Zanotti Zero Series Installation Manual Download

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INSTALLATION MANUAL

Refrigeration unit

Series Zero Direct-Drive

Z200 | Z250 | Z350 | Z380

Z380 Multi

rev.01

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

Support

Fitting

Metal clamps

NOTE

The silencing kit can be installed in both directions.

Summary of Contents for Zero Series

Page 1: ...Refrigeration excellence since 1962 REFRIGERATION UNIT Series Zero Direct Drive INSTALLATION MANUAL TRANSLATION OF THE ORIGINAL INSTRUCTIONS...

Page 2: ...ribed in this manual In case of doubt or difficulty in understanding or interpreting the manual the original official version indicated as ORIGINAL INSTRUCTIONS on the cover must be considered as the...

Page 3: ...ed materials 8 1 7 Refrigeration unit identification 9 1 8 Plant components 10 1 9 Installation Mode 11 2 TECHNICAL DATA 12 2 1 Dimensions and mounting measurements 12 2 1 1 Z200 12 2 1 1 1 Nose insta...

Page 4: ...43 3 6 Condenser unit installation 45 3 6 1 Nose installation 45 3 6 2 Roof installation 46 3 7 Evaporator installation 47 3 8 Piping connection 48 3 8 1 Connection diagram single temperature version...

Page 5: ...optional 67 3 18 1 Operating logic 67 3 18 2 Components 67 3 18 3 Installation 67 3 18 4 Injection thermostat 68 3 18 5 Cooling diagram with liquid injection valve kit installed 69 3 18 6 Wiring diagr...

Page 6: ...INSTALLATION MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 6 rev 01...

Page 7: ...for correct installation and maintenance of the unit 1 2 Symbols The manual uses some symbols which are used to draw the reader s attention and highlight some particularly important aspects SYMBOL MEA...

Page 8: ...a series of behaviours and obligations to be observed while performing the various installation activities envisaged on the unit This is to ensure personnel equipment and the environment remain safe...

Page 9: ...it Figure 1 and to the electrical panel Figure 2 Figure 1 Metal plate Figure 2 Plate on the electrical panel 1 Model identification 9 Code of wiring diagrams 2 Serial number 10 Low LP pressure bar 3 N...

Page 10: ...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 H...

Page 11: ...ANUAL rev 01 11 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...

Page 12: ...Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 12 rev 01 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 cond...

Page 13: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 13 Figure 8 Side view of the condenser unit evaporator...

Page 14: ...NSTALLATION MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 14 rev 01 Figure 9 Upper view of the condenser unit evaporator Evaporator fastening screws TE M8x120 Q ty...

Page 15: ...es Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 15 2 1 1 2 Roof installation Dimensions in mm in Figure 10 Front view of the condenser unit Figure 11 Side view of the co...

Page 16: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 16 rev 01 Figure 12 View from the top of the condenser unit Figure 13 Top View from the evaporator Evaporator fastening scre...

Page 17: ...es Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 17 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 vie...

Page 18: ...INSTALLATION MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 18 rev 01 Figure 16 Side view of the condenser unit evaporator...

Page 19: ...frigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 19 Figure 17 Upper view of the condenser unit evaporator Evaporator fastening screws TE M8x120 Q ty...

Page 20: ...rigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 20 rev 01 2 1 2 2 Roof installation Dimensions in mm in Figure 18 Front view of the condenser unit Figure 19 Side view of the co...

Page 21: ...Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 21 Figure 20 View from the top of the condenser unit Figure 21 Top View from the evaporator Evaporator fastening scre...

Page 22: ...rigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 22 rev 01 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 vie...

Page 23: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 23 Figure 24 Side view of the condenser unit evaporator...

Page 24: ...STALLATION MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 24 rev 01 Figure 25 Upper view of the condenser unit evaporator Evaporator fastening screws TE M8x120 Q ty...

Page 25: ...es Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 25 2 1 3 2 Roof installation Dimensions in mm in Figure 26 Front view of the condenser unit Figure 27 Side view of the co...

