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Zanotti Zer0 120 User Manual

Zanotti Zer0 120
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Zer0° 120
#0WSMZ120
Workshop Manual
#0WSMZ120
Once upon a time there was a Kingdom, where freshness was guaranteed,
and where values were maintained, in the best possible way,
with respect for all the inhabitants of the planet.
Once upon a time,
there was a Kingdom,
where service and loyalty to customers reigned.
Once upon a time,
there was a Kingdom...
and it’s still here.
King of Cold
®
W W W. Z ANOT TI.COM/USA
®

Table of Contents

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Zanotti Zer0 120 Specifications

General IconGeneral
BrandZanotti
ModelZer0 120
CategoryRefrigerator
LanguageEnglish

Summary

General Safety Notices

Refrigerant Oil Precautions

Details on handling refrigeration oil and avoiding eye contact.

Electrical Hazard Precautions

Safety measures for working with high voltage circuits on the unit.

Specific Warning and Caution Statements

Identifies hazards and levels of awareness for unit operation and maintenance.

Specifications

Compressor Data

Technical specifications for the unit's compressor.

Defrost Data

Information on defrost type and initiation settings.

Pressure Switch Data

Normal, open, and closed pressures for HP switches.

Refrigerant Charge

Approximate refrigerant charge values for R134a and R404a.

Condenser Fan Motor Specifications

Voltage, airflow, and current for condenser fan motors.

Evaporator Fan Motor Specifications

Voltage, airflow, and current for evaporator fan motors.

Solenoid Coil Specifications

Voltage, ohms, and current for solenoid coils.

Capacitors Specifications

Voltage and capacitance values for start and run capacitors.

Fuses and Motor Data

Lists fuse types, descriptions, and motor voltage/amperage ratings.

Z120 Maintenance Schedule

Maintenance A Tasks

Tasks for Maintenance A, including coil cleaning and oil checks.

Maintenance B Tasks

Tasks for Maintenance B, like replacing brushes and checking fans.

Maintenance E Tasks

Tasks for Maintenance E, such as checking connections and replacing filter driers.

SECTION 1 – Unit Description

1.1 Condensing Section

Details the condenser unit's design and components like the coil and filter drier.

1.1.1 Condenser Coil

Describes the condenser coil's function as a heat exchanger.

1.1.2 Filter Drier

Explains the filter drier's role in system cleanliness and moisture removal.

1.1.3 Compressor

Details the compressor type and its drive mechanism.

1.1.4 Receiver

Describes the receiver's function as a liquid reservoir.

1.1.5 High-Pressure Switch

Explains the high-pressure cut-out switch function.

1.1.6 CPR Valve

Describes the compressor pressure regulation valve's function.

1.1.7 Electric Standby Operation

How the unit operates during electric standby mode.

1.1.8 DC Motor

Explains the DC motor's role in road mode operation.

1.1.9 AC Motor

Explains the AC motor's role in standby mode operation.

1.2 Evaporator Section

Describes the evaporator assembly, including coil, fans, and expansion valve.

1.2.1 Thermostatic Expansion Valve

Details the TXV's role in regulating refrigerant flow.

1.2.2 Evaporator Coil

Describes the evaporator coil and its heat absorption process.

1.2.3 Defrost Coil

Explains the function of the defrost coil under the evaporator pan.

1.2.4 Evaporator Drain Tube Heaters

Describes heaters preventing drain tube blockage by ice.

1.2.4 Hot Gas Solenoid Valve

Explains the hot gas solenoid valve's function in heat/defrost modes.

1.3 Microprocessor and Control Box

Explains the control system, microprocessor board, and relays.

1.3.1 Microprocessor Board

Details the microprocessor board and its relays.

1.3.2 Control Box

Describes the components within the control box.

SECTION 2 – Unit Identification

2.1 Deciphering the Model Code

Explains how to interpret the ten-digit model code for unit details.

2.2 Deciphering the Serial Number

Details the structure of the 8-character serial number and its components.

SECTION 3 - Operation

3.1 Safety Devices

Lists safety components and devices that protect the unit from damage.

3.2 Refrigeration Circuit

Explains the operation modes: Cool, Null, Defrost, and Heat.

3.2.1 Cooling Mode

Details the vapor compression cycle during cooling operations.

3.2.2 Null Mode

Describes the unit's state when the setpoint is reached and no operation occurs.

3.2.3 Defrost and Heat

Explains the process of heating or defrosting using compressed gas.

3.2.4 Refrigeration Symbol Table

Provides definitions for symbols used in refrigeration diagrams.

3.2.5 Defrost System

Outlines how a defrost cycle is initiated and operates.

3.2.6 Manual Defrost

Procedure for initiating a defrost cycle via the in-cab control box.

3.2.7 Defrost Relay

Function of the defrost relay in controlling the defrost cycle.

3.2.8 Defrost Solenoid Valve

Explains the electrical valve controlling hot gas flow to the evaporator.

3.2.9 Condenser Inlet Valve

Describes the normally open valve that directs refrigerant flow.

