Copeland Scroll™ Compressor

Overview

Emerson is pleased to offer Copeland Scroll Large ZX condensing unit and EMP rack for refrigeration applications.

In addition to 2-9 HP condensing unit, Emerson expands Next Generation ZX platform to 12-20 HP medium temperature and low temperature condensing unit and rack, configuring with digital modulation for best in class energy efficiency and food safety.

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

Disclaimer

Thanks for purchasing Copeland Scroll™ Large ZX Condensing Unit and EMP Rack from Emerson. Large ZX Condensing Unit and EMP Rack exhibit market-leading quality in terms of cooling capacity and operating range, as part of product extension for Next Generation ZX platform in larger capacity range and installation variants. The product is designed to operate reliably and to deliver high operating efficiencies in medium and low temperature refrigeration applications. It also provides constant monitoring of the compressor operating conditions and displays the running or fault conditions of the condensing unit or rack.

In order to ensure the safe and reliable operation of the unit and rack, the installation of Large ZX Condensing Unit and EMP Rack must comply with industry standards. The selection, installation and maintenance of Large ZX Condensing Unit and EMP Rack must be carried out by professionals. This user manual does not include all industry guidelines for the installation of refrigeration equipment. For loss caused by inexperienced or untrained personnel or due to wrong installation design, it will not be a reasonable reason for responsibility.

If you have any questions, please contact the local sales office for unit or rack type and serial number on the nameplate for consultation. For example, the wiring diagram supplied with each unit or rack takes precedence over the wiring diagram in this manual if any discrepancy occurs, please refer to the attached wiring diagram in the unit or rack.

ZX condensing unit introduction

ZX series condensing units have gained market popularity and have achieved great success in the Asian market with their energy-saving and friendly control experience. ZX/ZXB/ZXD/ZXL/ZXLD units in Asia are used on-site by famous end-users and cold chain retailers. ZX platform products have been widely recognized in the global market. Specially developed models have been exported to the United States, Latin America, Europe and the Middle East markets.

Receiving your unit

All units are filled with dry nitrogen at a positive pressure before transportation. The unit and package are clearly labeled. The unit shut-off valve is equipped with a maintenance interface to check the unit pressure maintenance.

Caution!

When you receive a unit from Emerson or an authorized representative, it is very important to check the pressure of each unit. If it is found that packing pressure has disappeared, please contact Emerson or an authorized representative. Failure to report this may cause subsequent failure reports to be unobstructed.

Damage to the unit caused by the transport process should fall within the category of insurance claims and not be a manufacturing defect. It is also advisable to inspect the rest of the unit for obvious physical damage and inform Emerson or an authorized representative in case any is discovered.

ZX Platform Condensing Unit and EMP Rack were designed based on three factors demanded by industry users:

• Intelligent store solutions - A most innovative approach to enterprise facility management, Emerson Intelligent Store™ architecture integrates hardware and services, to provide retailers a single view into their entire work of facilities and understand what facilities actually cost to operate and maintain. The Intelligent Store architecture transforms data from store equipment and controls into actionable insights. Designed to deliver value in both new and existing stores, Emerson aims to help the retailers: Make better decisions on resources investment for greatest impact, Gain accurate feedback and customized service to your specific needs, Reduce operational costs and boost the profitability at most convenience.
• Energy efficiency - Utilizing Copeland Scroll™ compressor technology, variable speed fan motor, large capacity condenser coil and advanced control algorithms, energy consumption is significantly reduced. End-users can save more than 20% on annual energy costs rather than using hermetic reciprocating units.
• Reliability - Combining the proven reliability of Copeland Scroll compressors with advanced electronics controller and diagnostics, equipment reliability is greatly enhanced. Fault code alerts and fault code retrieval capabilities provide information to help improve speed and accuracy of system diagnostics. Integrated electronics provide protection against over-current, over-heating, incorrect phase rotation, compressor short cycling, high pressure resets, low pressure cut-outs. It can also send out a warning message to an operator when there is liquid floodback, which can prevent critical damage on the unit.

