Emerson ZXME020E, ZXME025E, ZXME030E, ZXME040E, ZXME050E Application Guidelines
...
Application Guidelines
Copeland EazyCool
™
Outdoor Condensing Units
ZX Range
C6.1.6/1017-1219/E
About these guidelines ................................................................................................ 1
1 Safety instructions ............................................................................................ 1
1.1 Icon explanation ................................................................................................................. 1
1.2 Safety statements .............................................................................................................. 1
1.3 General instructions ........................................................................................................... 2
2 Product description .......................................................................................... 3
2.1 General information about Copeland EazyCool™ ZX condensing units ........................... 3
2.2 EU Ecodesign Directive 2009/125/EC ............................................................................... 3
2.3 Main product features ........................................................................................................ 3
2.4 Product nameplate ............................................................................................................. 5
2.5 Nomenclature ..................................................................................................................... 6
2.6 Application range ............................................................................................................... 6
2.6.1 Qualified refrigerants and oils ................................................................................ 6
2.6.2 Application limits ..................................................................................................... 7
2.7 Bill of material .................................................................................................................... 7
2.8 P&I diagrams ..................................................................................................................... 8
2.8.1 ZXME units ............................................................................................................. 8
2.8.2 ZXLE units .............................................................................................................. 9
2.8.3 ZXDE units ........................................................................................................... 10
2.9 Main components description .......................................................................................... 11
2.9.1 Compressor .......................................................................................................... 11
2.9.2 Condenser fan(s) .................................................................................................. 11
2.9.3 Housing ................................................................................................................ 11
2.10 XCM25D Electronic controller – Features ....................................................................... 12
2.10.1 Description ........................................................................................................... 12
2.10.2 Functionalities ...................................................................................................... 13
2.10.3 Modbus communication ....................................................................................... 13
2.10.4 Main control & safety features .............................................................................. 14
2.10.5 Additional features for customization ................................................................... 15
2.11 XCM25D Electronic controller – Programming ................................................................ 20
2.11.1 Programming the local display ............................................................................. 20
2.11.2 Remote display CCM60 ....................................................................................... 21
2.11.3 Single commands ................................................................................................. 21
2.11.4 Double commands – Entering programming level 1 "Pr1" ................................... 22
2.11.5 How to program the parameters (Pr1 and Pr2) .................................................... 22
2.11.6 Entering programming level 2 "Pr2" ..................................................................... 22
2.11.7 Fast access menu ................................................................................................ 23
2.12 Controller keyboard .......................................................................................................... 23
2.12.1 How to lock the keyboard ..................................................................................... 23
2.12.2 How to unlock the keyboard ................................................................................. 23
2.13 Parameters level 1 – Required settings ........................................................................... 24
C6.1.6/1017-1219/E
2.14 Digital operation ............................................................................................................... 24
2.15 Pumpdown mode ............................................................................................................. 25
2.15.1 External pumpdown without XCM25D integration (not available on ZXDE units) 25
2.15.2 Pumpdown by the unit controller (not available on ZXDE units) .......................... 25
2.15.3 Pumpdown with room thermostat (not available on ZXDE units)......................... 26
2.15.4 Internal pumpdown with temperature sensor (case temperature) ....................... 26
2.16 Reset to factory settings – Emerson "Hot Key" ............................................................... 28
2.16.1 How to save factory settings or user settings ...................................................... 28
2.16.2 Applicable hot key for ZX units with XCM25D controller ...................................... 28
2.16.3 Location of the "Hot Key" plug connection on the XCM25D controller ................ 28
2.16.4 How to program a "Hot Key" from the controller (upload) .................................... 28
2.16.5 How to program a controller using an Emerson "Hot Key" (download) ............... 29
2.17 Troubleshooting – Alarm history ...................................................................................... 29
2.18 Compressor motor protection .......................................................................................... 30
2.19 System pressure protection ............................................................................................. 30
2.19.1 High-pressure safety switch ................................................................................. 30
2.19.2 High pressure: pressure relief valve ..................................................................... 30
2.19.3 Low-pressure safety switch – Optional ................................................................ 30
2.20 Other inputs of the XCM25D controller ............................................................................ 30
2.20.1 Customer-supplied control (room thermostat)...................................................... 30
