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Summary of Contents for Zanotti Zer0 120
- Page 1 ® Zer0° 120 Workshop Manual #0WSMZ120...
- Page 2 Z120 Workshop Manual Print Order Code# 0WSMZ120 Rev. 2 Release Dates and Revisions 2/27/2018 Released 5/30/2018 Rev. 2 – Figures, Specification, Sub-section 7.1...
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Page 3: Contents
If further information is required, Zanotti Corporation should be consulted. Sale of product shown in this manual is subject to Zanotti terms and conditions including, but not limited to, the Zanotti Warranty. Such terms and conditions are available upon request. Zanotti warranty will not apply to any Equipment that has been altered outside the manufacturer’s plants. - Page 4 Manual Code Number Section and page # Your name Company Name Phone Number Email *Corrections or Suggestions* Return to: Email to: Zanotti Transblock USA Corp. T-gostynski@zanotti.com 1810 underwood Blvd Delran, NJ 08028 Attn: Service Department...
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Page 5: Table Of Contents
Table of Contents Contents 3.2.3 Defrost and Heat ........16 3.2.4 Refrigeration Symbol Table ..... 17 3.2.5 Defrost system ........18 Contents ..............4 3.2.6 Manual defrost ........18 Table of Figures ............6 3.2.7 Defrost relay..........18 GENERAL SATEFY NOTICES ........1 3.2.8 Defrost solenoid valve (Hot Gas Solenoid Valve) ................. - Page 6 4.2.4 Removing the Manifold Gauge Set ..28 4.17.3 Condenser Coil ........42 4.3 REMOVING THE REFRIGERANT CHARGE ..28 4.17.4 Condensor Mounting Bolts ....42 4.4 REFRIGERANT LEAK CHECKING ...... 29 4.18 ELECTRICAL MAINTENANCE ..... 43 4.5 EVACUATION AND DEHYDRAYION ....29 4.18.1 In-cab controller ........
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Page 7: Table Of Figures
Table of Figures Figure 1 - Z120 Condensing Section Components ....................... 8 Figure 2 - Z120 Evaporator Section Components ......................9 Figure 3- CPU Board Component Diagram ......................... 10 Figure 4 - Control Box Components ........................... 11 Figure 5 - Unit Identification Tag ..........................12 Figure 6 - Z120 Cool Mode Refrigeration Diagram .................... -
Page 8: General Satefy Notices
NOT USE! WARNING: When servicing Zanotti units, use only those service tools certified for and dedicated to refrigerant and Polyol Ester compressor oils. Residual non-HFC refrigerants or oils will contaminate R- 404A and R-134A systems. - Page 9 Refrigeration oil Avoid refrigeration oil contact with the eyes. Avoid prolonged or repeated contact of refrigeration oil with skin or clothing. Wash thoroughly after handling refrigeration oil to prevent irritation. In case of eye contact, immediately flush with plenty of water for at least 15 minutes. Wash skin with soap and water. CONTACT A PHYSICIAN. Electrical Hazards (High voltage) When servicing or repairing a refrigeration unit, the possibility of serious or even fatal injury from electrical shock exists.
