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.
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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.

C6.1.6/1108-0509/E 3
2 Product description
2.1 Common information about Copeland EazyCool™ZX condensing units
Emerson Climate Technologies has developed the Copeland EazyCool™ZX Outdoor
Condensing Unit of second generation to meet primarily the demands of the food retail services
and logistics sectors. It is a refrigeration air-cooled condensing unit that uses the latest
Copeland®Brand Products patented Scroll technology as the main driver and has electronic
protection and diagnostics features built in the compact chassis. With a large coil, low speed fan
design coupled with built-in fan speed control, the new Copeland EazyCool™ZX product offers
a refrigeration condensing unit especially designed for night operation.
2.2 About this guideline
This guideline is intended to enable users to ensure the safe installation, starting, operation and
maintenance of Copeland EazyCool™ZX condensing units.
This guideline is not intended to replace the system expertise available from system
manufacturers.
For additional information, please refer to the Product Catalogue or to the Copeland®Brand
Products Selection Software accessible from the Emerson Climate Technologies website at
www.emersonclimate.eu.
2.3 Product range
The application range is between –30°C and 7°C evaporating temperature. This condensing unit
is released for R404A only. The single-fan units are ZXME020E, ZXME030E and ZXME040E (2,
3 and 4 hp nominal ARI MT) and the dual-fan units are ZXME050E, ZXME060E and ZXME075E
(5, 6 and 7.5 hp nominal ARI MT). These condensing units are built for robust outdoor
applications and have excellent air-conditioning wall-mountable type aesthetics.
2.4 Product nameplate
The condensing unit nameplate shows model designation and serial number, as well as locked
rotor amps, maximum operating current, safety pressures, refrigerant and weight.
The compressor has its own nameplate with all electrical characteristics.
2.5 Nomenclature
The model designation contains the following technical information about the compressor:
Z X M E XXX E - TFD - XXX
Unit family: ZX
Nominal capacity [HP]
Motor version
Bill of material number
Oil type: E = Ester oil
Market: E = Europe
M = Medium temp; L = Low temp (future); D = Digital (future)
Standard motor version available:
TFD: 380-420V / 3 Ph / 50 Hz
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2.6 Application range
2.6.1 Qualified refrigerants and oils
ZXME020E ZXME030E ZXME040E ZXME050E ZXME060E ZXME075E
Qualified refrigerant
Oil charge ( litre ) 1 1.1 1.85 1.85 1.85 1.85
Qualified servicing oil
R404A/R507
Emkarate RL 32 3MAF
Mobil EAL Artic 22 CC
Table 1: Qualified refrigerants and oils
2.6.2 Application limits
For application envelopes, please refer to the compressor application envelopes available in
Copeland®Brand Products Selection Software.
Evaporating temperature is from –30°C up to 7°C, and ambient temperature range depending on
model used. See Copeland®Brand Products Selection Software or literature for further
information.
2.7 Main component description
2.7.1 Compressor
Unit model Compressor model
ZXME020E ZX15KCE-TFD
ZXME030E ZX21KCE-TFD
ZXME040E ZX30KCE-TFD
ZXME050E ZX38KCE-TFD
ZXME060E ZX45KCE-TFD
ZXME075E ZX51KCE-TFD
Table 2: Compressor type used in ZX condensing unit
2.7.2 Condenser fan(s)
The condensers of the ZX condensing units are equipped with single-phase fans.
Diameter Voltage Power
input
mm V/ph/Hz (W)
ZXME020E
ZXME030E
ZXME040E
ZXME050E
ZXME060E
ZXME075E
450
2
1
246
116
60830
220-240
1~50
Condensing units N° of
fans
Fan
Motor
(W)
Fan
speed
(r/min)
Table 3: Condenser fans technical data

C6.1.6/1108-0509/E 5
2.8 Electronic board control and operating features
The function of the electronic board is to react to the On/Off signals received from devices such
as thermostat to operate and protect the ZX unit. The electronic board control panel is fitted as
standard and has been developed along with the compressor to provide the following control
and protection systems:
2.8.1 Electronic board features
Automatic liquid injection: The electronic board automatically injects cool liquid refrigerant into
the suction line of the Scroll compressor to reduce discharge temperatures generated when the
unit operates at increasing compression ratios. The electronic board controller reacts
automatically to a thermistor embedded in a pocket inserted into the top of the compressor. The
controller converts this signal for the linear stepper motor driving the liquid injection valve to a
position that enables the compressor to continue operating within its safe envelope. This
advanced control strategy extends the operating range and is not normally associated with a
standard refrigeration condensing unit of this size making this feature a clear point of
differentiation from the competition.
