Zanotti un0 060 Workshop Manual
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Zanotti un0 060 Workshop Manual

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un0◦
0MAN295-USA
WORKSHOP MANUAL

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Summary of Contents for Zanotti un0 060

  • Page 1 un0◦ 0MAN295-USA WORKSHOP MANUAL...
  • Page 2 UN0 Workshop Manual Print Order Code# 0MAN295A-USA Release Dates and Revisions 4/1/2018 Released – USA version released for printing...
  • Page 3 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 Attn: Service Department 1810 underwood Blvd Delran, NJ 08028...

  • Page 5: Table Of Contents

    1 - Table of Contents     General information ........................................9     Preface ..........................................9     Units generals ........................................10   Unit configurations ....................................10   Unit identification ..................................... 10   Serial number ......................................11   Unit model ........................................11  ...
  • Page 6 2 - Table of Contents     Description of the unit ......................................23     Condensing unit ......................................23   Nose mount ........................................ 23   Right side and electric box access ............................23   Driver-Left Side Access ................................. 24   Top door Access ....................................
  • Page 7 3 - Table of Contents     Cooling Circuit ........................................... 39     Cooling Diagrams ......................................39   Monoblock ........................................39   Split ..........................................39     Operations ........................................40   Pump Down Stop ...................................... 40   Recover Refrigerant ....................................42  ...
  • Page 8   CPR Valve Replacement ..................................63     KVC Hot Gas Bypass Capacity Regulator ..............................66   KVC Hot Gas Bypass Regulating Procedure ............................. 66   KVC Valve Replacement..................................67     Oil Separator ........................................69   Oil separator replacement ..................................69  ...
  • Page 9 4 - Table of Contents     Diesel Engine ..........................................87     Belts ............................................. 87   Tightening Information ..................................88   Service Belts Replacement ..................................89     Lubrication System ......................................92   Oil change ........................................92   Trochoid Pump Inspection Procedure ............................... 94  ...
  • Page 10 5 - Table of Contents     Electronics and wiring ......................................125     Cab Command ......................................125   Display ........................................125   Symbols key ....................................126   Buttons ........................................126   Driver Mode Menu ....................................127   SET Temperature Set-point Menu ..............................128  ...
  • Page 11   J22 Port ......................................143   J23 Port ......................................143   Low Voltage Wirings ....................................144   High Voltage Wirings ..................................... 145   Wiring diagram symbol-key ................................146     Digital Sensors ......................................147   SA Differential Air Switch ..................................147  ...
  • Page 12   YF2-3 Evaporator 2 or 3 Cooling Valve Coil ......................... 158   YC2-3 Evaporator 2 or 3 Heating Valve Coil ......................... 159   Motor-Fans - 7.6.3 ....................................159   M5 e M6 Condenser Motor-fans .............................. 159   M8, M9 e M10 Evaporator Fans ..............................160  ...
  • Page 13 6 - Table of Contents     Alarms & Troubleshooting ....................................171     Standard Alarms ......................................171   A01 - Room sensor ....................................171   A03 - Evaporator temperature probe failure ..........................171   A04 - Low Pressure Switch ................................... 172  ...
  • Page 14 7 - Table of Contents     Annex 1 ............................................191     Parameters - Single temperature version ............................191   Regulation Parameters Table ................................191   Defrost Parameter Table ..................................191   Alarm Parameter Table ..................................192   Starting Parameter....................................192  ...
  • Page 17 Section 1 General information...
  • Page 18 Contents of section     General information ........................................9     Preface ..........................................9     Units generals ........................................10   Unit configurations ....................................10   Unit identification ..................................... 10   Serial number ......................................11   Unit model ........................................11  ...

  • Page 20: General Information

    (F-gases); i.e. only suitable qualified staff can prevent personal injuries and environmental pollution. Every spare part, required in upkeep or repair operation, is signed on units exploded drawings of Zanotti dedicated website and it is available from our local dealers; Zanotti recommends original spare parts only.

  • Page 21: Units Generals

    General information 1.2 Units generals 1.2 Units generals UN0° range covers following cooling capacities (according ATP conditions): from 3’700W up to 5’700W at −20◦C from 6’100W up to 11’000W 0◦C. A diesel engine powers an alternative compressor through a coupling junction in road operations, while a scroll compressor ensures stand-by operations.

  • Page 22: Serial Number

    General information 1.2 Units generals Metal plate Serial number Serial number on the nameplate, allows identification of the manufacturing period of the unit for warranty purposes and allows to individuate clearly the proper lit of spare parts of the unit itself. 15 11 024 E Revision Year...

  • Page 23: Safety Precautions

    General information 1.3 Safety precautions Unit Diesel Engine Road Mode Compressor un0°060 3CA1 FK20/170 un0°080 3CA1 FK30/235 un0°100 3CB1 FK30/325 un0°120 3CB1 FK40/390 Table 1.2.2: T(400V/3/50Hz) Stand-By Configurations Unit Stand-by Compressor Absorption [A] Max Abs. [A] Inrush Current [A] un0°060 ZF11 6, 84 7, 73...

  • Page 24: Symbols Key

    General information 1.3 Safety precautions keep given protection active, is to practice consistency wearing and using specific equipments for each operation. PPE does not eliminate the hazard, it imposes a barrier between user and working environment. Nonabsorbent gloves Goggles, Safety Glasses or Full Face Shield Safety Shoes Long Pants, with their feet ends out from socks and shoes Appropriate tools...

  • Page 25: Specific Practices

    General information 1.3 Safety precautions CAUTION Hazardous waste materials such as oils, refrigeration gas, fuel, coolant, solvents, filter elements and batteries should be disposed of according local ordinances. Always put waste fluids in separate and sealed containers. Specific practices In order to avoid and prevent accidents, injuries or pollution, it is best practice to follow rules and use specific precautions in accordance with each operation or procedure.

  • Page 26: Refrigerant

    General information 1.4 Service tools First Aid Always after ingestion or inhalation contact a medical doctor. Refrigerant WARNING Eye contact can cause frostbite burns to eyes. Symptoms: Lachrymation, redness, swelling of tissue, frostbite. Burn. First Aid Immediately irrigate with eyewash solution or clean water, holding the eyelids apart for at least 10 minutes.

  • Page 27: Refrigeration Tools

    General information 1.4 Service tools 1.4 Service tools Standard tools Torque Wrench Metric Socket Set Metric Allen Key Set Metric Spanner Set Snap Ring Pliers Screwdrivers Light Source Inspection Mirror Wire Cutters Drill Pliers Air Compressor Refrigeration tools Schrader Valve Refrigerant Pressure Refrigeration Service Wrench Vacuum Pump...

  • Page 28: Brazing Tools

    General information 1.4 Service tools Brazing tools Soldering Flame and Metal Brush Deburring Tool Nitrogen Tank Filler Metal Engine service tools Drain Pan Filter Wrench Funnel Puller Tachometer Belt Tension Meter Gap Gauge Impact Gun Revolution-Meter Electric tools Wire Strippers Wire Crimpers Multimeter Scissors...

  • Page 29: Inspections

    General information 1.5 Inspections 1.5 Inspections Pre-loading Inspection Check pre-cooled products temperature, noting any variances on the manifest. Inspect these following chill box and unit components: 1. Chill box door and vent seals 2. Chill box door hinges and looker 3.
  • Page 31 Section 2 Description of the unit...
  • Page 32 Contents of section     Description of the unit ......................................23     Condensing unit ......................................23   Nose mount ........................................ 23   Right side and electric box access ............................23   Driver-Left Side Access ................................. 24   Top door Access ....................................25  ...

  • Page 34: Description Of The Unit

    Description of the unit 2.1 Condensing unit 2 Description of the unit 2.1 Condensing unit Nose mount Right side and electric box access Right side cover gives access to Electrical Box, Service Ports, Filter Drier, Scroll Compressor, Transformer. Unscrew right side cover. Slide and pull back removing left side cover.

  • Page 35: Driver-Left Side Access

    Description of the unit 2.1 Condensing unit Main accessible parts: 1) Service Ports 3.3.2 Section 2) Check Valves 3.3.4 Section 3) Filter Drier 3.4 Section 4) 3-ways solenoid Valve 3.3.3.3 Section 5) PMI Low Pressure Switch 5.3.3.1 Section 6) PMX High Pressure Switch 5.3.3.2 Section 7) P1MX Condenser Fan Switch 5.3.3.3 Section 8) SA Differential Air Switch 5.3.1 Section 9) Liquid Receiver Shut-off Valve 3.3.1 Section...

