Zanotti un0 060 Instruction manual
0MAN295A-USA
May 9
th
, 2017
Zanotti
USA CORP.
1810 Underwood Blvd. Delran, NJ 08075, USA Tel. 856-393-7230
t-gostynski@zanotti.com - www.zanotti.com/usa
0MAN295-USA
WORKSHOPMANUAL
un0◦
UN0 Workshop Manual
Print Order Code# 0MAN295A-USA
Release Dates andRevisions
4/1/2018 Released – USA version released for printing
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1 - Table of Contents
1General information................................................................................................................................................................................................... 9
1.1Preface ................................................................................................................................................................................................................. 9
1.2Units generals.................................................................................................................................................................................................. 10
Unit configurations...................................................................................................................................................................................10
Unit identification..................................................................................................................................................................................... 10
Serial number .............................................................................................................................................................................................11
Unit model................................................................................................................................................................................................... 11
1.3Safety precautions .........................................................................................................................................................................................12
General notices..........................................................................................................................................................................................12
PPE Personal Protective Equipment (in accordance with 89/686/EEC)........................................................................12
Symbols Key .....................................................................................................................................................................................13
General Practices....................................................................................................................................................................................... 13
Specific practices....................................................................................................................................................................................... 14
Working at height........................................................................................................................................................................... 14
Welding Procedures ......................................................................................................................................................................14
Engine and Compressor............................................................................................................................................................... 14
Refrigerant Oil..................................................................................................................................................................................14
Refrigerant ........................................................................................................................................................................................15
Low voltage and electrical battery ...........................................................................................................................................15
Electrical main..................................................................................................................................................................................15
1.4Service tools..................................................................................................................................................................................................... 15
Generic tools............................................................................................................................................................................................... 15
Refrigeration tools ....................................................................................................................................................................................16
Brazing tools ...............................................................................................................................................................................................16
Engine service tools .................................................................................................................................................................................17
Electric tools................................................................................................................................................................................................ 17
1.5Inspections .......................................................................................................................................................................................................18
Pre-loading Inspection............................................................................................................................................................................18
Post-Loading Inspection.........................................................................................................................................................................18
Enroute Inspection ...................................................................................................................................................................................18
2 - Table of Contents
2Description of the unit............................................................................................................................................................................................23
2.1Condensing unit .............................................................................................................................................................................................23
Nose mount ................................................................................................................................................................................................23
Right side and electric box access ............................................................................................................................................23
Driver-Left Side Access .................................................................................................................................................................24
Top door Access..............................................................................................................................................................................25
Bottom cover access......................................................................................................................................................................25
Under Mount ..............................................................................................................................................................................................26
Refrigeration side access.............................................................................................................................................................. 27
Engine side........................................................................................................................................................................................27
Front Door and Electrical Box Access.......................................................................................................................................28
2.2Evaporating section.......................................................................................................................................................................................30
Metal Cubic Monoblock..........................................................................................................................................................................30
Bottom and Side Windows.......................................................................................................................................................... 30
Front Air Delivery Windows ........................................................................................................................................................30
Removed drain pan access..........................................................................................................................................................31
Plastic Flat Split..........................................................................................................................................................................................32
Evaporator Back .............................................................................................................................................................................. 32
Removed Drain Pan Access.........................................................................................................................................................32
3 - Table of Contents
3Cooling Circuit ...........................................................................................................................................................................................................39
3.1Cooling Diagrams........................................................................................................................................................................................... 39
Monoblock ..................................................................................................................................................................................................39
Split................................................................................................................................................................................................................ 39
3.2Operations........................................................................................................................................................................................................40
Pump Down Stop......................................................................................................................................................................................40
Recover Refrigerant..................................................................................................................................................................................42
Vacuum Operation ...................................................................................................................................................................................42
Refrigerant Charge ...................................................................................................................................................................................43
Refrigerant leaks........................................................................................................................................................................................ 44