3.3 Control System

Overview of the microprocessor and in-cab controller.

3.3.1 Control System Description

Explains the interaction between the microprocessor and in-cab controller.

3.3.2 Microprocessor Module (CPU Board)

Details the functions controlled by the microprocessor.

3.3.3 In-Cab Controller

Describes the controller's role in user operations and interface.

3.4 Start Up

Procedures for starting the unit in different modes.

3.4.1 Starting Procedures

Steps for starting in road and standby modes.

3.4.3 Weekly Pre-trip Inspection

Essential checks before vehicle loading to prevent issues.

3.4.4 After Start Inspection

Checks to perform after the unit has started.

3.4.5 Loading Procedure

Steps for loading product to minimize frost and heat gain.

3.4.6 Post Load Procedure

Actions to take after loading product into the compartment.

3.4.7 Weekly Post Trip Checks

Routine inspections after the unit has completed a trip.

3.5 Alarm Management

How the unit handles and displays malfunctions.

3.5.1 Accessing Alarm Messages

Method to view recorded alarm codes and messages.

3.5.2 Reset Alarms

Procedure to clear active and archived alarm messages.

3.5.3 Alarms List

Comprehensive list of alarms, their causes, and remedies.

SECTION 4-System Maintenance

4.1 General Categories

Overview of regular servicing requirements for unit reliability.

4.1.1 Electrical Maintenance

Checks for defrost initiation, thermostat, shutdown circuits, and wiring.

4.1.2 Refrigeration Maintenance

Procedures for checking refrigerant levels and replacing filter driers.

4.1.3 Structural Maintenance

Visual inspection of hoses, leaks, and overall unit integrity.

4.2 Installing the Manifold Gauge Set

Safety precautions for connecting gauge sets to the system.

4.2.1 Manifold Gauge Components

Lists and identifies the parts of a manifold gauge/hose set.

4.2.2 Preparing Manifold Gauges for use

Steps to ready the manifold gauges before connecting to the system.

4.2.3 Connecting Manifold Gauges

Procedure for connecting the gauge set to the system's access ports.

4.2.4 Removing the Manifold Gauge Set

Steps for safely disconnecting the gauge set after service.

4.3 Removing the Refrigerant Charge

Procedure for safely evacuating and dehydrating the system.

4.6 Charging the Refrigeration System

Method for adding refrigerant charge to the system.

4.4 Refrigerant Leak Checking

Steps to identify and repair leaks in the refrigeration system.

4.5 Evacuation and Dehydration

Process for removing moisture and contaminants from the system.

4.7 Low Side Pump Down

Procedure for isolating and lowering pressure on the low side.

4.8 Checking the Refrigerant Charge

Methods to inspect refrigerant levels using the sight glass.

4.9 Checking and Replacing Filter-Drier

How to check for obstructions and replace the filter drier.

4.10 Pressure Switches

Information on removing and testing pressure switches.

4.11 Compressor

Procedures for compressor removal, installation, and oil checks.

4.12 Hot Gas & Condenser Solenoid Valve & Coils

Diagnosis and replacement of solenoid coils and valves.

4.13 Brazing Procedures

Guidelines for safe and effective brazing techniques.

4.14 Thermostatic Expansion Valve

Information on the TXV and its function in the system.

4.14.1 Expansion Valve Superheat Check & Adjustment

Steps to check and adjust superheat for proper valve operation.

4.14.2 Diagnosing Expansion valves

Troubleshooting expansion valve issues like frosting or poor cooling.

4.14.3 Replacing expansion valve

Steps for replacing the expansion valve assembly.

4.15 Adjusting the CPR Valve

Steps to adjust the Compressor Pressure Regulation valve.

4.16 Testing Defrost System

Procedure to test the defrost system's functionality.

4.17 Structural Maintenance

Routine inspections for unit integrity and component condition.

4.18 Electrical Maintenance

Troubleshooting and maintenance for electrical components and circuits.

SECTION 5 - Diagnosis

5.1 Troubleshooting Topics

Common issues affecting desired box temperature and their potential causes.

5.2 Troubleshooting by Symptom

Table correlating symptoms with possible causes and remedies.

5.3 Troubleshooting by Alarm Code

Guide to diagnosing issues based on specific alarm codes and icons.

SECTION 6 – Temperature and Pressure

6.1 Vapor Temp/Pressure Relationship

Table showing pressure-temperature relationships for refrigerants.

6.2 Pressures at 100°F Ambient

Expected pressure readings at specific set points and ambient temperatures.

Section 7 – Parameter Values

7.1 Parameter Issues

Overview of common parameter issues and their impact on unit operation.

Common Parameter Issues

Details on tS, FuS, IS/SS, and HtP parameters.

SECTION 8 - Wiring diagrams

Wiring Diagram Key

Defines abbreviations used in the electrical wiring diagrams.

General Safety Notices for Wiring Diagrams

Safety precautions relevant to electrical maintenance and wiring.

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