  • Page 36: Top Door Access

    Description of the unit 2.1 Condensing unit Top door Access Stand-by Compressor 3.9 Section LP service port 3.3.2 Section Road Compressor 3.10 Section Liquid line shut-off valve 10. Expansion Tank 5.3.2 Section Filter Drier and Sight Glass 3.4 Section 11. Engine Devices 5.6.4 Section HPL service port 3.3.2 Section 12.

  • Page 37: Under Mount

    Description of the unit 2.1 Condensing unit Discharge line Suction line Heat/defrost line Under Mount...

  • Page 38: Refrigeration Side Access

    Description of the unit 2.1 Condensing unit Refrigeration side access This side located close to door grid, gives access to most of refrigeration circuit components. Unscrew right side cover. Main accessible parts: 1. HPG service port 3.3.2 Section 2. Check Valves 3.3.4 Section 3.

  • Page 39: Front Door And Electrical Box Access

    Description of the unit 2.1 Condensing unit Front Door and Electrical Box Access Open cover door lockers by 8mm Allen key Main accessible parts: Unit door micro-switch 5.3.6 Section Filter Drier 3.4 Section Liquid Sight Glass 3.4 Section Stand-by Compressor 3.9 Section Electrical Box 5.2 Section ON/OFF Button 5.3.7 Section Road Compressor 3.10 Section...
  • Page 40 Description of the unit 2.1 Condensing unit Main accessible parts: TAL Transformer 5.7.1 Section Rectifier 5.7.2 Section PMI Low Pressure Switch 5.3.3.1 Section Condenser Motorfans 5.6.3.1 Section KVC Hot Gas Bypass Capacity Regulator 3.7 Section CPR Crankcase Pressure Regulation Valve 3.6 Section Liquid Receiver/Separator Shoot Off Valves of Compressors 3.3.1...

  • Page 41: Evaporating Section

    Description of the unit 2.2 Evaporating section 2.2 Evaporating section Metal Cubic Monoblock Bottom and Side Windows Main accessible parts: 1. Cubic Evp. Fan Motor 5.6.3.2.2 Section 2. Orifice and Expansion Valve 3.5 Section 3. Service Ports 3.3.2 Section 4. BA Cold Room Temperature Probe 5.5.1.1 Section 5.

  • Page 42: Removed Drain Pan Access

    Description of the unit 2.2 Evaporating section Removed drain pan access Remove drain pan screws and dismount drain pan. Main accessible parts: 1. BA Cold Room Temperature Probe 5.5.1.1 Section 2. BL Ev. Air Delivery Probe (Single temp unit only) 5.5.1.2 Section 3.

  • Page 43: Plastic Flat Split

    Description of the unit 2.2 Evaporating section Plastic Flat Split Evaporator Back Main accessible parts: 1. Fan Connectors 2. SA Differential Air Switch Split Single-Temp Unit only 5.3.1 Section Removed Drain Pan Access Remove drain pan screws 4mm allen key.
  • Page 44 Description of the unit 2.2 Evaporating section Main accessible parts: 1. Evaporator Heat Exchanger 2. Flat Evp. Motorfans 5.6.3.2.1 Section 3. Orifice and Expansion Valve 3.5 Section 4. Solenoid Valves 3.3.3 Section 5. Non return Check Valves 3.3.4 Section 6. SA Differential Air Switch equalization lines 7.
  • Page 45 Description of the unit 2.2 Evaporating section...
  • Page 47 Section 3 Cooling Circuit...
  • Page 48 Contents of section     Cooling Circuit ........................................... 39     Cooling Diagrams ......................................39   Monoblock ........................................39   Split ..........................................39     Operations ........................................40   Pump Down Stop ...................................... 40   Recover Refrigerant ....................................42   Vacuum Operation ....................................
  • Page 49   CPR Valve Replacement ..................................63     KVC Hot Gas Bypass Capacity Regulator ..............................66   KVC Hot Gas Bypass Regulating Procedure ............................. 66   KVC Valve Replacement..................................67     Oil Separator ........................................69   Oil separator replacement ..................................69  ...

  • Page 50: Cooling Circuit

    Cooling Circuit 3.1 Cooling Diagrams 3 Cooling Circuit 3.1 Cooling Diagrams Monoblock Figure 3.1.1: Standard Single Temperature Unit Cooling Circuit Split (a) Single Temperature Split Unit Cooling Circuit...

  • Page 51: Operations

    Cooling Circuit 3.2 Operations (b) Multi Temperature Unit Cooling Circuit 3.2 Operations Pump Down Stop Pump down procedure recovers and pushes all of unit refrigerant in condenser and liquid receiver, allowing some cooling circuit repairs without losing gas. Check always refrigerant for humidity contamination from sight glass, and eventually reclaim, recover and recycle refrigerant.
  • Page 52 Cooling Circuit 3.2 Operations Shut-off valve after liquid receiver. Wait that units automatically stops with low pressure alarm. Shut-off RS road and SS stand-by compressors suction valves. Check unit low pressure is lower than 0bar. CAUTION All unit refrigerant is sealed from compressors suction valves to liquid receiver valve. Main serviceable parts: •...

  • Page 53: Recover Refrigerant

    Cooling Circuit 3.2 Operations Recover Refrigerant This procedure recovers refrigerant from the unit, sealing it in a separate tank. Recovered refrigerant could be processed and purified with a recovery station and reintroduced in the circuit. Individual Protection Devices Goggles Gloves Open unit door.

  • Page 54: Refrigerant Charge

    Cooling Circuit 3.2 Operations Individual Protection Devices Goggles Gloves Access from unit cover door. Open all unit valves (shut-off and solenoid ones). Connect refrigeration mani- fold to LP and HPL. CAUTION More connection points should reduce vacuum time and increase vacuum quality. Recover refrigerant.

  • Page 55: Refrigerant Leaks

    Cooling Circuit 3.2 Operations Connect refrigeration manifold. Vacuum unit as in 3.2.3 Section procedure. UN0060 R404A 3, 5kg (7.7lb)  Charge refrigerant according UN0080 R404A 3, 5kg (7.7lb)  Electrical Box Sticker. UN0100 R404A 3, 5kg (7.7lb)  Close refrigerant manifold UN0120 R404A 4, 4kg (9.9lb) gauges and test unit. Refrigerant leaks Leaks can affect cooling system performance with refrigerant blow out or humidity penetration and contamination. Every sealed system leaks because flaws exist.

  • Page 56: Leak Search Procedure

    Cooling Circuit 3.2 Operations Leak Search Procedure Individual Protection Devices Goggles Gloves Recover Refrigerant. Charge 1kg of refrigerant. Fill with Nitrogen until 10bar pressure are equalized into cooling circuit. With turned off unit check every union, junction and shut off valve for leaks with electronic nose and detection spray.

  • Page 57: Basic Steps In Brazing

    Cooling Circuit 3.2 Operations Basic steps in brazing Individual Protection Devices Goggles, Gloves, Vest Ensure fit and clearance: Braz- ing uses the principle of capillary action to distribute the molten filler metal between the surfaces of the base metals. Therefore, during the brazing operation, you should take care to maintain a clearance between the base...

  • Page 58: Valves

    Cooling Circuit 3.3 Valves 3.3 Valves Shut-off Valves Closed Valve (fully tightened Spindle) Opening Valve Turn Spindle (pos. 1) counter clockwise until the end stop. When shut-off valve is fully opened service port (pos. Closed Service Port (pos. 2) with Fully Opened Valve (fully released 2) is closed.

  • Page 59: Valve And Gasket Replacement

    Cooling Circuit 3.3 Valves Valve and Gasket Replacement Recover refrigerant following 3.2.2 Section procedure. Purge valve which is to remove. Replace shut-off valve. CAUTION Check and replace valve gaskets. Vacuum unit following 3.2.3 Section procedure. Charge Refrigerant following 3.2.4 Section procedure.. Service ports HPG High Pressure Gas Service Port RS Road Compressor Suction...
  • Page 60 Cooling Circuit 3.3 Valves HPG High Pressure CND Condenser HPL High Pressure Liquid Gas Service Port Service Port Service Port EVP Evaporator LP Low Pressure RS Road Compressor Service Port Service Port Suction Service Port SS Scroll Compressor SD Scroll Compressor RD Road Compressor Suction Service Port Discharge Service Port...

