It is forbidden to distribute and/or duplicate, in any form, this manual, even partially, without the written authorisation of ZANOTTI S.p.A. ZANOTTI S.p.A. reserves the right to change, without prior notice, the characteristics of the product described in this manual.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi GENERAL INFORMATION ............... 7 Introduction ....................... 7 Symbols ......................7 Manufacturer’s contact details ................8 Safety standards ....................8 Manufacturer’s responsibility ................8 Disposal of used materials ................8 Refrigeration unit identification ................
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.5.1 Standard Evaporators ................. 32 2.1.5.2 Narrow Evaporators ................34 Weights ......................36 INSTALLATION ..................37 Tools required ....................37 Road compressor installation ................38 Unpacking the unit ...................
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.13 External power supply mode connection socket installation ......60 3.14 Loading oil for putting the refrigerator circuit into service ........ 61 3.15 Loading the system ..................62 3.16 Suction pressure regulator valve (CPR) ............
Z380 Multi 1 GENERAL INFORMATION 1.1 Introduction NOTE ZANOTTI S.p.A., the manufacturer of this refrigeration unit in question is referred to in the manual as Manufacturer. NOTE The company that purchased the refrigeration unit is referred to in the manual as Customer.
Any request for intervention, from the Customer's service department, or for clarification regarding the technical aspects of this document, must be addressed to: Zanotti S.p.A. Via M. L. King, 30 46020 Pegognaga (MN) Italy Phone +39 0376 5551 E-mail: info@zanotti.com...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 1.7 Refrigeration unit identification the model and serial number (or registration number) are shown on the metal plate attached to the side of the unit (Figure 1) and to the electrical panel (Figure 2). Figure 1 - Metal plate Figure 2 - Plate on the electrical panel Model identification...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 1.8 Plant components The refrigeration unit consists of the following parts (Figure 3): 1. Condenser unit, installed outside the isothermic crate. 2. Evaporative unit installed inside the isothermic crate. 3.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 1.9 Installation Mode The Zero Direct-Drive refrigeration unit condenser unit can be installed "nose-mounted" (Figure 4), i.e. on the front wall of the cold room, or "roof-mounted" (Figure 5), i.e. on the upper wall of the cold room Figure 4- Nose installation Figure 5 - Roof installation rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2 TECHNICAL DATA 2.1 Dimensions and mounting measurements 2.1.1 Z200 2.1.1.1 Nose installation Dimensions in mm [in]. Figure 6 - Front view of the condenser unit Figure 7 - Rear view of the condenser unit rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 8 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 9 - Upper view of the condenser unit + evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.1.2 Roof installation Dimensions in mm [in]. Figure 10 - Front view of the condenser unit Figure 11 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 12 - View from the top of the condenser unit Figure 13 - Top View from the evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.2 Z250 2.1.2.1 Nose installation Dimensions in mm [in]. Figure 14 - Front view of the condenser unit Figure 15 - Rear view of the condenser unit rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 16 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 17 - Upper view of the condenser unit + evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.2.2 Roof installation Dimensions in mm [in]. Figure 18 - Front view of the condenser unit Figure 19 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 20 - View from the top of the condenser unit Figure 21 - Top View from the evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.3 Z350 2.1.3.1 Nose installation Dimensions in mm [in]. Figure 22 - Front view of the condenser unit Figure 23 - Rear view of the condenser unit rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 24 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 25 - Upper view of the condenser unit + evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.3.2 Roof installation Dimensions in mm [in]. Figure 26 - Front view of the condenser unit Figure 27 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 28 - View from the top of the condenser unit Figure 29 - Top View from the evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.4 Z380 2.1.4.1 Nose installation Dimensions in mm [in]. Figure 30 - Front view of the condenser unit Figure 31 - Rear view of the condenser unit rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 32 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 33 - Upper view of the condenser unit + evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.4.2 Roof installation Dimensions in mm [in]. Figure 34 - Front view of the condenser unit Figure 35 - Side view of the condenser unit + evaporator rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 36 - View from the top of the condenser unit Figure 37 - Top View from the evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.5 Z380 Multi 2.1.5.1 Standard Evaporators NOTE For the dimensions of the condenser unit, refer to paragraph 2.1.4. Dimensions in mm [in]. Figure 38 - Side view of Standard evaporators rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 39 - Top View Standard evaporators Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.1.5.2 Narrow Evaporators NOTE For the dimensions of the condenser unit, refer to paragraph 2.1.4. Dimensions in mm [in]. Figure 40 - Side view of Standard evaporators rev.01...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 41 - Top View Standard evaporators Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 2.2 Weights NOTE Depending on the configuration, the total weight of an installation corresponds to the sum of the weights of the condenser unit and the evaporator(s). Refrigerant Model Condenser unit...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3 INSTALLATION 3.1 Tools required Before proceeding with the installation of the unit on the truck, it is necessary to check that you have the following tools available: Protective goggles and PPE •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.2 Road compressor installation NOTE The compressor, bracket and fixing kit are not supplied with the unit. NOTE Fill the compressor with oil before installation. Install the road compressor mounting kit as indicated in the supplier manual.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.3 Unpacking the unit To unpack the unit proceed as follows: Carefully remove the upper and side structures of the packaging crate, then remove the front panel •...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Remove the dividing box (3, Figure 44). • Figure 44 - Unpacking the condenser unit. Remove the screws that fix the unit (4) to the packaging crate. •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.4 Removal and mounting of the flaps of the condenser unit CAUTION DO NOT remove the side frame from the front, as shown in Figure 45, to avoid damaging the unit.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Remove the side frame. • Figure 48 - Removing the side frame 3.4.2 Assembly Following the removal procedure in reverse order, reassemble the side frame, making sure that the lower part of the side frame is correctly inserted in its guide (B, Figure 49).