2.20.2 Case temperature controller ................................................................................. 30
2.20.3 Ambient temperature sensor ................................................................................ 31
2.21 Alarm output (DO5) of the XCM25D controller ................................................................ 31
3 Installation ....................................................................................................... 32
3.1 Condensing unit handling ................................................................................................ 32
3.1.1 Transport and storage .......................................................................................... 32
3.1.2 Weights................................................................................................................. 32
3.2 Refrigeration piping connections ..................................................................................... 32
3.2.1 Refrigeration piping installation ............................................................................ 32
3.2.2 Brazing recommendations.................................................................................... 34
3.2.3 Brazing procedure ................................................................................................ 34
3.3 Electrical connection ........................................................................................................ 35
3.3.1 Power supply connections.................................................................................... 35
3.3.2 Maximum operating currents for cable selection ................................................. 35
3.3.3 Electrical wiring .................................................................................................... 36
3.3.4 Electrical protection standard (protection class) .................................................. 36
3.3.5 Main fuses ............................................................................................................ 36
3.4 Location & fixings ............................................................................................................. 37
4 Start-up & operation ........................................................................................ 39
4.1 Evacuation ....................................................................................................................... 39
4.2 Charging procedure ......................................................................................................... 39
C6.1.6/1017-1219/E
4.2.1 Refrigerant charging procedure ........................................................................... 39
4.2.2 Oil charging procedure ......................................................................................... 40
4.2.3 Oil separator ......................................................................................................... 40
4.3 Rotation direction of Scroll compressors ......................................................................... 40
4.4 Maximum compressor cycle ............................................................................................ 41
4.5 Checks before starting & during operation ...................................................................... 41
5 Maintenance & repair ...................................................................................... 42
5.1 Replacing a compressor .................................................................................................. 42
5.2 Condenser fins ................................................................................................................. 42
5.3 Electrical connections ...................................................................................................... 42
5.4 Routine leak testing ......................................................................................................... 43
5.5 Condenser fan(s) & motor(s) ........................................................................................... 43
6 Certification & approval .................................................................................. 43
7 Dismantling & disposal ................................................................................... 43
DISCLAIMER ............................................................................................................... 43
Appendix 1: Overview of the ZX unit components ................................................... 44
Appendix 2: Wiring diagram – ZXME / ZXLE / ZXDE units (380-420V / 3 Ph / 50 Hz)45
Appendix 3: Wiring diagram – ZXME / ZXLE units (230V / 1 Ph / 50 Hz) ................. 46
Appendix 4: Parameters level 1 ................................................................................. 47
Appendix 5: Alarm menu ............................................................................................ 48
Appendix 6: Additional features for customization .................................................. 53
Appendix 7: Temperature / resistance curve for B7 Sensor (customer option) ..... 57
Appendix 8: List of tables and figures ...................................................................... 58
C6.1.6/1017-1219/E 1
About these guidelines
The purpose of these application guidelines is to provide guidance in the application of Copeland
EazyCool™ ZX outdoor refrigeration condensing units. They are intended to answer the questions
raised while designing, assembling and operating a system with these products.
Besides the support they provide, the instructions listed herein are also critical for the proper and
safe functioning of the condensing units. The performance and reliability of the product may be
impacted if the product is not used according to these guidelines or is misused.
These application guidelines cover stationary applications only. For mobile applications, contact
Application Engineering as other considerations may apply.
1 Safety instructions
Copeland EazyCool™ ZX outdoor refrigeration condensing units are manufactured according to the
latest European safety standards. Particular emphasis has been placed on the user's safety.
These condensing units are intended for installation in machines and systems according to the
Machinery Directive MD 2006/42/EC. They may be put to service only if they have been installed in
these systems according to instructions and conform to the corresponding provisions of legislation.
For relevant standards please refer to the Manufacturer’s Declaration, available at
www.climate.emerson.com/en-gb.
These instructions should be retained throughout the lifetime of both the compressor and the
condensing unit.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to avoid
property damage and possible
personal injury.
High voltage
This icon indicates operations with a
danger of electric shock.
IMPORTANT
This icon indicates instructions to avoid
malfunction of the compressor.
Danger of burning or frost burn
This icon indicates operations with a
danger of burning or frost burn.
NOTE
This word indicates a recommendation
for easier operation.
Explosion hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
▪ Refrigerant compressors must be used in accordance with their intended use.
▪ Only qualified and authorized HVAC or refrigeration personnel are permitted to install,
commission and maintain this equipment.