Page 26: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 26 rev 01 Figure 28 View from the top of the condenser unit Figure 29 Top View from the evaporator Evaporator fastening scre...

Page 27: ...es Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 27 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 vie...

Page 28: ...INSTALLATION MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 28 rev 01 Figure 32 Side view of the condenser unit evaporator...

Page 29: ...frigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 29 Figure 33 Upper view of the condenser unit evaporator Evaporator fastening screws TE M8x120 Q ty...

Page 30: ...rigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 30 rev 01 2 1 4 2 Roof installation Dimensions in mm in Figure 34 Front view of the condenser unit Figure 35 Side view of the co...

Page 31: ...Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 31 Figure 36 View from the top of the condenser unit Figure 37 Top View from the evaporator Evaporator fastening scre...

Page 32: ...es Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 32 rev 01 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 F...

Page 33: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 33 Figure 39 Top View Standard evaporators Evaporator fastening screws TE M8x120 Q ty 4...

Page 34: ...unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 34 rev 01 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...

Page 35: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 35 Figure 41 Top View Standard evaporators Evaporator fastening screws TE M8x120 Q ty 4...

Page 36: ...evaporator s Refrigerant Model Condenser unit Road mode only Condenser unit Road mode External power supply mode Evaporator Kg lb Kg lb Kg lb R452A Z200 30 66 14 56 123 46 10 2 22 49 Z250 36 79 37 72...

Page 37: ...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 Drill Drill bits Tape Metro Mechanical...

Page 38: ...lti 38 rev 01 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 compress...

Page 39: ...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 Remove the coa...

Page 40: ...0 Z350 Z380 Z380 Multi 40 rev 01 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 The unit is ready to be attache...

Page 41: ...shown in Figure 45 to avoid damaging the unit Follow the procedure below to remove the flap Figure 45 Wrong removal of the side frame 3 4 1 Removal To remove the side frames of the condenser unit pro...

Page 42: ...lti 42 rev 01 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 s...

Page 43: ...i INSTALLATION MANUAL rev 01 43 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 Remove the lid seal...

Page 44: ...Z350 Z380 Z380 Multi 44 rev 01 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 howeve...

Page 45: ...tallation To install the condenser unit proceed as follows Prepare the installation and passage holes for the pipes and electrical cables following the model of the refrigeration unit and the installa...

Page 46: ...lation and passage holes for the pipes and electrical cables following the model of the refrigeration unit and the installation mode see 2 1 NOTE It is possible to pass the pipes and electricity cable...

Page 47: ...evaporator proceed as follows Allow the nitrogen to slowly escape from the suction liquid and defrosting lines by loosening the caps Remove the evaporator panel to access the fastening holes Prepare...

Page 48: ...s as indicated in the connection diagrams Figure 56 and Figure 57 CAUTION Avoid twisting or damaging the pipe when inserting the fitting NOTE Lubricate the hydraulic fittings with plenty of refrigeran...

Page 49: ...ection diagram single temperature versions Figure 56 Connection diagram single temperature 1 Defrosting line 10 mm 0 39 in S Road compressor suction line 16 mm 0 63 in 2 Suction line 16 mm 0 63 in 4 C...

Page 50: ...am Standard multi temperature versions Figure 57 Connection diagram Multi temperature 1 Defrosting line 10 mm 0 39 in 4 Condenser unit 2 Suction line 16 mm 0 63 in 5 Evaporator 1 3 Liquid line 8 mm 0...

Page 51: ...ion line junction S 2 Supply line junction D S Road compressor suction line 16 mm 0 63 in D Road compressor supply line 10 mm 0 39 in Install the connections 1 Figure 58 and 2 respectively on the suct...

Page 52: ...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...

Page 53: ...ching 500 microns keep the suction for about an hour Close the vacuum pump valve switch off the pump checking that the gauge reading for the vacuum pump does not exceed 2000 microns in the following t...

