Copeland Large ZX090BE User manual

Large ZX Condensing Unit
User Manual

Table of contents
Introduction 3
Safety Information 4
Nomenclature 6
Scope of Supply 6
PI Diagram 7
Technical Data 9
Features & Benets 10
Condensing Unit Layout 12
CoreSense Controller 13
Networking 18
Electrical Connections 20
Installation, System Processing, & Start-up 21
Troubleshooting 28
System Start-up & Operational Check Sheet 39

3
Introduction
Thank you for purchasing the Copeland™ Large ZX Condensing Unit for refrigeration
applications. This unit comes with a high efficiency Copeland fixed speed scroll compressor
with liquid / vapor injection technology.
This is the best-in-class unit available in the market within the capacity and operating range.
Copeland condensing units have been highly successful in global market and enjoys proven
success with its energy savings and customer friendly electronic features.
This document is designed to help the contractor and customer with the
installation, commissioning & operation of the Copeland Large ZX Condensing Unit.
Disclaimer
Please read through this operation manual to familiarize yourself with the installation,
commissioning, and operation of this product. Please do read the following information on
this page before proceeding with the rest of the user manual.
Copeland Large ZX scroll refrigeration condensing units should only be installed by
suitably qualified and experienced refrigeration technicians. No responsibility can be
accepted for damage caused by inexperienced or inadequately trained site technicians or
improper system design. All instructions and procedures described in this manual are based
on good refrigeration trade practices as applicable to this particular product. The
installation contractor may prefer to use variations to these recommendations. However,
the methods described in this manual represent the minimum requirements to avoid any
subsequent warranty claims for this equipment and its components. These instructions do
not cover the fundamentals of good electrical or refrigeration practice and are therefore
intended for use only by qualified and/or experienced personnel or technicians.
For additional inquiries, please consult your local sales office, quoting unit model and serial
number as shown on the nameplate. In case of ambiguity, the wiring diagram supplied with
each unit takes precedence over the diagram in this user manual.

4
1. Safety Information
1.1 Installation and commissioning work on CDU shall be carried out only by
qualified, refrigeration personnel who have been trained and instructed.
1.2 Copeland Large ZX condensing unit is manufactured according to the latest
safety standards. Emphasis has been placed on the user’s safety. For relevant
standards please refer to the manufacturer’s declaration, available on
request. You are strongly advised to follow these safety instructions.
1.3 Icon explanation
1.4 Safety Statements
a. Only qualified and authorized refrigeration personnel are permitted to
install, commission, and maintain this equipment.
b. Electrical connections must be made by qualified electrical personnel.
c. All valid standards for connecting electrical and refrigeration equipment
must be observed.
d. 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.
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to avoid
property damage and possibel
personal injury
High Voltage
This icon indicates operations with a
danger of electric shock
IMPORTANT
This icon indicates instructions to avoid
malfunction of the compressor
Danger of burning or frostbite
This icon indicates operations with a
danger of burning or frostbite
This word indicates a recommendation
for easier operation
Explosion hazard
This icon indicates operations with a
danger of explosion

5
1.4 General Instructions
Warning
System breakdown! Personal Injuries! Never install a system in
the field and leave it unattended when it has no charge, a holding
charge, or with the service valves closed without electrically
locking out the system.
Warning
High shell temperature! Burning! Do not touch the compressor
until it has cooled down. Ensure that the 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 ot without being connected to the
system.
Caution
Compressors contain oil & refrigerant under pressure. Release
pressure from both high & low side of compressor before
servicing.
Caution
Tube brazing and compressor operation can produce hot surfaces.
To avoid burns, allow surfaces to cool.
1.6 Safety Refrigerants/Lubricant
a. Please use correct refrigerant as designed to work in safe operating
envelope
b. Compressor is supplied with an initial oil charge. The standard oil charge
for use with HFC refrigerant is Polyolester Oil (POE) lubricant Emkarate
RL 32 - 3MAF.
1.7 Receiving your unit
All units are filled with an ideal gas at a positive pressure before
transportation. When you receive the unit from Emerson or an authorized
representative, it is important to check the pressure of each unit. If the
unit is found without any pressure on receipt, please contact Copeland
or their authorized distributor. Damage to the unit caused by the
transportation / handling 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 any physical damage and inform Copeland or
authorized distributor.

