COPELAND ZX 22-30HP Simplex ZX Condensing Unit User Manual

: September 9, 2024
: Copeland

Table of Contents

ZX 22-30HP Simplex ZX Condensing Unit
Product Information
Specifications
Product Usage Instructions
Safety Information
Installation & Commissioning
Refrigerant & Lubricant
Start-up
Troubleshooting
- FAQ
Q: Can I install and commission the unit myself?
Q: What refrigerant should I use with this unit?

ZX 22-30HP Simplex ZX Condensing Unit

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Product Information

Specifications

Model: Large ZX 22-30HP condensing unit
Manufacture Date: July 2024
Refrigerant: HFC
Lubricant: Emkarate RL 32 3MAF
Capacity: 22-30HP

Product Usage Instructions

Safety Information

It is crucial to follow safety guidelines and recommendations
provided in the manual to ensure personal safety and proper
functioning of the unit.

Installation & Commissioning

Installation and commissioning work should only be carried out
by qualified refrigeration personnel. Ensure electrical connections
are made by qualified electricians.

Refrigerant & Lubricant

Use only approved refrigerants and refrigeration oils. The
compressor comes with an initial oil charge of Emkarate RL 32 3MAF
for HFC refrigerant use.

Start-up

Before starting the unit, ensure that all safety precautions are
followed. Release pressure from both high and low sides of the
compressor before servicing.

Troubleshooting

If you encounter any issues with the unit, refer to the
troubleshooting section of the manual for guidance. If problems
persist, contact qualified service personnel.

FAQ

Q: Can I install and commission the unit myself?

A: No, installation and commissioning should only be done by
qualified refrigeration personnel.

Q: What refrigerant should I use with this unit?

A: Use the correct refrigerant designed to work within the safe
operating envelope of the unit. The recommended lubricant is
Emkarate RL 32 3MAF for HFC refrigerants.

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JULY 2024

USER MANUAL

Large ZX 22-30HP condensing unit

Table of contents

Introduction & disclaimer

3

Safety information

4

Nomenclature

5

Scope of supply

5

PI diagram

6

CDU models / data

7

Features & benefits

9

Physical layout

10

CoreSense controller

12

Networking

18

Electrical connections

19

Installation & start-up

20

Troubleshooting

26

Operational check sheet

29

About Copeland

32

2

Thank you for purchasing Copeland Simplex ZX Condensing Unit for refrigeration applications. This unit comes with high effciency Copeland fxed capacity scroll compressor and liquid / vapor injection technology. This is the best in class unit within the capacity and operating range available in the market. Copeland ZX series has been highly successful in global market and has proven success with its energy savings and customer friendly electronic features. This document is designed to help the contractor and customer for the installation, commissioning and operation of Copeland’s Simplex ZX condensing unit.
Disclaimer
Please read through this operation manual to familiarize yourself with the installation, commissioning, and operation of this product. Please do read the following information in this page before proceeding with the rest of the manual. The Copeland Simplex ZX scroll refrigeration condensing units should only be installed by suitably qualifed and experienced refrigeration technicians. No responsibility can be accepted 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 contractor 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 qualifed and/or experienced personnel or technicians. For any additional query, please consult your local sales offce, 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.
3

1. Safety Information
1.1 Installation and commissioning work on CDU shall be carried out only by qualifed, refrigeration personnel who have been trained and instructed.
1.2 Simplex 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
WARNING This icon indicates instructions to avoid personal injury and material damage.
High Voltage This icon indicates operations with a danger of electric shock
Danger of burning or frostbite This icon indicates operations with a danger of burning or frostbite
Explosion hazard This icon indicates operations with a danger of explosion
CAUTION This icon indicates instructions to avoid property damage and possibel personal injury IMPORTANT This icon indicates instructions to avoid malfunction of the compressor
This word indicates a recommendation for easier operation

1.5 General Instructions
Warning System breakdown! Personal injuries! Never install a system in the feld and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system.
Only approved refrigerants and refrigeration oils must be used. Warning High shell temperature! Burning! Do not touch the compressor until it has cooled down. Ensure that other materials in the area of the compressor do not get in touch with it. Lock and mark accessible sections.
Do not get contact with the compressor Caution Overheating! Bearing damage! Do not operate compressors without refrigerant charge or without being connected to the system. Caution Compressors contain oil and refrigerant under pressure. Release pressure from both high and low side of compressor before servicing. Caution Tube brazing and compressor operation can produce hot surfaces. To avoid burns, allow surfaces to cool.

