SERVICE TRAINING MANUAL

CONTENTS PAGE NO:

1. Company profile 2

2. Refrigeration unit installation 9

3. Working principle of Walk-in- Cold storage 11

4. Trouble Shooting Chart for -Cold Room & Freezer 14

5. Electrical wiring diagram 17

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Prompt Engineers Design Team develops perfect, tailor-made solutions for the most complex
needs of the industry.The variety of products & solutions of the company covers the “cold
chain” and “clean & energy efficient” lightweight construction.

2
In the cold chain [ cold solutions] vertical ,the company offers products right form farm/harvest
level cooling to process refrigeration, cold ware houses, distribution & cold dispensing at retail
level
Solutions covering the
following
user
segments;

Cold Rooms, Cold Warehoses, High RH Cold Stores for F&V Agro,
Low RH Seed Storages for Seeds, Ripening Chambers, Hospitality,
Blast Freezer/chillers, Pre-coolers, Potato cold stores Pharma,
Controlled Ambient Process Halls, Process Water chillers, Dairy, Food
CO2 Vapour chiller etc… Air cooled & Water cooled processing,
Food
service,
IQF, Spiral freezer, Blast Freezers, Pre Coolers, Process Cooling ,
Water chillers etc..
Food retail&
Retail.

Open Deck Chillers, Reach in Refrigerators [ 350/ 600/1000/2000

Ltr cap, Visi Coolers, Visi Freezers, Pizza Make Table, Chicken
Chillers, Thawing Cabinets, Proofers, Under Counter Products
Refrigerators - Plug in & Remote type
&
Prefabricateed Insulated Panel constructions for Clean rooms, Services
Dry warehousing, Clean zone Process Halls, Factory buildings,
Teleshelters, Insulated Corrugated Roofing, PEB structure with
Box in / box out construction. PUF/EPS/Rock wool insulation.
Clean Room class 1000 and above ,Walk on/Non walk on ceiling.

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 Project Management

Dedicated
Design &
Engineering
team
Complete Good
Integration of 1 Engineering
services and practices
utilities 2
6 A QUALITY
PROJECT
EXECUTION
5 ON TIME 3
On time
supplies and Establishment
dedicated 4 of site office
support from with
Operations Installation communicatio
team at site
with a
dedicated site

Projects will be handled from concept to commissioning by experienced professionals who will
ensure quality and high levels of workmanship.

Operations, Maintenance and Service Contracts: A dedicated team called “TEAM RINAC” led
by qualified, experienced service personnel is RINAC’s distinctive strength. Equipped with
advanced service facilities, they will ensure quick, comprehensive response to every customer
requirement. The service personnel are provided with regular in-house training to keep them
tuned into the rapidly changing industry trends. Several prominent companies from diverse
industries vouch for RINAC’s quality standards and service excellence.

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Certifications / credentials

Offices

HO #5, “Saraswathi Nivas”,Main channel road, Saraswathipuram, Ulsoor,

Bangalore 500 008 Tele : 080 25542929/41132998 Fax : 25511750
Email- [email protected] web : www.rinac.com
Bangalore # 25, 1st Floor, Karnasree Point, Anand Nagar, Marathahalli Ring Road,
Bangalore - 560 037 Tele : 080- 25238012 Email – [email protected]

Chandigarh SCO # 324-325, 1st floor, Sector 38 D, Chandigarh. 160 014,

Tele : (0172) 2625511 Email - [email protected]

Chennai No 70,The Taj Apartments, Ritherton Road, Puraswakkam, Chennai 600007

Tele : 044 26616427/25325304 Email – [email protected]

Delhi 101 - C, Kundan House, 1st floor, Hari Nagar, Ashram, New Delhi - 110 014
Tele : 011 – 2634 6590 / 91 / 92 26346590 [fax ] Email- [email protected]

Goa Xec Zoinodin Building, BOCADE Panjim , Goa - 403 001

Tele : 0832 – 2420259

Gujarat 605, Mahakant, Near SBI Ellisbridge , Ashram Road Ahmedabad - 380006.
Tele: (079) 2661 0189 / 2661 0279 [ fax ] Email – [email protected]

Hyderabad #38, 1st Floor, Anand Nagar, Malani Co-op Housing Society, Chinna Thokatta,
Bowenpally, Secunderabad - 500 011, Tele : 040 27951563 Email-
[email protected]
Kerala 37 / 862, Fathima Church Road, Elamkulam, Cochin - 682 020
Tele : 0484 – 2206166 Email : [email protected]

Kolkatta Suite No.1, 26/3, Ground floor, Ballygunge Circular road, Kolkatta 700019
Tele/fax : 033 24863230 Email – [email protected]