▪ Electrical connections must be made by qualified electrical personnel.
▪ All valid standards for connecting electrical and refrigeration equipment must be
observed.
▪ The national legislation and regulations regarding personnel protection must be
observed.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn where
necessary.
2 C6.1.6/1017-1219/E
1.3 General instructions
WARNING
System breakdown! Personal injuries! Never install a system in the field
and leave it unattended when it has no charge, a holding charge, or with the
service valves closed without electrically locking out the system.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
WARNING
High shell temperature! Burning! Do not touch the compressor until it has
cooled down. Ensure that other materials in the area of the compressor do not
get in touch with it. Lock and mark accessible sections.
CAUTION
Overheating! Bearing damage! Do not operate compressors without
refrigerant charge or without being connected to the system.
CAUTION
Contact with POE! Material damage! POE lubricant must be handled
carefully and the proper protective equipment (gloves, eye protection, etc.)
must be used at all times. POE must not come into contact with any surface
or material that it might damage, including without limitation, certain polymers,
eg, PVC/CPVC and polycarbonate.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
The contractor is responsible for the installation of the unit and should check the following points:
▪ Sufficient liquid sub-cooling in the line to the expansion valve(s) to avoid "flash-gas" in the liquid
line;
▪ Sufficient amount of oil in the compressor (in case of long piping additional oil must be charged).
C6.1.6/1017-1219/E 3
2 Product description
2.1 General information about Copeland EazyCool™ ZX condensing units
Emerson has developed the Copeland EazyCool™ ZX outdoor condensing unit of second generation
to meet primarily the demands of the food retail and food service sectors. It is a refrigeration aircooled condensing unit that uses the latest Copeland™ brand products patented Scroll technology
as the main driver and has electronic protection and diagnostics features built in the compact chassis.
The combination of large condensers and low speed fans allows for particularly quiet operation.
2.2 EU Ecodesign Directive 2009/125/EC
The European Directive 2009/125/EC with regard to ecodesign requirements for professional
refrigerated storage cabinets, blast cabinets, condensing units and process chillers requires
manufacturers to decrease the energy consumption of their products by establishing minimum
energy efficiency standards. Copeland™ brand products condensing units are prepared and
optimized to meet the requirements of the Ecodesign Directive. The integrated variable speed fan
and condenser reduce the noise level and energy consumption significantly. This, combined with
Copeland scroll technology, allows for high-efficiency operation.
For the rated cooling capacity, rated power input and rated COP value please refer to Copeland™
brand products Select software at www.climate.emerson.com/en-gb.
These guidelines meet the requirements of Regulation 2015/1095, Annex V, section 2(a), with regard
to product information, namely:
▪ (v) ➔ See chapter 2.6 "Application range"
▪ (vi) ➔ See chapters 5.2 "Condenser fins" and 5.4 "Routine leak testing"
▪ (vii) ➔ See chapters 2.10.4 "Main control & safety features" and 4.2 "Charging procedure"
▪ (viii) ➔ See chapter 7 "Dismantling & disposal"
2.3 Main product features
Copeland EazyCool ZX condensing units are released for multiple refrigerants. They are available in
two cabinet sizes and are equipped with one or two fans.
Depending on the compressor in use they are designed for medium-temperature or low-temperature
refrigeration applications.
