Zanotti DFZ
Zanotti DFZ
Zanotti DFZ
Preliminary information 48
Important safety warnings 48
Warranty 50
How to order spare parts 51
Disposing of the packing 51
Disposing of the machine 51
1. Description of the machine 52
1.1 Available models 52
1.2 Main technical specifications 52
2. Rating plate 57
3. Description of the central control unit 58
3.1 Description of the display (keys) 58
4. Operation 59
4.1 Before operating the unit 59
4.2 Setting the unit at work 59
4.3 Setting the operating set point 60
4.4 Turning on the refrigeration unit 61
4.5 Defrost 62
4.6 Maintenance 62
4.7 Displaying the temperature chart 63
4.8 Time and display contrast programming 65
4.8.1 Continuous operation 66
4.8.2 Disabling Diesel operation 66
4.8.3 Keyboard block 67
4.8.4 Print or record data 68
4.9 Alarms 70 GB
5. Goods loading procedure 74
5.1 Storage and stacking 74
5.2 Mobile partitions 75
5.3 Tips on the temperatures of carried goods 75
5.4 Recommendations on how to best use 75
your refrigerator unit
47
Preliminary information
Thank you for choosing one of the models of DFZ ZANOTTI refrigeration units.
This manual is addressed to the operators of DFZ ZANOTTI refrigeration units.
Inside you will find the necessary information to use and service the products
correctly, safety tips, warranty terms as well as suggestions on the best way of
transporting your goods. If you follow such instructions, you will be able to mini-
mize the service operations required and to extend the life of your unit.
ZANOTTI reserves the right to change the above data without previous notice.
Below you will find some recommendations concerning your safety as well as
instructions to follow when installing and using your machine.
Installation
When installing the unit, take all the necessary precautions (for example, lad-
ders, safety belts, helmets and protection gloves). The unit is fitted in the corre-
sponding hole on the cold room; you just have to introduce the monoblock refrig-
eration unit into the existent hole and fix it by using the standard bolts and nuts
supplied with the product.
Battery
If the refrigeration unit is left idle for some time, we recommend turning off the
machine by pressing the ON/OFF button located on the electronic control unit
first and then button 1 (fig. 1).
In this way, the electronic control unit is completely de-energized, thus protecting
the battery. Disconnect all electric circuits and both batteries (vehicle and refrig-
eration unit) before attempting any welding operation.
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Safety Tips
By drilling the walls of the unit or the isothermal cold room, you could damage
the electric wires or the refrigeration piping. Should such action be strictly nec-
essary, great care should be taken to avoid any damage.
Touching turning fans and moving belts can cause irreparable damage or injury.
Be careful with the blades of the condenser and evaporator; their edges are very
sharp.
The refrigeration oil used is a synthetic, mineral-base oil; it can irritate the skin in
case of long contacts or if after coming into contact with oil, the affected areas
are not carefully washed.
GB
Refrigerant
Some special safety warnings need to be reminded concerning the refrigerant.
DO NOT HANDLE THE REFRIGERANT BEFORE READING THE NOTES
BELOW.
If heated, the refrigerant gives off a gas that irritates the respiratory system.
Never heat a closed refrigerating system.
Be careful when servicing the refrigeration circuit. On contact with the air, the
pressurized refrigerant evaporates and it immediately frostbites whatever is in
close contact with it. Should this gas come into contact with the body, below are
some first aid measures:
1. Cover the affected area.
2. Quickly heat the frostbitten area with lukewarm water. AVOID USING HOT
WATER.
3. If there is no water available, wrap up the affected area carefully with a clean
cloth.
4. If the gas comes into contact with the eyes, rinse them immediately with run-
ning water and call an ophthalmologist.
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Engine
The PERKINS engines fitted on all DFZ ZANOTTI refrigeration units are
designed to keep pollution caused by exhaust gas at a minimum level. However,
we strongly recommend to avoid starting the engine in a confined area, as the
exhaust gas is toxic. The symptoms caused by carbon monoxide produced by
fuel combustion are the following:
– dizziness
– strong headache
– sleepiness
– vomiting.
If you should experience these symptoms with the engine on, try to breath clean
air immediately.
Only by having the unit checked on a regular basis you will be able to avoid the
troubles associated with its malfunctioning.
Warranty
Keep your warranty certificate carefully; you will be required to show it whenev-
er your refrigeration unit needs servicing.
50
How to order spare parts
When ordering spare parts, always include the serial number shown on the
machine's rating plate.
Dispose of all wooden, plastic and polystyrene packing in compliance with the
laws in force in the Country where the equipment is used.
