Emerson ZX Platform Condensing Unit, ZX Series, ZXL Series, ZXD Series Product Manual

ZX Platform Condensing Unit

Product Manual

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 more information, visit EmersonClimate.com.

Emerson’s nancial performance is embellished with a record of unmissed annual dividend for 55 consecutive years.

For FY11, Emerson was ranked No. 120 on Fortune 500, a list of America’s largest companies, and placed No. 1 in the

same list’s Electronics and Equipment category.

The company invested approximately $696 million in engineering, development and customer solutions development producing 773 patents worlwide from FY04 to FY10.

In 2010, 37% of the company’s global sales from new products are due to the application of innovative technologies.

Emerson Climate Technologies is pleased to offer the ZX platform refrigeration

condensing units (CDU) specically

designed for medium temperature (ZX-

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.

Index

Features and Value

ZX Design Platform .......................................................................................................................................................................................... 1

ZX Reliability Platform ...................................................................................................................................................................................... 1

ZX Performance Platform ................................................................................................................................................................................ 1

Standard Unit Features ..................................................................................................................................................................................... 2

ZX Platform Scroll Superiority .......................................................................................................................................................................... 3

Nomenclature .............................................................................................................................................................................................................. 4

Bill of Material (BOM) ................................................................................................................................................................................................... 4

Envelope

ZX Family: Medium Temperature ..................................................................................................................................................................... 5

ZXD Family: Digital Medium Temperature ...................................................................................................................................................... 5

ZXL Family: Low Temperature .......................................................................................................................................................................... 5

Physical Layout ............................................................................................................................................................................................................... 6

Application Guideline

Condensing Unit Handling............................................................................................................................................................................. 7

Installation .......................................................................................................................................................................................................... 8

Electrical Connection ....................................................................................................................................................................................... 9

Refrigeration Connections ............................................................................................................................................................................... 9

Vapor Injection Application Tip......................................................................................................................................................................... 9

Start Up And Operation .................................................................................................................................................................................... 10

Electronic Controller Assembly on a ZX Platform CDU

ZX/ZXL Controller Assembly …………………………………………………………………………………………………………………................................ 12

E2 Control Board ………………….………………………………………………………………………………........................................................ 14

E2 Control Board Dip Switch Setting ………………….……………………………………………………………………………............................ 15

Defrost Module Function Set .............................................................................................................................................................. 15

Diagnostic Initialization Message (ZX-MT and ZXL-LT ) ...................................................................................................................... 16

Diagnostic Messaging - LED Denition (ZX-MT and ZXL-LT ) .............................................................................................................. 16

E2 Controller Trip Set Points and Actions (ZX-MT and ZXL-LT Units) ………………………………………………….................................... 16

ZXD Controller Assembly ………………………..……………………………………………………………………………………………................................ 18

ZXD Electronic Controller ………………….………………………………………………………………………………………………………………… 19

Alarm Messaging - Digital Scroll Controller (ZXD) ........................................................................................……………………………. 23

Capacity and Power (kW)

ZX Family: Medium Temperature - R22

50 Hz ...........................................................................................................................................................……………………………...... 24

60 Hz ...............................................................................................................................................................…………………………….. 25

ZX Family: Medium Temperature - R404A/R507

ZXD Family: Digital Medium Temperature - R22

ZXD Family: Digital Medium Temperature - R404A/R507

ZXL Family: Low Temperature - R22

ZXL Family: Low Temperature - R404A/R507

Technical Data

ZX Family: Medium Temperature at 50 Hz - PFJ ...............................................................................................…………………………………...... 34

ZX Family: Medium Temperature at 50 Hz - TFD ...................................................................……………………………....................................... 35

ZX Family: Medium Temperature at 60 Hz - TF5/TF7 ..................................................................……………………………………………………… 36

ZXD Family: Digital Medium Temperature at 50 Hz - TFD .............................................................................................................................. 37

