Large ZX Condensing Unit

Introduction

Thank you for purchasing the Copeland™ Large ZX Condensing Unit for refrigeration applications. This unit features a high-efficiency Copeland fixed speed scroll compressor with liquid/vapor injection technology, positioning it as a best-in-class unit within its capacity and operating range. Copeland condensing units are recognized globally for their energy savings and user-friendly electronic features. This manual is designed to assist contractors and customers with the installation, commissioning, and operation of the Copeland Large ZX Condensing Unit.

Disclaimer

This operation manual provides essential information for the installation, commissioning, and operation of the product. It is crucial to read this information before proceeding. Copeland Large ZX scroll refrigeration condensing units must be installed by qualified and experienced refrigeration technicians. Emerson is not responsible for damage resulting from inexperienced technicians or improper system design. The procedures outlined are based on good refrigeration trade practices and represent minimum requirements to avoid warranty claims. These instructions do not cover fundamental electrical or refrigeration practices and are intended for qualified personnel only. For inquiries, contact your local sales office, quoting the unit model and serial number. In case of ambiguity, the wiring diagram supplied with the unit takes precedence.

1. Safety Information

Installation and commissioning work on the CDU must be performed only by qualified, trained, and instructed refrigeration personnel. The Copeland Large ZX condensing unit is manufactured according to the latest safety standards, with a strong emphasis on user safety. Refer to the manufacturer's declaration for relevant standards. Adherence to these safety instructions is strongly advised.

Icon Explanation

• WARNING ⚠️: Indicates instructions to avoid personal injury and material damage.
• High Voltage ⚡: Indicates operations with a danger of electric shock.
• Danger of burning or frostbite ?❄️: Indicates operations with a danger of burning or frostbite.
• Explosion hazard ?: Indicates operations with a danger of explosion.
• CAUTION ?: Indicates instructions to avoid property damage and possible personal injury.
• IMPORTANT ❗: Indicates instructions to avoid compressor malfunction.
• NOTE ?: Indicates a recommendation for easier operation.

Safety Statements

• Only qualified and authorized refrigeration personnel may 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.
• National legislation and regulations regarding personnel protection must be observed.

Use personal safety equipment, including safety goggles, gloves, protective clothing, safety boots, and hard hats where necessary.

General Instructions

• Warning: System breakdown! Personal Injuries! Never install a system and leave it unattended without charge, a holding charge, or with service valves closed without electrically locking out the system.
• Warning: High shell temperature! Burning! Do not touch the compressor until it has cooled down. Ensure other materials near the compressor do not touch it. Lock and mark accessible sections.
• Caution: Overheating! Bearing damage! Do not operate compressors without refrigerant charge or connection to the system.
• Caution: Compressors contain oil & refrigerant under pressure. Release pressure from both high & low sides before servicing.
• Caution: Tube brazing and compressor operation can produce hot surfaces. Allow surfaces to cool to avoid burns.

Safety Refrigerants/Lubricant

• Use the correct refrigerant as designed for the safe operating envelope.
• The compressor is supplied with an initial oil charge. The standard oil for HFC refrigerant is Polyolester Oil (POE) lubricant Emkarate RL 32 - 3MAF.

Receiving your unit

Units are shipped with an ideal gas at positive pressure. Upon receipt, check the pressure. If no pressure is found, contact Copeland or an authorized distributor. Damage during transportation/handling is an insurance claim, not a manufacturing defect. Inspect the unit for physical damage and report it.

2. Nomenclature

The model nomenclature follows a structure: ZX (Condensing unit family) - L (Temperature range) - 012 (Model identifier) - B (Generation) - E (Oil type) - TFM (Electrical Code) - 551 (Bill of Material).

3. Scope of Supply

The standard scope of supply for Large ZX / Scroll Rack Models (ZX 9-15HP and ZXLD) includes:

4. PI Diagram

The PI Diagram illustrates the refrigerant circuit for the ZX condensing unit. Key components shown include the Compressor (M1), Oil Separator, Crank Case Heater (R2), Condenser, Receiver, Electronic Expansion Valve (EXV), Filter Drier/Sight Glass, and various Ball Valves. Sensors and switches are also indicated, such as pressure transmitters (B2, B3), temperature sensors (B4, B5, B6), and LP/HP switches (F5).

For the ZXL units with EVI Technology, the diagram is similar but includes a Brazed Plate Economizer (PHE) and specific sensors for vapor inlet and outlet temperatures.

5. Models

The Copeland Large ZX condensing units are available in medium and low temperature ranges, with various horsepower ratings.

Medium temperature, 9 - 15HP

Low temperature, 10 - 20HP

6. Features & Benefits

The Large ZX platform condensing units were designed based on industry user demands, offering:

• Energy efficiency: Utilizes Copeland™ scroll compressor technology, variable speed fan motor, large capacity condenser coil, and advanced control algorithms to significantly reduce energy consumption. End-users can save over 20% on annual energy costs compared to equivalent reciprocating units.
• Reliability: Combines the proven reliability of Copeland scroll compressors with advanced electronics, controller, and diagnostics for enhanced equipment reliability. Fault code alerts and retrieval aid in faster, more accurate system diagnostics. Integrated electronics protect against over-current, over-heating, incorrect phase rotation, compressor cycling, high pressure resets, and low pressure cut-outs. It also provides warning messages for liquid flood back, preventing critical damage.

