1. Manuals
  2. Brands
  3. Copeland Manuals
  4. Refrigerator
  5. ZXD120BE-TFM
  6. User manual

Copeland ZXD120BE-TFM User Manual

Dubai sourced large condensing unit
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
USER MANUAL
Large ZX
condensing unit
User manual - Dubai sourced units

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ZXD120BE-TFM and is the answer not in the manual?

Questions and answers

Related Manuals for Copeland ZXD120BE-TFM

Summary of Contents for Copeland ZXD120BE-TFM

  • Page 1 USER MANUAL Large ZX condensing unit User manual - Dubai sourced units...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page Introduction Safety information Nomenclature Operating envelope Technical data Features & benefts Physical layout CoreSense controller Network wiring Electrical connection Installation, system processing and commissioning Troubleshooting System start-up and operational check sheet 2201/MEA/R/3/CDU/104/50 Large ZX condensing unit user manual...

  • Page 3: Introduction

    Introduction Thank you for purchasing Copeland large ZX condensing unit for refrigeration applications. This unit comes with high effciency Copeland fxed 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.

  • Page 4: Safety Information

    1. Safety information Installation and commissioning work on CDU shall be carried out only by qualifed, refrigeration personnel who have been trained and instructed. 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.

  • Page 5: General Instructions

    1.7 Receiving your unit All units are flled with dry nitrogen at a positive pressure before transportation. When you receive the unit from Copeland 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 Copeland or their authorized distributor.

  • Page 6: Nomenclature

    2. Nomenclature 3. Scope of supply ZXD 12 to 20 HP ZXLD 12 to 20 HP Liquid line flter 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...

  • Page 7: Operating Envelope

    Note: ZXD120/160BE maximum evaporating temperature is 0°C; Note: ZXLD120BE maximum evaporating temperature is 0°C; ZXD200BE maximum evaporating temperature is -4°C ZXLD160/200BE maximum evaporating temperature is -4°C 5. Models Technical data: 12 HP Model name ZXD120BE-TFM ZXLD120BE-TFM Nominal HP Compressor 3PH-380V/ 420V-50Hz 3PH-380V/ 420V-50Hz Power supply...

  • Page 8: Technical Data

    Technical data: 16 HP Model name ZXD160BE-TFM ZXLD160BE-TFM Nominal HP Compressor 3PH-380V/ 420V-50Hz 3PH-380V/ 420V-50Hz Power supply Fan motor 1PH-220V-50Hz 1PH-220V-50Hz Performance ET/AT/RGT °C -0.011441257 -0.2 R404A Capacity 15.5 1.32 Sound pressure level @1m dB(A) ZXD61KVE-TFD ZXJ25KCE-TFD Model name ZX61KVE-TFD ZXI25KCE-TFD Rated load ampere 11.1 + 11.1...

  • Page 9: Features & Benefts

    The Intelligent Store architecture transforms data from store equipment and controls into actionable insights. Designed to deliver value in both new and existing stores, Copeland aims to help the retailers: • Make better decisions on resources investment for greatest impact •...

  • Page 10: Design Features

    Condensing unit features: Copeland scroll compressor technology Highly effcient, 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. Copeland unique digital technology •...

  • Page 11: Physical Layout

    7. Physical layout of unit 12/16 HP Right side Left side 1010 1645 Control box Moisture indicator Suction connection size: 1-3/8” Liquid connection size: 3/4” 1090 4-Ø12 Oil observation 20 HP Right side Left side 1010 1645 Control box Moisture indicator Suction connection size: 1-3/8”...
  • Page 12 Weight 12/16/20 HP Max net weight: 362 Kg Max gross weight: 462 Kg Layout 15. Condenser 14. Receiver 6. Check valve 13. Solenoid valve 12. PHE group 1. Compressor 11. Sight glass 2. OM3 10. Liquid service valve 8. Suction service valve 3.

  • Page 13: Control Box Layout

    Control box layout Breaker 2 Controller Fan speed controller Breaker 1 24V transformer Breaker 1 & contactor 1 are for digital compressor Contactor 2 Internal connection Breaker 2 & contactor 2 are for fxed compressor Customer connection Capacitor Contactor 1 24V transformer Design for service Window - controller...