51
1. Description of the machine
The DFZ refrigeration units are made up of the following main components:
1. a condensing unit installed outside the isothermal box;
2. an evaporating unit installed inside the isothermal box;
3. an electronic central control unit located in the driver's cab of the vehicle.
All models are suitable to store products both at positive and negative tempera-
tures.
DFZ 425
P. on road P. rmains
52
DFZ 430
P. on road P. rmains
DFZ 435
P. on road P. rmains
53
DFZ 465
P. on road P. rmains
DFZ 495
P. on road P. rmains
54
DFZ 465U (Cubic Evaporator)
P. on road P. rmains
55
DFZ 465U (Flat Evaporator)
P. on road P. rmains
56
2. Rating plate
The DFZ ZANOTTI units are identified by plates located on the right side of the
condensing circuit. They contain all the information to be communicated to the
technicians in case of servicing, i.e.:
– model
– serial number
– voltage
– electrical input
– refrigerant
– weight of the unit
GB
11) Year of manufacture
12) ZANOTTI unit code
13) Serial number
14) Voltage: Road (V d.c.); Mains Supply (V/Ph/Hz)
15) Maximum Absorption (Road)
16) Mains Supply Absorption
17) Mains Supply Maximum Absorption
18) Refrigerating; Quantity
19) Weight of the unit
10) Wiring diagram number
Mese / Month
2000 1 2 3 4 5 6 7 8 9 10 11 12
Anno / Year
2001
2002
2003
57
3. Description of the central control unit
fig. 1
58
4. Operation
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4.2 Setting the unit at work
Press push-button 1 to turn on the driver's cabin control. The mask shown in
fig. 2 will appear after a few seconds.
This mask shows:
• TA1: Cold room temperature
• SP1: operating set point
• current date and time,
• type of diesel operation, either slow (LOW) or fast (HIGH).
fig. 2
CAUTION
Only use push-button 1 to turn off (or on) the electronic control unit if the refrig-
eration unit is not used. Always use the button only to turn the refrigerator on
and off (fig. 2).
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If two cold rooms are present, the mask will appear:
To program the set point of the second cold room SP2, proceed as follows:
- Press key : the cursor will start blinking under the present SP1 set point
value.
- Press the key until the value relating to SP2 is highlighted.
- Press the UP/DOWN key to change such value. GB
- Press key to store the defined value.
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WARNING
If the plug is connected before the diesel engine is stopped using the button
(fig. 2), the diesel engine will turn off and the electric motor will come on after
approximately 5 minutes.
Similarly, if power is interrupted during electric standby, automatic startup of the
diesel engine will take place after 5 minutes.
4.5 Defrost
Defrost is fully automatic. If needed, a defrost cycle can be forced by pressing
key .
During defrost, the icon appears in the main mask, on the top left area of the
display.
4.6 Maintenance
By pressing key on the main mask (fig. 1), you can access the mask below.
Then, by pressing key you will go to the maintenance mask shown below.
62
In this mask, you can see for how many hours the oil and oil filter have been
used, as well as the total working hours of the diesel engine and electric motor.
When the oil or oil filter have been used for over a limit number of hours, the sym-
bol will be displayed on the main mask; then, accessing the maintenance
mask the icons or will be displayed, to show that either the oil needs
changing or the oil filter element needs replacing.
To reset this warning signal, just press the key found by these icons for a few
seconds.
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USER'S HANDBOOK UPDATE
64
4.8 Time and display contrast programming
Starting from the main mask and pressing key first and then key , you will
access the mask below.
GB
By pressing key , you can access the mask where you can program the dis-
play's brightness and contrast:
CAUTION
If the driver's cabin control keys are not used for approximately 10 minutes, the
display will turn off. To
65
4.8.1 Continuous operation
This function allows the start/stop function of the Diesel motor to be
cut-out and kept in motion in a continuous way; to activate this function starting
from the main window press the key , the following window appears:
then press the key , instead of , will appear on the display indicating
activation of the continuous function.
now press and the cursor will begin to flash at NO, press the up key to enter
YES; lastly, confirm the value entered by pressing the key .
In this way the Diesel function is inhibited and in the event of power failure, the
main window will be as follows:
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4.8.3 Keyboard block
To prevent unwanted interventions the keyboard blocking function has been
introduced; activate it starting from the main window, press the key and
then the key , in this way the following window is accessed:
GB
where entering the password will automatically bring up the following window
which will be the only one that can be displayed and the on/off key will be the
only active key.
67
To unblock the keyboard press the MENU key and re-enter the password in the
following window
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Example:
From: 10/04/01
To: 12/04/01
Evp: 1
Res: 10 min
Sta: 12:00 (noon)
Sto. 14:00 (2 p.m.)