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Page 10: Specific Warning And Caution Statements
Electrical Hazards (Low Voltage) Low voltage Control circuits used in the refrigeration unit are low voltage (12/24 volts dc). This voltage potential is not considered dangerous, but the large amount of current available (over 30 amperes) can cause severe burns if shorted or grounded. Do not wear jewelry, watches or rings. These items can short out electrical circuits and cause severe burns to the wearer. -
Page 11: Contents
If starting unit for the first time after installation the compressor pressure regulating valve will need to be reset. If starting unit for the first time after installation or starting after adding/removing an optional feature or if Owners operating parameters have changed, the Configuration will need to be reset. -
Page 12: Specifications
SPECIFICATIONS Condenser fan motor Full load Condenser Airflow Voltage current (CFM) Compressor data (amp) Oil Charge Z120 4.5 @ 13V Component Oil Type (oz) Z120 2.3 @ 26V Compressor 1750 13.5 Polyol Ester 32 Evaporator fan motor Defrost data Full load Evaporator Airflow Type: hot gas or air defrost... -
Page 13: Z120 Maintenance Schedule
Z120 MAINTENANCE SCHEDULE Maintenance Schedule (Alarm Signal SEE or SEr) Instructions: Perform Maintenance A every 1000 hours Perform Maintenance B every 2000 hours Perform Maintenance E every 1000 hours (standby only) Working hours 1000 2000 3000 4000 5000 6000 7000 X1000 Break-in Maintenance A... -
Page 14: Section 1 - Unit Description
12/24 vdc motor cannot be started until the power cord is unplugged from the unit as the selection of road Zanotti Z120 refrigeration systems are designed for operation or standby operation is automatic. low and medium temperature applications on vans and small-sized trucks with one compartment. -
Page 15: Figure 1 - Z120 Condensing Section Components
Figure 1 - Z120 Condensing Section Components... -
Page 16: Evaporator Section
pressure, the liquid refrigerant evaporates at a 1.2 EVAPORATOR SECTION temperature sufficiently low enough to absorb heat from The evaporator is mounted on the ceiling inside the the air. Air movement over the evaporator is provided by vehicle box. The evaporator assembly consists of an an electric fan. -
Page 17: Microprocessor And Control Box
Defrost Switch is pressed or by the Defrost Timer. The 1.3.1 Microprocessor board Defrost Relay will remain energized until the defrost cycle All Printed Circuit Boards manufactured by Zanotti can is terminated by the CPU be easily identified by the Part Number stamped on them. -
Page 18: Control Box
Start Relay (KAV) 1.3.2 Control box Allows start capacitor to be powered during startup The standby relays are located into the control box. When the Electric Standby Relay is energized it turns on the AC Motor of the electric standby motor to drive the DC electric motor relay (KMC) compressor When vehicle key is on, power is to the unit, and all... -
Page 19: Section 2 - Unit Identification
SECTION 2 – Unit Identification Figure 5 - Unit Identification Tag 2.1 DECIPHERING THE MODEL CODE The ten-digit model code can be broken down to Character 6 understand the unit range, drive type, supply version, B = Supply Version Category model variant and refrigerant. -
Page 20: Deciphering The Serial Number
Character 7 B = Standby supply version Value Definition Only road 230/1/50 400/3/50 230/3/50 230/3/60 115/1/60 230/1/60 400/3/60 Character 8,9 00 = standard variant. These numbers identify main versions and features of the units itself Character 10 E = r134a refrigerant Value Definition R134a... -
Page 21: Section 3 - Operation
3.2.1 Cooling When cooling, the unit operates as a vapor compression refrigeration system. The main components of the system 3.1 SAFETY DEVICES are the reciprocating compressor, air-cooled condenser, The Zanotti Z120 machines are equipped with system thermostatic expansion valve, direct... -
Page 22: Null
Figure 6 - Z120 Cool Mode Refrigeration Diagram 3.2.2 Null Null mode is when the unit is powered on but reached setpoint. At the time the unit is in null mode. No relays are activated. The motors, fans, compressors, and solenoid are not activated. The thermostat energizes the power relay (KMC or K1) at box temperatures higher than set point. -
Page 23: Defrost And Heat