Mumbai 106, 1st floor, Bhagatni Enclave, Behind Asian Paints,Off. LBS. Marg, Bhandup
(W), Mumbai - 400 078 Tele : 022-25660719 Email – [email protected]

Pune 24, Gold Fields Plaza,Sasoon Road, Pune – 411 001

Tele: 020-2611 4147 / 2612 0237 Email – [email protected]

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Srilanka Mr. F.A. De Livera [M/s. Koolair Limited] 64, Dharmapala Marwatha
Colombo - 3, Srilanka. Tele: 94-1-575476 Fax: 94-1-716596/500643

UAE Mr.Srinivas Rao, Armada Corporation FZCO, Suite 410, JAFZA 15,
P.O. Box 18264, Dubai,United Arab Emirates.Tel: +971-4-8814681,
Fax: +971-4-8871297 Cell: +971-50-7565547 E-mail: [email protected],
URL: www.rinac.com

Factories

Cold room erecting procedure

● Check the level of the floor where the rooms are to be erected. In case of variations above
6mm advice customer to correct the same.
● In case of recessed flooring check the depth with respect to the thickness of insulation
and thickness of concrete
● Check diagonals of the room to be equal after marking for floor angles.

● The door panel has to be perfectly in plump vertically and horizontally for smooth
operation of the door.

● The door shutter should be locked while erecting the door panel.

● The cavity between the ceiling panel and the wall panel within the corner angle should
be filled with PUF through the pore holes from the top and capped for Freezer rooms.
● The location of the drain should be checked at the premises for locating the drain outlet
of the unit prior to making opening for drain pipe on the panel.

● A minimum of 1=50 slope is to be maintained while fixing the drain from the Eaporator
unit.

● Use only suitable size steel hole cutter for making entry openings for drain, refrigerant
lines, electrical cables etc.

● The drain line inside the Freezer room should be with GI pipe only and insulated with
minimum 50mm thk PUF sections and either cladded or finished with AL foil.

● Ensure that Non-heating portion of the door heater is taken out of the frame and
connected to the power point, to avoid localized heating and burnout of the connectors.

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 ● Fasteners like rivets, screws etc. for fixing flashings, and beltings should be in equal
pitch not more than 250 c/c.
● The sealant at panel joints should be uniformly applied using bottom of the sealant
tube. One tube of sealant can cover approx 20 RMT for a 3mm wide panel joint.

● The Evaporator unit should be generally located not facing the door and should be away
from the door to minimize ex-filtration.
1. Refrigeration unit installation

▪ While installing air-cooled condensing unit & evaporating unit, a minimum space of 450mm
shall be maintained between the unit and any wall at the backside. Similarly, a space equivalent
to the width of the unit shall be left between the unit & sidewalls and between the units, if more
than one unit is installed in a line.
▪ The condensing unit is located on vibration absorption pads on the MS stand. Air-cooled
condensing units, capable of withstanding outside weather condition, shall be located outside
the building where unrestricted natural ventilation is available.
▪ The evaporator unit is hung from the ceiling with protruded threaded rods and SS nuts. After
hanging the evaporator unit, pour water in the drain tray and check whether the drain lines
are sloped and water is draining out properly.
▪ To maximize storage space, ceiling mounted unit coolers shall be used.

2. Refrigeration piping & wiring

▪ Unless otherwise specified all refrigeration piping shall be made of refrigeration grade Type-L
or Type-K, hard drawn degreased sealed copper tubing. Alternately the use of Type-L
refrigeration grade soft copper tubing shall be permitted for smaller diameter up to 15mm, but
it should be straight and free of kinks and bends.

▪ Tubing shall be installed in a neat, workmanlike manner with horizontal running pipes, slightly
sloped towards the compressor to facilitate smooth flow of refrigerant / oil.

▪ The piping shall be carried out with minimum number of bends as far as possible. Wherever
soft pipes are bend to take a 90˚ turn offset the same by 90˚ and it shall be done with a pipe
bender.

▪ The spacing to be maintained between adjacent pipes shall be 1”. In case of lines running
vertical, all lines shall be in plump and equally spaced. Similarly, in the case of horizontal lines,
they shall be in level and equally spaced without any inclination.

▪ The supports shall be fixed in advance in order to maintain the level / straightness of piping.
Before the refrigerant piping circuit is sealed up, the pressure testing, tightness testing and
flushing of the system shall be carried out to ensure that the inside of the pipe is clean.

▪ For condensing units located at a higher level relative to the

evaporator unit, an inverted ‘U’ shall be given on the suction line near
the condensing unit and the evaporator unit to ensure oil return.