Leakage Test.....................................................................................................................................................................................44
Leak Search Procedure .................................................................................................................................................................45
Basic steps in brazing...............................................................................................................................................................................46
3.3Valves .................................................................................................................................................................................................................47
Shut-off Valves ...........................................................................................................................................................................................47
Opening Valve .................................................................................................................................................................................47
Opening Service Port (pos. 2)..................................................................................................................................................... 47
Valve and Gasket Replacement .................................................................................................................................................48
Service ports ...............................................................................................................................................................................................48
Valve Test ..........................................................................................................................................................................................50
Valve Replacement ........................................................................................................................................................................50
SAE Pressure Switch Replacement ...........................................................................................................................................51
Solenoid Valves.......................................................................................................................................................................................... 51
Solenoid Coil and Valve Tests..................................................................................................................................................... 51
Valve Disassemble.......................................................................................................................................................................... 52
YS 3-Way Replacement................................................................................................................................................................. 52
YK Capacity Control Valve Replacement ................................................................................................................................53
Non return Check Valves ........................................................................................................................................................................54
Check Valve Test .............................................................................................................................................................................54
Check Valve Replacement ...........................................................................................................................................................55
3.4Filter Drier and Sight Glass.......................................................................................................................................................................... 55
Filter Drier Replacement......................................................................................................................................................................... 56
3.5Orifice and Expansion Valve .......................................................................................................................................................................57
Expansion Valve Regulation.................................................................................................................................................................. 57
Orifice Replacement................................................................................................................................................................................. 58
Expansion Valve Replacement .............................................................................................................................................................60
3.6CPR Crankcase Pressure Regulation Valve.............................................................................................................................................62
CPR Regulating Procedure..................................................................................................................................................................... 62
CPR Valve Replacement.......................................................................................................................................................................... 63
3.7KVC Hot Gas Bypass Capacity Regulator................................................................................................................................................ 66
KVC Hot Gas Bypass Regulating Procedure ..................................................................................................................................... 66
KVC Valve Replacement.......................................................................................................................................................................... 67
3.8Oil Separator.................................................................................................................................................................................................... 69
Oil separator replacement..................................................................................................................................................................... 69
3.9Scroll Stand-by Compressor....................................................................................................................................................................... 72
Specifications............................................................................................................................................................................................. 72
Injection valve replacement ................................................................................................................................................................. 72
Stand-by Compressor Replacement .................................................................................................................................................. 74
3.10Alternative Road Compressor.................................................................................................................................................................... 76
Shaft Seal Replacement..................................................................................................................................................................... 76
Capacity Regulation Valve Replacement..................................................................................................................................... 77
Valve Plate Replacement .................................................................................................................................................................. 78
Road Compressor Replacement..................................................................................................................................................... 79
4 - Table of Contents
4Diesel Engine.............................................................................................................................................................................................................. 87
4.1Belts..................................................................................................................................................................................................................... 87
Tightening Information .......................................................................................................................................................................... 88
Service Belts Replacement..................................................................................................................................................................... 89
4.2Lubrication System........................................................................................................................................................................................ 92
Oil change.................................................................................................................................................................................................... 92
Trochoid Pump Inspection Procedure............................................................................................................................................... 94
PO Oil Pressure Switch Replacement ................................................................................................................................................. 96
4.3Cooling System ............................................................................................................................................................................................... 96
Water Pump ................................................................................................................................................................................................ 97
Replacement Procedure............................................................................................................................................................... 97
FTQ Temperature Switch Replacement.................................................................................................................................. 98
BH Temperature Sensor Replacement .................................................................................................................................... 99
Thermostatic Valve Replacement ...........................................................................................................................................100
Expansion Tank........................................................................................................................................................................................101
Replacement Procedure.............................................................................................................................................................101
Coolant Leaks Search.............................................................................................................................................................................102
4.4Propeller Supply System............................................................................................................................................................................102
Fuel Filter Replacement ........................................................................................................................................................................103
Fuel Pump..................................................................................................................................................................................................106