4 C6.1.6/1017-1219/E
Unit
Refrigerant
types
Displacement
@ 50 Hz
[m3/h]
Cooling
capacity*
[kW]
Nominal
power
[kW]
Rated
current
[A]
PS
high side
[bar]
PS
low side
[bar]
Medium temperature standard
TFD
PFJ
ZXME020E
R404A, 407A,
R407F, R507,
R448A, 449A
R134a,
R450A
& R513A
5.9
3.42
1.58
5.4
13.3
28.8
21
ZXME025E
6.7
3.89
1.66
5.2
12.9
ZXME030E
8.6
5.05
2.28
7.7
16.9
ZXME040E
11.7
6.58
3.29
10.8
24.0
ZXME050E
14.4
8.77
3.79
13.8
ZXME060E
17.1
10.05
4.41
14.1
ZXME075E
18.8
11.6
5.07
15.0
Medium temperature Digital
TFD
ZXDE030E
R404A,
R407A,
R407F, R507,
R448A, R449A
R134a, R450A
& R513A
8.3
5.13
2.21
7.2
ZXDE040E
11.4
7.21
2.72
8.9
ZXDE050E
14.4
8.65
3.67
12.3
ZXDE060E
17.1
10.1
4.46
12.4
ZXDE075E
18.8
11.4
4.83
15.0
Low temperature standard
TFD
PFJ
ZXLE020E
R404A, 407A,
R407F, R507,
R448A,
R449A
6.1
1.46
1.77
6.2
14.1
ZXLE025E
7.1
1.81
2.00
16.1
ZXLE030E
8.0
2.06
2.17
7.2
18.3
ZXLE040E
12.7
3.16
3.72
9.7
ZXLE050E
14.4
3.62
4.00
12.9
ZXLE060E
17.1
4.56
5.33
14.7
ZXLE075E
18.8
5.11
5.31
15.6
* Operating conditions for ZXDE, ZXME: R448A/R449A; Tevap = -10°C; Tamb = 32°C; suction gas = 20°C
* Operating conditions for ZXLE: R448A/R449A; Tevap = -35°C; Tamb = 32°C; suction gas = 20°C
Table 1: ZX condensing unit technical data
Unit
Outer dimensions
length/width/height with
closed cover [mm]
Net weight
[kg]
Fan
number
Liquid
receiver size
[litres]
Medium temperature standard
ZXME020E
424 / 1027 / 840
76
1
4.1
ZXME025E
79
ZXME030E
79
ZXME040E
91
ZXME050E
424 / 1029 / 1244
108
2
5.9
ZXME060E
112
ZXME075E
118
Medium temperature Digital
ZXDE030E
424 / 1027 / 840
82 1 4.1
ZXDE040E
424 / 1029 / 1244
104
2
5.9
ZXDE050E
108
ZXDE060E
112
ZXDE075E
118
Low temperature standard
ZXLE020E
424 / 1027 / 840
79
1
4.1
ZXLE025E
81
ZXLE030E
81
ZXLE040E
93
ZXLE050E
424 / 1029 / 1244
106
2
5.9
ZXLE060E
116
ZXLE075E
126
Table 2: ZX condensing unit features
C6.1.6/1017-1219/E 5
The figures hereafter show the overall physical dimensions of the ZX condensing units in millimetres:
Figure 1: Dimensions of models ZXME020E to ZXME040E, ZXDE030E and ZXLE020E to ZXLE040E (single-fan units)
Figure 2: Dimensions of models ZXME050E to ZXME075E, ZXDE040E to ZXDE075E and ZXLE050E to ZXLE075E
(dual-fan units)
2.4 Product nameplate
The condensing unit nameplate shows model designation and serial number, as well as locked rotor
amps, maximum operating current, safety pressures and weight.
The compressor has its own nameplate with all electrical characteristics.
6 C6.1.6/1017-1219/E
2.5 Nomenclature
The model designation contains the following technical information about the condensing unit:
Figure 3: Nomenclature ZX units
2.6 Application range
2.6.1 Qualified refrigerants and oils
Qualified
refrigerants
R404A, R407A, R407F, R507, R448A, R449A
R134a*, R450A*, R513A* (* = Not for ZXLE)
Qualified
servicing
oils
Emkarate RL 32 3MAF
Mobil EAL Arctic 22CC
Oil charge
in litres
ZXME020E
ZXME025E
ZXME030E
ZXLE020E
ZXLE025E
ZXLE030E
ZXDE030E
ZXDE040E
ZXLE040E
ZXLE050E
ZXDE050E
ZXDE060E
ZXDE075E
ZXME040E
ZXME050E
ZXME060E
ZXME075E
ZXLE060E
ZXLE075E
1
1.1
1.24
1.75
1.77
1.85
2.3
Table 3: Qualified refrigerants and oils
WARNING
Use of R450A and R513A refrigerants! Risk of compressor damage!
Migration of R450A or R513A into the compressor crankcase could cause low
oil viscosity, which could lead to compressor damage. When using R450A or
R513A it is critical to meet the following requirements:
▪ maintain adequate superheat settings with a minimum superheat of 8-10K;
▪ no liquid refrigerant migration into the compressor at any time, especially
during standstill, during or after defrost, or after reverse mode for example
in heat pumps;
▪ pumpdown is recommended (not for Digital units);
▪ the use of a crankcase heater is mandatory;
▪ retrofit to R450A and R513A is only allowed for compressors which are
approved for these refrigerants.