1.4 Safety Statements
a. Only qualifed and authorized refrigeration personnel are permitted to install, commission, and maintain this equipment.
b. Electrical connections must be made by qualifed 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.

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 flled with an ideal gas at a positive pressure before transportation.

Use personal safety equipment. Safety goggles, gloves, protective clothing, safety boots and hard hats should be worn where necessary.

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.
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.

4

2. Nomenclature
ZX

L

250

B

E

TFD

521

Condensing Unit Family L = Low Temp Blank = Medium Temp 22 to 30 HP Generation E = Ester Oil TFD = 380V/420V 3Ph = 50Hz 522 = Without Door

Base Model
3. Standard Scope of Supply
521 BOM
Replaceable Core Liquid Line Filter Drier Moisture Indicator Liquid Line Isolation Valve Oil Separator with Discharge Check Valve Accumulator Adjustable HP / LP Switch Fixed LP Safety Switch HP Transducer HP / LP pressure Gauge Compressor Isolation Valves Compressor Sound Jacket Compressor Oil level Monitoring Circuit breaker and contactor Fan speed control 0 10 V CoreSense Protection Intelligent store ready Receiver certifcation (PED) Receiver with Outlet Isolation Valve Pressure Relief Valve

Elect Code

BOM

ZX

ZXL

521

5

4. PI Diagram

LP Switch

HP

DLT

Switch Sensor

LP Catridge

Oil Return

Access Port

HP Transducer
Check Valve
Oil Separator

Condenser

Service Port Liquid Receiver PRV

Filter Drier Sight Glass
Service Valve

Liquid Injection EXV

Service
Customer Side Port
BVS

ZX

POS
1 2 3 4 5 6 7 8 9 10 11
F5
B2
B3 B4 B5 B6

Description
Compressor M1 with isolation valves Oil separator Crank case heater R2
Condenser
Receiver
…
Electronic expansion valve
Filter drier/Sight glass
Ball valve, Liquid line
…
Fixed LP cartridge switch
Adjustable HP/LP dual pressure switch
Pressure transmitter, HP
Discharge line temperature sensor
… … Ambient temperature sensor

LP Switch

HP Switch

DLT Sensor

Oil Return Access Port

HP Transducer
Check Valve
Oil Separator

Service

T-ambient

Port Liquid Receiver

Condenser

PRV

Sight Glass Filter Drier
Service Valve

Customer Side Service Port BVS

T-vapor out
P H E
T-vapor in
EXV
T-vapor in

ZXL with EVI Technology

POS
1
2 3 4 5 6
7
8 9 10

Description
Compressor M1 with isolation valves
Oil separator
Crank case heater R2
Condenser
Receiver Brazed plate economizer Electronic expansion valve
Filter drier/Sight glass
Ball valve, Liquid line Accumulator

F5

Adjustable HP/LP dual pressure switch

B2

Pressure transmitter, HP

B3

Discharge line temperature sensor

B4

Vapour in temperature sensor

B5

Vapour out temperature sensor

B6

Ambient temperature sensor

6

5. CDU Models/Data

POS ZX220BE ZX250BE ZX300BE

Ambient temperature
(°C)
27 32 38 43 27 32 38 43 27 32 38 43

Capacity evaporating temperature (°C)

Power evaporating temperature (°C)