Replacement Procedure.............................................................................................................................................................106
Air Filter Cartridge Replacement .......................................................................................................................................................107
Speed Solenoid........................................................................................................................................................................................108
Engine RPM Regulation..............................................................................................................................................................108
Speed Solenoid Replacement ..................................................................................................................................................108
Start Stop Solenoid Valve.....................................................................................................................................................................109
4.5Electric System ..............................................................................................................................................................................................110
ALT Alternator..........................................................................................................................................................................................110
Voltage Regulator Replacement .............................................................................................................................................110
Replacement Procedure.............................................................................................................................................................111
E1 Glow Plugs...........................................................................................................................................................................................112
Current Absorption Test.............................................................................................................................................................112
Electrical Resistance Test............................................................................................................................................................113
Replacement Procedure.............................................................................................................................................................113
4.6Transmission ..................................................................................................................................................................................................114
Coupling Junction ..................................................................................................................................................................................115
Flexible Element Replacement...........................................................................................................................................................116
5 - Table of Contents
5Electronics and wiring...........................................................................................................................................................................................125
5.1Cab Command ..............................................................................................................................................................................................125
Display ........................................................................................................................................................................................................125
Symbols key....................................................................................................................................................................................126
Buttons .......................................................................................................................................................................................................126
Driver Mode Menu..................................................................................................................................................................................127
SET Temperature Set-point Menu.....................................................................................................................................................128
Single temperature ......................................................................................................................................................................128
Multi temperature ........................................................................................................................................................................128
Alarm Log Menu......................................................................................................................................................................................129
SERV Service Menu .................................................................................................................................................................................129
EVP Evaporators Management Menu ..............................................................................................................................................130
Scheduled Maintenance Menu ..........................................................................................................................................................131
PROG Programming Menu ..................................................................................................................................................................132
Parameters Modification............................................................................................................................................................133
Input/Output Management......................................................................................................................................................133
- Clock Configuration ..................................................................................................................................................................134
- Configuration ..............................................................................................................................................................................134
5.2Electronic Boards..........................................................................................................................................................................................135
CPU board..................................................................................................................................................................................................135
J1 & J2 Cab Command ports.....................................................................................................................................................136
J6 Power Supply port ..................................................................................................................................................................136
J7 Temperature Probes port .....................................................................................................................................................137
J8 CPU board Input port.............................................................................................................................................................137
J9 CPU board Output port.........................................................................................................................................................138
Relay Board................................................................................................................................................................................................139
J10 Pwr Board Ground Port.......................................................................................................................................................140
J12 Pwr Board Port.......................................................................................................................................................................140
J19 Pwr Board Input Port ...........................................................................................................................................................141
Multi-Temperature Expansion Boards .............................................................................................................................................142
Expansion Relay Board................................................................................................................................................................142
J24 Port ............................................................................................................................................................................................142
J25 Port ............................................................................................................................................................................................142
2ndand 3rdEvaporator Boards ...............................................................................................................................................143
J20 Port ............................................................................................................................................................................................143
J21 Port ............................................................................................................................................................................................143
J22 Port............................................................................................................................................................................................143
J23 Port............................................................................................................................................................................................143
Low Voltage Wirings..............................................................................................................................................................................144
High Voltage Wirings.............................................................................................................................................................................145
Wiring diagram symbol-key................................................................................................................................................................146
5.3Digital Sensors ..............................................................................................................................................................................................147
SA Differential Air Switch .....................................................................................................................................................................147
FTQ Water Temperature Switch.........................................................................................................................................................147
SAE Pressure Switches ..........................................................................................................................................................................148
PMI Low Pressure Switch Specifications:..............................................................................................................................148
