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cold- room
technicians’
hand-book
( REVISED )
1
‘Foster’ cold- room
Technicians’ Hand-book
Contents Page
General Information 3
Circuit/Layout Diagrams
Walk-In-cold rooms 9 - 17
Walk-In-Freezer rooms 20 - 25
Normal Operation
Appendix :
2
FOSTER
WALK-IN-COLD-ROOM
GENERAL INFORMATION
3
generator is connected after little delay, to one of the
cooling units only, to continue the cooling. The unit to
work from generator is to be pre-selected by selector
switch on the cold room panel. When Mains power returns
the generator power is cut off and the generator is
stopped and also the Mains power is reconnected to the
units automatically by the generator panel. Also, during
the running of the generator, if its lube oil pressure
becomes low or the engine temperature becomes high the
generator is stopped automatically and an alarm is
given (The alarm can be put off by bringing the MAN/AUT
selector switch to ‘0’ position
4
Automatic Defrostion: The moisture in the air inside the
cold-room gets frozen and form frost on the
evaporator coils of the units. For better
cooling efficiency they are to be melted
from time to time.
5
FOSTER
6
COLD ROOM
GENERATOR PANEL:
7
COLD-ROOM PANEL: (new type)
COOLING UNITS
CB2, circuit breaker – to trip – OFF the unit control & fans
in case of Fault or overload.
C1, contactor for compressor – to put the compressor ON & OFF.
8
DESCRIPTION OF MAIN COMONENTS
Mains
1*220v
9
12 V .DC from Battery
A1
MAN / AUT(1-2) closed on
Either selection
R1= Dc sensing relay
*R1 (1-3)remains closed so
long correct DC voltage is
available from any of
Battery/charging rectifier bill
opens when DC is available
from dynamo when
generator is running.
M = Starting motor of
generator engine.
R2 = Alarm relay
@ T1 (9-11) closes after
preset time on Starting
Failure.
10
220 V. GENERATOR PANEL (Part)
‘ FOSTER ‘ WALK-IN-COLD-ROOM
N1 = Mains sensing
relay.
NK – mains
contactor.
DIAGRAM :1
11
220 V. GENERATOR PANEL (PART)
‘ FOSTER ‘ WALK-IN-COLD-ROOM
TERNATOR *M1=
Generator
220 V Breaker, normally
1Ø kept CLOSED
T3 delay to operate,
Allows generator to
build up voltage
T2 = Stop timer
220 V.AC
TO COLD-ROOM
PANEL
DIAGRAM :3
COLD ROOM OPERATING FROM GENERATOR SUPPLY
12
12 V.DC from Battery
T2 = stopping time,delay to
release, holds itself & RH2
for preset time (through
T2(1-3) to allow the engine
to stop completely.
13
GENERATOR PANEL (PART)
‘ FOSTER ‘ WALK –IN – COLD / FREEZER-ROOM
12 V . DC from Battery
DIAGRAM :5
14
COLD ROOM PANEL(220V 1-Ø)
(New type)
DIAGRAM :6
15
DIAGRAM :7
16
12 V .DC SUPPLY & BATTERY CHARGING CIRCUIT
Generator – Panel
(Part)
DIAGRAM :8
17
DESCRIPTION OF MAIN COMPONENTS
GENERATOR PANEL
18
COLD-ROOM PANEL (and cold-room)
19
DESCRIPTION OF MAIN COMONENTS
Mains
3*400/231V
20
21
FREEZER ROOM OPERATING FROM MAINS SUPPLY
DIAGRAM : 1(a)
22
400 V(3-Ø)GENERATOR PANEL(part)
FOSTER WALK-IN-FREEZER-ROOM
400 V.
3 -0 AC
TO
Cold – room
Panel
* M1 = Generator
Breaker
Normally kept
CLOSED.
T3 delay to operate,
allows generator to
build up voltage.
.