3.2.3 Defrost and Heat When low-pressure refrigerant vapor is compressed to a high-pressure the temperature rises and the mechanical energy is transferred to the gas as it is being compressed. This energy is referred to as the “heat of compression” and is used as the source of heat during the heating or defrost cycle. -
Page 24: Refrigeration Symbol Table
3.2.4 Refrigeration Symbol Table Symbol Definition Symbol Definition Solenoid Valve (N.O Liquid /N.C normally Receiver open/closed) Condenser H/P switch Defrost Coil Evaporator Filter Drier Fan motor Sight Glass Air Direction Expansion DC Electric Motor Valve Compressor AC Electric Motor Regulating Valve (CPR) Rotalock 2 Cylinder... -
Page 25: Defrost System
The defrost solenoid valve is energized by the pin 3.2.5 Defrost system 26. When the defrost solenoid valve is energized it routes A defrost cycle can be started by pressing the manual hot refrigerant gas to the evaporator. defrost switch or automatically by the defrost timer, when the unit is in cool mode and below 35°F. -
Page 26: Control System
3.3 CONTROL SYSTEM 3.3.3 In-cab controller The in-cab controller is mounted in the cab and allows the 3.3.1 Description driver to carry out the control operations: Control System consists of microprocessor and the in-cab controller. The Microprocessor includes the temperature control software and necessary input/output circuitry to inter- face with the in-cab controller. -
Page 27: Figure 10- In-Cab Controller Lcd Screen Definitions
In-cab controller LCD screen description COLD MODE LED – it shows the unit is carrying out the cold cycle. DEFROST MODE LED – it shows that the unit is carrying out the cold cycle. STAND-BY LED – it shows that the unit is operating in stand-by mode. -
Page 28: Start Up
Display Set Point Temperature Operation in stand-by mode During normal operation, press the <SET> button to Check that supply voltage corresponds to the one shown display the Set point temperature. in the data plate (tolerance: +/-10% on nominal voltage), then insert the plug. Press the ON button for 3 seconds: Enter Set Point Temperature the operation and standby icons light up;... -
Page 29: After Start Inspection
fastened. Wires and terminals should be free of to pull hot loads down to temperature. corrosion, cracks or moisture. 3.4.6 Post Load Procedure Be sure all the doors are closed and locked. • DEFROST DRAINS. Check the defrost drain hose and Adjust the thermostat to the desired •... -
Page 30: 3Alarms List
E01 : air return probe 3.5.3Alarms list When the sensor doesn’t return the proper input to the microprocessor the label E01 is displayed and the unit SEE : electric standby maintenance interval. stops. It appears when the working hours of the standby operation exceed the pre-set value. -
Page 31: Microprocessor Parameters
parameter 3.6 MICROPROCESSOR PARAMETERS Press <SET> to select the parameter If starting the unit for the first time after installation The Current value will flash, and use the or starting after adding/removing an optional <UP> and <DOWN> arrow buttons to select a new value. feature or if operating parameters have changed, the Press <SET>... - Page 32 “dF” = Interval between defrost cycles [hour] The time interval in hours between the beginnings of two defrost cycles. Factory set is to 3 hours. “PAb” = Differential for battery voltage warning alarm The battery voltage pre-alarm is activated when voltage is lower than road mode voltage bt –...
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Page 33: Service Alarm Management
command module and alternate with the temperature; no 3.6.4 Service Alarm Management acoustic signal is activated. It is possible to adjust some parameters to create an alarm to remind the operator to arrange for Press any key to reset the alarm. However, the alarm will maintenance. -
Page 34: Section 4-System Maintenance
SECTION 4-System Maintenance • visually inspect unit for damaged, loose or broken parts (weekly, monthly, semi- annual, annual inspect/service) Beware the unit may turn on unexpectedly. The clean defrost drains (weekly, monthly, semi- • unit may cycle the fans and compressor annual, annual inspect/service) unexpectedly according to the operating logic. -
Page 35: Manifold Gauge Components
Manifold gauge/hose set with self-sealing hoses is 4.2.3 Connecting Manifold Gauges required for service of models covered within this To connect the manifold gauge/hose set for reading manual. pressures, do the following: 4.2.1 Manifold Gauge Components Connect low side service hose fitting to Compound gauge or Low side gauge the suction access port. -
Page 36: Refrigerant Leak Checking
