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TECHNICAL HANDBOOK

WALKINFREEZER

FOR THE REPAIR AND MAINTENANCE OF


WALK-IN-COOLER/FREEZERS

TECHNICAL HANDBOOK
FOR THE REPAIR AND MAINTENANCE OF
WALK-IN-COOLER/FREEZERS

Edition:April,2009

TABLE OF CONTENTS
TECHNICAL HANDBOOK ................................................................................. 1
FOR THE REPAIR AND MAINTENANCE OF.................................................. 1
WALK-IN-COOLER/FREEZERS ....................................................................... 1
TECHNICAL HANDBOOK ................................................................................. 2
FOR THE REPAIR AND MAINTENANCE OF.................................................. 2
WALK-IN-COOLER/FREEZERS ....................................................................... 2
Chapter1:Effectivevaccinestore ........................................................................... 1
Introduction................................................................................................................................................... 2
Spaceplanning.............................................................................................................................................. 2
2.1
Planningvaccinestore...................................................................................................................... 2
2.2
Vehicleloadingbay ............................................................................................................................ 3
2.3
Refrigerationequipmentarea....................................................................................................... 3
2.4
Vaccinepackingarea ........................................................................................................................ 5
2.5
Choosingasite...................................................................................................................................... 7
3
Buildingstandards....................................................................................................................................... 8
4
VaccineSafety........................................................................................................................................... 10
1
2

Chapter2:Coldrooms .......................................................................................... 16
1

3
4

Technicalspecificationsofcoldrooms/freezerrooms......................................................... 17
1.1
SpecificationsofWIC .......................................................................................................................17
1.2
SpecificationsofWIF .......................................................................................................................20
ProcedureforInstallationofcoldroom........................................................................................... 25
2.1
Installationofpanel.........................................................................................................................27
2.2
Installationofshelves......................................................................................................................29
2.3
Installationofroomlight&connectingdoorheater......................................................29
2.4
Installationofpressureventilator(Breeder).......................................................................29
EngineeringdiagramsforassemblingandinstallationofWIC/WIF....................................... 30
ComponentsofWIC/F............................................................................................................................. 41
4.1
Coldroompanels ...............................................................................................................................41
4.2
Coolingunits........................................................................................................................................41
4.3
Coolingunit(EUROMON2) ...........................................................................................................44
4.4
Cold/freezerroomcontrolpanel ...............................................................................................49
Coldroomprogramming........................................................................................................................ 49
5.1
Factorysetting....................................................................................................................................50
5.2
Modifyingthemasterlogsettings .............................................................................................53
5.3
Interpretingtheoperatingmessages.......................................................................................56
5.4
Diagnosisofproblems .....................................................................................................................56
AlarmSystem ............................................................................................................................................. 58
6.1
Installation ...........................................................................................................................................58
6.2
Operation ..............................................................................................................................................59
6.3
Setup........................................................................................................................................................59
6.4
Maintenance ........................................................................................................................................60

Chapter3:Preventivemaintenance...................................................................... 62
1
2
3
4

RoutineMaintenance ............................................................................................................................ 63
DailyCheckUp........................................................................................................................................... 64
Weeklychecks............................................................................................................................................ 65
Monthlychecks ......................................................................................................................................... 66

Monitorroutineandemergencymaintenance ............................................................................. 67

Chapter4:Powersupplyandgenerators .............................................................. 68
1

Generatorandcontrolpanel................................................................................................................ 69
1.1
Engine.....................................................................................................................................................69
1.2
Alternator .............................................................................................................................................69
1.3
ControlPanel.......................................................................................................................................69
1.4
Installation ...........................................................................................................................................70
1.5
Sequenceofoperationofrelaysincontrol ............................................................................71
1.6
Maintenancescheduleofgenerator .........................................................................................73

Chapter5:Temperaturemonitoring ..................................................................... 74
Thermometers ........................................................................................................................................... 75
Temperatureplotters.............................................................................................................................. 76
Computerizedtemperaturerecorders ............................................................................................. 76
3.1
Multichannelcomputerizedtemperaturemonitoringsystem ...................................76
3.2
Wirelesstemperaturedatalogger ............................................................................................82
1
Temperatureindicators....................................................................................................................... 87
1.1
VaccineVialMonitor(VVM).........................................................................................................87
1.2
FridgeTag............................................................................................................................................88
1.3
FreezeTag............................................................................................................................................89
2
Summary..................................................................................................................................................... 90
1
2
3

Chapter6:SparepartsandToolkit ....................................................................... 91
3
4

Listofspareparts ................................................................................................................................... 92
ToolkitforRefrigeratortechnician...................................................................................................102

Chapter7:troubleshooting................................................................................. 106
1

Possiblefaults,observationsandrepairactionsforcoldrooms ..........................................107

Abbreviations

Abbreviation

Definition

0C

DegreeCelsius

Ampere

AC

AlternateCurrent

AMC

AnnualMaintenanceContract

BCG

BacilleCalmetteGurin(tuberculosisvaccine)

CFC

Chlorofluorocarbon

Cm

Centimeter

DC

DirectCurrent

DG

DieselGenerator

DPT

Diphtheria,PertusisandTetanus

DT

Diphtheria,andTetanus

EEFO

EarlyExpireFirstOut

FIFO

FirstinFirstOut

GMSD

GovernmentMedicalStoreDepot

Hept.B

HepatitisB

Hz

Hertz(CycleperSecond)

IP

Icepacks

KVA

KiloVoltAmpere

KW

KiloWatt

Meter

Mfd

Microfarad

Abbreviation

Definition

OPV

OralPolioVaccine

RPM

RotationperMinute

T.T

TetanusToxoid

UIP

UniversalImmunizationProgramme

Volt

VVM

VaccineVialMonitor

WIC

WalkinCooler

WIC/F

Walkincooler/Walkinfreezer

WIF

WalkinFreezer

Acknowledgement
The technical handbook for repair and maintenance of cold rooms
was prepared with technical contributions from State Health
Transport Office (SHTO) Pune (Government of Maharashtra),
Ministry of Health and Family Welfare, Government of India and
UNICEF.
GenerousfinancialsupportfromNorwayIndiaPartnershipInitiative
(NIPI)facilitateddevelopmentofthistraininghandbook.

Chapter1:EffectiveVaccineStore

Contents
$Introduction
This handbook has been prepared for refrigeration technicians for
repair and maintenance of cold rooms/freezer rooms. It offers
technical guidance and reference material for components of
cold/freezer rooms. Introduction section guides the reader on how to
usethisbook.

$Guidelinesforeffectivevaccinestore
Cold room is the storage facility where large quantities of vaccines
could be stored for longer duration.. Cold/freezer rooms have been
installed at National Stores (GMSD) (also referred as primary stores)
and State/Regional/Divisional stores (also referred as intermediate
stores). To effectively manage these vaccine stores, WHO has issued
guidelines (WHO/V&B/02.341). This section has incorporated these
guidelinesforreadyreference.Theseprovidegeneralrulesfordeciding
the ideal location of cold/freezer rooms and establish required
standardsofelectricsupplyandpowerconnections.Italsoprovidesthe
standards on adequate size of vaccine storage area, packaging area
andstorekeeperslayout.

$Howtolookaftercoldroomandfreezerroom
Thissectionguidesusersonbasicsofhowtolookafterthecoldroom
andfreezerroom.

Guidelines for establishment or improving primary and intermediate vaccine stores. Vaccine
and Biologicals, World Health Organization, Geneva. 2002

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1 Introduction
One of the most important links in the cold chain is Walkin
Cooler/FreezerRooms(WIC/F).Walkincoolers(WIC)areusedfor
bulkstorageofvaccinesat+20 Cto+8 0 CandWalkinFreezer
(WIF) for storage of vaccines at () 250 C to () 150 C. WIF also
supportpreparationoficepacks(IP)atStatelevelorRegionallevel
storage. The name Walkin means that one can walk into the
storagespacesinsidetheserooms.
India is using cold chain infrastructure which was established
gradually since 1985. As a result cold chain equipment of various
make and mixed technology could be found in the vaccine stores.
Thissituation createsspecialchallenges forrefrigerationmechanics
toserviceandmaintaintheequipmentoftechnologyrangingfrom20
yearsoldtothelatestmodels.
Intherecentyearstherehasbeensignificantchangeinrefrigeration
technology and instrumental control design. Though the basic
functions of the equipment remains the same, there is considerable
advances in their design like introduction of CFC free refrigerants,
modern control systems with microprocessors, built in electronic
switchingdevices,digitaldisplay,blistertypeoperatingswitchesetc.
Maintenance work now requires new repair tools, instruments and
equipment.2Onlytheminimuminformationthatisrequiredforday
to day repair and maintenance have been provided. For more
technicaldetail,pleaserefertoequipmentmanual..

2 Spaceplanning
2.1 Planningvaccinestore
Spaceisrequiredinavaccinestoreforavehicleloadingbay,aroom
to accommodate the refrigeration equipment, a room to store dry
stores such as diluents, droppers, packing materials and other
consumables such as injection equipment, waste management
suppliesandspareparts,aroomtopackthevaccinefordispatch,and
anofficeforthestorekeepingstaff.Ifpossiblethedifferentactivities
shouldbehousedinthesamebuilding,althoughbulkyconsumables
such as injection equipment and spare parts may have to be stored
elsewhere.

A list of recommended tools & instruments is given separately towards the end of this
handbook

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2.2 Vehicleloadingbay
Thedetaileddesign ofa vehicle loadingbay is governed bythe size
andtypeofvehicleused.Considerationshouldbegivento:
1. Access: The loading bay and the route to it must be planned to
alloweasyaccessforthelargestvehicleused.
2. Security: Vaccines are high cost value. The loading bay area
should therefore be visible from the storekeepers office to ensure
security.
3. Weather protection: A loading bay should preferably have a
projecting canopy to protect workers, vehicles and vaccines from
sunlight,rainorsnowduringloadingandunloading.
4. Loading dock: Delivery vans can be loaded from ground level.
However, it is more convenient to load and unload lorries from a
loadingdockthatisatthesamelevelasthefloorofthevehicle.This
makesitpossibletouseatrolleytowheelvaccineintothevehicle.A
raisedloadingdockshouldbebetween1.2and1.4metresabovethe
vehicleparkingarea.Ideally,itshouldbebuilttomatchtheheightof
thedeliveryvehicle.
5. Special requirements for refrigerated vehicles: Some states
have refrigerated vehicles to distribute vaccine from the primary
store to intermediate stores. A refrigerated vehicle must be fitted
withatemperaturelogger;thereshouldbeaweatherproofelectrical
outlet to power the vehicles refrigeration unit during loading and
unloading operations; and there should be sufficient space to store
deliverycratesiftheseareusedinplaceofcoldboxes.
2.3 Refrigerationequipmentarea
Therefrigerationequipmentareashouldbelaidoutsothatdiluents
andOPVdropperscanbestorednearbyoneasilyaccessibleshelves
close to the cold store. Each vaccine manufacturer supplies diluent
thatisonlycompatiblewithitsownvaccine.Itisveryimportantthat
diluentsbesystematicallystoredandsubjectedtothesamerigorous
stock control procedures as the vaccines with which they are
intended to be used. Experience shows that good control of diluent
stock is more likely to be achieved when it is stored close to the
vaccinewithwhichitistobeused.
The information in this section assumes that prefabricated cold
stores with twin packaged refrigeration units are in use. Figure 1
shows typical layouts and clearances for cold stores in a range of
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sizesfrom5 m3to 40 m3. Figure 2shows thelayout andclearances
requiredaroundWIC/F.

Figure 1: Standard sizes of cold rooms

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Figure 2: Overview of a vaccine store with a cold room

Theinternal heightof WIC/F where stock is movedby hand should


notexceed2.3metres.Thislimitensuresthatthevaccineonthetop
shelves is accessible without the use of steps. WIC/F should be
planned so that they accommodate the greatest possible length of
shelving, taking into account the locations of the entrance door and
the refrigeration units. A square plan is not necessarily the most
spaceefficient,especiallyinsmallerunits.
Vaccineboxesshouldbearrangedsothatthereisfreemovementof
airbetweenthevaccinepackages,whichshouldbestoredabout5cm
away from the walls of the room. This allows air movement behind
the stock and ensures an even temperature. Slatted shelving also
assistsaircirculationandisthereforepreferabletosolidshelving.
2.4 Vaccinepackingarea
Figure3isaschematiclayoutforatypicalvaccinepackingarea.The
sizeofthespacerequireddependsonthemaximumdailytransaction
andthenumberofstaffemployed.Thepackingareashouldconnect
toadirectroutebetweentheWIC/Fandthevehicleloadingarea.It
must not form part of a main circulation route because it has to be
kept cool possibly by airconditioning and secure. Vaccine packing
involves a number of linked activities, all of which should be
accommodatedinthesamespace.

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Figure3:Organizationdiagramandlayoutofpackingarea

Thepackingareashouldbelaidoutsoastoencouragealogicalflow
of work. Vaccines should be moved as little as possible in order to
minimizetheriskofbreakage. Thereshouldbeasinkinthepacking
areaforhandwashingandprovisionfor hygienichanddrying.
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2.5 Choosingasite
The checklist below outlines the main steps in the process of site
selection.
1. Determine the size of the store and its access requirements:
Usingthe informationgivenabove,calculatethefloorarearequired
forthevaccine storeandthesizeofdeliveryvehicles.
2. Reviewpotentialsites:
Considerthefollowingalternatives.
a) Space in a government warehouse or other government building
that canbeadaptedforthepurpose.
b) Commercialwarehousesthatcanbepurchasedorrented.
c) Emptysitesthatcanbedeveloped.
3. Assessnaturalhazards:
Considerthefollowing.
a) Are any of the potential sites at particular risk from natural
hazards,e.g. tidalsurges,stormsorearthquakes?
b) Whatprecautionscanbetakentoguardagainsttheserisks?
c) If any of the preferred sites were to be severely damaged, how
would this affect the routine immunization programme and a post
disaster emergencyresponse?
4. Comparethesuitabilityofpossiblesites:
Considerthefollowingissuesbefore asiteisfinallyselected:
Access
a) Is the site close to the relevant transport links, including
roadsandairport?
b) Isthesitewellservedbypublictransport?Publictransport
is needed by store staff. It may also be required by health
workerswhencollecting vaccine.
c) Is the site conveniently located for permanent and
supervisorystaff?
d) Istheroutetothesiteaccessiblethroughouttheyear?
e) Isthereadequateaccessandparkingspaceforvehicles?
Services
a) Doesthesitehaveareliablemainselectricitysupply?
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b) Isthereastandbygenerator?
c) Doesthesitehaveareliabletelephoneservice?
Security
a) Wouldthesitebesecure?
b) Could the store be properly monitored and supervised
outsidenormal workinghours?
Sitedevelopment
a) Isthesitewelldrainedandwithoutanyriskofflooding?
b) Aregroundconditionssuitableforbuildingeconomically?
c) Couldthesitebedevelopedatanacceptablecost?

