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Summary of Contents for Zanotti Zero Z120b
- Page 1 Refrigeration excellence since 1962 REFRIGERATION UNIT Zero Z120b INSTALLATION MANUAL TRANSLATION OF THE ORIGINAL INSTRUCTIONS...
- Page 2 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.
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Page 3: Table Of Contents
Refrigeration unit INSTALLATION MANUAL Zero Z120b GENERAL INFORMATION ............... 6 Introduction ....................... 6 Symbols ......................6 Manufacturer’s contact details ................7 Safety standards ....................7 Manufacturer’s responsibility ................7 Disposal of used materials ................7 Refrigeration unit identification ................8 Plant components ..................... - Page 4 Refrigeration unit INSTALLATION MANUAL Zero Z120b Evaporator installation ..................29 Piping connection .................... 30 3.7.1 Connection diagram ................31 Check for system leaks and vacuum ............... 32 Electrical connections ..................34 3.9.1 Diagram of electrical connections ............34 3.9.2 Device connection ................35 3.9.3...
- Page 5 Refrigeration unit INSTALLATION MANUAL Zero Z120b Cooling diagram ....................51 Wiring diagram - Road mode/ External power supply mode version ....52 Wiring diagram - Road mode only version ............53 4.3.1 Key ....................... 54 rev.01...
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Page 6: General Information
Zero Z120b 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. -
Page 7: Manufacturer's Contact Details
Refrigeration unit INSTALLATION MANUAL Zero Z120b 1.3 Manufacturer’s contact details For any type of information or clarification regarding use, etc., the Manufacturer’s Technical Office is always at the disposal of the Customer’s requests. The latter should ask questions in clear terms, with references to this manual, always indicating the data on the identification plate of the refrigeration unit in question. -
Page 8: Refrigeration Unit Identification
Refrigeration unit INSTALLATION MANUAL Zero Z120b 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). -
Page 9: Plant Components
Refrigeration unit INSTALLATION MANUAL Zero Z120b 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. Electronic control and command power unit (HMI) , located inside the vehicle cab (in-cab controller). -
Page 10: Installation Mode
Zero Z120b 1.9 Installation Mode The condenser unit of the Zero Z120b series refrigeration unit can be installed "nose-mounted" (Figure 4), i.e. on the front wall of the refrigerator cold room, or "roof-mounted" (Figure 5), i.e. on the upper wall of the cold room or vehicle. -
Page 11: Technical Data
Refrigeration unit INSTALLATION MANUAL Zero Z120b 2 TECHNICAL DATA 2.1 Dimensions and mounting measurements 2.1.1 Nose installation Dimensions in mm [in]. Figure 6 - Front view of the condenser unit Figure 7 - Rear view of the condenser unit rev.01... - Page 12 Refrigeration unit INSTALLATION MANUAL Zero Z120b Figure 8 - Side view of the condenser unit + evaporator rev.01...
- Page 13 Refrigeration unit INSTALLATION MANUAL Zero Z120b Figure 9 - Upper view of the condenser unit + evaporator Evaporator fastening screws: TE M8x120 (Q.ty 4). rev.01...
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Page 14: Roof Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 2.1.2 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... - Page 15 Refrigeration unit INSTALLATION MANUAL Zero Z120b 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...
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Page 16: Weights
Refrigeration unit INSTALLATION MANUAL Zero Z120b 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). Coolant Model Condenser unit Condenser unit Evaporator... -
Page 17: Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 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 • •... -
Page 18: Unpacking The Unit
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.2 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 • and the installation kit components supplied with the unit. - Page 19 Refrigeration unit INSTALLATION MANUAL Zero Z120b Remove the dividing box (3, Figure 15). • Figure 15 - Unpacking the condenser unit. Remove the screws that fix the unit (4) to the packaging crate. • The unit is ready to be attached to a lifting device.