DIAGRAM : 3(a)
23
‘FOSTER’ WALK- IN-(FREEZER ROOM)
DIAGRAM : 6(a)
24
‘FOSTER’ WALK- IN-(FREEZER ROOM)
25
TROUBLE
SHOOTING
FOSTER
COLD-ROOM
26
FOSTER WALK COLD-ROOM
OPERATION & TROUBLE –SHOOTING
# Before switching the mains power supply ON, keep the MAN/AUT selector on the
generator-panel at ‘0’ position and On-OFF ‘switch (S1) of cooling units at OFF positions.
The power supply for the cold room panel is extended (from the above
R &O terminal points either from mains (as explained above) or from
the Alternator of the Generating Set (which we will discuss later
under network failure condition.
Both the cooling units are similar ,but only one unit works at a
time as per selection by selector ‘b2’ of cold room panel.
On putting ‘ON’ the switch of the unit, the ‘power’ neon will glow
and Evaporator-Fan will run. The Evaporator fan runs continuously
so long the unit is ‘ON’, When the temperature inside the cold
room is higher than required and the unit is not in defrost cycle
the thermostat will operate the contactor C1. In turn the
compressor and condenser fan will start functioning and
‘Refrigeration’ neon will glows accordingly. When the required low temperature is
attained inside the cold room thermostat cuts off
the contactor C1 which, in turn stops the compressor. The
‘condenser-fan’ also stops and ‘Ref neon goes off’. When the
temperature inside cabinet again rises and attains the
preselected / present higher limits, the thermostat will again operate
and the above action will be repeated. This way the temperature
inside the cold room will be maintained within the required ranges.
27
2.Alarm Condition
As soon as the main power fails. Relay N1 and NK drop off and
lamp X2 extinguishes.
28
When mains power supply will return relay N1 will operate
again but NK will not operate and also X2 will not glow. Now
to stop the engine press STOP button (Ref Daig 3 & 4) On
pressing STOP button relays T2 and RH2 will operate and T2
will hold itself and RH2 for present time (20 sec) to permit the
engine to stop completely.
If engine failure alarm lamp X1 glows and give alarm signal and the generator is observed
to be not functioning or in standstill, it
will indicate any of the following:
29
a) Starting Failure: Under power failure condition when MAN/AUT
selector is at 2 (AUTO) position, NK releasing operates RH1 (as
detailed earlier at 3c) and also Relay T1 gets supply to
operate. But it actually operate only after the lapse of
present time (20 sec) If the engine tried but could not start
during above time, T1 will operate and will release RH1 and
hence stops starter (M) and also blocks further start command
(If generator starts within the present time of T1 of GK will
operate before the above present time. Then T1 will be
prevented from operation and no alarm will come).
b) Too low lube oil pressure: If lube oil pressure becomes low
(normal) 2.B BAR 40 Psi in the engine while running the oil
switch (P) in the engine will operate which will in turn
operate Relay R2 and Alarm lamp X1 will glow and also
audio-alarm will come. R2 operating operates RH2 and T2 and
engine will stop detailed earlier at 3c R2 will hold itself
and X1 till it is reset (To reset bring MAN/AUT selector
switch to 0 position).
30
Trouble-Shooting (Genr Panel/ MAINS-CKT)
Circuit breakers trip off/ fuses blow off when there is an overload
in the circuit in which they are incorporated. In such cases
reset (put on again) the circuit breaker/replace the blown – off
fuse with one of same capacity and observe if the same trips off/blows-
off again. If trip/blow-off occurs again this will mean
that there is a persistent fault in the circuit. Assistance from
Maintenance Engineer will be necessary to rectify them.
31
B) NO POWER FAILURE; POWER AVAILABLE UPTO (2T1 6
0 (4T2 ON NK RELAY BUT GENERATOR IS RUNNING.
If OK
If operating
If operating
After replacement, the engine should—if not— NOTIFY MAINTENANCE
Stop now and mains power to cold room ENGINEER
Panel will be available
32
C) IN CASE OF POWER FAILURE GENERATOR IS RUNNING BUT UNIT NOT
WORKING
If OK If OK not
Operating operating
NOTIFY MAINTENANCE
ENGINEER
If available
Proceed as per
‘F’ in page. 10
33
D) GENERATOR DOES NOT START IN CASE OF POWR FAILURE
Check MAN/AUT selector position. If it is at ‘0’ or MAN (I) Position, the generator will not
start automatically. Change position to AUT (2), the generator should start automatically,
If it does not start, then change selector position to MAN (1) and try to start manually.