4.5 EVACUATION AND DEHYDRAYION Moisture can seriously damage refrigerant systems. The presence of moisture in a refrigeration system can have many undesirable effects. The most common are copper plating, acid sludge formation, “freezing- up” of the expansion valve by free water, and formation of acids, resulting in metal corrosion 4.5.1 Preparation Figure 12- Vacuum Pump Connections... -
Page 37: Charging The Refrigeration System
NOTE: If the system will not come down to 500 The most satisfactory method of charging the circuit is as microns, there is probably a leak in the system or in the follows: evacuation and charging equipment hoses. Find and 1. -
Page 38: Low Side Pump Down
4.7 LOW SIDE PUMP DOWN 4.8 CHECKING THE REFRIGERANT CHARGE This procedure can be used to perform replacement If the unit has an insufficient charge of refrigerant, the on refrigeration parts on the low side of the evaporator will be “starved” and the box temperature will refrigeration system. -
Page 39: Checking And Replacing Filter-Drier
4.9.2 Replacing the Filter-Drier Remove refrigerant charge or perform a low side pump down (Section 4.3 & 4.7) Remove the drier mounting clip, then replace the filter-drier. Following drier replacement, evacuate and recharge unit (refer to sections 4.4, 4.5, & 4.6). -
Page 40: Pressure Switches
NOTE: IF THE HIGH/LOW-PRESSURE SWITCH DOES NOT 4.10 PRESSURE SWITCHES PASS THE OHM TESTING WHILE INSTALLED AND PRESSSURES ARE IN TOLERANCE. REPLACE SWITCH IMMEDIATLY. (Pressure above 0 and below 450 with OPEN- LINE on switch) Do not use a nitrogen cylinder without a pressure regulator. -
Page 41: Compressor
4.11 COMPRESSOR 4.11.4 Adding extra oil to the system Correct pulley alignment and proper belt tension are The location for adding oil in the compressor is located very important factors in compressor installation. The behind the compressor head. Remove the brass plug to fill. compressor pulley must be perfectly aligned with the The correct oil to use in a unit using R404A or R134A is electric motor pulley components. -
Page 42: Hot Gas & Condenser Solenoid Valve & Coils
NOTE: Always replace oil with new fresh oil taken 4. No ground from board pin NE- from a sealed container only. a. Check connection and ohms from frame ground to NE- NOTE: Always replace the system filter drier anytime b. If Pin NE- is not receiving a ground the system has been opened for service. -
Page 43: Replacing Solenoid Coil
side port are not the same. If they are the same 2. Verify coil type, voltage and frequency. This pressure. The High side port should be significantly information appears on the coil voltage plate lower in pressure and the coil housing. 3. -
Page 44: Replacing Valve Internal Parts
Note: Most common brazing alloy is 15% PhosCopper 4.12.4 Replacing Valve Internal Parts Brazing Alloy along with hard flux Scotch pads and Oxide sanding paper will ensure you clean corrosion and burs from the metal Protect nearby items such as wiring harnesses plastics and Do not damage or over tighten the enclosing tube other components of the refrigeration system. -
Page 45: Thermostatic Expansion Valve
The Thermal Expansion valve is mounted on liquid line just 4.14 THERMOSTATIC EXPANSION VALVE next to the evaporator and the TXV bulb is placed on the evaporator port outlet. Figure 21- TXV location Drawing Figure 20 - Expansion Valve Components 1. -
Page 46: Expansion Valve Superheat Check & Adjustment
Using the equation below you can calculate your 4.14.1 Expansion Valve Superheat Check & superheat: Adjustment a. Remove insulation from expansion valve SUPERHEAT = A⁰F – B⁰F bulb and suction line. where: = Equalizer line Temp in ⁰F (read from thermocouple) b. -
Page 47: Diagnosing Expansion Valves
m. Loosen flare 4.14.2 Diagnosing Expansion valves disconnect equalizer line from NOTE: Perform low side pump down, compressor expansion valve. capacity test, controlled refrigerant level check, etc. Repair as needed before continuing. n. The TXV bulb is located below the center Symptoms may include of the suction line. -
Page 48: Testing Defrost System
When adjusting the compressor pressure regulating 4.16 TESTING DEFROST SYSTEM valve (CPR), the unit must be running in heating or To test the defrost system, run the unit on cool until the defrost mode. This will ensure a suction pressure evaporator coil temperature is below above the proper CPR setting. -
Page 49: Structural Maintenance
