Installation and Commissioning of Control Panel

1. Product Introduction:
Blue Cold control system is used to control refrigeration equipment installed in cold room and
cold storage which can have temperature range from 20̊ C to -45̊ C vary according to product
and application.

2. Safety Instructions:

A requirement of fault-free operation and fulfillment of any rights to claim under

warranty is that these instructions and notes are followed. Therefore read these
instructions before working with the installation.

These instructions also contain important information concerning service. They are
therefore to be kept near the installation. If certain sections of operating instruction are
not clear or missing in your opinion, then report this immediately to Blue Cold
Refrigeration. Damage due to false interpretation or false acceptance of operating
instruction does not fall under the warranty.

If the installation not being installed immediately, store in a dry, dust-free and almost
vibration- free room.

These operating instructions contain fundamental information and precautionary notes.

Please read the manual thoroughly prior to installation of unit, electrical connection and
commissioning. It’s essential to read all other addition operation manuals.

In order to prevent damage to the equipment or personnel, only authorized trained staff
who are specialists for electronics is allowed to operate the system. The relevant local
safety regulations as well as special conditions of authorities in charge are to be
respected.

In order to spot the possible malfunction of the system in a quick and reliable way, the
system always has to be under supervision while in operation.

Always turn off main switch (the power) for repair or maintenance work and out or
secure the system against unintentional start up.

Always close ball valves and turn off the pressure before repair and maintenance work.

Check before putting installation into operation if all driven items have covers. Also
check if all safety measures are operational.
Never bypass safety installations, the function of the safety installations always has to be
guaranteed.

In case of disturbances or damages, shutdown the installation immediately in order to

avoid further damage. When the installation without our authorization is continued to
operate, any further damage is excluded from our responsibility.
3. Drawing & Part List:

S. No. Description
1 MCB
2 Contactor (K1)
3 Contactor (K2)
4 Contactor (K3)
5 Contactor (K4)
6 LVM (Low Voltage Monitor)
7 Thermal O/L Relay for Compressor (For K1 & K2)
8 Controller
9 Casing / Encloser

4. Mounting Instructions:
The Control Unit main board is supplied screws and spring washers for mounting into the
Control Unit box. The earth lug from the wiring loom must be earthed to ensure the
effectiveness of the surge suppression board.
Mount the Extinguishing Control Unit Main Board as follows:
• Align the main board chassis mounting slots with the lower studs of the Unitbox.
• Insert the main board into the Unit box so that the main board chassis rests on the studs.
• Insert the mounting screws, spring washers and the free earth lug of the wiring loom, and
tighten screws.
5. Main Characteristics:
• Cold room temperature displaying and regulation with decimal point
• Evaporator temperature displaying from parameter
• Plant control activation/deactivation
• Plant alarms signaling (probe error, minimum and maximum temperature alarm,
compressor protection)
• LED indicators and large display illustrate system status.
• User-friendly keypad.
• Evaporator fans management
• Manual and automatic defrost (static, through heaters)
• Cold room light activation through key on the panel or through door-switch
• Direct control of compressor, defrosting elements, evaporator fans, room light with outputs
directly connectable to the various units.

6. Receiving, Unpacking and Checking Procedure:

• Remove the transport casing.
• Visually inspect the terminal.
• Check that all items are included in accordance with the delivery documents.
• Check for transport damages.

7. Transport and Storage:

Every panel is packed to be delivered without damages in normal transport conditions. Incase
of following transport it must be verified that:
• No objects or free parts could be inside the panel.
• The door is correctly closed and locked.
• In case of not using the original package, protect the product to allow transport without
any damages.
• Storage room must have an adequate temperature and low humidity value; then avoid
contact between the electrical panel and aggressive contaminating substances that could
prejudice functionality and electrical security.
8. Assembly & Installation:
OBJECTIVE- To lay down the procedure to specify the responsibilities of production department.

SCOPE- This SOP describes the functions and responsibilities of production department.