6
2. Nomenclature
3. Scope of Supply
ZX L 012 B E -TFM -551
Condensing unit family
Blank = Medium Temp
L = Low Temp
MT: 9 - 15 HP
LT: 10 - 20 HP
Generation
E = Polyolester oil
TFM = 380V/420V, 3ph, 50 Hz
Bill of Material
Base model Electrical Code Bill of Material
Large ZX / Scroll Rack Model ZX (9 -15HP) ZXLD
BOM 551 551
Liquid Line Filter Drier  
Moisture Indicator  
Oil Separator  
Accumulator 
Adjustable LP Control Switch  
Fixed LP Safety Switch 
Fixed HP Safety Switch  
CoreSense Protection  
Intelligent store ready  
Fan speed controller  
Circuit breaker  
Compressor Sound Jacket  
Receiver certication (UL/PED)  
Pressure Relief Valve  

7
4. PI Diagram
ZX
Position Description
1 Compressor M1
2 Oil Seperator
3 Crank Case Heater R2
4 Condenser
5Receiver
6 —
7 Electronic Expansion Valve
8 Filter Drier / Sight Glass
9 Ball Valve, Liquid line
Position Description
10 Ball Valve, Suction line
11 —
F5 Adjustable LP/HP Dual Pressure Switch
B2 Pressure Transmitter, HP
B3 Discharge Line Temperature Sensor
B4 —
B5 —
B6 Ambient Temperature Sensor

8
ZXL with EVI Technology
Position Description
1 Compressor M1
2 Oil Seperator
3 Crank Case Heater R2
4 Condenser
5Receiver
6 Brazed Plate Economizer
7 Electronic Expansion Valve
8 Filter Drier / Sight Glass
9 Ball Valve, Liquid line
Position Description
10 Ball Valve, Suction line
11 Accumulator
F5 Adjustable LP/HP Dual Pressure Switch
B2 Pressure Transmitter, HP
B3 Discharge Line Temperature Sensor
B4 Vapour In Temperature Sensor
B5 Vapour Out Temperature Sensor
B6 Ambient Temperature Sensor

9
Family ZX
Nominal Rating Horsepower HP 9 10 13 15
Model name ZX090BE ZX100BE ZX130BE ZX150BE
Unit Performance Sound Pressure
Level @ 1m dB(A) 60 / 66 60 / 66 61 / 67 64 / 67
Compressor
Rated Load Ampere amp 17.5 20.0 25.0 27.9
Locked Rotor
Ampere amp 111 118 140 174
Oil Type POE
Oil Recharge
Volume 3.14
Fan Motor
Number of Fans Unit 1
Diameter mm 710
Maximum Speed rpm 1010
Air Flow Total m3/h 16632 16632 15372 15372
Total Fan Motor
Power Input W855 855 980 980
Others
Oil Seperator Volume liters 0.6
Receiver Volume kg 17
Pipes Suction OD inch 1 3/8”
Liquid OD inch 3/4”
Dimension W x H x D mm 1200 x 882 x 2044
Weight Net kg 308 310 316 318
Gross kg 373 375 381 383
5. Models
Medium temperature, 9 - 15HP
Low temperature, 10 - 20HP
Family ZXL
Nominal Rating Horsepower HP 10 13 15 20
Model name ZXL100BE ZXL130BE ZXL150BE ZXL200BE
Unit Performance Sound Pressure
Level @ 1m dB(A) 61 / 67 64 / 69 64 / 69 70 / 71
Compressor
Rated Load
Ampere amp 21.7 23.0 23.0 28.6
Locked Rotor
Ampere amp 118 118 139 168
Oil Type POE
Oil Recharge
Volume 3.25 vvv
Fan Motor
Number of Fans Unit 1
Diameter mm 710
Maximum Speed rpm 1010
Air Flow Total m3/h 16632 16632 15372 15372
Total Fan Motor
Power Input W855 855 980 980
Others
Oil Seperator Volume liters 0.6
Receiver
Volume kg 17
Pipes Suction OD inch 1 3/8”
Liquid OD inch 3/4”
Dimension W x H x D mm 1200 x 882 x 2044
Weight Net kg 334 334 340 340
Gross kg 399 399 405 405