Page 54: ...the evaporators depending on the version Connect the BA cold room probe 9 Connect the defrosting valve YS 6 if supplied Connect the defrost termination thermostat FTS 8 if supplied Connect the injecti...

Page 55: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 55 Figure 62 Electrical connections...

Page 56: ...Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 56 rev 01 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...

Page 57: ...nt the formation of ice inside the condensate drain hoses it is possible to install a defrost resistance if supplied The drain resistance ES 6 Figure 62 must be installed in parallel to the defrosting...

Page 58: ...ain hose must slope down from the remote evaporators to the wall drains with no kinks or droop To install the drain hoses proceed as follows Connect the drain hoses to the discharge outputs 1 Figure 6...

Page 59: ...igeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 59 3 12In cab controller installation Figure 66 Installation of the support Figure 67 Connector connec...

Page 60: ...ceed as follows Using the screws provided fix the socket 3 Figure 68 to the external wall of the cold room Position the connecting cable 2 between the socket 3 and the condenser unit 1 and fix it usin...

Page 61: ...il Level i e the quantity of oil already present in the road compressor Example Refrigerant charge 1 5 Kg 1 500 cc approximately COL 150 cc SOQ 1 500 x 15 225 cc Oil to be added SOQ COL 225 150 75 cc...

Page 62: ...pproximately 1000 rpm and turn the unit on Open the lower side valve of the gauge manifold and the collant bottle valve and add refrigerant slowly until no bubbles can be seen through the liquid level...

Page 63: ...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...

Page 64: ...t heat or defrost mode Run compressor at High Speed Remove protective lid 1 unscrewing it by hand Remove the inner locking nut with an 8mm Allen key Regulate maximum suction pressure to 2 2 barg 31 9p...

Page 65: ...erate as follows Connect a pressure gauge to the evaporator output line Operate the unit in cold mode Measure the temperature near the valve probe Figure 71 Pressure and temperature measurement Turn c...

Page 66: ...Z200 Z250 Z350 Z380 Z380 Multi 66 rev 01 The standard overheating values are as follows These values may vary depending on the application and model of the unit Cold room temperature Overheating 0 C 3...

Page 67: ...suction line As soon as the compressor discharge temperature reaches 100 C 230 F the thermostat installed on the compressor discharge line opens the injection valve to lower the exhaust temperature an...

Page 68: ...s Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 68 rev 01 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 approp...

Page 69: ...unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 69 3 18 5 Cooling diagram with liquid injection valve kit installed Figure 75 Cooling diagram with liquid inject...

Page 70: ...MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 70 rev 01 3 18 6 Wiring diagram with liquid injection valve kit installed Figure 76 Wiring diagram with liquid injecti...

Page 71: ...mpressor exhaust gas b Heating mode it pushes most refrigerant from the condenser and the liquid receiver to the evaporator This establishes a higher pressure and temperature during heating mode incre...

Page 72: ...INSTALLATION MANUAL Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi 72 rev 01 3 19 4 Wiring diagram with the heating kit installed Figure 78 Wiring diagram with heating kit...

Page 73: ...Refrigeration unit Series Zero Direct Drive Z200 Z250 Z350 Z380 Z380 Multi INSTALLATION MANUAL rev 01 73 3 19 5 Cooling diagram with installed heating kit Figure 79 Cooling diagram with heating kit...

Page 74: ...ional 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 Si...

Page 75: ...om the driver s position Hoses should not be taut they should be able to absorb vibrations and be shortened in case of leaks Hoses should not be allowed to rub against moving parts sharp parts or part...

Page 76: ...ooling diagram single temperature version 1 Liquid spyglass 9 Condenser 2 Pressure regulator valve 10 Liquid receiver 3 Oil separator 11 Dehydrating filter 4 Low pressure service socket 12 Low pressur...

Page 77: ...Dehydrating filter 2 Pressure regulator valve 12 Low pressure switch 3 Oil separator 13 Stand by Compressor 4 Low pressure service socket 14 Electric motor 5 Evaporator 1 expansion valve 15 High press...

Page 78: ...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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