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.5 Lifting the condenser unit To lift the condenser unit proceed as follows: Remove both side frames, as indicated in paragraph 3.4.1. • Remove the lid. •...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Attach a suitable lifting device to the four holes (3, Figure 51) of the frame and lift the unit. • Figure 51 - Lifting points CAUTION At the end of the installation, and however before remounting the unit lid, reposition the gaskets (1,Figure 50) and (2).
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.6 Condenser unit installation NOTE The right side of the condenser unit is equipped with a removable door (1, Figure 52) for the passage of cables and pipes. Figure 52 - Right side door of condenser unit 3.6.1 Nose installation To install the condenser unit proceed as follows:...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Prepare an external channel (3, Figure 54) for passage of the Road compressor pipes. • Figure 54 - External channel 3.6.2 Roof installation To install the condenser unit proceed as follows: Prepare the installation and passage holes for the pipes and electrical cables, following the model •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Pass the pipes and the electrical connection cables to the evaporator through the hole on the • roof. • Fix the unit with the screws provided. 3.7 Evaporator installation DANGER The evaporator contains nitrogen under pressure.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.8 Piping connection On the condenser unit and on the evaporators, in correspondence with the fittings of the lines, there are adhesives that bear the same letters and numbers as indicated in the connection diagrams (Figure 56 and Figure 57).
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.8.1 Connection diagram - single temperature versions Figure 56 - Connection diagram - single temperature Road compressor suction line Defrosting line Ø 10 mm [0.39 in] Ø...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.8.2 Connection diagram - Standard multi temperature versions Figure 57 - Connection diagram - Multi temperature Defrosting line Ø 10 mm [0.39 in] Condenser unit Suction line Ø...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.8.3 Installation of charge junction/gauge connection of road compressor Figure 58 - road compressor installation Suction line junction (S) Supply line junction (D) Road compressor suction line...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.8.4 Vacuum pump connection The manifolds of the vacuum pump can be connected to the fittings installed on the suction sockets (1, Figure 58) and exhaust (2) of the vehicle compressor or, alternatively, to the low pressure outlet (1, Figure 59) of the service and the high pressure outlet (2, Figure 60) on the liquid receiver shut off valve.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.9 Check for system leaks and vacuum The vacuum is created by closing the shut-off valves of the unit and connecting the pressure gauge •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.10 Electrical connections NOTE The Figure 62 shows an example of a standard wiring diagram. Please refer to the specific wiring diagram of the version you are installing before proceeding with the connections.
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi Figure 62 - Electrical connections rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.10.1 Sub-key fuse installation kit The sub-key fuse installation kit is supplied separately and consists of the following components: Fuse base • Blade fuse, 5A •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.10.2 Discharge heater installation In order to prevent the formation of ice inside the condensate drain hoses, it is possible to install a defrost resistance, if supplied.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.11 Condenser drain hoses installation CAUTION Connect the drain hoses only by means of "T" or "Y" junctions. NOTE For proper drainage, the drain hose must slope down from the remote evaporators to the wall drains with no kinks or droop.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.12 In-cab controller installation Figure 66 - Installation of the support Figure 67– Connector connection rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.13 External power supply mode connection socket installation DANGER Do not connect the cable to the power supply during installation. To install the External power supply plug, proceed as follows: Using the screws provided, fix the socket (3, Figure 68) to the external wall of the cold room •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.14 Loading oil for putting the refrigerator circuit into service Adding oil to the system according to the instructions below will result in the SOQ (System Oil Quantity), which is the correct amount of oil in the system.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.15 Loading the system Connect the refrigerant bottle to the gauge manifold and place it on a scale. • Connect the refrigerant bottle valve and drain the pressure gauge fitting line. •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.16 Suction pressure regulator valve (CPR) The Suction pressure regulator valve (CPR) 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 at start with equilibrated circuit (e.g.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.16.1 Adjusting the CPR valve To regulate the CPR valve, operate as follows: Turn on the unit in road mode. • Connect low pressure gauge to suction line by LP service port. •...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.17 Expansion valve The thermostatic expansion valve regulates the injection of refrigerant into the evaporators. 3.17.1 Expansion valve adjustment. To regulate the expansion valve, operate as follows: Connect a pressure gauge to the evaporator output line •...
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Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi The standard overheating values are as follows: These values may vary depending on the application and model of the unit. Cold room Overheating temperature 0°C (32°F) 8K (14°F) - 20°C (- 4°F)
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.18 Liquid injection valve kit (optional) 3.18.1 Operating logic In order to reduce the exhaust temperature of the Road compressor, the liquid injection valve injects liquid into the suction line.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.18.4 Injection thermostat Install the FTI injection thermostat (3, Figure 74) on the compressed air supply line (2) and fix it with the appropriate clamp (1). Figure 74 - Injection thermostat rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.19 Single temperature heating kit (optional) 3.19.1 Operating logic This option allows the unit to have two functions: a) Cooling mode: inject liquid into the suction line to reduce the temperature of the compressor exhaust gas.
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.19.4 Wiring diagram with the heating kit installed Figure 78 - Wiring diagram with heating kit rev.01...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.20 Silencer kit (optional) For insulated vehicles, if excessive noise and abnormal vibrations are generated by pulsations in the road compressor supply pipe, a silencer is required on the compressor supply line. Figure 80 - Silencer kit Silencer Gasket...
Refrigeration unit Series Zero Direct-Drive INSTALLATION MANUAL Z200 | Z250 | Z350 | Z380 Z380 Multi 3.21 Final checks All mounting holes and access holes should be sealed with silicone or foam. Check with a sheet of paper that the fans blow in the right direction. The drain hoses should be slanted on all evaporators.