COLD STORAGE SYSTEM

I. INTRODUCTION
Cold storage is a critical component in the food supply chain. Without rapid
cooling and appropriate storage conditions, produce deteriorates rapidly. Nutritional
losses and even spoilage of entire crops can occur. Initial rapid cooling to extract latent
field heat extends shelf life and maintains quality produce (Kraemer, R et.al.).
Cooling can be defined as the decrease of temperature of a substance or medium
below temperature of its environment. Refrigeration is a process of lowering the
temperature and maintaining it in a given space for the purpose of chilling foods,
preserving certain substances, or providing an atmosphere conductive to bodily comfort
(Akdemir, 2008).
II. DISCUSSION
A. Cold Storage System
Cold storage is the one widely practiced method for bulk handling of
the perishables between production and marketing processing. It is one of the
methods of reserving perishable commodities in fresh and whole some state for a
longer period by controlling temperature and humidity with in the storage system
(Krishnakumar, 2002). The most important factor in cold storage is ambient
temperature. As a rule, the temperature in cold storage is higher than 1-2°C, which
is the freezing point temperature of stored fruit and vegetable (Akdemir, 2008).
Cold storage is a special kind of room, the temperature of which is kept very
low with the help of machines and precision instruments. Cold storages are
essential for extending the shelf life, period of marketing, avoiding glut, reducing
transport bottlenecks during peak period of production and maintenance of quality
of produce. The development of cold storage industry has therefore an important
role to play in reducing the wastages of the perishable commodities and thus
providing remunerative prices to the growers.
In addition to helping maintain quality, postharvest cooling also provides
marketing flexibility by allowing the grower to sell produce at the most appropriate
time. Having cooling and storage facilities makes it unnecessary to market the
produce immediately after harvest. Postharvest cooling is essential to delivering
produce of the highest possible quality to the consumer. Cold storage can be
combined with storage in an environment with added of carbon dioxide,
sulfur dioxide, etc. according to the nature of product to be preserved
(Krishnakumar, 2002).
Classification of Cold Storage Based on Purpose:
1. Bulk cold stores: Generally, for storage of a single commodity which
mostly operates on a seasonal basis E.g.: stores for potatoes, chilies, apples etc.
2. Multi-purpose cold stores: It is designed for storage of variety of commodities,
which operate practically, throughout the year.

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3. Small cold stores: It is designed with pre-cooling facilities. For fresh fruits and
vegetables, mainly for export oriented items like grapes etc.
4. Frozen food stores: It is designed for with or without processing and freezing
facilities for fish, meat, poultry, dairy products and processed fruits and
vegetables.
5. Mini units /walk in cold stores: It is located at distribution center.
6. Controlled atmosphere (CA) stores: It is mainly designed for certain fruits and
vegetables.
Classification of Cold Storage Based on the Storage Conditions:
1. Short-term or temporary storage
Short-term or temporary storage is usually associated with retail
establishments such as supermarkets, where rapid turnover of the product is
normally expected. Depending upon the product the storage period may vary from
1 to 15 days.
2. Long-term storage, and
Long-term storage is usually associated with large-scale cold storages. The
storage period again depends upon the type of product and also the condition of
the product at which it is brought in to the cold storage. This period may be as
short as 7 to 10 days for sensitive products such as ripe tomatoes and as long as 6
to 8 months for products such as onions and potatoes.
For short and long term storage, the product is cooled and stored at a
temperature that is slightly above the freezing point. Depending upon the product,
the storage temperature varies and in general it may lie anywhere between - 2oC to
16oC.
3. Frozen storage
Frozen storage, most of the food products can be stored for considerably
longer periods, sometimes as high as a few years. However, certain fresh products
such as tomatoes cannot be stored under frozen conditions. The storage
temperatures for frozen foods typically lie between –23 oC to –12oC, with –18oC being
the most frequently employed storage temperature.
B. Parts and/ Components of Cold Storage System
General components of cold rooms:
1. Polyurethane panel. It includes the entire panel, ceiling panel and room panel,
which is made from import pipeline, auto-perfusion foaming, import black
material, double-side pressed colored steel panel with protective coating and the
thickness is generally 100 mm, 120 mm and 150 mm.
2. Polyurethane foaming material that is used for filling the interstices between
anatomizes.
3. Various steel panel folding and inside and outside wall.
4. Curtain, which is air wind.

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5. Frozen door with standard manual.
6. The compressors and condensation units.
7. Ceiling unit cooler, copper pipes which have aluminum radiating fins, quality
steel plate outer shell with plastic covering and electro thermal melting frost.
8. A pipeline connecting refrigeration.
9. Refrigeration and expansion valve.
10.Refrigeration pipe along with heat preservation.
11.Machine units, unit coolers, starting wires and wire-threading pipes that are
used in room lighting.
12.Complete electrical automatic control system.
13.Water-flowing pipes, melting frost, preserving cold electric warm wires and heat
preservations in the melting water-flowing pipe.
14.R22 refrigerant or other refrigerants.
15.Some other auxiliary parts like airproof ointment, various types of steel,
fasteners, rivet and consuming parts.

Figure 1: Installation Schematic Drawing

Source: Haier Group

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Main parts of cold room:
1. Compressor
Cold storage compressors have a compact frame, wear well and wide-ranging
applications. Refrigerant compressor adopts an efficient condenser and gives full
play to the condenser of the effect of heat transfer. They adopt an advanced level of
technology and equipment for production to make sure a reliable manufacturing
quality and dry filter, liquid screen, hand valve, solenoid valves and electrical
control box according to the requirement.

Figure 2: Bitzer Compressor Condensing Units for Refrigeration

Source: Shanghai Meluck Refrigeration Equipment Co., Ltd.

2. Air-cooler condenser:
The speed of air-cooled condenser is low and it has big air volume and high
efficiency of the blower. The air-cooled condensers have low noise and it works
smoothly. The air cooled condensers make use of independent switch, are safe and
also convenient. Fans have high waterproof motor and has long life. These
condensers use high-grade seamless pipe, long life and they do not corrode easily.
The coil out-frame is produced by high quality steel plate which has high strength,
are corrosion resistant an easy to assemble.

Figure 3: RUIXUE Cooling Condenser

Source: Zhejiang RUIXUE Refrigeration Equipment Technology Co., Ltd.

3. Ceiling unit cooler:

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 It uses thin walled brass and the punching the second flanging create a
highly efficient aluminum fins from the mechanical expanding. They have a high
efficiency of heat conduction and uses anti-moisture fan, low temperature
resistant, air volume, low noise and reliable operation. It uses stainless steel tube
electric defrosting system, coil tube which is electrically heated. It uses quality
steel panel and spray technology and it is corrosion resistant.

Figure 4: RUIXUE Refrigeration air cooled freezer evaporator air cooler

Source: Zhejiang RUIXUE Refrigeration Equipment Technology Co., Ltd.

4. Cold air wind curtain:

It is installed in the top of the door, blow lower temperature to divide the air
in an out of the room through which the cold air loss can be avoided. It is favored
by many users because of its nice, slick design, reliability and better price.

Figure 5: Chengyi Air Curtain

Source: Guangzhou Chengyi Electrical Appliance Co., Ltd.

5. Electronic control box:

Electronic control boxes can be measured over the level of the liquid, weight
and temperature for several objects. They have a transfinite alarm function along
with high safety. They match 380 V or 220 V external socket with the task of a
small distribution electronic box.

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 Figure 6: Electric Controller Box
Source: Shengzhou City Resour Products Supplying Co., Ltd.

6. Cold storage door:

High quality materials are used for cold storage door and the overall
framework of the entire closed structure, rigid polyurethane foam, external and
internal review of cold storage gate which is according to the requirements and
selections of the customer like painted color steel or an aluminum or galvanized
panel etc. refrigerator doors with a rational structure, moisture absorption, devoid
of rust, light weight, good insulation properties, aesthetics an ideal frozen door.
(Carter, 2016)

Figure 6: Schematic diagram of the cold room

Source: Ugwu and Ogbonnaya, 2012

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 Figure 7: Cold Storage Room
Source: Danfoss

C. Safety Operations
The following safety operations were taken from Coolstores & Cold Storage Risk
Management Guide by the NZI Risk SolutionsTM.
1. Field representatives must always follow safety instructions by the cold storage
operator. If entering a cold room, the representatives were supposed to have an
escort with them.
2. Cold stores can be sub-zero chambers and can create sudden thermal shock
and chill to the body. If entering a cold store, do not spend too much time
inside the room. Each cold store will have a supply of warm jackets as needed.
3. Refrigeration machines are located outside the cold rooms in open or inside a
designated machine room. Stand well clear of operational machines; do not
wear loose clothes like scarves that can get sucked into running fans.
4. Cold Atmosphere (CA) cold stores can have very low oxygen levels - Do not enter
inside a CA chamber.
5. Cold stores can have icy and slippery floors and usually humid. Always wear
proper laced shoes for conducting this survey.
6. If required, wear the provided hard hat, especially in cold stores with overhead
storage.
7. When visiting cold chambers designed for spices, wear the face mask provided
at the facility to avoid inhaling strong spice aroma.
8. Do not enter any enclosed space without permission and then only when you
are accompanied by an escort.
9. Follow walking zones and markings to avoid mishap with machines and
working staff.
10.Do not touch or press any buttons or switches at the facility visited.

