Emerson Copeland Large ZXD120BE-TFM User manual

Large ZX Condensing Unit
User Manual - Dubai Sourced Units

Table of contents
Introduction 2
Safety Information 3
Nomenclature 5
Operating Envelope 6
Technical data 6
Features & Benets 8
Physical Layout 10
CoreSense Controller 15
Network Wiring 24
Electrical connection 26
Installation, System Processing and Commissioning 28
34
System Start-Up and Operational Check Sheet 45
Troubleshooting
1

Introduction
Thank you for purchasing Copeland Large ZX Condensing Unit for refrigeration applications.
This unit comes with high efficiency Copeland™ fixed and digital scroll compressor with
enhanced vapor injection technology.
This is best in class unit within the capacity and operating range available in the market.
Emerson ZX series has 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 for the installation, commis-
sioning & operation of Emerson’s Large ZX Condensing Unit.
Disclaimer
Please read through this operation manual to familiarize yourself with the installation, com-
missioning, and operation of this product. Please do read the following information in this
page before proceeding with the rest of the manual.
The Emerson™ Large ZX scroll refrigeration condensing units should only be installed by
suitably qualified and experienced refrigeration technicians. No responsibility can be accept-
ed 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 contrac-
tor 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 any additional query, 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 manual.
2

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 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.
3

1.5 General Instructions
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 polyol ester (POE) lubricant Emkarate RL 32 3MAF.
1.7 Receiving your unit
All units are filled with dry nitrogen 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 found to be without any
pressure on receipt, please contact Emerson 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 Emerson or
authorized distributor.
4

ZX D 120 B E TFM 523
Condensing unit family
D= Digital medium temp
LD= Digital low temp
12-20HP
Generation
E= Ester oil
TFM= 380V/420V-3ph-50 HZ
BOM
2. Nomenclature
3. Scope of Supply
ZXD 12 to 20 HP ZXLD 12 to 20 HP
523 523
Liquid Line Filter Drier
Moisture Indicator
Oil Separator
Oil Reservoir
Combination Oil Separator / Reservoir
Accumulator
LP Transducer
HP Transducer
Fixed LP Safety Switch
Adjustable LP Safety Switch
Service Junction Box
CoreSense Protection
Digital Modulation
Intelligent Store Ready
Fan Speed Controller
Circuit Breaker
Compressor Sound Jacket
Receiver Certification (UL/PED)
Pressure Relief Valve
HP/LP Pressure Gauge
BOM
5

R404A
ZXD Digital medium temperature
48
10
-20 -4 0
Evaporating temperature °C
Note: ZXD120/160BE maximum evaporating temperature is 0 °C;
ZXD200BE maximum evaporating temperature is -4°C
Ambient temperature °C
Fan speed control function for lower than 10°C ambient
Maximum suction gas temperature 18.3 °C
R404A
ZXLD Digital low temperature
48
43
10
-40 0-4-15
Note: ZXLD120BE maximum evaporating temperature is 0 °C;
ZXLD160/200BE maximum evaporating temperature is -4°C
Evaporating temperature °C
Maximum suction gas temperature 5°C
Ambient temperature °C
Fan speed control function for lower than 10°C ambient
4. Operating Envelope
5. Models
Technical Data: 12 HP
ZXD120BE-TFM ZXLD120BE-TFM
Compressor 3PH-380V/ 420V-50Hz 3PH-380V/ 420V-50Hz
Fan Motor 1PH-220V-50Hz 1PH-220V-50Hz
Performance ET/AT/RGT °C -0.011441257 -0.2
R404A Capacity kW 24.22 11.76
COP kW 2.41 1.3
Sound Pressure Level @1m dB(A) 65 69
ZX45KCE-TFD-558 ZXI18KCE-TFD-557
ZBD45KQE-TFD-538 ZXJ18KCE-TFD-557
Rated Load Ampere A 9.6 + 10.1 11.1+ 11.1
Locked Rotor Ampere A 74 74
Oil Type POE POE
Oil Charge L 1.9 + 1.8 1.9 + 1.9
Number of Fan 2 2
Diameter mm 600 600
Fan Speed rpm 930 930
Air Flow
m3/h
13940 13940
Total Fan Motor Power W 700 700
Oil Separator /
Reservoir Charge
L 0.6/4 0.6/ 4
Receiver Volume L 17 17
Suction Pipe OD inch 1 3/8" 1 3/8"
Liquid Pipe OD inch 3/4" 3/4"
Dimension (W x D X H) mm 1645*1010*1066 1645*1010*1066
Weight
（
Net
）
kg 357kg 362kg
WeightGross
）
kg 457kg 462kg
Fan Motor
Others
Model Name
Nominal HP
12
Power Supply
Compressor
Model name
6