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Page 20: Removal And Mounting Of The Flaps Of The Condenser Unit
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.3 Removal and mounting of the flaps of the condenser unit CAUTION DO NOT remove the side frame from the front, as shown in Figure 16, to avoid damaging the unit. Follow the procedure below to remove the flap. -
Page 21: Assembly
Refrigeration unit INSTALLATION MANUAL Zero Z120b Remove the side frame. • Figure 19 - Removing the side frame 3.3.2 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 20). -
Page 22: Lifting The Condenser Unit
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.4 Lifting the condenser unit To lift the condenser unit proceed as follows: Remove both side frames, as indicated in paragraph 3.3.1. • Remove the lid. • Remove the lid seal (1,Figure 21) and (2). - Page 23 Refrigeration unit INSTALLATION MANUAL Zero Z120b Attach a suitable lifting device to the four holes (3, Figure 22) of the frame and lift the unit. • Figure 22 - Lifting points CAUTION At the end of the installation, and however before remounting the unit lid, reposition the gaskets (1,Figure 21) and (2).
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Page 24: Condenser Unit Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.5 Condenser unit installation NOTE The right side of the condenser unit is equipped with a removable door (1, Figure 23) for the passage of cables and pipes. Figure 23 - Right side door of condenser unit 3.5.1 Nose installation... - Page 25 Refrigeration unit INSTALLATION MANUAL Zero Z120b Prepare an external channel (3, Figure 25) for passage of the Road compressor pipes. • Figure 25 - External channel rev.01...
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Page 26: Roof Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.5.2 Roof installation To install the condenser unit proceed as follows: Drill the roof using the template (1, Figure 26) supplied. • Figure 26 - Roof drilling template Prepare the installation and passage holes for the pipes and electrical cables, following the model •... - Page 27 Refrigeration unit INSTALLATION MANUAL Zero Z120b Pass the pipes and the electrical connection cables to the evaporator through the hole on the • roof. • Fix the unit with the components indicated in Figure 28. Figure 28 - Roof mount kit...
- Page 28 Refrigeration unit INSTALLATION MANUAL Zero Z120b The unit is installed • Figure 30 - Condenser unit installed rev.01...
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Page 29: Evaporator Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.6 Evaporator installation DANGER The evaporator contains nitrogen under pressure. Before installation, release the nitrogen as described in this paragraph. To install the evaporator proceed as follows: Allow the nitrogen to slowly escape from the suction, liquid, and defrosting lines by loosening the •... -
Page 30: Piping Connection
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.7 Piping connection The condenser unit and the evaporators both have adhesives at the connection points of the lines that bear the same letters and numbers as those shown in the connection diagrams (Figure 31). -
Page 31: Connection Diagram
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.7.1 Connection diagram NOTE The following diagram is one of the possible versions of the refrigerator group and is intended to illustrate only the connections between pipes. The cooling diagram may therefore differ from the supplied version, and the links apply to all versions. -
Page 32: Check For System Leaks And Vacuum
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.8 Check for system leaks and vacuum Connect the vacuum pump manifolds to the low pressure service socket (1, Figure 32) and to the • high pressure outlet (2, Figure 33) on the liquid receiver shut off valve. - Page 33 Refrigeration unit INSTALLATION MANUAL Zero Z120b The vacuum is created by closing the shut-off valves of the unit and connecting the pressure gauge • manifold to the copper lines. • Start the vacuum pump and maintain suction until it reaches 500 microns.
