Emerson ZX Manuel utilisateur

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

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

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

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.

ll instructions & procedures described in this manual are recommendations based

on what is considered to be good refrigeration trade practice (applied to this particula

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

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.

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.

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

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)

Fig 4. The Defrost Module

Fig 5. The Diagnostic Module (now

available without Buzzer )

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)

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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