Compressor phase reversal: Ensures that the compressor remains running in one direction
only – necessary for a compliant Scroll compressor to compress and pump refrigerant. Reset is
automatic once the phase rotation is correct for the compressor.
Motor current overload protection is provided (also via the electronic board) eliminating the
need for external current protection for the compressor motor.
Fixed low- and high-pressure switches: These are non-adjustable protection devices to
prevent the compressor operating outside of its safe evaporating and condensing pressure
ranges. Reset is automatic for a set number of trips, and then the unit will lock out and require
manual restart. The latter feature is important to prevent the ZX unit cycling under these controls
for a long period of time.
Acrankcase heater is wired through a normally closed contact of the compressor contactor in
the usual manner, becoming energized whenever the compressor cycles off.
In addition to the above, the ZX has the following features:
Liquid line assembly (filter drier and sight glass/moisture indicator) - fitted
Anti corrosion treatment to the condenser fins - supplied as standard
Adjustable LP switch for low-pressure pump down control - fitted
The electronic board is also the base controller for the connection of many optional and
customer supplied functions such as:
Main load controller (or thermostat)
Evaporator electric defrost heater contactor
Evaporator fan contactor
Diagnostic module: This option provides the ZX with a self-diagnostic function, signalling
individual component failure in three ways:
(a) Visible LED combination
(b) Remote audible buzzer
(c) A dialer connection for the purpose of sending a common fault signal through
a telephone service to a remote location.
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2.8.2 Electronic board description
Figure 1: Electronic board
Figure 2: Diagnostic module
Remote buzzer connector
Dialer
connector
7-Segment LEDs
Main board
3
-
Phase Power Supply Input
3
-
Phase Detect Module
Compressor Current Sensing
(Hi/Lo) Setting Dip-Switch
EXV Driver
Compressor Type
Setting Rotary-Switch
Switch Mode
Power Supply
High Voltage Outputs
Diagnosis Module
Connector
1-Phase Power
Supply Input Defrost Module Connector
MCU
Temperature sensors
High/Low Pressure
Switch Connectors
Evaporator Fan Mode
Setting Dip-Switch

C6.1.6/1108-0509/E 7
2.8.3 Diagnostic signal
Display LED 1 - Unit Status LED 2 - Error/Warning Code
Idle (stops when reaches set-
point) No error/warnings
Run Compressor Phase Error (wrong phase
sequence/loss of phase)
About to start(*) Compressor Inside Thermal Protector Trip
Defrost Compressor Over Current
Stop due to error Discharge Gas Overheat
Lockout Compressor High Pressure Cut-out
Compressor Low Pressure Cut-out
DLT Thermistors Failure
Ambient Temperature Sensor Failure
Mid-coil Temperature Sensor Failure
System Liquid Floodback Warning
Table 4: Definition of diagnostic signal
(*) This signal is for Fresh Start, Normal Start Program and any start request delay.
NOTE: All error/warning messages are priority-ranked from highest to lowest.
If unit is initially powered on, the diagnosis module will show signals as follows:
(1second) -> (3 seconds) -> (3 seconds) ->
- Software version number.
- Unit identification code
“F” - With OD Fan Speed Control; “－” - Without OD Fan Speed Control
“L ” - ZXL; “－” - ZX
- Power On (see Table 6)
Unit Type OD Fan Speed
Control Software Version No. Unit Identification Code
ZX Yes 02 – F
ZX No 03 – –
Table 5: Initialization signals
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Events LEDs Events LEDs
Unit Off / Phase “U” or “N” missing Off When com-
pressor On
Power On W/O error DLT Thermistors Failure When com-
pressor On
Compressor On W/O error PHE Vapour Inlet Temp.
Sensor Failure (only ZXL) When com- pressor On
Compressor about
to turn On O,1 W/O error PHE Vapour Outlet Temp.