RESPONSIBILITY-
• Execution : Trained and authorized Technicians
• Checking : Production Manager

ACCOUNTABILITY- HOD Production / Assigned Designee.

PROCEDURE-
• Check the unit there is no scratch and damage
• Make sure that all the components as per in the documents
• Connect the main line to the control panel box as per given in the manual
• Check the supply voltage in the control panel
• Ensure, all the operations in the control panel working properly
• Finally connect the control panel to the Refrigeration system
9. Connection Details * :

*Subject to change according to customized requirement

10. Operation:
• Ensure the incoming supply.
• Check the R, Y, B phase indication and check the voltage of each phase by using voltage
selector switch.
• Switch on the main incomer and respective each motor of compressor incomers.
• Check the unit is running properly without any interruption
• Ensure that all the operation in Control Panel working correctly.

11. Electrical Wirings:

For the electrical wirings please refer to the wiring diagram and technical characteristics of the
panel model to be installed.
• Panel power supply must be on a dedicated line, and must be placed a device suitable for
protection against indirect contacts upstream the line(differential interruptor).
• Do not fit power supply wiring and signal wiring (probes/sensors and digital inputs) in the
same race ways or ducts.
• Do not use multi-polar cables in which there are wires connected to inductive/power loads
or signaling wires (e.g. probes/sensors and digital inputs).
• Minimize the length of connector wires so that wiring does not twist into a spiral shape as
this could have negative effects on the electronics.
• When it is necessary to make a probe/sensor extension, the wires must have a cross-
section of at least 1mm2.
• All wiring must be of a cross-section suitable for relevant power levels. Insulation degree
must be compatible with the applied voltages. Preferably use cables with insulator not
propagating the flame and a low toxic smoke emission if interested by fire.

12. Verification Before Use:

After doing the wirings, please verify using the wiring diagram on the correct execution of the
connections.
• Please check the correct screw clamping.
• Check, when possible, the correct functioning of the outside protection devices.
• Please correctly calibrate the motor circuit breaker (if present) dedicated to the compressor
• After powering the electrical panel, please check the correct current absorption on the
loads, and after few hours of functioning check the good tightening of screws on terminal
blocks (included power supply line connection).

13. Maintenance:
Before proceeding with maintenance operations please follow these security prescriptions:
• The electrical panel must be without voltage.
• Prevent the presence of unauthorized staff around the intervention area.
• Positioning of suitable notices to signal "Device under maintenance".
• Wear suitable and without free appendixes work cloths (overalls, gloves, shoes).
• Remove if worn, every object which can get entangled in any part of the panel.
• Suitable tools for the maintenance operations must be at disposal.
• Tools must be correctly cleaned and greased.
• Necessary technical documentation to execute maintenance intervention must be at
disposal (wiring diagrams, tables, drawings, etc….)
• At the end of the maintenance operations please remove all the residual materials and
make a careful cleaning inside panel.
14. Trouble Shooting:
Before going for trouble shooting, make sure that system should be isolated from the
operation.

WARNING

Dangerous voltage capable of causing shock is present in this system. Use extreme caution
when handling, testing and adjusting. Only qualified personnel should service.
Note:
Replace failed MCB’s, Indication lamps & Contactors etc... with exactly same specification /
rating after fault analysis.

SL. NO. POSSIBLE CAUSES POSSIBLE ACTIONS

• Check clearance of MCB's & MCCB’s

• Check for any over loading
Frequent Tripping of MCB's.
1 • Check the MCB's & MCCB’s operation
& MCCB‘s
without load (disconnect secondary wire)
• Check Secondary control wiring

• Check voltage at lamp

2 Indication lamps not working
• Check the voltage level as applicable

For VFD Over Temperature • Check Air flow

3
O/P Phase loss • Check Motor Connection

15. Warranty:

Products are covered by warranty period against all manufacturing defects as from the date
indicated on the product ID code or from the date of product registration card, if present.
Customers are entitled to have defective products repaired, spare parts and labor included.
Transport expenses and risk shall be met entirely by the customer. Repairs carried out under
warranty do not prolong or renew the warranty expiration date.