If OK
If ok
If ok
5. Return selector to ‘MAN’ & ‘AUTO’ positions one after another and observe again if
Generator can be started, if not = NOTIFY
Maintenance Enginer
ALARM /AUT STOP Lamp ‘x1’ will glow (& give give audio alarm) in case of any of
the following failure: Reset alarm by turning ‘MAN/AUT’ ‘SELECTOR to ‘0’ position once.
(Alarm will get cancelled in case of 1 & 2 below but will activate again in case of 31.
a) Check fuel lever in generator engine fuel tank, if empty, fill up,
34
NOTE: *Turn MAN/AUT Selector to 0 before removing the battery & turn
into AUT or MAN position after replacement.
(d) Try to start the generator again. If does not start – notify
Maintenance Engineer.
(a) Check lube oil level in the engine chamber – If less – add
required quantity
(b) Start generator and observe lube oil pressure on the gauge. It
should be normally 2.8 BAR (40 psi). If the pressure is observed to be
around the same, but alarm comes on again – the pressure – switch may be defective
(which may have to be replaced) or generator might have stopped due to high engine
temperature.
NOTE: If mains power supply return within the above OFF period of
Generator, it will be extended automatically to the cold-room panel
by operation of N1 & NK. In that case, wait till engines cools down
& then turn selector to AUTO position for turn selector to AUT and
allow the engine to cool down.
35
F) COLD ROOM PANEL / UNIT
Power supply( either from MAINS or GENRATOR) is available at R-O, outlet terminals of
generator – panel , but UNIT not working.
If ON
3 . Check switch ‘S1’ and Circuit – Breakers CB1, CB2 on selected unit if OFF Put ON
If ON
And
If cold room temp is higher then pre set – and also if not in defrost cycle, compressor,
•
cond fan should run and refrigeration neon should glow – if not – NOTIFY
Maintenance Enginer.
NOTE : If all the above are working but yet, no cooling is obtained, observe the “sight-
glass” in the unit, if you can see the liquid gas. If no ges is observed or, only bubbles
are observed – Refrigerant must have leaked out from the system.
NOTE : Repeat steps 3 & 4 above, with the other unit also. By selecting the same with
selector b3 on cold – room panel and NOTIFY OBSERVATIONS TO Maintenance
Engineer.
36
H) COLD ROOM-TEMPERATURE OBSERVED TO BE DIFFERENT THAN THE
SET RANGE
Normally, the unit thermostat are adjusted in such a way that units
starts working when the cold room inside temperature is around 8’0C
and goes of when temperature comes down to around 40C
is observed that actual temperature during normal operation varies
than the pre-set range NOTIFY Maintenance Engineer.
NOTE:(When large quantity of fresh vaccines is put inside the room the temperature
may go up temporarily but will come down again after some time – this may not be
considered as abnormality. However if temperature remains above 8’0C for more
than an hour alarm in the cold room panel will come. Reset by turning selector to 0
position.
I) MAINTENANCE OF BATTERY
a) Open the cap on each cell and measure the specific gravity of the acid in each
cell with a hydrometer. Record the readings in a table. The gravity can very from 1.28
(when full charged) to 1.12 (when completely charged) if the gravity is blow 1.23
battery is to be charged separately. NEVER DISCONNECT THE BATTERY
BEFORE ‘FUSE S 3 is taken out’. Refix fuse after battery is reconnected.