27.40 32.90 92.10 45.90 53.40 61.70 15.05 15.45 15.90 16.50 17.15 18.00

25.70 30.80 36.50 42.80 49.80 57.50 16.40 16.85 17.35 17.90 18.55 19.35

28.10 33.30 39.00 45.40 52.40

18.70 19.25 19.85 20.50 21.20

30.60 35.80 41.60 48.00

21.10 21.70 22.30 23.10

33.50 40.10 47.30 55.40 64.10 73.50 18.95 19.55 20.30 21.10 22.00 23.20

31.30 37.40 44.10 51.50 59.60 68.40 20.70 21.40 22.10 22.90 23.90 25.00

34.10 40.10 46.80 54.10 62.00

23.80 24.70 25.50 26.50 27.60

42.70 49.30 56.50

28.00 29.00 30.10

41.20 49.20 58.10 67.90 78.60 90.00 22.80 23.60 24.40 25.40 26.60 28.00

38.50 45.90 54.10 63.20 73.00 83.70 24.90 25.80 26.70 27.70 28.90 30.30

51.90 49.20 57.30 66.20 75.80

28.70 29.70 30.80 32.00 33.40

52.30 60.30 69.10

33.80 35.00 36.40

Technical data MT, 22 – 30 HP TWM: 380~420V/3Ph/50Hz
Nominal rating Model name

Family

Performance Sound Pressure Level

Compressor Fan Motor

Rated Load Ampere Locked Rotor Ampere Oil Type Oil Recharge Volume Qty Diameter Maximum Speed Air Flow Total Fan Motor Power
Oil Separator Receiver Volume

Other

Pipes Dimension

Weight

Horsepower HP

@1m

dB(A)
Amp Amp

Total Input Volume R404a Suction OD Liquid OD WXDXH Nett Gross

Liters Pieces
mm rpm m3/hr W Liters kg Inch Inch mm Kg Kg

22 ZX220BE

ZX 25 ZX250BE

30 ZX300BE

73

74

31.4 225 4.38
29592 2300
1 5/8 7/8 400 465

41.4

57.9

272

310

POE

6.51

6.00

2

710

1010

29592

25200

2300

2600

0.6

31.8

2 1/8

1 1/8

2013 x 872 x 2120

410

420

475

485

7

Performance table
LT 25 – 30 HP R404A

Model ZXL250BE ZXL300BE

Ambient temperature
(°C)
27 32 38 43 27 32 38 43

Capacity evaporating temperature (°C)

Power evaporating temperature (°C)

-40 -35 -30 -25 -20 -15 -40 -35 -30 -25 -20 -15

18.25 21.80 26.30 31.60 37.80 44.90 13.60 14.40 15.20 16.15 17.20 18.40

17.75 21.40 25.80 30.90 36.70 43.40 14.90 15.75 16.70 17.70 18.75 19.95

16.80 20.70 25.00 29.90 35.30 41.40 16.70 17.70 18.75 19.80 20.90 22.20

19.70 24.10 28.80 34.00 39.70

19.55 20.70 21.90 23.10 24.30

23.00 27.50 33.00 39.70 47.50 56.40 16.50 17.45 18.50 19.65 21.00 22.40

22.30 27.00 32.50 38.80 46.10 54.40 18.05 19.15 20.30 21.50 22.90 24.40

21.10 26.00 31.40 37.50 44.40 51.90 20.20 21.50 22.80 24.20 25.60 27.10

30.20 36.20 42.70 49.70

25.20 26.70 28.20 29.80

Technical data LT, 10 – 20 HP TEM: 380~420V/3Ph/50Hz
Nominal rating Model name

Family

Performance

Sound Pressure Level

Compressor Fan Motor

Rated Load Ampere Locked Rotor Ampere Oil Type Oil Recharge Volume Qty Diameter Maximum Speed Air Flow Total Fan Motor Power
Oil Separator Receiver Volume

Other

Pipes Dimension

Weight

Horsepower

HP

@1m
Total Input Volume R404a Suction OD Liquid OD WXDXH Nett Gross

dB(A)
Amp Amp
Liters Pieces
mm rpm m3/hr W Liters kg Inch Inch mm Kg Kg

ZX

22

30

ZX220BE

ZX300BE

75

37.1

46.7

246

310

POE

6.00

2

710

1010

29592

25200

2300

2600

0.6

31.8

2 1/8

7/8

2013 x 872 x 2120

440

455

505

520

8

6. Features and benefts
Simplex ZX platform condensing units were designed based on demands by industry users:
Energy effciency Utilizing Copeland scroll compressor technology, variable speed fan motor, large capacity condenser coil and advanced control algorithms, energy consumption is signifcantly 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 food back, which can prevent critical damage on the unit.

