Emerson ZX User manual

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ZX OUTDOOR REFRIGERATION
CONDENSING UNIT
USER MANUAL
Emerson Climate Technologies (Suzhou) Co., Ltd.

CONTENTS
Section Item Page No.
1.0 Disclaimer 4
2.0 Introduction to the ZX Refrigeration Condensing Unit (CDU) 5
2.1 Product Description
2.2 Basic and Optional Configurations
2.3 Control Features
2.4 Diagnostic and Defrost Features
2.5 Advantages
2.6 ZX Value Story
2.7 Application Types
3.0 Nomenclature 14
4.0 Receiving your ZX unit 15
5.0 Physical Layout of the ZX 16
6.0 Dimensions and Installation Clearences 20
7.0 Essential Commissioning Tools and Equipment 23
8.0 Electrical Installation 24
9.0 Refrigeration Piping Installation 24
10.0 Start-up-Leak Checking, Evacuation & Charging 28
10.1 Initial Pressure Testing (by vacuum and nitrogen)
10.2 Leak Test (by refrigerant with nitrogen pressurization)
10.3 Evacuation
10.4 Charging and Commissioning
11.0 E2 Control and Operating Features 33
12.0 Operation and Set-up of the E2 Unit Controller 35
12.1 Compressor/Unit Setting
12.2 Compressor Motor Protection
12.3 Compressor Pressure Protection
12.4 Compressor Discharge Temperature Protection
12.5 Other Inputs to the E2 Board
12.6 Other Outputs from the E2 Board
13.0 Operation and Set-up of Optional Modules 40
13.1 Diagnostic Module
13.2 Defrost Module
14.0 Maintenance 44
15.0 Spare Parts List 46
16.0 Troubleshooting 48
17.0 Addendums:
17.1 General Technical Data 50
17.2 ZX Wiring Diagram 51
17.3 Capacity (kW) at 50Hz for Refrigerant R22 52
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LIST OF ILLUSTRATIONS
Page No.
Fig.1 ZX Single Fan Unit (ZX200, ZX300 & ZX400) 5
Fig.2 ZX Dual Fan Unit ( ZX 500, ZX600 & ZX 750) 6
Fig.3 E2 Control Board 7
Fig.4 The Defrost Module 8
Fig.5 The Diagnostic Module 8
Fig.6 The Diagnostics Interpretation Chart 10
Fig.7 ZX Nomenclature 14
Fig.8 ZX 600 TFD (with front panel open to expose the components) 16
Fig.9 Fan and Fan Motor exposed 17
Fig.10 Location of the Fixed High and Low Pressure Switches 17
Fig.11 Liquid Injection System 18
Fig 12 3 –Dimensional View 19
Fig.13 Physical Dimensions 21/22
Fig.14 Four Port Charging Manifold 23
Fig 15 Electronic Vacuum Gauge 24
Fig 16 Commisioning Hook-Up and Essential Equipment 27
Fig 17 Schraeder Valves with and without depressors 28
Fig 18 E2 Unit Controller Board – Layout and Major Components 35
Fig 19 E2 Control Reference Guide 38
Fig 19 Diagnostic Module details 40
Fig 20 Defrost Module details 42
Fig 21 Defrost Module Settings 42
Fig 22 E2 Board connected to the Modules 43
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1.0 Disclaimer
Thank you for purchasing this product. We hope that you will find this product meeting
your refrigeration needs efficiently and effectively. Please read through this Use
r
Manual thoroughly to familiarize yourself with the value-added features of this product
and how to use it optimally to suit your needs. Please do read the following
paragraphs in this page before proceeding with the rest of the Manual.
The ZX Outdoor 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.
A
ll instructions & procedures described in this manual are recommendations based
on what is considered to be good refrigeration trade practice (applied to this particula
r
product.) The installation contractor may prefer to use variations to these
recommendations however it is to be noted that the methods described in this manual
represent the minimum required to avoid any subsequent warranty claims for this
equipment or it’s component parts. These instructions do not cover the fundamentals
of good electricity or refrigeration practice and are therefore intended for use only by
qualified and/or experienced personnel as mentioned above or those technicians
certified by us.
These instructions are general in nature for this family of products (ZX) and due to ou
r
policy of continuous improvement some of the detail may not apply to the unit you are
installing. If in doubt, please consult your local sales office, quoting unit Model and
Serial number as shown on each unit nameplate. The wiring diagram supplied with
each unit takes precedent over the diagram in this manual in case of any ambiguity.