ZXD Family: Digital Medium Temperature at 60 Hz - TF7 ............................................................................................................................... 38

ZXL Family: Low Temperature at 50Hz - TFD ................................................................................................................................................... 39

ZXL Family: Low Temperature at 60Hz - TF5/TF7 ............................................................................................................................................. 40

Wiring Diagram ........................................................................................................................................................................................................... 41

Packing Information .................................................................................................................................................................................................... 46

Conversion Chart ............................................................................................................................................................................................................ 46

Pressure Temperature Chart at Sea Level ......................................................................................................................................................................... 47

Contact Lists .................................................................................................................................................................................................................... 49

ZX – Reliability Platform

Emerson Climate Technologies has designed the ZX platform CDUs with extended operational capability in tough climatic conditions. With our vast experience in the refrigeration industry, ZX platform CDU is designed with a good protection scheme. ZX protection scheme detect conditions that could cause damage to the compressor, initiates a warning, temporary shutdown and auto restarts. The control system will allow a complete shutdown requiring manual restart only after several iterations of repeated warnings and temporary shutdowns are carried out. The control system is driven by the built-in “E2 Controller”. Figure 02 shows the control strategy of the E2 Controller in a schematic form.

ZX – Performance Platform

Emerson Climate technologies with its leadership in scroll compression technology, apply the most advanced techniques to maximize

the possible operational efciency at specic application envelopes. ZX MT CDU applies a patented suction-line injection technology. Scroll compressor inherently operates at higher efciency at MT application conditions. The suction-line injection provides a more

reliable MT operating envelope.

ZX MT CDU applies ZX series scroll compressor with liquid injection into the suction-line using an electronic expansion valve (EXV). The EXV maintains an optimum feed of partially vaporized liquid refrigerant in the compressor suction to maintain a safe discharge gas temperature. The controlled discharge gas temperature provides a more reliable solution for the MT envelope.

ZXL LT CDU applies vapor injection technology to achieve higher efciency in LT refrigeration. Vapor injection allows an economizer cycle to be applied on a scroll compressor thereby greatly enhancing compressor efciency. This technology can be likened to 2- stage compression with economizer cycle. Vapor injection improves efciency by as much as 12% over a liquid injection system of the same

type. ZXL LT CDU applies ZXI series vapor injected compressor with vapor injection plate heat exchanger (PHE) to implement the vapor injection technology.

ZX – Design Platform

The ZX platform CDUs are designed to provide the best operational cost savings on a year around basis. Refrigeration equipment

operate continuously for7 days, 24 hours and 365 days. The ZX and

ZXI compressors, injection scheme and heat exchanger designs

are optimized to provide best efciencies at annual averaged

temperature rather than at typical rating conditions. The typical ambient on an annual basis follows a normal distribution pattern. The highest and lowest ambient happens only for few hours as

shown in gure 01.

Hours

Low Ambient High Ambient

Figure 01. Shows Annual Typical Ambient Pattern

Real Time Monitoring

Of CDU Conditions

Warning Mode

Temporary Shutdown,

Signal, Auto Restart

Lock Out Mode

Alarm, Dialer Relay

Activation, Manual Restart

Figure 02. Control Strategy of the E2 Controller

ZX Platform Condensing Unit was designed based on three factors demanded by industry users:

Energy Efficiency - Utilizing Copeland Scroll

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

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.

Flexibility - The slim shape and light weight make the ZX Condensing Unit aesthetically appealing and easy to install. The ultra

quiet variable-speed fan motor signicantly reduces exterior sound levels, allowing additional location exibility. Combined with wall mounting capability, the ZX Condensing Unit delivers unmatched exibility.

ZX Condensing Units are greatly suitable for walk-in cooler and freezer applications.

The advance scroll compressor technology, fan speed control and electronic controller are precisely collaborated in all units. It also introduces variable-speed fan motors that go beyond national standards. Guaranteed dependable performance and

operation in food service applications while conveying higher energy efciency and lower sound levels are the main objectives.

