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Application GuidelinesCopeland EazyCoolOutdoor Condensing Unitsfor A2L ApplicationsZX Range

About these guidelines . 11Safety instructions . 11.1 Icon explanation . 11.2 Safety statements . 11.3 General instructions . 22Product description . 32.1 General information about Copeland EazyCool ZX condensing units . 32.2 EU Ecodesign Directive 2009/125/EC . 32.3 Main product features and dimensions . 32.4 Product nameplate . 52.5 Nomenclature . 52.6 Application range . 62.6.1Qualified refrigerants and oils . 62.6.2Application limits . 62.7 BOM variations . 62.8 P&I diagrams . 72.8.1ZXMY units . 72.8.2ZXDY units . 82.9 Main components description . 92.9.1Compressor . 92.9.2Condenser fan(s) . 92.9.3Housing . 92.10 XCM25D Electronic controller – Features . 102.10.1 Description . 102.10.2 Functionalities . 102.10.3 Modbus communication . 112.10.4 Main control & safety features . 112.10.5 Additional features for customization . 122.11 XCM25D Electronic controller – Programming . 182.11.1 Programming the local display . 182.11.2 Remote display CCM60 . 192.11.3 Single commands . 192.11.4 Double commands – Entering programming level 1 "Pr1" . 202.11.5 How to program the parameters (Pr1 and Pr2) . 202.11.6 Entering programming level 2 "Pr2" . 202.11.7 Fast access menu . 212.12 Controller keyboard . 212.12.1 How to lock the keyboard . 212.12.2 How to unlock the keyboard . 212.13 Parameters level 1 – Required settings . 22AGL Unit ZX A2L E Rev00

2.14 Digital operation . 222.15 Pumpdown mode . 232.15.1 External pumpdown without XCM25D integration (not available with ZXDY units)232.15.2 Pumpdown by the unit controller (not available with ZXDY units) . 232.15.3 Pumpdown with room thermostat (not available with ZXDY units) . 242.15.4 Internal pumpdown with temperature sensor (case temperature) . 252.16 Reset to factory settings – Emerson "Hot Key" . 262.16.1 How to save factory settings or user settings . 262.16.2 Applicable hot key for ZX units with XCM25D controller . 262.16.3 Location of the "Hot Key" plug connection on the XCM25D controller . 262.16.4 How to program a "Hot Key" from the controller (upload) . 262.16.5 How to program a controller using an Emerson "Hot Key" (download) . 272.17 Troubleshooting – Alarm history . 272.18 Compressor motor protection . 282.19 System pressure protection . 282.20 Other inputs of the XCM25D controller . 282.20.1 Customer-supplied control (room thermostat). 282.20.2 Case temperature controller . 282.20.3 Ambient temperature sensor . 282.21 Alarm output (DO5) of the XCM25D controller . 283Installation . 293.1 Condensing unit handling . 293.1.1Transport and storage . 293.1.2Weights. 293.2 Refrigeration piping connections . 303.2.1Refrigeration piping installation . 303.2.2Brazing recommendations. 313.2.3Brazing procedure . 323.3 Electrical connection . 323.3.1Power supply connections. 333.3.2Maximum operating currents for cable selection . 333.3.3Electrical wiring . 333.3.4Electrical protection standard (protection class) . 333.3.5Terminal box . 333.3.6Low-pressure protection . 343.3.7Crankcase heater . 343.3.8Insulation material . 343.3.9Sound and vibration . 343.3.10 High-potential testing. 343.3.11 Circuit breaker with overcurrent protection . 353.4 Location & fixings . 35AGL Unit ZX A2L E Rev00

4Start-up & operation. 374.1 Strength-pressure test . 374.2 System tightness test . 374.3 Evacuation . 374.4 Charging procedure . 384.4.1Refrigerant charging procedure . 384.4.2Oil charging procedure . 394.4.3Oil separator . 394.5 Rotation direction of scroll compressors . 394.6 Maximum compressor cycle . 394.7 Checks before starting & during operation . 394.8 Pressure fluctuations in case of digital unit . 404.9 Pumpdown cycle . 405Maintenance & repair . 415.1 General considerations . 415.2 Qualification of workers . 415.3 Preparation and work procedure . 425.4 Disassembling system components . 425.5 Exchanging the refrigerant . 425.6 Replacing a compressor . 425.7 Replacing the crankcase heater . 435.8 Electrical terminations . 445.9 Condenser fins . 455.10 Routine leak testing . 455.11 Condenser fans & motors . 456Certification & approval . 457Dismantling & disposal . 45DISCLAIMER . 46Appendix 1: Overview of the ZX unit components . 47Appendix 2: Wiring diagram – ZXMY units (380-420 V / 3 Ph / 50 Hz) . 48Appendix 3: Wiring diagram – ZXDY units (380-420 V / 3 Ph / 50 Hz). 49Appendix 4: Parameters level 1 . 50Appendix 5: Alarm menu . 51Appendix 6: Additional features for customization . 56Appendix 7: Temperature / resistance curve for B7 Sensor (customer option) . 60Appendix 8: List of tables and figures . 61AGL Unit ZX A2L E Rev00