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2.0 Introduction to the ZX Refrigeration Condensing Unit
Copeland Asia Pacific launched the ZX Condensing Unit (CDU) a new refrigeration product to
the Asian market to primarily meet the demands of the food retail services and logistics sector.
The ZX Condensing Unit (CDU) is a Refrigeration Air-Cooled Condensing Unit that uses the
Copeland patented scroll technology as the main driver and has Electronic Protection,
Diagnostics and Communication Features in-built into the compact chassis.
Fig 1. Single Fan Unit
( ZX 200, ZX 300 & ZX 400 )
2.1 Product Description
The application range of the first release is between –15 C to 5C Evaporating Temperature and
27 C and 43 C Ambient (without Fan Speed Control) This CDU is released with both R22 and
R404A Refrigerants. The Single Fan units are ZX 200, ZX 300 and ZX 400 (2, 3 and 4 hp nominal
ARI MT) and the Dual Fan units are ZX 500 , ZX 600 and ZX 750 ( 5,6 and 7.5 hp nominal ARI
MT). These CDU’s are built for Robust Outdoor Applications and have excellent
Air-Conditioning wall-mountable type Aesthetics.
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Fig 2. Dual Fan Unit
( ZX 500, ZX 600 & ZX 750 )
The fact that the Scroll Compressors are manufactured at either Copeland ‘s China or Thailand
plants means that the design initiatives have taken a low cost- high technology approach, the
ZX is a very affordably designed CDU.
With a large Coil, small Fan design coupled with Built-In Fan Speed Control (Optional), the ZX is
one of the Quietest Refrigeration CDU on the market.
As mentioned in the first paragraph, the ZX uses electronics extensively in its Protection,
Diagnostics and Communication features. These features are controlled by the E2 Electronics
Control Board. The E2 provides Base Control functions related to Temperature Controller,
Defrost, Evaporator Fan control etc., Compressor Protection e.g. Current Overload , Voltage
Imbalance, Anti – Phase Reversal etc. , Liquid Injection Control which keeps the discharge
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head temperature within safe and acceptable limits, Self- Diagnostics (Optional) which receives
Operating Status, Alarm and Warning from the E2 Micro Controller Unit and displays these for
easy and rapid trouble-shooting and maintenance and finally Communication Capability that
allows the E2 to dial out to specified numbers via a Dialer Module. Development is in progress to
integrate the E2 Board with the CPC Einstein E2 Control and Monitoring System which will then
enable the ZX to be part of an entire Emerson Climate Technologies Integrated Store
Solution.
Fig 3. The E2 Control Board
2.2 Basic and Optional Configuration
The ZX is marketed with both a Basic configuration and a Basic plus additional Option
Package. The Basic ZX CDU consists of a Chassis, Condenser Coil and Fan/s, Electronic Control
Board (E2 Board + Protective Casing), a ZX Compressor with a Crankcase Heater, Liquid
Receiver with Rotalock Valves, Liquid Injection Electronic Expansion Valve (EXV) with Capillary
Tube, Fixed High Pressure and Low Pressure Switches, a Top Cap Thermistor and lead wire and
Suction and Liquid Service Valves.
The ZX basic and Option Packages both consist of a Liquid Line Assembly,
Condenser Fan Speed Control, Diagnostic Module, Defrost Control Module, Oil Separator,
Adjustable LP switch, Isolating Switch, Buzzer module (supplied loose without cable)
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Fig 4. The Defrost Module
Fig 5. The Diagnostic Module (now
available without Buzzer )
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2.3 Control Features
As mentioned earlier, the ZX CDU Control System evolves around the E2 Board and one of it’s
primary functions is the Automatic Liquid Injection system that ensures that the ZX Compressor
operates within a safe envelope. This is carried out with an injection of Liquid Refrigerant Into the
Scroll Suction, this process has a global patent on it. The Injection is based on measuring the
Scroll Head Temperatures and sending that data to the E2 Board which has a built-in Algorithm
that converts this temperature signal specific digital instructions and sends to a Stepper Motor
Driving An EXV. The EXV accordingly supplies Liquid Refrigerant to keep the Compressor Head
Temperatures within Safe Levels.