3 Buildingstandards

Vaccine stores should be housed in permanent buildings, which


should be designed and constructed to a good standard that is
appropriateforlocalclimaticconditions. Temporarybuildingsshould
be avoided since it is difficult to relocate WIC/F. They are rarely
satisfactoryandareexpensive tomaintain.
If the store is in an area affected by flooding it should be on high
groundorraised abovefloodlevel.Thelossofamajorvaccinestore
inanaturaldisasterhaspotentially lifethreateningconsequencesfor
thepopulationconcerned.
If an existing building is used it must be in good condition. If
necessaryitshouldbe repairedandupgradedfirst.
The following minimum standards are desirable in any vaccine
storage building. Most are essential in a primary or intermediate
store.
Roofandceilings
Roof and ceiling of the cold rooms should be in good condition,
completelyfreefromleaks.
Roofspaceshouldbeinsulatedand/orventilatedinhotclimateareas
andinsulatedincold climateareas.
Ceiling should be in good condition and freshly painted. The ceiling
shouldcompletely sealofftheroofspaceinordertoprotectagainst
dustandpests.
Wallsandcolumns
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Should be in good condition, free of cracks and other structural
defects. Freefromrisingorpenetratingdamp,termites.
Insulatedincoldclimates.
Insulations should be nicely finished internally and externally to a
goodstandard.Theinternalfinishes shouldbedustfree.
Windows,screensanddoors
Windows should be in good condition, with no broken glass, and
shouldhave securelocksorcatches. Allwindowopeningsshouldbe
fittedwithsecuritygrilles. Allexternaldoorsandallinternaldoorsto
roomscontainingvaluableitems shouldbefittedwithsecuritylocks.
Floors
Flooring should be smooth, level and completely free from rising
damp.Suitablyfinishedwithfloorpaint,tiles,terrazzo,vinylsheetor
someotherwashable dustfreesurface. Floorsonwhichcoldstores
aretobebuiltmustbeleveledtoatoleranceof3 mmoverthearea
ofthecoldstore.
Itisdesirableforcoldstorestoberaisedonalowplinth(2550mm).
This preventswaterusedforfloorwashingfromrunningunderthe
floor panels. Alternatively, the junction between the cold store and
thefloormaybesealed withwaterproofmastic.
Fireprotection
The building should be easily accessible to the fire service. A water
hydrant shouldbeprovidedifthisisrequiredbythefireservice.
The building should not contain a kitchen or other significant fire
hazard. The building should be of noncombustible construction or
shouldbelined withnoncombustiblesheetmaterials.
Rooms used for storing packing materials and other combustible
items should be isolated from the vaccine store by fireresisting
constructionandby fireresistingselfclosingdoors.
Flammablerubbish,suchascartonsandboxes,mustnotbeallowed
to accumulateinthestore.
Smoking should be forbidden and No Smoking signs should be
displayed throughoutthestore.
The building should be fitted with fire and smoke detectors
connectedtoan externalalarmsounder.

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There should be at least one carbon dioxide or powder fire
extinguisher close to the entrance door for extinguishing electrical
fires.
In addition there should be at least two carbon dioxide, powder or
water extinguisherswithin30metresofanypartofthevaccinestore
forextinguishing othertypesoffire.
Firedetection and firefighting equipment must be inspected
regularly, and staff must receive adequate training in firefighting
techniquesandemergency action.Thereshouldberegularfiredrills.
Electricalservices
Allpowerandlightingcircuitsmustbeinasafecondition,testedand
approved tonationalstandardsbyaqualifiedengineerorelectrician.
Powercircuitsservingrefrigerationequipmentmustberatedtosuit
therequired refrigerationstartingandrunningloads.
Ancillary electrical equipment (fans, airconditioners, light fittings,
etc.) should have no significant electrical or mechanical defects.
Heatingandwatersupplysystems
Allpipeworkshouldbeingoodcondition,freeofleaks.
Heatingsystemsshouldbefullyoperationalandcontrollable.
Drainage
Drainagesystemsshouldbefullyoperationalandfreeofblockages.
Thesurfacewaterdrainagesystemtothebuildingandsitemustbe
effective evenattheheightoftherainyseason.
Pestcontrol
The building should be designed and maintained so as to minimize
infestation byinsects,termites,rodents,batsorotherpests.
Cleaning
The building should be cleaned two or three times a week and
adequate equipmentshouldbeavailableforthispurpose.
Security
The building should be secured against breakins and should be
locatedsothat accesstoitiscontrolled.

4 Vaccine Safety
Theprimarytaskwhenlookingafteracoldroomorfreezerroomis
to protect the vaccines from damage. All vaccines are virtually
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damaged if they are exposed to excessively high temperatures. On
the other hand, some vaccines are quickly destroyed if they are
frozen. Damaged vaccines lose their potency and children who are
immunized with such vaccines are not protected against those
diseases.
Knowcorrectstoragetemperatureofeachvaccine.
Learn the correct storage temperature for each vaccine. Keep a
storage temperature checklist in the vaccine store so that you can
checkifyouareindoubt.

Primary

Intermediate
State
-15C to -25C

BCG

WHO no longer recommends that freezedried vaccines be stored at -20C. Storing


them at -20C is not harmful but is
unnecessary. Instead, these vaccines should
be kept in refrigeration and transported at
+2C to +8C.

MMR
MR

Health post

District

OPV

Measles

Health centre

YF
+2C to +8C

Hib freeze-dried
HepB
DT
DTP
DTP-HepB
Hib liquid
Td
TT

Diluent vials must NEVER be frozen. If the manufacturer supplies a freeze-dried vaccine packed with its
Diluent, ALWAYS store the product at between +2C and +8C. If space permits, diluents supplied
separately from vaccine may safely be stored in the cold chain between +2C and +8C.

Figure 4: WHO norms for storing vaccine

Temperaturesensitivityofvaccines
WHO recommends the range of temperatures for storing and
transportingvaccineonthebasisofdatasuppliedbymanufacturers.
Each vaccine has its own specific storage requirements so it is
extremely important to know how long, and at what temperature,
eachvaccinecanbestored.

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All vaccines can be stored at positive temperatures (between +2 C
and +8 C). However, only some vaccines can be stored at negative
temperatures(between15Cand25C).
Lossofpotencyduetoheat
Vaccines that have been exposed to temperatures above +8 C may
lose their potency over time. The vaccine vial monitor (VVM) must
alwaysbeusedtoguidedecisionsontheuseofvaccine.
Freezing
TheTseriesofvaccines(DTP,DT,dT,Td,TT),HepB,liquidHiband
liquid pentavalent vaccine should always be stored between +2 C
and +8 C as they are damaged by freezing; they may also be
damagedbyexposuretofreezingtemperatures.HepBisthevaccine
mostsensitivetofreezingtemperatures.Themostcommoncause of
exposure to freezing temperatures is the failure to correctly
conditionicepackspriortotransport.Toreducetheoverallriskof
freeze damage to vaccines, one should follow the best practices as
outlined in the Aidememoire for prevention of freeze damage to
vaccines given at the end of this manual (WHO/IVB/07.09). If it is
suspectedthatvaccineshavebeenexposedtofreezingtemperatures,
performtheshaketest(seeAnnex3)beforedecidingwhether the
vaccine is damaged or not. A VVM does not indicate if a vaccine has
beenfrozen.
StandardoperatingproceduresinWIC/F
Keepdoorclosed&lockedUseinternalplasticstripcurtain.
AvoidopeningtheWIC/Fdoorunlessitisabsolutelynecessarytodo
so. If the WIC/F is not fitted with an internal plastic strip curtain,
always close the door when you are working inside. (Important:
CheckbeforehandthatWIC/Fcouldbeopenedfreelyfrominsideand
youwearproperwinterclothing)
Switchoffinternallightwhennotneeded.
Switch off the interior light as soon as you have finished working
inside.Thelightbulbgivesoff heatandthismakestherefrigeration
plantrunlongerthannecessary.
Lockthedoor
KeeptheWIC/Flockedandmakeonepersonresponsibleforthekey.
Makesurethatasparekeyiskeptinasafeplace.
Monitorstoragetemperatureatleasttwiceaday.
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Monitor the temperature of every WIC/F at least twice a day and
recorditinthelogbook.
Stackvaccinecorrectly
Make sure the sufficient space around the vaccines for air
circulations.Leaveagapof5cmfromthewallandthevaccinebox.
Donotallowoverloading.
Do not keep vaccine on the floor of the WIC/F. Stack the vaccine in
shelvesonly.
Neverkeepfreezesensitiveinfrontofevaporators.
Never keep any vaccine underneath the cooling units. (Dripping
watermaydamagevaccineboxes)
Neverkeepanyloosevialinthecoldroom.
FollowEEFOandFIFO
StorevaccinesothatEarlyExpiryFirstOut(EEFO)andFirstinFirst
out(FIFO)couldbeeasilyfollowed.Necessaryadjustmentshouldbe
made for VVM status. Make sure that vaccine is stacked on the
shelves systematically so as to encourage EEFO/VVM stock
management. Vaccines with early expiry or advance stage of VVM
shouldbestoredontoporfrontforearlydelivery.
Avoidfreezing.
VaccinecanfreezeinsideaWICforanyofthefollowingreasons:
1. Vaccine stored too close to evaporator. The air coming from the
evaporatormaybebelow0Cuntilithasmixedproperlywiththe
air in the room. The danger zone typically extends for 50 cm in
front of the evaporator. Vaccine must not be stored within this
zone.
2. Thermostat set incorrectly. This may reduce the temperature
throughouttheroomtobelow0C.
Temperature monitoring is not regular that in turn fails to
identifylowtemperatureforcorrectiveaction
Not properly conditioning3 the icepacks before putting them
incoldboxesforvaccinetransportation

Procedure to condition the ice-packs: (1) remove ice-packs from freezer, (2) keep at room
temperature on table to allow their temperature to rise to 0C beads of water cover their
surface and ice inside moves on shaking, (3) use the ice-packs in cold box/vaccine carrier.
Now ice-packs cannot freeze the vaccine!

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3. In cold climates where the cold room is located in an unheated
space,thetemperatureoutsidethecoldroomisclosetoorbelow
0Cthevaccineinsidetheroommayfreeze.Acoldroominacold
climate should be built in a space that is permanently heated.
Alternatively,itshouldbefittedwithathermostaticallycontrolled
heatercircuitthatmaintainstheinsidetemperaturebetween+2C
and +8C, even if the outside temperature is below 0C. Out side
heaterscanalsobeprovidedtoincreasetheambienttemperature.
Makeacontingencyplan
MakesureyouknowwhattodoiftheWIC/Froombreaksdown.
Every vaccine store must have a contingency plan for keeping
vaccine safe if the refrigeration equipment fails. It is impossible to
give precise directions about how this should be done, as
circumstances vary. Whatever the circumstances, however, the
followingthreerulesapplyinanemergency.
Someofthepossiblecontingencyoptionsareindicatedbelow.
Move the vaccine to another cold store (Government or
private).
Borroworhirearefrigeratedvehicle.
Obtainicefromacommercialicemakerandstoreitinsidethe
WIC/Finplasticormetalcontainers.Closelymonitortheroom
temperatureandkeeptheicesupplyreplenisheduntilrepairs
arecarriedout.
Warning:Neverusedryice.Dryicemaylowerthetemperatureofthe
WICtobelow0C.Moreover,whenitevaporates(sublimes)itgivesoff
carbon dioxide gas. This may build up in the cold room and could
suffocateanybodywhoenterstheroom.
Followtheguidancegivenbelowformakingcontingencyplan.
Prepareatleasttwoalternativeplans.
Whateverplansyouchoose,makesuretheyarediscussedand
agreed beforehand with your staff and with all the other
partiesinvolved.
Confirm the plan in writing. Keep a copy in the vaccine store.
Makesureallstaffknowswhereitis.
Check alternative stores to ensure that they are in good
condition,haveadequatespaceandarecapableofmaintaining
vaccine at the correct temperature. There is no point moving
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stocktoanothercoldroomiftheresultisthatallyourfreeze
sensitivevaccineisfrozenanddestroyed.
Do not wait until an emergency occurs. Rehearse the plans
beforetheyareneeded.
Prepare a list of emergency contact names, addresses and
telephone numbers and post a copy of the list in the vaccine
store.Keepthelistuptodate.
Make sure that emergency contacts can be made both inside
andoutsidenormalworkinghours.

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Chapter2:Coldrooms

Contents
ThecoldroomsinIndiahavebeensourcedfromvarious
manufacturers.Itisnotpossibletoprovidecomprehensiveinformation
ofallthemodelsinusehoweverthissectionisbasedoncoldrooms
suppliedbyHURREE.Theinformationisbyandlargeapplicableto
mostofthemodels.Theinformationincludedinthissectionis:

$TechnicalspecificationsofWIC/WIFmodels
$Engineeringdiagramsforassemblingandinstallationof
WIC/WIF

$Technicalspecificationsofcomponentsofcoldrooms
$Sparepartsreferenceguide(asusedinGMSD)
$Programmingguideofcoolingunits(compressor,defrosting)
$Troubleshootingguide

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1 Technical specifications of cold rooms/freezer