Intelligent Store

• Better decision making

Highest efficiency

• Lower energy bills

Reliability

• Lower maintenance cost

Nomenclature

Large ZX Condensing unit

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
• Provides digital modulation control

Emerson unique digital technology

• Proven reliable modulation technology for end user energy saving, accurate temperature control and best food safety

Enhanced vapor injection

• High efficient solution for refrigeration application

Design features

• Real-time monitoring of compressor operating conditions
• Compressor reverse rotation protection
• Compressor over current protection
• Compressor internal motor protector trip
• Discharge gas over heat protection
• Over voltage protection
• High pressure protection
• Low pressure cut-out
• Refrigerant floodback warning
• Compressor minimum off time
• Internal thermal sensor failure warning
• Compressor oil shortage protection
• Intelligent Store Solution: Communication and retail store monitoring

EMP Scroll rack

Bill of material

Envelope

Large ZX Condensing unit

ZXD Digital medium temperature

Maximum suction gas temperature: 18.3°C

Fan speed control function for lower than 10°C ambient

Evaporating temperature °C

Note: ZXD120/160BE maximum evaporating temperature is 0 °C; ZXD200BE maximum evaporating temperature is -4 °C

ZXLD Digital low temperature

Maximum suction gas temperature: 5°C

Fan speed control function for lower than 10°C ambient

Evaporating temperature °C

Note: ZXLD120BE maximum evaporating temperature is 0 °C; ZXLD160/200BE maximum evaporating temperature is -4 °C

EMPD/EMPLD Envelope

EMPD Digital medium temperature

Maximum suction gas temperature: 18.3°C

Evaporating temperature °C

Note: EMPD120/160BE maximum evaporating temperature is 0 °C; EMPD200BE maximum evaporating temperature is -4 °C

EMPLD Digital low temperature

Maximum suction gas temperature: 18.3°C

Evaporating temperature °C

Note: EMPLD120BE maximum evaporating temperature is 0 °C; EMPLD160/200BE maximum evaporating temperature is -4 °C

Technical data

Large ZX condensing Unit

Large ZX condensing Unit

Physical layout

The following picture shows the outline of 12-16HP Large ZX condensing unit.

Oil observation window

Moisture indicator observation window

Figure 1. 12-16HP Large ZX layout

The normal oil level should be lower than the upper observation port, but higher than the lower observation port. If the oil level is lower than the lower observation port, replenish oil immediately. When the unit is running, replenish from the unit's suction service valve using a high pressure oil gun.

Digital compressor

Fixed compressor

Electronic oil control

Oil filter

Filter drier

Accumulator (LT unit only)

Liquid receiver

Oil separator (reservoir)

Discharge check valve

Check valve

PHE (except for ZXD120BE)

EXV valve (except for ZXD120BE)

Upper oil sight glass

Lower oil sight glass

Moisture indicator

Figure 2. Main components of 12-16HP Large ZX

The following picture shows the outline of 12-16HP EMP Scroll Rack.

Liquid level alarm

Oil observation window

Pressure safety valve

Liquid receiver

Figure 5. EMP Rack layout

CoreSense™ controller view window

Moisture indicator observation window

High/Low pressure gauge

Fix speed compressor

Digital compressor

Electronic oil control

Oil filter drier

Dischage line check valve

Oil separator (reservoir)

Suction accumulator (Low temp model only)

Suction header

Compressor discharge service valve

Upper oil sight glass

Lower oil sight glass

Moisture indicator

Electronic expansion valve

Plate heat exchanger (except EMPD120E)

HP & LP gauge

Core type liquid filter drier

Figure 6. Main components of EMP Rack

The following pictures shows the outlines of 20HP Large ZX condensing unit and EMP scroll rack.