About these guidelinesThe purpose of these application guidelines is to provide guidance in the application of Copeland EazyCool ZX outdoor condensing units. They are intended to answer the questions raised whiledesigning, assembling and operating a system with these products.Besides the support they provide, the instructions listed herein are also critical for the proper andsafe functioning of the condensing units. The performance and reliability of the product may beimpacted if the product is not used according to these guidelines or is misused.These application guidelines cover stationary applications only. For mobile applications, contactApplication Engineering as other considerations may apply.1Safety instructionsCopeland EazyCool ZX outdoor condensing units are manufactured according to the latestEuropean safety standards. Particular emphasis has been placed on the user's safety.These condensing units are intended for installation in machines and systems in accordance withthe European Machinery Directive MD 2006/42/EC, the Pressure Equipment DirectivePED 2014/68/EU and the Low Voltage Directive LVD 2014/35/EU. They may be put to service onlyif they have been installed in systems according to instructions and conform to the correspondingprovisions of legislation.IMPORTANT: Only dedicated compressors and condensing units are allowed to be used withflammable refrigerants. Emerson marks all compressors and units that are qualified forflammable refrigerants with a sticker indicating the usage of such refrigerants. Systems usingflammable refrigerants must be executed correctly while observing safety rules, as specifiedin corresponding safety standards such as, but not limited to EN 378. They must comply withany and all applicable legislation and regulations. Ensuring compliance remains the user’sresponsibility.These instructions should be retained throughout the lifetime of both the compressor and thecondensing unit.You are strongly advised to follow these safety instructions.1.1Icon explanationWARNINGThis icon indicates instructions toavoid personal injury and materialdamage.Fire hazardThis icon indicates a risk of flammableatmosphere.High voltageThis icon indicates operations with adanger of electric shock.CAUTIONThis icon indicates instructions toavoid property damage and possiblepersonal injury.Danger of burning or frostbiteThis icon indicates operations with adanger of burning or frostbite.IMPORTANTThis icon indicates instructions toavoid malfunction of the compressor.Explosion hazardThis icon indicates operations with adanger of explosion.NOTEThiswordindicatesarecommendation for easier operation.Danger of explosive atmosphereThis icon indicates a risk of explosiveatmosphere.1.2Safety statements Condensing units must be employed only for their intended use. The system has to belabelled according to the applicable standards and legislation. Only qualified and authorized RACHP personnel are permitted to install, commission andmaintain this equipment. Only competent personnel (as specified in EN 13313) qualifiedfor flammable refrigerant handling is permitted to commission, initiate and maintain theAGL Unit ZX A2L E Rev001

compressor/refrigeration systems; non-trained personnel, including the user, are notallowed to do so and must call on an expert.The maximum refrigerant charge is specified in standards such as, but not limited toEN 378, EN 60335-2-40 and EN 60335-2-89. The system designer shall implement all safetymeasures defined by the applicable standards and the maximum refrigerant charge shallnot be exceeded.If a flammable atmosphere is detected, immediately take all necessary precautions tomitigate the risk as determined in the risk assessment.Electrical connections must be made by qualified electrical personnel.All valid safety standards for connecting electrical and refrigeration equipment must beobserved.The national legislation and regulations regarding personnel protection must be observed.Use personal safety equipment.Safety goggles, gloves,protective clothing, safety boots and hard hats should be worn wherenecessary.1.3General instructionsWARNINGPressurized system! Serious personal injuries and/or systembreakdown! Accidental system start before complete set-up must be avoided.Never leave the system unattended without locking it out electrically when it ison vacuum and has no refrigerant charge, when it has a holding charge ofnitrogen, or when the compressor service valves are closed.WARNINGSystem breakdown! Personal injuries! Never install a system in the fieldand leave it unattended when it has no charge, a holding charge, or with theservice valves closed without electrically locking out the system.System breakdown! Personal injuries! Only approved refrigerants andrefrigeration oils must be used.WARNINGHigh shell temperature! Burning! Do not touch the compressor until it hascooled down. Ensure that other materials in the area of the compressor do notcome into contact with it. Lock and mark accessible sections.CAUTIONOverheating! Bearing damage! Do not operate compressors withoutrefrigerant charge or without being connected to the system.CAUTIONContact with refrigerant oil! Material damage! Polyolester oil (POE) mustbe handled carefully and the proper protective equipment (gloves, eyeprotection, etc.) must be used at all times. POE must not come into contactwith any surface or material that it might damage, including without limitation,certain polymers, eg, PVC/CPVC and polycarbonate.IMPORTANTTransit damage! Compressor malfunction! Use original packaging. Avoidcollisions and tilting.The contractor is responsible for the installation of the unit and should check the following points: Sufficient liquid sub-cooling in the line to the expansion valve(s) to avoid "flash-gas" in the liquidline; Sufficient amount of oil in the compressor (in case of long piping additional oil must be charged).2AGL Unit ZX A2L E Rev00