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6. Features & Benets
Large ZX platform condensing units were designed
based on demands by industry users:
Energy efficiency -Utilizing Copeland™ scroll compressor technology, variable speed fan
motor, large capacity condenser coil and advanced control algorithms, energy consumption
is significantly reduced. End-users can save more than 20% on annual energy costs
compared to equivalent reciprocating units.
Reliability -Combining the proven reliability of Copeland scroll compressors with advanced
electronics controller and diagnostics, equipment reliability is greatly enhanced. Fault code
alerts and fault code retrieval capabilities provide information to help improve speed and
accuracy of system diagnostics. Integrated electronics provide protection against over-
current, over-heating, incorrect phase rotation, compressor cycling, high pressure resets,
low pressure cut-outs. It can also send out a warning message to an operator when there is
liquid flood back, which can prevent critical damage on the unit.

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Condensing Unit Features
Copeland™ scroll compressor technology
Highly efcient, ultra-quiet and highly reliable.
Congured with CoreSense controller
Provides electronic diagnosis, protection, and communication modules for energy-
saving and reliable unit control. Provides digital modulation control.
Enhanced vapor injection (ZXL only)
Vapor injection provide high efciency for refrigeration application
Well-tuned electronics algorithm with one big PHE to sub-cool the liquid temperature,
and feed gas into the compressors’ 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 ood back warning
•Compressor minimum off time
•Compressor oil level protection
•Intelligent store Solution: Communication and retail store monitoring

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7. Condensing Unit Layout
9 -15 HP Unit
10 - 20 HP Unit

13
8. CoreSense Controller
CoreSense Layout
Contactor Customer connection
terminal block
Transformer
CoreSense
Power isolation switch

14
LED descriptions
LED Status Description
ON Compressor1 is running
Flashing Compressor1 is ready to start
ON Reserved
Flashing Reserved
ON Condensing fan is running
ON Reserved
ON Display with °C
Flashing Programmable mode
LED Status Description
ON Browsing the service menu
Flashing Browsing the fast access menu
ON A new alarm happened
Flashing Browsing the alarm menu
ON An alarm is occurring
ON Reserved
-Reserved
Keyboard descriptions - single button
Set Display target set point; In programming mode, select a parameter or confirm an operation.
Reset Hold for 5 seconds to reset any lockouts if the current state of the controller allows 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 codes 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).

15
Keyboard descriptions - combined buttons
Pr1 parameter (1st level) Browse and Modification
+Press and hold for about 3 seconds to lock (Pon) or unlock (PoF) the keyboard.
+Pressed together to exit programming mode or menu; under rtC and Par, this combination allows the user to go
back to previous level.
+Pressed together for 3 seconds allows access to first level of programming mode.
+Pressed together for 3 seconds allows access to EXV manual setting.
Controller initialization message
When the unit is initially powered on, the controller will display the following.
Step Action Phenomenon and description
1 Power on controller All LEDs will light up for 3 seconds.
2Firmware version will be displayed for 3 seconds.
3 Parameter setting file (bin file number) identifier will be displayed for 3 seconds.
4Normal display (actual suction temperature will be displayed on ZXV/ZXD unit, condensing
temperature will be displayed on ZX/ZXL/ZXB unit)
Step Action Phenomenon and description
1Press “ ” + “ ” Enter menu to select “PAr” (parameter) or “rtC”
2Press “ ” or “ ” Select “rtC”
3Press “ ”
“n01” , minute
“n02” , hour
“n03” , day
“n04” , month
“n05” , year (last two digits)
4Press “ ”Display actual value
5Press “ ” or “ ” Modify the value
6Press “ ”Press“SET” : the value will flash for 3 seconds, then move to the next value
7Press “ ” + “ ” Exit to “rtC”
8Press “ ” + “ ” Exit to main menu (or wait for 120 seconds and exit automatically)