Fan motor terminal box

CoreSense™ controller view window

Liquid level alarm light (EMP Rack only)

Moisture indicator oberservation window

Fixed speed compressor

Digital compressor

HP guage

LP guage

Fixed speed compressor discharge line check valve

Electronic oil control

Oil filter drier

Moisture indicator

Liquid filter drier

Discharge header

HP guage LP guage

Oil separator observation window

Discharge line check valve

Check valve

Oil Separator

Liquid Receiver

Upper and lower oil level sight glass

Accumulator

Ambinet temperature sensor

Low voltage wire entry loop

High voltage wire entry loop

Liquid line service valve

Suction line service valve

BOM-651 (Large ZX w/ remote condenser)

Separate upper condenser part and lower compressor part, add condenser inlet/outlet service valve

Figure 9. 20HP layout

EMPD/EMPD Scroll rack (w/o condenser)

Offer only lower compressor part, add condenser inlet/outlet service valve

Suction header

Main components for BOM-651 (w/ remote condenser) and EMP Rack (w/o condenser) :

The main components and layout are basically same with outdoor installed version condensing unit

Bigger size oil separator and liquid receiver are configured in the consideration of larger refrigerant charge in system with condenser remotely installed

Pay attention to the location of suction pipe, discharge pipe, liquid pipe and sub-cooled pipe and avoid wrong piping connection

Liquid receiver

Pressure safety valve

Discharge line check valve

Oil separator

Check valve

Discharge pipe (Cond in)

Liquid pipe (Cond out)

Suction pipe (Evap out)

Sub-cooled liquid pipe (Evap in)

Figure 10. 20HP main components

Electrical module

Figure 3. Electrical module of 12-16HP Large ZX

Circuit breaker 1

Circuit breaker 2

Fan speed control

24V Transformer

CoreSense™ controller

Customer terminals

Contactor 1

Contactor 2

Capacitor

Internal terminals

24V Transformer

Figure 7. Electrical module of EMP Rack

Circuit breaker 1

Circuit breaker 2

Fan speed control

Alarm LED

24V Transformer

CoreSense™ controller

Customer terminals

Contactor 1

Contactor 2

Relay

Internal terminals

24V Transformer

Figure 11. 20HP electrical module

CoreSense™ controller

Liquid level alarm light 2 (only for EMP rack)

Emergency mode switch ¹ (only for short time running)

Compressor contactor

Low voltage wire entry loop

Internal terminals

Circuit breaker

Time relay (only for emergency mode)

Customer terminals

High voltage wire entry loop

LED descriptions

Note:

This function is available in Large ZX as standard offering. For EMP rack, this function is available only when customer has connected air cooled condenser fans to rack controller.

Figure 12. 20HP service valve location

Note: Figure 12 list service valve of 20HP outdoor type condensing unit. The condenser inlet and outlet pipe valve are not listed in this picture, for details of these valve location please refer to Figure 10.

Compressor 1 (Digital) suction valve

Compressor 1 (Digital) discharge valve

Compressor 1 (Digital) EVI pipe valve

Compressor 1 (Digital) oil return hand valve

Compressor 2 (Fixed speed) oil return hand valve

Compressor 2 (Fixed speed) suction valve

Compressor 2 (Fixed speed) discharge valve

Suction pipe valve

Compressor 2 (Fixed speed) EVI pipe hand valve

Oil pipe valve

Liquid receiver valve

Condenser valve

Liquid pipe valve

Keyboard descriptions - Single button

SET

Displays target set point; In programming mode, select a parameter or confirm an operation.

Start

Hold for 5 seconds to reset any lockouts if the current state of the controller allow for it to be reset.

Up

Enter the fast access menu; In programming mode, browse the parameter codes or increases the displayed value.

Down

In programming mode it browses the parameter code or decreases the displayed value

Service

Enter the service and alarm menu.

Defrost

Hold for 3 seconds to start a manual defrost or terminate an active defrost (Not available at the moment).

Keyboard descriptions - Combined buttons

SET + ⌂

Press and hold for about 3 seconds to lock (Pon) or unlock (Pof) the keyboard.

SET + ⌃

Pressed together to exit programming mode or menu; under rtC and PAr, this combination allows the user to go back to previous level.

SET + ⌄

Pressed together for 3 seconds allows access to first level of programming mode.

SET + ⌅

Pressed together for 3 seconds allows access to EXV manual setting.

Controller display upon start-up

Bin files number range

RTC (Real Time Clock) setting

After installation and initial power on, it is critical to double check the parameters below:

Replacing controller

After a new controller is replaced and initial power is on, it is critical to reset parameters defined on the label below the nameplate on the unit panel. Here is an example of a label:

Controller Parameter Default Setting

Notes:*Ensure that parameter [07 is set to match the actual refrigerant used. If not, set [07 following label "Unit Operation Setting After Installation".