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▪ In case of two evaporators with one condensing unit, the pipe line
from the main liquid line heading to each evaporator shall be of equal
length and laid in such a way that, ‘Bull heading effect’ is avoided.

▪ For longer ‘vertical’ suction line piping, a loop shall be provided at 3

to 4 meters interval for smooth flow of refrigerant and oil return.

▪ A branch suction line shall enter a main suction line at the top. Header Piping shall be
arranged in such a way that, the refrigerant or oil in the pipe shall not drain from the suction
line into the coil.

▪ Ensure that the holes made on panels for pipe entry shall be at the required locations only and
made only with hole saw cutter.
▪ Holes shall be made with minimum clearance and sealed properly from both faces with PUF /
Silicon sealant.
▪ If the refrigeration / condensate piping crosses a civil wall, additional pipe sleeves shall be given
on the civil wall and the piping shall pass through the sleeve.
▪ In case of freezer room units, check the liquid line and hot gas line and then terminate the final
joints at the evaporator correctly to avoid interchanging of line.

▪ All wiring associated with this installation shall be heat and moisture resistant
type.

▪ Extreme care shall be taken to keep all refrigerant piping clean and dry. Each length shall be
inspected and swabbed with a cloth soaked in refrigerant oil, if any dirt, filling or moisture is
found present on it.

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Technical description and working principle of Walk-in- Cold storage and
Walk -in –freezer room
Introduction: -

The walk in cold storage is used for storing of various perishable materials under controlled
temperature / RH condition so as to retard its degradation. The controlled condition is achieved by
means of refrigeration.
Refrigeration is the process of lowering the temperature less than the surrounding. There
are so many refrigeration processes like vapour compression, vapour absorption, and steam jet
refrigeration. For walk in cold store supplied by RINAC the type of refrigeration used is vapor
compression with Freon refrigerant. Considering the same our reference of refrigeration system in
the succeeding paragraph would be merely vapour compression type only.

Working principle: -

Vapour compression refrigeration system works on the principle of Bell-colemann cycle. The
working of the same is illustrated in the succeeding paragraph.

The low temperature and low pressure refrigerant is sucked by the

Compressor through suction pipe and suction valve. The refrigerant is
Compressed by the compressor to a high temperature high-pressure vapour and discharges to the
condenser through discharge valve and pipe.
The condenser removes the heat absorbed by the refrigerant in the process of cooling the product as
well as the heat of compression. The high pressure and high temperature vapour will be condensed
to high pressure and high temperature liquid and then it flows to a HP receiver / to evaporator as
the case may be through a filter drier and expansion valve. The receiver is incorporated only whenever
the length of pipe erected is more to facilitate pump down. Filter drier is incorporated to absorb /
filter moisture and other sediments from the refrigerant which is essential for the smooth functioning
of the system.

The expansion valve reduces the pressure and temperature of the liquid refrigerant and then the low
temperature and low-pressure liquid vapour mixture enters the evaporator. Since the evaporator is
installed in the room it absorbs the heat from the room and cools it to the required temperature.
During the heat absorption, the refrigerant is converted to low pressure and low temperature vapour
and then it passes to the compressor through the suction pipe and valve and the cycle repeats.

Now let us consider the practical working of walk-in-cold store. The cold room consists of the
following assemblies: -

i) The insulated chamber made of insulated RPUF/EPS panels of various thickness and
lamination (PCGI/PCGI, PCGI/SS etc.)

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ii) The outdoor unit also called the condensing unit consisting of compressor, condenser coil,
condenser fan, filter drier, hand shut off valve, Receiver, liquid line solenoid valve etc.
iii) Indoor unit also called the evaporating unit consisting of expansion valve, distributor,
evaporator coil and fans.
iv) Interconnecting refrigerant piping between indoor and outdoor unit.
v) Electrical panel housed in the condensing unit for starting the various components like
compressor, condenser, evaporator etc.
vi) Electrical wiring between the controller, electrical starter panel and evaporator.
vii) Control panel to control the working of the system.

Operation: -
The incoming power supply is connected to the MCB of the electrical panel and power is
available to the system. When the MCB is put to ON position. From the control panel / controller
based on the set point and actual temperature sensed by the sensor placed in the return air
path, the control voltage go to the overhead relay/ fuse of the evaporator and evaporator fan gets
on. The compressor and condenser fan starts after the preset time delay. The compressor and
condenser fan runs along with the evaporator fan till the set point is reached and thereafter the
condenser fan and compressor gets off and only evaporator fan runs. Whenever the actual
temperature in the room rises above the set point, the control voltage goes to the compressor
relay and the cycle repeats.