16
Quick access menu browse - sensors status and actual values
Step Action Phenomenon and description
1Press “ ” Enter quick access menu, will display“P1P” (Press “Up” or “Down” to view other sensors
2Press “ ”View the actual value of “P1P”
3Press “ ”Change to next sensor code
4Press “ ” + “ ” Exit (or exit automatically after waiting for 60 seconds)
Sensor code and values descriptions
(“nP”, “noP”, or“nA” mean that the
sensor does not exist; “Err” means that
the sensor fails, out of range,
disconnected, or does not configure
correctly)
•P1P : Pressure value of suction (only in ZXD & ZXV)
•P2t : Temperature value of condenser mid coil
•P2P : Pressure value of discharge (not used)
•P3 : Discharge line temperature
•P4 : PHE vapor inlet temperature sensor
•P5 : PHE vapor outlet temperature sensor
•P6 : Ambient temperature sensor
•P7 : Not used
•SH : PHE superheat
•oPP : EXV opening step
•LLS : Status of the liquid line solenoid valve
•Std : Condensing temperature setting point
•Aoo : Percentage of the analog output
•dSo : Percentage of the PWM output driving the valve of the digital scroll
compressor
•Lt : Minimum room temperature
•Ht : Maximum room temperature
•HM : Time Menu (hour & minute)
Access alarm code (maximum of 50 record)
Step Action Phenomenon and description
1Press “ ”Display “SEC”
2Press “ ”Display “A01”
3Press “ ”Display alarm code in “A01”
4Press “ ”Display “A02”
5Press “ ”Display alarm code in “A02”
6…
7Press “ ” + “ ” Exit (or exit automatically after waiting for 15 seconds)

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Exact timing of the alarm
Step Action Phenomenon and description
1Press “ ” Display “SEC”
2Press “ ”Display “A01”
3Press “ ”Display alarm code in “A01”
4Press “ ”Display “Hr”
5Press “ ”Display the alarm exact timing: hour
6Press “ ”Display “Min”
7Press “ ”Display the alarm exact timing: minute
8Press “ ”Display “Day”
9Press “ ”Display the alarm exact timing: day
10 Press “ ”Display “Mon”
11 Press “ ”Display the alarm exact timing: month
12 Press “ ”Display “yEA”
13 Press “ ”Display the alarm exact timing: year
14 Press “ ” + “ ” Exit (or exit automatically after waiting for 15 seconds)
Upload the program from the controller to hot-key
Step Action Phenomenon and description
1Inert Hot-Key when the
controller is ON
2Press “ ”
the “uPL” message appears followed by a flashing “End” label
(Note: if display “Err”, it means it fails to upload program to Hot-Key.
Please restart the process.)
3Press “ ”“End” will stop flashing
4Turn-off the controller
and remove Hot-Key
5 Turn-on the controller
Download the program from hot-key to controller
Step Action Phenomenon and description
1 Turn-off the controller
2 Insert hot-key
3 Turn-on the controller The “doL” message will blink followed a by a flashing “End” label (Note: if display “Err”,
it means it fails to download program to the controller. Please restart the process.)
4 Controller will restart working with the new parameters after 10 seconds
5Remove hot-key

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9. Networking
Dixell XWEBPRO serial address - Wiring
• 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.
Correct network wiring
Incorrect network wiring

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ZX CDU connected to XWEBPRO
ZX CDU connected to the Dixell XWEBPRO with the Intelligent Store solution
module using RS485 ModBUS.
Connect the ZX CDU to the ModBUS network as shown below. Connect the network
cable to the three-terminal connector on the XWEB port that has been configured as
ModBUS port (COM 12, 13, 14).
Connect port “13” of XWEBPRO to port “D0485 +” of CoreSense™and port “12” of
XWEB300D to port “D1485 -” of CoreSense for RS485 communication.
XWEB300D Connected to the Intelligent Store Solution Module