  • Page 61: Valve Test

    Cooling Circuit 3.3 Valves Valve Test Spray foam detection solution on service port. Check for foam or bubbles presence. CAUTION Test gives better re- sults with more than 10bar (145psi) difference between line and external pressure. Inspect with electronic nose. Valve Replacement Recover Refrigerant 3.2.2 Section.

  • Page 62: Sae Pressure Switch Replacement

    Cooling Circuit 3.3 Valves SAE Pressure Switch Replacement SAE threat Pressure Switches are installed on service ports, all which provided with valves, thus pressure switch replacement keeps cooling circuit sealed. Unscrew pressure switch from service port. Check service port valve for leakage.

  • Page 63: Valve Disassemble

    Cooling Circuit 3.3 Valves Valve Disassemble Remove fixing nut and coil. Unscrew cover from valve body. CAUTION Valve cover holds a compressed spring! It may hump out by itself. Remove and inspect valve diaphragm and plunger. Remove and check O-ring. Visually check for dirt and clean inside valve.

  • Page 64: Yk Capacity Control Valve Replacement

    Cooling Circuit 3.3 Valves Disconnect 3-way valve from copper tubes with soldering flame. Clean pipe ends with a special brush and blow with dry nitrogen. CAUTION Never blow with normal air, it contains too much humidity. Place new valve in position. CAUTION Using test coil check valve operativity before.

  • Page 65: Non Return Check Valves

    Cooling Circuit 3.3 Valves Unscrew coil fixing nut or seeger ring and remove solenoid coil from valve. Disconnect YK valve from copper tubes with soldering flame. Clean pipe ends with a special brush and blow with dry nitrogen. CAUTION Never blow with normal air, it contains too much humidity.

  • Page 66: Check Valve Replacement

    3.4 Filter Drier and Sight Cooling Circuit Glass Check Valve Replacement Disconnect unit from electrical supplies (Battery and Main). Open unit door and right or refrigeration side cover and fold down electrical Box. Recover Refrigerant 3.2.2 Section. Disconnect check-valve from copper tubes with soldering flame.

  • Page 67: Filter Drier Replacement

    3.4 Filter Drier and Sight Cooling Circuit Glass Filter Drier Replacement Individual Protection Devices Goggles, Gloves, Vest Recover refrigerant following procedure of 3.2.2 section. CAUTION Ensure that cooling circuit is completely purged. Switch off and disconnect unit from electrical supplies (Battery and Main). Unscrew Filter Drier and Sight Glass 22mm nuts holding filter with 19mm wrench.

  • Page 68: Orifice And Expansion Valve

    3.5 Orifice and Expansion Cooling Circuit Valve Connect refrigeration man- ifold to LP low pressure and HPL liquid hight pressure service ports. Vacuum contaminated part of cooling circuit only. Reopen unit valves. Orifice and Expansion Valve Thermostatic expansion valve regulate the injection of refrigerant liquid into evaporators. It controls refrigerant flow by superheat.

  • Page 69: Orifice Replacement

    3.5 Orifice and Expansion Cooling Circuit Valve Open exp. valve cap and adjust overheating rotating spindle; A full turn clockwise increase over- heating of 4K(°C) (7°F ), viceversa one turn counterclockwise decrease of the same amount. Orifice Replacement Pump down unit 3.2.1 Section. Ensure that liquid receiver discharge and compressors suction valves are closed.
  • Page 70 3.5 Orifice and Expansion Cooling Circuit Valve Switch off and disconnect unit from electrical supplies (Battery and Main). Dismantle evaporator cover (split and undermount units only). Unscrew expansion valve inlet 22mm nut holding valve with 19mm wrench. Remove and replace orifice assembly.

  • Page 71: Expansion Valve Replacement

    3.5 Orifice and Expansion Cooling Circuit Valve Expansion Valve Replacement Pump down unit 3.2.1 Section. Ensure that liquid receiver discharge and compressors suction valves are closed. Switch off and disconnect unit from electrical supplies (Battery and Main). Dismantle evaporator cover (split and undermount units only). Cut plastic fasten and remove sensing bulb protective insulation...
  • Page 72 3.5 Orifice and Expansion Cooling Circuit Valve Remove and flash equalization line with nitrogen. Remove expansion valve holding valve body with 19mm wrench. Holding valve body with 19mm wrench install new valve. Reconnect equalization line. CAUTION Before reconnecting check equalization line for obstruction.

  • Page 73: Cpr Crankcase Pressure Regulation Valve

    3.6 CPR Crankcase Pressure Cooling Circuit Regulation Valve 3.6 CPR Crankcase Pressure Regulation Valve CPR Crankcase Pressure Regulation Valve is a protection device, which avoids compressor overload and liquid return, limiting maximum suction pressure. It is useful at the end and during defrost or heating operations, under certain conditions, and also at start with equilibrated circuit (e.g.

  • Page 74: Cpr Valve Replacement

    3.6 CPR Crankcase Pressure Cooling Circuit Regulation Valve Regulate maximum suction pressure to 2, 2barg (31.9psig) by turning CPR setting screw; 1 turn clockwise to increase pressure value of 0.17bar (2.5psi) or in the opposite direction to decrease it of same quantity. CAUTION Inside under protection cap remove looking nut to...
  • Page 75 3.6 CPR Crankcase Pressure Cooling Circuit Regulation Valve Release CPR valve from fixing brackets and remove all of valve supports. Remove valves from EVP evaporator and LP service ports. Flux nitrogen approx. 0, 35barg (5.1psig) from evaporator service port, to prevent dirt and oxidation during welding operations.
  • Page 76 3.6 CPR Crankcase Pressure Cooling Circuit Regulation Valve i Clean pipe ends with a special brush and flow with dry nitrogen. CAUTION Never flow with normal air, it contains too much humidity. Braze new CPR valve in position. CAUTION Wrap CPR valve in a wet rag, which must be warmer than ambient avoiding moisture condensation.

  • Page 77: Kvc Hot Gas Bypass Capacity Regulator

    3.7 KVC Hot Gas Bypass Cooling Circuit Capacity Regulator 3.7 KVC Hot Gas Bypass Capacity Regulator KVC hot gas bypass capacity regula- tor valve is used to adapt compressor capacity to actual evaporator load by supplying a replacement capacity in the form of hot/cool gas.

  • Page 78: Kvc Valve Replacement

    3.7 KVC Hot Gas Bypass Cooling Circuit Capacity Regulator Setup −20°C (−4°F ) compartment temperature to −25°C (−13°F ), keeping only one evaporator operating, in this way all of other evaporators are isolated by solenoid valves. Remove KVC cap unscrewing by hands.
  • Page 79 3.7 KVC Hot Gas Bypass Cooling Circuit Capacity Regulator Release KVC valve from fixing brackets and remove all of which. Flux nitrogen (approx. 0, 35barg) from LP service port, to prevent dirt and oxidation during welding Fuse with brazer flame KVC welding line and disconnect old valve. Clean pipe ends with a special brush and flow with dry nitrogen.

  • Page 80: Oil Separator

    Cooling Circuit 3.8 Oil Separator 3.8 Oil Separator Oil is required in a cooling system just by compressors to prevent seize due to friction and thermal expansion. Oil separator is equipped on Zer0o range as a standard, it increases compressor life ensuring a good lubrication. Oil, as particulate, is entrained into refrigerant gas coming from compressor, oil separator divides, collects and returns oil to compressors.
  • Page 81 Cooling Circuit 3.8 Oil Separator Remove FGS Scroll Protection from inlet tube. Remove pressure switches and service ports valves avoiding burn or heat damage. Close 3 service ports with caps avoiding dirt and water contamination. Disconnect oil separator with soldering flame from copper tubes.
  • Page 82 Cooling Circuit 3.8 Oil Separator Braze new oil separator in position. Clamp liquid injection thermostat to inlet tube coming from scroll compressor. Re-install service port valves. CAUTION Check condition and eventually replace. Re-install pressure switches. Open all unit valves and Vac- uum unit 3.2.3 Section.

