EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL
CONTENTS Section Item 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 15.0 16.0 17.0 LIST OF ILLUSTRATIONS Page No. Disclaimer 1 Introduction to the ZX refrigeration condensing unit (CU) 2 2.1 Product description 2.2 SILVER and GOLD configurations 2.3 Control features 2.4 Diagnostic and defrost features 2.5 Advantages 2.6 Emerson condensing unit makes for exceptional value 2.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 1.0 Disclaimer Thank you for purchasing the Emerson scroll refrigeration condensing unit. We hope that you will find this product meeting your refrigeration needs efficiently and effectively. Please read through this Product Manual thoroughly to familiarize yourself with the value-added features of this product and how to use it optimally to suit your needs.
2.0 Introduction to the Emerson outdoor refrigeration condensing unit Emerson Climate Technologies, a Division of Emerson Electric Ltd. launched the ZX Condensing Unit (CU), a new refrigeration product to the Asian market to primarily meet the demands of the food retail services and logistics sector.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL State-of-the-art electronics provide protection, diagnostics and communication features in the ZX. These features are controlled by the custom-designed, custom-built E2 Electronics Control Board. The E2 provides: * base control functions related to the system temperature controller, defrost, evaporator fan control etc. * compressor protection e.g. current overload, voltage imbalance, anti - phase reversal etc.
2.2 Silver and Gold Configuration The ZX is marketed in two customer-friendly configurations that carry their own unique labels: SILVER and GOLD. This is clearly explained through the nomenclature diagram and the Bill-Of-Material (BOM) table in Fig 7.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 2.3 Control Features The ZX CU Control System evolves around the E2 Board and one of its primary functions is control of the Automatic Liquid Injection system. The liquid injection method is a unique and Emersonpatented technology. This technology ensures that the ZX compressor operates within a safe envelope.
2.4 Diagnostic and defrost features The Diagnostic module (Optional) is also installed within the chassis and has 5 LEDs (Light Emitting Diodes ) that can either be ON, OFF or BLINKING.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 2.5 Advantages Some key advantages that the Emerson ZX CU has over similar units in the market are: * It is extremely affordable and has a very low noise level. * It is cost effective and more affordable: it comes with in-built state-of-the-art technology such as the E2 Board with several programmed algorithms and the diagnostic module.
2.7 Application Types The versatile Emerson ZX is suitable for a wide variety of applications: Supermarkets (medium to small) Cold rooms Convenience stores Independent cold rooms Fast food chains and restaurants Small flake ice machines (250 to 750 kg per day @ -15 oC evaporating temperature) Process room cooling (10 oC room temperature) Water cooling (PHE/Tube-in-tube evaporators) 3.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Silver Bill of Material (BOM) Numbers 300 350 301 Gold 351 400 450 401 451 420 Liquid Line Filter Driver & Liquid Sight Glass Oil Separator Adjustable Low Pressure Switch Fan Speed Controller Diagnostic Module Romote Buzzer Circuit Breaker (Isolating Switch) Compressor Sound Jacket Accessory Defrost Module Accessory Note: BOM 300,301,400,401 is for China Only BOM 350,351,450,451 is for Rest OF Asia only ( excluding Australia and New
5.0 Physical layout of the unit The following illustration identifies the major components and where these are located in the ZX unit. Diagnostic module (Gold) Defrost module (optional) Isolating switch(Gold) E2 Electronic control board Fan Electrical terminal block Oil separator Receiver Sight-glass Scroll compressor Suction line service valve Condenser coil Adjustable low pressure switch Liquid line service valve Filter drier Crankcase heater Receiver outlet valve Fig 8.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Fig 9. Compressor chamber (close-up) 3 Blade propeller fan Receiver Fan bracket/mounting Fig 10.
Fixed HP switch Fixed LP switch Fig 11.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Fig 13. 3-D view of single fan ZX (not to scale: not meant to be used for dimensions or installation) Fig 14.
6.0 Dimensions and installation clearances Fig 15. shows the overall dimensions of the unit. It is recommended that a clearance of 300 mm from the wall (or the next unit) be maintained from the unit's left and rear panel; whereas a clearance of 500 mm should be maintained from the unit's right, top and front panels (as viewed from the front of the unit). Both service access and airflow have been considered in making these recommendations.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 950 1029 112 213 91 173 110 840 388 ZX0200, 0300, 0400 (Single fan units) 580 424 110 1242 388 ZX0500, 0600, 0750 (Dual fan units) 950 1029 213 112 91 173 580 424 Fig.