  • Page 14: Refrigerant Charge

    Vacuum and refrigerant charge Service port 1, 11, 14 Vacuum Refrigerant charge • Keep all the valves open • Charge liquid refrigerant on the high side of the system • Vacuum from service port 1, 11, 14 • Continue to charge controlled liquid refrigerant from suction service valve after switching on the compressor •...
  • Page 15 Oil flter replacement Service valve on oil reservoir Oil flter • Close valve 16 and 8 • Disconnect tube connection at two ends Ball valve • Unfasten clamp of oil flter • Remove the oil flter out Clamp 2201/MEA/R/3/CDU/104/50 Large ZX condensing unit user manual...

  • Page 16: Coresense Controller

    8. CoreSense controller LED description Status Description Status Description Compressor 1 is running Browsing the service menu Flashing Compressor 1 is ready to start Flashing Browsing the fast access menu Compressor 2 is running A new alarm happened Flashing Compressor 2 is ready to start Flashing Browsing the alarm menu Condensing fan is running...
  • Page 17 Controller display upon start-up Step Action Phenomenon and description Power on controller All LEDs will light up for 3 seconds Firmware version will be displayed for 3 seconds Parameter setting fle (bin fle) identifer will be displayed for 3 seconds Normal display (actual suction temperture will be displayed) RTC (real time clock) setting Step...
  • Page 18 Evaporating temperature Step Action Phenomenon and description Press " > 3 seconds " Press SET button for more than 3 seconds, the measurement units (°C) will fash together Press " " or " " Modify the number for target evaporating temperature Press "...

  • Page 19: Replacing Controller

    Replacing controller After a new controller is replaced and initial power is on, it is critical to reset parameters defned on the label below the nameplate on the unit panel. Here is an example of a label: 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: Pr1 parameter (1 level) browse and modifcation...
  • Page 20 Pr2 parameter (2 level) browse and modifcation Step Action Phenomenon and description Press " " + " " > 3 seconds Enter Menu to select PAr (parameter) or rtC, enter into parameter browse & setting mode. Press " " or " "...
  • Page 21 Access alarm code (maximum of 50 record) Step Action Phenomenon and description Press " " Display SEC Press " " Display A01 Press " " Display alarm code in A01 Press " " Display A02 Press " " Display alarm code in A02 Press "...
  • Page 22 Quick access menu browse - sensor status and actual values Step Action Phenomenon and description Press " " Enter quick access menu, will display P1P (Press Up or Down to view other sensors) Press " " View the actual value of P1P Press "...
  • Page 23 Exact timing of the alarm Step Action Phenomenon and description Press " " Display SEC Press " " Display A01 Press " " Display alarm code in A01 Press " " Display Hr Press " " Display the alarm exact timing: hour Press "...
  • Page 24 Upload the program from the controller to hot-key Step Action Phenomenon and description Insert hot-key when the controller is on The uPL message will appear followed by a fashing End label Press " " (Note: If Err is displayed, it means it failed to upload the program to hot-key.

  • Page 25: Network Wiring

    9. Network wiring Copeland XWEB serial address • Connect to the ModBUS network using cable with shielded wires, minimum section 0.75mm2 (e.g. BELDEN8761). • Do not connect shield to ground. • Do not connect the "Gnd" terminal. • Remember to draw a map of the line. This will help you to fnd an error if something is wrong.
  • Page 26 (JMP2 on the back side of the unit). Do not add the jumper if XWEB is placed in the middle of the RS485 line. Large ZX CDU connected to XWEB Large ZX CDU connected to the Copeland XWEB with the intelligent store solution module using RS485 Modbus. Connect the ZX CDU to the ModBUS network as shown on fgure 11.

  • Page 27: Electrical Connection

    10. Electrical connections ZXD/ZXLD condensing unit wiring diagram TFM : 380/420V, 50Hz, 3Ph + N 2201/MEA/R/3/CDU/104/50 Large ZX condensing unit user manual...
  • Page 28 ZXD120 condensing unit wiring diagram TFM : 380/420V, 50Hz, 3Ph + N 2201/MEA/R/3/CDU/104/50 Large ZX condensing unit user manual...

  • Page 29: Installation, System Processing And Commissioning

    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. a. Location and fxing Large ZX should always be installed in a location that ensures clean air fow. The minimum operating space for unit is described in below fgure.