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11.These facilities are primarily food zones – maintain personal hygiene when
visiting cold stores. Do not conduct survey if you are suffering fever, cold or
contagious disease.
12.If you hear any alarm, immediately evacuate to the closest exit and stand clear
for the operators to function.
General Fire Safety
Use unique insulation systems that rely on foamed plastic panels that do
not perform well in fires. A proven method of controlling a cold store fire is with a
properly designed and maintained automatic sprinkler system. However, it’s
important to have hand-operated fire extinguishers available as well. Fire
extinguishers should be installed by approved contractors and mounted on
brackets with clear signage indicating their positions so they can be easily located
in an emergency. They require annual servicing by approved contractors to ensure
they remain ready for use and they should also be checked regularly by staff on
site.
Fire sprinkler systems and automatic fire detection systems. Fire sprinkler
systems automatically detect a fire, transmit an alarm to the Fire Service as a
result of water flow and control or extinguish the fire. Sprinklers provide 24/7 fire
protection as needed in the immediate vicinity of the fire. Where a sprinkler system
is installed in a temperature controlled environment, it is important that all rack
flues (the clear vertical lines of sight from the floor to ceiling within rack storage
areas) are kept clear of stored stock at all time.
Evacuation procedure. In the event of an emergency, the speed with which
people can safely exit the building can mean the difference between life and death.
It is recommended that fire exits, doors relating to fire exits and paths of travel to
fire exits, be routinely checked to ensure they are not obstructed or impeded in
anyway. Checking of fire exits should form part of your regular hazard inspection
regime, and notices providing clear instruction on how to evacuate and raise the
alarm should be displayed at the main exit doors.
Hot work fire safety
There are a number of risk factors associated with hot work, including a
high risk of fire. Hot work includes: welding, flame cutting, disc cutting, grinding,
blow lamps, brazing, burning off, soldering and the use of hot air guns.
Identifying hot work hazards:
1. Where possible, move the hot work object to a designated safe location, such as
a welding bay.
2. If the hot work object cannot be moved, relocate all movable fire hazards to a
safe place.
3. If the hot work object cannot be moved and if all fire hazards cannot be
relocated, provide guards to confine the heat, sparks and slag, and protect the
immovable fire hazards.

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4. Establish a ‘Fire Watch Duty’ and assign people key responsibilities for
overseeing the hot work. Where possible, a fire hose should be available to use,
if required.
5. To eliminate the risk of fire, conduct a final check for hot spots 30 minutes after
hot work is completed
Hot work precautions. The following factors must be considered before a hot work
permit can be issued:
1. Ensure hand-operated fire extinguishers or hose reels are readily available.
2. Ensure manual fire alarm system, if installed, is operational.
3. Ensure sprinkler system, if installed, is operational.
4. Isolate automatic fire alarm detection system, if installed. Contact your fire
alarm maintenance contractor to isolate the alarm.
5. Train hot work operators to perform the work safely.
6. Identify, isolate, remove, protect or disconnect all hazards, as appropriate.
7. Restrain compressed gas cylinders.
8. Maintain all equipment so it’s in good working order.
Flooding
Preventing flood and water damage to stock. Flash flooding can cause
substantial damage which may be avoided by carrying out some simple steps:
1. Keep stock off the floor.
2. Clean external drains of leaves, vegetation and other waste regularly.
3. Ensure that all internal drains are also cleaned regularly.
4. Check external guttering regularly – a few leaves blocking downpipes can cause
a lot of flooding.

Figure 8: Downpipes
Source: NZI Risk SolutionsTM

Security
Clearly establish facility boundaries:
1. Use separate areas for dispatching and receiving goods. Where possible, provide
physical barriers between these two areas.
2. Where possible, provide a separately fenced yard area that encloses the cold
store dispatching and receiving doors.

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3. Establish a policy that prohibits personal vehicles from being driven into the
shipping and receiving yard area.
4. Keep the gate to the exterior yard area locked at all times when the cold store is
closed.
5. Do not allow employee or visitor parking near cold store shipping and receiving
doors.
Worker safety
While this guide is specifically focused on the buildings and assets of a
business, it is impossible to ignore the fact that the modern cold store can be a
dangerous work environment. Common injuries for many cool store and cold
storage workers include those caused by slips, trips and falls.
Worker safety risk management procedures. Creating a safety culture for
those working within a cool store is important. Cool store workers are independent
people, often working without direct supervision as they go about their daily work
activities. Holding regular safety committee meetings and reviewing accidents or
‘near miss’ incidents are important activities to help embed safety as a business as
usual activity.
Forklifts: Train, evaluate and certify all operators to ensure they can operate
forklifts safely. ` Regularly maintain forklifts, including tyres. Before using a
forklift, examine it for hazardous conditions which would make it unsafe to
operate. Follow safe procedures for picking up, putting down and stacking loads.
Drive safely, never exceed speed limits and slowdown in congested areas or those
with slippery surfaces.
Materials storage. Employers need to make sure cold store workers follow a
set of best practice methods for the storage of materials to avoid these accidents,
including: stacking loads evenly and straight, placing heavier loads on lower or
middle shelves, removing one object at a time from shelves, and keeping aisles and
passageways clear and in good repair.
Good housekeeping. To help prevent slips and trips it is wise to eliminate
loose material, spilt liquids, unnecessary steps, and boxes from the floor and dark
areas with poor lighting. In addition, it’s important to use anti-slip floor tape.
Loading docks: Drive forklifts slowly on docks and dock plates. Secure dock
plates and check if the plate can safely support the load. Keep clear of dock edges
and never back up forklifts to the dock’s edge. Provide visual warnings near dock
edges. Prohibit ‘loading dock jumping’ by employees (jumping down off the loading
dock). Ensure that dock ladders and stairs meet Building Code safety
specifications.

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 Figure 9: Worker Safety
Source: NZI Risk SolutionsTM

Material storage
Shelving and racking systems. Shelving and racking systems should be
designed and maintained so they can withstand the effects of an earthquake. Items
stored above 1.2 metres high and weighing more than 5kg must be restrained in
order to prevent them from falling onto the ground or personnel working beneath.
Palletised goods. In frequently occupied areas, palletised goods should be
restrained to prevent them from creeping and/or falling from the racking system. In
order to reduce any toppling effect, the height of shrink wrapped pallets should not
exceed two times their base. Shrink wrapping should extend around the base of the
pallet so the goods and the pallet form one unit. Pallets should be in good condition
– broken pallets should be removed from service.
Hazardous substances. Extra care needs to be taken when shelving
hazardous substances. If incompatible hazardous substances fall from shelving in
an earthquake and their packaging is breached, chain reactions such as the release
of hazardous gases or sparks leading to a fire could occur.
In addition, keep extra supplies of hazardous substances in segregated
areas. Keep filled gas cylinders stored as close to the ground as possible, or securely
enclosed in a cage or similar that allows air to circulate through.
Heavy items stored below two metres in open shelving. Certain supplies of
stock, such as shrink-wrapped, canned or bottled goods, are heavy enough to cause
serious injuries or death if they fall off shelves onto workers or shoppers. Heavy or
solid items should not be stacked more than 1.2m high without restraint to prevent
causing injury during an earthquake. Heavy items must not be stored near
frequently occupied areas or near doors/exits to prevent blockage during an
earthquake.
Tips for preventing injuries to workers and product damage in pallet racking
include: Stack loads evenly and straight on shelves. Place heavier loads on lower or
middle shelves. Remove one object at a time from shelves. Keep aisles and
passageways clear and clean. Caution: Do not try to change or repair pallet racking

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yourself, including cutting, welding, modifying, rearranging or adding other
components. Replace damaged racks immediately using professional, experienced
contractors.