7.0 Essential service/installation tools, equipment and materials Before start-up, the technician needs to assemble the correct tools and equipment for the task. Apart from the normal refrigeration service technician tools, electrical test equipment and hand tools, the following items are essential for the installation of hermetic refrigeration systems: * Reliable electronic vacuum gauge. (Fig.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 8.0 Electrical installation Caution! This work should be carried out only by suitably qualified electricians. Please check the unit nameplate and run ample capacity three phase and single phase (including neutral and earth wiring) to each unit. A suitably rated isolating switch (this is also an option that could be selected) should be fitted immediately adjacent to each unit .
All pipes should be adequately supported to prevent sagging which can also create oil traps. The recommended support distance is as below: Tube size Maximum distance between two supports (m) 12.7mm (1/2 inch) 1.20 16.0mm (5/8 inch) 1.50 22.0mm (7/8 inch) 1.85 28.5mm (11/8 inch) 2.20 The solenoid valve should be installed close to the indoor TXV. To avoid oxidation from taking place inside the tube during brazing, charge no more than 0.1MPa nitrogen through the tube when brazing the joint.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL ATMS 5000 1500 GOOD Vacuum gauge VG-60 700 O N O F F 1000 400 300 200 50 MICRONS VACUUM GAUGE ZX UNIT Supco 100 Evaporator Expansion valve Shraeder conn. 4 LL Solenoid valve AIRFLOW HP Interconnecting Note: Remove both Piping Schraeder cores (Insulated) before evacuation & charging. MP 4 AIRFLOW LP Suction service hose.
10.0 Leak checking and evacuation (See Fig.18 ) The following assumes that the installation contractor has certified the condensing unit to be leak-free on arrival (refer to Section 4.0) - this is important to verify before proceeding with the following. Leak checking is particularly important for field-connected systems. Typically, field systems lose as much as 20-30% of their refrigeration charge annually. This is not only an unnecessary expense but also damaging to the environment.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 10.3 Evacuation Note that the following procedure is based upon achieving an actual system vacuum standard and it is NOT TIME DEPENDENT! Step-by-step: * Check suction capability of the vacuum pump with a gauge before commencing evacuation process. The vacuum pump must be rated to achieve a vacuum level of at least 300 microns. * Connect the vacuum gauge to the system. We have included a convenient point for this on the unit (See Fig.7).
10.4 Charging and commissioning IMPORTANT! TO BE CLEARLY UNDERSTOOD PRIOR TO RUNNING ANY SCROLL COMPRESSOR! It is important to realize that the scroll compressor design requires system charging as quickly as possible - with liquid refrigerant into the liquid line. This is to avoid running the compressor when there is an insufficient volume of suction gas to cool not only the motor, but also the rotating scrolls.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 11.0 E2 control and operating features The function of the E2 is to react to the ON/OFF signals it receives from various devices (e.g., thermostat) to operate and protect the ZX unit.
Compressor phase reversal ensures that the compressor runs only in one direction - a necessity for a compliant scroll compressor to compress and pump refrigerant. Reset is automatically set to the correct phase rotation of the compressor. Voltage protection ensures that the compressor only operates within the very wide design voltage tolerance of the three-phase motor.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 12.0 Operation & set-up of the E2 board Microprocessor Controller Unit Temperature Sensor Inputs High and Low Pressure Control Liquid Injection Control Compressor Selector Rotary Switch (not to be tampered with by the User) Current Abnormality Coils 3 Phase Protection Module High Voltage Output Digital Switching Power Supply Power and Thermostat Input Fig.
12.1 Compressor/unit setting 12.3 Compressor pressure protection Each ZX unit model has a unique ZX compressor model and this has to be programmed in the set-up of the E2 controller. For this purpose a compressor rotary switch is located near the top right hand corner of the E2 board (see the diagram in the previous page). This is a factory setting and should not be re-set thereafter. Any tampering with this compressor rotary switch will result in warranty claims becoming null and void. 12.3.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 12.4 Compressor discharge temperature protection Abnormally high discharge line temperature can damage the scroll sets as well as the compressor motor. The ZX employs a patented liquid injection process that injects liquid refrigerant into the suction line as previously described. Activation of the liquid injection valve is in response to a clip-on thermistor located at the discharge line of the ZX scroll compressor.
Fig 20 . E2 Control reference guide Failure/Incident Type E2 Reaction (E2 event in brackets & italics) Setting High pressure cut-out Contact Open 2.8 ±0.1Mpa Contact Close 2.1 ±0.07Mpa Execute STOP program and after 3 minutes run normal START program to restart the CU. HP error signal is set to the 6th request for reset and system will be locked out. The Diagnostic LEDs will light-up. (HP Cut-out) Low pressure cut-out Contact Open 0.1 ±0.05Mpa Contact Close 0.2 ±0.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Failure/Incident Type Compressor Rapid Cycling E2 Reaction (E2 event in brackets & italics) Setting Minimum 3 minutes OFF time Any start request will be postponed until 3 minutes if the compressor has stopped within the preceding 3 minutes. If start request is postponed, the diagnostic LEDs will light-up(Compressor About To Start) Outdoor Sensor Failure The diagnostic LEDs will light-up.
