Emerson ZXME020E, ZXME025E, ZXME030E, ZXME040E, ZXME050E Application Guidelines

...
4 (1)

Application Guidelines

Copeland EazyCool

Outdoor Condensing Units

ZX Range

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

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

CAUTION

This icon indicates instructions to

This icon indicates instructions to avoid

avoid personal injury and material

property damage and possible

damage.

personal injury.

High voltage

 

 

 

IMPORTANT

This icon indicates operations with a

 

 

 

This icon indicates instructions to avoid

 

 

 

 

 

 

danger of electric shock.

 

 

 

malfunction of the compressor.

 

 

 

 

 

Danger of burning or frost burn

NOTE

This word indicates a recommendation

This icon indicates operations with a

for easier operation.

 

 

 

danger of burning or frost burn.

 

 

 

 

 

 

 

 

 

Explosion hazard

 

 

 

 

This icon indicates operations with a

 

 

 

 

danger of explosion.

 

 

 

 

1.2Safety 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.

C6.1.6/1017-1219/E

1

1.3General 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).

2

C6.1.6/1017-1219/E

2 Product description

2.1General 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.

2.2EU 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"

2.3Main 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.

C6.1.6/1017-1219/E

3

 

 

 

 

Refrigerant

 

 

Displacement

 

 

Cooling

 

 

Nominal

 

 

Rated

 

 

PS

 

 

PS

 

 

Unit

 

 

 

 

@ 50 Hz

 

 

capacity*

 

 

power

 

 

current

 

 

 

 

 

 

 

 

types

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

high side

 

 

low side

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[m /h]

 

 

[kW]

 

 

[kW]

 

 

[A]

 

 

 

[bar]

 

 

[bar]

 

 

 

 

 

Medium temperature standard

 

 

 

 

TFD

 

 

PFJ

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME020E

 

 

 

5.9

 

3.42

 

1.58

 

5.4

 

 

13.3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME025E

 

 

R404A, 407A,

 

6.7

 

 

3.89

 

 

1.66

 

 

5.2

 

 

12.9

 

 

 

 

 

 

 

ZXME030E

 

R407F, R507,

8.6

 

5.05

 

2.28

 

7.7

 

 

16.9

 

 

 

 

 

 

 

 

R448A, 449A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME040E

 

 

 

11.7

 

 

6.58

 

 

3.29

 

 

10.8

 

 

24.0

 

 

 

 

 

 

 

 

 

 

R134a,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME050E

 

14.4

 

8.77

 

3.79

 

13.8

 

 

 

 

 

 

 

 

 

 

 

R450A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME060E

 

 

& R513A

 

17.1

 

 

10.05

 

 

4.41

 

 

14.1

 

 

 

 

 

 

 

 

 

 

ZXME075E

 

 

 

18.8

 

11.6

 

5.07

 

15.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Medium temperature Digital

 

 

 

 

TFD

 

 

 

 

 

 

 

 

ZXDE030E

 

R404A,

8.3

 

5.13

 

2.21

 

7.2

 

 

 

 

 

 

 

 

 

ZXDE040E

 

 

R407A,

 

11.4

 

 

7.21

 

 

2.72

 

 

8.9

 

 

 

 

 

 

 

 

ZXDE050E

 

R407F, R507,

14.4

 

8.65

 

3.67

 

12.3

 

 

28.8

 

21

 

 

R448A, R449A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXDE060E

 

 

R134a, R450A

 

17.1

 

 

10.1

 

 

4.46

 

 

12.4

 

 

 

 

 

 

 

 

ZXDE075E

 

& R513A

18.8

 

11.4

 

4.83

 

15.0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Low temperature standard

 

 

 

 

TFD

 

 

PFJ

 

 

 

 

 

 

 

ZXLE020E

 

 

 

6.1

 

1.46

 

1.77

 

6.2

 

 

14.1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXLE025E

 

 

 

 

 

7.1

 

 

1.81

 

 

2.00

 

 

 

 

 

16.1

 

 

 

 

 

 

 

ZXLE030E

 

R404A, 407A,

8.0

 

2.06

 

2.17

 

7.2

 

 

18.3

 

 

 

 

 

 

 

 

R407F, R507,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXLE040E

 

 

 

12.7

 

 

3.16

 

 

3.72

 

 

9.7

 

 

 

 

 

 

 

 

 

 

 

 

 

R448A,

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXLE050E

 

14.4

 

3.62

 

4.00

 

12.9

 

 

 

 

 

 

 

 

 

 

 

R449A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

Outer dimensions

Net weight

 

Fan

 

 

Liquid

 

 

Unit

length/width/height with

 

 

 

receiver size

 

 

[kg]

 

number

 

 

 

 

 

closed cover [mm]

 

 

 

[litres]

 

 

 

 

 

 

 

 

 

 

 

Medium temperature standard

 

 

 

 

 

 

ZXME020E

 

76

 

 

 

 

 

 

 

ZXME025E

424 / 1027 / 840

79

 

1

 

4.1

 

 

ZXME030E

79

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME040E

 

91

 

 

 

 

 

 

 

ZXME050E

 

108

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME060E

424 / 1029 / 1244

112

 

2

 

 

5.9

 

 

ZXME075E

 

118

 

 

 

 

 

 

 

 

Medium temperature Digital

 

 

 

 

 

 

ZXDE030E

424 / 1027 / 840

82

 

1

 

4.1

 

 

 

 

 

 

 

 

 

 

 

 

ZXDE040E

 

104

 

 

 

 

 

 

 