  • Page 83: Scroll Stand-By Compressor

    3.9 Scroll Stand-by Cooling Circuit Compressor 3.9 Scroll Stand-by Compressor Scroll Compressor ensure cooling operation during Stand-by mode. Compressor operativity is provided with liquid injection that protect compressor from overheating during operation. Specifications Unit Compressor un0°060 ZF11 un0°080 ZF13 un0°100 ZF15 un0°120 ZF18...
  • Page 84 3.9 Scroll Stand-by Cooling Circuit Compressor Purge from LP service port. Holding body disconnect injection valve. Remove sensing bulb. Replace valve holding body while screwing. CAUTION A 90° orientation on the valve is recommended. CAUTION Sensing bulb capillary should not contact the compressor during operation.

  • Page 85: Stand-By Compressor Replacement

    3.9 Scroll Stand-by Cooling Circuit Compressor Stand-by Compressor Replacement Open unit top cover (Nose Mount) or open unit front door (Under Mount). Open unit bottom cover. Recover refrigerant 3.2.2 Section. Close all of compressors Valves. Disconnect Unit from Electrical Supplies (Battery and Electrical Main).
  • Page 86 3.9 Scroll Stand-by Cooling Circuit Compressor Disconnect compressor from electrical wires. Remove and replace compressor (c:: 45kg c:: 99lb) by using a lifter. CAUTION Do not tighten fixing screws. Remove scroll compressor head cap. CAUTION Pay attention to keep bulb positioning spring into its groove.

  • Page 87: Alternative Road Compressor

    3.10 Alternative Road Cooling Circuit Compressor 3.10 Alternative Road Compressor Alternative Compressor, driven by diesel engine trough a coupling junction, ensure cooling operation during Road mode. Individual Protection Devices Shoes, Goggles, Gloves Shaft Seal Replacement Put compressor on a workbench and remove junction hub following compressor replacement procedure just to "paragraph j"...

  • Page 88: Capacity Regulation Valve Replacement

    3.10 Alternative Road Cooling Circuit Compressor Install spring (pos. 1) engaging catch in crankshaft. Push shaft seal assembly (pos. 2,3 and 4) engaging spring second catch. CAUTION Avoid rubber rings scratches. Install shaft cover (pos. 6) with paper gasket (pos. 5) dry and screw in a diametrically opposite sequence.

  • Page 89: Valve Plate Replacement

    3.10 Alternative Road Cooling Circuit Compressor Valve Plate Replacement Put compressor on a work- bench following compressor replacement procedure just to "paragraph i" Unscrew valve plate in a diametrically opposite sequence. Remove valve plate (pos. 4). Clean plate cover (pos. 2) and cylinder block from gaskets and oil residuals. CAUTION Don’t let any residues fall into compressor.

  • Page 90: Road Compressor Replacement

    3.10 Alternative Road Cooling Circuit Compressor Road Compressor Replacement Disconnect unit from all electrical supplies (Electrical main and Battery). Open unit cover door. Remove bottom cover. Shut off both compressors oil line and road suction and discharge CAUTION Shut off both com- pressors1 oil line valves, avoiding oil dripping.
  • Page 91 3.10 Alternative Road Cooling Circuit Compressor Remove bolts from bell- housing (q.ty 8)in a diametrically opposite sequence. Sliding back compressor and bell-housing assembly from engine flange. Using a lifter remove compressor. Disconnect junction hub from compressor unscrewing drive shaft screw. Remove bell-housing from compressor.
  • Page 92 3.10 Alternative Road Cooling Circuit Compressor Dismount oil return shut off valve. Install oil return shut off valve on new compressor. Remove 4 screws from new road compressor. Install bell-housing on to a new compressor. CAUTION With a rubber hammer ensure bell housing contact with compressor.
  • Page 93 3.10 Alternative Road Cooling Circuit Compressor Place new compressor in position. Slide compressor forth until bell-housing touch engine flange. Join bell-housing to engine flange screwing in a diametrically opposite sequence. CAUTION Tightening torque: 44N m (389lb − in) Fasten compressor to its frame basement. CAUTION! Tightening torque: 74N m (655lb−in).
  • Page 95 Section 4 Diesel Engine...
  • Page 96 Contents of section     Diesel Engine ..........................................87     Belts ............................................. 87   Tightening Information ..................................88   Service Belts Replacement ..................................89     Lubrication System ......................................92   Oil change ........................................92   Trochoid Pump Inspection Procedure ............................... 94  ...

  • Page 98: Diesel Engine

    Diesel Engine 4.1 Belts 4 Diesel Engine 4.1 Belts Individual Protection Devices Googles Gloves Proper tools...

  • Page 99: Tightening Information

    Diesel Engine 4.1 Belts Tightening Information This diesel engine service belt system, provides belt tightening by split pulleys. As shown in Figure 5.1.1 Split pulley shoulders force belt in position, as pulley V narrows, belt goes further from fulcrum becoming tighter, while as V widens, belt runs closer slacking.

  • Page 100: Service Belts Replacement

    Diesel Engine 4.1 Belts Service Belts Replacement Disconnect Unit from Electrical Supplies (Battery and Electrical Main). Remove left side cover. Remove water pump pulley external halve. (pos. 6). Remove crankshaft pulley external halve. Replace water pump belt (pos. 6).
  • Page 101 Diesel Engine 4.1 Belts Reinstall water pump pulley according aside drawing (pos.s 5,11,16,21 & 22). CAUTION Internal spacer number at Table 5.1.1 Completely screw screws (pos.16) until their heads touch pulley. CAUTION Tightening torque:9Nm (80lb-in) Turn pulley helping belt reaching its working position. Check Water pump belt tension according Table 5.1.1 •...
  • Page 102 Diesel Engine 4.1 Belts Reinstall crankshaft pulley according aside drawing (pos.s 3, 11, 16, 21 & 22). CAUTION Internal spacer number at Tab. 5.1.1 Completely screw screws (pos.16) until their heads touch pulley. CAUTION Tightening torque: 9Nm (80lb − in) Turn pulley helping belt reach- ing its working position.

  • Page 103: Lubrication System

    Diesel Engine 4.2 Lubrication System 4.2 Lubrication System Oil change Unit comes supplied with oil specification 10W40, suitable for atmospheric temperatures range from -15 a +35 °C. For temperatures out of this range, select the proper viscosity of the oil according the table aside. In the table below overall quantity of oil is given for each model Unit Engine model...
  • Page 104 Diesel Engine 4.2 Lubrication System Individual Protection Devices Googles Gloves Proper tools Switch off and disconnect unit from electrical supplies (Battery and Main). Remove and clean filler cap accessing from top cover (nose mount). WARNING!! ! Hot parts can cause severe burns. Open check window under bottom cover.

  • Page 105: Trochoid Pump Inspection Procedure

    Diesel Engine 4.2 Lubrication System Put small pan or rags under oil filter. Unscrew filter counterclock-Awise RECYCLABLE Waste according local dispositions. Clean oil filter support mating (contact) surface. Lubricate with clean oil gasket of new filter. Fill filter with oil, subtracting quantity from total amount. Screw filter clockwise until rubber gasket touches mating face, tighten a further half turn.
  • Page 106 Diesel Engine 4.2 Lubrication System Individual Protection Devices Googles Gloves Proper tools Loosen and remove service belts. Remove the crankshaft pulley. Remove the gear case cover. Remove the lube oil pump cover from the gear case cover. Remove the pressure regu- lating valve from the lube oil pump cover.

  • Page 107: Po Oil Pressure Switch Replacement

    Diesel Engine 4.3 Cooling System Measure the outside diameter of inner rotor centering location part and the hole diameter of gear case cover. Calculate the clearance from that difference. PO Oil Pressure Switch Replacement Individual Protection Devices Googles Gloves Disconnect units from electrical supplies (battery and main). Open unit door cover.

  • Page 108: Water Pump

    Diesel Engine 4.3 Cooling System Water Pump Replacement Procedure Individual Protection Devices Goggles Gloves Disconnect units from electrical supplies (battery and main). Remove left side cover Remove water pump belt and pulley. Release a coolant hose clamps and drain water, than reconnect the tube.

  • Page 109: Ftq Temperature Switch Replacement

    Diesel Engine 4.3 Cooling System Remove protection cover plate and gasket from new water pump. Install pump on cylinder head. Mount temperature switch and sensor. Fill coolant from expansion tank cap. CAUTION! Securely tighten cooling system filler caps. Turn water pump few turn by hand. Check water pump installation for leaks.

  • Page 110: Bh Temperature Sensor Replacement

    Diesel Engine 4.3 Cooling System Open driver side or Engine side cover. Remove part of engine coolant avoiding big drain. CAUTION! ! Wait that coolant is not dangerously hot. Unscrew and replace FTQ switch 22mm wrench. CAUTION! Replace gasket lubri- cating before to install.