rooms
1.1 SpecificationsofWIC
WalkinCoolerisrequiredtostorevaccinesatatemperaturebetween
2to80C.
OperationalRequirements
Constructed of prefabricated, modular complete with floor and
ceiling panels, mounted on a flat, solid concrete base, WIC provide
total,24hour,allseasonreliablevaccinestoragetemperatureunder
allconditions.
All refrigeration machinery must be provided with 100% standby
capacity, with duplicate, independent controls, pipe work,
instrumentation and machinery, to provide against failure of the
primarysystem.Automaticchangeoverandstartingofthesecondary
system is to be provided, activated by thermostatic or electrical
control.
TechnicalSpecifications
Internal Temperature : +2 to +80 C adjustable (i) during 430 C
continuous ambient (ii) 320C continuous ambient (iii) 45/050 C
day/nightcyclingtemperatures
Construction: Outer and internal: plastic coated galvanized steel
panelsornoncorrosivemetallicpanelsorfiberglasspanels.
Dimensions:Internalheightof8feet.
Floordimensions:18'(L)12'(B)minimum3"abovethegroundlevel.
Floorshouldbecementconcreteandproperlyleveledandthepanels
shouldbefittedonthis.
Insulation:Urethanefoamorextrudedpolystyrenefoamcorebonded
tononcorrosivemetalorfiberglasspanels.
Door is with frame heating heavy duty lock with internal safety
release,shelvingsystemandprovisionofplasticcurtainsonthedoor
way. Door(s) to WIC are lockable with 100% failsafe provision for
openingfrominside.Eachentrancedoorhasanincandescentvapor
proof light mounted on the interior of the door section. The door
dimensionsare3'(W)x6'(H)
Dual Refrigeration system (100% standby) air cooled refrigeration
units, plug in type, automating defrosting (electric or hot gas) CFC
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free refrigerant are provided. Tropicalized units are suitable for
ambienttemperatureupto450C.
Generatorshouldbecompletewithautomaticcontrolandbattery.
Wall mounted seven days digital thermometer of 4 digits LCD/LED
Display with data logging capability of 7 days with suitable printer
forreportgenerationwithremotesensorisnormallyavailable.
HighandLowtemperaturealarmunitareprovided.
Condensing unit(s) usually comprise of compressor, forced air
condenser, oil separator, liquid receiver to carry full charge,
filter/dryerwithflareconnections,serviceandisolatingstopvalves,
highandlowpressuredialgaugesandoillevelsightglass.
If the gross volume of WIC is 16 cubic meters approx then the
internalvolumeisapproximately14cubicmeters.
Storageconditionscouldbemaintainedat+20 C80 Ccontinuously,
by controlling the thermostat on WIC. The condensing unit(s) fitted
with high and low pressure cutouts, timeoperated electric defrost
control and compressor motor overloads work together to provide
therequiredtemperaturerange.
WIC are normally fitted with either locally made or manufacturer
suppliedshelvingapproximately600mmwidex600mmpitchfitted
onallwalls.Shelvescarryvaccinevialsincartonboxesandpackages.
The material of the shelves should be non corrosive medical grade
stainlesssteeltotakeloadofatleast20kgpersquarefoot.
Evaporators are forceddraught, electricdefrost, ceilingmounted
unitswithfittedcondensatedriptrayanddrainconnection.
Theroomshouldbefittedwithapressurereleaseventwhichshould
open and allows enough outside air to enter and rebalance any
pressuredifference.
Voltagestabilizerbroadspecifications:
KVARating:Assuitable.
Forsinglephase:InputVoltage160260VAC50Hzandoutput220
240VAC50Hz
For three phase: Input Voltage 275440 V 50 Hz; Output: 400 V+/
1%,50Hz.Threephasefourwires.
Common Specifications: 34 seconds cut off and 2 minutes restart
delay. Facilities should be provided for manual control of output.
Arrangementsshouldallowdirectsupplybypassingthestabilizerin
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case of failures, voltmeter and indicators are normally on the front
panel, with suitable safety and protection devices. Quick start
arrangementforbypassingrestartdelaymaybeavailable.
Recommended
Spare
parts
kit
for
operations
Evaporator/condenserfanmotor;Compressor:capacitor;contactor;
auxiliary relay; defrost timer; dual pressure switch; thermostat;
drier; control switch; fuse, automatic; transformer; high pressure
switchandanyotherrecommendeditem.
Recommended spare parts kit for maintenance of the generator
includes:Spareparts:(inonekit)setoffanbelts10;waterpump1;
fuelpump,withplungeranddeliveryvalve1;setoffrontandrearoil
seals10;gasketO/Hset1;setofpistonrings1setsofdecarburizing
joints2;setofnozzles1;setofinletandexhaustvalves,withguides
1; set of brushes 1; set of rubber parts 10; set of hose pipes 10 ;
air/oil/fuelfilters10;Otherrecommendeditems set:Mainsisolator
switch;fuseprotectionforallphasesforthegenerator;aseethrough
fuelgauge(1each)
Special service tools for WIC/F for refrigeration unit using non
CFC refrigerant: leak detector; servicemans kit in special case (R
134aorR404orothernonCFCrefrigerant),includingvalves,hoses
andmanometers;refrigerantscylinder(R134aorR404orothernon
CFCrefrigerant)),12kg;compressoroiltobeusedwith(R134aor
R404orothernonCFCrefrigerant)
Environmentalfactors
The WICs are capable of operating continuously in ambient
temperatureof5to450Candrelativehumidityof1590%
Complete installation is normally done by the supplier inclusive of
installationofstabilizer,drainagesystemandassemblyofthepanels
and installation of refrigerator units, data logger, generator and
complete earthing and smoke evacuation system, but not including
allcivil,electricalandallotherrelatedworkrequiredforinstallation.
PowerSupply
Power input: 220240V/ 50Hz ACSinglephase or380400VAC 50
HzThreephasefittedwithappropriateIndianplugsandsockets.
Suitablestandbygeneratorset,dieseloperated,220240V/50HzAC
Single phase or 380400V AC 50 Hz Three phase depending upon
voltage requirement of the WIC is normally available.. Output from
generator should be suitable to start and run both cooling units of
WIC. The diesel tank capacity should be minimum 8 hours
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continuousrunning.GeneratorshouldconformtoCPCGuidelineson
sound proof canopy type. Complete installation including earthing
and civil works and fitting should be done in such a way that the
smokeshouldbeemittedoutsidethegeneratorroom/building.
Standards,SafetyandTraining
Electrical and refrigeration components and the panels should have
nationalorinternationalapprovalslikeUL,NSForBIS.
Comprehensive warranty for 2 years and 5 years AMC after
warranty. Normally have local service facility .The service provider
should have the necessary equipments recommended by the
manufacturer to carry out preventive maintenance test as per
guidelinesprovidedintheservice/maintenancemanual.
Provision may be available for all operational and maintenance
training to the end users after successful installation and
commissioning.
Documentation
Followingsaregenerallyprovidedbythemanufacturer:
Certificate of inspection from an independent laboratory
approved
/recognized
by
WHO/UNICEF/National
AccreditationBoard/STQCLabsisessential
List of Equipments available for providing calibration and
routine maintenance support as per manufacturer
documentationinservice/technicalmanual.
List of important spare parts and accessories with their part
numberandcosting.
User/Technical/MaintenancemanualssuppliedinEnglish.
Log book with instruction for daily, weekly, monthly and
quarterlymaintenancechecklist.
The job description of the hospital technician and company service
engineershouldbeclearlyspeltout
1.2 SpecificationsofWIF
Walk in Freezer is required for storing vaccines at - 200C.
Operational Requirements
WIFareconstructedofprefabricated,modularpanelscompletewith
floorandceiling,mountedonaflat,solidconcretebase.AWIFmust
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provide total, 24hour, allseason reliability under all conditions for
thestoredmaterials.
All refrigeration machinery provided with 100% standby capacity,
with duplicate, independent controls, pipe work, instrumentation
and machinery, to provide against failure of the primary system.
Automatic changeover and starting of the secondary system is
provided,activatedbythermostaticorelectricalcontrol.
Recommendedsparepartskitstobeprovidedfornormaloperation,
a provision of a service contract covering routine and emergency
maintenance requirements is generally available, and details of
installationcommissioning and guaranteeperiod are stated
separately.
Technical Specifications
Internal Temperature: 200C +/ 50C adjustable (i) during 430C
continuous ambient (ii) 320C continuous ambient (iii) 45/050C
day/nightcycletemperatures.
Construction: Outer and internal: plastic coated galvanized steel
panelsornoncorrosivemetallicpanelsorfiberglasspanels.
Dimensions:Internalheightof8feet.
Floor dimensions: 18'(L) 12 (B) minimum 3" above the ground
level.Floorshouldbecementconcreteandproperlyleveledandthe
panelsarefittedonthis.
Insulation:Urethanefoamorextrudedpolystyrenefoamcorebonded
tononcorrosivemetalorfiberglasspanels.
Door is provided with frame heating heavy duty lock with internal
safetyrelease,shelvingsystemandplasticcurtainsonthedoorway.
Door(s)tocoldroomsarelockablewith100%failsafeprovisionfor
openingfrominside.Eachentrancedoorhasanincandescentvapor
proof light mounted on the interior of the door section. The door
dimensionsarenormally3'(W)x6(H)
Dual Refrigeration system (100% standby) with air cooled
refrigeration units, plug in type, automating defrosting (electric or
hotgas)havingCFCfreerefrigerantareinstalled.Refrigerationunits
aretropicalizedtomakethemsuitableforambienttemperatureupto
450C.
Suitablestandbygeneratorset,dieseloperated,220240V/50HzAC
Single phase or 380400V AC 50 Hz three phase depending upon
voltage requirement of the WIF is installed. Output normally is
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suitable to start and run both the cooling units. The diesel tank
capacityshouldbeminimum8hourscontinuousrunning.Generator
should conform to CPC Guidelines on sound proof canopy type.
Complete installation including earthing and civil works and fitting
should be done such that the smoke should be emitted outside the
generator room and building. Generator normally have complete
automaticcontrolandbatterysystem.
Wall mounted seven days digital thermometer of 4 digits LCD/LED
Display with data logging capability of 7 days with suitable printer
for report generation with remote sensor is provided for. High and
Lowtemperaturealarmunitisalsoincluded.
Condensing unit(s) generally comprises of compressor, forced air
condenser, oil separator, liquid receiver to carry full charge,
filter/dryerwithflareconnections,serviceandisolatingstopvalves,
highandlowpressuredialgaugesandoillevelsightglass.
If the WIF has gross volume of 16 cubic metersapproximately then
theinternalvolumeisaround14cubicmeters.
StorageconditionsofWIFismaintainedat200C50Ccontinuously,
controlledbythermostatoneachcoldroom,withcondensingunit(s)
fitted with high and low pressure cutouts, timeoperated electric
defrostcontrolandcompressormotoroverloads.
Cold room(s) are generally fitted with either locally made or
manufacturer supplied shelving of approximately 600 mm wide x
600 mm pitch fitted on all walls; shelving store vaccine vials in
carton/boxes/packages. The material of the shelves should be non
corrosivemedicalgradestainlesssteeltotakeloadofatleast20kg
persquarefoot.
Both evaporators are forceddraught, electricdefrost, ceiling/wall
mountedunitswithfittedcondensatedriptrayanddrainconnection.
TheWIFshouldbefittedwithapressurereleaseventwhichshould
open and allows enough outside air to enter and rebalance any
pressuredifference.
Voltagestabilizerbroadspecifications
KVARating:Assuitable.
Forsinglephase:InputVoltage160260VAC50Hzandoutput220
240VAC50Hz
For three phase: Input Voltage 275440 V 50 Hz ;Output : 400 V+/
1%,50Hz.Threephasefourwires.
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CommonSpecs
Stabilizers should have 34 seconds cut off and 2 minutes restart
delayalongwithfacilityformanualcontrolofoutput.Arrangements
fordirectsupplybypassingthestabilizerincaseoffailures,voltmeter
andindicatorsonfrontpanel,suitablesafetyandprotectiondevices
maybeavailable.Quickstartarrangementforbypassingrestartdelay
ishelpful.
System Configuration Accessories, spares and consumables
Recommended Spare parts kit for operations. One kit should
includethefollowingcomponents:
Evaporator/condenser fan motor; compressor capacitor; contactor;
auxiliary relay; defrost timer; dual pressure switch; thermostat;
drier; control switch; fuse, automatic; transformer; high pressure
switchandanyotherrecommendeditem.
Specialservicetoolsforfreezerroomsforrefrigerationunitwith
non CFC refrigerant. Kit include: leak detector; servicemans kit in
specialcase(R134aorR404orothernonCFCrefrigerant),including
valves, hoses and manometers; refrigerants cylinder (R134a or
R404orothernonCFCrefrigerant)),12kg;andcompressoroiltobe
usedwith(R134aorR404orothernonCFCrefrigerant)
Recommendedsparepartskitsformaintenanceofthegenerator
Thekitshouldinclude:
Spare parts: set of fan belts 10; water pump 1; fuel pump, with
plungeranddeliveryvalve1;setoffrontandrearoilseals10;gasket
O/Hset1;setofpistonrings1setsofdecarburizingjoints2;setof
nozzles 1; set of inlet and exhaust valves, with guides 1; set of
brushes 1; set of rubber parts 2; set of hose pipes 1 ; air/oil/fuel
filters10;Otherrecommendeditemsset:Mainsisolatorswitch;fuse
protectionforallphasesforthegenerator;aseethroughfuelgauge(
1each)
Environmental factors
The WIF is capable of operating continuously in ambient
temperatureof5to450Candrelativehumidityof1590%.
Completeinstallationisdonebythesupplierinclusiveofinstallation
of stabilizer, drainage system and assembly of the panels and
installationofrefrigeratorunits,datalogger,generatorandcomplete
earthing and smoke evacuation system but not including all civil,
electricalandallotherrelatedworkrequiredforinstallation.
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Power Supply
Power input: 220240V/ 50Hz ACSinglephase or380400VAC 50
HzthreephasefittedwithappropriateIndianplugsandsockets.
Standards,SafetyandTraining
Electricalandrefrigerationcomponentsandthepanelshavenational
orinternationalapprovalslikeUL,NSForBIS.
Comprehensive warranty generally is for 2 years and 5 years AMC
after warranty. May have local service facility.The service provider
normally have the necessary equipments recommended by the
manufacturer to carry out preventive maintenance test as per
guidelinesprovidedintheservice/maintenancemanual.
All operational and maintenance training to the end users after
successfulinstallationandcommissioningmaybeprovided.
Documentation
Followingdocumentmayavailableforsafekeeping:
Copy of Certificate of inspection from an independent
laboratory approved /recognized by WHO/UNICEF/National
AccreditationBoard/STQCLabsisessential
List of Equipments available for providing calibration and
routine maintenance support as per manufacturer
documentationinservice/technicalmanual.
List of important spare parts and accessories with their part
numberandcosting
User/Technical/MaintenancemanualsinEnglish.
Log book with instructions for daily, weekly, monthly and
quarterlymaintenancechecklist.
The job description of the hospital technician and company
serviceengineer.

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2 ProcedureforInstallationofcoldroom

Figure 5: Erection plan for cold room

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Figure 6: Mounting the cooling unit

$ Important: Look for the numbers / marks on the panels. They

needtomatchforjoiningtwopanels.Identifyandarrangethepanels
accordingly.Installationoftheroomshouldbedoneinthefollowing
order:

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Figure 7: Overview of installation and assembly

2.1 Installationofpanel
Installthefloorpanelsfirst.
Startinstallationofthewallpanelsfromonebackcorner.Startone
cornerpanelandfixonewallpaneloneachside.Goontillallthe

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backandsidepanels,exceptthelastwallpanelononeside.This
spacewillbenecessarytoinstallthecoolingunit2fromthisside.
Install two roof panels from back and dont install the front roof
panelnow.
InstallOnefrontwallpanel(14)(formountingcoolingunit)fromthe
cornerpanel(13)onthesidewhereallthewallpanelsinstalled.(At
present,thespacefordoorpanelandanotherfrontwallpanel,one
corner panel, one sidewall panel and the front roof panel are
empty)
BringCoolingunitIintothespacemeantforthedoor,liftitupover
the front panel and place the same on the grooves provided on the
frontwallpanel.

$ NOTE: The two grooves provided for mounting the cooling unit
maybelittlenarrowtofittheunitproperly.Thesidesmayhavetobe
widenedbyabout5mm.Cut/filethesided
AfterfittingtheCoolingunit1,installthedoorpanel.

$Important:Keepthedoor framefirminpositionbyfixingpieces
ofplank/timberwithscrewstotheframeandfixingtheotherendof
the plank/timer on the middle roofpanel. Otherwise there is a
dangerofthedoorfallingdown.
InstalltheotherfrontwallpanelandmounttheCoolingunit2onit,
fromtheopenside,byliftingandbringingoverthepanel.
Installthelastsidewallpanelandthenthelastcornerpanel.
Installthefrontroofpanel.
Fit the floor strip and the front strip on the threshold of the door
withscrews.
Fit the plastic curtain on the door, from inside, with 6 screws, by
drillingholesatsuitablepositions,ifnecessary.
Fillupallthespaceinthefourgroovesinthetwofrontwallpanels
(On which the freezing units are mounted) with PUF foaming
(supplied).