Notes: C07 is accessible in Pr1 parameter, and the other parameters are assessible in Pr2 parameter

The step-by-step procedure to access and modify the Pr1 and Pr2 parameters are outlined below:

Pr1 parameter (1st level) browse and modification

Pr2 parameter (2nd level) browse and modification

Quick access menu browse - Sensor status and actual values

Sensor code and values descriptions

P1P Suction pressure sensor

P2P Condensing pressure sensor

P3t Digital compressor discharge line temperature sensor

P4t PHE vapor inlet temperature sensor

P5t PHE vapor outlet temperature sensor

P6t Ambient temperature sensor

P7t ON-OFF compressor discharge line temperature sensor

SH PHE superheat

OPP EXV opening percentage

LLS Solenoid valve status (not used)

Std Condensing temperature set point

Aoo Fan's analog output signal percentage

dso Percentage of PWM output driving the valve of the Digital Scroll compressor

Lt Minimum cold room temperature (unused)

Ht Maximum cold room temperature (unused)

tU1 #1 voltage sensor

tU2 #2 voltage sensor

tU3 #3 voltage sensor

tA1 #1 current sensor

tA2 #2 current sensor

Hm Time menu

(nP, noP, or nA means that the sensor does not exist; Err means that the sensor fails, out of range, disconnected, or does not configure properly)

Access alarm code (Maximum of 50 record)

Exact timing of the alarm

Upload the parameter settings from the controller to Hot-Key

Download the parameter settings from Hot-key to controller

Network wiring

Dixell XWEB300D serial address

• Connect to the ModBUS network using cable with 2 or 3 shielded wires, minimum section 0.5mm² (e.g. BELDEN8772).
• Do not connect shield to ground.
• Do not connect the "Gnd" terminal.
• Remember to draw a map of the line. This will help you to find an error if something is wrong.
• RS485 devices are polarity sensitive.

Figure 13. Correct network wiring

Figure 14. Incorrect network wiring

Dixell XWEB300D Configuration

XWEB300D is compatible with CDU/Rack if XWEB has the library of Large ZX and EMP Rack CoreSense™ controller.

Login into XWEB

• Go to Information Information
• If this is not present, follow the steps below:
  • Open Dixell website (https://dixell.com/xweb300d-xweb500-xweb500d/eng/), then login (registration required)
  • Go to support System sw update XWEB300D XWEB500XWEB500D
  • Download the upgrade package with your web browser, then login into XWEB
  • Go to information System Update Menu
• Provide the XW5 patch file
• Once the file has been selected wait until the upgrade procedure ends (XWEB reboots)
• Verify the installation ended succesfully by checking into the menu
• Go to Information Information for string

Log in again and setup the ZX CDU/EMP rack

• Go to Configuration Devices (drop down menu)
• Go to Actions New
• Enter the device name in the Name field (e.g. ZX CDU)
• Select "XCM25D" in the Model field
• Enter the ModBUS address in the RS485 Address field
• Refer to setting of paramater "t01" in pr2 level in CoreSense™, default setting is "1"
• Click New

Termination resistor for XWEB300D

If XWEB300D is placed at the beginning or end of the line, please install its termination resistor by adding a jumper in position 2 (JMP2 on the back side of the unit). Do not add the jumper if XWEB300D is placed in the middle of the RS485 line.

Large ZX CDU / EMP Rack connected to XWEB300D

Large ZX CDU/EMP Rack connected to the Dixell XWEB300D with the Intelligent Store Solution module using RS485 Modbus.

Connect the ZX CDU to the ModBUS network as shown on figure 15.

Connect the network cable to the three-terminal connector on the XWEB300D port that has been configured as ModBUS port (COM 12, 13, 14).

Connect port "13" of XWEB300D to port "485 +" of CoreSense™ and port "12" of XWEB300D to port "485 -" of CoreSense for RS485 communication.