Contact your local Application Engineering representative for any further
information.
NOTE: ZXDE & ZXLE units are equipped with an oil separator. This separator is pre-charged
with 0.5 liter of oil.
C6.1.6/1017-1219/E 7
2.6.2 Application limits
For application envelopes, please refer to the compressor application envelopes which can be found
in Copeland™ brand products Select software, available at www.climate.emerson.com/en-gb.
ZX condensing units can be used with an ambient temperature from -15°C to 45°C. For lower ambient
temperatures please contact your local Application Engineering representative.
2.7 Bill of material
BOM
Family
Introduction
date
Controller concept
Oil
separator
Suction
accumulator
302
ZXME
08/2008
Electronic main board
No
No
452
ZXLE
07/2010
Electronic main board
Yes
Yes
ZXDE
EC2-552 (Emerson - Alco)
Yes
No
303
ZXME
03/2013
Electronic main board
No
No
453
ZXLE
03/2013
Electronic main board
Yes
Yes
ZXDE
XC645 (Emerson - Dixell)
Yes
No
304
ZXME
01/2015
XCM25D (Emerson - Dixell)
No
No
454
ZXLE
01/2015
XCM25D (Emerson - Dixell)
Yes
Yes
ZXDE
Yes
No
Table 4: BOM history
NOTE: These guidelines are of application only for BOM 304 and 454. For previous
generations (BOM 302/452 & BOM 303/453) the dedicated guidelines can be downloaded from
www.climate.emerson.com/en-gb.
8 C6.1.6/1017-1219/E
2.8 P&I diagrams
2.8.1 ZXME units
Figure 4: P&I diagram for ZXME units
Position
Description
Comments
Fast access
menu
1 (M1)
High-efficiency Copeland Scroll compressor
2 (M2)
Condenser with 1 or 2 fans
3
Liquid receiver with service valve
4
Filter drier / sight glass combination
5 (Y1)
Expansion device for suction line injection
6
Service valve, suction line
7
Service valve, liquid line
PSL (S2)
Adjustable low-pressure switch (not factorymounted)
System safety
(option)
PSH (S1)
Non-adjustable high-pressure switch
System safety
PTL (B1)
Suction pressure sensor, low pressure
Compressor setpoint
P1P
PTH (B2)
Pressure sensor, high pressure
Fan speed control
P2P
TT1 (B3)
Discharge temperature sensor
Compressor safety
P3t
TT2 (B6)
Ambient temperature sensor
Additional functions
P6t
Table 5: Legend of the P&I diagram for ZXME units
C6.1.6/1017-1219/E 9
2.8.2 ZXLE units
IMPORTANT
Absence of insulation on the liquid line in ZXLE units! Air moisture
condensation and lack of performance! Moisture will condensate on the
liquid line and cause water droplets. The liquid line can pick up additional heat
from the ambient which will adversely affect the sub-cooling desirable for the
liquid refrigerant before it enters the expansion valve. Both the suction and
liquid interconnecting piping between the ZX unit and the evaporator should
be insulated to avoid condensation.
