Emerson Copeland EazyCool ZX Series User manual

Outdoor Condensing Units
ZX Range

C6.1.6/1108-0509/E
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 Common information about Copeland EazyCool™ZX condensing units.........................3
2.2 About this guideline............................................................................................................3
2.3 Product range ....................................................................................................................3
2.4 Product nameplate.............................................................................................................3
2.5 Nomenclature.....................................................................................................................3
2.6 Application range...............................................................................................................4
2.6.1 Qualified refrigerants and oils ................................................................................4
2.6.2 Application limits.....................................................................................................4
2.7 Main component description..............................................................................................4
2.7.1 Compressor............................................................................................................4
2.7.2 Condenser fan(s)....................................................................................................4
2.8 Electronic board control and operating features................................................................5
2.8.1 Electronic board features .......................................................................................5
2.8.2 Electronic board description...................................................................................6
2.8.3 Diagnostic signal ....................................................................................................7
2.9 Compressor / Unit setting ..................................................................................................8
2.10 Compressor motor protection ............................................................................................9
2.11 Compressor pressure protection .......................................................................................9
2.11.1 High pressure.........................................................................................................9
2.11.2 Low pressure..........................................................................................................9
2.12 Other inputs to the board...................................................................................................9
2.12.1 Customer-supplied control (thermostat).................................................................9
2.12.2 Case temperature controller.................................................................................10
2.12.3 Condenser coil & ambient air thermistors ............................................................10
2.13 Other outputs from the electronic board..........................................................................10
2.13.1 Liquid line solenoid valve (not supplied) ..............................................................10
2.13.2 Defrost heater contactor coil (not supplied) .........................................................11
2.13.3 Evaporator fan contactor coil (not supplied).........................................................11
2.14 Dimensions in mm ...........................................................................................................11
3 Installation....................................................................................................... 13
3.1 Condensing unit handling ................................................................................................13
3.1.1 Transport and storage..........................................................................................13
3.1.2 Weights.................................................................................................................13
3.2 Electrical connection........................................................................................................13
3.2.1 Power supply connections....................................................................................13

C6.1.6/1108-0509/E
3.2.2 Wiring diagram .....................................................................................................13
3.2.3 Electrical protection standard (protection class) ..................................................15
3.3 Refrigeration connections................................................................................................15
3.3.1 Refrigeration piping installation............................................................................15
3.3.2 Brazing recommendations....................................................................................15
3.3.3 Brazing procedure................................................................................................16
3.4 Location & fixings.............................................................................................................17
4 Starting up & operation................................................................................... 19
4.1 Evacuation .......................................................................................................................19
4.2 Charging procedure .........................................................................................................19
4.2.1 Refrigerant charging procedure ...........................................................................19
4.2.2 Oil charging procedure.........................................................................................20
4.3 Rotation direction of Scroll compressors.........................................................................20
4.4 Maximum compressor cycle ............................................................................................20
4.5 Checks before starting & during operation ......................................................................20
5 Maintenance & repair...................................................................................... 21
5.1 Replacing a compressor..................................................................................................21
5.2 Condenser fins.................................................................................................................21
5.3 Electrical connections......................................................................................................21
5.4 Electronic panel ...............................................................................................................22
5.5 Routine leak testing .........................................................................................................22
5.6 Condenser fan(s) & motor(s) ...........................................................................................22
6 Certification & approval.................................................................................. 22
7 Dismantling & disposal................................................................................... 22

C6.1.6/1108-0509/E 1
1 Safety instructions
Copeland EazyCool™ZX Outdoor Refrigeration Condensing Units are manufactured according
to the latest European and US 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
EC Machines directive. 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 Manufacturers Declaration, available on request.
These instructions should be retained throughout the lifetime of the compressor as well as the
condensing unit.
You are strongly advised to follow these safety instructions.
1.1 Icon explanation
WARNING
This icon indicates instructions to
avoid personal injury and material
damage.
CAUTION
This icon indicates instructions to
avoid property damage and possible
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. NOTE This word indicates a
recommendation for easier operation.
Explosion Hazard
This icon indicates operations with a
danger of explosion.
1.2 Safety statements
Refrigerant compressors must be employed only for 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.
Use personal safety equipment. Safety goggles, gloves,
protective clothing, safety boots and hard hats should be worn
where necessary.
Safety
instructions
Product
description
InstallationStarting up &
operation
Maintenance &
repair
Certification &
approval
Dismantling &
disposal

2 C6.1.6/1108-0509/E
1.3 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.
System breakdown! Personal injuries! Only approved refrigerants and
refrigeration oils must be used.
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.
IMPORTANT
Transit damage! Compressor malfunction! Use original packaging. Avoid
collisions and tilting.
The contractor, responsible for the installation of the unit, should ensure sufficient liquid sub-
cooling in the line to the expansion valve(s) to avoid “flash-gas” in the liquid line.
It is of vital importance that the discharge stop valve has been fully opened before the
compressor is started. If the discharge stop valve is closed or partly closed an unacceptable
pressure with accordingly high temperatures may develop on the discharge outlet in the
compressor. When operating with air the so-called diesel effect may occur, ie, the air sucked in
is mixed with oil gas and can explode due to the high temperature, and thereby destroy the
compressor.