

Brown

8

9 01

6

7

3

5
4

Input:

230VAC

Blue

Blue

Digital Scroll Controller

Fan Speed Controller

White

21

N

N

ALARM LIGHT

Blue

16

17

Cold Start

Connection

Case Temp

Thermostat

Or

Liquid Line

Switch

26

ZXD Condensing Unit Wiring Diagram

(Without Fan Speed Control Function)

TFD: 380V/420V-50Hz-3Ph

ATTENTION: Unit MUST be grounded!

27

General Information

Technical data are correct at the time of printing. Updates may occur, and should you need conrmation of a
specic 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, specications, 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 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 xed 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 ammable substances.

Emerson Climate Technologies cannot be held responsible for any damage caused by using these substances.

Asia 02 A01 10 – R01 Issued 08/2014 – GSCAA001

Emers
©2014 Emerson Climate Technologies, Inc. All rights reserved.

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