Figure 5: P&I diagram for ZXLE units
Position
Description
Comments
Fast access
menu
1 (M1)
High-efficiency Copeland Scroll compressor
2
Oil separator
Pre-charged with 0.5 L
3
Check valve
4 (M2)
Condenser with 1 or 2 fans
5
Liquid receiver with service valve
6
Plate heat exchanger for enhanced vapour injection
(EVI)
7 (Y1)
Expansion device for enhanced vapour injection (EVI)
8
Filter drier / sight glass combination
9
Service valve, liquid line
10
Service valve, suction line
11
Liquid separator
PSL (S2)
Adjustable low-pressure switch (not factory mounted)
System safety (option)
PSH (S1)
Non-adjustable high-pressure switch
System safety
PTL (B1)
Suction pressure sensor, low pressure
Compressor setpoint
P1P
PTH (B2)
Pressure sensor, high pressure
Fan speed control
P2P
TT1 (B3)
Discharge temperature sensor
Compressor safety
P3t
TT2 (B6)
Ambient temperature sensor
Additional functions
P6t
TT3 (B4)
Vapour in temperature sensor
EVI control
P4t
TT4 (B5)
Vapour out temperature sensor
EVI control
P5t
Table 6: Legend of the P&I diagram for ZXLE units
10 C6.1.6/1017-1219/E
2.8.3 ZXDE units
Figure 6: P&I diagram for ZXDE units
Position
Description
Comments
Fast access
menu
1 (M1)
High-efficiency Copeland Scroll compressor
(ZBD for Digital)
2
Oil separator
Pre-charged with 0.5 L
3 (M2)
Condenser with 1 or 2 fans
4
Liquid receiver with service valve
5
Filter drier / sight glass combination
6
Service valve, liquid line
7
Service valve, suction line
PSL (S2)
Adjustable low-pressure switch (not factory
mounted)
System safety
(option)
PSH (S1)
Non-adjustable high-pressure switch
System safety
PTL (B1)
Suction pressure sensor, low pressure
Compressor setpoint
P1P
PTH (B2)
Pressure sensor, high pressure
Fan speed control
P2P
TT1 (B3)
Discharge temperature sensor
Compressor safety
P3t
TT2 (B6)
Ambient temperature sensor
Additional functions
P6t
Table 7: Legend of the P&I diagram for ZXDE units
C6.1.6/1017-1219/E 11
2.9 Main components description
2.9.1 Compressor
Medium temperature
Low temperature
Unit model
Compressor model
Unit model
Compressor model
Standard
ZXME020E
ZX15KCE-TFD/PFJ
ZXLE020E
ZXI06KCE-TFD/PFJ
ZXME025E
ZX19KCE-TFD/PFJ
ZXLE025E
ZXI08KCE-PFJ
ZXME030E
ZX21KCE-TFD/PFJ
ZXLE030E
ZXI09KCE-TFD/PFJ
ZXME040E
ZX29KCE-PFJ
or ZX30KCE-TFD
ZXLE040E
ZXI14KCE-TFD
ZXME050E
ZX38KCE-TFD
ZXLE050E
ZXI15KCE-TFD
ZXME060E
ZX45KCE-TFD
ZXLE060E
ZXI18KCE-TFD
ZXME075E
ZX51KCE-TFD
ZXLE075E
ZXI21KCE-TFD
Digital
ZXDE030E
ZBD21KCE-TFD
ZXDE040E
ZBD29KQE-TFD
ZXDE050E
ZBD38KQE-TFD
ZXDE060E
ZBD45KQE-TFD
ZXDE075E
ZBD48KQE-TFD
Table 8: Compressor models cross reference
2.9.2 Condenser fan(s)
The condensers of the ZX condensing units are equipped with single-phase fans.
Condensing units
Nr. of
fans
[pcs]
Fan
speed
[rpm]
Diameter
[mm]
Voltage
[V/ph/Hz]
Power
input
[W]
Medium temperature
Low
temperature
Standard
Digital
ZXME020E
ZXLE020E
1
830
450
220-240V /
1 Ph / 50 Hz
123
ZXME025E
ZXLE025E
ZXME030E
ZXDE030E
ZXLE030E
ZXME040E
ZXLE040E
ZXDE040E
2
246
ZXME050E
ZXDE050E
ZXLE050E
ZXME060E
ZXDE060E
ZXLE060E
ZXME075E
ZXDE075E
ZXLE075E
Table 9: Condenser fans technical data
2.9.3 Housing
ZX condensing units with BOM 304 & 454 have specific housing features:
▪ Controller-window in the cabinet door. The window is IP54 and shows the current value of the
electronic controller.
▪ The main power switch is installed on the cabinet door and allows to de-energize the unit without
opening the cabinet door. To open the door the main power switch must be in off position.
▪ The quick-locks allow for easy and quick opening of the cabinet door by means of the cabinet
key.
▪ The cabinet key is delivered with the unit. It is attached to one of the piping connections by means
of a cable strap.
12 C6.1.6/1017-1219/E
Figure 7: ZX unit housing
2.10 XCM25D Electronic controller – Features
The XCM25D controller is designed to be a powerful, flexible controller for use in multiple
applications. It has been developed for condensing units and allows the adjustment of all relevant
parameters by the user.
2.10.1 Description
WARNING
Electrical pins under voltage! Electrical shock hazard! There are unused
fast-on pins (C1 & DO2) on the XCM25D which could be under voltage. They
are covered by insulated fast-on flags in the factory. Handle carefully when
removing insulating flags during service on site.