The Warranty does not cover:

• Damages resulting from tampering, impact or improper installation of humidifier and
its accessories.
• Behavior inconsistent with Manufacturer’s prescriptions and instructions.
• Damages caused by repairs made by unauthorized persons.
• Damages caused by natural phenomena as lightning, natural calamities, etc.
• Warranty cover may be refused if the device is modified or changed.
• Any consequential damages that may be caused due to failure.
16. Name Plate Marking:

17. Dismantling:

Please taken necessary safety precautions before starting disposal & dismantaling like
hand glouse, goggles, jacket & safety shoes etc.
• Kindly ensure incoming supply of panel should be OFF.
• Remove the filed cables & internal cables for using the suitable screw driver &
spanner.
• Remove the componenets using suitable screw driver & spanner.
• Once all the componenets removed from the mounting plate, remove mounting
plate using suitable spanner.
• Remove the hinge pin using hammer & flat rod.
• Remove the door using by hands

18. Disposal:

Do not dispose of electrical appliances/components as unsorted municipal waste, use separate

collection facilities. Contact your local government for information regarding the collection
system available. If electrical appliances/components are disposed off in landfills or dumps,
hazardous substances can leak into the groundwater and get into the food-chain, damaging
your health and well being.
Once dismantling is done, Individual equipment’s shall be packed and stored properly for
disposal.

a) Electrical & Electronic Components:

Once the operation cycle of the component is completed, can be given to e-waste
management system.
b) Metallic & Plastic Parts:
Can be taken for recycling once the operation lifetime of the device is completed.
 Check list for Installation and Commissioning of Control Panel

1. Check visually inspect the terminal

2. Check that all items are included in accordance with the delivery documents

3. Check for transport damages

4. Check no objects or free parts could be inside the panel

5. Check the door is correctly closed and locked

6. check Storage room must have an adequate temperature and low humidity value

(If you want to store)

7. Check the contact between the electrical panel and aggressive contaminating

substances that could prejudice functionality and electrical security

8. Check the panel power supply must be on a dedicated line, and must be placed

a device suitable for protection against indirect contacts

9. Ensure that do not fit power supply wiring and signal wiring (probes/sensors

and digital inputs) in the same race ways or ducts

10. Ensure that do not use multi-polar cables in which there are wires connected to

inductive/power loads or signaling wires (e.g. probes/sensors and digital inputs)

11. Check to minimize the length of connect or wires so that wiring does not twist into

a spiral shape as this could have negative effects on the electronics

12. Make sure that when it is necessary to make a probe/sensor extension, the wires

must have a cross-section of at least 1mm2

13. Check the control panel fixed properly

14. Check the cold room temperature displaying correctly

15. Check the unit control activation/deactivation

16. Check the unit alarm working properly

17. Ensure the LED indicators and large display, illustrate system status.

18. Ensure that defrost operation condition

19. Make sure that cold room light ON/OFF correctly

20. Check the insulation of connecting wires

21. Ensure that during maintenance, electrical panel must be without power

22. Ensure that authorized staff only do the maintenance work

23. Check the tools must be correctly cleaned and greased during maintenance

24. Check clearance of MCB's & MCCB’s

25. Check for any over loading

26. Check voltage at lamp

27. Make sure that all wiring is properly connected and routed away from heat

sources, electromagnetic devices, and moving components

28. Check proper relay operation

29. Check the permanent labels affixed

30. Ensure that units/equipment accessible for maintenance/replacement

31. Check the fuses installed and labeling of wire done correctly

32. Make sure that all electrical connections are tight

33. Verify the proper grounding installed for components and unit

34. Check th unit placed in safe and operatable

35. Check the power supply flow into the circuit as per standard

36. Check the system running properly