  • Page 111: Thermostatic Valve Replacement

    Diesel Engine 4.3 Cooling System Thermostatic Valve Replacement Individual Protection Devices Goggles Gloves Disconnect units from electrical supplies (battery and main). Open driver side or Engine side cover.

  • Page 112: Expansion Tank

    Diesel Engine 4.3 Cooling System Remove part of engine coolant avoiding big drain. CAUTION! Wait that coolant is not dangerously hot. Dismount water pump topper flange releasing thermostat. Replace thermostat and close water pump assembly. CAUTION! Tightening torque: Refill engine coolant from expansion tank. CAUTION! Securely tighten cooling system filler cap.

  • Page 113: Coolant Leaks Search

    Diesel Engine 4.4 Propeller Supply System Refill engine coolant from expansion tank. CAUTION! ! Securely tighten cooling system filler cap. Coolant Leaks Search Individual Protection Devices Goggles Gloves Disconnect unit from electrical supplies (Battery and Main). Open expansion tank cap and pour coolant dye inside. Close expansion tank cap.

  • Page 114: Fuel Filter Replacement

    Diesel Engine 4.4 Propeller Supply System Fuel Filter Replacement Individual Protection Devices Goggles Gloves Proper tools Disconnect Unit from Electrical Supplies (Battery and Electrical Main). Remove left side cover.(Nose Mount Unit) or Open unit front cover door.(Under Mount Unit)
  • Page 115 Diesel Engine 4.4 Propeller Supply System Unscrew fuel filter anti- clockwise. RECYCLABLE Waste according local dispositions. Clean oil filter support mating (contact) surface. Lubricate new filter gasket with clean oil. Fill Filter with fuel.
  • Page 116 Diesel Engine 4.4 Propeller Supply System Screw filter clockwise until rubber gasket touches mating face, tighten a further half turn. Check Fuel level. Reconnect unit battery. Activate Fuel Pump from Digital Output Management menu. Loosen air bleeding bolt on fuel filter support unscrewing 2 to 3 turns.

  • Page 117: Fuel Pump

    Diesel Engine 4.4 Propeller Supply System Fuel Pump Fuel pump usually does not require any maintenance, best practice is periodically check propeller system for leaks. Replacement Procedure Individual Protection Devices Goggles Gloves Proper tools Put drain pan under fuel pump. Disconnect fuel pump plug.

  • Page 118: Air Filter Cartridge Replacement

    Diesel Engine 4.4 Propeller Supply System Run fuel pump from Digital Output Management menu for 1 minute to remove air from fuel circuit. Bleed residual air from diesel filter. Test unit and check for fuel leaks. Air Filter Cartridge Replacement Switch off and disconnect unit from electrical supplies (Battery and Main).

  • Page 119: Speed Solenoid

    Diesel Engine 4.4 Propeller Supply System Speed Solenoid Engine RPM Regulation un0o engine run at 2 different speeds according driver setup or unit requirements. Both speed are adjustable by regulating screws that limit accelerator lever stroke Open unit door. Check speed symbol on cab command. Low Speed or High Speed Measure engine speed with an RPM meter.

  • Page 120: Start Stop Solenoid Valve

    Diesel Engine 4.4 Propeller Supply System Adjust joint nut until accelerator lever touches low speed regulating screw. Fully check operativity enabling High Speed from Digital Output Management menu, and eventually adjust joint nut. Start Stop Solenoid Valve Disconnect units from electrical supplies (battery and main). Open unit door.

  • Page 121: Electric System

    Diesel Engine 4.5 Electric System 4.5 Electric System ALT Alternator Alternator converts rotational mechanical energy into electric energy, which supplies all of electrical devices during road mode. un0o logic monitoring alternator voltage and comparing with VAM [V ] parameter obtains engine state. Individual Protection Devices Goggles Gloves...

  • Page 122: Replacement Procedure

    Diesel Engine 4.5 Electric System Replacement Procedure Open left side cover. Remove alternator belt opening crankshaft split pulley. Disconnect and remove alternator. Install alternator pulley on new alterantor CAUTION Tightening torque: 75N m (664lb − in) Install new alternator. CAUTION Tightening torque: 20N m (177lb −...

  • Page 123: E1 Glow Plugs

    Diesel Engine 4.5 Electric System Connect 9th wire to D+. Connect red positive wire to B+. CAUTION Negative pole con- nection is ensure by alternator metal body. E1 Glow Plugs Part # Current Resistance 3RMD299 5,5A 0,6 Ω 3RMD453 5,5A 2,4 Ω...

  • Page 124: Electrical Resistance Test

    Diesel Engine 4.5 Electric System Electrical Resistance Test Disconnect unit from electrical supplies. Open unit door and remove engine side cover. Remove rocker cover assembly unscrewing 9 bolts. Disconnect glow plug from engine harness. Connect multi-meter black lead to a good ground point.

  • Page 125: Transmission

    Diesel Engine 4.6 Transmission Disconnect units from electrical supplies (battery and main). Open unit top cover Remove rocker cover assembly unscrewing 9 bolts. Disconnect glow plugs from wire. Clean with a paper towel engine face area where rocker cover gasket sits. Unscrew glow plugs.

  • Page 126: Coupling Junction

    Diesel Engine 4.6 Transmission Coupling Junction Elastic Coupling transmits torque power from diesel engine to compressor shafts, damping torsional vibrations and accommodating little misalignments. Advantages of Flexible Coupling instead of Belts System are: • Stronger Coupling • Increased MTBF (Mean Time Between Failure) •...

  • Page 127: Flexible Element Replacement

    Diesel Engine 4.6 Transmission Individual Protection Devices Googles Gloves Proper tools Flexible Element Replacement Disconnect Unit from Electrical Supplies (Battery and Electrical Main). Open unit cover door. Remove bottom cover. Shut off both compressors oil line and road suction and discharge CAUTION Shut off both com- pressors1 oil line valves, avoiding oil dripping.
  • Page 128 Diesel Engine 4.6 Transmission Remove bolts from bell- housing (q.ty 8)in a diametrically opposite sequence. Sliding back compressor and bell-housing assembly from engine flange, just enough to access cou- pling flexible elements. Replace the flexible elements taking care of their correct positioning.
  • Page 129 Diesel Engine 4.6 Transmission Restore compressor connec- tions keeping valves closed. WARNING Vacuum compressor in order to remove humidity introduced during air exposure, before reopening valves. Open valves. Reinstall bottom cover.
  • Page 131 Section 5 Electronics and Wirings...
  • Page 132 Contents of section     Electronics and wiring ......................................125     Cab Command ......................................125   Display ........................................125   Symbols key ....................................126   Buttons ........................................126   Driver Mode Menu ....................................127   SET Temperature Set-point Menu ..............................128  ...
  • Page 133   J22 Port ......................................143   J23 Port ......................................143   Low Voltage Wirings ....................................144   High Voltage Wirings ..................................... 145   Wiring diagram symbol-key ................................146     Digital Sensors ......................................147   SA Differential Air Switch ..................................147  ...
  • Page 134   YF2-3 Evaporator 2 or 3 Cooling Valve Coil ......................... 158   YC2-3 Evaporator 2 or 3 Heating Valve Coil ......................... 159   Motor-Fans - 7.6.3 ....................................159   M5 e M6 Condenser Motor-fans .............................. 159   M8, M9 e M10 Evaporator Fans ..............................160  ...

  • Page 136: Electronics And Wiring

    Electronics and wiring 5.1 Cab Command 5 Electronics and wiring 5.1 Cab Command Display Single Temperature Multi Temperature...

  • Page 137: Symbols Key

    Electronics and wiring 5.1 Cab Command Symbols key Automatic or Continuous working mode Slow diesel engine running Low diesel engine speed Fast diesel engine running High diesel engine speed Stand-by mode Diesel mode Cooling mode Defrosting mode Heating mode Cold room Actual Temperature Set-Point Temperature Alarm Activive or Present in memory An alarm has caused permant unit stop...

  • Page 138: Driver Mode Menu

    Electronics and wiring 5.1 Cab Command Access programming menu Access scheduled maintenace menu Disable Blackout mode (Symbol indicates actual option state) Enable Blackout mode (Symbol indicates actual option state) Access to Service menu Return to previous menu Increase set-point Temperature Decrease set-point Temperature Move cursor down into menu or decrease value Move cursor into menu or increase value...