Prn: PRINTER
With the data thus entered press the key to print all the data from 10/04/01
to 12/04/01 recorded from 12 noon to 2 p.m. every 10 minutes. GB
Whenever using download on PC, the Hyperterminal present in the windows
accessories must be accessed.
Carry out a new connection (giving it a name), enter the COM on which to con-
nect the PC and enter the following properties in the window:
bit per second 9600
bit of data 8
parity nil
stop bit 1
hardware flow control
when click OK.
At this point the PC is ready to receive the data that will be sent by pressing the
key on the control cabin.
The data thus transmitted can be stored on file simply by selecting Save from the
File menu.
Each time this program is accessed it will no longer be necessary to enter all the
data as described above; simply open the connection created (which has been
given a name).
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4.9 Alarms
Every time an alarm occurs, the icon starts blinking and the buzzer goes off.
To silence the buzzer, just press any key.
To see the alarm mask, press key ; in this way, you will access the mask
below where you will see the different alarm codes.
Each alarm code has a relevant description which can be seen in the string at
the bottom of the display. ON indicates an active alarm status while OFF indi-
cates a non-active one.
To go from an alarm code to the next, you should press key To go to the next
alarm page, you should press key .
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Alarm code Description Type
71
A04 Pressure switch alarm
This alarm occurs when either the high or low pressure switch trips. The high
pressure switch may trip due to poor cleaning of the condenser or loosened con-
denser fan belts.
The low pressure switch may trip due to refrigerant leaks. By tripping it causes
the machine to stop until the alarm itself disappears.
A05 Low battery level alarm
This alarm occurs if battery power is lower than 11.5V. It turns the machine off
until power remains above 11.5V for at least 1'. Warning: making the engine work
for short periods (with frequent peaks) causes the battery to exhaust.
A06 Cargo area sensor failure alarm
This alarm causes the machine to permanently stop until the problem has been
solved. To start the machine again, it must be reset using the procedure
described in the paragraph above and the ON/OFF key must be pressed.
A07 Defrost sensor failure alarm
It is a warning alarm which has no consequences on the operation of the
machine.
A08 Starting failure/damaged alternator
This alarm may occur if the diesel engine did not start after the maximum num-
ber of startup attempts (factory-set at 5).
Possible causes include: broken alternator, loose belts, no fuel. If the same alarm
occurs during electric standby, it should be attributed to a broken alternator.
To start the machine again, you need to reset the alarm by following the proce-
dure described in the above section and press the ON/OFF key .
A09 High/low temperature alarm
This alarm occurs if the differential between actual temperature of the cold room
and the temperature value set using the control exceeds a factory-set limit. It is
a warning alarm which has no consequences on the operation of the machine.
A10 Radiator water level alarm (optional)
It is a warning alarm which has no consequences on the operation of the
machine.
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A11 Oil level alarm (optional)
It is a warning alarm which has no consequences on the operation of the
machine.
A12 Air filter alarm
This alarm occurs if the air filter cartridge is clogged. Replace the cartridge. It is
a warning alarm which has no consequences on the operation of the machine.
A13 Oil filter alarm (optional)
It is a warning alarm which has no consequences on the operation of the
machine.
A14 Power card not present
This is a warning alarm which occurs if connection between the power card and GB
the driver's cabin control is missing.
A15 Damaged condensing sensor alarm (optional)
It is a warning alarm which has no consequences on the operation of the
machine.
A16 Damaged water sensor alarm
It is a warning alarm which has no consequences on the operation of the
machine.
A17 Door switch open alarm
This alarm occurs if the protection grate located on the machine is open. This
alarm prevents motor startup.
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5. Goods loading procedure
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5.3 Tips on temperature of carried goods
Product -Reference temperature
Bananas -15°C (55/60°F)
Fresh fruit and vegetables -4/6°C (39/43°F)
Fresh meati and seafood -2°C (36°F)
Milk and dairy products -2/6°C (36/43°F)
Ice-cream -20/-25°C (-15/-20°F)
Deep frozen fruit and vegetables -18°C (0°F)
Deep frozen meat and fish -20°C (-10/0°F)
THESE TEMPERATURES ARE FOR REFERENCE PURPOSES ONLY. ANY TEMPERATURE SUPPLIED BY
RECEIVER OR CARRIER WILL PREVAIL. GB
5.4 Recommendations on how to best use your refrigerator unit
• Make sure the doors remain open as little as possible.
• Before selecting the required cold room temperature, check the temperature
of the goods to be carried.
• 0/15 cm (4/6 in) is the minimum clearance between the cargo and the walls of
the cold room.