Safety: -
The system is provided with safety devices like HP/LP cutouts, compressor OLR/ single-phase
preventer etc. which ensures that power supply will be available to compressor only when there
are healthy conditions.

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Compressor
The compressor (sealed in the compressor housing) draws cold, low pressure refrigerant gas from
the evaporator and pumps hot, high pressure refrigerant gas out to the condenser

The compressor is the heart of the system. The compressor does just what it’s name is. It
compresses the low pressure refrigerant vapor from the evaporator and compresses it into a
high pressure vapor.

The inlet to the compressor is called the “Suction Line”. It brings the low pressure vapor into
the compressor.

After the compressor compresses the refrigerant into a high pressure Vapor, it removes it to the
outlet called the “Discharge Line”.

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Condenser
The “Discharge Line” leaves the compressor and runs to the inlet of the condenser.

Because the refrigerant was compressed, it is a hot high pressure vapor (as pressure goes up –
temperature goes up).
The hot vapor enters the condenser and starts to flow through the tubes.

Cool air is blown across the out side of the finned tubes of the condenser (usually by a fan or
water with a pump).

Since the air is cooler than the refrigerant, heat jumps from the tubing to the cooler air (energy
goes from hot to cold – “latent heat”).
As the heat is removed from the refrigerant, it reaches it’s “saturated temperature” and starts to
“flash” (change states), into a high pressure liquid.

The high pressure liquid leaves the condenser through the “liquid line” and travels to the
“metering device”. Sometimes running through a filter dryer first, to remove any dirt or foreign
particles.

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 Oil separator

OIL SEPARATOR to be used with flooded systems, low temperature systems and systems with long
runs of piping or other factors that tend to cause oil return problems. They help maintain oil volume
levels in the compressor oil sump

Solenoid valve
A solenoid valve is an electromechanical valve for use with liquid or gas controlled by running or
stopping an electric current through a solenoid, which is a coil of wire, thus changing the state of
the valve. The operation of a solenoid valve is similar to that of a light switch, but typically controls
the flow of air or water, whereas a light switch typically controls the flow of electricity. Solenoid
valves may have two or more ports: in the case of a two-port valve the flow is switched on or off; in
the case of a three-port valve, the outflow is switched between the two outlet ports. Multiple
solenoid valves can be placed together on a manifold.

Solenoid valves are the most frequently used control elements in fluidics. Their tasks are to shut
off, release, dose, distribute or mix fluids. They are found in many application areas. Solenoids
offer fast and safe switching, high reliability, long service life, good medium compatibility of the
materials used, low control power and compact design.

Besides the plunger-type actuator which is used most frequently, pivoted-armature actuators and
rocker actuators are also used.

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Hand shutoff valve
A ball valve is a valve that opens by turning a handle attached to a ball inside the valve. The ball
has a hole, or port, through the middle so that when the port is in line with both ends of the valve,
flow will occur. When the valve is closed, the hole is perpendicular to the ends of the valve, and
flow is blocked. The handle or lever will be in line with the port position letting you "see" the valve's
position. The ball valve, along with the butterfly valve and plug valve, are part of the family of
quarter turn valves.

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Drier
The filter/dryer is in the liquid line between the condenser and the expansion valve. This dryer
filters out any foreign particulate matter and also contains a desiccant to absorb any moisture that
may be present in the system.

Liquid Sight glass

A moisture indicating LIQUID SIGHT GLASS should be installed in the liquid line between the
receiver and as close as possible to the expansion valve on the evaporator. If it is mounted on the
condensing unit, it will be mounted downstream of the receiver outlet service valve and immediately
after the liquid line drier. It will change color if there is moisture present in the system. It also allows
the contractor to detect a shortage of refrigerant or flash gas in the liquid line. Bubbles are not
normally visible in the sight glass of a properly charged system; however it is normal to see bubbles
appear in the sight glass for a few minutes when the compressor starts. Bubbles in a sight glass
installed on the condensing unit must never be used as the final indicator for shortage of refrigerant
in the system.

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Thermostatic expansion valve
A very common type of metering device is called a TX Valve (Thermostatic Expansion Valve). This
valve has the capability of controlling the refrigerant flow. If the load on the evaporator changes,
the valve can respond to the change and increase or decrease the flow accordingly.

The TXV has a sensing bulb attached to the outlet of the evaporator. This bulb senses the
suction line temperature and sends a signal to the TXV allowing it to adjust the flow rate. This
is important because, if not all, the refrigerant in the evaporator changes state into a gas, there
could be liquid refrigerant content returning to the compressor. This can be fatal to the
compressor. Liquid cannot be compressed and when a compressor tries to compress a liquid,
mechanical failing can happen. The compressor can suffer mechanical damage in the valves
and bearings. This is called” liquid slugging”.