PMX High Pressure Switch ........................................................................................................................................................149
P1MX Condenser Fan Switch ...................................................................................................................................................149
PO Oil Pressure Switch..........................................................................................................................................................................150
FTS1-2 Defrost End Temperature Switches ...................................................................................................................................150
MP Unit Door Micro-switch .................................................................................................................................................................151
ON/OFF Button........................................................................................................................................................................................151
MPC Cold-Room Door Micro-switch (optional)............................................................................................................................151
5.4Electrical Protection Devices.................................................................................................................................................................... 152
FMIS Circuit Breaker...............................................................................................................................................................................152
FM1 Thermal Overload relay...............................................................................................................................................................152
FGS Scroll Compressor Protection Thermostat ............................................................................................................................153
Fuses ...........................................................................................................................................................................................................153
KB Battery Relay ......................................................................................................................................................................................153
5.5Temperature Probes ...................................................................................................................................................................................154
Probe Testing Procedure......................................................................................................................................................................154
BA Cold Room Temperature Probe........................................................................................................................................154
BL Ev. Air Delivery Probe (Single-temp unit only) .............................................................................................................154
BH Engine Coolant Temperature Probe ...............................................................................................................................155
BA2-3 2
nd
or 3
rd
Cold RoomProbe (Multi-temp unit only).............................................................................................155
BE External Temperature Probe optional.............................................................................................................................155
5.6Managed Devices.........................................................................................................................................................................................156
Single-temperature unit Solenoid Valve Coils..............................................................................................................................156
YK Starting Capacity Control Valve Coil................................................................................................................................156
YS 3-Way Defrost Valve Coil......................................................................................................................................................156
Multi-temperature unit Solenoid Valve Coils................................................................................................................................ 157
YK Starting Capacity Control Valve Coil................................................................................................................................157
YP Capacity Control Valve Coil ................................................................................................................................................157
Y3V 3-Way Defrost Valve Coil................................................................................................................................................... 157
YF1 Evaporator 1 Cooling Valve Coil .....................................................................................................................................158
YC1 Evaporator 1 Heating Valve Coil..................................................................................................................................... 158
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
5.6.3.2.1FlatEvp.Motorfans.....................................................................................................................................160
5.6.3.2.2CubicEvp.FanMotorSpecifications:..........................................................................................................160
Engine Devices.........................................................................................................................................................................................160
PN Fuel Pump ................................................................................................................................................................................160
Fuel Start/Stop Valve...................................................................................................................................................................161
YAV Speed Solenoid ....................................................................................................................................................................161
HI Acoustic Alarm....................................................................................................................................................................................162
Managing Relays .....................................................................................................................................................................................162
5.7Power Supplies..............................................................................................................................................................................................162
TAL Transformer......................................................................................................................................................................................162
Rectifier.......................................................................................................................................................................................................163
Battery.........................................................................................................................................................................................................163
KSF Phase Sequencer Relay.................................................................................................................................................................163
K1-2 Contactors .......................................................................................................................................................................................164
ALT Alternator..........................................................................................................................................................................................164
5.8Running logic.................................................................................................................................................................................................165
Road Mode ................................................................................................................................................................................................165
Starting Sequence........................................................................................................................................................................165
Automatic Cooling Mode Operation Sequence.................................................................................................................166
Continuous Cooling Mode Operation Sequence ..............................................................................................................166
6 - Table of Contents
6Alarms & Troubleshooting...................................................................................................................................................................................171
6.1Standard Alarms ...........................................................................................................................................................................................171
A01 - Room sensor..................................................................................................................................................................................171
A03 - Evaporator temperature probe failure.................................................................................................................................171
A04 - Low Pressure Switch...................................................................................................................................................................172
A07 - Water Temperature.....................................................................................................................................................................173
A08 - Door Microswitch ........................................................................................................................................................................173
A10 - Oil Pressure ....................................................................................................................................................................................174
A11 - High Pressure ................................................................................................................................................................................175
A14 - Net compressor high temperature........................................................................................................................................176
A15 - Low Battery....................................................................................................................................................................................176
A16 - Engine Failure ..........................................................................................................................................................................177
A17 - Alternator Failure....................................................................................................................................................................178
A18 – Water sensor error.................................................................................................................................................................179
6.2Inactive Alarms..............................................................................................................................................................................................180