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Page 34: Electrical Connections
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.9 Electrical connections 3.9.1 Diagram of electrical connections NOTE The Figure 34 shows an example of an wiring diagram in one of the possible configurations. Please refer to the specific wiring diagram of the version you are installing before proceeding with the connections. -
Page 35: Device Connection
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.9.2 Device connection NOTE The wires are marked with an identification number which is also shown on the wiring diagram. Connect the M5 and M8 fans (3, Figure 34) of the evaporators, depending on the version. -
Page 36: Battery Connection
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.9.3 Battery connection Connect the positive pole of the vehicle battery to the terminal (2, Figure 35) of the KMC main • relay (1). Connect the negative pole of the vehicle battery to the connection pin (3). -
Page 37: Sub-Key Fuse Installation Kit
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.9.4 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 • • Connector Figure 36 - Sub-key fuse kit... -
Page 38: Discharge Heater Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.9.5 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. The drain resistance ES (Figure 34) must be installed in parallel to the defrosting valve YS using •... -
Page 39: Condenser Drain Hoses Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.10 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. -
Page 40: In-Cab Controller Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.11 In-cab controller installation Figure 39 - Installation of the support Figure 40– Connector connection rev.01... -
Page 41: External Power Supply Mode Connection Socket Installation
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.12 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 41) to the external wall of the cold room •... -
Page 42: Loading The System
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.13 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. • Keep the low-pressure side valve of the gauge manifold closed. Open the high-pressure side •... -
Page 43: Suction Pressure Regulator Valve (Cpr)
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.14 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. -
Page 44: Adjusting The Cpr Valve
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.14.1 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. • •... -
Page 45: Expansion Valve
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.15 Expansion valve The thermostatic expansion valve regulates the injection of coolant into the evaporators. 3.15.1 Expansion valve adjustment. To regulate the expansion valve, operate as follows: • Connect a pressure gauge to the evaporator output line Operate the unit in cold mode •... - Page 46 Refrigeration unit INSTALLATION MANUAL Zero Z120b 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) 4K (7°F) Figure 45 - expansion valve adjustment rev.01...
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Page 47: Heating Kit (Optional)
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.16 Heating kit (optional) 3.16.1 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. -
Page 48: Cooling Diagram With Installed Heating Kit
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.16.4 Cooling diagram with installed heating kit Figure 47 - Cooling diagram with heating kit rev.01... -
Page 49: Wiring Diagram With The Heating Kit Installed
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.16.5 Wiring diagram with the heating kit installed Figure 48 - Wiring diagram version Road mode/External power supply mode with heating kit rev.01... -
Page 50: Final Checks
Refrigeration unit INSTALLATION MANUAL Zero Z120b 3.17 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. -
Page 51: Appendix
Refrigeration unit INSTALLATION MANUAL Zero Z120b 4 APPENDIX 4.1 Cooling diagram Figure 49 - Cooling diagram Liquid spyglass Condenser Pressure regulator valve Liquid receiver Low pressure service socket Dehydrating filter Liquid injection valve AC current motor Expansion valve Stand-by compressor... -
Page 52: Wiring Diagram - Road Mode/ External Power Supply Mode Version
Refrigeration unit INSTALLATION MANUAL Zero Z120b 4.2 Wiring diagram - Road mode/ External power supply mode version rev.01... -
Page 53: Wiring Diagram - Road Mode Only Version
Refrigeration unit INSTALLATION MANUAL Zero Z120b 4.3 Wiring diagram - Road mode only version rev.01... -
Page 54: Key
Refrigeration unit INSTALLATION MANUAL Zero Z120b 4.3.1 Key Cold room temperature probe Straightening condenser Run condenser Start capacitor Discharge heater Heater Condensate drain heater Motor fuse M1 Electronic control unit Overload relay F1TR Thermistor F6-F6/1 Condenser fan fuse F8-F9-F10-F11 Evaporator fan fuse... - Page 55 Refrigeration unit INSTALLATION MANUAL Zero Z120b Transformer Thermo switch Main connector YCA-YCB Solenoid valve heating cycle YFA-YFB Solenoid valve cooling cycle Road mode clutch Solenoid valve reversal cycle Stand-by clutch Condenser solenoid valve Injection solenoid valve Defrost solenoid valve rev.01...
- Page 56 Zanotti S.p.A. M. L. King, 30 46020 Pegognaga (MN) Italy Tax Code/VAT No. 0185670203 T. +39 0376 5551 F. +39 0376 536554 info@zanotti.com www.zanotti.com...
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