Intelligent Store Highest efficiency Reliability

Better decision making Lower enery bills Lower maintenance cost

Condensing unit features:
· Copeland scroll compressor technology Highly effcient, ultra quiet and highly reliable.
· Confgured with CoreSense controller Provides electronic diagnosis, protection, and communication modules for energy saving and reliable unit control. Analogue modulation for fans.
· Enhanced vapor injection (ZXL only)
Vapor injection provide high effciency for refrigeration application
Well tuned electronics algorithm with one big PHE for supplying sub cooled liquid to the evaporator thus increasing the refrigeration effect and supplying cool gas into the compressor through the EVI port cooling the discharge of the compressor.
Design features
9 Real time monitoring of compressor operating conditions
9 Compressor reverse rotation protection 9 Compressor over current protection 9 Compressor internal motor protector 9 Discharge gas overheat protection 9 Over voltage protection 9 Under voltage protection 9 High pressure protection 9 Low pressure protection 9 Refrigerant food back warning 9 Compressor minimum off time 9 Compressor oil level protection 9 Intelligent store solution: Communication and retail
store monitoring

9

7. Physical layout of the unit
ZX: 22-30 HP MT

Check Valve

Oil Separator

Control Box

Compressor HP/LP Switch

Liq. Receiver Filter Drier

10

ZXL: 25-30 HP LT
Oil Separator
Compressor HP/LP Switch

Check Valve Control Box

Liq. Receiver Filter Drier

11

8. CoreSense controller

EV: EXV Connection port

VNR: Remote display connection port

H-K: Hot key connection port

485: RS485 Connection port

DI3: LP Switch connection Port
AI2 AI7: Temp sensor connection ports

AI1: Pressure transducer connection ports

Supply: Power supply connection port (24VAC from transformer)

Current transformer holes

R-S-T:

Voltage measurement

connector

TO1:

Triac output

1 (Fan motor

connecter)

TO2: Triac output 2 (Digital valve connecter)

DI1: Unit on/off control

DO4:

Neutral:

Crankcase

Common terminal connector (TFD/PFJ/ heater

TF7: neutral; TF5: common) terminal) connector

DO5: Alarm dry contact output connector DO1/DO2/C1: Reserved connector
DO3: Compressor contactor output connector C2: HP switch input connector

12

LED descriptions

LED
1 2

Status
On Flashing
On Flashing
On
On On Flashing

Description
Compressor 1 is running
Compressor 1 is ready to start Compressor 2
is running Compressor 2 is ready to start
Condensing fan is running1
Digital compressor is unloading
Display with C
Programmable mode

LED
!
!

Status
On Flashing
On Flashing
On On
_

Description
Browsing the service menu Browsing the fast access menu
A new alarm happened
Browsing the alarm menu
An alarm is occuring
Liquid line solenoid valve on
Reserved

Keyboard descriptions – Single button
Set Displays target set point; In programming mode, select a parameter or confrm an operation. Start Reset Hold for 5 seconds to reset any lockouts if the current state of the controller allow for it to be reset.
Up Enter the fast access menu; In programming mode, browse the 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).

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 frst level of programming mode.
Pressed together for 3 seconds allows access to EXV manual setting.

13

Refrigerants

Step

Action

1

Press

2

Press

3

Press

4

Press

5

Press

6

Press

7

Press

8

Press

Phenomenon and description Enter menu to select PAr (parameter) or rtC Select PAr (parameter) Confrm selection Browse to parameter C07 Confrm selection Select refrigerant to be used The number will fash for 3 seconds and confrm the refrigerant selection Exit (or exit automatically after waiting for 120 seconds)

Replacing controller

After a new controller is replaced and initial power is on, it is critical to reset parameters defined on the label below the nameplate on the unit panel. Here is an example of a label:

Model Parameter
H07

Controller Parameter Default Setting Description
Digital compressor MCC

Default Value

H09

Digital compressor current protection

H27

Fixed compressor MCC

H28

Fixed comrpessor current protection

H13

MIN. operating voltage

H14

Max. operating voltage

C07*

Refrigerant

Notes: *Ensure that parameters C07 is set to match the actual refrigerant used. If not, set C07 following label “Unit Operation Settig After Installation”.