Figure 15. XWEB300D connected to the Intelligent Store Solution module

Installation

Electrical connection

Power supply

Large ZX CDU/EMP Rack are delivered with a holding charge of neutral gas. The condensing unit should be located in such a place to prevent any dirt, plastic bag, leaves, or papers from covering the condenser and its fins. The unit must be installed without restricting the airflow. A clogged condenser will increase the condensing temperature, thus reducing the cooling capacity, which leads to a high-pressure switch tripping. Clean the condenser fins on a regular basis.

Large ZX CDU/EMP Rack electrical connection to the power supply must be made by qualified technicians, who should refer to the electrical diagrams located inside the electric connection panel. The units are designed for power supply at ± 10% voltage tolerance. The circuit breaker must be switched off before opening the front panel. The unit must be grounded before electrical use.

Electrical wiring

Before commissioning, ensure the neutral "N" wire is connected to the terminal block ("N" furthest to the right). After proper connection of the ZX condensing unit, the control LED on the power board and control board will light up (see wiring diagrams for more details). Customers' wire size needs to be selected to allow for the maximum operation current of each unit.

Refrigeration piping installation

All interconnecting pipes should be of refrigeration grade, clean, dehydrated and must remain capped at both ends until installation. Even during installation, if the system is left for any reasonable period of time (e.g. two hours), pipes should be re-capped to prevent moisture and contaminants from entering the system.

Do not assume that the service connection sizes on the unit (at the service valves) are the correct size to run your interconnecting refrigeration pipes. The service valve sizes have been selected for convenience of installation, and in some cases (larger units), these may be considered too small. However, for the very short pipes within our units, these service connection sizes are adequate. All interconnecting pipes should be sized to satisfy the duty required.

The suction line of condensing unit or rack must be well insulated. Large ZX and EMP Rack are featured with vapor injection, thus the liquid line must be insulated too, because the liquid line can pick up additional heat from the ambient and adversely affect the sub-cooling desirable for the liquid refrigerant before it enters the expansion valve.

The pipe should be sized to ensure optimum performance and good oil return. The sizing must also take into account the full capacity range through which this particular unit will need to operate.

Pipe runs should be kept as short as possible, using the minimum number of directional changes. Use large radius bends and avoid trapping of oil and refrigerant. This is particularly important for the suction line. The suction line should ideally slope gently towards the unit. Recommendation slope is 1/200~1/250. P traps, double risers and reduced pipe diameters may be required for suction lines where long vertical risers cannot be avoided.All pipes should be adequately supported to prevent sagging which can create oil traps.

The recommended pipe clamp support distance is shown below:

When brazing, the system should be protected with an inert gas such as nitrogen at a very low pressure. Only materials and components approved for refrigeration engineering are suitable.

It is necessary that all impurities (dirt, brazing scale, flux, etc.) are removed from the system before operation to avoid breakdowns. Many of these impurities are so small that they can pass through a filter and enter the suction side of the compressor. Other blockages can occur in the suction filter, and a high pressure drop can cause damage. For this reason, it is strongly recommended the usage of a large suction filter (which causes only a minimal drop of pressure) on all installations which are to be assembled on site in cases where the required cleanliness cannot be guaranteed. The suction filter core is highly recommended to be changed after first time 72 hours commissioning.

For selection of Emerson flow controls STAS filter drier for Large ZX or EMP Rack please contact Application Engineering in your region.

Liquid line insulation

Large ZX and EMP Rack are featured with vapor injection, the liquid line must be insulated with at least 19 mm thick, to avoid sub-cooling loss through heat absorption from ambient.

Brazing recommendations

Maintain a flow of oxgen-free nitrogen through the system at a very low pressure during brazing. Nitrogen displaces the air and prevents the formation of copper oxides in the system. If copper oxidization is allowed to form, the copper oxide material can be swept later through the system and block screens such as those protecting capillary tubes, thermal expansion valves, and accumulator oil return holes. This minimizes any entry of contaminants and moisture.

• Remove the liquid line connetion cap.
• Then remove the suction connection cap.
• Open both valves midway. Care should be taken to avoid the holding charge from releasing too quickly.
• Be sure that tube fitting inner diameter and tube outer diameter are clean prior to assembly.
• Since both tubes are extended from the condensing unit housing, Emerson recommends insulating the housing by using a wet cloth on the copper tubing.