• When parking, leave your vehicle in the shade and make sure that the DFZ
ZANOTTI refrigeration unit does not remain idle for a long time.
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6. Using the unit safely
The DFZ ZANOTTI units are built to keep the operators safe. The use of protec-
tion gloves is, in any case, fundamentally important during controls, repairs, and
maintenance for every action which the operator must carry out inside the unit,
whether when handling the evaporator or the condenser which can injure his
hands with their fins or to avoid burns caused by accidental contact with the unit's
hot parts.
6.2 Refrigerants
The refrigerant contained in the refrigeration system can cause serious injuries if
it should come into contact with any part of the body: burnings, frostbite and even
blindness, if it comes into direct contact with the eyes. That's why the regulations
applicable to the handling of refrigerants during maintenance operations provide
that the customer calls the nearest service center to have the unit service or
repaired.
6.3 Battery
It is strictly forbidden to smoke while checking the unit. In fact, the batteries
release small amounts of hydrogen which by igniting can cause the battery to
explode and the operator to be seriously injured or blinded.
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7. Routine maintenance
MAINTENANCE INTERVALS
Warning
• Check coolant and lubricating oil levels every day.
• Use synthetic oil with 15W-40 viscosity.
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Important
• Carry out the following maintenance operations after one year:
- renovating refrigerant,
- checking and adjusting valve clearances,
- checking that the cylinder heads are well tightened,
- checking that the injectors are in good working condition.
BELTS
FILTERS
1. Oil filter
3. Air filter
78
8. Troubleshooting guide
Should you find any other faults, check the alarm pages on the keyboard locat-
ed on the vehicle's dashboard.
In case of further problems, contact the nearest ZANOTTI dealer.
79
9. Abstract of the “A.T.P. Europe” regulation (march 1974)
Authorization for vehicles used to carry perishable foodstuffs. Prior to the begin-
ning of its operation, the refrigerated vehicle must be authorized by the
Departmental Veterinary Service.
Note: the "K" factor of vehicle bodies to be included in class C must be equal to, or lower than 0.4 W/m2°C.
80
SYMBOLS, ITEMS AND IDENTIFICATION PLATES
TO BE AFFIXED ON REFRIGERATED VEHICLES.
Refrigeration plate: this wording must be followed by the identification items
according to the following list:
• Class A standard refrigerated vehicle FNA
• Class A reinforced refrigerated vehicle FRA
• Class B reinforced refrigerated vehicle FRB
• Class C reinforced refrigerated vehicle FRC
In addition to the above mentioned identification items, the plate must also show
the expiry date of the authorization certificate (month and year), for example: GB
FRC
6-2000
(6 = month (June) 2000 = year)
Important
Check the expiry date on the authorization certificate on a regular basis. During
transportation, the authorization certificate or the temporary certificate must be
produced to the authorized agents upon their request. In order to obtain an
authorization to use an isothermal vehicle as a refrigeration group, a request to
change the authorization certificate must be sent to the regional health boards.
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Wiring diagram key
82
Tagliando di garanzia
Guarantee coupon - Coupon de garantie - Garantieabschnitt - Cupón de garantía
Ore funzionamento
Hours of operation - Heures de fonctionnement - Betriebsstunden - Horas de funcionamiento
N. documento
Document no. - N° de document - Dokumentennummer - N° de documento
Ore funzionamento
Hours of operation - Heures de fonctionnement - Betriebsstunden - Horas de funcionamiento
N. documento
Document no. - N° de document - Dokumentennummer - N° de documento
Ore funzionamento
Hours of operation - Heures de fonctionnement - Betriebsstunden - Horas de funcionamiento
N. documento
Document no. - N° de document - Dokumentennummer - N° de documento
Tagliando di garanzia
Guarantee coupon - Coupon de garantie - Garantieabschnitt - Cupón de garantía
Ore funzionamento
Hours of operation - Heures de fonctionnement - Betriebsstunden - Horas de funcionamiento
N. documento
Document no. - N° de document - Dokumentennummer - N° de documento
Ore funzionamento
Hours of operation - Heures de fonctionnement - Betriebsstunden - Horas de funcionamiento
N. documento
Document no. - N° de document - Dokumentennummer - N° de documento
Ore funzionamento
Hours of operation - Heures de fonctionnement - Betriebsstunden - Horas de funcionamiento
N. documento
Document no. - N° de document - Dokumentennummer - N° de documento
0MAN129A del 10/2002
ZANOTTI S.p.A. -
46020 PEGOGNAGA (Mantova) - Italy
Via Martin L. King, no 30 - Tel. (0376) 5551- Telefax (0376) 536554
E-mail: [email protected] - Internet: http://www.zanotti.com