14

Pr1 parameter (1st level) browse and modification

Step

Action

Phenomenon and description

1

Press

Enter menu to select PAr (parameter) or rtC

2

Press

Select PAr (parameter)

3

Press

Confrm, select, and browse Pr1 parameters

4

Press

Browse to Pr1 parameters

5

Press

View the actual number of the Pr1 parameters

6

Press

7

Press

8

Press

Modify the actual number of the Pr1 parameters
Press SET: the number will fash for 3 seconds and confrm the modifcations; Will go to the next Pr1 parameter
Exit (or exit automatically after waiting for 120 seconds)

Quick access menu browse – Sensor status and actual values

Step

Action

Phenomenon and description

1

Press

Enter quick access menu, will display P1P (Press Up or Down to view other sensors)

2

Press

View the actual value of P1P

3

Press

Change to next sensor code

4

Press

Exit (or exit automatically after waiting for 60 seconds)

P1P Suction pressure sensor

P2P Condensing pressure sensor

P3t Digital compressor discharge line temperature sensor

P4t PHE vapor inlet temperature sensor

P5t PHE vapor outlet temperature sensor

P6t Ambient temperature sensor

P7t ON OFF compressor discharge line temperature sensor

5H PHE superheat

oPP EXV opening percentage Sensor code and values descriptions (nP, noP, or nA means that the sensor does LL5 Solenoid valve status (not used)

not exist; Err means that the sensor fails,

Std Condensing temperature set point

out of range, disconnected, or does not configure properly)

Aoo Fan’s analog output signal percentage dso Percentage of PWM output driving the valve of the Digital Scroll compressor

Lt Minimum cold room temperature (unused)

Ht Maximum cold room temperature (unused)

tU1 #1 voltage sensor

tU2 #2 voltage sensor

tU3 #3 voltage sensor

tA` #1 current sensor

TA2 #2 current sensor

Hm Time menu

15

Access alarm code (Maximum of 50 record)

Step

Action

1

Press

Display SEC

Phenomenon and description

2

Press

Display A01

3

Press

Display alarm code in A01

4

Press

Display A02

5

Press

Display alarm code in A02

6

…

7

Press

Exit (or exit automatically after waiting for 15 seconds)

Exact timing of the alarm

Step

Action

1

Press

2

Press

3

Press

4

Press

5

Press

6

Press

7

Press

8

Press

9

Press

10

Press

11

Press

12

Press

13

Press

14

Press

Display SEC

Phenomenon and description

Display A01

Display alarm code in A01

Display Hr

Display the alarm exact timing: hour

Display Min

Display the alarm exact timing: minute

Display dAy

Display the alarm exact timing: day

Display Mon

Display the alarm exact timing: month

Display yEA

Display the alarm exact timing: year

Exit (or exit automatically after waiting for 15 seconds)

16

Upload the program from the controller to Hot-Key

Step

Action

Phenomenon and description

1

Insert Hot key when the controller is on

2

Press

The uPL message will appear followed by a fashing End label (Note: If Err is displayed, it means it failed to upload the program to hot key. Please restart the process.)

3

Press

End will stop fashing

4

Turn off the controller and remove the Hot key

5

Turn on the controller

Download the program from Hot-key to controller

Step

Action

Phenomenon and description

1

Turn off the controller

2

Insert Hot key

3

Turn on the controller

The doL message will blink followed by a fashing End label (Note: If Err is displayed, it means it failed to download the program to Hot key. Please restart the process.)

4

Controller will restart working with the new parameters after 10 seconds

5

Remove Hot key

17

9. Networking
Dixell XWEBPRO Serial Address – Wiring
· Connect to the ModBUS network using cable with 2 or 3 shielded wires, minimum section 0.5mm2 (e.g. BELDEN8772) · Do not connect shield to ground. · Do not connect the “Gnd” terminal. · Remember to draw a map of the line. This will assist you in finding fault with communication issues. · Please respect the polarity of RS485 devices.
ZX CDU Connected to XWEB PRO
· 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 in Figure 5. Connect the network cable to the three terminal connec
tor on the XWEB port that has been configured as ModBUS port (COM 12, 13, 14). · Connect port “13” of XWEBPRO to port “RS485 +” of CoreSenseTM and port “12” of XWEB300D to port “RS485 ” of CoreSense
for RS485 communication.

XWEB300D Connected to the Intelligent Store Solution Module

Correct Network Wiring

Incorrect Network Wiring

18

ZX/ZXL-TWM/TEM Condensing Unit Electrical Wiring Diagram

TWM/TEM : 380/420V, 50Hz, 3Ph + N NOTES:

BU
U

1.Dashed Line ”

” is wired by installer

2.Earth “E” wire termination not shown for clarity.