  • Page 139: Set Temperature Set-Point Menu

    Electronics and wiring 5.1 Cab Command Driver Mode enables a short menu with temperature set, manual defrost and alarm visualization allowed only. (cc) To Quit from Driver Mode press and hold together 2 (SET) and 3 (no label) buttons from left. (dd) Press SET button to enable password input.

  • Page 140: Alarm Log Menu

    Electronics and wiring 5.1 Cab Command Alarm Log Menu (mm) Press button to access Alarm Log. As long as symbol is displayed, alarm is active and it is not possible to reset alarm or unlock motor. (nn) Press button to unlock unit after a permanent stop.

  • Page 141: Evp Evaporators Management Menu

    Electronics and wiring 5.1 Cab Command Alternator Voltage: Battery Voltage: Water Temperature: (ss) Press to skip page. Evap. Air Temp. ΔT evaporator air Diesel Engine Hours: Electric Motor Hours: (Last page) (tt) Press to return to previous page. Press BACK to quit.

  • Page 142: Scheduled Maintenance Menu

    Electronics and wiring 5.1 Cab Command Scheduled Maintenance Menu This menu gives information about required scheduled maintenance procedure and countdown reset for operators after up- keeping operation. (zz) Press button to slide Menu. (aaa) Press for Programming Menu. This Menu gives information about required scheduled maintenance.

  • Page 143: Prog Programming Menu

    Electronics and wiring 5.1 Cab Command PROG Programming Menu (ggg) Press button to slide Menu (hhh) Press PROG for Programming Menu. (iii) Press SET button to enable password input. (jjj) buttons to select 11(Programming Password). (kkk) Press SET button to confirm. (lll) Press PROG accessing programming Menu.

  • Page 144: Parameters Modification

    Electronics and wiring 5.1 Cab Command Parameters Modification (nnn) to move into parameter values and to skip page. (ooo) Press SET to enable modification of highlighted parameter. Use to modify parameter value. Than press SET again to confirm setting up new value. Input/Output Management (ppp) to move into parameter values and...

  • Page 145: Clock Configuration

    Electronics and wiring 5.1 Cab Command - Clock Configuration (sss) Press SET to enable highlighted value modifica- tion. (ttt) to setup value. (uuu) Than press SET again to confirm modification. - Configuration (vvv) to move into parameter values and to skip page. (www) Press SET to enable modification of highlighted parameter.

  • Page 146: Electronic Boards

    Electronics and wiring 5.2 Electronic Boards 5.2 Electronic Boards CPU board...

  • Page 147: J1 & J2 Cab Command Ports

    Electronics and wiring 5.2 Electronic Boards J1 & J2 Cab Command ports Wire From Cab C. Blue Cab C. Brown Cab C. Black Cab C. J2 sig Orange Cab C. J6 Power Supply port Wire From NE196 J19 - pin6...

  • Page 148: J7 Temperature Probes Port

    Electronics and wiring 5.2 Electronic Boards J7 Temperature Probes port Wire J8 CPU board Input port Wire From MPC (Optional) ON/OFF FMI, FM1S FTS1-2...

  • Page 149: J9 Cpu Board Output Port

    Electronics and wiring 5.2 Electronic Boards J9 CPU board Output port Wire J 19 − 10 J 19 − 5 J 19 − 4 J 19 − 8 J 19 − 7 J 19 – 3 J 19 – 1...

  • Page 150: Relay Board

    Electronics and wiring 5.2 Electronic Boards Relay Board...

  • Page 151: J10 Pwr Board Ground Port

    Electronics and wiring 5.2 Electronic Boards J10 Pwr Board Ground Port Wire From NE102 NE103 FMI, FM1S NE104 NE105 ON/OFF NE106 NE107 FTS1-2 NE108 NE1010 NE1012 J12 Pwr Board Port Wire From/To Fuel Valve Emergency Board NE126 NE127 NE128 Fuel Valve NE129 NE121O Emergency Board...

  • Page 152: J19 Pwr Board Input Port

    Electronics and wiring 5.2 Electronic Boards J19 Pwr Board Input Port Wire From J9-15 J9-12 KPR1 J9-6 KYAV J9-5 K8-9-10 NE196 J6-(-) J9-11 J9-10 J9-4...

  • Page 153: Multi-Temperature Expansion Boards

    Electronics and wiring 5.2 Electronic Boards Multi-Temperature Expansion Boards Each evaporator equipped in a multi-temperature unit is provided with 2 solenoid valves, which allow to control evaporators cooling and heating or defrosting operations. To manage all of this valves unit logic requires these following expansion boards.

  • Page 154: 2Nd And 3Rd Evaporator Boards

    Electronics and wiring 5.2 Electronic Boards and 3 Evaporator Boards nd  rd  Adr3 Regulation Parameters (7.2.1 section) respectively to identify 2nd and 3rd evaporators. J20 Port Wire From/To KVE1 J21 Port Wire From/To J22 Port Wire From/To J23 Port Wire From/To Brown J3-H...

  • Page 155: Low Voltage Wirings

    Electronics and wiring 5.2 Electronic Boards Low Voltage Wirings...

  • Page 156: High Voltage Wirings

    Electronics and wiring 5.2 Electronic Boards High Voltage Wirings...

  • Page 157: Wiring Diagram Symbol-Key

    Electronics and wiring 5.2 Electronic Boards Wiring diagram symbol-key LABEL DESCRIPTION LABEL DESCRIPTION Glow plug and capacity control +pin Condenser fan managing relay Starter positive contact Capacity Control Relay Alternator KPR1 Glow plug and starting capacity control relay BA -2-3 Cold room temperature probe Stand-by relay Environmental temperature probe...

  • Page 158: Digital Sensors

    Electronics and wiring 5.3 Digital Sensors 5.3 Digital Sensors Digital sensors give binary signals to CPU board which elaborating info, according programmed logic, manages all unit devices. Binary signals O or 1 represents a contact state Opened or Closed, all of these sensor are just working as switches, opening and closing their contact according pressure, temperature or other specific sensing conditions.

  • Page 159: Sae Pressure Switches

    Electronics and wiring 5.3 Digital Sensors Digital Input menu label: Water Temp Alarm: AO7 - Water Temperature Testing Procedure: Put temperature switch into coolant or oil and heat fluid test- ing sensor. Normally opened when temperature rises above 107 − 113[°C] (225 − 235[°F ]) contact should close.

  • Page 160: Pmx High Pressure Switch

    Electronics and wiring 5.3 Digital Sensors PMX High Pressure Switch Specifications: Circuit unipolar State N.C. Opens at > 32barg (464psig) Recloses at < 27barg (392psig) Connections: Port-Pin by Wire J10 − 6th NE106 J8 − 13rd 73 Functions: Pressure Switch PMX trips when discharge side pressure rises over >...

  • Page 161: Po Oil Pressure Switch

    Electronics and wiring 5.3 Digital Sensors PO Oil Pressure Switch Specifications: Circuit unipolar State N.O. Opens at < −0.3 ± 0.1barg (4 ± 2psig) Connections: Port-Pin by Wire J10 − 11th NE1011 J8 − 9th Functions: Pressure Switch PO trips when engine oil pressure drop below −...

  • Page 162: Mp Unit Door Micro-Switch

    Electronics and wiring 5.3 Digital Sensors MP Unit Door Micro-switch Specifications: Circuit unipolar State N.C. Opens at Cover Door opening Connections: Port-Pin by Wire J10 − 8th NE108 J8 − 15th 61 Function: MP trips when unit door is opened and A08 Alarm stopping unit until door is closed.

  • Page 163: Electrical Protection Devices

    5.4 Electrical Protection Electronics and wiring Devices evaporator ice formation and air exchange between cold- room and hot environment. Digital Input menu label: Door Open Alarm: A09 - Door open 5.4 Electrical Protection Devices FMIS Circuit Breaker Specifications: Circuit 3 Phases from Electrical Main by L1, L2 e L3 wires Transformer by L4, L5 e L6 wires Voltage...

  • Page 164: Fgs Scroll Compressor Protection Thermostat

    5.4 Electrical Protection Electronics and wiring Devices FGS Scroll Compressor Protection Thermostat Specifications: Circuit unipolar from J9 − 7thpin by 33 wire FM1 pin by 68 wire Supply voltage 12V State N.C. Opens at 105°C (221°F ) Functions: FGS is a temperature switch that opens scroll compressor supply circuit, in case of its dis- charge temperature rises over maximum admitted.