Sensor Failure (only ZXL) When com-
pressor On
Defrost W/O error Try to
restart
Try to
restart
Compressor High Pressure
Cut-out System lock
Discharge Gas
Overheat Error System lock Compressor Low Pressure
Cut-out Try to restart
When com-
pressor On Try to restart
Outdoor Ambient
Temp. Sensor
Failure When com-
pressor Off
Compressor Over Current System lock
When com-
pressor On Compressor Wrong Phase Sequence / Loss of Phase System lock
Condenser Mid-coil
Temp. Sensor
Failure When com-
pressor Off Warning – System Liquid Floodback When com- pressor On
Warning – Compressor intends to start but current transformers sense no current
Table 6: Common signals
2.9 Compressor / Unit setting
Each ZX unit model has a unique compressor model and this has to be programmed in the set-
up of the electronic board controller. For this purpose a compressor rotary switch is located near
the top right-hand corner of the electronic board (shown on Fig. 1 above). This is factory set and
should not be re-set after leaving the factory. Any tampering with this compressor rotary switch
may result in any warranty claim becoming null and void.
For maintenance purpose, the electronic board (replacement) needs to be configured according
to the compressor use (please see underneath settings to be done on the electronic board).
Compressor Model**
Rotary
Switch
2-bit Dip-switch 3-bit Dip-switch
0 On/On Off/Off/Off
ZX15KCE-TFD 1 On/On
ZX21KCE-TFD 2 On/On
ZX30KCE-TFD 3 On/On
ZX38KCE-TFD 4 On/On
ZX45KCE-TFD 5 On/On
ZX51KCE-TFD 6 On/On
Evaporator fan
On/Off logic
same as
compressor
Table 7: Setting of switches
NOTE: Please set switches to the right position according to compressor model.

C6.1.6/1108-0509/E 9
2.10 Compressor motor protection
The electronic board protects the compressor motor against the following:
Over current
Loss of any one phase
Incorrect phase rotation
If the compressor motor current exceeds a pre-defined current limit (non-adjustable), then the
electronic board shuts down the unit and generates an error signal to the LED’s on the board.
For this function to operate, two of the main phase supply lines to the compressor (compressor
via the contactor) are routed through the current abnormality coils.
2.11 Compressor pressure protection
2.11.1 High pressure
A sensor is registered by the electronic board. The sensing device is a non-adjustable, high-
pressure switch that will open in the event of an abnormally high discharge pressure (above
28 bar).
The unit will stop and then restart automatically after a 3-minute delay and after unit
pressure has decreased to 24 bar.
After 5 successive HP cut-outs over 1 hour, the unit will lock-out.
2.11.2 Low pressure
In a similar way to the high-pressure sensor, the electronic board registers the switching action
of a non-adjustable, low-pressure switch that will open in the event of an abnormally low suction
pressure (below 1 bar).
The unit will stop then restart automatically after a 3-minute delay and when unit
pressure attains 2 bar.
2.12 Other inputs to the board
2.12.1 Customer-supplied control (thermostat)
The electronic board accepts a normal 220 volt AC input On/Off signal (such as the switching
action of a normal commercial thermostat) and relays a similar action as an output to the
compressor contactor in the case of a thermostat-controlled system (refer to the wiring diagram
in section 3.2.2). If the system is controlled by low-pressure cut-out for a multiple evaporator
system and/or pump down system, the electronic board accepts signals directly from an
adjustable low-pressure switch (optional).
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2.12.2 Case temperature controller
An alternative method of system temperature control can be used. The electronic board accepts
an input from a common commercial thermostat.
High-pressure cut-out
Contact open 30 bar
± 1.5 bar
Contact close 24 bar
± 1.5 bar
Execute STOP program and show out the signal of HP cut-out,
after 3 minutes run normal START program to restart the CDU.
On the 6th request for reset, HP error is set and system will be
locked out.
(HP cut-out)
5 auto resets are
allowed within 1
hour
Low-pressure cut-out
Contact open 1 bar
± 0.5 bar
Contact close 2 bar
± 0.5 bar
Execute STOP program and show out the signal of LP cut-out,
after 3 minutes run normal START program to restart the CDU.
Discharge gas
overheat DLT over 132°C
Execute STOP program and show out the error message, after 3
minutes run normal START program to restart the CDU. On the
6th request for reset, DLT Error is set and system will be locked
out.
(DLT over limit)
5 auto resets are
allowed within 1
hour
Discharge line sensor
failure
If both the discharge line and coil-in sensors are under-range
(80°C and 10°C) after 3 minutes of the compressor starting, show
out the error message. When both the discharge line and coil-in
sensors fail, the error message will be shown.