Other Compressor Protection features are Compressor Phase Reversal (Scroll Compressor
Will Not Compress In Reverse ), Voltage Imbalance Protection , Loss of Phase Protection,
Motor Current Overload (Built-In and therefore External Current Protection not Required ),
Non-Adjustable High And Low Pressure Switches (Automatic Reset For Nos. Of Trips, Then
Lockout [For HP Only] And Require Manual Restart), Liquid Floodback Protection
(Measurement of Discharge Superheat To Predict Liquid Floodback), Fresh Start Programs (To
Ensure Safe Start-Ups After Long Periods Of Inactivity) and the Crankcase Heater (Energized
When Compressor Stops)
Due to the Condenser Fan Speed Control Function, the Ambient Operating Range can be
reduced to –30 C which is useful in start-up and for operations during winter operation. The
ambient temperature below which Fan Speed Control Option is recommended is 25 C .
The Base Control function is for Connection Of Optional / Customer
Supplied Functions such as Temperature Controller or Thermostat, Electric Defrost Heater
Contactor, Evaporator Fan Contactor, Output For Dialer, Compatibility With CPC’s Einstein
Control & Monitoring System (coming)
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2.4 Diagnostic and Defrost Features
The Diagnostic Module (Option) is also installed within the Chassis and has a 5 LED’s (Light
Emitting Diodes ) that can either be ON, OFF or BLINKING. The Combination of these 5 LED’s
with these 3 different LED status can provide the different system status as shown in Fig 6 below :
Fig 6. The Diagnostics Interpretation Chart
Status Event LED Status
D1 D2 D3 D4 D5
Normal Unit OFF/Phase 'U' or 'N' missing
Normal Power ON
Normal Compressor ON
Normal Fresh Start/Normal Start
Normal Defrost ON
Fault DLT Overlimit
Fault Ambient sensor failure
Fault MCT sensor failure
Fault DLT Thermistor failure
Fault HP Cut Out
Fault Compressor Over Current
Fault Compressor Incorrect Phase sequence
Fault Compressor Voltage Imbalance
System Liquid Floodback
Fault Compressor about to turn ON & Ambient sensor failure
On DLT Discharge Line Temperature
MCT Mid Coil Temperature
Off
Blink
Warning
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For e.g. If the 5 LED’s display as follows : D1 ( Blink) , D2 (On) , D3 (On) , D4 (Blink ), D5 (On) ,
then this is an indication of a potential Liquid Floodback situation. In this case, the Refrigeration
Technician who responses to the Diagnostic alarm will save valuable time and go straight for the
root cause of the issue, an iced-up evaporator due to defrost malfunction , faulty evaporator fan ,
faulty or oversized TXV or even wrong evaporator selection ( to high Delta T for a LT Application )
The Diagnostic Module can be connected to a Remote Buzzer which alarms the recipient to a
potential issue with the CDU.
The ZX Defrost Module (Optional) is a Time-Initiated and Time-Terminated with Manual Button
to Override The Settings i.e. To Stop Or Start Defrost. A Remote Manual Defrost Button can also
be connected to the Defrost Module.
2.5 Advantages
The key advantages that the ZX CDU has over similar units is that it is extremely affordable and
has a very low noise level in comparison to other units on the market. To be cost effective and
more affordable the ZX CDU has Built-In Technology which includes the E2 Board with all the
programmed algorithms and the Diagnostic Module. The other key advantage is the Copeland
Compliant Scroll which has a Low Noise Level (60 dBA at 1m), Very Low Oil Carryover (About
0.2 % compared to Reciprocating systems that have a 2-3 % Oil Circulation Rate ), the Ability To
Withstand Substantial Liquid Floodback (Scroll Set) and finally a High Efficiency ( EER @ ARI MT
Rating Between 2.4 To 2.75)
2.6 The ZX Value Story
The Value of the ZX CDU based on the above can be summarized in to the Key Value Points as
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follows:
Energy Saving - More efficient than the Hermetic And Semi-Hermetic Reciprocating & Rotary
Compressors
Service Saving -The Diagnostic Module Pin-Points the Issue, reducing service time
Reduced Food Spoilage – Reduced Food Spoilage With Good Unit Reliability And Advance /
Early Warning Diagnostics Capability
Compressor Replacement – Ability to withstand Prolonged Liquid Floodback & Good Discharge
Temperature Control
Great Aesthetics – Can be installed Outdoors like an Air Conditioning Unit
Built-In Electrical Fuses, Contactors and Connectors– No Switchboard Required
Fan Speed Control – Low Sound Level and Lower Energy Consumption
Ventilation – Easy To Retrofit For Discharge Air Extraction
Machine Room Saving – Eliminate Wasteful Space, Mount The ZX On The Wall
The following explains why the ZX is more Energy Efficient:
Scroll Compressor
Large Suction And Discharge Ports – Reduces Pressure Losses Incurred In Suction And
Discharge Processes Physical Separation Of These Ports Reduce Heat Transfer To The Suction
Gas
No Leakage Past Piston Rings
Absence Of Valves And Re-Expansion Volumes And Continuous Compression High
Volumetric Efficiency
Flatter Capacity Curve (Than Reciprocating) Over Wide Ambient Range
Condenser Fan-Coil Design
Small Fan – Large Coil Combination
Condenser Fan Speed control (Option)
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Built-In Delays in the E2 Board ( reduce Total Runtime)
Lower Night Loads
2.7 Application Types
The ZX can be applied to a variety of installations these are listed below:
Supermarkets (medium to small)
Coldrooms
Convenience Stores
Independent Coldrooms
Fast Food Chains and Restaurants
Small Flake Ice Machines (250 to 750 kg per day) @ -15 deg C evap)
Process Room Air Cooling (10 deg C room temperatures)
Water Cooling Applications (PHE/Tube-in-Tube evaporators)
3.0 ZX Nomenclature
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Fig 7. ZX Nomenclature
4.0 Receiving Your ZX Unit
All units are shipped with a holding charge of Dry Nitrogen inside at a low but positive pressure.