Normally TXV's are set to maintain 10 degrees of superheat. That means that the gas returning
to the compressor is at least 10 degrees away from the risk of having any liquid.

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T 2/TE 2 thermostatic expansion valves are used for liquid injection into evaporators on both
refrigeration and air conditioning systems using fluorinated refrigerants. T 2/TE 2 is supplied
with an interchangeable orifice assembly for easy stocking and service.

TX 2/TEX 2,
flare/flare, R22,
element / valve
body

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 TN 2/TEN 2, TS 2/TES 2,
flare/flare, flare/flare, R404A TZ 2/TEZ 2,
R134a, element / R507, element / flare/flare, R407C,
/ valve body valve body element / valve body

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Evaporator coil
Evaporator coil The evaporator is where the heat is removed from your house , business or
refrigeration box.

Low pressure liquid leaves the metering device and enters the evaporator.

Usually, a fan will move warm air from the conditioned space across the evaporator finned coils.

The cooler refrigerant in the evaporator tubes, absorb the warm room air. The change of
temperature causes the refrigerant to “flash” or “boil”, and changes from a low pressure liquid
to a low pressure cold vapor.

The low pressure vapor is pulled into the compressor and the cycle starts over.

The amount of heat added to the liquid to make it saturated and change states is called “Super
Heat”.

One way to charge a system with refrigerant is by super heat.

Measure Evaporator Superheat:

Get pressure readings of the suction line leaving the evaporator to get refrigerant saturation
pressure-temperature. Refrigerant saturation temperature is the pressure-temperature, when
the refrigerant is turning from a low-pressure liquid to a low-pressure vapor (absorbing heat).
At saturation pressure-temperature, both liquid and vapor are at the same temperature.

Convert pressure to temperature with a P/T chart. If reading is obtained at the compressor, not
at the evaporator line leaving, you may have to add a few pounds of pressure due to pressure
drop in the suction line.

Take a temperature reading at the leaving suction line of the evaporator.

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 Compare both, the saturated temperature and the leaving suction line temperature.
Subtracting one from the other, the difference is the amount the refrigerant gas has heated past
saturated temperature.
Accumulator
A SUCTION LINE ACCUMULATOR is used to prevent liquid refrigerant from reaching the
compressor. Liquid flood back can occur for various reasons such as a malfunctioning expansion
valve, refrigerant overcharge, hot gas defrost cycle or extremely low load on the evaporator. An
accumulator should be used if frost or dirt collect on the evaporator coil(s). This can reduce the
heat transfer. Some suction line accumulators are equipped with a built in suction to liquid line
heat exchangers. All hot gas defrost systems must use an accumulator.

The main function of the Suction Accumulator in a refrigeration or heat pump system is to protect
the compressor from liquid slugging. Liquid refrigerant can dilute the oil, wash out the bearings,
and damage valve reeds. The un-evaporated portion of refrigerant returning in the suction line is
trapped in the separator, allowing only vapor refrigerant and oil to leave and return to the
compressor. Suction Line Accumulator comprise of a sufficiently sized vessel with an optimized ’U’
shaped internal tube to minimize pressure drop and maximize flow through the vessel. Positive oil
return is accomplished through a strainer protected injection orifice. The inlet to the U tube is
located above and behind the vessel inlet to eliminate any possibility of high velocity liquid
carryover.

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Dual pressure controller (HP/LP)

Pressure controls are for use in refrigeration and air conditioning systems to give protection
against excessively low suction pressure or excessively high discharge pressure. The controls
are also used for starting and stopping refrigeration compressors and fans on air- cooled
condensers.

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Oil pressure switch

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Water pressure switch

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Evaporator pressure regulator

Evaporator regulators are mounted in the suction line of refrigeration and air conditioning
systems. They are used to maintain a constant pressure corresponding to a constant temperature
on the evaporator. They also protect against too low and evaporating pressure by throttling down
when the pressure falls below the set value.

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 Crankcase pressure regulators
Crankcase regulators are installed in the suction line of refrigeration systems. They are used to
protect the compressor motor against overload experienced during startup after long off periods or
just after defrost periods.

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Pressure and temperature regulators, pilot operated main valve
PM valves are pilot operated main valves for regulating pressure and temperature in refrigeration
systems.
PM valves can be used on the high and low pressure sides, in wet and dry suction lines, and in
liquid lines without phase change (i.e. where no expansion takes place in the valve).
The function of a PM valve depends solely on the pilot pressure applied to the valve, either from
pilot valves or in the form of external pilot pressure.
PM 1 has one connection for pilot pressure/pilot valve, while PM 3 has three pilot pressure/pilot
valve connections. The associated Danfoss pilot valves can either be screwed directly into the main
valve or be connected via an external pilot line.