The controller is designed for usage in an outdoor refrigeration unit. It is rated to be used for the
following environment:
▪ Outdoor controller ambient temperature for operation: -40C to 60C
▪ Ambient temperature for storage: -40C to 80C
▪ Maximum humidity: 90% at 48C (non-condensing)
▪ Board power: 24V AC +15%/-20%
▪ Voltage sensing capabilities - Single phase: 100-120, 200-240V AC ± 10%
▪ Voltage sensing capabilities - Three phase: 200-240, 380-460, 575V AC ± 10%
The units of measure are selectable. The factory default unit is [bar] (always considered relative) for
pressure and [°C] for temperature.
Figure 8: Electronic controller
C6.1.6/1017-1219/E 13
2.10.2 Functionalities
The controller allows for easy commissioning by the technician with the factory settings at the highest
program level. It also offers the possibility to make substantial changes to the system optimization in
further programming levels. Advanced functionalities can also be activated.
The following functions are covered by the controller:
▪ Condensing unit control
▪ Case control
▪ Condenser fan control
▪ Defrost
▪ Voltage and current sensing (compressor protection)
▪ Liquid and vapour injection
▪ System EXV control
▪ Digital compressor control
▪ Modbus/Canbus communication
NOTE: The XCM25D controller includes all the functions necessary for the control of the ZX
units. For additional functionalities please contact your local Application Engineering
representative.
Figure 9: XCM25D controller functionality overview
2.10.3 Modbus communication
The XCM25D controller can communicate via Modbus (RS-485) connection to provide all running
data. Additional commands can also be activated through Modbus connection. The Modbus map is
available on request from the Application Engineering department at Emerson.
A pre-configured X-Web Supervisor device is also available and allows easy handling and
connectivity with the XCM25D controller.
Figure 10: Modbus port and termination jumpers
NOTE: If the XCM25D controller is connected in chain the termination jumpers must be
removed.
Condenser fan
control
Digital Scroll
control (ZXDE)
Superheat
control EVI
(ZXLE)
Liquid injection
(ZXME)
Alarm
management
Electrical
protection
Monitoring of the discharge
line temperature
14 C6.1.6/1017-1219/E
2.10.4 Main control & safety features
Suction pressure control: Each unit is equipped with a suction pressure transmitter. The XCM25D
controls the suction pressure by evaluating the input signal of the pressure transmitter. When using
a digital unit (ZXDE), the setpoint (C16) and proportional band (C17) need to be adjusted. The suction
pressure regulation for ZXME or ZXLE units has to be defined by compressor cut-in (C01) and cutout (C02) values. The signal of the suction pressure transmitter is also used for additional
functionalities, pumpdown and keeping the compressor running within the approved envelopes.
Condensing pressure control: Each unit is equipped with a high-pressure transmitter. The
XCM25D controls the condensing pressure by regulating the fan speed corresponding to the highpressure transmitter signal. The unit controller can regulate the condensing pressure in two ways.
The first approach is to keep a constant condensing temperature. This mode is utilized by the factory
settings. The pre-adjusted setpoint is 27°C as a universal setting. If lower condensing pressure is
required set up the condenser setpoint (E39) to a lower value. The second control way is fan
modulation based on compressor envelope. This mode of setpoint control is only available if a suction
pressure input is not used. The parameter (E38) enables/disables the mode as needed. If this
function is unused, the condensing temperature setpoint will be set as a parameter (E39) value. The
compressor is allowed to run different minimum condensing temperatures based on the suction
pressure of the compressor. This is the most energy efficient way to minimize the condensing
temperature as much as possible.
Automatic liquid injection on ZXME: The electronic controller automatically instructs liquid
refrigerant to be injected into the suction line of the Scroll compressor to reduce discharge
temperatures generated when the unit operates at increasing compression ratios. The electronic
controller reacts automatically to a thermistor which is attached to the discharge line on all ZXME
units. The controller converts this signal for the linear stepper motor driving the liquid injection valve
to a position that enables the compressor to continue operating within its safe envelope.
Automatic enhanced vapour injection (EVI) on ZXLE: Control of an electronic expansion device
based on the superheat in the additional heat exchanger for the EVI Scroll compressor to create
subcooling in liquid refrigerant coming from the receiver. In case of excessive discharge line
temperatures (DLT) the superheat control is ignored and the controller will work in liquid injection
mode in order to reduce the discharge gas temperature.