BU
YE
V

052-3885-00 04/13/2023

EXV

P LP SW

YE

DISCHARGE PRESSURE TRANSDUCER

DISCHARGE SENSOR DLT

PHE SENSOR VAPOR-IN

PHE SENSOR VAPOR-OUT

FIXED LP SAFETY SWITCH

ELECTRONIC EXPANSION VALVE

19

RD
W
RD BK
N PE
E Q1
BU YE RD
K1
BU YE RD
T1 T2 T3 M1

2/T1

1/L1

4/T2

3/L2

6/T3

5/L3

RS485

RD

Q2

Q3

9

95

96

A1-RST 10

/B:3

BU

1

2

3

BN BK BU

RD 8
GY
F5

5

1

3

2

BK 11

4
6 A1-DI1 /B:2
BN

L1 L2 M21

L3

WH 4

RD 5

ANALOG INPUT (0-10V)

WH
RD
ANALOG INPUT (0-10V)

L1 L2 L3 M22

YE BU

6 GY
7 /B:3 BU

A11

T2

T1

M2

M1

A1
EV + – G + – VNR + – DI3 AI7 AI6 AI5 AI4 AI3 AI2 AI1 H-K COMMUNICATE
F1

T1
T2 ANALOG OUTPUT (0-10V)
-+
R S T TO1 TO2

CONTROLLER

250VAC 5A

NEUTRAL

DI1 DO4 C2 DO3 DO2 C1 DO1 DO5

B U Y E

R D

B N

B K

B N

B K

B U

G Y

R D

Y E

B U

A1-T01 /B:3

45

12

/B:7

/A:5

/B:5 /A:3

19

18

17

R2
K1

BK

B3

BU 15

BU 8

1 RD

16 BN

24VAC 20VA
7 BN
TF2

230V 3
BK

BN BU

13 BN
14

A1-C2 /B:2

RD 1

7 BN

230V BK 3

TF1

24VAC 20VA
8 BU

ALARM
AL1 AL2

ZX ONLY

SENSOR AMBIENT

ZXL ONLY

10. Electrical Connections

11. Installation, System processing and commissioning
Utmost care must be taken while handling the Simplex ZX condensing unit. Please go through the contents below to ensure proper handling. 11.1 Location and Fixing Simplex ZX unit should always be installed in a location that ensures suffcient air fow. The minimum operating space for unit is described in below fgure. Both service access and airfow have been considered in making these recommendations. Where multiple units are to be installed in the same location, the contractor needs to consider each individual case carefully. There can be many variations of unit quantities and available space and it is not the intention of this manual to go over these. Ideally, the unit should be mounted on a solid concrete slab with anti vibration pads between unit feet and concrete. However, the Simplex ZX condensing unit has also been designed for wall mounting on suitable brackets. Wall mounting brackets are not included. Another factor to consider in fnding a good installation site is the direction of the prevailing wind. For example, if the air leaving the condenser faces the prevailing wind, the air fow through the condenser can be impeded, causing high condensing temperatures ultimately resulting in reducing unit life. A baffe or defector plate could be a remedy for this situation.
11.2 Location and Fixing 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. The service valve sizes have been selected for convenience of installation and in some cases (larger units) these may be considered too small. However, for the very short pipe run within our units, these service connection sizes are adequate. 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. Use large radius bends and avoid trapping of oil and refrigerant. This is particularly important for the suction line. The suction line should ideally slope gently towards the unit. Recommendation slope is 1/200~1/250. P traps, double risers and reduced pipe diameters may be required for suction lines where long vertical risers cannot be avoided. All pipes should be adequately supported to prevent sagging which can create oil traps.
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The recommended pipe clamp support distance is shown in the table.