(DLT thermistor
Incorrect phase
sequence/Loss of
phase
Inapplicable for 1~ph
compressor
If 3-phase supply is incorrectly connected to the contactor
terminals, the system will be locked out and show out the error
message.
(Compressor incorrect phase sequence)
Unit will not start
unless it is re-wired
correctly
Over current Different settings for different
compressors
Execute STOP program and show out the error message, after 3
minutes run normal START program to restart the CDU. On the
6th request for reset, over current error is set and system will be
locked out.
(Compressor over current)
5 auto resets are
allowed within 1
hour
Power cut In case there is a power
outage
Upon the return of power supply, E2 will start the unit on a fresh
start mode.
(Fresh start)
Compressor rapid
cycling Minimum 3 minutes OFF time
Any start request will be postponed until 3 minutes if the
compressor has stopped within last 3 minutes. If start request is
postponed, the status of compressor will be shown through
diagnosis module.
(Compressor about to start)
Fresh start program
If ambient temperature is less
than 38°C when the
compressor is about to start
Compressor will start for 3 seconds and stop for 20 seconds. This
happens for 3 cycles then the compressor runs continuously.
The status of fresh start is shown through diagnosis module.
Electrical failure
(Protector trip)
Compressor intends to start
but current transformers
sense no current Error message will be shown through diagnosis module
Failure/Incident Type Setting Electronic Board Reaction Reset Procedure
Table 8: Electronic board 2C control reference guide
2.12.3 Condenser coil & ambient air thermistors
These two thermistor type sensors are supplied by Emerson Climate Technologies and
connected to the electronic board for condenser fan speed control. This is usually applicable
where low ambient and (sometimes) low condensing temperatures are likely to adversely affect
refrigeration performance and control.
2.13 Other outputs from the electronic board
2.13.1 Liquid line solenoid valve (not supplied)
An On/Off output connection is provided and wired to the main terminal strip for convenience to
assist the customer for wiring of the liquid line solenoid valve coil into the unit. When the
customer uses LP switch for pull down system, the solenoid valve should be driven by customer
thermostat.
NOTE: The solenoid valve has to be fitted externally by the customer. The solenoid coil
voltage rating is to be 220VAC and the board can accommodate current ratings of 30VA
(hold) or 300VA (inrush). If the rating of solenoid coil is larger than the limit, please use a
proper contactor to control the valve instead of connecting the solenoid coil to board
directly.

C6.1.6/1108-0509/E 11
2.13.2 Defrost heater contactor coil (not supplied)
An On/Off output connection is provided on the electronic board for direct connection of a
customer-supplied contactor (coil) for convenience when the defrost option is included.
Terminals are male spade type. Coil voltage rating should be 220VAC and current ratings 30VA
(hold) and 330VA (inrush).
2.13.3 Evaporator fan contactor coil (not supplied)
An On/Off output connection is provided on the electronic board for direct connection of a
customer supplied contactor (coil) for convenience when the evaporator fan is included.
Terminals are male spade type. Coil voltage rating should be 220VAC and current ratings 30VA
(hold) and 330VA (inrush).
2.14 Dimensions in mm
The figures hereunder show the overall dimensions of the ZX condensing units:
Figure 3: Physical dimensions of ZXME020E, ZXME030E and ZXME040E (Single-fan units)
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Figure 4: Physical dimensions of ZXME050E, ZXME060E and ZXME075E (Dual-fan units)

C6.1.6/1108-0509/E 13
3 Installation
WARNING
High pressure! Injury to skin and eyes possible! Be careful when
opening connections on a pressurized item
Copeland EazyCool™ZX condensing units 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 reduce the cooling
capacity, and lead to a high-pressure switch tripping. Clean the condenser fins on a regular
basis.
3.1 Condensing unit handling
3.1.1 Transport and storage
WARNING
Risk of collapse! Personal injuries! Move compressors only with
appropriate mechanical or handling equipment according to weight. Keep in
the upright position. Do not stack single boxes on top of each other. Keep the
packaging dry at all times.
Figure 5
3.1.2 Weights
ZXME020E 98
ZXME030E 100
ZXME040E 107
ZXME050E 118
ZXME060E 121
ZXME075E 153
Weight (kg)Condensing unit
Table 9: Weights
3.2 Electrical connection
3.2.1 Power supply connections
The electrical connection of the ZX condensing unit to the power supply must be made by
qualified technicians, who should refer to the electrical diagrams located inside the electric
connection panel.