A02 - External temperature probe failure.......................................................................................................................................180
A05 – Oil level...........................................................................................................................................................................................180
A06 - Air Filter...........................................................................................................................................................................................180
A09 - Door open ......................................................................................................................................................................................181
6.3Troubleshooting...........................................................................................................................................................................................182
Condenser fan is not running .............................................................................................................................................................182
Evaporator fan is not running.............................................................................................................................................................183
F20 Fuse blows often.............................................................................................................................................................................183
Unit does not start after blackout......................................................................................................................................................184
Unit not performing...............................................................................................................................................................................185
7 - Table of Contents
7Annex 1 ......................................................................................................................................................................................................................191
7.1Parameters - Single temperature version ............................................................................................................................................191
Regulation Parameters Table..............................................................................................................................................................191
Defrost Parameter Table.......................................................................................................................................................................191
Alarm Parameter Table..........................................................................................................................................................................192
Starting Parameter..................................................................................................................................................................................192
Sensors Configuration Parameter Table .........................................................................................................................................193
Digital Input Management Table.......................................................................................................................................................193
Digital Output Management Table...................................................................................................................................................193
7.2Parameters – Multi Temperature Version ............................................................................................................................................194
Regulation Parameters Table..............................................................................................................................................................194
Defrost Parameter Table.......................................................................................................................................................................194
Alarm Parameter Table..........................................................................................................................................................................195
Starting Parameter..................................................................................................................................................................................195
Sensors Configuration Parameter Table .........................................................................................................................................196
Digital Input Management Table.......................................................................................................................................................196
Digital Output Management Table...................................................................................................................................................196
Section 1
General information
Contents of section
1General information................................................................................................................................................................................................... 9
1.1Preface ................................................................................................................................................................................................................. 9
1.2Units generals.................................................................................................................................................................................................. 10
Unit configurations...................................................................................................................................................................................10
Unit identification..................................................................................................................................................................................... 10
Serial number .............................................................................................................................................................................................11
Unit model................................................................................................................................................................................................... 11
1.3Safety precautions .........................................................................................................................................................................................12
General notices.......................................................................................................................................................................................... 12
PPE Personal Protective Equipment (in accordance with 89/686/EEC)........................................................................12
Symbols Key .....................................................................................................................................................................................13
General Practices....................................................................................................................................................................................... 13
Specific practices....................................................................................................................................................................................... 14
Working at height........................................................................................................................................................................... 14
Welding Procedures ......................................................................................................................................................................14
Engine and Compressor............................................................................................................................................................... 14
Refrigerant Oil..................................................................................................................................................................................14
Refrigerant ........................................................................................................................................................................................15
Low voltage and electrical battery ...........................................................................................................................................15
Electrical main..................................................................................................................................................................................15
1.4Service tools..................................................................................................................................................................................................... 15
Generic tools............................................................................................................................................................................................... 15
Refrigeration tools ....................................................................................................................................................................................16
Brazing tools ...............................................................................................................................................................................................16
Engine service tools .................................................................................................................................................................................17
Electric tools................................................................................................................................................................................................ 17
1.5Inspections ....................................................................................................................................................................................................... 18
Pre-loading Inspection............................................................................................................................................................................18
Post-Loading Inspection.........................................................................................................................................................................18
Enroute Inspection ...................................................................................................................................................................................18
9
1.1 Preface General information
1 General information
1.1 Preface
This Workshop manual provides details and service procedure for un0◦range from 2012. Amendments and additional
sections will be issued by Zanotti engineers keeping this manual upgraded, covering latest models.
This manual is exclusive property of Zanotti SPA, neither partial nor total publications or reprints are therefore permitted
without express authorization of the company.
Zanotti technical department produces this manual to assist skilled technicians in maintenance and efficient repairing of un0◦
units.
Cooling system and diesel engine can contain hazardous substances, such as oils, ozone depleting substances (ODS) and
fluorinated gases (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.
This manual suits for next models
3
Table of contents
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