Recommended brazing materials:

• a copper/ phosphorous or copper/phosphorous/silver alloy rod should be used for joining copper to copper whereas to join dissimilar or ferric metals, use a silver alloy rod, either flux coated or seperate.
• Use a double tip torch.

Location and fixing

Large ZX and EMP Rack should always be installed in a location free of other source of heat radiation and not be blown by wind in winter time. The place should have clean air circulation. The minimum operating space for unit or rack are described in below figures. Where multiple units or racks are to be installed in the same location, the contractor needs to consider space for each equipment carefully. The installation location should avoid the affecting to surrounding residents, without air blows directly to residents' windows.

The units or racks should be mounted on a solid concrete slab with anti-vibration pads between unit/rack feet and concrete. When the installation location is easy of water accumulation, the mounting base should have a certain height of cement base station at about 300 mm. At snowy areas, there should be additional cover be installed on top of the unit/rack besides a cement base in the bottom. The snow cover should be mounted at least 1500 mm higher than top of the unit/rack.

Power connection side

Air flow direction

Figure 16. 12-16HP Large ZX fixing

Expansion valve selection for low ambient application

For systems expected to operate in varying ambient conditions - namely summer and winter temperatures - the expansion valve (TXV or EXV) sizing should take into consideration the maximum expected saturated condensing temperature at high ambient conditions (summer) and the minimum expected saturated condensing temperature during low ambient conditions (winter).

The chosen expansion valve's operating capacities should all be well within these limits to ensure satisfactory system performance

The liquid refrigerant from the low temperature ZXLD and EMPLD unit / rack in liquid line is subcooled to very low temperature when it goes through PHE, so system expansion valve selection should take it into consideration. The table below lists the reference liquid line temperature.

Figure 17. 12-16HP EMP Rack fixing

Figure 18. 20HP Unit fixing

Lifting of unit/rack

Condensing unit and rack should always be kept vertical during transportation or operation. Refer to the figures below for the lifting method.

Center line

Center of gravity

Figure 19. 12-16HP Large ZX and EMP rack lifting

Figure 20. 20HP Unit lifting

Start up and operation

Before commissioning, make sure that all valves in condensing unit or rack are fully opened. Make sure that each protector's wiring is normal and in working condition.

Leak detection and pressure holding

During pressure holding, the high pressure should be less than 18 barg, and the low pressure should be less than 12 barg. Vacuum method is also allowed to detect leaks.

Vacuuming

Do not use the compressor to vacuum the system!

The evacuation procedure is based upon achieving an actual system vacuum standard and is not time dependent. Before the installation is put into commission, it has to be evacuated with a vacuum pump. Proper evacuation reduces residual moisture to 50ppm. The installation of adequately sized access valves at the furthest point from the compressor in the suction and liquid lines is advisable. To achieve undisturbed operation, the compressor valves are closed and the system is evacuated down to 0.3 mbar/0.225 Torr. Pressure must be measured using a vacuum pressure (Torr) gauge on the access valves and not on the vacuum pump; this is done to avoid incorrect measurements resulting from the pressure gradient along the connecting lines to the pump.

Before vacuuming, make sure the manual valves are opened. Please refer to the figure on the right, vacuum operation must be performed separately from points A, B and C.

Point A

Point B

Point C (except for ZXD120BE)

Refrigerant charging procedure

The scroll compressor design requires system charging as quickly as possible with liquid refrigerant into the liquid line. This will avoid running the compressor under conditions where there is insufficient suction gas. Sufficient gas is available to cool not only the motor but also the scrolls. Temperature builds up very quickly in the scrolls if this is not done. Do not charge vapor refrigerant into Large ZX condensing unit or EMP Rack. The suction service valves must be fully opened at any time while the compressor is running.

Refrigerant should be fully charged before start-up. The best filling port is at the liquid line service valve. If one-time charge from liquid line is not enough, charging the refrigerant at compressor running may cause to multiple pressure cut off and delayed restart, during which by-pass the low-pressure control and low-pressure protection are prohibited.

For charging adjustment, it is recommended to check the liquid sight glass just before the expansion valve.