  • Page 30: Refrigeration Piping Installation

    b. Refrigeration piping installation All interconnecting pipes should be of refrigeration grade, clean, dehydrated and must remain capped at both ends until installation. Even during installation, if the system is left for any reasonable period (say two hours), pipes should be re- capped to prevent moisture and contaminants from entering the system. Do not assume that the service connection sizes on the unit (at the service valves) are the correct size to run your interconnecting refrigeration pipes.
  • Page 31 e. Brazing recommendation Maintain a fow 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 32: Leak Check

    g. Start-up & operation Initial pressure test (by vacuum and nitrogen) Step-by-step • 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 33 Additional oil charing in the system Copeland 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 34: Maintenance

    i. Checks before starting and during running the system • Check all the valved are fully opened. • Check the oil level of compressor and the reservoir after running the unit for some time. • Check the discharge line temperature which is to be below 125°C. •...

  • Page 35: Troubleshooting

    12. Troubleshooting Alarm codes Level Description The unit (including the compressor) will keep running, but some status & data is already Warning in an unsafe range; alarm dry-contact will not close; reset automatically The unit (including the compressor) may run not with full functions; Alarm alarm dry-contact will not close;...
  • Page 36 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 37 Code Description Possible reasons Action Reset Automatically when the Low evaporator super heat difference of discharge Liquid food back warning or Too much liquid injection temperature and condensing to the compressor temperature is higher than settings and time delay Fix speed compressor Fix speed compressor Automatically when discharge The digital compressor...
  • Page 38 Digital compressor Fixed-speed compressor Fault phenomenon Direct cause Inspection analysis and adjustment Before the folowing troubleshooting, frst of all ensure the correctness, robustness and reliability of all wings. 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 39 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 forgot to open One-by-one confrmation of system processes Improve ventilation and ensure that the return air The ambient temperature is too high or temperature of the condenser is equal to the the air intake channel is blocked...
  • Page 40 Fault phenomenon Direct cause Inspection analysis and adjustment Measure operating low pressure. Need to confrm whether the low pressure set in controller is correctly, whether Low pressure during normal operation the controller or low pressure switch is faulty. If there is a fault, replace the corresponding device.
  • Page 41 Fault phenomenon Direct cause Inspection analysis and adjustment If the compressor starts frequently during the defrosting process: Need to confrm whether the unit selection is too large, the Operating suction pressure low due to low load expansion valve selection is too small. Consider taking all indoor evaporator synchronization defrosting procedures Check if the low pressure rises during stop, replace Leakage of liquid line solenoid valve...
  • Page 42 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 too low or too high Confrm the oil level and perform oil drain or replenishment Release some of the refrigerant from the stop valve liquid...
  • Page 43 Fault phenomenon Direct cause Inspection analysis and adjustment When the breaker is closed, the breaker has Circuit breaker cannot be turned on after closing 380V input voltage and output voltage Natural wiring error Any line-to-neutral voltage is 220VAC Controller has Whether the two fuses next to Broken fuse no display...
  • Page 44 Fault phenomenon Direct cause Inspection analysis and adjustment Measure the resistance between the terminals of the compressor to determine if the resistance is infnite and whether the three-phase resistance is balanced. After the compressor is fully cooled, try Built-in compressor protection to start again.

  • Page 45: Temperature Sensor Resistance Table

    Temperature sensor resistance table Temperature ( C) Discharge line temperature 1522k 457k 5.8k 3.4k sensor resistance (Ω) Condensing tempreature, PHE vapor inlet and outlet 111k 67.7k 42.5k 27.3k 17.9k 5.82k temeprature and ambient temperature sensor resistance (Ω) 2201/MEA/R/3/CDU/104/50 Large ZX condensing unit user manual...

  • Page 46: System Start-Up And Operational Check Sheet

    System start-up and operational check sheet Client details Facility/customer name: Address: Contact details: Installer: Installation date: Condensing unit info CDU model: Serial number: CDU location: Indoor unit make / model: System details System operation Room/case ID: COMP voltage: Pipe length (approx): COMP current: OAT @ start-up/check: Suction pressure:...
  • Page 47 About Copeland Copeland is a global leader in sustainable heating, cooling, refrigeration and industrial solutions. We help commercial, industrial, refrigeration and residential customers reduce their carbon emissions and improve energy effciency. We address issues like climate change, growing populations, electricity demands and complex global supply chains with innovations that advance the energy transition, accelerate the adoption of climate friendly low GWP (Global Warming Potential) and natural refrigerants, and safeguard the world’s most critical...

This manual is also suitable for:

Zxld120be-tfmZxd160be-tfmZxld160be-tfmZxd200be-tfmZxld200be-tfm

Table of Contents