Copeland Large ZX090BE User Manual
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Copeland Large ZX090BE User Manual

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Large ZX Condensing Unit
User Manual

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Summary of Contents for Copeland Large ZX090BE

  • Page 1 Large ZX Condensing Unit User Manual...

  • Page 3: Table Of Contents

    Table of contents Introduction Safety Information Nomenclature Scope of Supply PI Diagram Technical Data Features & Benefits Condensing Unit Layout CoreSense Controller Networking Electrical Connections Installation, System Processing, & Start-up Troubleshooting System Start-up & Operational Check Sheet...

  • Page 4: Introduction

    Introduction Thank you for purchasing the Copeland™ Large ZX Condensing Unit for refrigeration applications. This unit comes with a high efficiency Copeland fixed speed scroll compressor with liquid / vapor injection technology. This is the best-in-class unit available in the market within the capacity and operating range.

  • Page 5: Safety Information

    Installation and commissioning work on CDU shall be carried out only by qualified, refrigeration personnel who have been trained and instructed. Copeland 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...
  • Page 6 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 Copeland or authorized distributor.

  • Page 7: Nomenclature

    2. Nomenclature Base model Electrical Code Bill of Material 3. Scope of Supply Large ZX / Scroll Rack Model ZX (9 -15HP) ZXLD Liquid Line Filter Drier   Moisture Indicator   Oil Separator   Accumulator  Adjustable LP Control Switch ...

  • Page 8: Pi Diagram

    4. PI Diagram Position Description Position Description Compressor M1 Ball Valve, Suction line Oil Seperator — Crank Case Heater R2 Adjustable LP/HP Dual Pressure Switch Condenser Pressure Transmitter, HP Receiver Discharge Line Temperature Sensor — — Electronic Expansion Valve — Filter Drier / Sight Glass Ambient Temperature Sensor Ball Valve, Liquid line...
  • Page 9 ZXL with EVI Technology Position Description Position Description Compressor M1 Ball Valve, Suction line Oil Seperator Accumulator Crank Case Heater R2 Adjustable LP/HP Dual Pressure Switch Condenser Pressure Transmitter, HP Receiver Discharge Line Temperature Sensor Brazed Plate Economizer Vapour In Temperature Sensor Electronic Expansion Valve Vapour Out Temperature Sensor Filter Drier / Sight Glass...

  • Page 10: Technical Data

    5. Models Medium temperature, 9 - 15HP Family Nominal Rating Horsepower Model name ZX090BE ZX100BE ZX130BE ZX150BE Sound Pressure Unit Performance @ 1m dB(A) 60 / 66 60 / 66 61 / 67 64 / 67 Level Rated Load Ampere 17.5 20.0 25.0...

  • Page 11: Features & Benefits

    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.
  • Page 12 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. Enhanced vapor injection (ZXL only)

  • Page 13: Condensing Unit Layout

    7. Condensing Unit Layout 9 -15 HP Unit 10 - 20 HP Unit...

  • Page 14: Coresense Controller

    8. CoreSense Controller Power isolation switch CoreSense Customer connection Contactor terminal block Transformer CoreSense Layout...
  • Page 15 LED descriptions Status Description Status Description Compressor1 is running Browsing the service menu Flashing Compressor1 is ready to start Flashing Browsing the fast access menu Reserved A new alarm happened Flashing Reserved Flashing Browsing the alarm menu Condensing fan is running An alarm is occurring Reserved Reserved...
  • Page 16 Keyboard descriptions - combined buttons Press and hold for about 3 seconds to lock (Pon) or unlock (PoF) the keyboard. Pressed together to exit programming mode or menu; under rtC and Par, this combination allows the user to go back to previous level. Pressed together for 3 seconds allows access to first level of programming mode.
  • Page 17 Quick access menu browse - sensors status and actual values Step Action Phenomenon and description Enter quick access menu, will display“P1P” (Press “Up” or “Down” to view other sensors Press “ ” View the actual value of “P1P” Press “ ”...
  • Page 18 Exact timing of the alarm Step Action Phenomenon and description Display “SEC” Press “ ” Display “A01” Press “ ” Display alarm code in “A01” Press “ ” Display “Hr” Press “ ” Display the alarm exact timing: hour Press “ ”...

  • Page 19: Networking

    9. Networking Dixell XWEBPRO serial address - Wiring • Connect to the ModBUS network using cable with 2 or 3 shielded wires, minimum section 0.5mm (e.g. BELDEN8772) • Do not connect shield to ground. • Do not connect the “Gnd” terminal. •...
  • Page 20 ZX CDU connected to XWEBPRO ZX CDU connected to the Dixell XWEBPRO with the Intelligent Store solution module using RS485 ModBUS. Connect the ZX CDU to the ModBUS network as shown below. Connect the network cable to the three-terminal connector on the XWEB port that has been configured as ModBUS port (COM 12, 13, 14).