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Figure 8: Details of typical insulated panel

2.2 Installationofshelves
Therailsformountingtheshelvesshouldbefittingtouchingtheroof
andtheotherendbeingabout10cmabovethefloor.
2.3 Installationofroomlight&connectingdoorheater
Fit the room light at the centre of the room on the roofpanel and
takeoutthecablefromtopofroom,ifrequiredbydrillinga holein
theroofpanel.
Fittheroomlightswitchontheleftsideofthedoorpanel(belowthe
coolingunit).Fixthejunctionontopoftheroof,preferablynearthe
leftsideofthedoorpanel.Makeconnectionform7NPEofFreezer
room panel for input power to the junction box. Make room light
andswitchconnectionsfromthejunctionbox.
2.4 Installationofpressureventilator(Breeder)
Pressure Ventilator is to be installed on the
outside, on the wall panels. Select a suitable
location,25cmbelowtheroof&wallpanels
joint,suchthatthejointandalsothevertical
railfixedfortheshelves(inside)areavoided.
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Drillaholefirstandthenwidenthesamewithcutterorchiselsuch
thatthepipeofthePressureVentilatorcanbeinsertedsmoothly.The
panels can be cut easily as they are quite soft. While inserting the
pipe for final fixing, apply Mastic on the outside of the pipe. Fix the
PressureVentilatortotheoutsidewallswithscrews.
AfterinstallationoftheFreezer/coolingunit,aholeistobedrilledon
thewallatasuitablelocationonthewalltobringthedefrostwater
drain pipe (from inside of the room) to the defrost water tray
(outside the room), on the Unit. The metal L is to be connected to
theendofthepipe,preferablykeepingtheopenenddownwardsand
touching the tray. The plastic tube may melt, if it comes to the hot
traysurface.

IMPORTANT

$ Connect the cable for doorheater connection (along with the


cable for light) from terminals 7 & n of the freezer room control
panel.Inthedrawingitisshowntobeconnectedfromterminals9&
10 (i.e. from the Faulty circuit safety switch 300 mA, which is a
circuit breaker). It was observed that if the earthing is not proper,
thissafetyswitchtripsoffveryoften,whenconnectedfrom910.So,
the supply for the door heating is also taken from 7N. KEEP F40
BREAKEROFF.

$ Freezer room control panel main switch must be turned to off


positiontoopenthefrontcover.

$ The generator control panel comes along with the generating


set,intwoparts.Thepanelandtheelectronicsunitseparately.They
need to be assembled together. This panel can be mounted on the
wall, using the laminated board (Black) provided. In case, the
generatorisinstalledinthesameroomasthatoftheWIC/F,thiscan
befixedontheWIC/Foutsidewallsalso.

3 Engineeringdiagramsforassemblingandinstallationof
WIC/WIF

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Figure 9: Schematic diagram of cooling unit

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Figure 10: Power supply control circuit

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Legend
F1
F2
F11
F12
F13
FB1
H1
H2
K1
K2
K11
K12
K13
K21
K22
K23
KAP3
KAP4
S1
S11
S12
S13
S14
S15
X1
X2
X3
XA
XB

Description
Circuitbreaker,10A,(K1circuit)
Circuitbreaker,16A,(Generatorpowercircuit)
Circuitbreaker,16A,(CoolingUnitI)
Circuitbreaker,16A,(CoolingUnitII)
Circuitbreaker,16A,(Roomlight&3.4Vrectifier)
Transformerfor3.4Vrectifier
Signallight(Red)(Enginefailureindication)
Signallight(Yellow)(DriveMemory)
Contactor(Networkpower)
Contactor(Generatorpower)
Sequencerelay(Networkpower)
Timedelayrelay(Networkpower)
Relay(NetworkpowerSensing)
Sequencerelay(Generatorpower)
Timedelayrelay(Generatorpower)
Relay(Drivememory)12V.DC
CircuitCard(Generatorcontrol)
3.4V.Rectifiercircuitcardforrecordersupply
MainSwitch(Networkpower&12V.DC.inputs)
SelectorswitchUNITI/UNITII(ForGeneratorsupply)
PressbuttonRESET(Drivememory)
PressbuttonSTOP(Generator)
PressbuttonSTART(Generator)
Selectorswitch,HAND/AUTODRIVE(Generator)
Plug
Terminalstrip
Junctionbox
Terminalstrip(KAP3)
Terminalstrip(KAP3)

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Figure 11: Cooling unit

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Legend
C1
C2
F1
H1
H2
K1
M1
M2
M3
P1
R7
S1
S2
S3
S4

Description
Capacitor(Evaporatorfanmotor)
Capacitor(Condenserfanmotor)
Circuitbreaker
Signallight,Green(Mainsupplyindication)
Signallight,Yellow(Defrostingindication)
Contactor(Powerinputtocompressormotor)
Contactormotor,400V.3
Contactorfanmotor,220V.1
Evaporatorfanmotor,220V.1
DefrostTime
Varistor(K1circuit)
ON/OFF/switch,power
Thermostat(Compressormotorcontrolcircuit)
Pressostat(Compressormotorcontrolcircuit)
Pressostat(Compressormotorfancircuit)

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Figure 12: alarm unit

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Legend
A2
A11
G1
H1
H2
K1
K2
P1
S1
S2
S3
S4

Description
Alarmcentre
Alarmdevice
Battery,(8x1.5V.)(Internal)
Signallight,Green,(Networktoovoltage)
Signallight,RedAlarm
Alarmrelay12V.DC.(Temp.tooHigh)
Alarmrelay12V.DC(12.V.DC.failure)
Delaytimer(K1relay)
MainswitchforAlarmcenter
Testbutton(Alarmoperation)
AlarmThermostat(Temp.tooLow)
AlarmThermostat(Temp.tooHigh)

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Figure 13: Temperature recorder

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Legend
A3
G1
K1

Description
Recorderunit
Lightbattery,3.4VsizeAA/IEC,R6(Internal)
Changeoverrelay(Internal/Externalpower)

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Figure 14: Generator control unit

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4 ComponentsofWIC/F
4.1 Coldroompanels
Theseareprefabricatedinsulatedroomsassembledinsideastoreor
largerroom.Suitableshelvesareprovidedinsidethemforstoringthe
vaccines.
4.2 Coolingunits
This insulated room is kept
cold by two nos. of cooling
/freezing units, mounted on
its walls. The working of the
coolingunitsarecontrolledby
their thermostat to maintain
theinsidetemperaturewithin
+20 Cto+80CincaseofWalk
inColdRooms and ()250 C
to()150CincaseofWalkin
Freezer Rooms. One Cooling
/Freezing unit is sufficient to
maintain the temperature in
the required range. The
second unit is provided as
standby.
Note: Only one unit works at any time. But in the old models of the
WICs the thermostats of the units are so adjusted that one unit
works when the inside temperature is about +50C and goes off at
about +40C and the other works when the temperature is about +70C
and goes off at about +60C.
Therefore, when the temperature is around +50C, only one unit
works. But, if due to door opening, storage of new vaccines, higher
ambienttemperature,and powerfailureetc.the temperature of the
coldroomrisesabove+70C,boththeunitsworktogether.Whenthe
temperaturecomesdowntoabout+60C,the2ndunitstopsandonly
the first unit works and maintain the vaccines at the lower
temperature.
Theevaporatorsfansofthecooling/freezingunits(insidethecold/
freezerroom)blowthecoldairfromtheevaporatorandcirculateit
insidetheroom.Theyruncontinuously.
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Thecondenserfansoftheunits(outsidethecold/freezerroom)cool
the condenser coils and they run only when the compressor is
runningandsufficientpressurebuildsupinthecondensers.
Defrosting of the evaporator is done automatically by the defrost
timer in the Master Log, at preset intervals for predetermined
periods.Thisallowsthefrosttomeltanddrainout.
Table 1: Components specification
Description
Specification
Coolingunit(WIF1620m3)
Type

JB0036401(MPN16)

Pressure

26Bar
Compressor

Make

Maneurop/MPN16A

Model

LTZ44HM4VE,Thermally
protected

Voltage

460v3phase50Hz

Amp

10Amp

Frequency

LR47a

Refrigerant

507/404

Pressure

bar25/363psi

Lubricant

LubricantsPOE160z
Coolingunit(WIF32m3)

Type

JB0036401

Pressure

26Bar
Compressor

Make

Maneurop/MPN36A
Reciprocating

Model

LTZ50HM4VE,Thermally
protected

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Description

Specification

Voltage

400v350Hz

Frequency

LR47a

Refrigerants

507404

Pressure

Bar25/363psi

Lubricant

LubricantsPOE160z
Condenserfan

Make

FMV(MadeinFrance)

Type

JA350VD

Voltage

230v1.2Amp230w

Airflow

3600m3/h

Capacitor

MFAJA5MF5%450V;
Evaporatorfan

Make

FMV

Type

A404PL25

Voltage

230V,1.9A

RPM

1500RPM

Airflow

5000m3/h
Temperaturerecorder

DCdrybattery

1.5voltD.C

Model

D31690

Temperaturechart

+15cto35c
Temperaturesupervisor

Model

VHA12/41

ACAdaptor

9voltD.C.(Battery)

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Table 2: Refrigerants for various compressor models

Sr.
No.

CompressorModel Refrigerant

MTZ644VM

R134a

MTZ734VM

R134a

MTZ804VM

CFC

Application

CFCfree

Walk in Cold Room 16.5 c


capacity

CFCfree

Walk in Cold Room, 20 c


capacity

R134a

CFCfree

WalkinColdRoom 32cumcapac

LTZ0284VM

R404a

CFCfree

WalkinFreezer,12cum

LTZ0444VM

R404a

CFCfree

WalkinFreezer,1620cum

LTZ0504VE

R502a

CFCfree

WalkinFreezer,32cum

TAJ4511A

R12

CFC

Walkincooler16.5cumHuurre

ASPERA(J6626M) R12

CFC

Walkinfreezer32cum,Huurre

CAJ4511

CFC

Walkincooler16.5cumFoster

R12

4.3 Coolingunit(EUROMON2)
( Remember to physically inspect
the equipment upon arrival for any
damages.Reportwithin48hrsforany
damage to primary packaging or
equipmentitself.
( In case of medium or longterm
storage of cooling unit without use,
leave protective and insulation
elementsinpositionandstoreinsafe
anddryarea.

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Figure 15: Mono block layout

Themonoblockunitmaybeeasilywallmountedinthecoldstorage
room. At least two fastening points have been incorporated on the
compressorsidetofasten(withscrew)themonoblockunit(outside
thecoldstorageroom).
( Attention: The monoblock unit must be installed with a spirit
level to ensure the inclination required for evacuation of defrost
water,isrespected.
Cuttingthecoldstorageroomwall
Themonoblockunitisinstalledinthecoldstorageroomwalleither
by creating two recesses in the top panel section (see fig. A), or by
cuttingapaneltosuittheunitcoolerdimensions.Thispanel isthen
fastened to the rear support of the monoblock unit (see fig. B). In
bothcases,thefinalsealingisachievedwithamasticseam.

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Before installing the ceiling panel on the cold storage room, two
notches and a 25 hole must be made. After having removed the
foam and folded back the metal tabs, insert the arms of the
monoblockunitinthegrooves.
Fitthecoldstorageroomceilingpanel.

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After installation of the ceiling panel, cut the panel to suit the unit
cooler dimensions. Allow for passage of the arms. Fasten the mono
block unit to the cutout section. Insert the unit cooler section into
thecoldstorageroom.
4.4 Cold/freezerroomcontrolpanel
The cooling /freezing units run from 230/400 volt, single/three
phase, 50 Hz. AC power supply, normally
form the mains (Network) power and in
caseofitsfailurefromtheGeneratorpower.
The Cold / Freezer Room panel receives
1/3 phase electricity from the Generator
Control panel (Either mains or Generator
power) and supplies 1/3 phase power to
Cooling /Freezing units and single phase
(230V) power to room lights, Door Heater,
Alarm system adapter and also to the
PressureReliefValueheaterincaseofWIF.

5 Coldroomprogramming
Thefunctioningofcoldroomcanbeprogrammedthroughthemaster
log.Masterlogshouldbeusedtoconfigurethefollowingparameters:
1) Setpoint(CompressorcutoffpointinDegreeC)
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2) Differential(Compressorstarttriggerpoint)
3) Defrostingcycle
4) Alarmsettings(Lowandhightemperaturealarms)
5) Functioningofevaporatorandcondenser
Cold rooms that are supplied with Master log have factory pre
settings that can be used to standardize the required mode of cold
roomoperation.

CAUTION: Master log should only be modified by technically


qualified personnel when required. The faulty settings can damage
thevaccineinbulkvolumeandwillalsocausedamagetocoldroom
hardware.
5.1 Factorysetting
.Table3belowshowsthedefaultfactorysettingsforeachoftheparameter.
ThesesettingsaredifferentforWICandWIFasindicatedbelow.
Table 3: Default factory settings of master log

Display

Parameter

WIC(L1)

WIF(L5)

C1(0C)

Setpoint(forinsidetemperature)

18

C2(0C)

Temp.Controldifferential

C3(hr)

Timebetween2defrosts

912

C4(0C)

Endofdefrostingtemperature

15

C5(min)

Maximumdefrostingtime

45

20

C6(0C)

Hightemperaturedefault
difference

C7(0C)

Lowtemperaturedefault
difference

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Display

Parameter

WIC(L1)

WIF(L5)

C8(min)

Alarmdelaytime

45

45

C9

Fanoperation

C0

Energysavingdefrostfunction

CH

(Notinuse)

(0)

(0)

S1Sensorvalue

Readonly

Readonly

S2SensorValue

Readonly

Readonly

MC

CompressorOperation

32

Descriptionofparameters

$C1andC2:Setpointanddifference

$ C3: Time between defrosts. Sets the time, in hours, between 2


defrosts when parameter C0=0 (energy saving Defrost inactive).
WhenC0=2;3;4;5;6;7or8,C3setsthemaximumtimebetween2
defrosts.

$C4:Endofdefrostingtemperature.Whendefrostingiselectricalor
hot gas (L2 or L5): sets the cut off temperature for battery heating
(measuredbysensorS2).
Note: The value of C4 should be checked as mentioned in the
subsequentsectionanduseonlyrecommendedsettings.

$ C5: Maximum defrosting time. Sets the defrosting time for


programsusingairdefrosting(L1).Forotherdefrostingsystems,the
heatingtimeislimitedincaseofSensor2(S2)malfunction.
Note:C5=0meansnodefrosting.

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TIME-TEMPERATURE GRAPH
0
1

10

11

Defrost stops at 4.50 hrs


Defrost starts at 3.45 hrs

Defrost stops at 8.50 hrs

Temperature

-5
Defrost starts at 7.50
hrs

C5, Defrost Time

C5, Defrost Time

-10
C3, Time Between two defrost
C4, End of Defrost temperature

-14

-14

-15
-16

C1

-16
C2/

-18

-18

-18
-19

C2/2

-20

-20

-20

-20

-25

TIME

$C6: High Temperature default. Maximum difference between set


point(C1)andthemaximumtemperatureinsidecoldroomreadby
sensorS1.

$ C7: Low temperature default. Maximum difference between set


point (C1) and the minimum temperature inside cold room read by
sensorS1.

$ C8: Alarm delay time. Delay for display and start of alarm after
faultdetection.