  • Page 165: Temperature Probes

    Electronics and wiring 5.5 Temperature Probes 5.5 Temperature Probes Probe Testing Procedure All of these temperature probes are Resistance Thermometer, thus their electrical resistance [Ω] is dependent on temperature, it can be tested at 10kΩ at 25°C (77°F ). BA Cold Room Temperature Probe Functions: It is clamped on evaporator to measure evaporator inlet air, thus cold room temperature.

  • Page 166: Bh Engine Coolant Temperature Probe

    Electronics and wiring 5.5 Temperature Probes BH Engine Coolant Temperature Probe Functions: It is installed on water pump, it allow to check coolant temperature, and it is used to calculate engine pre- heating time and unit waiting time. Connection: J7 - BH SERV menu Displayed Temperature Label: Water Temp.

  • Page 167: Managed Devices

    Electronics and wiring 5.6 Managed Devices 5.6 Managed Devices Single-temperature unit Solenoid Valve Coils YK Starting Capacity Control Valve Coil Functions: Operate compressor capacity control during starting operations. Connections: Managed by Relay: KPR1 Port-Pin by Wire Protected by Fuse: FA11 PwrB - NE Digital Outputmenulabel: Specifications:...

  • Page 168: Multi-Temperature Unit Solenoid Valve Coils

    Electronics and wiring 5.6 Managed Devices Multi-temperature unit Solenoid Valve Coils YK Starting Capacity Control Valve Coil Functions: Operate defrost solenoid valve. Connections: Managed by Relay: KPR1 Port-Pin by Wire Protected by Fuse: FA11 PwrB - NE Specifications: Digital Output menu label: Supply voltage DC Pre-heating Power Absorption...

  • Page 169: Yf1 Evaporator 1 Cooling Valve Coil

    Electronics and wiring 5.6 Managed Devices YF1 Evaporator 1 Cooling Valve Coil Functions: Open evaporator liquid income line. Connections: Managed by Relay: KF1 Port-Pin by Wire J24 − 2nd Protected by Fuse: FA4 J24 − 7th NE257 Specifications: Digital Output menu label: Supply voltage DC Cooling Power Absorption...

  • Page 170: Yc2-3 Evaporator 2 Or 3 Heating Valve Coil

    Electronics and wiring 5.6 Managed Devices YC2-3 Evaporator 2 or 3 Heating Valve Coil Functions: Open evaporator liquid income line. Connections: Managed by Relay: KC2 by Port-Pin by Wire J 20 – 1st KC2-F4/B Protected by Fuse: F4/B pwrB - NE Specifications: Digital Output menu label: Supply voltage DC...

  • Page 171: M8, M9 E M10 Evaporator Fans

    Electronics and wiring 5.6 Managed Devices M8, M9 e M10 Evaporator Fans Managed by Relay: K8, K9 and K10 Ports: J13, J14, J15, J16, J17 and J18 Protected by Fuses: F8,F9,F10,F11,F12,F13 Digital Output label: Evaporator Fans 5.6.3.2.1 Flat Evp. Motorfans Specifications: Supply voltage DC Power Absorption...

  • Page 172: Fuel Start/Stop Valve

    Electronics and wiring 5.6 Managed Devices Fuel Start/Stop Valve Specifications: Supply voltage DC Power Absorption Flow Rate 2 l/min (33GPH) Operating Temp. Range: −40 to 80 [°C] (−40 to 180[°F ]) Connections: Managed by Relay: KFP Port-Pin by Wire J 20 – 1st J12 −...

  • Page 173: Hi Acoustic Alarm

    Electronics and wiring 5.7 Power Supplies HI Acoustic Alarm Functions: Buzzer inform about unit starts and alarm with an acoustic signal. Specifications: Connections: Voltage 12V DC Port-Pin by Wire Absorption 0.02A J09 − 2nd Tone Fast Pulse (3Hz ± 20%) J19 −...

  • Page 174: Rectifier

    Electronics and wiring 5.7 Power Supplies Rectifier Function: Rectifier converts alternating current(AC), which periodically reverses direction, into direct current(DC) Battery Specifications: Tension 12V Electrical Charge: 100Ah Function: Power Cab Command and starting system when unit is turned off. Alarm: A15 - Low battery KSF Phase Sequencer Relay Function: Power Cab Command and starting system when unit is turned off.

  • Page 175: K1-2 Contactors

    Electronics and wiring 5.7 Power Supplies K1-2 Contactors Specifications: Contacts: 3 N.O. and 1 N.C. Up to 690V AC and 220V DC. Control Voltage: 24 − 250V 50/60Hz or 12 − 250V DC. Functions: These relays are connected to scroll compressor with different phase sequences and KSF relay choose which one is proper one to activate.

  • Page 176: Running Logic

    Electronics and wiring 5.8 Running logic 5.8 Running logic This chapter is to expose unit logic into each different operative phase according relative parameters. Road Mode This section is to describe road mode operation logics, which for un0o range are always involving diesel engine. Starting Sequence un0°...

  • Page 177: Automatic Cooling Mode Operation Sequence

    Electronics and wiring 5.8 Running logic Automatic Cooling Mode Operation Sequence When running in Automatic Mode, unit stops operations every time cold-room reaches SP set-point temperature, waiting that difference between TA actual and SP set-point temperatures exceeds dF differential to restart with required operations. ON Signal.
  • Page 179 Section 6 Alarms & Troubleshooting...
  • Page 180 Contents of section     Alarms & Troubleshooting ....................................171     Standard Alarms ......................................171   A01 - Room sensor ....................................171   A03 - Evaporator temperature probe failure ..........................171   A04 - Low Pressure Switch ................................... 172  ...

  • Page 182: Alarms & Troubleshooting

    Alarms & Troubleshooting 6.1 Standard Alarms 6 Alarms & Troubleshooting 6.1 Standard Alarms A01 - Room sensor A03 - Evaporator temperature probe failure...

  • Page 183: A04 - Low Pressure Switch

    Alarms & Troubleshooting 6.1 Standard Alarms A04 - Low Pressure Switch...

  • Page 184: A07 - Water Temperature

    Alarms & Troubleshooting 6.1 Standard Alarms A07 - Water Temperature A08 - Door Microswitch...

  • Page 185: A10 - Oil Pressure

    Alarms & Troubleshooting 6.1 Standard Alarms A10 - Oil Pressure...

  • Page 186: A11 - High Pressure

    Alarms & Troubleshooting 6.1 Standard Alarms A11 - High Pressure...

  • Page 187: A14 - Net Compressor High Temperature

    Alarms & Troubleshooting 6.1 Standard Alarms A14 - Net compressor high temperature A15 - Low Battery...

  • Page 188: A16 - Engine Failure

    Alarms & Troubleshooting 6.1 Standard Alarms A16 - Engine Failure...

  • Page 189: A17 - Alternator Failure

    Alarms & Troubleshooting 6.1 Standard Alarms A17 - Alternator Failure...

  • Page 190: A18 - Water Sensor Error

    Alarms & Troubleshooting 6.1 Standard Alarms A18 – Water sensor error...

  • Page 191: Inactive Alarms

    Alarms & Troubleshooting 6.2 Inactive Alarms 6.2 Inactive Alarms These following alarms should not usually occur, because they depends from sensors which are not standardly equipped in this unit range. Inactive alarm guidelines consists in checking alarm related sensor presence and alarm disabling by unit parameters. A02 - External temperature probe failure A05 –...

  • Page 192: A09 - Door Open

    Alarms & Troubleshooting 6.2 Inactive Alarms A09 - Door open This alarm may be active if a cold room door micro switch has been equipped and its parameters are enabled. Essentially A09 alarm stops units while cold room door is opened.

  • Page 193: Troubleshooting

    Alarms & Troubleshooting 6.3 Troubleshooting 6.3 Troubleshooting Condenser fan is not running...

  • Page 194: Evaporator Fan Is Not Running

    Alarms & Troubleshooting 6.3 Troubleshooting Evaporator fan is not running F20 Fuse blows often...

  • Page 195: Unit Does Not Start After Blackout

    Alarms & Troubleshooting 6.3 Troubleshooting Unit does not start after blackout...