Figure 10: Material Storage

Source: NZI Risk SolutionsTM

Electrical safety
The need for electrical installation inspection and maintenance. All electrical
installations need regular maintenance. Switchboards wear and need replacement
as time progresses and demands on the installation change. Equally, network
system upgrades can affect fault-trip levels.
Storage and handling of environmentally hazardous substances
Keys to best practice handling and storage of hazardous substances:
1. Store all hazardous substances correctly.
2. Make sure that all hazardous substances are labelled correctly.
3. Segregate substances when required.
4. Use correct procedures when dispensing.
5. Isolate exposures with ventilators at source.
6. Make sure you use the right safety equipment.
7. Have emergency plans in place.
8. Always dispose of hazardous waste in accordance with the law.
Control measures:
The following control measures were taken from the Cold Storage Facilities by
SafeWork SA, 2016.
1. Reducing worker exposure to the cold, where possible – consider using upright
or deep freezers instead of walk-in cold rooms
2. Reducing the time workers are in cold rooms – restrict to the shortest time
period possible
3. For periods of more than about 10 minutes, ensuring clothing suits the
temperature and duration of activity and minimises skin exposure to the cold
(e.g. thermal/fleece jumper, gloves, hat etc.)
4. Ensuring walk-in cold rooms internal door opening mechanisms are in good
working order and are regularly maintained and tested
5. Ensuring walk-in cold rooms have emergency alarm buttons fitted and regularly
tested so that anyone trapped inside can send for help
6. Using slip-resistant floor surfaces to reduce slip hazards

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7. Maintaining good housekeeping practices when stacking and storing items to
remove trip hazards
8. Ensuring adequate lighting is provided for the tasks in the work space
9. Using a buddy system to provide an immediate support in the event of an
emergency and avoiding people working in isolation
10.Having emergency response procedures in place with appropriate training and
regular test drills
11.Having reliable communications systems in place that you test regularly
12.Assessing manual handling tasks and implementing systems to eliminate the
risk of injury
13.Providing appropriate personal protective equipment (PPE) to suit the working
conditions (e.g. footwear and clothing) and making sure workers wear it.
Mobile phones may not work within cold rooms. Do not rely on them as a
communications device unless they have been tested and regularly checked for the
location. Frozen batteries may also disable the device.
It is important to induct and train workers and supervisors so they
understand the hazards and risks of working in a cold environment, including the
adverse effects of exposure to cold. Thermal stress may increase fatigue and affect
an individual’s ability to work safely and without risk to their own safety of that of
others. Everyone should be trained in the workplace’s safe work policies,
procedures and practices, including emergency response. Training requirements
should also be reviewed and updated when new items of plant are introduced or
when personnel change. In workplaces where safe work procedures and worker
training and instruction are the primary risk control measures, a greater level of
supervision is required.
D. Maintenance Operations
One of the most important aspects of a cold room system for efficient cooling
is refrigeration. Including proper maintenance of compressors, fan coil units or
FCUs, the condenser and the evaporators, unlike any other equipment the overall
cold room refrigeration system should undergo daily, monthly, quarterly and
annual preventative maintenance checks (1Cold Ltd., 2014).
Daily
1. Check each compressor for any oil leakage
2. Check all Freon levels for each system
3. Check the evaporator for possible ice formation
4. Check if PLC switchboard functions properly
5. Check secondary system’s head pressure
6. Check proper cold room temperature
Monthly
1. Perform daily maintenance checks
2. Check system efficiency
a. Ensure that condenser coil fins are clean
b. Ensure that the evaporator and unit cooler fins are clean

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 c. Ensure reverse blowing is working properly
d. Ensure proper cooling in full load
e. Ensure refrigerant levels are well-maintained and working properly
f. Ensure that control valves are working properly.
g. Ensure defrosting functions are working properly
h. Ensure evaporators are working properly
3. Clean evaporator casing and blower fans
4. Calibrate cold room temperature
5. Perform a system functional test and check for any malfunctions
Quarterly
1. Perform monthly maintenance checks
2. Check overall functionality of cold rooms
Annually
1. Perform daily, monthly and quarterly checks accordingly
2. Perform chemical washing on heat exchanger, as needed
Cold stores are delivered by the constructer in working condition, verified by
commissioning tests, thermal scans and third-party accreditation. To enable the
intended design life to be achieved a well-considered programme of regular
inspection and preventive maintenance should be put in place. Two elements of a
cold store require maintenance: the refrigeration equipment and the insulated
envelope. Close attention should be paid to both of these elements. It is essential
not to neglect the insulated envelope, although in the short term this might appear
less important.
Owing to their size, cold stores of all three types are likely to store products
with a substantial total value. To minimize the risk of product loss, most cold
stores should have a duplicate refrigeration system, an emergency power supply
and a sophisticated temperature monitoring and alarm system, all of which also
need to be maintained.
Maintenance operations recommended by the World Health Organization (WHO),
2015 for cold storage facilities are the following:
a) Refrigerators and freezers. Keep clean by regularly washing with mild soapy
water solution. Check operation of thermostat and defrost system (if fitted).
Keep door seals clean, avoiding build-up of material between folds and at
corners. Remove build-up of ice (use the defrost system or a blunt scraper).
Keep drains free of debris. Check appliance level – give a small fall to the rear
(no more than 4 mm) to ensure door closure. Clean condenser coil (fins), ensure
fins and cooling fan and any grilles are free of dust, fluff and debris.
In the case of absorption refrigeration systems, which are fully sealed
and under relatively high pressure, repairs can only be made to the heater and
thermostat, although inverting the entire refrigerator for a few hours can
sometimes bring an apparently dead unit back to life.

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b) Maintaining the cooling system. Cooling systems require regular maintenance.
It is therefore necessary to check that the secondary system cuts in when the
temperature exceeds the allowable maximum. The operating methodology
and/or the control system should be designed so that the two refrigeration
systems run alternately; this ensures that a problem with either system is
quickly identified. The maintenance programme should also include checking
the response of the system to temperatures below the allowable minimum. In
particular there should be an independent cut-off mechanism to prevent low
temperature excursions.
c) Maintaining insulated panels and vapour control sealing. Maintenance
programmes usually concentrate on the cooling equipment and the insulated
envelope is frequently neglected. Responsibility for the upkeep and the
maintenance of the insulated envelope and vapour sealed panel joints should be
given to a nominated person who has a clearly defined role to ensure that this
work is carried out. There should be a comprehensive standard operating
procedure (SOP) describing the appropriate maintenance and corrective work.
Cold store insulated envelopes are constructed from preformed insulated
sandwich panels; typically corrosion-protected metal sheets with a core of
foamed insulation. The insulated panels require a vapour control membrane to
resist the infiltration of atmospheric water vapour into the insulation core. An
impermeable barrier to prevent this happening is essential and can be likened
to the hull of a ship. An ineffective vapour barrier will allow water vapour to
penetrate, condense and freeze within the insulating core material or on the
internal surfaces of the panels. This degrades the surfaces and leads to a loss of
insulating effectiveness, panel delamination and possible structural collapse.
d) Condensation control outside the cold store enclosure. Condensation on the
structure and in the roof voids of the building enclosing a cold store is a
recurring problem. Condensation occurs when air saturated with water vapour
comes into contact with cold surfaces. The amount of water vapour which air
can support is a function of the air temperature. As the temperature increases,
the air can contain a greater and greater amount of water vapour per unit
volume.
To avoid condensation, it is necessary to ventilate voids with ambient air.
Effective ventilation ensures that the dew point in the void is identical to the
dew point of the external ambient air.
e) Frost-heave control. Frost heave occurs when water in the subsoil beneath a
continuously running freezer room freezes over time. This can occur even if the
floor is insulated and the resulting expansion of the subsoil can fracture and lift
the floor slab. Frost heave is typically prevented by installing a heater mat
under the freezer room floor. Ideally the mat should also extend below narrow
perimeter voids outside the freezer room enclosure.
f) Cold store panel insulation. The recommended insulation thickness for panels
with a polystyrene core is 200 mm. Polyurethane insulation is more efficient

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 and core panels can be thinner; typically 100 to 170 mm for freezer rooms, and
100 mm for cold rooms and controlled ambient stores. A correctly specified
panel insulation thickness should prevent the insulation surface temperature
from falling more than 2 °C below the external air temperature, hence avoiding
the dew point and resulting condensation.
g) Insulation for refrigeration pipes and other penetrations. To prevent
condensation under all conditions, refrigeration pipework, electrical cables and
other penetrations should be enclosed with an insulation sleeve 50–75 mm
thick. These sleeves must extend for a sufficient distance beyond the cold store
panel to prevent the surrounding air from cooling below the dew point. They
should also be enclosed in a vapour-proof membrane to prevent condensation
occurring within the insulation itself. In addition, good ventilation needs to be
maintained over the surface of the sleeves.
h) Refrigerated containers. Checks that should be made by the cargo owner are as
follows:
a. check to ensure the inside of the container is clean and free of debris;
b. visual check on skin integrity covering insulation;
c. check on integrity of door seals and locking mechanism;
d. check on drains;
e. check on fresh air setting;
f. check on temperature setting.