Technical Data: 16 HP
Technical Data: 20 HP
ZXD160BE-TFM ZXLD160BE-TFM
Compressor 3PH-380V/ 420V-50Hz 3PH-380V/ 420V-50Hz
Fan Motor 1PH-220V-50Hz 1PH-220V-50Hz
Performance ET/AT/RGT °C -0.011441257 -0.2
R404A Capacity kW 29 15.5
COP kW 2.4 1.32
Sound Pressure Level
@1m
dB(A) 69 69
ZXD61KVE-TFD ZXJ25KCE-TFD
ZX61KVE-TFD ZXI25KCE-TFD
Rated Load Ampere A 11.1 + 11.1 14.6 + 14.6
Locked Rotor Ampere A 74 102
Oil Type POE POE
Oil Charge L 1.9 + 1.9 1.9 + 1.9
Number of Fan 2 2
Diameter mm 600 600
Fan Speed rpm 930 930
Air Flow
m
3
/h
13940 13940
Total Fan Motor Power W 700 700
Oil Separator/ Reservoir
Charge
L 0.6/4 0.6/ 4
Receiver Volume L 21.6 21.6
Suction Pipe OD inch 1 3/8" 1 3/8"
Liquid Pipe OD inch 3/4" 3/4"
Dimension (W x D X H) mm 1645*1010*1066 1645*1010*1066
Weight
（
Net
）
kg 362kg 362kg
Weight
（
Gross
）
kg 462kg 462kg
Compressor
Model name
Fan Motor
Others
Model Name
Nominal HP
16
Power Supply
ZXD200BE-TFM ZXLD200BE-TFM
Compressor 3PH-380V/ 420V-50Hz 3PH-380V/ 420V-50Hz
Fan Motor 1PH-220V-50Hz 1PH-220V-50Hz
Performance ET/AT/RGT °C -0.011441257 -0.2
R404A Capacity kW 37.3 17.41
COP kW 2.31 1.43
Sound Pressure Level
@1m
dB(A) 69 69
ZXD78KVE-TFD ZXJ25KCE-TFD
ZX78KVE-TFD ZXI28KCE-TFD
Rated Load Ampere A 14.6+14.6 14.6+14.6
Locked Rotor Ampere A 102 121
Oil Type POE POE
Oil Charge L 1.9+1.9 1.9+1.10
Number of Fan 2 2
Diameter mm 630 630
Fan Speed rpm 920 920
Air Flow m
3
/h 16410 16410
Total Fan Motor Power W 960 960
Oil Separator/ Reservoir
Charge
L 0.6/ 4 0.6/ 4
Receiver Volume L 21.6 21.6
Suction Pipe OD inch 1 3/8" 1 3/8"
Liquid Pipe OD inch 3/4" 3/4"
Dimension (W x D X H) mm 1645*1010*1235 1645*1010*1235
Weight
（
Net
）
kg 362 kg 362 kg
Weight
（
Gross
）
kg 462 kg 462 kg
20
Power Supply
Compressor
Model name
Fan Motor
Others
Model Name
Nominal HP
7