TROUBLE SHOOTING CHART FOR -COLD ROOM & FREEZER

SYSTEM TROUBLESHOOTING CHART:
Problem Possible causes Possible corrective steps

1)Check and correct the power

1)In coming power problem
supply with help of client's
2) Check electrical circut and motor
winding for shorts or grounds
2)Fuse blown
investigate for possible over loading.
Compressor not Replace fuse after fault is corrected.
running 3)Measure the current and correct it
before resetting->root cause for
3)Over load relay tripped.
drawing excess current to be
identified before resetting.
4)Defective contactor or coil 4)Repair or replace
5)Safety devices tripping (a)Check the suction pressure.
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 (b)Check the solinoid coil
c)Check the discharge pressure
(d)Check oil pressure.
(e)Check thermostat set point.
6)Check all wire junctions,Tighten all
6)Loose connection in wiring
terminal screws.
1)Flooding of refrigerant into 1)Check setting of expansion valve or
crankcase over charged refrigerant.
2)Mounting spring and boiting not 2)Check mounding spring,tighten
proper bolts.
3)Overhaul the compressor and
3)Worn out compressor parts.
Compressor replace worn out parts.
noisy or (a)Check the discharge pressure.
vibrating. (b)Check the condensor coil and clean
4)Internal pressure safety valve it.
open(condensor) ©Check the condensor fan rotation
and correct it.
(d)Check the safety valve and replace
if necessary
1)Check electrical connection and
1) Fan not working.
motor of condensor fan.
High discharge 2)Over charged refrigerant 2)Remove excess refrigerant
pressure 3)Non-condensable refrigerant 3) Replace refrigerant.
4) Condenser coil chocked. 4) Clean coil.

1)Check for leaks. Repair and add

1)Insufficient refrigerant in system
refrigerant.
Low discharge 2)Compressor reeds by passing 2)Rectify and replace defect reeds.
pressure (a)Regulate the fan speed.
3) Ambient temp. Is very low. (b)Fan should be control in
addition of hp cutout
1)Replace valve reads,gasket,oil
1)Discharge by passing seperator,hot gas solinoid valve as
High suction desired.
pressure 2)Expansion valve over feeding 2)Check feeler bulb/regulate
superheat.
3)Over charge refrigerant 3)Remove excess refrigerant.
1)Lack of refrigerant 1)Check for leaks. Repair and add
refrigerant.
2)Drier chock 2)Repalce.
3)Expansion valve filter chock 3)Clean.
Low suction
4) Expansion valve malfunctioning. 4)Check and reset for proper
pressure
superheat
5)Compresser section filter chock. 5)Clean.
6)Evaporater dirty or ice formation 6)Clean evaporater coil/Defrost
on coil. the coil.
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 7)Evaporater fan not running. 7)Check fan
winding,contactor,coil,OLR,fuse.
1) Clogged oil filter. 1) Clean.
2)Excessive liquid in crankcase. 2) Check crankcase heater
adjusted superheat.Clean
evaporator coil ice.
3)Worn out oil pump /defective oil 3)Replace
pipe.
Low or No oil
4)Compresser working in wrong 4)To be corrected
pressure.
direction.
5)Low oil level 5)Defrost system/Check and add
oil.
6)Oil pressure faulty 6)Repair or replace it
7)Worn out bearing 7)Replace and overhaul the
compressor.

1)Improper piping or traps 1)Correct piping and provide U

traps
2)Lack of refrigerant 2)Check for leaks and repair. Add
Not maintaining
refrigerant.
compressor oil
3)Compressor oil ring worn. 3)Replace.
level.
4)Refrigerant flood back. 4)Maintain proper super heat at
compresser.
5)Oil seperator faulty 5)Repair or replace
1)Blown valve plate gasket. 1)Replace.

2)Oil seperator by passing. 2)Repair or replace.

3)Valve reads by passing 3)Replace.
4)Hot gas by passing. 4)Check hot gas solinoid valve
Compressor and replace.
inernal protector 5)Insufficiant refrigerant in system. 5)Add refrigerant.
switch open. 6)Insufficiant superheat at 6)Adgest super heat.
compressor.
a)Condensor fan is not working or
running reverse direction check
7)Discharge pressure is too high
and correct it.
b)Condensor coil chock.clean it.
1)Temperature sensor faulty or loose 1)Check the sensor and repair or
connection. replace.
2)Temperature seting wrong. 2)Check the set point and correct
it.
3)Door not closing properly. 3)Check the door
Temperature not alignment,gasket,lock and correct
maintain it.
4)Compressor not running. 4)Check fuse,OLR,contactor or
coil HP,LP ,OP,INT and correct it.
5)Ice formation in evaporater coil. 5)Defrost coil and check fan
running reverse direction and
correct it.