E. Troubleshooting Operations
Keeping the cold storage structure and cooling system in optimum condition
will help with ensuring high quality product and meet processor and retail demand
over longer periods. Some issues can be resolved using storage techniques,
however some will need to be addressed by a qualified contractor (Warbick, J.,
2017).
Table 1: Troubleshooting for Cold Storage
Problem: Some product are freezing

Possible causes are: Possible solutions are:

Thermostat is set too cold, its Adjust the thermostat to a higher

differential is too wide or the location temperature. Decrease the temperature
of the thermostat (or its sensor) is differential (on-off). Relocate the thermostat
poor. (or its sensor) or replace the thermostat.

Product is stacked too high and is Avoid stacking product too close to the air
directly in the airstream from the coils. stream from the coils. Install baffles under
the coils to deflect cold air above the
product.

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Product is touching or is too close to Re-insulate, especially on concrete
freezing walls (in winter or if next to a foundations and keep product away from
freezer). cold walls.

Evaporator coils are dirty or have one Clean evaporator coils or repair fans.
or more fans not functioning, causing
the leaving air temperature to be
colder.

One coil may not be functioning Have a technician check coils and valves for
properly (with multiple coils) causing proper refrigerant flow, operating pressure
the leaving air temperature from others and temperatures (superheat settings).
coils to be colder.

Poor air flow. Use a smoke generator to find dead air

spots. Relocate coils or increase their fan
capacity. Install air tubes and/or extra
circulation fans. Lay out containers to
promote good air distribution.

Problem: Some products are shrivelling

Possible causes are: Possible solutions are:

Storage relative humidity Clean evaporator coils (if dirty). Replace non-functional
is too low. fans.
Check the defrost frequency (duration and termination)
as it may be adding excessive heat to the room or
allowing excessive frosting between cycles.
Have a contractor check the system and coils for efficient
operation and proper operating temperatures. Adjust
superheat settings on expansion valves.
Have a contractor check system sizing (compressor vs.
evaporator coil sizing and temperature difference at
actual design conditions).
Increase coil size or install more coils so they can operate
at a lower temperature difference between "cold" air
leaving the coils and air that the product "feels." This
reduces air dehumidification.
Install humidification equipment that can supply ultra-
fine or atomized mist (it's hard to put water back into
desiccated product).
Product is warm and Remove field heat more rapidly and promptly after
moist while cold air is dry harvest so there is less vapour pressure difference
and pulls moisture out. between the product and storage air. Thus less incentive
Vapour pressure for moisture to leave the product and cause desiccation.
differential too high.

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Wooden containers and Wet the wooden containers before putting in long term
the storage structure storage. Tests show that wooden bins can increase 10%
itself is drawing moisture in weight by absorbing moisture.
out of the air and
product.
Products such as pome See possible solutions under freezing. Pome fruit that has
fruit appear wrinkled been slightly frozen does not shrivel from moisture loss
when slightly frozen. and
Problem: Some products are sweating or has free water on it

Possible causes are: Possible solutions are:

Warm, moist air is Reduce infiltration of warm air by minimizing door
entering the room opening time, installing a strip curtain (or air curtain),
through door openings or preventing wind pressure and/or cooling of the adjacent
air leaks in the room. area.
Warm, moist air from Keep "cold" product being stored for longer periods in a
recently placed product is separate room from "hot" product being cooled. Install
hitting cold product. more refrigeration to reduce dramatic air temperature
increases.
Warm, moist air is Allow product to warm up gradually; condensation is
condensing on the cold unavoidable if product is put directly into a warm, moist
product after the product atmosphere or add air conditioning for the packaging
has been removed from area.
storage.
Defrost duration may be Check the defrost frequency, duration and termination to
too long and/or prevent excessive heat being added to room.
termination may not be
working, allowing room
temperature to rise too
high.
Defrost water from Drain condensate away or onto the floor if possible to
evaporator coils is help humidify the storage.
dripping on produce
Humidification system Install humidification equipment that can supply ultra-
droplets are too large or fine or atomized mist or adjust, calibrate or replace the
humidistat is set too high humidistat.
or is out of calibration.

Problem: Product is displaying premature ripening, discolouring, and loss of

leaves (plants)

Possible causes are: Possible solutions are:

178
Ethylene gas may be Remove high ethylene producing fruits in the storage area
present. (e.g., apples, pears, cantaloupes, plums, peaches,
apricots, muskmelons, tomatoes). Avoid using forklifts
that emit ethylene in the exhaust. Thoroughly ventilate
storage rooms before use. Also ventilate during use
provided there is adequate refrigeration to handle the
extra load from the ventilation.
Storage temperature may Lower the storage temperature. Add more refrigeration, if
be too high. inadequate.
Defrost cycles are too Check defrost for correct frequency, duration and
long and/or adding too termination.
much heat to the room.
Product is stacked too Leave space between rows and layers of product and
tight, preventing it from stack in a manner that allows good airflow through it.
cooling.

Problem: Product has odours or off-flavours

Possible causes are: Possible solutions are:

Products nearby that Remove crops such as cabbage, rutabagas, celery,
readily transfer odours potatoes, onions, lettuce or garlic.
and/or off-flavours.

Problem: Product is rotting

Possible causes are: Possible solutions are:

Product is too warm and Provide quick and uniform rapid cooling after harvest.
is respiring and aging Maintain the recommended temperature during the
rapidly. storage period.
Product damaged, Increase culling rates before storage. Do not expect
overripe or of poor quality storage to turn poor quality product into a top quality
before storage. product with a long shelf life.
Building Related Issues
Problem: Walls and/or ceiling are condensing or mouldy

Possible causes are: Possible solutions are:

Interior surfaces are Install more insulation to warm up wall surfaces above
colder than the room air the room air's dew point (condensation). Tighten up the
hitting it. Surface building and provide better airflow in these areas.
temperatures and
moisture level are ideal

179
for mould growth.

Excessive moisture or Reduce infiltration of warm air by minimizing door

warm moist air is opening time, installing a strip curtain (or air curtain),
entering the room. preventing wind pressure and/or cooling the adjacent
area.
Insulation in ceiling or Remove wet insulation. Allow surfaces to dry out and
walls is saturated. replace insulation with adequate spray foam insulation.
Problem: Walls and/or ceiling are rotting

Possible causes are: Possible solutions are:

Moisture migrating into Before reconstruction, determine why and how to prevent
wood cladding/structure. moisture from migrating in again
Improper installation of Determine appropriate vapour barrier location, if needed.
or missing vapour barrier.
Incorrect type of Re-insulate if needed, possibly with different insulation.
insulation used or
inadequate insulation
value installed.
Water leaking in from roof Repair roof or other source of water leak and dry out or
or other sources. replace wet insulation etc.
Problem: Ceiling is dripping

Possible causes are: Possible solutions are:

Poor attic ventilation Provide 1 m2 of unrestricted eave inlet vent area per 600
allowing a buildup of hot, m2 of ceiling, with same unrestricted peak vent area, or
moist air in the attic. mechanically ventilate at 1 air change/2 minutes.
Insufficient attic Remove wet insulation. Allow surfaces to dry out and
insulation causing replace insulation with adequate spray foam insulation
condensation which drips
through the cracks.
Improper installation of Add enough insulation to prevent its temperature on the
or missing vapour barrier. warm side from cooling to the dew point (condensation) of
the warm air in the attic. Vapour barrier location depends
on vapour pressure drive direction (warm side). A vapour
barrier may not be advisable depending on building use.

Problem: Floor is drying out even when floor is sprayed with water

Possible causes are: Possible solutions are:

180
Storage relative humidity Install more coils so they can operate at a lower
is too low. temperature difference between "cold" air leaving the coils
and air that the product "feels." This reduces air
dehumidification. Install humidification equipment that
can supply ultra-fine or atomized mist, it is hard to put
water back into desiccated product.
Floors have cracks for Flood floors to see if water runs away, especially along
water to escape. concrete foundation. Seal if necessary.

Problem: Inside air temperature fluctuates during storage period

Possible causes are: Possible solutions are:

Thermostat not located Install thermostats in average room airflow, usually in
properly and does not the return airflow to evaporator coils. Relocate
sense average room thermostats away from warm/cold walls, doors, lights,
temperature. cold air leaving the coils or hot product.
Poor quality or insensitive Recalibrate thermostat including differential or replace
thermostats (differential thermostat. Use good equipment since uniform
too wide). temperature control is vital for maintaining product
quality.
Defrost cycles are not set Check defrost for correct frequency, duration and
or working correctly, termination.
allowing excessive
frosting between cycles or
adding too much heat to
room.
Airflow not uniform Use a smoke generator to determine location of dead air
throughout storage. spots. Relocate evaporator coils or increase the capacity
of their fans (if possible). Install air tubes and/or extra
fans. Rearrange storage containers to allow for more
uniform airflow.