6. Features & Benefits
Large ZX platform condensing units were designed based on three factors
demanded by industry users:
Intelligent Store™ solutions - A most innovative approach to enterprise facility manage-
ment, Emerson Intelligent Store architecture integrates hardware and services, to provide retail-
ers 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 action-
able 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 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.
8

Condensing Unit Features:
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
• Vapor injection provide high efficiency 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.
To Compressor 2
To Compressor 1
Vapor In
Temperature Sensor
Liquid In
Filter
Liquid Out
Vapor Out
Temperature Sensor
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 flood back warning
Compressor minimum off time
Compressor oil level protection
Intelligent store Solution: Communication and retail store monitoring
9

7. Physical Layout of Unit
1645
1645
1090
Control Box
Moisture Indicator
Oil Observation
Suction Connection
Size: 1-3/8”
Liquid Connection
Size: 3/4”
Control Box
Moisture Indicator
Oil Observation
Suction Connection
Size: 1-3/8”
Liquid Connection
Size: 3/4”
1010
10661235
Right side Left side
980
950
4-Ø12
1090
12/16 HP
20 HP
1010
Right side Left side
980
4-Ø12
950
10

Max Net Weight: 362 Kg Max Gross Weight: 462 Kg
Weight
12/16/20 HP
1740
1472
1140
15. Condenser 14. Receiver 6. Check Valve
13. Solenoid Valve
1. Compressor
2. OM3
3. Ball Valve
4. Oil Filter 7. Oil Separator
5. Accumulator
20. Service Valve
19. Oil Tank
9. Filter Drier
8. Suction Service Valve
10. Liquid Service Valve
11. Sight Glass
12. PHE Group
Layout
18. HP Switch
Oil Service Valve
Check Valve
17. EXV
16. HP/LP Transducer
Check Valve
16. HP/LP Transducer
17. EXV
18. HP Switch
Oil Service Valve 11

Control Box Layout
Design for Service
Customer Connection
Breaker 1
Breaker 2
Fan Speed Controller
Capacitor
Internal Connection
24V Transformer
24V Transformer
Controller
Contactor 1
Contactor 2
Breaker 1 & Contactor 1 are for Digital Compressor
Breaker 2 & Contactor 2 are for Fixed Compressor
Window - Controller
Window - Sight Glass
Window - Oil Separator
(High Level)
Window - Oil Separator
(Low Level)
Window – Controller
• Evaporating Temperature
• Message: Alarm & Warning
Window – Oil Reservoir
• Ideal oil level should be higher
than low level and lower than high
level
• Add oil immediately if oil level is
lower than low level
• Continue to run and keep watching
oil level if oil level is higher than high
level
12

• Disconnect power supply to the unit / disconnect
cables to compressor & om3 / use compressor
isolation valves and oil ball valve
• De-braze the tubes off (3 locations)
• Unfasten compressor’s mounting bolt
• Remove the compressor out
Service Port 1, 11, 14
Vacuum and Refrigerant Charge
Compressor Replacement
Vacuum
• Keep all the valves open
• Vacuum from service port 1, 11, 14
Refrigerant Charge
• Charge liquid refrigerant on the high side of the system
• Continue to charge controlled liquid refrigerant from suction service valve after
switching on the compressor
• For the unit which has vapor injection, it is necessary to charge 0.5kg-1.0kg more
after clear sight glass
500 mm
710 mm
Ball Valve
13

Oil Filter Replacement
• Close valve 16 and 8.
• Disconnect tube connection at two ends
• Unfasten clamp of oil filter
• Remove the oil filter out
Service Valve
on Oil Reservoir
Oil Filter
Ball Valve
Clamp
14