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 6)Shortage of refrigerant 6)Check for leaks and
repair.Added refrigerant.
7)Check condensor coil and clean
7)Dischare pressure too high. it.
a)Fan is runing reverse direction
check and correct it.
3)Evap.Exp. Valve bulb loose. 3)Clamp it properly.
4)Discharge pressure too high. 4)Check fan rotation and correct
it or clean condensor coil.
5)Wrong head gasket. 5)Install correct gasket.

1) Shortage of gas. 1)Check for leaks. Repair and add

refrigerant.
2) Fan not working. 2)Check fuse electrical connection
and motor winding,fan relay not
Ice formation in working,Repair or replace it.
Evaporator coil 3)Fan running revere direction 3)Check the fan rotation and
correct it.
4) Improper Defrosting cycle 4)Check the D/F programe and
2nd sensor or wire.repair or
replace.
5) Evaporator coil dirty. 5)Clean the coil.
6) Door not closing properly. 6)Check the door alignment
gasket,lock,etc.repair or replace.

ELECTRICAL WIRING DIAGRAM COLD ROOM

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ELECTRICAL WIRING DIAGRAM FREEZER ROOM

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ELECTRICAL WIRING DIAGRAM COLD ROOM

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Temperature controllers and setting

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Temperature controllers and setting

DIXEL Controller

Refrigeration controller XR-02CX

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Refrigeration controller XR-60C

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 Fans settings

Alarms

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Refrigeration controller XR-03CX

Parameters
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Defrosting

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System cylinder

Putting humidifier in to operation

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Setting the output limitation

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Probes and Display

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66
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Blast freezers

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 TROUBLE SHOOTING CHART FOR -BLAST FREEZER
SYSTEM TROUBLESHOOTING CHART:
Problem Possible causes Possible corrective steps

1)Check and currect the power

1)In coming power problem
supply with help of client's
2)Check electrical circut and
motor winding for shorts or
2)Fuse blown grounds investigate for possible
over loading.Replace fuse after
fault is corrected.
3)Measure the current and
correct it before resetting->root
3)Over load relay tripped.
cause for drawing excess current
Compressor not
to be identified before resetting.
running
4)Defective contactor or coil 4)Repair or replace
(a)Check the suction pressure.
(b)Check the solinoid coil
5)Safety devices tripping c)Check the discharge pressure
(d)Check oil pressure.
(e)Check thermostat set point.
6)Check all wire
6)Loose connection in wiring junctions,Tighten all terminal
screws.
1)Flooding of refrigerant into 1)Check setting of expansion
crankcase valve or over charged refrigerant.
2)Mounting spring and boiting not 2)Check mounding spring,tighten
proper bolts.
3)Overhaul the compressor and
3)Worn out compressor parts.
replace worn out parts.
Compresser noisy
(a)Check the discharge pressure.
or vibraing.
(b)Check the condensor coil and
4)Internal pressure safety valve clean it.
open(condensor) ©Chech the condensor fan
rotation and correct it.
(d)Check the safety valve and
replace if necessary
1)Check electrical connection and
1)Fan not working.
motor of condensor fan.
High discharge 2)Over charged refrigerant 2)Remove excess refrigerant
pressure 3)Non-condensable refrigerant 3)Replace refrigerant.
4)Condenser coil chocked. 4)Clean coil.

1)Check for leaks. Repair and add

1)Insufficient refrigerant in system
refrigerant.
Low discharge
2)Compressor reeds by passing 2)Rectify and replace defect
pressure
reeds.
3)Ambient temp.is very low. (a)Regulate the fan speed.

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 (b)Fan should be control in
addition of hp cutout

1)Replace valve reads,gasket,oil

1)Discharge by passing seperator,hot gas solinoid valve as
High suction desired.
pressure 2)Expansion valve over feeding 2)Check feeler bulb/regulate
superheat.
3)Over charge refrigerant 3)Remove excess refrigerant.
1)Lack of refrigerant 1)Check for leaks. Repair and add
refrigerant.
2)Drier chock 2)Repalce.
3)Expansion valve filter chock 3)Clean.
4)Expansion valve malfunctioning. 4)Check and reset for proper
superheat
Low suction
5)Compresser section filter chock. 5)Clean.
pressure
6)Evaporater dirty or ice formation on 6)Clean evaporater coil/Defrost the
coil. coil.
7)Evaporater fan not running. 7)Check fan
winding,contactor,coil,OLR,fuse.