Zanotti. Always carefully follow the specific instructions of the manufacturer of the detergent. Clean the coils during scheduled maintenance When using a cleaning solution (Zanotti code: 3ACQ006), inspections. Remove any debris (e.g., leaves or plastic follow these directions: wrap) that reduces the air flow. -
Page 50: Electrical Maintenance
setpoint temperature, unit must be in cool 4.18 ELECTRICAL MAINTENANCE mode b. Evaporator coil temperature must be lower than 2.0 ± 3.0°C (36.0 ± 5.0 °F) c. Check parameters Temperature displayed is out of range : Be aware of live circuits. High Voltage AC can cause injury or death. -
Page 51: Dc Motor Maintenance
transformer output voltage is acceptable, go to step 3. 3. Check the rectifier output voltage (DC). If this voltage is less than approximately 12/24V, the rectifier bridge is defective. If the rectifier output voltage is acceptable, go to step 4. 4. -
Page 52: Section 5 - Diagnosis
SECTION 5 - Diagnosis the system. DO NOT operate the unit if there is an indication of low charge. FAULTY EXPANSION VALVE ADJUSTMENT: High superheat settings will starve the evaporator causing low suction pressure. Low superheat settings will flood the Beware of unannounced starting of the unit. - Page 53 DIRT IN THE EXPANSION VALVE SCREEN: Reclaim the refrigerant charge, remove the screen and clean. Moisture is in the system will collect at the expansion valve and freeze. This is indicated by abnormally low suction pressure. Replace the drier, dry the system and recharge. ICE ON THE EVAPORATOR COIL: Note operation under DEFROST CYCLE.
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Page 54: Troubleshooting By Symptom
5.2 TROUBLESHOOTING BY SYMPTOM Symptom Possible Causes Remedy Shortage of refrigerant Defrost cycle not terminated 4.16 Abnormal pressure 4.8 & 6 Hot gas solenoid valve 4.12 malfunction Evaporator needs defrosting Expansion valve bulb 4.14 improperly mounted Expansion valve bulb making 4.14 poor contact Expansion valve open too... - Page 55 Improperly wired Check wiring against diagram Low line voltage Check line voltage, determine location of voltage drop Relay contacts not closing Check by operating manually. Replace relay Motor not running Fuses Blown Replace Open circuit in motor winding Check terminal leads High-pressure cut-out open Eliminate cause of excessive pressure 1.1.6 &...
- Page 56 Shortage of refrigerant Repair leak and recharge Plugged expansion valve Clean expansion valve Compressor loses oil Wrong oil viscosity Use proper oil Short cycling Refer to “unit short cycling” Expansion valve set too low, Adjust expansion valve Frosted or sweating suction admitting excess refrigerant Shortage of refrigerant Repair leak and recharge...
- Page 57 Evaporator fan motor not Check parameters operating Abnormal pressure In-cab controller not working No power to valve Hot gas solenoid malfunction Improper wiring or loose connections Unit not heating Valve improperly assembled Movement of plunger restricted due to corroded or worn parts, foreign material lodged in valve, bent or dented enclosing tube Compressor drive (clutch...
- Page 58 Shortage of refrigerant Air through condenser to cold Air through evaporator restricted Evaporator needs defrosting Too much compressor oil in the system Expansion valve closed to much (too high superheat) Low suction pressure Expansion valve partially closed by ice or dirt Restricted line on low side Restricted dryer Gauge out of calibration...
- Page 59 Air through evaporator restricted Evaporator needs defrosting Expansion valve bulb making poor contact Expansion valve open too much (too low superheat) Expansion valve capillary Suction line frosting eroded or leaking Liquid refrigerant entering the compressor Evaporator fan not operating Overcharge of refrigerant No refrigerant Loose mounting bolts Compressor...
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Page 60: Troubleshooting By Alarm Code
5.3 TROUBLESHOOTING BY ALARM CODE Icon Alarm Description Possible causes Possible remedies Following a signal from the low- - Perform a manual - Refrigerant leakage pressure switch , the display defrost and ensure - Evaporator packaged shows the led alarm that the evaporator is of ice error code PRl(PrL). - Page 61 Icon Alarm Description Possible causes Possible remedies The alarm PAb(PAb) indicates a -The alternator is not -Check the battery decrease in the supply voltage. charging charge If the drop is too high, the -Battery not in good -Check the efficiency display shows Ab(Ab) and the Battery condition...