NOTE: The ZXLE units have an additional subcooling of about 30K. This must be considered
when selecting the expansion device.
Compressor phase reversal: Ensures that the compressor keeps running in one direction only
(clockwise = right rotation) – necessary for a compliant Scroll compressor to compress and pump
refrigerant. Reset is automatic once the phase rotation is correct for the compressor.
Motor current overload protection: This feature eliminates the need for external current protection
for the compressor motor.
Fixed high-pressure switches: This is a non-adjustable protection device designed to prevent the
compressor from operating outside of its safe high-pressure range. Reset is automatic for a set
number of trips (7) then the unit will lock out and require manual restart. This feature is important to
prevent the ZX unit from cycling under these controls for a long period of time.
▪ ZXLE & ZXME units: 28 bar cut-out / 21 bar cut-in.
▪ ZXDE units: 28.8 bar cut-out / 24 bar cut-in.
Adjustable high-pressure limitation: The unit controller provides the possibility to stop the unit at
a required discharge pressure which is lower than the cut-out value of the fixed high-pressure switch.
Detailed instructions can be found in chapter 2.10.5 "Additional features for customization"
hereunder.
Discharge temperature protection: Each unit is equipped with a discharge line sensor (NTC). The
information from the NTC sensor is used to activate liquid injection when required. The XCM25D
controller will stop the compressor if discharge temperatures reach unacceptable levels.
Adjustable low-pressure alarm (from S/N 16EZ08855M onwards): The unit controller features an
adjustable low-pressure alarm managed by the suction pressure sensor. The factory setting of this
alarm is the lowest permitted pressure of the refrigerant with the lowest pressure-vapour properties.
If needed the user can modify this value according to the required application.
▪ ZXME & ZXDE units: 0.5 bar rel
▪ ZXLE units: 0.1 bar rel
C6.1.6/1017-1219/E 15
In case of very low cut-out pressure on ZXLE units it is possible that the suction pressure will get
lower than 0.1 bar rel due to the 5-second switching off delay. In this case the user can deactivate
the low-pressure alarm with parameter D13 or activate the alarm delay with parameter D12.
Option: Adjustable low-pressure switches PS1: This device protects the system against low
pressure operation. It must be adjusted depending on running conditions and potential special
requirements like pumpdown. The compressor envelopes published in Select must be respected at
all times. In case of controller breakdown, the low-pressure switch could be used for emergency
operation (rewiring required).
A crankcase heater is directly connected to the controller. The crankcase heater will be energized
when the ambient sensor is below a given value (10°C) and the compressor has been off for a period
of time (5 minutes). The minimum off time does not apply at initial power up.
In addition to the above, the ZX condensing unit has the following features:
▪ Liquid line assembly (filter drier and sight glass/moisture indicator)
▪ Anti-corrosion treatment to the condenser fins
The electronic controller is also the base controller for the connection of many optional and customer
supplied functions such as:
▪ Main load controller (or thermostat)
▪ Evaporator electric defrost heater contactor
▪ Evaporator fan contactor
▪ Superheat controller for one electronic expansion device (not available on ZXLE units)
2.10.5 Additional features for customization
A lot of additional features are provided by the XCM25D controller. In the European design of the
electrical panel a few of the additional functionalities are prearranged and can easily be installed by
connecting additional hardware to the electrical terminals. The tables in Appendix 6 show the
parameters that have to be changed in case a special feature of the controller should be activated.
The tables do not show the required settings which have to be done by the system operator, eg,
choosing correct setpoints for different components and different applications.
NOTE: After programming an additional function, the system will have to be restarted. To
engage system restart, switch off the main power supply, wait for 5 seconds and switch it on
again.
Component
Description
Prearranged terminals /
Wiring diagram
S2
Low pressure switch, optional; can be ordered
factory-installed.
Terminals: X1.2 / X1.7
Y3
Solenoid valve liquid line (not available on
ZXDE units)
Terminals: X1.N / X1.8
S3
Room thermostat for pumpdown or direct
control
Terminals: X1.9 / X1.10
Alarm contact
Sensor for evaporator or room
Terminals: X1.11 / X1.12
Sensor B7
Sensor for evaporator or room (NTC10kΩ)
Terminals: X1.13 / X1.14
Table 10: Prearranged additional connections
Figure 11: Prearranged additional connections
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