ZX Platform Condensing Unit

Figure 03. ZX Platform CDU Features

Standard Unit Features

• Pre-painted enclosures for corrosion protection.

• Heavy duty steel base with 23 mm raised legs.

• Brass service valves located externally for

easy access.

• Raised electrical access panel for easier

serviceability.

• Receivers with fusible plug, liquid shut-off valve

and charging port.

• Easy to read moisture indicator.

• Variable-speed PSC fan motors.

• Advanced performance alert diagnostics.

• Over-sized condenser coils with additional n

corrosion protection for coastal zones.

• Light weight, slim-line prole for maneuverability

and ease of installation.

• All units are factory tested for braze joint leaks,

wiring connections, electrical continuity and startup performance.

• Oil separator and accumulator standard on low

temperature models.

• Operating ambient is 48°C to -23°C*.

Proprietary Electronic Algorithms to Control Fan Speed, Optimizing Energy Performance for Local Seasonal Ambient Temperatures

Copeland Scroll Compressor Technology

• High Efciency

• Ultra Quiet

• High Reliability

Variable Speed PSC Fan Motors

• High Efciency

• Ultra Quiet

• Optimizes Air-

Flow for Maximum Heat Transfer

Oversized Condenser Coil for Maximum Heat

Transfer

• 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

Diagnostic

Digital

Messaging

Built-in ZX Platform

Controller

- Shuts down unit during failure

- With real time monitoring of compressor operating conditions

ZXD Series

ZX and ZXL Series

Diagnostic Protection Increased Reliability and Lower Maintenance Costs

Flexibility More Installation Options

Highest Efciency

Lower Energy Bills

ZX Platform – Scroll Superiority

Scroll compressors deliver atter capacity compared to reciprocating compressor condensing units due to the high volumetric efciency of scroll compressors. Flatter capacity can otherwise be described as lower change in capacity with change in outdoor ambient. This is

schematically shown in Figure 03. Flatter capacity brings certain inherent advantages, which highly benet users and stored products.

Some of the benets of atter capacity on ZX platform CDUs are described below.

1. Smaller unit selection: Condensing units are selected to match the required refrigeration capacity at the highest required

ambient. Flatter capacity allows a smaller unit selection compared to reciprocating compressor CDU.

Lower operating cost: At lower ambient conditions, ZX platform CDU delivers capacity closer to the cooling load. In

contrast, reciprocating compressor CDU delivers capacity in far excess of what is required. This helps the ZX platform CDU to

operate at relatively higher evaporating temperature. Higher evaporating temperatures improve compressor efciency. In

addition, higher evaporating temperature reduces the rate of ice formation on the evaporator coils/frost build-up. Lower frost

build-up improves the evaporator heat exchange efciency. It also reduces the defrost heat demand, thereby resulting in lower energy

needed for defrost.

Freshness of food: Another benet of higher evaporating temperature is reduced dehumidication by the evaporator coil.

This allows higher relative humidity in cold room or cold cases. Higher relative humidity reduces weight shrinkage and improves freshness of stored product.

Low Ambient High Ambient

Higher

Evaporating Temp

ZX Capacity

Reciprocating Capacity

Allows

Smaller Unit

Figure 04

Features Owner/Enterprise Benefit

Energy improvement (More than $350 per year) •Lower operating costs

Sound improvement

• Creating a more comfortable environment for guests

• Beneficial for regions with noise ordinances

Diagnostic protection capabilities

• Reduces cost of nuisance calls

• Extends life of your equipment

• Reduces potential service costs

• Maintains your equipment to original standards, maintaining energy efficiency and temperature control

• Have confidence in what your contractor is fixing

Slim profile, lighter weight, and optional wall mount capability

• Lower installation costs

• Improved appearance of your enterprise site

• Avoids more costly solutions for potential location issues

*For applications outside these guidelines, please contact Application Engineering.