Problem: Inside air temperature is warmer than desired during storage period

Possible causes are: Possible solutions are:

Inadequate refrigeration. Install more refrigeration cooling capacity.

Insufficient insulation for Install minimum R-20 in walls, R-24 in attic and R-12 on
summer use. the foundation. Floors are seldom insulated in Ontario,
but for year-round use the cost can be justified.
Poor attic ventilation. Provide 1 m2 of unrestricted eave vent inlet area per 600
m2 of ceiling, with same unrestricted peak vent area, or
mechanically ventilate at 1 air change/2 minutes.

181
Hot sunny days with a Paint roof chalk white and provide adequate attic
dark roof surface. ventilation, since attic temperatures can reach 60°C if the
roof is a dark colour.
Airflow not uniform or of Use smoke generators to determine the location of dead
insufficient capacity in air spots. Relocate evaporator coils or increase the
storage. capacity of their fans (if possible). Install air tubes and/or
extra fans. Rearrange storage containers to allow more
uniform airflow.
Poor thermostat location Install thermostats in average room airflow, usually in
that senses cold return airflow to evaporator coils. Avoid locating
temperatures. thermostats on outside cold walls, near doors or near the
cold air leaving evaporator coils.

Problem: Inside air temperature is colder than desired during the storage period

Possible causes are: Possible solutions are:

Thermostat poorly located Install thermostats in average room airflow, usually in
and senses warmer return airflow to evaporator coils; avoid location
temperatures. thermostats on outside warm walls or near doors or
lights.
Insufficient insulation for Install minimum R-20 in walls, R-24 in attic and R-12 on
winter use. foundation. Floors are seldom insulated in Ontario, but
for year-round use, the cost can be justified.

Problem: Inside air temperature is not uniform

Possible causes are: Possible solutions are:

Airflow is not uniform or Use smoke generators to determine the location of dead
is insufficient for product air spots. Relocate evaporator coils or increase the
capacity in storage. capacity of their fans (if possible). Install air tubes and/or
extra fans. Rearrange storage containers to allow more
uniform airflow.
Short-circuiting of air Avoid alleys/openings that allow air to by-pass product or
directly back to the storage containers. Air will always take the easiest path
evaporator coils because and air must be forced to travel a meandering path to
of poor storage container maximize cooling potential. Use a smoke generator to
arrangement. inspect for short-circuiting.

Problem: The storage air smells bad or is difficult to breathe

Possible causes are: Possible solutions are:

182
Gases such as carbon Look for and dispose of decaying product. Install a small
dioxide or ethylene may exhaust fan that provides ventilation of 1 or 2 air
be present in excessive changes/day. Some newer storages (not built as
quantities as a result of Controlled Atmosphere storages) are very tight so there is
decay or respiration. no natural air-change ventilation.

Problem: Evaporator coils are icing up and run a lot of condensate

Possible causes are: Possible solutions are:

Coils running at too low a Clean coils and ensure that all fans are blowing in the
temperature correct direction.
Increase coil temperature. This may require larger
capacity evaporator coils.
Defrost system not Repair defrost system or install a more effective one,
running properly. since the relative humidity should be high for most crops.
Storage relative humidity Some crops such as onions, garlic or squash require
is high. lower humidities.

Problem: Electrical consumption is rising

Possible causes are: Possible solutions are:

Insulation is wet or Correct moisture problem and re-insulate with an
missing. insulation that is more suitable for cold storages.

Higher volume of product Install more refrigeration as crop production rises.

being cooled than before. Properly size the system to reduce costs.
Product is entering Earlier varieties and variable weather may mean
storage hotter than in harvested product is warmer, requiring more refrigeration
previous seasons. capacity than before.
Building less tight or Re-tighten the building since they do become less tight
doors open more often. over time. Install flaps over access doors.
Dirty evaporator coils or Clean evaporator and condenser coils.
condenser coils (on
outdoor units).
Malfunctioning Get equipment serviced by a qualified refrigeration
refrigeration equipment. contractor familiar with the needs of farm produce.

The following table was taken from Service Manual by the Haier Medical and
Laboratory Products Co., Ltd.
Table 2: Troubleshooting Procedures for Haier Cold/Freezer Rooms Only

183
 Troubles Possible Cause Corrective Action
Compressor 1. Power failure 1. Contact power company
fails to 2. Disconnect switch open 2. Close switch and check
start(no hum) 3. Burned-out compressor motor circuits
4. Control circuit open 3. Replace
a. Overload protector tripped 4. Locate cause and repair
b. Thermostat setting too high a. Check overload
c. Low-pressure control open b. Set to lower temperature
d. High-pressure control open c. Reset and check pressures
e. Loose wiring d. Reset and check pressures
5. Repair wiring
Compressor 1. Improperly wired 1. Rewire unit
will not start 2. Low voltage to unit 2.Determine reason and correct
(hums and 3. Burned-out compressor motor 3.Replace compressor motor
trips overload 4. Mechanical problems in 4. Replace compressor
protector) compressor 5.Install crankcase heater
5. Liquid refrigerant in
compressor crankcase
Compressor 1. Defective overload protector 1. Replace overload protector
starts and 2. Low voltage to unit 2. Determine reason and correct
runs, but 3. Defective run capacitor 3. Determine reason and replace
short cycles 4. High discharge pressure 4. Open compressor discharge
5. Suction pressure too low service valve. Purge possible
6. Suction pressure too high overcharge of refrigerant. Provide
7. Compressor too hot sufficient condenser cooling air to
8. Shorted motor winding unit
9. Dirty or iced evaporator 5. Properly charge system with
10. Low-pressure control refrigerant. Increase load on
differential set too close evaporator.
11. High pressure control 6. Reduce air flow over
differential set too close evaporator. Purge overcharge of
12. Erratic thermostat refrigerant. Replace compressor
valves
7. Properly charge system with
refrigerant.
8. Replace compressor
9. Increase air flow over
evaporator. Replace broken belt.
Replace defective fan motor.
10. Readjust differential.
11. Readjust or replace control
12. Relocate or replace
thermostat
Unit operates 1. Short of refrigerant 1. Repair leak and recharge unit
excessively 2. Thermostat contacts stuck 2. Clean contacts or replace
closed thermostat.
3. Excessive load 3. Check heaters, load and
4. Evaporator coil iced replace unit accordingly; replace
5. Restriction in refrigerant insulation
system 4. Defrost unit and check

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 6. Dirty condenser operation
7. Restricted air over evaporator 5. Locate and remove
8. Inefficient compressor 6. Clean condenser
7. Determine cause and correct
8. Check compressor valves and
repair
Compressor 1. Traps in hot gas and/or 1. Reroute lines to provide proper
loses oil suction lines pitch
2. Refrigerant velocity too low in 2. Resize risers or install oil
risers return traps
3. Shortage of refrigerant 3. Repair leak and recharge
4. Liquid refrigerant flooding 4. Adjust expansion valve; alter
back to compressor refrigerant charge on capillary
5. Gas-oil ratio low tube system
6. Plugged expansion valve or 5. Add 1 pt of oil for each 10 1b
strainer of refrigerant added to the factory
7. Compressor short cycling charge
8. Superheat too high at 6. Clean or replace
compressor suction 8. Change location of TXV bulb or
adjust superheat to return wet
refrigerant to the compressor
Compressor 1. Lack of compressor oil 1. Add oil to correct level
noisy 2. Tubing rattle 2. Reroute tubing
3. Mounting loose 3. Repair mounting
4. Oil slugging 4. Adjust oil level or refrigerant
5. Refrigerant flooding charge
compressor 5. Check expansion valve for leak
6. Dry or scored shaft seal or oversized orifice
7. Internal parts of compressor 6. Check oil level
broken or worn 7. Overhaul compressor
8. Compressor drive coupling 8. Tighten coupling and check
loose alignment
Unit low on 1. Ice or dirt on evaporator 1. Clean coil or defrost
capacity 2. Expansion valve stuck or dirty 2. Clean or replace expansion
3. Improper TXV superheat valve
adjustment 3. Adjust expansion valve
4. Wrong size expansion valve 4. Replace valve
5. Excessive pressure drop in 5. Adjust expansion valve
evaporator 6. Clean or replace strainer.
6. Clogged strainer 7.Subcool liquid or add
7. Liquid flashing in liquid line refrigerant
Space 1. Control setting too high 1. Adjust control
temperature 2. Expansion valve too small 2. Replace valve
too high 3. Evaporator too small 3. Replace coil
4. Insufficient air circulation 4. Correct circulation
5. Shortage of refrigerant 5. Repair leak and recharge
6. Expansion valve plugged 6. Clean or replace
7. Inefficient compressor 7. Check efficiency
8. Restricted or undersized 8. Clear restriction or resize lines
refrigerant Lines 9. Clean and defrost evaporator