1)Clooged oil filter.

1)Clean.
2)Excessive liquid in crankcase. 2)Check crankcase heater adjusted
superheat.Clean evaporator coil ice.
3)Worn out oil pump /defective oil 3)Replace
Low or No oil pipe.
pressure. 4)Compresser working in wrong 4)To be corrected
direction.
5)Low oil level 5)Defrost system/Check and add oil.
6)Oil pressure fauilty 6)Repair or replace it
7)Worn out bearing 7)Replace and overhaul the
compressor.
1)Improper piping or traps 1)Correct piping and provide U traps

2)Lack of refrigerant 2)Check for leaks and repair. Add

Not maintaining
refrigerant.
compressor oil
3)Compressor oil ring worn. 3)Replace.
level.
4)Refrigerant flood back. 4)Maintain proper super heat at
compresser.
5)Oil seperator faulty 5)Repair or replace
1)Blown valve plate gasket. 1)Replace.

Compressor 2)Oil seperator by passing. 2)Repair or replace.

inernal 3)Valve reads by passing 3)Replace.
protector switch 4)Hot gas by passing. 4)Check hot gas solinoid valve and
open. replace.
5)Insufficiant refrigerant in system. 5)Add refrigerant.

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 6)Adgest super heat.
6)Insufficiant superheat at
compressor.
a)Condensor fan is not working or
running reverse direction check and
7)Discharge pressure is too high
correct it.
b)Condensor coil chock.clean it.
1)Temperature sensor faulty or loose 1)Check the sensor and repair or
connection. replace.
2)Temperature setting wrong. 2)Check the set point and correct it.
3)Door not closing properly. 3)Check the door
alignment,gasket,lock and correct it.
Temperature 4)Compressor not running. 4)Check fuse,OLR,contactor or coil
not maintain HP,LP ,OP,INT and correct it.
5)Ice formation in evaporator coil. 5)Defrost coil and check fan running
reverse direction and correct it.
6)Shortage of refrigerant 6)Check for leaks and repair. Added
refrigerant.
7)Discharge pressure too high. 7)Check condenser coil and clean it.
a)Fan is running reverse direction
check and correct it.

1)Shortage of gas. 1)Check for leaks. Repair and add

refrigerant.
2)Fan notworking. 2)Check fuse electrical connection
and motor winding,fan relay not
working,Repair or replace it.
3)Fan running revers direction 3)Check the fan rotation and
Ice formation in
correct it.
Evaporator coil
4) Improper Defrosting cycle 4)Check the D/F programe and
2nd sensor or wire.repair or
replace.
5)Evaporator coil dirty. 5)Clean the coil.
6)Door not closing properly. 6)Check the door alignment
gasket,lock,etc.repair or replace.
1)Short of refrigerant. 1)Check for leaks. Repair and add
refrigerant.
2)Discharge pressure too low. 2)Low ambient on air rgeulated
Suction pressure
fan RPM.
abnormaly low
3)CPR not functioning properly. 3)Check the pressure before CPR
and after CPR than set
requirement pressure
1)Blown gasket(Low stage) 1)Replace gasket
Ice on compressor
2)Malfunctioning or broken low 2)Currect it and replace valve
stator cover or
stage reeds. reeds.
crank case.
3)Wrong high stage head gasket. 3)Install correct gasket.
1)De superheating exp.valve not 1)repair or replace.
Inter Stage
functioning properly.
pressure too high.
2)Replace gasket.

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 3)Malfunctioning or brocken high 3)Repair or replace.
stage reeds.
2)Blown gasket(discharge to inter 1)Cleand exp.valve filter set
stage) superheat correctly. Check drier
chocking it needed replace.
Crankcase too hot 2)Desuperheating liquid solinoid 2)Check electrical connection and
valve not working. coil repair or replace.
3)Shortage of refrigerant. 3)Check leak and repair and add
refrigerant.
1)Inter stage pressure too low. 1)Replace gasket(discharge to
inter stage)
2)Inter stage pressure too high. 2)Wrong high stage head gasket
Suction pressure correct it.
abnormaly high 3)Evap.Exp. Valve bulb loose. 3)Clamp it properly.
4)Discharge pressure too high. 4)Check fan rotation and correct it
or clean condensor coil.
5)Wrong head gasket. 5)Install correct gasket.
1)Blow gasket(low stage) 1)Replace gasket.
Inter stage 2)Malfunction or broken low stage 2)Currect it and replace valve
pressure too low reeds. reeds.
3)Wrong hirh-stage head gasket 3)Install correct gasket.

All Electrical diagrams

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