ZXDE050E

424 / 1029 / 1244

108

 

2

 

 

5.9

 

 

ZXDE060E

112

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXDE075E

 

118

 

 

 

 

 

 

 

 

Low temperature standard

 

 

 

 

 

 

ZXLE020E

 

79

 

 

 

 

 

 

 

ZXLE025E

424 / 1027 / 840

81

 

1

 

4.1

 

 

ZXLE030E

81

 

 

 

 

 

 

 

 

 

 

 

 

ZXLE040E

 

93

 

 

 

 

 

 

 

ZXLE050E

 

106

 

 

 

 

 

 

 

ZXLE060E

424 / 1029 / 1244

116

 

2

 

 

5.9

 

 

ZXLE075E

 

126

 

 

 

 

 

 

 

Table 2: ZX condensing unit features

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

C6.1.6/1017-1219/E

Emerson ZXME020E, ZXME025E, ZXME030E, ZXME040E, ZXME050E Application Guidelines

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)

2.4Product 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.

C6.1.6/1017-1219/E

5

2.5Nomenclature

The model designation contains the following technical information about the condensing unit:

Figure 3: Nomenclature ZX units

2.6Application range

2.6.1 Qualified refrigerants and oils

 

Qualified

 

 

 

 

 

R404A, R407A, R407F, R507, R448A, R449A

 

 

 

 

refrigerants

 

 

 

 

 

R134a*, R450A*, R513A* (* = Not for ZXLE)

 

 

 

 

Qualified

 

 

 

 

 

 

 

 

Emkarate RL 32 3MAF

 

 

 

 

 

 

 

servicing

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Mobil EAL Arctic 22CC

 

 

 

 

 

 

 

oils

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME030E

 

 

 

 

 

 

 

 

 

 

 

ZXME040E

 

 

 

 

 

 

 

 

 

 

 

ZXLE020E

 

 

 

 

 

 

 

 

ZXDE050E

 

 

 

 

 

 

 

 

 

 

ZXME020E

 

 

 

 

 

 

 

ZXLE040E

 

 

 

 

ZXME050E

 

 

ZXLE060E

 

 

Oil charge

 

 

 

 

ZXLE025E

 

 

ZXDE040E

 

 

 

 

ZXDE060E

 

 

 

 

 

 

 

 

ZXME025E

 

 

 

 

 

 

ZXLE050E

 

 

 

 

ZXME060E

 

 

ZXLE075E

 

 

in litres

 

 

 

 

ZXLE030E

 

 

 

 

 

 

 

ZXDE075E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME075E

 

 

 

 

 

 

 

 

 

 

 

ZXDE030E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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.

6

C6.1.6/1017-1219/E

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.

2.7Bill of material

 

BOM

 

 

Family

 

 

Introduction

 

 

Controller concept

 

 

Oil

 

 

Suction

 

 

 

 

 

 

 

 

date

 

 

 

 

separator

 

 

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.

C6.1.6/1017-1219/E

7

2.8P&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 factory-

 

 

System safety

 

 

 

 

 

 

 

mounted)

 

 

(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

8

C6.1.6/1017-1219/E

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

 

 

 

 

 

 

C6.1.6/1017-1219/E

 

 

 

9

 

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

 

 

System safety

 

 

 

 

 

 

 

mounted)

 

 

(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

10

C6.1.6/1017-1219/E

2.9Main 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

 

ZXLE040E

 

ZXI14KCE-TFD

 

 

or ZX30KCE-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

 

 

Fan

 

 

Diameter

 

 

Voltage

 

 

Power

 

 

Medium temperature

 

 

Low

 

 

fans

 

 

speed

 

 

 

 

 

 

input

 

 

 

 

 

 

 

 

 

 

[mm]

 

 

[V/ph/Hz]

 

 

 

 

Standard

 

 

Digital

 

 

temperature

 

 

[pcs]

 

 

[rpm]

 

 

 

 

 

 

 

 

[W]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME020E

 

 

 

 

 

ZXLE020E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME025E

 

 

 

 

 

ZXLE025E

 

1

 

 

 

 

 

 

 

 

 

 

123

 

ZXME030E

 

 

ZXDE030E

 

ZXLE030E

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME040E

 

 

 

 

 

ZXLE040E

 

 

 

 

830

 

450

 

 

220-240V /

 

 

 

 

 

 

 

ZXDE040E

 

 

 

 

 

 

 

 

 

1 Ph / 50 Hz

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ZXME050E

 

 

ZXDE050E

 

 

ZXLE050E

 

2

 

 

 

 

 

 

 

 

 

 

246

 

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.

C6.1.6/1017-1219/E

11

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: -40 C to 60 C

Ambient temperature for storage: -40 C to 80 C

Maximum humidity: 90% at 48 C (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

 

12

C6.1.6/1017-1219/E

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.

Condenser fan

Digital Scroll

Liquid injection

control

control (ZXDE)

(ZXME)

Superheat control EVI (ZXLE)

Monitoring of the discharge

Electrical

Alarm

line temperature

protection

management

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.

C6.1.6/1017-1219/E

13

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

14

C6.1.6/1017-1219/E

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

 

Terminals: X1.2 / X1.7

 

 

factory-installed.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Y3

 

 

Solenoid valve liquid line (not available on

 

 

Terminals: X1.N / X1.8

 

 

 

 

ZXDE units)

 

 

 

 

 

 

 

 

 

 

 

 

S3

 

Room thermostat for pumpdown or direct

 

Terminals: X1.9 / X1.10

 

 

control

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

C6.1.6/1017-1219/E

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