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 9. Evaporator iced or dirty
Suction line 1. Superheat setting too low 1. Adjust superheat setting
frosted or 2. Expansion valve stuck open 2. Clean or replace valve
sweating 3. Evaporator fan not running 3. Correct problem
4. Overcharge of refrigerant 4. Correct charge
Liquid line 1. Restricted drier or strainer 1. Replace drier or strainer
frosted or 2. Liquid line shut-off valve 2. Open valve
sweating Partially closed
Hot liquid 1. Expansion valve open too 1. Adjust expansion valve
line wide 2. Repair leak and recharge
2. Refrigerant shortage
Top of 1. Refrigerant shortage 1. Repair leak and recharge
condenser 2. Refrigerant overcharge 2. Remove part of charge
Coils cool 3. Inefficient compressor 3. Check efficiency and correct
when unit is
operating
Unit in 1. Ice plugging expansion valve 1. Apply hot wet cloth to
vacuum-frost orifice expansion valve body; an
on expansion 2. Expansion valve strainer increase in suction pressure
valve only plugged indicates moisture; install a new
drier
2. Clean strainer or replace valve
High head 1. Overcharge of refrigerant 1. Purge overcharge
pressure 2. Air in system 2. Purge air
3. Dirty condenser 3. Clean condenser
4. Unit in too hot location 4. Relocate unit
5. Water-cooled condenser 5. Clean or replace condense
plugged
Low head 1. Shortage of refrigerant 1. Repair leak and recharge
pressure 2. Cold unit location 2. Provide warm condenser air
3. Inefficient compressor valves 3. Replace leaky valves
4. Leaky oil return valve in oil 4. Repair or replace
separator
High suction 1. Evaporator overloaded 1. See previous entry ″Unit
pressure 2. Expansion valve stuck open operates excessively”
3. Expansion valve too large 2. Repair or replace valve
4. Leaking compressor suction 3. Replace valve
valves 4. Replace suction valves or
5. Evaporator too large compressor
5. Resize evaporator
Low suction 1. Shortage of refrigerant 1. Repair leak and recharge
pressure 2. Evaporator under loaded 2. Clean or defrost evaporator
3. Liquid line strainer clogged 3. Clean or replace strainer
4. Plugged expansion valve 4. Clean or replace valve
5. Last charge on TXV power 5. Replace power assembly
assembly 6. Adjust or replace thermostat
6. Space temperature too low 7. Replace valve
7. Expansion valve too small 8. Check for plugged external
8. Excessive pressure drop equalizer

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 through Evaporator 9. Resize compressor
9. Oversized compressor
Evaporator 1. Automatic defrost control 1. Replace control
coil iced over erratic or inoperative 2. Rewire control
2. Automatic defrost control 3. Replace control
improperly wired 4. Relocate element
3. Defective defrost control 5. Replace or adjust control
thermal element
4. Improperly installed control
thermal element
5. Defrost control termination
point too low
Cold room 1. Defrost control incorrectly 1. Rewire defrost control
remains in wired 2. Replace defrost control
defrost cycle 2. Automatic defrost control 3. Replace or adjust control
inoperative 4. Clean or replace solenoid valve
3. Defrost control termination 5. Relocate unit or provide heat
point too high
4. Defrost solenoid valve stuck
open
5. Room temperature too
low(below 55°F or 12.8°C)
Water 1. Drain tube plugged 1. Clean tube
collects in 2. Drain tube frozen 2. Check drain heater element
bottom of 3. Split drain trough and repair or replace
EMC cooler 4. Evaporator baffle not properly 3. Replace trough
installed 4. Install baffle properly
5. Humid plate not adjusted 5. Adjust humid plate
properly 6. Adjust door or replace gasket
6. Door gasket not sealing
properly
The following table was taken from System Trouble Shooting Fault Location by
Danfoss, 2002.
Table 3: System Trouble Shooting Fault Location for Refrigeration and Air
Conditioning

Symptom Possible cause Action

Condensing a) Air or other non- a) Purge the condenser by using
pressure too condensable gases in reclaim system, start and run
high. Air- refrigerant system. system until it reaches running
and water- b) Condenser surface too temperature. Purge again if
cooled small. necessary.
condensers. c) Refrigerant system charge b) Replace condenser with larger
too large (liquid collection in size.
condenser). c) Recover refrigerant until
d) Condensing pressure condensing pressure is normal.
regulation set for too high a The sight glass must remain full.
pressure. d) Set for the correct pressure.
Condensing a) Dirt on condenser surface. a) Clean condenser.

187
pressure too b) Fan motor or blade defective b) Replace motor or fan blade or
high. Air- or too small. both.
cooled c) Air flow to condenser c) Remove air inlet obstruction or
condensers. restricted. move condenser.
d) Ambient temperature too d) Create fresh air inlet or move
high. condenser. Change rotation of fan
e) Incorrect air flow direction motor. On condensing units, air
through condenser. must flow through condenser and
f) Short-circuit between then to compressor.
condenser fan airside pressure f) Install a suitable duct, possibly
and suction sides. to outdoor air.
Condensing a) Cooling water temperature a) Ensure lower water temperature.
pressure too too high. b) Increase water quantity,
high. Water- b) Water quantity too small. possibly using automatic water
cooled c) Deposits on inside of water valve.
condensers. pipes (scale etc). c) Clean out condenser water
d) Cooling water pump tubes, possibly by deacidification
defective or stopped. d) Investigate cause, replace or
repair cooling water pump if fitted.
Condensing a) Condenser surface too large. a) Establish condensing pressure
pressure too b) Low load on evaporator. regulation or replace condenser.
low. Air- and c) Suction pressure too low, b) Establish condensing pressure
water- cooled e.g. insufficient liquid in regulation.
condensers. evaporator. c) Locate fault on line between
d) Compressor suction and condenser and thermostatic
discharge valves might be expansion valve (see "Suction
leaking. pressure too low").
e) Condensing pressure d) Replace compressor valve plate.
regulator set for too low a e) Set condensing pressure
pressure. regulator for correct pressure.
f) Un-insulated receiver placed f) Move receiver or fit it with
too cold in relation to suitable insulating cover.
condenser (receiver acts as
condenser).
Condensing a) Temperature of cooled air a) Establish condensing pressure
pressure too too low. regulation.
low. Air- b) Air quantity for condenser b) Replace fan with smaller unit or
cooled too large. establish motor speed regulation.
condensers.
Condensing a) Water quantity too large. a) Install WVFX automatic water
pressure too b) Water temperature too low. valve or set existing valve.
low. Water- b) Reduce water quantity by using
cooled a WVFX automatic water valve, for
condensers. example.
Condensing a) Differential on start/stop a) Set differential on lower value or
pressure pressure control for condenser use valve regulation (KVD + KVR)
hunts fan too large. It can cause or use fan motor speed regulation.
vapour formation in liquid line b) Set thermostatic expansion valve
for some time after start of for higher superheat or replace

188
 condenser fan because of orifice with smaller size.
refrigerant collection in c) Replace valves with smaller size.
condenser.
b) Thermostatic expansion
valve hunting.
c) Fault in KVR/KVD
condensing pressure
regulating valves (orifice too
large).
d) Consequence of hunting
suction pressure.
Discharge a) Suction pressure too low a) Locate fault on line from receiver
line because of: to suction line.
temperature 1) Insufficient liquid in Replace compressor valve plate.
too high. evaporator. Omit heat exchange or possibly
2) Low evaporator load. select smaller heat exchanger.
3) Leaking suction or
discharge valves.
4) Superheat too high in heat
exchanger or suction
accumulator in suction line.
b) Condensing pressure too
high
Discharge a) Liquid flow to compressor
line (thermal valve superheat
temperature setting too low or bulb location
too low. incorrect).
b) Condensing pressure too
low
Liquid level a) Insufficient refrigerant in a) Investigate cause (leakage,
in receiver system. overcharge in evaporator), repair
too low. b) Evaporator overcharged. fault and charge system if
1) Low load, leading to necessary.
refrigerant collection in c) Place receiver together with
evaporator. condenser. Air-cooled condensers:
2) Thermostatic expansion Establish condensing pressure
valve fault (e.g. superheat regulation by fan motor speed
setting too low, bulb location regulation, e.g. type VLT.
wrong).
c) Refrigerant collection in
condenser because condensing
pressure lower
than receiver pressure
(receiver placed warmer than
condenser)
Liquid level Refrigerant charge in system Recover a suitable quantity of
in receiver too large refrigerant, but condensing
too high. pressure must remain normal and
Refrigeration the sight glass free of vapour.
output

