SPECIAL PROJECT
Background
In 2019, Cold Control were approached by a specialist temperature control solutions client to develop the evaporator sections on a number of temporary glycol chiller systems.
They required a multi-purpose temporary glycol cooler that could do both chill and freeze applications, in both 25kw and 50kw models.
Solution
Looking at the project in hand, it was clear that Cold Control would need to firstly select the right cooler, then build the control panel and manage the wiring of the units.
Working with an Italian cooler manufacturer, Cold Control started the project by selecting two coolers to do the required duties. Next, AJ Grant, Refrigeration Development Manager at Cold Control, designed the control panel alongside a control panel specialist that would operate the cooler in either mode. It was designed like a suitcase so that it was portable, with ‘plug and play’ functionality.
Cold Control spent two days at the specialist temperature control client’s depot to build the prototypes – one for each model. Once finalised, the build itself took place at Cold Control’s workshop in Ropley, Hampshire.
The frames and control valves for the system were supplied by the specialist temperature control solutions client. The coolers were mounted into each frame in the workshop. Next, they fitted the evaporators with commando sockets and wired the individual components to their corresponding socket. This included the complete wiring of the fans, defrost heaters, peripheral heaters, control valve, temperature probes; then connecting them to their commando socket on the cooler. All commando sockets for the components were different so that nothing could be incorrectly plugged into the wrong socket, ensuring optimum ease of use. These sockets matched the commando sockets on the control panel. With the wiring and addressing done on the cooler, Cold Control then needed to provide a 10m cable loom for each unit. Each loom was made up of 5 individual cables with commando sockets fitted at each end of each cable, then wrapped in a protective wrap.
After wiring the coolers, the Glycol pipework from the valve to the cooler was then braised in, lagged and valve assembly completed.
Once these two stages were finalised, the units were pressure tested to ensure pipework was leak tight. The control panel was then programmed to desired parameters and each control panel was then connected via the unit’s cable loom, followed by individual tests of all components and functions.
Outcome
Initially, this project was designed as a temporary solution for customer sites affected by a disaster and temporary warehouses, for example. But with the coronavirus outbreak, Cold Control were asked to manufacturer 22 additional units to be used around the country.
Cold Control’s team of engineers were working around the clock, 7 days per week, to get the units built and delivered to the sites. What was expected to have taken 13 weeks, took just 6 weeks for Cold Control to complete.
The specialist temperature control solutions client is absolutely delighted with the speed at which the project was completed and the performance of each of the units.