b) The acid level in the cells should be about 5 to 10 mm above the top of the
seperators. If not refill with distilled water (never add
ACID)
37
appendix
Appendix Content
38
APPENDIX a
FOSTER
Cold-Room
Sequence of operation
of relays
1.Mains power ON 40
2.Mains power OF selector at AUTO starting failure 40
3.Generator RUNNING Selector at AUTO/MANUAL 41
4.Mains power Returns selector at AUTO 42
5.Mains power OFF Selector at MANUAL 43
6.Mains power RETURNS Selector at MANUAL 43
Cold-room Panel 44
Solo Units 45
39
Foster Cold – Room
Generator / power – supply panel
LEGEND :
+ = Operator / Close
- = release / open
(-) = not operate
(+) = held operated
MAINS POWER ‘ON ‘
+ -
N1 _(8-11) prevents auto start
(6-7)+ prepares auto stop ckt
+
(1-3)
+ +
MAINS POWER ‘ OFF ‘ Select at ‘ AUTO ‘ – R1 - (1-3) prepares start – ckt
+
NK N1- _ (1-3) – prevents Nkoperation
(8-11)+
(main
Contact) RH1 T1 (start)
Disconnect ‘MAINS’
+
Supply ckt. from (87-30) (after pre-set time,20 sec)
Cold-room panel
+
M (starts) T1 + _ (1-4)- if generator could not
Start during above preset time
(9-11)+ This contact prevents further start
command releases RH1 hence m
ALARM +
+ + -
X1 R2 _ (1-4) prevents RH1 operation
(9-11)+ prepares RH2 path
+
(6-7)
* STARTING FAILURE
40
FOSTER COLD – ROOM
Generator / power – supply panel
GENERATOR ‘ RUNNING ‘
R1 - T3 (starts)
(main (51-52)-
+
Contacts)
(-)
T1 IF GENERATOR RUNS WITHIN
Extend ‘GENERATOR’ THE PRE-SET TIME DELAY OF
Supply to cold-room In case OPERATION OF T1(20 sec).
Panel (at R.O) R1 doesnot release i.9 GK OPERATES BEFORE
THE LAPSE OF ABOVE PRE-SET
TIME (20 SEC),T1 WILL NOT
OPERATE & HENCE ALARM CKT.
WILL REMAIN IN-OPERATIVE
FOR THE ABOVE PERIOD.
-
RH 1
(87-30)-
M – (stops)
*The above sequence of operation is common for both ‘ AUTO ‘ and ‘ MANUAL ‘
position Of selector – switch.
41
FOSTER COLD – ROOM
Generator / power – supply panel
(1-3)+
-
GK _ (main contacts)- withdraw
(+) generator supply from cold-room
RH2, T2 holds operated panel
for pre-set time (51-52)+ prepares RH1ckt
(standby)
(after lapse of (13-14)- prevents auto–stop ckt
Pre-set time of T2) (5-6)- prevents low lube oil
alarm ckt.
- +
T2 (61-62)
42
FOSTER COLD – ROOM
Generator / power – supply panel
(main contacts)-
‘ START ‘ Button Pressed
Disconnect ‘ MAINS ‘
Supply from (contacts) +
Cold – room panel
RH1 +
+
(87-30)
+
M (starts)
After Generator pick up speed,
‘ START ‘ button Released
(contacts)
RH1 –
GENERATOR ‘ RUNNING ‘
(see page) (87-30)-
-
M (stop)
(contacts)+
RH 2 + T2 +
(87-30)+
+
STOP SOLENOID
* Next sequence of operation
Similar to that detailed in page C ,
for selector at ‘ AUTO ‘
43
FOSTER
COLD ROOM PANEL (New type)
1 phase , 220V
Sequence of operation
B1+
T1+
C1 +
ALARM +
(supply at 5-6)
44
FOSTER COLD – ROOM
“ SOLO “ UNITS
S1+
+ +
Power Evpr T1 (working , normal)#
Neon Fan
+
(6-7)
(If system refrigerant pressures
Within pre-set limits, HP/ LP+)
+ + +
C1 Condr Refrign
Fan Neon
+
(1-2)
COMPRESSOR +
THERMOSTAT +
+ + +
C1 Condr Refrign
Fan Neon
)+
(1-2
+
COMPRESSOR
DEFROSTING : 2 cycles of 20 min. duration each per day at 12 hours intervals (pre – set)
T1 (Working, during defrosting)
(6-7)-
+ + +
C1 CONDr REFRIGN
FAN NEON
(1-2)+
+
COMPRESSOR - # After defrosting period T1 (6-7) again & normal
Running continues as above
45