189
normal
Liquid level a) Partial blockage of a Find the component and clean or
in receiver component in liquid line. replace it.
too high. b) Thermostatic expansion
Refrigeration valve fault (e.g. superheat too
output too high, orifice too small, lost
low (possible charge, and partial blockage).
compressor
cycling)
Filter drier a) Partial blocking of dirt a) Check whether there are
cold, dew or strainer in filter drier. impurities in the system, clean out
frosting b) Filter drier completely or where necessary, replace filter
possible. partly saturated with water or drier.
acid. b) Check whether there is moisture
or acid in the system, clean out
where necessary and replace filter
drier (burn-out filter) several times
if necessary. If acid contamination
is severe, replace refrigerant and
oil charge, install DCR filter drier
with interchangeable core in
suction line.
Moisture Moisture in system. Check system for leakage. Repair if
indicator necessary. Check system for acid.
discoloured. Replace filter drier, several times if
Yellow. necessary. In severe cases it can be
necessary to change refrigerant
and oil.
Brown or Impurities, i.e. small particles Clean out system if necessary.
black. in system. Replace SGI sight glass and filter
drier.
Vapour a) Insufficient liquid sub 1) Replace liquid line with tube of
bubbles in cooling from large pressure suitable diameter.
sight glass drop in liquid line because: 2) Replace liquid line with tube of
ahead of 1) Liquid line too long in suitable diameter.
thermostatic relation to diameter. 3) Replace sharp bends and
expansion 2) Liquid line diameter too components causing too large a
valve. small. pressure drop.
3) Sharp bends, etc. in liquid 4) Check for impurities, clean out if
line. necessary, replace filter drier.
4) Partial blockage of filter b) Reduce ambient temperature or
drier. install heat exchanger between
5) Solenoid valve defect. liquid and suction lines or insulate
b) Insufficient liquid sub liquid line, possibly together with
cooling because of heat suction line.
penetration of liquid line, c) Swap over cooling water inlet
possibly from high and outlet.
temperature around liquid (Water and refrigerant flow must
line. be opposite).

190
 c) Water-cooled condensers: e) Replace valve or open it fully.
Insufficient sub cooling f) Install heat exchanger between
because of wrong cooling water liquid and suction lines ahead of
flow direction. rise in liquid line.
d) Condensing pressure too g) Replace or reset KVR regulator
low. at correct value.
e) Receiver stop valve too small h) If necessary, replace regulation
or not fully open. with
f) Hydrostatic pressure drop in condensing pressure regulation via
liquid line too high (height valves
difference between (KVD + KVR) or with fan motor
thermostatic expansion valve speed regulation, type VLT.
and receiver too large). i) Recharge system, but first make
g) Badly or incorrectly set sure that none of the faults named
condensing pressure under a), b), c), d), e), f), g), h) are
regulation causing liquid present, otherwise there is a risk of
collection in condenser. the system becoming overcharged.
h) Condenser pressure
regulation by start/ stop of
condenser fan can cause
vapour in liquid line for some
time after fan start.
i) Insufficient liquid in system.
Air coolers. a) Lack of or poor defrost a) Install defrost system or adjust
Evaporator procedure. defrost procedure.
blocked by b) Air humidity in cold room 1) Recommend packaging of items
frost. too high because of moisture or adjust defrost procedure.
load from: 2) Repair fissures. Recommend
1) Unpackaged items. that door be kept closed.
2) Air ingress into room
through fissures or open door.
Air coolers. Refrigerant supply to
Evaporator evaporator too small because
frosted only of:
on line near a) Thermostatic expansion
thermostatic valve defect, e.g.
expansion 1) Orifice too small.
valve, severe 2) Superheat too high.
frost on 3) Partial loss of bulb charge.
thermostatic 4) Dirt strainer partly blocked.
expansion 5) Orifice partly blocked by ice.
valve. b) Fault as described under
"Vapour bubbles in sight
glass".
Air coolers. Fins deformed. Straighten fins using a fin comb.
Evaporator
damaged.
Air humidity a) Evaporator surface too large. a) Replace evaporator with smaller
in cold room Causes operation at excessive size.
too high, evaporating temperature b) Establish humidity regulation

191
room during short running periods. with hygrometer, heating elements
temperature b) Load on room too low, e.g. and KP62 safety thermostat.
normal. during winter (insufficient
dehumidification because of
short total running time per 24
hours).
Air humidity a) Cold room poorly insulated. a) Recommend improved
in room too b) High internal energy insulation.
low. consumption, e.g. lights and b) Recommend less internal energy
fans. consumption.
c) Evaporator surface too c) Replace evaporator with larger
small, causes long running size
times at mainly low
evaporating temperatures.
Air a) Room thermostat defect. 1) Recommend placing of smaller
temperature b) Compressor capacity too load or increased system capacity.
in cold room small. 2) Recommend reduction of energy
too high. c) Load on room too high consumption or increased system
because of: consumption.
1) Loading of non-cooled items. 3) Recommend better insulation.
2) High energy consumption, 4) Recommend repair of fissures
e.g. for lights and fans. and least possible door opening.
3) Cold room poorly insulated. Replace evaporator with larger size.
4) High air ingress. f) Set evaporating pressure
d) Evaporator too small. regulator at correct value. Use a
e) Insufficient or no refrigerant pressure gauge.
supply to evaporator. g) Set low-pressure control at
f) Evaporating pressure correct cut-out pressure. Use a
regulator set for too high pressure gauge.
evaporating pressure. h) Set capacity regulating valve at
g) Cut-out pressure on low- lower opening pressure.
pressure control set too high. i) Set valve for higher opening
h) Capacity regulating valve pressure if the compressor will
opens at too high evaporating withstand it.
pressure.
i) Opening pressure of
crankcase pressure regulator
set too low.
Air a) Room thermostat defect: b) If absolutely necessary,
temperature 1) Cut-out temperature set too establish thermostat controlled
in cold room low. electrical heating
too low 2) Bulb location wrong.
b) Ambient temperature very
low.
Suction a) Compressor too small. a) Replace compressor with larger
pressure too b) One or more compressor size. b) Replace valve plate.
high. disc valves leaking. c) Replace, repair or adjust
c) Capacity regulation defective capacity regulation.
or incorrectly set. d) Recommend less load or replace
d) System load too high. compressor with larger size, or

192
 e) Hot gas defrost valve install KVL crankcase pressure
leaking. regulator.
e) Replace valve.
Suction a) Thermostatic expansion b) Replace orifice with smaller size.
pressure too valve superheat setting too low c) Replace HE heat exchanger
high and or bulb located incorrectly.
suction gas b) Thermostatic expansion
temperature valve orifice too large.
too low c) Leaking liquid line in heat
exchanger between liquid and
suction lines.
Suction Low-pressure control set Adjust or replace low-pressure
pressure too incorrectly, or defective. control KP 1 or combined pressure
low, constant control KP 15.
running.
Suction a) Low system load. a) Establish capacity regulation or
pressure too b) Insufficient refrigerant in increase low pressure control
low, normal evaporator, because of: differential.
operation or 1) Insufficient refrigerant in c) Replace with larger evaporator.
compressor receiver. d) Replace or repair fan.
cycling. 2) Liquid line too long. e) If necessary, replace evaporator
3) Liquid line too small. and/or suction line.
4) Sharp bends, etc. in liquid f) Establish a defrost system or
line. adjust defrost procedure.
5) Filter drier partly blocked. g) Increase brine concentration and
6) Solenoid valve sticks. check frost protection equipment.
7) Inadequate liquid sub h) Check cause and correct fault.
cooling.
8) Fault at thermal valve.
c) Evaporator too small.
d) Evaporator fan defective.
e) Pressure drop in evaporator
and/or suction line too large.
f) Lack of or inadequate
defrosting of air cooler.
g) Freezing in brine cooler.
h) Insufficient air or brine
through cooler
i) Oil collection in evaporator.
Suction a) Thermostatic expansion 1) Replace KVC capacity regulating
pressure valve super- heat too low valve with smaller size.
hunts. b) Thermostatic expansion 2) Set for greater difference
Thermostatic valve orifice too large. between cut-in and cut-out
expansion c) Capacity regulation fault pressures.
valve 1) Capacity regulating valve too
operation. large.
2) Pressure control(s) for stage
regulation incorrectly set.
Suction Hunting normal