  • Page 22: Installation, System Processing, & Start-Up

    11. Installation, System Processing and Commissioning Utmost care must be taken while handling the Large ZX condensing unit. Please go through the contents below to ensure proper handling. 11.1 Location and Fixing Large ZX should always be installed in a location that ensures clean air flow. The minimum operating space for unit is described in below figure.
  • Page 23 The pipe should be sized to ensure optimum performance and proper oil return. The sizing must also consider 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.
  • Page 24 11.5 Brazing Recommendation Maintain a flow of oxygen-free nitrogen through the system at a very low pressure during brazing. Nitrogen displaces the air and prevents the formation of copper oxides in the system. If copper oxidization is 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.
  • Page 25 11.6 Start-up & Operation 11.6.1 Initial pressure test (vby vacuum and Nitrogen) Step-by-step 1. Use a 4-port gauge manifold with 3/8” hose and connections to the vacuum pump. The vacuum gauge does not have to be connected for this part of the process.
  • Page 26 8. Check and record the ambient temperatures and the system pressure with calibrated approved instruments. This process is to be carried out every 8-12 hours during the pressure testing process. 9. If the test pressures cannot be maintained, repeat the leak testing process employing the isolation of sections of the system to determine the source of leaks.
  • Page 27 11.6.5 Additional Oil Charing in the System Additional Oil Charing in the System - Emerson Large ZX units are supplied with oil charge in the compressor as well as the oil separator / reservoir. However, depends on the length of interconnecting piping and the refrigerant charge in the system, there might be additional oil requirement.
  • Page 28 11.6.6 Checks before starting and during running the system 1. Check all the valved are fully opened 2. Check the oil level of compressor and the reservoir after running the unit for some time. 3. Check the discharge line temperature which is to be below 125 °C. 4.

  • Page 29: Troubleshooting

    12. Troubleshooting Alarm Codes Level Descriptions The unit (including the compressor) will keep running, but some status & data is already in an Warning unsafe range; alarm dry-contact will not close; reset automatically The unit (including the compressor) may run not with full functions; alarm dry-contact will Alarm not close;...
  • Page 30 Code Description Possible Reasons Action Reset Three-phase 3-Ph voltages are imbalance warning not balanced Digital compressor over Digital compressor current The compressor Automatically current alarm is larger than settings will be tripped with time delay Digital compressor over The compressor will be Digital compressor over Press “Start”...
  • Page 31 Code Description Possible Reasons Action Reset Automatically when the Low evaporator difference of dsicharge super hear or too much temperature and Liquid flood back warning liquid injection to the condensing temperature is compressor higher than setting and time delay Automatically when Fix speed compressor Fix speed compressor The compressor...
  • Page 32 Digital compressor Fixed-speed compressor Fault phenomenon Direct cause Inspection analysis and adjustment Before the following troubleshooting, first of all ensure the correctness, robustness and reliability of all wiring Check whether the low pressure reaches the low pressure set point Check terminal No. 3 and NEUTRAL neutral line for 220VAC The controller did not receive a start signal Check whether the wiring of terminal block No.
  • Page 33 Fault phenomenon Direct cause Inspection analysis and adjustment If the high pressure is high (high pressure protection value 30 kg): Shutoff valve or other system valve One-by-one confirmation of system processes forgot to open Improve ventilation and ensure that the return air The ambient temperature is too high temperature of the condenser is equal to the ambient or the air intake channel is blocked...
  • Page 34 Fault phenomenon Direct cause Inspection analysis and adjustment Measure operating low pressure. Need to confirm whether the low pressure set in controller is correctly, whether the controller or low pressure switch is faulty. Low pressure during normal operation If there is a fault, replace the corresponding device. Also refer to [3.
  • Page 35 Fault phenomenon Direct cause Inspection analysis and adjustment If the compressor starts frequently during the defrosting process: Need to confirm whether the unit selection is too Operating suction pressure large, the expansion valve selection is too small. low due to low load Consider taking all indoor evaporator synchronization defrosting procedures Check if the low pressure rises during stop, replace the...
  • Page 36 Fault phenomenon Direct cause Inspection analysis and adjustment Compressor reverse running Swap any two-phase wiring Check if the high-pressure pressure is running high, The compressor is overloaded whether the low-pressure pressure is low, and whether the pressure ratio is too large. The compressor oil level is Confirm the oil level and perform oil drain or replenishment...
  • Page 37 Fault phenomenon Direct cause Inspection analysis and adjustment Circuit breaker cannot be When the breaker is closed, the breaker has turned on after closing 380V input voltage and output voltage Natural wiring error Any line-to-neutral voltage is 220VAC Whether the two fuses next to Broken fuse Controller has the contactor are damaged...
  • Page 38 Fault phenomenon Direct cause Inspection analysis and adjustment Measure the resistance between the terminals of the compressor to determine of the resistance is infinite and whether the three-phase resistance is balanced. After the compressor is fully cooled, try to start again. Built-in compressor protection If normal operation can be performed again, please refer to [Compressor overcurrent], [Discharge pressure...
  • Page 39 Fault phenomenon Direct cause Inspection analysis and adjustment Check whether the external device has remote communication with the controller, and whether there is any abnormality in the remote communication wiring and signal transmission. If the signal continues Code "L86" Controller to be written into the controller, it will cause its Controller internal memory is abnormal internal memory...

  • Page 40: System Start-Up & Operational Check Sheet

    13. System Start-Up and Operational Check Sheet...
  • Page 42 About Emerson Emerson (NYSE: EMR), headquartered in St. Louis, Missouri (USA), is a global technology and engineering company providing innovative solutions for customers in industrial, commercial, and residential markets. Our Emerson Automation Solutions business helps process, hybrid, and discrete manufacturers maximize production, protect personnel and the environment while optimizing their energy and operating costs.

This manual is also suitable for:

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