ZX Platform Condensing Unit

Nomenclature

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

Unit Family

= Medium Temp

L = Low Temp

D = Digital Medium Temp

2.0 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

TF7=380 - 3ph - 60 Hz

Bill of Material

Base Model Electrical Code Bill of Material

BOM

CDU Family ZX ZXL ZXD

BOM 401 451 451 461 471 450 451 461

Liquid Line Filter Dryer/Sight Glass

Oil Separator

Accumulator

Adjustable LP Switch

Fixed LP Switch

E2 Controller

Diagnostic Module

Buzzer

Digital Scroll Controller

Fan Speed Controller

Circuit Breaker

Sound Jacket

Defrost Module ACC ACC ACC ACC

Filter Drier V

Notes: E2 controller has fan speed control function

“V” indicates are type connection

“ACC” indicates accessory

Envelope

ZX Family : Medium Temperature

Refrigerant –R404A/ R507, R22 Maximum Suction Gas Temperature: 20

R404A/ R507

R22 Except ZX0750

Ambient Temperature

-20-15 125

Evaporating Temperature0C

Fan Speed Control Function For Ambient Lower Than 100C

ZX Medium Temperature at 50 Hz - PFJ / TFD

Note : For model ZX0750 Max Amb: 43°C , Max Evap: 5°C

Fan Speed Control Option

For Ambient Lower Than 10

Refrigerant –R404A/ R507, R22 Maximum Suction Gas Temperature: 20

Ambient Temperature

2101-51-02- 50

Evaporating Temperature0C

ZXD Digital Medium Temperature at 50 Hz - TFD

at 60 Hz - TF7

Note : For model ZXD075/E Max Amb: 43°C , Max Evap: 5°C

R404A/ R507 18°C RGT

R404A/ R507 10K SH

R22 10K SH

ZXD Family : Digital Medium Temperature

Refrigerant –R404A/ R507, R22 Maximum Suction Gas Temperature: 20

R404A/ R507

R22 Except ZX0750

Ambient Temperature

-20-15 125

Evaporating Temperature0C

Fan Speed Control Function For Ambient Lower Than 10

ZX Medium Temperature at 50 Hz - PFJ / TFD

Note : For model ZX0750 Max Amb: 43°C , Max Evap: 5°C

Refrigerant –R404A/ R507, R22 Maximum Suction Gas Temperature: 20

R404A/ R507

R22

Ambient Temperature

551-02-

Evaporating Temperature0C

Fan Speed Control Function For Ambient Lower Than 100C

ZX Medium Temperature at 60 Hz - TF5/7

ZXL Family : Low Temperature

051-04-

C Ambient

051-04-

C Ambient

Refrigerant –R404A/ R507, R22 Maximum Suction Gas Temperature: 20

ZX Platform Condensing Unit

Physical Layout of the ZX Platform CDU

The unique features of ZX platform CDU as described above are quite different from the conventional CDUs available in the market. Apart from this, ZX platform CDU also comes with a package of other conventional features which are part of a well designed condensing unit.

ZX- MT, ZXL-LT E2 Controller ZXD Digital Scroll Controller

Scroll Compressor

Figure 05: Identies the electronic controller assembly on a ZX Platform CDU

Figure 06: 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

ZXI Vapor Injected Scroll Compressor

Vapor Injection control EXV

Vapor Injection Tube To Compressor

Vapor/ Liquid Sub Cooling PHE

Condensing Unit Handling

Transport and Storage

Move ZX/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.

Application Guideline

In ZX MT units, suction line injection is applied to the compressor suction. Suction line injection allows a reliable and efcient MT

envelope of up to -15°C (R22) and -20°C (R404A) evaporating temperature. In suction line injection, a part of liquid refrigerant is

added into the compressor suction gas. Suction injection de-superheats the suction gas and controls the compressor discharge temperature. This is implemented through electronic control by the E2 controller and an electronic expansion valve (EXV). The E2 monitors the compressor discharge temperature and optimizes the opening of the EXV for optimal discharge gas control.