$C9:Fanoperation.
C9=0;fanlinkedtocompressoroperation
C9=1; fan operates continuously (Note this parameter is only
usedbyL1andL2)

$ C0: Energy saving Defrost (Intelligent defrosting principle). The

system continuously monitors the difference between the


evaporationtemperatureandthetemperatureinthecoldroom.The
unit functions optimally by using a microprocessor. It checks the
increaseofthisdifferenceaftertoomuchfrostingintheevaporator.
The time between two defrosts is thus optimized in relation to the
operatingconditions.
If C0 = 0: Defrosting by clock defrosts are stated in cycles by
parameterC3.

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If C0 = 2, 3, 4, 5, 6, 7 or 8: Defrosting on request Starts the
intelligentdefrostingfunctionforprogramsL2andL5.
The parameter is set to 3 on delivery. Modifying this parameter
changesfunctionalsensitivityanddefrostfrequency.
If C0=2: Maximum sensibility of detection system. This causes
increaseddefrostfrequency.
If C0=8: Minimum sensitivity of detection system. This causes
reduceddefrostfrequency.

Note:TocancelthisfunctiononWIF,setparameterC0to0and
setparameterC3from4to6hours(timebetween2defrosts).

$1: Sensor S1. Instantaneous value of sensor S1 (inside


temperatureofcoldroom).Thisisreadonly.
$ 2: Sensor S2. Instantaneous value of sensor S2 (sensor on
evaporator).Thisisreadonly.

Table 4: Setting of C4 and C5 according to the type of equipment.

Description
PositionofS2
onevaporator
coil

P13A

N36A

(16m3WIC/WIF)

(32m3WIC/WIF)

Program

L1(WIC)

L5(WIF)

L5(WIF)

+150C

+250C

C4
C5

45Minutes

20Minutes

5.2 Modifyingthemasterlogsettings
Programmodification
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Coldroomprogrammodification(selectionofcoldroommodefrom
L1 to L5) is possible during the 4 seconds when the display flashes
andshowstheprogramnumberwhenswitchingonthecoolingunit.
ForexampleforWIF,whenswitchedon,masterlogdisplaysL5for
4seconds.
Table 5: Program modification

Action

Result

Press+3times,andthenpress
once.

ThedisplayshowsL0.

$ValidatebypressingV.

ThedisplayshowsL1flashing.

$Press+ortounthroughthe

DisplaywillshowL1toL5oneverypress.

$ValidatebypressingV.

The program loads as when energizing,


the new program is displayed and all the
equipmentselectricalfunctionsaretested
(CF,finalinspection,displayed).

programlisttodisplaytheselected
program

The cold room temperature is displayed


andregulationcyclestarts.
Note:ThisprocedurecanchangethemodeofcoldroomfromWIFtoWIC.User
shouldbecarefulinmodifyingthesesettings.
Afterachangeofprogram,theC1andCHsetpointsaresettothefactorydefault
valuesfortheselectedprogram

Readingandmodifyingthecoldchambersetpoint
In normal operation the set point of the cold room can be read or
modified(ParameterC1).
Thedisplayinmasterlogshowstheinsidetemperatureofcoldroom
(fromsensorS1).
Table 6: Reading and modifying the cold chamber set point.

Action

Result

Press+or for3seconds.

ThedisplayshowsC1andthesetpoint(in
DegreeC)alternately.

$Ifthesetpointiscorrect(desired

NOChangeinsetpointvalue.

value):ValidatebypressingV.

$Ifthesetpointisincorrect(need

The new set point will be displayed on


LED.

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Action

Result

tobechanged),press+or as
oftenasnecessarytodisplaythe
valuedesired(1press=1unit).

$ValidatebypressingV.

Set point changed. Cold room will now


operateonnewsetpoint.

Forceddefrosting
Table 7: Forced defrosting

Action

Result

Press+and atthesametimefor3
seconds.

Displayshowsddflashing.

$ValidatebypressingV.

Display shows dd permanently during


thedefrost.

$Thecoldroomtemperaturecanbe
seenbypressingVduringdefrosting
$Defrostingcanbestoppedby
switchingOFFandON.

Displaysthecoldroomtemperature.

Defrosting stops and cold room will


resumebacktheoperation.

Note:Manualdefrostingmovestheautomaticdefrosts.Thenextone
takesplaceafterthetimesetinC3,ifC0isinactiveorequaltozero.
Controlandmodificationofinstalledparameters
Table 8: Control and modification of installed parameters

Action

Result

Press+, andVatthesametimefor
3seconds.

DisplayshowsIn(Installer)flashing.

$ValidatebypressingV.

Display shows C1 Alternating with the


parametervalue.

$aparametercanbemodifiedusing

Change the default value of selected


parameter.

+andandthenvalidatewithV
$EachnewpressonVdisplaysthe
nextparameterwithitsvalue

Parse through all the parameters and


changevalueasdesired.

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Note: It is necessary to validate the last set point to return to the
normal display mode. Without manipulation of the keyboard, the
displayturnstothenormalmodeafter4minutes.

+
V

- 16oC

In

+
V
-

In

+
V
+
V
+
V
-

C I

CI

-18

-18

-17

-17

-18

All 3 buttons pressed. Cold Room


temperature display will change to
In Master log is ready

Press V In will change to CI.


Master log is sensing value of
CI

Press V CI will change


to its set value. Master log
is ready to accept
changes for new values of
CI
When + is pressed value of
CI increases
When + is pressed value of
CI decreases

Figure 16: Pictorial representation of programming sequence

5.3 Interpretingtheoperatingmessages
At any point of time, master log may flash any of these following
indicators.Theseindicatorsindicateasexplainedintablebelow.
Table 9: Interpretation of indicators.

Indicator

Interpretation

HT

(High temperature alarm): Inside temperature is


abovemaximumlimit

LT

(Low temperature alarm) : Inside temperature is


belowminimumlimit

PP

Probe Failure short circuit, circuit open, without


probe

EE

Memoryerror.

5.4 Diagnosisofproblems
Table:Problemdiagnosis
Faultindicator
F1blinksalternatively

Problem
description
Differencebetweenthe

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Faultindicator

Problem
description

Diagnosis

withcoldroom
temperature.

temperatureofSensor
1(Coldroom)andSensor
2(evaporator)isless
then20Cduringalarm
delayperiod(S1S2<
20C).i.eTheevaporator
temperatureisnearly
equaltothecoldroom
temperature.

F2Blinksalternatively
withcoldroom
temperature

Differencebetweenthe
$Fansareoutoforder
temperatureofSensor
1(Coldroom)andSensor $Icingofthe
2(evaporator)ismore evaporator.
then200Cduringalarm
Note:Atthefirststartup,
delayperiod(S1S2>
F2mayappear.
200C).thisshowsan
evaporatorproblem

Greenlightblinks

Defrostwasendedby
defrostingtimerset
throughC5parameter
andnotbysensor2on
evaporator.

leakageofrefrigerant.
Note:Fornegative
application(with
capillaryexpansion
device),theevaporator
notbeingfilledenough,
F1mayappear.Toavoid
that,programanalarm
delaylongerthen45
minutesifnecessary.

$Checkthelocationof
S2(Sensor2)

$Maximumdurationof
defrostistooshort,
increasetimesetinC5
$Notenoughdefrost,
lowerC3(timebetween
twodefrosts)when
intelligentdefrostingis
notusedorlowerC3
whilethisfaultexist.

T1Blinksalternatively
withcoldroom
temperature

HighTemperaturealarm.
Coldroomtemperature
ishigherthenhigh
temperaturealarmset
throughC6

$Messageoccursonly
afteralarmtimedelayset
throughC8hasreached.
Checkcoldroomforhigh
temperature.

T2blinksalternatively
withcoldroom
temperature

Lowtemperaturealarm.
Coldroomtemperature
islowerthenlow
temperaturealarmset
throughC7.

$Messageoccursonly
afteralarmtimedelayset
throughC8hasreached.
Checkcoldroomforlow
temperature

Note:T1,T2orA1aredisplayeduntilpressingVonkeypad.

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Faultindicator

Problem
description

A1isdisplayed

Auxiliaryinputisclosed.

S1Blinksalternatively
with

Thecondensingunit
worksonits4lasthours
historicalaccount

Diagnosis

$PressVtoreset
$S1sensorfaultyor
shortcircuited.
Whenswitchingonthe
historicalaccountisfixed
to50%ONand50%OFF

S2Blinksalternatively
withcoldroom
temperature

S2sensorfault

S2(evaporatorsensor)
faultyorshortcircuit.
Theendofdefrostis
detectedbythemaximim
durationtimesetbyC5.

S1,S2andBlinks
alternatively

S1andS2sensorsfaulty

ChecksensorS1andS2.

6 AlarmSystem
An Alarm system is provided to monitor the cold /freezer room
temperature.ItactuatesAudioandVisualalarmimmediately,incase
of the temperature goes down &
crosses the lower setting. But
whenthe temperature risesto the
upper set limit, it operates with a
preset delay. In alarm condition,
pressing a button can stop the
Audio alarm, but Visual alarm will
continue till the alarm condition
prevails or the alarm system is
switched off. There is also a test
button provided to test the
functioningofthealarmsystem.
6.1 Installation
ThealarmunitVHA12/41hastobemountedonawallby4screws
(platescrew04,2x22).Beforethat,youmustremovethetoplidof
thecase.Locationsofthefixingholesareatthecornersofthecase.
After the case has been tightly mounted on the wall, you should
installthe9Vbatteryintoitsholder.Finallyclosethelidofthecase.
It is possible to connect up to 4 temperature sensors to the VHA
12/41.
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Theaudibleremotealarmbuzzerhasitsownconnectionpositionsas
wellastheelectricsupplyfromthetransformer.Thetransformeris
connectedtoasupplywith230V.
Theconnectionpositionsaremarkedonthelidofthealarmunit.The
temperaturesensorisinstalledwithafastenerandplatescrews.
6.2 Operation
TheVHA12/41temperaturealarmunitiscontinuouslymonitoring
allthesensorsattachedtoit.
Whenever, the temperature of any sensor deviates from the preset
valid operating range, an alarm condition is activated. The upper
temperaturelimitcanbe+30Cmaximumandthelowerlimit40C
minimum.
The alarm condition on the lower limit causes an alarm action
immediately, but on the upper limit the alarm action is delayed by
0.99 minutes depending on the preset value. The alarm is indicated
byared LED lamp andalso by audible signal, ifan optional remote
alarm unit has been connected. That audible alarm can be
acknowledgedandsilencedbyapushbuttononthealarmunit.The
alarm unit indicates the channel causing the alarm condition by
flashingthedisplay,whenthatchannelnumberisonthedisplay.
TheLEDlampAlarm/Lowbatlightsduringapowercutunlesslow
batteryconditionhasbeendetected.
6.3 Setup
Setup procedures are carried out by three push buttons. These
buttonsareplacedunderthelid.
PushandkeepdowntheSETbuttonabout4secondtoactivatethe
programmingmode.Thenyoucanseeatext140orlNN,where
in the place of the NN is the currently preset lower limit value. The
firstdigit(here:1)correspondstothecurrentchannelnumber.
Hit the UP button to advance the list of the available setup
parameters.YoucanpushtheDNbuttontomovebackwardonthe
samelist.Thetextdisplayedchangesaccordingtotheparameter.The
following paragraphs 3.1 to 3.4 will explain these parameters in
detail.Aftermodificationsaredone,justleavethebuttonsandwait.It
takes10secondtoresumethenormaldisplay.
Lowerlimit:displayedl40orlNN

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The underscore mark reminds you o lower limit setup. Set the
desired lower limit value by pushing and keeping down the SET
buttonwhileyoutapeitherUPbuttonorDNbuttontoadjustthe
valueupordown.Whenthewishedvaluehasbeenreached,release
theSETbutton.orlNN
Upperlimit:displayedl30orlNN
Theoverscoremarkremindsyouoftheupperlimitsetup:Setthe
desired upper limit value by pushing and keeping down the SET
buttonwhileyoutapeitherUPbuttonorDNbuttontoadjustthe
valueupordown.Whenthewishedvaluehasbeenreached,release
theSETbutton.
Calibration:displayedIc0orIc+NorIcN
The c character reminds you of the calibration setup. This setup
phaseisnotnecessaryifthetemperaturereadingforthechannelis
perfectlyaccurate.Inthismodeyoucannowcalibratethereadingof
the actual channel. Thats synonymous to correcting a possibly
inaccuratereading.Thecorrectionisdonebysettingacertainoffset
value on the display. An example: The alarm unit shows +7 C
although the correct temperature would be +5 C. To correct that
value,anoffsetof2shouldbeadded inordertogetintoit.Setthe
displaytextuntilIc2readsonit.Thecalibrationrangeisfrom9C
to +9 C. Set the desired calibration value by pushing and keeping
down the SET button while you tap either UP button or DN
button to adjust the value up or down. When the wished value has
beenreached,releasetheSETbutton.
Upperlimitdelay:displayed1:99or1:NN
Thecoloncharacterremindsyouoftheupperlimitdelaysetup.Set
thedesiredupperlimitdelaybypushingandkeepingdowntheSET
buttonwhileyoutapeitherUPbuttonorDNbuttontoadjustthe
valueupordown.Whenthewishedvaluehasbeenreached,release
theSETbutton.
6.4 Maintenance
The9Vbatteryshouldbereplacedafteroneyearofdutyorafterlong
powercutperiods.
InAlarmcondition,acknowledgebypressingtheRedbuttononthe
indicatorunit.ThiswillstoptheAudiosignalonly,buttheblinkingof
theindicatorlamp(LED)willcontinuetillthealarmconditionisover
orAlarmunitisputoff.Now,ascertainthetemperatureinthecold
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room from the temperaturerecorder or from the dials of the
thermostats on the cooling units (which will be indicated by the
blackhandonthedial).
(a) If the temperature in the coldroom has gone below +2C,
observewhichofthecoolingunitsisrunningitscompressor.Noteit
andputOFFthisunitimmediately.(Thismaybeduetodefectinthe
thermostatinthisunit,whichmayhavetobereplaced,ifrequired).
Also, open the coldroom door till the temperature rises to above
+2Candthealarmconditionisoverandthencloseit.
(b) If the temperature in the coldroom is observed to be higher
than +10 C examine the coolingunits if they are working.
Temperature may rise sometimes, inspite of both the coolingunits
working normally. This is possible in situation when a fresh lot of
vaccineofconsiderablequantityisputintothecoldroomwhilethe
ambienttemperatureisconsiderablyhigh.Insuchcases,there isno
other alternative but to wait and keep the units running under
observation. If you feel, you can keep the alarm circuit OFF by its
switchuntilrequiredtemperatureisreached.
If it is observed that the Alarm is for high temperature but cooling
units are not working then there may be some trouble in the
Electricalsystem.

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Chapter3:PreventiveMaintenance
Contents
Guideonpreventivemaintenance
Preventivemaintenanceofcoldroomsshouldbescheduledand
practicedbyrefrigerationtechnicianandcoldroomincharge.This
sectionprovidestheguideonhowtoplanandschedulethepreventive
maintenanceofcoldrooms.
Thissectionprovidesachecklist,acopyofwhichshouldbeattachedto
eachcoldroomasalogsheetofpreventivemaintenance.