For Large ZX unit and EMP rack, configured with PHE sub-cooler, please charge liquid refrigerant from point C. After starting up, you can continue to charge liquid refrigerant from point A. When there is insufficient refrigerant charge, there is gas in the moisture indicator, the controller will show E47 (electronic expansion fully open) or E48 (injection shortage) warnings. After there is no gas bubble in the moisture indicator, please continue to charge about 1 kg of refrigerant.

Oil charging procedure

Emerson Large ZX and EMP Rack are supplied with oil charge in compressor at the factory. Please confirm the oil level in the oil sight glass of the compressor after a short period of trial operation. If the oil level is above half of the sight glass, it can be considered sufficient oil. If oil charging is needed, charge oil through the needle valve port on the suction service valve.

When the length of one-way pipeline exceeds 20m, it is necessary to add oil at mid-glass in the upper oil sight glass of the oil reservoir before unit start up. If the oil level goes down below the lower oil sight glass after system running stable, it is suggested to add oil at least to mid-glass in the lower oil sight glass.

Qualified refrigerant and oil

Refrigerant

Check before starting & during operation

• Check all the valves are fully opened, to prevent trapping liquid.
• After starting and running stable, it is recommended to check the compressor oil level to confirm whether it is necessary to refuel the oil (halfway up the sight glass).
• Discharge line temperature should be lower than 125°C, discharge pressure should be lower than 28 barg, and the operating current is within the normal range.
• The oil sump temperature at the bottom of the compressor should be within the safe range shown in the figure below:

Evaporation temperature (°C)

Oil sump temperature (°C)

Safe Area

Feasible

Insecure area (Excessive cooling diluent)

Evaporation temperature (°C)

Alarm codes

Troubleshooting

Fault phenomenon

Direct cause

Inspection analysis and adjustment

Before the following troubleshooting, first of all ensure the correctness, robustness and reliability of all wiring.

Temperature sensor resistance table

Wiring diagram

ZXD160, ZXLD120/160 Condensing unit

ZXD120 Condensing unit

ATTENTION:Unit Must Be Grounded!

ZXD120 Condensing Unit Wiring Diagram

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

NOTES:

1. Dashed line " " is wired by installer.

2. Neutral "N" and Earth "E" wirings are not shown in harnesses for clarity.

EMPD/EMPLD Rack Wiring Diagram

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

NOTES:

1.Dashed line "--" is wired by installer.

2. Neutral "N" and Earth "E" wirings are not shown in harnesses for clarity.

20HP wiring diagram

ZXD/ZXLD Condensing Unit Wiring Diagram

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

NOTES:

1. Dashed line "--" is wired by installer.

2. Neutral "N" and Earth "E" wirings are not shown in harnesses for clarity.

3. The Paddle Switch only SHORT-TERM in emergency situation.

WIRE COLOR NOTE:

BU--Blue

BK-Black

OG-Orange

BN---Brown

GNYE--Yellow/Green

YE--Yellow

WH--White

RD-Red

General information

Technical data are correct at the time of printing. Updates may occur, and should you need confirmation of a specific value, please contact Emerson clearly stating the information required.

Emerson cannot be held responsible for errors in capacities, dimensions, etc., stated herein. Products, specifications and data in this literature are subject to change without notice.

The information given herein is based on data and tests which Emerson believes to be reliable and which are in accordance with today's technical knowledge. It is intended for use by persons having the appropriate technical knowledge and skill, at their own discretion and risk. Emerson's products are designed and adapted for fixed locations. For mobile applications, failures may occur.

The suitability for this has to be assured from the plant manufacturer, which may include making appropriate tests.

Note: The components listed in this catalogue are not released for use with caustic, poisonous or flammable substances. Emerson cannot be held responsible for any damage caused by using these substances.

About Emerson

Emerson (NYSE: EMR), headquartered in St. Louis, Missouri (USA), is a global technology and engineering company providing innovative solutions for customers in industrial, commercial, and residential markets. Emerson's Automation Solutions business helps process, hybrid, and discrete manufacturers maximize production, protect personnel and the environment while optimizing their energy and operating costs. Emerson's Commercial and Residential Solutions business helps ensure human comfort and health, protect food quality and safety, advance energy efficiency, and create sustainable infrastructure. For more information visit Emerson.com.

Notes