In ZXL LT units, vapor injection is applied to the compressor. Vapor injection enhances the compressor efciency by applying 2-stage

compression with an economizer refrigeration cycle. Vapor injection eliminates the need for liquid injection, which would otherwise have been required to operate a reliable LT envelope down to -40°C evaporating temperature. In vapor injection, a part of liquid refrigerant is expanded and passed through a heat exchanger. In the heat exchanger, this expanded refrigerant absorbs heat from the main liquid line and sub-cool the main liquid. The expanded refrigerant vaporizes while passing through the heat exchanger and is supplied back into the scroll intermediate pockets through the vapor-injection tube. The sub-cooling of the main liquid increases the

compressor capacity by as much as 30%. The gure 14 below identies the key components of the vapor injection assembly.

Figure 07: Key Components Of The Vapor Injection Assembly

max 300 Kg

Storage

Transport

max 300 Kg

Net Weight

ZX ZXD ZXL

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

ZX0200/E 76 ZXD0400/E

104 ZXL0200/E 79

ZX0250/E 79 ZXD0500/E

112 ZXL0250/E 81

ZX0300/E 79 ZXD0600/E

114 ZXL0300/E 81

ZX0400/E

91 ZXD0750/E

122 ZXL0350/E 93

ZX0500/E 108 ZXL0400/E 93

ZX0600/E 112 ZXL0500/E 106

ZX0750/E 118 ZXL0600/E 116

ZX0760/E 121 ZXL0750/E 121

Notes: 1 100 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

121 kg for models under 60 Hz TF7

127 kg for models under 60 Hz TF7

ZX Platform Condensing Unit

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 ns. The unit must be installed without restricting the airow. A clogged condenser will increase the condensing temperature, thus reduce the cooling capacity, and lead to a high-

pressure switch tripping. Clean the condenser ns on a regular basis.

Installation / Piping Instructions

It is recommended that a clearance of 8 inches from the wall (or the next unit) be maintained from the unit’s left and rear panel whereas

a clearance of 20 inches is to be maintained from the unit’s right, top and front panels. Both service access and air ow have been

considered in making these recommendations. Where multiple units are to be installed in the same location, careful consideration for proper clearance needs to be given to each individual unit.

Ideally, the unit should be mounted level on a solid concrete slab with rubber strips between unit feet and concrete. However, these units have been designed for mounting on suitable brackets for wall mounting. In this case it is equally important that the spatial guidelines given above are followed, and additional consideration needs to be given for possible air recycling if units are stacked above and below each other. In general terms, air by-pass around each condenser and between each unit should be avoided at all times.

Pipe sizing should not only be of sufcient size to ensure optimum performance and good oil return, but it also needs to take into

account the full capacity range through which this particular unit will need to operate. Follow the ASHRAE guidelines for proper piping practices.

Location and Fixing

The unit should always be installed in a location that ensures clean air ow. 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 airow 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 nding 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 ow through the condenser can be impeded, causing high condensing temperatures ultimately resulting in reducing unit life. A bafe is a remedy for this situation.

Dual Fan Unit

4 to 7.6 HP

388

110

580

2-R7.5MM GROOVE

1242

500300

500

1029

172

300500

Liquid Service Valve

Suction Service Valve

Power Supply Hole

424

352

2 Holes 15mm DIA

Single Fan Unit

2 to 4 HP

840

500

300

7070

1029

300500

Power Supply Hole

Suction Service Valve Liquid Service Valve

172

424

352

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

Electrical Connection

Power Supply

The ZX condensing unit electrical connection to the power

supply must be made by qualied 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 the 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.

Refrigeration Connections

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

1/200~1/250. 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.

ZXL Liquid Line Insulation

ZXL liquid line should be insulated with a 19 mm insulation thickness. Temperature could be as low as –15°C.