3.2.2 Wiring diagram
Before commissioning, ensure that the neutral "N" wire is connected on the terminal block
(extreme right "N"). After proper connection the control LED on power board and control board
will lighten.
See diagram next page.
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14 C6.1.6/1108-0509/E

C6.1.6/1108-0509/E 15
3.2.3 Electrical protection standard (protection class)
Scroll compressors up to ZX51 are IP21 according to IEC 34.
Fan IP44 according to IEC 34.
Solenoid valve coils: IP65 according to DIN 43650.
3.3 Refrigeration connections
3.3.1 Refrigeration piping installation
IMPORTANT
All interconnecting piping should be of refrigeration grade, clean, dehydrated
and remain capped at both ends until installation. Even during installation, if
the system is left for any reasonable period of time (say 2 hours), pipes
should be re-capped to prevent moisture and contaminant from entering the
system.
It is advisable to insulate both the suction and liquid interconnecting piping between the ZX unit
and the evaporator. Usually the suction line is insulated, but the liquid line is not. However 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 also create oil traps. The
recommended support distances are shown in Table 10 below:
Tube size Max distance
between 2 supports
12.7 mm (1/2 inch) 1.20 m
16.0 mm (5/8 inch 1.50 m
22.0 mm (7/8 inch) 1.85 m
28.5 mm (11/8 inch) 2.20 m
Table 10
IMPORTANT
Do not assume that the service connection sizes on the unit (at the service
valves) are in fact 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 pipe run within our units these service
connection sizes are adequate. All interconnecting piping should be sized to
satisfy the duty required.
3.3.2 Brazing recommendations
IMPORTANT
Blockage! Compressor breakdown! Maintain a flow of oxygen-free
nitrogen through the system at very low pressure during brazing. Nitrogen
displaces the air and prevents the formation of copper oxides in the system.
If allowed to form, the copper oxide material can later be swept through the
system and block screens such as those protecting capillary tubes, thermal
expansion valves, and accumulator oil return holes.
Contamination or moisture! Bearing failure! Do not remove the plugs until
the compressor is set into the unit. This minimises any entry of contaminants
and moisture.
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16 C6.1.6/1108-0509/E
Remove the fishtails (= compressed tube ends) by cutting them off in the following
sequence:
1. Remove the discharge connection fishtail
2. Then remove the suction connection fishtail
Removing the plugs in this sequence prevents oil mist from coating the suction tube
making brazing difficult.
Be sure tube fitting inner diameter and tube outer diameter are clean prior to assembly.
Both tubes are extended from the condensing unit housing, therefore we recommend to
isolate 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 a silver alloy rod either flux coated or with a separate flux would be used.
Use a double-tipped torch.
Figure 6: Sectional view
3.3.3 Brazing procedure
For brazing of the tubes, please refer to Figure 7 and procedure hereunder:
1. Fit the copper tube into the compressor tube.
2. Heat area 1. As the tube approaches brazing temperature:
3. Heat area 2 until braze temperature is attained. It is
necessary to heat the tube evenly. Move the torch up and
down and rotating around the tube.
4. Add braze material to the joint while moving the torch
around the joint to flow braze material around the
circumference.
5. Then heat area 3. This will draw the brazing material down
into the joint.
Figure 7: Suction tube brazing
NOTE: The time spent heating area 3 should be minimal. As with any brazed joint,
overheating may be detrimental to the final result.
To disconnect:
Heat joint areas 2 and 3 slowly and uniformly until solder softens and tube can be pulled out
of the fitting.
To reconnect:
See the procedure above.
WARNING
Danger of frostbite! Liquid line should be insulated with 19 mm insulation
thickness. Temperature could be as low as –15°C.
During brazing
protect housing
with damp cloth
During brazing
pull back line
insulation
End of tube

C6.1.6/1108-0509/E 17
3.4 Location & fixings
IMPORTANT
The unit should never be installed adjacent to a dust source. External fouling
of the condenser fins also leads to high condensing temperatures, and will
reduce the life of the unit.
It is recommended that a clearance of 300 mm from the wall (or the next unit) be maintained
from the unit left and rear panels whereas a clearance of 500 mm is to be maintained from the
unit 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 go over these here. However, in general terms,
air by-pass around each condenser and between the units should be avoided at all times.
Figure 8: End elevation & elevation views - Single-fan unit
Figure 9: End elevation & elevation views - Dual-fan unit
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
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