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1 Routine Maintenance
Keepthespaceoutsidetheroomcool
Keep the space outside the cold room or freezer room as cool as
possible.Condenserunitsgiveoffaconsiderableamountofhotair.If
this hot air is not removed from the environment, the efficiency of
the cooling units is reduced. Trees or screens help to shade the
buildingthathousesthecoldstore.Goodventilationremovesthehot
air. Alternatively, air conditioning may have to be used to keep the
spacecool.
Keepthecondenserunitwellventilated
Do not allow rubbish and packaging to accumulate in the vaccine
storagearea.Itisessentialtomaintainfreeairmovementaroundthe
condensingunits.
Carryoutminormaintenance:

$Cleantheroom
$Adjustthermostat.
$Checklockandhingesofdoor.
$Manualdefrostingifneeded.
Maintainthestandbygenerator:

$Keepbatterycharged.
$Keepdieseltankfull.
$Runthegeneratoreveryweek.
$Maintainlogbook.
Knowwhereswitchesandfusesare:
Find out where the main switch and electrical fuses are. Make sure
thatyouhavesparefusesandknowhowtofitthem.
Knowyourchangeoverswitchandcontrolpanelofgenerator:
Find out what is the maximum permissible ampere. Call technician
whenampereshowsmorethanpermissiblelimit.
Know your service agency and update the AMC with full
clarifications.

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Find out the name and telephone number of the service agency
and/or the telephone number of the maintenance technician. Have
thenumbersreadyforuseincaseofemergency.
Listentothecoolingequipment
Listen to the cooling equipment when it is working correctly. This
helpsyoutoknowwhatisnormalworkingsoundandidentifyfaults
beforetheybecometooserious.Coolingequipmentrunsmoreoften
duringthehotseasonthanduringcoolerperiods.Incoldweatherit
may run very infrequently. The running time of the cooling
equipmentincreasesifthedoorisopenedfrequently.
Learn about the working of the automatic changeover system.
Generallythisissetupsothatonecoolingunitrunsfor24hoursand
anothertakesoverforthefollowing24hours.Thisisknownasduty
sharingandensuresthatbothunitsgetthesameamountofuse.

2 DailyCheckUp
Temperature:Autotemperaturerecordingandtwiceaday
Check the temperature of the WIC/F twice each day. Cold rooms
must be kept between +2C and +8C. Freezer rooms must be kept
between15Cand25C.Maintainlogbookifautomaticsystemdoes
notwork
CheckinsidetheWIC/F.

$Istheairflowfromtheevaporatornormal?
$Istheevaporatorfanrunningquietly?
$Is there water on the floor? If there is, the evaporator

drainpipemaybeblocked.

CheckoutsidetheWIC/F.

$Removeanyrubbish.
$Check for signs of vermin such as cockroaches, mice, rats
andbats.

$Cleanthefloortwiceaweek.
Attheendofthedaymakesurethat:

$AlllightsintheWIC/Fareswitchedoff;
$ThereisnobodyinsidetheWIC/F;
$ThedoortotheWIC/Fisclosedandlocked.
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3 Weeklychecks
Changethetemperaturechart
Ifyouhaveachartrecorderwithapaperdisc,changethediscatthe
end of each week. Write the start date on the new chart. Write the
finishdateontheoldchartandkeepitsafelyinafileforatleast12
months. If the recorder is operated by clockwork, wind up the
mechanism.Refilltheinkcontainersandcheckthepens.
1. Changetherefill/penifneeded.
2. Setthethermostatifneeded

Checktheliquidsightglasses:
Ifthecoolingunitshaveaccessiblesightglasses,checkthat bothare
filledwithliquidandshowdryconditions.Ifyouseebubbles,there
may be a leak of refrigerant. If the moisture indicator shows wet,
the filterdrier probably needs changing. Ask the service agency or
maintenancetechniciantocheckandreplaceitifnecessary.
Checkicebuildupontheevaporator
Check the ice formation on the evaporators. Look at the pipes and
fins.Mostmoderncoolingunitshaveanautomaticdefrostingsystem.
If they are coated with ice more than 6 mm thick, the evaporator
needsdefrostingandtherecouldbeadefectinthedefrostingsystem.
Asktheserviceagencyormaintenancetechniciantocheck.
Checkthealarmsystem.
Pressthetestbutton.Thealarmshouldsound.Ifitdoesnotthealarm
may be faulty. Ask the service agency or maintenance technician to
checkitimmediately.
Checkthestore
1. StackasperEEFO/FIFO
2. CheckVVM
3. Checkmostfreezesensitivevaccine,aretheyfrozen!!
RunthestandbyGenerator.
Checktheoilandfuellevelsandfillupifnecessary.Checkthebattery
electrolytelevelifthebatteryisoftheopentype.Runthegenerator
untilithaswarmedupandmakesurethatitisoperatingcorrectly.

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4 Monthlychecks
Checktheroomenclosure:
Check the WIC/F enclosure every month to make sure there are no
majorproblems.
Checkthepanels
Checkthebottomsofthepanelstoseeifthereareanysignsofrust.
Rust may occur if the panel coating is damaged and if water is left
after the floor has been washed and that collects under the floor
panels.
Inspectthepaneljointsinternallyandexternally.Thereshouldbeno
evidence of movement along the joint lines and no sign of
condensation or ice buildup. If the joints are not tight and well
sealedthepanelsmayabsorbmoisture.Thisreducestheefficiencyof
insulation. Furthermore, moisture may freeze inside the joints and
forcethepanelsapart.
Inspect the area around the evaporator. This is usually the coldest
partoftheroom.Ifthereisiceorcondensationonthepanels,oneor
both of the following factors (door and strip curtain) could be
responsible.(??)
Checkthedoor
Go inside the room and ask a colleague to close the door from
outside.

$Testtheactionoftheinternalsafetyreleasehandle.Doesit
workproperly?Ifnot,callthemaintenancetechnician.

$A WIF should have an electrically heated door seal. If the

doorsealheaterisnotworkingthedoormayfreezeshut.Ifthedoor
is difficult to open and there is ice around the door seal, the heater
maynotbeworking.Callthemaintenancetechnician

$A WIF should be fitted with a pressure release vent. Every

timeyouentertheWIFyouletinacertainamountofwarmair.When
thiscoolsitcontractsandnegativepressurebeginstobuildupinside
the room. The pressure release vent then opens and allows enough
outside air to enter and rebalance the pressure. However, if the
pressurereleaseventisblocked,thenegativepressureremains,and
the door becomes very difficult to open. If the door is difficult to

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open,checkthereleaseventtoseeifitisicedup.Removetheiceif
youcan.Ifyoucannotdothis,callthemaintenancetechnician.
Checkthestripcurtain
Aninternalplasticcurtainreduces(1)theamountofhumidairthat
enters the WIC/F, (2) the amount of cold air that escapes when the
doorisopened.Ifplasticcurtainisfitted,checktoensurethatitisun
damaged. If it is damaged, instruct the maintenance technician to
replaceit.
Checkstock,anyvaccinestoredformorethanrecommendedperiod.
Checkthefoundationboltofcompressor.
CheckthelubricationoilofGeneratorandserviceitifneeded.

5 Monitorroutineandemergencymaintenance
Ensurethattheserviceagencyormaintenancetechniciancarriesout
allroutineservicingasrecommendedbythemanufacturer(s)within
warranty period and under the AMC of the WIC/F and the cooling
and monitoring equipment. Ensure that you receive a copy of the
servicechecklistasevidencethattheworkhasbeencorrectly done.
Someofthenecessaryroutinechecksare:
Oilandrefrigerantleakcheck;
Drivebelttensioncheck;
Routine cleaning of compressor components, including the
condensercoilandfins;
Doorsealcheck;
Temperature control check, using the temperature charts as
evidence;
Replacement of components before failure occurs as part of a
plannedpreventivemaintenance(PPM)regime.

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Chapter4:Powersupplyand
generators

Contents
$Standardsofelectricalconnections
Coldroomsshouldbeprovidedwithcontinuousqualitypowersupply.
Thissectionguidesusersonqualityofelectricalconnectionsand
amenitiesrequiredforcoldroomstofunctioneffectively.

$Sizing,repairandmaintenanceofgenerators
Thecapacityofageneratoraspowersupplybackupintheeventofgrid
powersupplyfailureshouldbeadequatetocoverthepower
requirementsaspernumbers,typesandsizesofcoldroomsinstalledin
thevaccinestore.Alsoadequateprovisionoffuelsupply,repairand
maintenanceshouldbemadeavailableontime.Thissectionguides
userontechnicalspecificationsofgeneratorsanditsmaintenance.

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1 Generatorandcontrolpanel

TokeeptheWIC/Funitsrunningintheeventofmainspowerfailure,
a standby generator is provided. In case of power failure, the
generatorcanstartautomatically
A Diesel Generating set has three parts, Engine, Alternator and
control panel connected together. The KVA rating of the alternator
andpaneldependsuponthepowerrequiredtorunthecoolingunits
and how many cooling units are connected/functioning at a given
time.
1.1 Engine
Suitable size diesel engines are coupled with the alternator. The
engineshouldbewatercooled,generatingsufficienttorqueat 1500
RPM. It should have provision of auto/manual shut down at low
lubricatingoilpressureandhightemperature.
1.2 Alternator
The alternator generates AC voltage of 440 volt in case of three
phaseand230voltinsinglephaseat50cycles/secfrequency.
Thealternatorofthegeneratorhastwomainparts:
a) Rotor:Itisarotatingpartofthealternator.Therearetwotypes
ofrotor:
a. SALIENTPOLEType
b. SmoothCylindrical
b) Stator: It is a stationary part and generally armature coil is
woundonStator.
1.3 ControlPanel
In case of Automatic selection, the Generator Control panel senses
the Mains power failure and sends signal automatically to start the
generator.Ifthegeneratorcouldnotstartonthefirststartingsignal,
the control unit sends two more start signals to the generator at
intervals. Even then, if the generator could not start, Generator
Failurealarmisgiven(Thiscanbeputoffbybringingselectorswitch
formodeofoperationtoSTOPposition,once).
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Whenthegeneratorstartsandrun,thepowerfromthegeneratoris
connected, with a delay, to the cooling / freezing unit selected.
Whenthemainspowerreturns,thegeneratorpowersupplyiscutoff
and the Mains power is reconnected to the unit and also the
generator is stopped automatically, with a delay, by the Generator
Control Panel. Whenever the generator runs, the run hour counter
registersthetimeofrunningofthegenerator.
Note:Alsointhecaseofsinglephaseandlow/highvoltageinthe
Mainssupply,thesameisdisconnectedandthegeneratorstartsand
provides generatorpower tothe selectedWIC/F unitautomatically.
GeneratorControlpanelalsomonitorsthefunctioningoftheEngine.
IncaseofLowlubeOilPressureorHighEngineTemperatureitstops
theengineandgivesalarm.

IMPORTANT: The 12V battery on the generator is not only for


starting the engine, but also for supply of 12V DC to the Generator
Control Panel. So, if the battery voltage is low or the battery is
discharged, both will not function properly. As a result, in case of
powerfailureneitherthegeneratorwillstartautomaticallynorwillit
bepossibletostartmanually.

1.4 Installation
The DG set should be installed on a solid concrete foundation
havingatleastsixreinforcedfoundationbolts.
Keep at least 1 meter away from the surrounding walls and
other equipments to prevent fire hazards and provide
adequateventilation.
TheDGsetshouldoperateonlyontheleveledsurface.Keeping
setonunleveledsurfacemayresultfuelspillageandoilpump
may not get the lubricating oil, causing seizer of crank shaft
bearings.
NeverruntheDGsetinclosearea,theexhaustgasescontains
poisonouscarbonmonooxide.Ensurethesmokeisreleasedin
theopenareaatasufficientheightoutsidethebuildingwhere
WIC/Fisinstalled.

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Keep DG set in locked condition so that no unwanted person
mayaccesstheDGset.
The DG set should be earthed properly. Never run the set
withoutproperearthing.
Alwaysuserecommendedlubricatingoilbythemanufacturers
dependingupontheambienttemperature.Fortheselectionof
thelubricatingoilgrade,anticipatedlowesttemperatureatthe
time of start should be considered in the winter season and
highesttemperatureofthedayduringsummerseason.
Table 10: Recommended* mono-grade lubricating oils as per ambient temperature

Ambient
Viscosity
Temperature No.

B.P

15to5oC

SAE10W

5oCto+10oC

H.P

Castrol IOC

Caltex

B.A
HP
Super prem.
oil
10
10W

CRB10

Servo
super
10

MLB
10W

SAE20W

B.A
HDX
Super 20
oil
20W

CRB20

Servo
ultra
10W

MLB20

+10oCto+45oC

SAE30W

B.A
HDX
Super 30
oil
20W

CRB30

Servo
super/
pride
30W

MLC30

Above+45oC

SAE40

B.A
HDX/ CRB/D
Super MILCY 40
oil
40
20W

Servo
super/
pride
40W

MLC40

* Consult the service manual of the DG set provided by the


manufacturerandfollowtherecommendations.
1.5 Sequenceofoperationofrelaysincontrol

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1.6 Maintenancescheduleofgenerator

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Chapter5:Temperaturemonitoring

Contents
$Temperaturemonitoringdevices
Monitoringofcoldroomtemperatureensures
thatthevaccinehasbeenkeptinsecured
conditions.Thissectionprovidesuserwith
technicalguidanceonvarioustypesof
temperaturemonitoringdevicesandhowto
operatethem.

$Maintenanceoftemperaturemonitoringdevices
Temperaturemonitoringdevices,especiallythemechanicaldevices
requireregularmaintenance.Thissectionprovidesthelistofspare
partsandserviceablecomponentsoftemperaturemonitoringdevices.

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WHO recommends monitoring of the temperature of all cold chain
equipmentincludingWIC/Fatleasttwiceaday.Itiscriticaltoensure
that the quality (potency) of vaccine is maintained at national and
regional stores by stocking the vaccines at recommended
temperatures. It is very critical, therefore, to monitor the
temperaturesofWIC/Froundtheclock.
Temperature monitoring is regular and continuous process. There
are several ways of monitoring the temperature and some methods
are more relevant for monitoring temperature of cold rooms at
national/state/regional vaccine stores, while others are more
relevantatperipherylevelorfortransportation.
Broadly classifying, there are 4 types of temperature monitoring
devices,namely:
1) Thermometers
2) TemperaturePlotters
3) Computerizedtemperaturerecorders
4) Temperatureindicators

1 Thermometers
Thermometers are used to monitor the temperature of IceLined
Refrigerators (ILR) and Deep Freezers. These thermometers should
beplacedinsidethebasketnexttostoredvaccine.
Care should be taken that the thermometers are not placed next to
the cabinet wall. If incorrectly placed, the readings may not reflect
theactualtemperatureatwhichthevaccineisstored.
The staff should be thoroughly trained on how to read the
thermometers.TherearethermometersthatcanbebothusedinDF
andILR,whereassomecanonlybeusedinILR.
Thethermometershouldneverberemovedfromrefrigerators.The
temperature should be recorded twice a day, every day, once in
morningandonceinafternoon.
Temperatureshouldberecordedonsuppliedtemperaturerecording
logbook.
Thelogbookshouldbeverifiedandsignedbysupervisoronroutine
basis.