Codes HZ

Phase

Voltages

PFJ 50

220/240

TFD 50

380/420

TF7 60

380

TF5 60

200/230

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

Typical Liquid Line Temperature oC

R22 Ambient °C

Evap Temp oC 20 27 32 38 43 48

-40 -11 -3 7 7 11 14

-35 -8 -1 9 9 13 16

-30 -4 2 12 12 16 19

-25 0 5 14 14 19 23

-20 5 9 18 18 22 26

R404A Ambient°C

Evap Temp °C 20 27 32 38 43 48

-40 -8 -1 3 8 13 19

-35 -4 2 6 11 15 21

-30 0 6 9 13 18 23

-25 5 10 13 17 21 26

-20 9 14 17 20 24 30

ZXL-LT Unit (Liquid Line Temperature)

Vapor Injection: Specic Application Tips

ZXL-LT CDU

ZXL-LT CDU applies vapor injection technology. As explained in the previous section, vapor injection improves LT operational

efciency and provides a reliable LT envelope. Vapor injection sub cools the main liquid line using the economizer cycle. The sub cooling of liquid line calls for some specic application tips which are applicable only for ZXL-LT CDU. They are;

1. Liquid line pipe connecting the CDU service valve to the evaporator expansion valve has to be well insulated separately. The

recommended insulation thickness is 12.5 mm (1/2 inches)

2. The lower liquid in temperature can increase the evaporator expansion valve capacities. Please follow valve manufactures recommended liquid temperature correction factors for proper selection of evaporator expansion valve.

ZX Platform Condensing Unit

OUTSIDEINSIDE UNIT

End of tube

During brazing protect housing with damp cloth

During brazing pull back fire insulation

Start Up and 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 insufcient suction gas. Sufcient 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 tting 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

ZX CDUs are delivered with a full oil charge in both the compressor and the oil separator. The oil level should be visible in the compressor sight glass. All systems will trap some oil and in some cases it may be necessary to add oil if pipes are long, if the vertical rise is high and if the piping is not well designed. The oil level should be monitored carefully during commissioning, checked after 4 – 8 hours and checked again after 24 hours of normal operation. The ideal oil level is between ¼ and ¾ sight glass level but if any oil is visible in the sight glass the compressor can operate safely. If oil is not visible in the sight glass proceed as follows:

1. Perform a manual defrost on all evaporators simultaneously.

2. Operate the compressor (at 100% load for ZXD) for 5 minutes after defrost is complete. The unit will automatically tend to

operate (at 100% load for ZXD) after defrost as the evaporators recover their set-point temperatures.

3. Check that the oil level is at ¼ sight glass or higher but not over the top of the sight glass.

4. If oil is not visible add oil until the level reaches the ¾ sight glass level.

Brazing Recommendations

Maintain a ow 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.

• Be sure that tube tting 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 ux coated or with a separate coating.

• Use a double tip torch.

Typical Values With Individual Values Within +/-5oC Note: ZXL CDU is designed with vapor injection technology. The condenser liquid line temperature will be sub cooled by the vapor injection plate heat exchanger.

R22 Ambient °C

-15 10 13 21 21 25 30

-10 15 17 25 25 29

-5 20 22 29 29 33 0 26 26 33 33 37

R404A Ambient°C

-15 13 18 21 24 28 34

-10 16 22 25 29 33

-5 20 26 29 33 37 0 23 29 33 38 42

Adding Oil

The simple and ideal way to add oil is to pump the oil into the suction side when the unit is running. Discharge pressure from the unit or refrigerant pressure from a cylinder can be used to force oil into the suction side. The oil will go directly into the compressor and the level increase will be immediate.

NEVER CLOSE THE UNIT SUCTION VALVE AND USE THE COMPRESSOR TO SUCK OIL FROM A CONTAINER THAT IS AT ATMOSPHERIC PRESSURE. THIS COULD DESTROY THE SCROLL COMPRESSOR IN A MATTER OF SECONDS.