Key benefits include:

• Intelligent store: Leads to better decision making.
• Highest efficiency: Results in lower energy bills.
• Reliability: Contributes to lower maintenance costs.

Condensing Unit Features

• Copeland™ scroll compressor technology: Highly efficient, ultra-quiet, and highly reliable.
• Configured with CoreSense controller: Provides electronic diagnosis, protection, and communication modules for energy-saving and reliable unit control, including digital modulation control.
• Enhanced vapor injection (ZXL only): Offers high efficiency for refrigeration applications. Features a well-tuned electronics algorithm with a large PHE to sub-cool liquid temperature and feed gas into the compressor's EVI ports.

Design Features

• Real-time monitoring of compressor operating conditions
• Compressor reverse rotation protection
• Compressor over current protection
• Compressor internal motor protector
• Discharge gas overheat protection
• Over voltage protection
• Under voltage protection
• High pressure protection
• Low pressure protection
• Refrigerant flood back warning
• Compressor minimum off time
• Compressor oil level protection
• Intelligent store Solution: Communication and retail store monitoring

7. Condensing Unit Layout

The condensing unit layout differs slightly between the 9-15 HP and 10-20 HP models. Key components visible in the diagrams include the BLDC/EC Fan, Control Box, Core-Sense™ controller, Liq. Receiver, Oil Separator, Compressor, Filter Drier, LP Switch, and for the 10-20 HP units, an Accumulator and BPHE Economizer.

8. CoreSense Controller

The CoreSense controller is a central unit for managing the condensing unit. It includes a power isolation switch, contactor, and various connection ports for sensors, communication, and customer connections. The controller features an LED display and buttons for operation. Detailed descriptions are provided for LED indicators, single-button keyboard functions (Set, Reset, Up, Down, Service, Defrost), and combined button operations (e.g., keyboard lock/unlock, menu navigation). The manual also outlines the controller initialization message sequence and procedures for browsing and modifying parameters (Pr1 parameter).

Quick access menu allows viewing sensor status and actual values (e.g., pressure, temperature, EXV opening step). Access alarm code functionality allows retrieval of up to 50 alarm records.

The controller also manages alarm timing, program upload/download to/from a hot-key, and provides detailed troubleshooting steps for various fault phenomena related to sensors, inputs, and configuration.

9. Networking

The Dixell XWEBPRO serial address requires specific wiring for ModBUS network connectivity. Use 2 or 3 shielded wires (minimum 0.5mm²) and do not connect the shield or 'Gnd' terminal to ground. RS485 devices are polarity sensitive. A correct network wiring diagram is provided, illustrating the connection between the Dixell XWEBPRO and multiple controllers. An incorrect wiring example highlights potential issues.

The ZX CDU connects to the Dixell XWEBPRO via RS485 ModBUS for the Intelligent Store solution. The connection involves linking the XWEBPRO's port 13 to CoreSense's 'D0485 +' and XWEB300D's port 12 to CoreSense's 'D1485 -'.

11. Electrical Connections

This section details the electrical wiring diagram for the ZX/ZXL-TFM Condensing Unit (380/420V, 50Hz, 3Ph + N). It includes a legend for components, cable colors, and terminal designations. The diagram illustrates connections for the controller, compressor motor, fan motor, contactors, switches, and sensors. Installer-wired components are indicated by dashed lines. Notes specify BOM dependencies and the omission of earth wire termination for clarity.

11. Installation, System Processing, & Start-up

Utmost care is required when handling the Large ZX condensing unit.

11.1 Location and Fixing

Install the unit in a location ensuring clean airflow, with adequate minimum operating space as depicted in diagrams. Consider service access and airflow. For multiple units, careful case-by-case consideration is needed. Ideally, mount the unit on a solid concrete slab with anti-vibration pads.

11.2 Refrigeration Piping Installation

Interconnecting pipes must be refrigeration grade, clean, and dehydrated, capped at both ends. If the system is left open for more than two hours, re-cap pipes to prevent moisture ingress. Service valve sizes are for installation convenience and may not be ideal for all interconnecting pipe runs; however, they are adequate for short runs within the unit. Pipe sizing should ensure optimum performance and oil return, considering the full capacity range. Pipe runs should be short, with minimal directional changes, using large radius bends to avoid oil trapping, especially on the suction line. The suction line should slope gently towards the unit (1/200~1/250 slope). P traps, double risers, and reduced pipe diameters might be needed for long vertical risers. Pipes must be adequately supported to prevent sagging.

11.3 Refrigerant line insulation

• Insulate suction lines with minimum 1" thickness closed-cell insulation for low-temperature circuits.
• Liquid lines for vapor injection (ZXL units) require minimum 3/4" insulation.
• Suction and liquid lines should not be taped or soldered together.

11.4 Electrical

• All electrical work must comply with the National Electrical Code and local codes.
• Power supply must match the unit's nameplate specifications.
• Voltage fluctuations exceeding 10 percent must be corrected.
• Ensure all protective devices are in place and wiring is secure before starting the unit.