Tube Size 1/2 inch 5/8 inch 7/8 inch 1 1/8inch 1 5/8inch

Max distance between 2 clamp supports 1.20 m 1.50 m 1.85 m 2.10 m 2.27 m

11.3 Refrigerant line insulation · Insulate suction lines from the evaporators to the condensing unit with minimum 1″ thickness closed cell type
insulation on low temperature circuits. · Liquid lines of vapour injection (ZXL unit) to be minimum of 3/4″ insulation. · Suction and liquid lines should never be taped or soldered together.
11.4 Electrical · All electrical work must be done in accordance with the National Electrical Code and existing local codes. · Power supply must be the same as specifed on the unit’s name plate. · Voltage fuctuations in excess of 10 percent must be corrected. · Before starting the unit, ensure that all protective devices are in place and that all wiring is secure.
11.5 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. This minimizes any entry of contaminants and moisture. · Remove the liquid line connection cap. · Then remove the suction connection cap. · Open both valves midway. · Care should be taken to avoid the holding charge from releasing too quickly. · Be sure tube ftting inner diameter and tube outer diameter are clean prior to assembly. · Since both tubes are extended from the condensing unit housing, we recommend insulating the housing by using a
wet cloth on the copper tubing. · Recommended brazing materials: a copper / phosphorous or copper / phosphorous / silver alloy rod should be used
for joining copper to copper whereas to join dissimilar or ferrous metals, use a silver alloy rod, either fux coated or use additional fux. · Use a double tip torch.

OUTSIDE

INSIDE UNIT

End of Tube
During brazing protect housing with damp cloth

During brazing pull back fire
insulation

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11.6 Expansion Valve Selection Consideration
As the Simplex ZXL units are with vapour injection compressors, (except the ZX units), need to consider subcooled liquid temperature while selecting the expansion valve as given below.

Standard supply temperature °C

R404A

Evaporation temperature °C
40 35 30 25 20 15

Ambient temperature °C

20

27

32

38

43

48

8

1

3

8

13

19

4

2

6

11

15

21

0

6

9

13

18

23

5

10

13

17

21

26

9

14

17

20

24

30

13

18

21

24

28

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11.7 Start-up & Operation
Initial pressure test (by vacuum and nitrogen).
Step by step:
a. 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.
b. Connect the gauges to service ports provided on receiver valve and suction tube. In order to remove any non condensable that may have entered the system during installation, follow these steps:
c. Start the vacuum pump. The evaporator fan should be running, and the compressor crankcase heater is energized at this point. This will involve powering up the unit so it is important to disconnect the live feed wire to the compressor contactor (so the compressor cannot run, and the crankcase heater can be energized).
d. Open both valves on the manifold and then open the main vacuum valve on the pump. Run the system until the vacuum level of 0.85 bar (as read on manifold gauge) is achieved.
e. Shut off the main vacuum pump valve. Check for vacuum rise using the manifold compound gauge. A rise would indicate a large leak.
f. If vacuum holds for 10 minutes, break vacuum with nitrogen and pressurize to 20 bar. Check for leaks and repair leakage.
Leak Check
The success of all the subsequent commissioning depends on a leak free system, free of contaminants, free of oxides, free of non condensable’ s, that has been evacuated to a low vacuum and charged with the prescribed refrigerant.
Leak test is particularly important for feld connected systems. Typically, feld systems lose as much as 20%30% of their refrigeration charge annually. This is not only an unnecessary expense but also damages the environment. Compressor oil can be lost at the same time as refrigerant and eventually lead to compressor failure. (Time spent on leak test will eventually reduce the time spent on the evacuation process).
Ensure that all service valves are open during the leak test process. It is important to recheck all joints within the unit as well as the external joints. · The unit is shipped with a holding charge of dry nitrogen and should be leak free. · Ensure that the test pressure do not exceed the system design pressures. · Do not expose system pressure control LP to test pressures below the design pressure. This can damage the pressure
controls. · Using an approved, calibrated electronic gas leak detector, leak test the entire system paying attention to all joints.
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· Periodically check functionality of the electronic leak detector during this process. · To further check system integrity, spray a soapy water solution over joins then visually inspect for bubbles. · Leave the system under pressure for a designated period (24 Hours). · 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. · 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. Repair the leak and repeat the leak testing process until system can be signed off as leak free and approved by authorized personnel. · Record findings and confirm pressure testing process completion.
Evacuation · After the system is leak checked, connect approved dual stage vacuum pump sized to application with fresh oil in the
vacuum pump. · Ensure all inline system shut off valves and solenoid valves are fully open. · Evacuate the system to 300 microns. · In case of non availability of micron gauge, a triple evacuation is recommended.
Charging and commissioning reminders: · The scroll compressor design requires system charging with liquid refrigerant into the liquid line. · Do not vapor charge the Simplex ZX Scroll unit. After ensuring all valves are opened and system is vacuumed properly, only
then start the refrigerant charging process.
Step by step: a. Ensure that there is no power supply to the Simplex ZX unit. The Liquid Line solenoid needs to be kept open for the charging
process and this may require a temporary power feed to it. b. Connect the refrigerant cylinder to main service hose and purge line at the manifold end. c. Ensure correct orientation of the refrigerant cylinder. Follow cylinder labeling/instructions so that liquid refrigerant can be
charged into the system. This will be charged through the high pressure side of the manifold and Simplex ZX unit liquid service valve. Charge at least 70% of the required refrigerant in the system before starting the comp. Please do not bypass LP cutout during initial operation. d. The compressor can then be started, and the unit continued to be charged (with controlled liquid refrigerant through the suction service valve). The quantity of charge should always be measured. See note. e. The system needs to be operated down to its design evaporating temperature before you can be sure the charge is correct. It is at this point that the normal refrigeration operational checks can be carried out such as checking the liquid line sight glass for violent bubbles and the operating pressures. Continue to charge about 1 kg after all the bubbles are gone in the liquid line sight glass. During this charging process the controller might show alarms E47 (EXV fully open) and E48 (injection shortage) which is to be ignored as unit is not completely charged. Refrigerant charging is regarded full/complete when the operating temperature of the system has been stable for some time and the liquid line sight glass is clear.
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11.8 Additional Oil Charing in the System
Copeland Simplex 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. If the oil level in the oil reservoir goes below the lower sight glass after the system running for some time, customer needs to charge additional oil charge through suction line using manual oil pump and raise the oil level at least up to mid level of the lower sight glass.