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Suitable labeling is prominently displayed on both our unit and the packaging.
It is very important to check that this holding pressure remains present when you
receive each unit from us or our authorized representatives
Several schraeder type connections are provided for the convenient checking of the integrity of
the holding charge
Once you have checked the holding charge and find that the charge is missing , you should
immediately inform us or our authorized representative. To not do so, may void your claim for
some other fault later on. Transit damage is essentially an insurance matter and not a warranty
matter.
It is also advisable to check the rest of the unit for obvious physical damage and then act in the
same manner as described above.
5.0 Physical Layout of the ZX
The following illustration identifies the major components and where these are located in the ZX
unit.
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E2 Electronic
Control Board
Compressor
2 x 500Dia Fan
and Fan Guard
Crankcase
Heater
Defrost Module
(Option)
Electrical
Terminal Block
Receiver Inlet
Valve
Receiver
Diagnostic
Module (Option)
Sight-Glass
(Option)
Liquid Line
Service Valve
Suction Line
Service Valve
Receiver Outlet
Valve
Filter Drier
(Option)
Fig 8. ZX 600 TFD ( with front panel open to expose the components)
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Fan
Bracket/Mounting

500mm Dia
3 Blade Propelle
r
Fan
Fig 9 . Fan and Fan Motor exposed ( Fan Guard removed)
Fixed LP Switch
Fixed HP Switch
Fig 10. Location of the Fixed High and Low Pressure Switches
Top Cap
Thermistor
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Injection Line
Electronic
Expansion
Injection Valve
Injection
Capillary Tubing
Fig 11. A ZX 600 during assembly ( showing the patented Injection System )
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Fig 12. 3-Dimensional Views of Selected Component Layout ( not to be used for
dimensioning or installation)
6.0 Dimensions and Installation Guidelines
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Fig 13. shows the overall dimensions of the ZX units. It is recommended that a clearance of 300
mm from the wall (or the next unit) be maintained from the unit’s Left and Rear panel whereas a
clearance of 500 mm to be maintained from the units Right, Top and Front panels. ( seen facing
the front of the unit) Both Service Access and airflow have been considered in making these
recommendations.
Where multiple units are to be installed in the same location, the contractor needs to consider
each individual case carefully. There can be many variations of unit quantities and available
space and it is not the intention of this manual to over these here. But in general terms, air by-pass
around each condenser and between each unit should be avoided at all times.
Ideally, the unit should be mounted level on a solid concrete slab with rubber strips between unit
feet and concrete. However the ZX has also been designed for mounting on suitable brackets for
wall mounting. In this case it is not only equally important that the spatial guidelines given above
are followed but additional consideration needs to be given for possible air recycling if units are
stacked above and below each other.
Other factors to consider in finding a good installation site includes the direction of the prevailing
wind. For example if the leaving air from the condenser faces the prevailing wind, the air flow
through the condenser can be impeded, causing high condensing temperatures and ultimately
resulting in reducing the life of the unit. A baffle is one remedy for this situation.
The unit should never be installed adjacent to a dust source (dirt road). External
fouling of the condenser fins also leads to high condensing temperatures, and once
, will reduce the life of theagain unit.
Fig. 13 Physical Dimensions
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