Tools required: Manifold gauge set and hoses, oil tank of ~ 1 litre volume with suitable connections, oil, refrigerant.

Qualified Refrigerants And Oil

REFRIGERANT OIL

R404A/507 Emkarate RL 32 3MAF Mobil EAL Artic 22 CC

R22 Suniso 3GS

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

ZX ZXD ZXL

Model BOM Model BOM Model BOM

401 451 ALL ALL

ZX0200/E 1.18 1.68 ZXL0200/E 1.06 ZX0250/E 1.33 1.83 ZXL0250/E 1.06 ZX0300/E 1.33 1.83 ZXL0300/E 1.06

ZXL0350/E 1.74 ZX0400/E 1.83 2.33 ZXD0400/E 1.74 ZXL0400/E 1.74 ZX0500/E 1.83 2.33 ZXD0500/E 2.27 ZXL0500/E 1.74 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

Scroll Compressor Rotation Direction

Rotation Direction of Three Phase Scroll Compressors will only compress in one rotational direction. 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 phasing of the power. Since there is a 50-50 chance of connecting power in

such a way as to cause 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. Verication of proper rotation direction

is made by observing that suction pressure drops and discharge pressure rises when the compressor is energized. Reverse rotation of a

scroll compressor also results in substantially reduced current draw compared to specication sheet values. Suction temperature will be

high, discharge temperature will be low and the compressor may be abnormally noisy. There is no negative impact on durability caused by operating three phase Copeland Scroll compressors in the reversed direction for a short period of time (under one hour). After several minutes of operation in reverse, the compressor’s motor protection system will trip the compressor off. If allowed to repeatedly restart and run in reverse without correcting the situation, the compressor will be permanently damaged. All three phase scroll compressors are

identically wired internally. As a result, once the correct phasing is determined for a specic system or installation, connecting properly

phased power leads to the same terminals will maintain proper rotation direction.

Brief Power Interruptions

Brief power interruptions (less than ½ second) may result in powered reverse rotation of single-phase refrigeration scroll compressors. High-pressure discharge gas expands backward through the scrolls at power interruption causing the scroll to orbit in the reverse direction. If power is reapplied while this reversal is occurring, the compressor may continue to run noisily in the reverse direction for several minutes until the compressor internal protector trips. This has no negative effect on durability. When the protector resets, the compressor will start and run normally.

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 oil level in the compressor(s) and see if there

is a need to add oil to ensure a sufcient oil level (halfway up the sight glass).

ZX Platform Condensing Unit

Fault Temporary Shutdown/Auto Restart Lock Out Errors/Manual Restarts

Phase Reversal/ Loss Of Phase Incorrect 3 Phase Sequence

High Pressure Trip < 5 Trips In 1 Hour 6th Trip Within 1 Hour

Low Pressure Trip (only on MT Units) At Every LP Trip No Lock Out

Discharge Gas Temperature Overheat < 5 Trips In 1 hour 6th Trip Within 1 Hour

Compressor Over Current < 5 Trips In 1 Hour 6th Trip Within 1 Hour

Compressor Short Cycling 3 Minutes Between Starts No Lock Out

Excessive Suction Flood Back ~ 20% Flood Back, Warning Only No Lock Out

Discharge Sensor Failure (only on LT Units) < 5 Trips In 1 Hour 6th Trip Within 1 Hour

Other Thermal Sensor Failures Warning Only No Lock Out

Table 02

E2 Fault Detection Items

* Compressor Phase Reversal

* Loss of Phase (In 3 Phase Models)

* Compressor Over Current

* Compressor Protector Trip Detection

* Discharge Gas Temperature Over Heat

* High Pressure Cut Out

* Low Pressure Cut Out (MT CDU Only)