193
pressure
hunts.
Electronic
expansion
valve
operation.
Suction gas Refrigerant supply to a) Charge refrigerant to correct
temperature evaporator too small because: level.
too high a) System refrigerant charge
too small.
b) Defect in liquid line or
components in that line
c) Thermostatic expansion
valve super- heat setting too
high, or bulb charge partly
lost.
Suction gas Refrigerant supply to
temperature evaporator too large because:
too low. a) Thermostatic expansion
valve super- heat set too low.
b) Thermostatic expansion
valve bulb located incorrectly
(too warm or in poor contact
with piping).
Compressor a) Compressor capacity too a) Establish capacity regulation
cycling (cut- high in relation to load at any using KVC capacity regulating
out via low- given time. b) Compressor too valve or parallel-coupled
pressure large. compressors.
control). c) Opening pressure of b) Replace compressors with
evaporating pressure regulator smaller size.
set too high. c) Using a pressure gauge, set KVP
regulator at correct value.
Compressor a) Condensing pressure too b) Replace high-pressure control
cycling (cut- high. KP 5 or combined pressure control
out via high- b) High-pressure control KP 15.
pressure defect. c) Using a pressure gauge, set
control). c) High-pressure control cut- pressure control at correct value.
out set too low. Avoid compressor cycling by using
high pressure control with manual
reset.
Discharge Discharge pipe temperature Replace valve plate.
pipe too high
temperature
too high
Compressor Flow of liquid refrigerant from Set thermostatic expansion valve
too cold. evaporator to suction line and for lower superheat using MSS
possibly to compressor method.
because of incorrectly set
thermostatic expansion valve.

194
Compressor a) Compressor and possibly a) Reduce evaporator load or
too hot. motor overloaded because replace compressor with larger
evaporator load and thereby size.
suction pressure too high. b) Locate fault on line between
b) Poor motor and cylinder condenser and thermostatic
cooling be- cause of: expansion valve.
1) Insufficient liquid in 3) Replace valve plate.
evaporator. 4) Omit heat exchange or possibly
2) Low evaporator load. select smaller HE heat exchanger.
3) Suction and discharge
valves not tight.
4) Superheat too severe in heat
exchanger, or in suction
accumulator in suction line.
c) Condensing pressure too
high
Knocking a) Liquid hammer in cylinder a) Set thermostatic expansion valve
sound: a) because of liquid flow to for lower superheat using MSS
Constant. b) compressor. method.
During start b) Oil boiling because of liquid b) Install heating element in or
build up in crankcase. under compressor crankcase.
c) Wear on moving compressor c) Repair or replace compressor.
parts, especially bearings.
Compressor. a) Oil quantity too large. a) Drain oil to correct level, but
Oil level in b) Refrigerant absorption in first ensure that the large quantity
crankcase crankcase oil because of too is not due to refrigerant absorption
too high. On low an ambient temperature. in the oil.
high load, b) Install heating element in or
otherwise under compressor crankcase.
not. During
standstill or
start.
Compressor. a) Oil quantity too small. a) Fill oil to correct level, but first
Oil level in b) Poor oil return from be sure that the oil quantity in the
crankcase evaporator be- cause: crankcase is not a result of oil
too low. 1) Diameter of vertical suction collection in the evaporator. Install
lines too large. oil lock at 1.2 m to 1.5 m from
2) No oil separator. vertical suction lines. If liquid
3) Insufficient fall on horizontal supply is at the bottom of the
suction line. evaporator it can be necessary to
c) Wear on piston/piston rings swap inlet and outlet tubes (liquid
and cylinder. supply uppermost).
d) On parallel-coupled c) Replace worn components.
compressors: d) In all circumstances: the
1) With oil equalising tube: compressor started last is most
Compressors not on same subject to oil starvation.
horizontal plane. Equalising 1) Line up compressors so that
pipe too small. they are in same horizontal plane.
2) With oil level regulation: Install larger equalising pipe. Fit
Float valve partly or wholly vapour equalising pipe if

195
 blocked. Float valve sticking. necessary.
e) Oil return from oil separator 2) Clean or replace level container
partly or wholly blocked, or with float valve.
float valve sticking. e) Clean or replace oil return pipe
or replace float valve or whole oil
separator.
Compressor a) High refrigerant absorption a) Install heating element in or
Oil boils in crank- case oil because of under compressor crankcase.
during start. low ambient temperature. b) Oil separator too cold during
b) Systems with oil separator: start. Install thermostat-controlled
Too much absorption of heating element or solenoid valve
refrigerant in oil in separator with time delay in oil return tube.
during standstill. Fit non return valve in discharge
pipe after oil separator.
Compressor. a) Flow of liquid refrigerant a) Set thermostatic expansion valve
Oil boiling from evaporator to compressor for higher superheat using MSS
during crankcase. method.
operation. b) Systems with oil separator: b) Replace float valve or whole oil
Float valve not closing separator.
completely.
Compressor. System contamination arising In all circumstances: Change oil
Oil from: and filter drier.
discoloured. a) Cleanliness not observed a) Clean out refrigerant system if
during installation. necessary.
b) Oil breakdown because of b) Clean out refrigerant system if
moisture in system. necessary.
c) Oil breakdown because of c) Locate and remedy cause of
high dis- charge pipe excessive discharge pipe
temperature. temperature. Clean out system if
d) Wear particles from moving necessary.
parts. d) Clean out refrigerant system if
e) Inadequate cleaning after necessary. Replace worn parts or
motor burn- out. install new compressor.
e) Clean out refrigerant system. Fit
DA "burn-out" filter. Replace filter
several times if necessary.
Compressor. a) Insufficient or no voltage for b) Locate fault. Have fault repaired
Will not start. fuse group. and change fuses.
b) Blown group fuses. c) Locate fault. Have fault repaired
c) Fuse in control circuit and change fuses. Switch on.
blown. d) Locate and repair fault or
d) Main switch not on. replace protector.
e) Thermal protection in motor 3) Clean out refrigerant system,
starter cut out or defective, e.g. replace compressor and filter drier.
as a result of: Clean out refrigerant system if
1) Excessive suction pressure. necessary, replace compressor and
2) Condensing pressure too filter drier. Locate and remedy
high. cause of excessive current
3) Dirt or copper deposition in consumption, start system when
compressor bearings, etc. windings have cooled down (can

196
4) Supply voltage too low. take a long time). Locate and
5) Single phase drop out. remedy cause of motor overload,
6) Short-circuited motor replace contactor. Replace
windings (motor burn-out). contactor with larger size.
f) Motor winding protectors cut j) Replace motor with larger size.
out because of excessive Locate and remedy cause of acid
current consumption. formation, remove compressor,
g) Contactors in motor starter clean out refrigerant system if
burnt out because: necessary, fit new "burn-out" filter,
1) Starting current too high. refill with oil and refrigerant,
2) Contactor undersized. install new compressor.
h) Other safety equipment cut k) 1) Clean out system and install
out, incorrectly set or defective: new filter drier and new
Oil differential control (no oil, compressor.
oil boiling). High-pressure 2) Clean out system and install
control. Low-pressure control. new filter drier and new
Flow switch (insufficient brine compressor.
concentration, brine pump
failure, blocked brine circuit
filter, evaporating temperature
too low). Frost protection
thermostat (insufficient brine
concentration, brine pump
failure, blocked brine circuit
filter, evaporating temperature
too low).
i) Regulating equipment cut
out, incorrectly set or defective:
Low-pressure control, Room
thermostat.
j) Motor windings burnt out.
Open compressor: Compressor
and motor overloaded. Motor
undersized Hermetic and semi
hermetic compressor:
Compressor and motor
overloaded. Acid formation in
refrigerant system.
k) Bearing or cylinder seizing
because of:
1) Dirt particles in refrigerant
system.
2) Copper deposition on
machined parts because of
acid formation in refrigerant
system.
3) Insufficient or no lubrication
as a result of:
- Defective oil pump.
- Oil boiling in crankcase.

197
 - Insufficient oil.
- Oil collection in evaporator.
- Poor or no oil equalisation
between parallel-coupled
compressors (oil starvation in
compressor started last).
Compressor Cut-out pressure of low-
runs pressure control set too low, or
constantly, defective control.
suction
pressure too
low.
Compressor a) Compressor suction and/ a) Replace valve plate.
runs discharge valve not tight. b) Recommend lower load, or
constantly, b) Compressor capacity too low replace compressor with larger
suction in relation to load at any given size.
pressure too time.
high.

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