  • Page 196: Unit Not Performing

    Alarms & Troubleshooting 6.3 Troubleshooting Unit not performing...
  • Page 199 Annex 1 Parameters...
  • Page 200 Contents of section     Annex 1 ............................................191     Parameters - Single temperature version ............................191   Regulation Parameters Table ................................191   Defrost Parameter Table ..................................191   Alarm Parameter Table ..................................192   Starting Parameter....................................192  ...

  • Page 202: Annex 1

    7.1 Parameters - Single Annex 1 temperature version 7 Annex 1 7.1 Parameters - Single temperature version Regulation Parameters Table Label Description Value °C °F 1st Diesel intervention Differential 1st Stand-by intervention Differential °C °F 2nd Engine speed Differential °C °F Lower temperature set-point limit °C...

  • Page 203: Alarm Parameter Table

    7.1 Parameters - Single Annex 1 temperature version Alarm Parameter Table Value - according s/n end letter Label Description High temperature alarm °C °F Low temperature alarm °C °F Temperature alarm hysteresis °C °F Oil Pressure Alarm exclusion at starting Delay after water temperature alarm reset Delay after door microswitch alarm reset Starting alarm presence time...

  • Page 204: Sensors Configuration Parameter Table

    7.1 Parameters - Single Annex 1 temperature version Sensors Configuration Parameter Table Label Description Value Environmental probe presence Evaporator air delivery probe presence Cold room probe calibration °C °F Measure unit selection °C °F Digital Input Management Table Another column, present in cab command menu, indicates actual sensor state (ON/OFF) read by CPU board. Label (Sensor) Logic Abilitation...

  • Page 205: Parameters - Multi Temperature Version

    7.2 Parameters – Multi Annex 1 Temperature Version 7.2 Parameters – Multi Temperature Version Regulation Parameters Table Label Description Value 1st Diesel intervention Differential °C °F 1st Stand-by intervention Differential °C °F Engine speed Differential °C °F Lower temperature set-point limit °C °F Higher temperature set-point limit...

  • Page 206: Alarm Parameter Table

    7.2 Parameters – Multi Annex 1 Temperature Version Alarm Parameter Table Value - according s/n end letter Label Description High temperature alarm °C °F Low temperature alarm °C °F Temperature alarm hysteresis °C °F Oil Pressure Alarm exclusion at starting Delay after water temperature alarm reset Delay after door microswitch alarm reset Starting alarm presence time...

  • Page 207: Sensors Configuration Parameter Table

    7.2 Parameters – Multi Annex 1 Temperature Version Sensors Configuration Parameter Table Label Description Value Environmental probe presence Evaporator air delivery probe presence Cold room probe calibration °C °F Measure unit selection °C °F Digital Input Management Table Another column, present in cab command menu, indicates actual sensor state (ON/OFF) read by CPU board. Label (Sensor) Logic Abilitation...
  • Page 211 VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. SOL. AVVIAM. COMP. COMP. STARTING SOL. CANDELETTE GLOW PLUGS SOLEN.SBRIN. DEF. SOLENOID SOLEN.ACCEL. HIGH SPEED S. POMPA NAFTA FUEL PUMP 1210...
  • Page 213 1210 RELE' VENTILATORI FANS RELAY RELE' VENTILATORI FANS RELAY RELE' MOT. AVVIAMENTO STARTING RELAY RELE' PRERISCALDO CRANKCASE HETAING RELAY RELE' POMPA NAFTA DIESEL FUEL PUMP RELAY MORSETTO + TERMINAL + ECCITAZIONE ALTERNATORE ALTERNATOR EXCITING MORSETTO - TERMINAL -...
  • Page 215 11,5V 400-230V 11,5V 400-230V 11,5V 400-230V 1012 2-14 tttttttttt tttttttttt 2-13 2-11 MOTORINO D'AVVIAMENTO STARTING MOTOR HCO119...
  • Page 217 2-12 ON/OFF 2-11 TERMOST. ACQUA WATER THERM. Motore yammar RETE SUPPLY POLMONE 2-11 AIR SWITCH 1010 2-13 PRES. MIN. LOW PRES. SWITCH Motore yammar 1011 P.OLIO 2-13 OIL PRES. SWITCH 2-13 TERMICO 2-11 THERMAL SWITCH 2-12 CLIXON 2-14 2-15 MICRO 2-12 DOOR SWITCH PRES.
  • Page 221 4-12 1-14 1-15 1-11 1-10 1-10 VENT. EVAP. FAN EVAP. 1-13 VENT. EVAP. 4-10 FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. SOL. PARTENZA COMP. COMP. STARTING SOL. (OPTIONAL) 1-14 CANDELETTE GLOW PLUGS SOLEN.SBRIN.
  • Page 223 2-10 1210 2-11 3-11 2-13 RELE' VENTILATORI FANS RELAY RELE' VENTILATORI 2-12 FANS RELAY tttttt RELE' MOT. AVVIAMENTO 2-15 STARTING RELAY RELE' PRERISCALDO 2-13 CRANKCASE HETAING RELAY RELE' POMPA NAFTA 2-14 DIESEL FUEL PUMP RELAY MORSETTO + TERMINAL + ECCITAZIONE ALTERNATORE 1-15 ALTERNATOR EXCITING MORSETTO -...
  • Page 227 4-12 1-14 1-15 1-11 1-10 1-10 VENT. EVAP. FAN EVAP. 1-13 VENT. EVAP. 4-10 FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. SOL. PARTENZA COMP. COMP. STARTING SOL. (OPTIONAL) 1-14 CANDELETTE GLOW PLUGS SOLEN.SBRIN.
  • Page 229 2-10 1210 2-11 3-11 RELE' VENTILATORI 2-13 FANS RELAY RELE' VENTILATORI 2-12 FANS RELAY tttttt RELE' MOT. AVVIAMENTO 2-15 STARTING RELAY RELE' PRERISCALDO 2-13 CRANKCASE HETAING RELAY 2-14 RELE' POMPA NAFTA DIESEL FUEL PUMP RELAY MORSETTO + TERMINAL + ECCITAZIONE ALTERNATORE 1-15 ALTERNATOR EXCITING MORSETTO -...
  • Page 233 4-12 VENT. EVAP. FAN EVAP. VENT. EVAP. 4-10 FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. VENT. EVAP. FAN EVAP. SOL. AVVIAM. COMP. COMP. STARTING SOL. CANDELETTE GLOW PLUGS SOLEN.SBRIN. DEF. SOLENOID SOLEN.ACCEL. HIGH SPEED S. POMPA NAFTA FUEL PUMP 1210...
  • Page 235 2-10 1210 2-11 3-11 RELE' VENTILATORI 2-13 FANS RELAY RELE' VENTILATORI 2-12 FANS RELAY tttttt RELE' MOT. AVVIAMENTO 2-15 STARTING RELAY RELE' PRERISCALDO 2-13 CRANKCASE HETAING RELAY RELE' POMPA NAFTA 2-14 DIESEL FUEL PUMP RELAY MORSETTO + TERMINAL + ECCITAZIONE ALTERNATORE ALTERNATOR EXCITING MORSETTO - TERMINAL -...
  • Page 237 2-11 MOTORINO D'AVVIAMENTO STARTING MOTOR HCO119...
  • Page 239 2-12 ON/OFF TERMOST. ACQUA WATER THERM. 2-11 Motore yammar NE 104 LIVELLO LIQUIDO VASO DI ESPANS. LIQUID LEVEL FOR RESERVE TANK POLMONE 2-11 AIR SWITCH 1010 2-13 PRES. MIN. LOW PRES. SWITCH 1011 P.OLIO 2-13 OIL PRES. SWITCH 2-13 Motore yammar 2-14 2-12 CLIXON...
  • Page 243 MOTORINO D'AVVIAMENTO STARTING MOTOR HCO119...
  • Page 245 ON/OFF TERMOST. ACQUA WATER THERM. Motore yammar RETE SUPPLY POLMONE AIR SWITCH 1010 PRES. MIN. LOW PRES. SWITCH 1011 P.OLIO OIL PRES. SWITCH Motore yammar CLIXON MICRO DOOR SWITCH PRES. MASSIMA HIGH PRES. SWITCH SONDA AMBIENTE ROOM SENSOR SONDA ACQUA WATER SENSOR CONTAGIRI 2 SONDA EVAP.
  • Page 248 Zanotti USA CORP. 1810 Underwood Blvd. Delran, NJ 08075, USA Tel. 856-393-7230 t-gostynski@zanotti.com www.zanotti.com/usa...

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