* Excessive Refrigerant Flood Back

*Compressor Minimum Off Time

* E2 Sensor Failures

Table 01

Electronic Controller Assembly on a ZX Platform CDU

ZX/ZXL Controller Assembly

ZX platform E2 control offers multiple features which are unique to refrigeration condensing units. E2 real-time control monitors and

optimizes the suction or vapor injection performance to offer efcient performance in ZX MT and LT units. E2 also monitors compressor

operating parameters, so as to protect the system from unsafe operating parameters such as passing through a peak temperature hour

of a peak ambient day; or drop-out of a power-phase; or continued refrigerant loss in the system. E2 controller detects these situations and, as a rst step, will initiate some corrective actions.

For example, when the LT unit experiences an extreme temperature day, E2 control decides to switch from vapor-injection-optimization to discharge-gas temperature-control to allow the compressor to run safely and pass the extreme weather hours.

Another fault condition which is common in refrigeration systems is compressor overload. If the condenser coils are not cleaned regularly, the compressor operating discharge pressures rises. This condition is gradual and in conventional CDUs, no advance warning is provided to the user on this approaching undesirable situation. Ultimately, in such a situation, the internal protector in the compressor trips. Two problems arise due to internal protector-trip. First: there is no alarm to detect the trip and second: a compressor internal protector reset may take as long as an hour. This could be critical for the quality of frozen food in freezers or cases. On the other hand, ZXL E2 controller detects the overload externally and actions a temporary shutdown. E2 Diagnostics will then start transmitting a fault

signal. After multiple attempts, and if the error repeats itself as high as six times within an hour, the E2 will nally shutdown the unit to

avoid expensive compressor failure.

The E2 will activate a buzzer to send an alarm signal at unit-lockout which then requires a manual restart. The buzzer is a standard part of the ZX platform Gold version CDU . The buzzer can be remotely mounted and has volume and mute capability. The E2 is also designed to activate an externally connected telephone dialer to send fault notice on a preset telephone number.

ZX platform units are designed to operate under extreme ambient temperatures of up to 48°C. This extremely high-ambient envelope,

combined with the intelligent E2 controller, provides unparalleled benets to customers.

The E2 control is also designed to apply a ZX defrost (DF) module. The ZX DF module is a basic time initiated DF module and is supplied as an optional accessory. The DF module has two rotary switches by which the user can set up the defrost duration and defrost interval. The DF module also enables a manual defrost as an override to the rotary switch setting of defrost interval.

The E2 controller consists of two electronic board assemblies: E2 power board and control board. The power board supplies constant DC power to the E2 control board. The E2 control board carries the intelligent chip containing the canned programs. The entire assembly is pre-installed and wired in the factory on a new unit. Both electronic boards carry a LED light . If the LED lights are on after power-up of the unit, it indicates normal and proper operation of the electronic boards. Once these lights are on, the rest of the unit including the compressor is monitored and digital messages are shown on the diagnostic panel.

Table 01 shows a list of fault detections enabled by E2 controller and diagnostics on ZX platform CDU. The diagnostics are standard features on the Emerson ZX platform Gold version.

Table 02 summarizes fault conditions under which the E2 controller initiates “temporaryshutdown—with-auto-restart” and “lock-out trip-condition with- manual-restart.”

2-Bit Dip Switch

3-Bit Dip Switch

Rotary Switch

E2 Control Board

Power Isolation Switch

E2 Power Board

Compressor Contactor

Diagnostic Module

Fuse Holder Electrical Cable connectors

Defrost Module (optional)

Defrost Duration (in Minutes)

Defrost Interval (In Hours)

E2 Connector

Manual Defrost

Button

Remote Connector For Manual Defrost

Remote Buzzer

With Volume

E2 Display Diagnostic

Remote Buzzer

With Volume

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Emerson ZX Platform Condensing Unit, ZX Series, ZXL Series, ZXD Series Product Manual

Specifications and Main Features

Frequently Asked Questions

User Manual