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2 Temperatureplotters
ColdroomtemperatureplotterisacomponentofWIC/Fwhichtakes
and plots the temperature readings every one hour on a circular 7
daytemperaturechart.Thesensorofthisplotterisinstalledinside
the WIC/F. The plotter is a mechanical device which has no
dependenceonelectricity.
The sheet/chart should be replaced every week. The weekly sheet
shouldbemarkedclearlywithstartingandendingdate,referenceof
WIC/Fandnameofthestore.
Plotter requires regular maintenance in terms of replacement of
plottingpen/ink.Thismightneedreplacementevery6months.

3 Computerizedtemperaturerecorders
The best way to monitor the WIC/F temperature is through
computerized temperature monitoring system. This kind of
monitoringwillleadtorealtimetemperaturemonitoringfor24hrs.
It gives automatic report generation (daily, weekly and monthly),
automatic alert on landline, mobile phones, Fax, emails and
alarms/hooters.
Computerizedmonitoringsystemisoftwotypes:
1. Wiredtemperaturemonitoringsystem(e.g.Multilog)
2. Wirelesstemperaturemonitoringsystem(e.g.Cobalt)
3.1 Multichannelcomputerizedtemperaturemonitoringsystem

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The Multilog has been designed to perform two major tasks. It
records the temperature from installed and connected sensors at a
definedfrequency.ThedataloggeristriggeredONtostartrecording
throughthe computersoftware. The data logginghowever does not
require the computer intervention. The computer is required to
trigger the data logger to start recording and to download the
recorded temperature readings. The computer intervention is also
required to reset the data logger to clear the memory. The second
function of Multilog is to raise alarms in case of temperature
violation.
.

Figure 17: Specifications of 16 sensor data logger

Loggingtemperaturedata
The Multilog is programmed to record the temperature from 16
sensors at the preset frequency intervals. The Multilog has the
capacity of recording/storing 2000 temperature readings. The
frequency of temperature recording can be between 1 minute to
every 60 minutes. The recommended frequency of recording
temperatureisevery60minutesandthedevice,therefore,iscapable
of recording the temperature for 83.3 days without computer
intervention. When needed, data could be downloaded to computer
within83daysanddataloggerisresettorecordfreshreadings.The
data can be downloaded to a computer in one of the two fashions
discussedbelow:
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Monitoringthetemperature,raisingalarms
ThesecondfunctionofMultilogistomonitortheWIC/Ftemperature
and raise the alarm in case of temperature violation. The safe
temperaturerangecanbecustomizedforeverysensor.Usercanalso
define which sensors are critical to raise alarm. For the alarms to
function, the instant monitor feature of the software should be
turnedon,andthecomputershouldbeONandrunningallthetime.
Alarmsdonotfunctionwhenthecomputerhasbeenswitchedoff.
WhentheinstantmonitorisON,thetemperatureofalltheinstalled
and connected sensors is shown on the computer. The temperature
ofallthesensorsisrefreshedonthecomputermonitorevery1hour
orasfrequentas30secondsasspecifiedbytheuser.
Apartfromraisingtheaudiblealarmthroughtheinternalspeakerof
the Multilog and through the connected speakers of the computer,
the Multilog also raise the dialout alarm through the device called
autodialer. The autodialer should however, be connected to an
active phone line or a SIM card and should be in ARMED or
Activatedstate.Theautodialeralarmsusersinformofaphonecall
or a SMS in case of temperature violation. The dialer can be
configuredtodialoutandalarmupto6people(6phonenumbers).
The dialer has an online acknowledgement feature and stops
alarmingpeopleoncetherecipientofthecallacknowledgesthecall.
OrganizationofMultilog
The16sensorMultilogisdesignedtoreadthetemperaturefrom16
sensors.Thereare4boardsinsidetheMultilog.Eachboardconnects
to4sensorseach.Eachboardisconnectedtocomputerusingserial
port. This requires 4 free serial ports at computer end. PCs are
normallynotequippedwith4slotsofserialports,hence,aserialport
multiplier card is supplied with the Multilog. This card should be
inserted in the free PCI slot. The card comes with a CDROM of
softwaredriverfiles.Thesoftwaredriverfilesonceinstalled,adds5
newportstothecomputerhardware(1fortheserialportmultiplier
and 4 additional serial port slots). Each of these newly added serial
ports connects to the Multilog boards. The hardware setup is
complete by connecting all the 16 sensors (4 sensors each in 4
boards) to Multilog and connecting 4 serial cables from Multilog to
computerserialportMultiplier.
ContentsofMultilogset
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TheMultilogsetcontainsfollowingitems:
Table 11: Contents of multilog set
Itemname

Image

Remarks

Thisboxshouldbeinstalledonawall
nexttothecomputer(withinthe
distanceof1.6meters).

Multilogbox

16sensorcablesof20
meterlengtheach

Typically,6sensorsarerequiredfora
vaccinestorewith1coldroom.

13.7Vlithiumthionyl
chloridebattery

ThisbatteryisfittedinsidetheMultilog
andisusedforpoweringMultilogfor
loggingtemperature.ThisbatteryisNOT
RECHARGEABLE.Itshouldbereplaced
after1year.

1rechargeablealarm
battery

ThisBatteryisfittedinsidetheMultilog
andisusedforraisingaudiblealarm.
Thisbatterisrechargeableandshould
bechargedonregularbasis.Thelifeof
thebatteryis4years.

Thischargerissuppliedwiththe
Multilogbox.Thechargerconnectsto
Multilogboxandchargesthealarm
battery.

Alarmbatterycharging
poweradaptor

ThisCDcontainsthesoftwareof
Multilog.Thesoftwarecanalsobe
downloadedfromwebsite
http://www.remonsys.comCheckfor
updatedversionofsoftwareonthe
website.

CDROMofMultilog
software

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Itemname

Image

Remarks

Autodialer(Landline
based)

Autodialershouldbefixedtoawallnext
toMultilog.Itshouldbeconnectedtoa
telephoneline.

Autodialer(GSMbased)

ThisisanoptionalGSMbasedauto
dialerthatusesSIMcardtosendthe
alertSMSmessagesandcallphonesin
caseofemergency.

ThiscardshouldbeinsertedinPCIslot
ofdesktopcomputer.Thehardware
installationshouldfollowsoftware
installationusingtheCDROMprovided.

PCIserialportmultiplier
card

CDROMPCIcarddriver
files

ThisCDincludesthedriverfilesofthe
PCIcard.Thecomputersrunningon
WindowsXPcaninstallthesoftware
fromfolder[cd
drive]:/pci/winxp2000/driver

Incasethesensorcableneedextension,
Thesensorcablecanbeextendedupto
200meters.

Sensorcableextensionwire

Sensorcableextensionjoint
box

Thisjointboxshouldbeusedtoprotect
thesensorcablejointwithextension
cable.

Specifications
AdedicatedcomputerisrequiredtobeconnectedtoMultilog.This
computershouldbeconnectedtoUPS(foruninterruptedpower

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supplyasthecomputershouldberunning24hoursoftime.The
minimumconfigurationrequiredisasfollows:
1) A desktop with Pentium IV processor and Intel based
motherboard(Multilogcannotbeoperatedfromalaptop)
2) 256MBofRAM
3) 40MBoffreespace
4) FreePCIslottoinserttheserialportcard
5) 1 KVA UPS with external battery bank to provide power
backupofmorethen12hours
6) 1colorprinter(laserjetordeskjet)
7) Speakers (not mandatory, but this helps in raising audible
alarmintensity)

Computerplacement
Computershouldbeplacednexttoaroomwall.TheMultilogshould
bepermanentlyfixedonthewallandthecablesfromMultilogshould
bepermanentlyconnectedtothecomputerthroughPCIserialport
replicatorsuppliedwiththeMultilog.
Computermustnotbeinstalledonamobiletable.
Batteries
It is most important that replacement batteries are of the correct
type and fitted in the correct polarity. Please take care when
handling the batteries and do not insert/remove the batteries by
pullingontheconnectingwires.Pleaserefertothediagramfittedto
theinsideoftheMultiloglidtoidentifyandlocatethebatteries.

BatteryType1:(PartNo:MLBATT1)
Isarechargeablebatteryandshouldbereplacedevery4yearswith
asimilartypeofbattery.
CAUTIONNeverfitanordinarytypeofPP3battery.
This battery has a Velcro patch on its side to hold it in place inside
the Multilog case. To replace the battery ease off the terminal
connectorandthengentlyeasethebatteryfromitsVelcrorestraint.

BatteryType2:(PartNo:MLBATT2)

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These are special 3.7V lithium thionylchloride battery packs. It is
recommend that they should be replaced annually. To replace a
batterygentlyeasethebatteryconnectorfromthecircuitboard.

AutoDialerBatteries(LandlineBased)

Autodialerispoweredby3replaceablesizeAAmanganesealkaline
batteries.Thesebatteries
AutoDialerBatteries(SIMbased)

This autodialer is supplied with Power Adaptor: DC12v/1.25A and


backupbatteriesof3xAAsize1.2volt/2200mANiMHRechargeable
Batterywithstandbytimeof20hours.
3.2 Wirelesstemperaturedatalogger
The best way to monitor the cold room temperature is through
computerized temperature monitoring system. This monitoring will
lead to real time temperature monitoring for 24 hrs. It gives
automaticreportgeneration(daily,weeklyandmonthly),automatic
alertonlandline,mobilephones,Fax,emailsandalarms/hooters.
Wireless temperature monitoring system has been especially
designed to monitor the temperature of cold rooms and freezer
rooms.
ThesensorsareplacedatideallocationinsidetheWIC/WIFwhichis
connected by wire to the radio module installed outside the cold
room. Each module is capable of accommodating 8 sensors. Radio
moduletransmitstherealtimedatathroughradiofrequencytoradio
receiver.Radioreceiverisconnectedtocomputerwherethedatais
interpreted.
This system is capable of recording temperature at user defined
frequencywhichcanrangefromevery1minutetoevery1hour.The
idealfrequencyofrecordingthetemperatureisevery1hour.
Radio modules and radio receiver works with electrical power
supplywithastandbybatterybackup.
The standby battery should be checked on periodic basis. This may
needreplacementevery6months.
The system is capable of generating periodic reports such as, daily,
weeklyandmonthlytemperaturelinecharts.

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.

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Daily Temperature Graph

13

Automaticreportgenerationisthesameasinthecaseofwireddata
loggers.
SensorPositioning
Thesensorsshouldbeinstalledasperthepositionsmentionedinthe
tablebelow.Howeverexceptionsshouldbenotedanddulyapproved
bycoldchainspecialistorengineeronsite.
Thesensorcableshouldbeprotectedwithaplasticcasingright
throughthesensortip(with20cmgapbetweentipandtheplastic
casing)tothedataloggerconnectingpoint.
Table 12: Recommended position of sensors inside WIC/F

Sensor
number

Position

Remarks

Roomtemperature

Tobeinstalledintheareausedfor
packingthevaccine

Installednexttocoldroomthermometer
(thermostatsensor)

Thissensorshouldbeusedtoverifythe
thermostatreadinginthecoldroom
temperatureindicator

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Sensor
number

Position

Installedbehindtheleftevaporatorfromthe
door

Thissensorshouldindicatethe
operatingbehaviorofleftcompressor

Installedbehindtherightevaporatorfrom
thedoor

Thissensorshouldindicatethe
operatingbehavioroftheright
compressor

Installedintheshelfatasuitablelocation
oppositetotheleftevaporator

Thissensorshouldindicatethe
temperatureattheshelfwherevaccine
isstored

Installedintheshelfatasuitablelocation
oppositetotherightevaporator

Thissensorshouldindicatethe
temperatureattheshelfwherevaccine
isstored

TobeusedexclusivelyonlyforWIF:leftor
firstcompressorfromdoor

IncasethereisnoWIF,proceedto
sensor912fornextcoldroom

TobeusedexclusivelyonlyforWIF:Rightor
secondcompressorfromdoor

IncasethereisnoWIF,proceedto
sensor912fornextcoldroom

Remarks

912

Repeatthesensorlocationfrom3to6insecondcoldroom

1316

Repeatthesensorlocationfrom3to6inthirdcoldroom

Table 13: Temperature alarm specifications


Hightemperature Lowtemperature
alarm
alarm
Typeofcoldroom

Delay

DegreeC

DegreeC

(mins)

WalkinCooler

+100C

20C

60

WalkinFreezer

100C

60

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Diagramofsensorlayout

Figure 18: Layout of a typical cold room

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1 Temperature indicators
1.1 VaccineVialMonitor(VVM)
Vaccinevialmonitorsareheatsensitivechemicalsappliedtothevial
label or cap. They show whether the vial has been exposed to
excessiveheatsinceleavingthefactory.
Ifthesquareislighterthanthecircle,thevialcanbeusedunlessthe
expiry date, or other instructions dictate that the vial should be
discarded.

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1.2 FridgeTag
Fridge tag is a 30 days temperature logger
which is especially designed for
ILRs. This device records the
Maximum
and
minimum
temperature of every day for 30
days.
Device also indicates whether there
has been any alarming temperature
situation in the past 30 days. In case
there is a
high or low temperature violation, the device shows ALARM on
LCDscreen.Iftherehavebeennoinstancesoftemperatureviolation,
theOKcomesonscreen.
FridgeTag has two modes, namely monitoring mode and reading
mode.Thedeviceisalwaysinmonitoringmode,unlessuserpresses
theREADbuttontogetintoreadmode.
Once the device in read mode, user can press READ button to go
through the temperature history of past 30 days. The cycle of
readingthetemperaturehistorycontinueswithTodaysMaximum
followedbyTodaysMinimum,followedbyyesterdaysMaximum,
followedbyYesterdaysMinimumandsoonitcontinuesforpast30
days.Thedevicereturnsbacktomonitoringmodeafter30minutes
ofnotpressingthereadbutton.
While showing the history, in case of a temperature violation, the
device also shows the time in HH:MM format for the duration of
violation.

NOTE: Fridge tag is meant ONLY for monitoring the


temperatureofvaccinestoredin+2to+80Cstorage

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1.3 FreezeTag
Itisanelectronicdevicethatindicateswhetherthedevicehasbeen
exposed to temperature below 0 0C for more then 1 hour. It is
differentfromFridgeTag.
Thedevicehas2states(OK(9)andcross()).Thedevicestaysin
OKmodeaslongasithasnotbeenexposedtofreezingtemperature.
Once the device is exposed to below 00C, the device is changed
permanentlytoCROSSstate.
Freeze tag should be placed along with freeze sensitive vaccines
(Hep.B,DPT,TT,DTetc.)
The vaccines should never been used without shake test when
Freezetagshowsthecrossmark.

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2 Summary
Table below summarizes the types of temperature monitoring
devicesusedtomonitorthevaccinetemperaturesinIndia.

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Chapter6:SparepartsandToolkit

Contents
$Listofspareparts
MinistryofHealthandFamilyWelfarehascodedthelistofspareparts
ofWIC/F.Thissectionprovidestheextensivelistofthesespareparts
withthecodenumberstobeusedforrequestingthepartsfor
replacement.

$Toolkitforrefrigerationtechnicians
Techniciansrequireanidealsetoftoolkitforrepairandmaintenance
ofcoldrooms.Thischapterprovidesthedescriptionoftoolsrequiredas
apartofkit.