11.5 Brazing Recommendation

Maintain a flow of oxygen-free nitrogen at low pressure during brazing to prevent copper oxide formation. Copper oxide can block screens and valves. Remove connection caps, open valves midway, and take care to avoid rapid release of holding charge. Ensure tube fitting inner diameter and outer diameter are clean. Insulate the housing near the tubes with a wet cloth. Use copper/phosphorous or copper/phosphorous/silver alloy rods for joining copper, or silver alloy rods for dissimilar/ferric metals. A double tip torch is recommended.

11.6 Expansion Valve Selection Consideration

For ZXL units with vapor injection compressors, subcooled liquid temperature must be considered when selecting the expansion valve. A table provides standard supply temperatures and corresponding ambient temperatures for R404A refrigerant.

11.6 Start-up & Operation

11.6.1 Initial pressure test (vacuum and Nitrogen)

Use a 4-port gauge manifold. Connect gauges to service ports. Start the vacuum pump with the evaporator fan running and crankcase heater energized (disconnect live feed to compressor contactor). Run until vacuum reaches -0.85 bar. Shut off the pump and check for vacuum rise. If vacuum holds for 10 minutes, break vacuum with nitrogen and pressurize to 20 bar, checking for leaks.

11.6.2 Leak Check

A leak-free system is critical. Field systems can lose 20-30% of charge annually. Ensure all service valves are open. Test pressure must not exceed system design pressures. Use an approved electronic gas leak detector and soapy water solution for checks. Leave the system under pressure for 24 hours. Record ambient temperatures and system pressure every 8-12 hours during testing. Repeat leak testing if pressures cannot be maintained.

11.6.3 Evacuation

After leak checking, connect a dual-stage vacuum pump. Ensure all shut-off and solenoid valves are open. Evacuate to 300 microns. Triple evacuation is recommended if a micron gauge is unavailable. System charging requires liquid refrigerant into the liquid line; do not vapor charge.

11.6.4 Charging and Commissioning

Ensure no power supply to the unit. Keep the Liquid Line solenoid open (may require temporary power). Connect the refrigerant cylinder, purge the line, and ensure correct cylinder orientation. Charge at least 70% of the required refrigerant through the high-pressure side before starting the compressor. Do not bypass the LP cutout. Start the compressor and continue charging with controlled liquid refrigerant through the suction service valve. Monitor quantity and check the liquid line sight glass for bubbles. Alarms E47 and E48 may appear during partial charging and should be ignored. Charging is complete when operating temperature is stable and the sight glass is clear.

11.6.5 Additional Oil Charing in the System

Units are supplied with oil, but additional oil may be required based on piping length and refrigerant charge. If the oil level in the reservoir drops below the lower sight glass, add oil through the suction line using a manual oil pump to reach the mid-level of the lower sight glass. Recommended oils for refrigerants like R404A, R507, R448A, R449A, R407F include Emkarate RL 32 3MAF and Mobil EAL Arctic 22 CC.

11.6.6 Checks before starting and during running the system

Verify all valves are open. Check compressor and reservoir oil levels after running. Ensure discharge line temperature is below 125°C. Suction and discharge pressures must be within the operating envelope. Operating current should correspond to pressures. The compressor bottom shell temperature should be within the safe range, as illustrated by a graph showing oil sump temperature vs. evaporation temperature.

11.6.7 Maintenance

Condenser Fins: Clean condenser fins regularly (at least every two months) to prevent high condensing temperatures and poor performance. Use a liquid detergent diluted with water. Brush downward to remove heavy deposits before washing.

Routine Leak Test: Check all joints for leaks annually. Inspect condenser fans and motors annually. Fastenings may loosen, bearings may wear, and fans may require cleaning. Always turn off electrical power before cleaning or maintenance.

12. Troubleshooting

This section provides guidance for diagnosing and resolving issues based on alarm levels (Warning, Alarm, Lock) and specific error codes. It details possible reasons, actions, and reset procedures for various faults, including sensor failures (pressure, temperature), current/voltage issues, phase loss, over/under voltage, high/low pressure faults, and communication errors. A detailed table lists fault phenomena, direct causes, and inspection/adjustment steps for common problems like compressor not starting, abnormal noise, low cooling capacity, and controller malfunctions. A temperature sensor resistance table is also provided for reference.

13. System Start-Up and Operational Check Sheet

This section provides a comprehensive checklist for system start-up and operational verification. It includes fields for client details (name, address, contact, installer, date), condensing unit information (model, serial number, location, indoor unit details), system details (room ID, pipe length, OAT, leak test duration, leak tightness, evacuation, refrigerant charge), and system operation parameters (voltage, current, pressures, temperatures, superheat, subcooling, adjustable LP setpoint, design/operating temp, room temp, condenser fins). It also includes a section for comments and diagrams illustrating compressor superheat and subcooling calculations.

About Emerson

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Contact lists

Contact information is provided for various regions, including United Arab Emirates, South Africa, Saudi Arabia, and Egypt, with phone numbers, toll-free numbers, and addresses.