- Page 62 This symbol appears when Connection wire Check the wire and there is no communication between the in-cab the connections on between in-cab controller and controller and the CPU the in-can controller No keyboard the CPU board board is defective or and CPU board.
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Page 63: Section 6 - Temperature And Pressure
SECTION 6 – Temperature and Pressure 6.1 VAPOR TEMP/PRESSURE RELATIONSHIP Vapor Temperature/Pressure Relationship Fahrenheit r134a r404a Fahrenheit r134a r404a 18.5 27.3 72.5 17.4 29.1 75.6 16.9 30.9 78.8 16.2 32.7 82.1 15.4 34.5 85.5 14.7 36.5 13.7 38.6 92.5 12.7 40.7 96.2 11.7... -
Page 64: Pressures At 100⁰F Ambient
6.2 PRESSURES AT 100⁰F AMBIENT The table below shows good pressure readings when measured at set points 35F and 0F and in 100⁰F ambient temperatures. Higher ambient temperatures can be simulated by covering the condenser coil to produce higher pressures. Refrigerant Suction Discharge... -
Page 65: Setting Values Single-Temperature - R404A/R134A - Without Stand-By Option
SETTING VALUES single-temperature - R404a/R134a - without stand-by option Reverse Air defrost Hot gas defrost cycle defrost Label Description Heating Heating Heating function function function heating with heating with with function electrical function reverse hot gas heaters cycle Operating modes: CL=cold, C-H=cold/heat, flag HPU= cold/heat with reverse cycle °F... -
Page 66: Setting Values Single-Temperature - R404A/R134A - With Stand-By Option
SETTING VALUES single-temperature - R404a/R134a - with stand-by option Reverse Air defrost Hot gas defrost cycle defrost Label Description Heating Heating Heating function function function heating with heating with with function electrical function reverse hot gas heaters cycle Operating modes: CL=cold, C-H=cold/heat, flag HPU= cold/heat with reverse cycle °F... -
Page 67: Section 8 - Wiring Diagrams
SECTION 8 - Wiring diagrams This section contains electrical wiring diagrams covering the Z120. The following general safety Most electronic components are susceptible to notices supplement the specific warnings and damage caused by electrical static discharge. In cautions appearing elsewhere in this manual. They certain cases, the human body can have enough are recommended precautions that must be static electricity to cause resultant damage to the... -
Page 69: Z1006 Rev.2
Y/ G 1 (NERO) 2 (BIANCO) Y/ G 3 (ROSSO) Y/ G... - Page 71 10 B 1 (NERO) 10 B 2 (BIANCO) 3 (ROSSO) R 56K-3W tttttttttt...
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Page 73: Wiring Diagram Key
WIRING DIAGRAM KEY ABBREVIATION DEFINITION ABBREVIATION DEFINITION ROOM PROBE M8-11 EVAPORATOR FAN MOTOR RECTIFICATION CAPACITOR DIRECT CURRENT MOTOR RUN CAPACITOR P1MX HIGH-PRESSURE FAN SWITCH START CAPACITOR LOW-PRESSURE SWITCH HEATER HIGH-PRESSURE SWITCH DISCHARGE HEATER TRANSFORMER CONDENSATE DRAIN HEATER THERMO-CONTACT M1 MOTOR FUSE MAIN CONNECTOR ELECTRONIC CONTROL PANEL YCA-YCB SOLENOID HEATING CYCEL... - Page 74 King of Cold Once upon a time there was a Kingdom, where freshness was guaranteed, and where values were maintained, in the best possible way, with respect for all the inhabitants of the planet. Once upon a time, there was a Kingdom, where service and loyalty to customers reigned.
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Questions and answers
F1t chyba co znamena
The F1t error for the Zanotti Zer0 120 indicates an issue with the electric motor protection. Possible causes include a defective stand-by motor, low supply voltage, a short circuit in the stand-by motor, or the power source being too far from the unit. When the correct pressure value is restored, the unit restarts automatically.
This answer is automatically generated