CChhaapptteerr66SSppaarreePPaarrttssaannddTToooollKKiitt

3 List of spare parts


Following list of spare parts provides the code number guide to
techniciansforrequestingthesepartsfromGMSDforreplacementof
faulty parts. GMSD normally stores these spare parts and supplies
arebasedonspecificrequestastheneed.

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Table 14: List of other spare pars

Sr.No. NameofTheSpareparts

CodeNo

CondenserFanMotor(Huurre)FMV

0841

ContactorAllenBradley(AB)K1

0347

Capacitor8mfdrunning

0169

M.C.B.Legrand1pole6Amps

0054

(865)(CircuitBraker)
8

Battery9voltD.C.

IntermotorLombardiniSlauzi

(WICGenerator)Flange
10

CompressorRubberGromete

11

ShaftSealAssemblyWICGen.Lombardini

0386

12

OverLoadProtector(O.L.P.)

0117

13

TestUnitAlarmWIC(Huurre)

0059

14

DoorHeatersWIC

0138

15

InkCapsulesWICGraphunit

0332

16

SolenoidSwitchWICGenLombardini

0445

17

ContactorAllenBradley(863)

0093

18

ContactorAllenBradely(858)

0094

19

MCB3PoleLegrand(03451)

0091

20

ContactorGeneratorABB(854)

0094

21

MCB1Pole(864)

0090

22

Capacitor5mfdRunning

23

Condencer/Evaporatorfan

0111

MotorForFosterWIC
24

DiodeRed

25

ContactorStromburg220volts

0132

26

Thermostat Dial Type Long Cappily 40 to +40 0492


0C.(RECORDINGTHERMOMETER)

27

Capacitor3mfd(Facton)

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Sr.No. NameofTheSpareparts

CodeNo

28

Capacitor10mfd,25volt

0338

29

CircuitBreaker10A,1pole

090

30

SignallampTelemechanic

0345

31

Contactor(K1/K2)Telmechanic

358

32

Aux.Contactor(K4)Telmechanic

349

33

MainsVoltageWatchingUnit

0351

Electromatic
34

TimeLagRelay(PirkanElektron)

0353

35

ControlRelayForAutoStart(K33)Electromatic

0354

36

Aux. Relay (KM l, KM2) Schier, 12V DC/ 40 0355


A,07.1200.20

37

PushButtonSwitchTelmechanic

0358

38

PhaseSequenceMeter

0368

39

PushButtonSwitchTelmechanic

0367

40

DiodeBlackTelmechanic

0369

41

Relay(Zettler)

0352

42

Condencer/ Evaporator Fan Motor HUURRE 0047


/WIC(EDN)

43

CompressorAsperaJ6226M,3ph.

0046

44

Voltmeter0to500VRQ72E

0357

45

Ameter0to50ARQ72E/50ARF

0356

46

LomberdenoGeneratorSolenoidSwitch(56006 0407
&276A)

47

ContactorTimerLR3D1316ThermoOverLoad

0344

48

Contactor16A/230VStrombergK2

0132

49

Relay11Pin250v/10A,24V/10A

0097

50

AuxlaryContactorBlock

0157

51

ContactorLAZEN140M0349K4

0349

52

IndicatorBase9519,9520,9521

54

PencialCell(BatteryforAlarmUnit)

0336

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Sr.No. NameofTheSpareparts

CodeNo

55

PushButtonGreen

0201

56

IndicatingLampCoverYellow

0056

57

Press(push)ButtonBlack

0103

58

ThermostatMountingPlate/Clamp)

0010

59

ThermostatCheckNut(ILR/DF)

0012

60

ToggleSwitch

61

BlaserMotorConnectingWiremaleFemale(ILR 0011
/DF,TerminalClips)

62

MCB1Pole16AmpsAEGELFA

0340

63

ContactorTelmechanicLC1,D2510P7

65

LineControler34Y155380

66

TimerElectronic

ModelTG45/SC833
67

StopSolenoidHonda

68

Thermostat(40 to +40) Long Cappilary Dial 0492


TypeHUURRE(RECORDINGTHERMOMETER)

70

Relay12VDC52410RD2Nfu

0098

71

StartSolenoidHondaGenset

0447

72

GasketForHondaGenset

0078

73

CarbonBrushForHondaGenset

0234

74

IndicatorLamp(WIC)

0066

75

AuxilaryContactorTelmechanic

76

Lomberdine(Genset)Slauzivolmolaite

77

OilForCompressor

78

Fuses8A

0198

81

PCBKAP3

0099

82

PCBKAP4

0100

83

TimeDelayRelay

0096

84

FanMotorEvaporator/FosterWIC25Watt.

0111

85

FanMotorGuardFoster

0114

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Sr.No. NameofTheSpareparts

CodeNo

86

FanMotorBladeFoster

0113

87

ChargingRelay12VDCGenset

0229

88

Drier3/8"

0120

89

Relay(Potential)GE3ARR3/A3AV3

0116

90

CapacitorRunning15mfd

0119

100

CapacitorStart88/108mfd

0118

101

Fuses5Amps

0197

102

Fuseholder

0196

103

ContactormainABB/NK

0156(0497)

104

ContactorAlternatorABB/GK

0160(0496)

105

Contactor220Volts

0132

107

Compressor,techumsehuropaforcoolingunit

0839

108

Condensor fan -FMV-LAMEL 230 v ,0.85 amp, 0841


1500 rpm

109

Evaporator fan -FMV- LAMEL made in france

0842

110

Compressor connector ABB

0843

111

Drain tube heater

0844

112

Compressor thermal protector (klixon)

0845

113

Connector -sprecher +schi

0846

114

Contector -sprecher +schi 25 amp, 230 v

0847

115

circuit breaker-legrand

0849

116

circuit breaker-legrand

0850

117

Flow heater

0851

119

drain tube heater

0853

120

Compressor Contactor ABB-09-30-10

0854

121

Condenser fan

0855

122

Evaporator fan

0856

123

Master Log- Electrical regulator

0857

124

S 1 Ambient Sensor

0859

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Sr.No. NameofTheSpareparts

CodeNo

125

S 2 Defrost Sensor

0860

126

H.P Switch

0861

127

Generator - Panel Power Control unit

0862

128

Defrost Timer

0865

129

Solenoid valve

0866

130

Temperature Recorder (HUURRE)

0867

131

Temperature Supervisor

0868

132

Temperature recorder Chart

0869

133

Alarm unit

0870

134

Stop solenoid

0871

135

Start solenoid

0872

4 ToolkitforRefrigeratortechnician
Followingtablelistsallthestandardtoolsrequiredforrepairand
maintenanceofWIC/WIF.Refrigerationtechniciansshouldensure
theavailabilityofthesetoolsallthetime.

S.No.

Item detail

Quantity.

1 1/4 socket set

2 121 RG4 ball valve blue

3 121 RG4 ball valve red

4 12V drill/screwdriver with 2 batteries

5 Access valve A31004M

10

6 Adjustable wrench 10 Bahco

7 Adjustable wrench 4 Bahco

8 Adjustable wrench 6 Bahco

9 Adler junior saw 150 mm SB

10 Aluminum tool box

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S.No.

Item detail

Quantity.

11 Combination pliers 2628/G180

12 Diagonal cutting pliers

13 Nose pliers G2430/G160

14 Screwdriver 100 x 5,5

15 Screw driwer no 0

16 Bit set 25 pc

17 BS10 5/8tube bender spring 5/8

18 BS6 3/8 tube bending tool

19 Capillary tube cutter 14215

20 Charging line CL60B

21 Charging line set of 3 CCL 36

22 Charging lineCL60R

23 Charging unit with Abs.vaccum gauge, two stage pump, solenoid


valve and suction and pressure gauge

24 Circular pocket mirror 14225

25 CTV1 Valve core tool

26 Cutting wheel 127B

27 Drier 20g. x2,l mm

10

28 Emery paper 5 m

29 Extra bit holder

30 F8020 Digital clamp tester AC current, AC voltage and resistance


Ohm

31 Flare nut NS4-10 5/8

32 Flare nut NS4-4

10

33 Flare nut NS4-6 3/8

10

34 Flare nut NS4-8 l/2

35 Forceps

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S.No.

Item detail

Quantity.

36 FT 195 3/16- 5/8 flaring tool

37 Gasket for piercing pliers

38 Hammer 300 Gram

39 Reamer

40 Maxi piercing pliers

41 Measuring tape 3 m

42 Needle for piercing pliers

43 NWS Crimping pliers

44 NWS ELECTRICIANS crimping pliers 235 mm

45 process tube w/o schraeder 10 pcs 6x400mm

46 Rechargeable Torch

47 Round file with handle

48 RT902 Digital thermometer with minimum/maximum data hold


and alarm

49 RX1 TIF electronic leak detector

50 Safety goggles

51 Flat file with handle

52 Set of cable lugs

53 Set of spanners 6-22 mm

54 Solder 1 mm

55 Soldering iron 40 w

56

Key set 2-10 mm

57 Stanley saw blades pack of 10

58

Tube-cutter l/8 - 1 1/8

59 Tube bender BS 8 1/2

60 Tube bender spring BS 4

61 Tube cutter TC 127

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S.No.

Item detail

Quantity.

62 Valve adaptor K1- 9

63 Vernier Caliper 150 mm

64 Vise grip Pinch off Pliers

65 Digital scale

66

Digital multi meter

67 Digital Clamp tester, AC current, AC voltage and resistance Ohm

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Chapter7:troubleshooting

Contents
$Troubleshootingguide
Thissectionprovidestheguideontroubleshootingthemostcommon
problemsassociatedwithperformance,repairandmaintenanceof
WIC/F.

CChhaapptteerr77TTrroouubblleeSShhoooottiinngg

1 Possiblefaults,observationsandrepairactionsforcold
rooms

Observations

Fault

Actions/suggestion

1.WICtemperaturehigh.

Gasleakage

Repairallleakage,conduct
leakagetestandrechargegas
upto20psisuctionpressure

2.Lowsuctionpressure
(good20unit)
3.Servicevalveleaks
(Conductsoaptest)
4.Evaporatorpipeleaking
5.Noliquid/bubblesinsight
glass
6.Compressorstops/trips
onHP/LP.
7.Leakageinflarenut
connectiontoHP/LP1
8.Leakageincapillarytube
9.Leakageinfromnon
returnvalveoncharging
tube
1.Excessnoisewhilerunning 1.Compressor
2.Highampereconsumption defective

1.Replacecompressorand
rechargethegas.

(Max.20amps)

2.Replacecontactor

3.Compressortoohot

2.C1contactor
defective

3.Replacerelay/capacitor

4.Compressornot
running/trips

3.Starting
relay/capacitor
defective.

1.UnittripsoffoftenonHP

Condenserfanmotor
burnt/jammed

Repairtheshaftandbush/
lubricatethecondensermotor
fanorreplaceit

Evaporatorfanmotor
jammed/burnt

Repair/replacefanmotor

1.WICtemperaturefalling
down

1.faultythermostat
settingsor
Thermostatdefected

Reset/Replacethermostat

Didnottriponlowpressure
(7psi)

HP/LPPressostat
defect

Checkthesetting.At25psiit
shouldbecutoffatjustabove
0psi.Replaceifrequired

2.Runningslowandsome
timestops
1.Evaporatorhot
2.Morefrostonevaporator

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Observations

Fault

Actions/suggestion

Driercold

Drierchocked

Replacedrier

Noautodefrosting

Checktheheatlimitand
changethesettingifrequired

Suctionlinewarm
Currentless(about4amps)
HeavyIceformationon
evaporator

Defrostmanuallyorby
shortingtheheatlimit
terminalsincaseoffosterWIF.
Setorreplacemasterlogin
caseofHuurreWIF

AlarmonwhenWIC
temperatureOK,noeffectof
pressingresetbutton

Alarmcircuit
defective

1.CheckT1&itscircuitand
wiring.

F1MCBtripswhenunit
switchedON

VaristorR7
defective/shorted

Replace

Temperaturerecordernot
working

1.Windingof
transformerFB1
burnt

1.Rewoundandrefit.

2.Relaycontact
defective
3.3.4voltcelllow
battery.
4.Defectincircuit.

2.Replacecontactrelayordry
cell

4.Checkcircuitandrepair.

Alarmdoesnotsound

A1sounderdefective
ordisconnected

ConnectorReplacesounder

GeneratorEnginedifficultto
start

1.Nofuelintank.

1.Fillthetank

2.Loose/brokenfuel
pipe

2.Tightorreplacethefuelpipe

3.Faultyfuelinjector
nozzle.

3.Grindandcalibratethe
injectororreplaceifrequired.

Enginestartsbutfires
intermittentlyorstopssoon.

Lackoffuelsupply

Tightenallfuelconnections.

Water/dustinfuel

Fuelfilterchocked

Drainthefueltankandrefill
cleanfuel.

Faultyinjector/fuel
pump
Lowengineoil
pressure

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mss

Replacethefilter
Checkandreplace
injector/Calibratefuelpump

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CChhaapptteerr77TTrroouubblleeSShhoooottiinngg
Observations

Fault

Actions/suggestion

Callserviceengineer

Enginelackspowerwith
dirtyexhaust:

Lackoffuelsupply

Fillthefueltank

ChockedAirCleaner

ChockedExhaust
Silencer

Cleanorreplaceifrequired

Overloading

Avoidoverloading

Failureofwater
supply

Checkthesystem.

Overheating

Lubricatingoillevel
low

Cleansilencer

Checkoillevelandtopupif
necessary.

TTeecchhnniiccaallH
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CChhaapptteerr77TTrroouubblleeSShhoooottiinngg

Sourceofinformation
Usershandbookforvaccinecoldroomsorfreezerrooms.
Geneva,2002(unpublisheddocumentWHO/V&B/02.31;
availablefromVaccinesandBiologicals,WorldHealth
Organization,1211Geneva27,Switzerlandandonthe
Internetatwww.who.int/vaccinesdocuments/DocsPDF02/
www712.pdf).
2.
Howtolookafteracoldroomorfreezerroom:self
assessmenttool.Geneva,2002(unpublisheddocument
WHO/V&B/02.30;availablefromVaccinesandBiologicals,
WorldHealthOrganization,1211Geneva27,Switzerlandand
ontheInternetatwww.who.int/vaccinesdocuments/
DocsPDF02/www711.pdf).
3.
WHO/UNICEFEffectivevaccineStoreManagementInitiative
Module14,WHO/IVB/04.1620UNICEF/Immunization.03
04
4.
ServiceManual,DANFOSS,RI.8A.B2.02/09/2001coolingunit
WalkinCooler/WalkinFreezer.
5.
ExperiencefrominstallationofcoldroomsinIndia2008:IT
PowerIndia
6.
ServiceManual,WalkinFreezer/CoolerHurrey1999.
7.
ServiceManualFosterWalkinCooler1996.
8.
ManualandguidelinesforoperatingMultilog:Computerized
temperaturemonitoringdevicePhilippinesAugust2008
PreparedbyUNICEF
9.
PresentationsofM/sLisaLineAstiaLimited,onWireless
dataloggers.
10. ServiceManualofKirloskarGreenGen.Set,2006
11. DieselEnginesMaintenanceManualandPartsbook,Kirloskar
OilEnginesLimited2004.
1.

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HaannddbbooookkffoorrCCoollddRRoooom
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