Qualifed refrigerant and oil

Refrigerant R404A

Oil
Emkarate RL 32 3MAF Mobil EAL Arctic 22 CC

11.9 Additional Oil Charing in 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 deg C. · Suction and discharge pressures are within the operating envelope. · The operating current is corresponding to the suction and discharge pressures. · The compressor bottom shell is within the safe range as shown below

Oil sump temperature (°C)

100 90 80 70 60 50 40 30 20 10 0
-10

Evaporation temperature (°C)

-20

-15

-10

-5

0

5

Safe Area

Feasible

Insecure area (Excessive cooling diluent)

0

10

20

30

40

Evaporation temperature (°C)

10 30 20 10 0 -10
50

Oil sump temperature (°C)

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11.10 Maintenance Condenser Fins Condenser fns become dirty over time as ambient air is induced to the condenser. Dirty coil surfaces result in high condensing temperatures and poor unit performance. Regular cleaning is recommended with frequency depending on the installation and the surrounding environment. As a general guide, it is advisable to do this at least once every two months. Fins should be cleaned with liquid detergent diluted with clean water. Before washing, a light brush downward (in the direction of the fns) should be done to remove heavy deposits. Electrical Connections Check tightness of electrical connections occasionally Routine Leak Test All joints should be checked for leaks during site visits. All joints should be leak tested once a year. Condenser Fan(s) and Motor(s), an annual inspection of these items is recommended. Fastenings may loosen, bearings may wear, and fans may require cleaning of solid deposits which can cause imbalance.
TURN OFF OR DISCONNECT THE ELECTRICAL POWER SOURCE BEFORE CLEANING THE CONDENSER COIL OR DOING MAINTENANCE.
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12. Troubleshooting

Alarm codes

Level
Warning Alarm Lock

Description
The unit (including the compressor) will keep running, but some status & data is already in an 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 not close; reset automatically The unit (including the compressor) stops working; alarm dry contact will close; manual reset is needed

Diagnostics

Alarm code

Description

Possible reason Hardware error

Action

E01

Suction pressure probe failure alarm

Probe failure or out of range

No (ZXD Unit Only)

Reset
Automatic Reset when the probe restarts working

E02

Condensing temperature probe failure alarm

Probe failure or out of range Function: fan speed control is Automatic Reset when the

( 40 ~ 110°C)

disabled

probe restarts working

E03

Discharge temperature probe failure alarm

Probe failure or out of range ( 40 ~ 180°C)

Function: discharge temperature protection is
disabled