8. CoreSense Controller
LED Status Description LED Status Description
On Compressor 1
is running On Browsing the
service menu
Flashing Compressor 1
is ready to start Flashing Browsing the
fast access menu
On Compressor 2
is running On A new alarm happened
Flashing Compressor 2
is ready to start Flashing Browsing the
alarm menu
On Condensing fan
is running On An alarm is occuring
On Digital compressor
is unloading On Liquid line
solenoid valve on
On Display with C
_ Reserved
Flashing Programmable mode
LED descriptions
1
2!
!
Keyboard descriptions - Single button
Keyboard descriptions - Combined buttons
Set Displays target set point; In programming mode, select a parameter
Reset Hold for 5 seconds to reset any lockouts if the current state of the
controller allow for it to be reset.
Up ehtesworb,edomgnimmargorpnI;unemsseccatsafehtretnE
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).
Press and hold for about 3 seconds to lock (Pon) or unlock (Pof) the keyboard.
siht,rAPdnaCtrrednu;unemroedomgnimmargorptixeotrehtegotdesserP
combination allows the user to go back to previous level.
Pressed together for 3 seconds allows access to EXV manual setting.
Start
15

Controller display upon start-up
Step Action Phenomenon and description
1 Power on controller All LEDs will light up for 3 seconds.
2 Firmware version will be displayed for 3 seconds.
3seconds.
4 Normal display (actual suction temperature will be displayed)
Step Action Phenomenon and description
1 Enter menu to select
2 Select rtC
3 Press
n01, minute
n02, hour
n03, day
n04, month
n05, year (last two digits)
4 Press Display actual value
5 Press Modify the value
6 PressPress SET
value
7 Press Exit to rtC
8 PressExit to main menu (or wait for 120 seconds and exit automatically)
RTC (Real Time Clock) setting
16

Evaporating temperature
Step Action Phenomenon and description
1Press > 3 seconds Press SET button for more than 3 seconds, the measurement units
2 Press Modify the number for target evaporating temperature
3 PressPress SET
Refrigerants
Step Action Phenomenon and description
1 Press Enter menu to select PAr (parameter) or rtC
2 Press Select PAr (parameter)
3 Press
4 Press Browse to parameter C07
5 Press
6 Press Select refrigerant to be used
7 Pressselection
8 Press Exit (or exit automatically after waiting for 120 seconds)
17

Replacing controller
After a new controller is replaced and initial power is on, it is critical to reset parameters
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:
Controller Parameter Default Setting
MODEL
Parameter Description Default Value
H07 Digital Compressor MCC
H09 Digital Compressor Current Protection
H27 Fixed Compressor MCC
H28 Fixed Compressor Current Protection
H13 MIN. Operating Voltage
H14 MAX. Operating Voltage
C07*Refrigerant
Notes:*Ensure that parameter C07 is set to match the actual refrigerant used.
If not, set C07 following label "Unit Operation Setting After Installation".
Pr1 parameter (1 level) browse and modification
st
Step Action Phenomenon and description
1 Press Enter menu to select
2 Press Select PAr (parameter)
3 Press
4 Press Browse to Pr1 parameters
5 Press View the actual number of the Pr1 parameters
6 Press Modify the actual number of the Pr1 parameters
7 Press Press SET
8 Press Exit (or exit automatically after waiting for 120 seconds)
18

Pr2 parameter (2nd
Step Action Phenomenon and description
1Press>3 seconds Enter Menu to select PAr (parameter) or rtC, enter into
parameter browse & setting mode.
2 Press Select PAr (parameter)
3 Press
4 Press Find parameter “ t18”
5 Press “PAS 0--”,
“0321”)
6 Press Change value to "3"
7 Press Display “ 30-”, “ 0
8 Press Change value to“ 2”
9 Press Display “ 320”, “ 0
10 Press Change value to “ 1”
11 Press
12 Press Browse detailed Pr2 level parameter name
13 Press View current parameter setting values
14 Press Change parameter setting values
15 Press then display next parameter name
16 Press Display “ Par”, exit parameter browse & setting mode.
17 Press Exit to main menu
level) browse and modification
19