12.6 Other outputs from the E2 board 12.6.1 Liquid line solenoid valve 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. Note: The solenoid valve option (if ordered), is for external fitting by the customer. The solenoid coil voltage rating is to be 220VAC and the board can accommodate current ratings of 50VA (hold) or 100VA (inrush). 12.6.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Fig 6.
13.2 The defrost module This factory-supplied accessory provides a basic time-initiated, time terminated defrost controller. It is located below the electrical panel inside the top of the compressor compartment (Fig 25). It includes a manual actuating button for the customer to override the initiation settings at any time. This button also initiates defrost in the event of an iced-up call when the system needs to be de-iced immediately. Refer to Fig.22 wherein the main components have been identified.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Fig. 24 Diagnostic module, defrost module and temperature sensors connected to the E2 unit controller Circuit breaker E2 board Electrical connectors Compressor contactor Diagnostic module Defrost module Fig.
14.0 Maintenance Condenser fins: Over time, with exposure to ambient air, condenser fins can become dirty. Dirty coil surfaces result in high condensing temperatures and poor unit performance. Regular cleaning is recommended, the frequency of cleaning being dependent on the installation and the surrounding environment. As a general guide, it is advisable to do this at least once-in-two-months.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Routine leak testing All joints within the system should be checked for leaks during site visits. If you find oil imprint around the joints or in the ground near the joints, there may be a leak in the joint. All joints within the system should be leak tested oncea-year. This is purely a recommendation based on thermal expansion/contraction that normally occurs in the unit piping.
PART NO. PART NAME PART NO.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL 16.
With additional tools, the technician can find out more about the system using the following table as a guide: Refrigerant Overcharge Refrigerant Undercharge Restriction at the Filter Drier Low Evaporator Airflow Blocked or Dirty Condensor Coil TXV with lost bulb charge High Evaporator Airflow Dragging or Seizing Compressor Electrical Phase Imbalance Non-Condensibles in system High : Higher than Normal Discharge Discharge Pressure Temperature Low High High Low High Low Low Low High High Low Low High High
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Addendum 17.
Addendum 17.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Addendum 17.
Addendum 17.
EMERSON OUTDOOR REFRIGERATION CONDENSING UNIT PRODUCT MANUAL Addendum 17.3 Capacity (kW) & Power (kW) at 50Hz for refrigerant R22 Model ZX0200 ZX0300 ZX0400 ZX0500 ZX0600 ZX0750 Ambient Temp.oC Capacity (kW) Power (kW) Evaporating Temperature (oC) Evaporating Temperature (oC) -15 -10 -5 0 5 -15 -10 -5 0 5 27 2.84 3.61 4.18 4.95 5.87 1.36 1.40 1.45 1.51 1.57 32 2.65 3.33 4.01 4.75 5.61 1.49 1.54 1.62 1.68 1.75 38 2.38 3.11 3.81 4.55 5.37 1.66 1.78 1.
Addendum 17.4 Capacity (kW) & Power (kW) at 50 Hz for refrigerant R404A Model ZX020E ZX030E ZX040E ZX050E ZX060E ZX075E Ambient Temp.oC Capacity (kW) Power (kW) Evaporating Temperature (oC) Evaporating Temperature (oC) -25 -20 -15 -10 -5 0 5 -25 -20 -15 -10 -5 0 5 27 2.74 3.30 3.90 4.44 5.08 5.79 6.60 1.62 1.65 1.68 1.72 1.78 1.89 2.05 32 2.50 3.06 3.59 4.12 4.68 5.29 5.96 1.78 1.81 1.83 1.86 1.92 2.02 2.17 38 1.71 2.22 2.70 3.16 3.64 4.16 4.
Contact us at: Asia Pacific Headquarters Emerson Climate Technologies Ltd. 10/F, Pioneer Building 213, Wai Yip Street Kwun Tong, Kowloon Hong Kong S.A.R P.R.China Tel: (852) 2866 3108 Fax: (852) 2520 6227 Australia Emerson Climate Technologies Australia Pty Ltd Unit R7, 391 Park Road, Regents Park NSW 2143 Australia Tel: (61-2) 9795 2800 Fax: (61-2) 9738 1699 China - Beijing c/o Emerson Climate Technologies (Suzhou) Co.
