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Cool Room Issue Addressed in Bowral
Job summary
Cool room freezing and failing to reach setpoint reported at a Bowral site. Inspection identified defrost cycle, compressor relay, controller, and door seal faults, and the unit was left operational at the customer's request.
Customer report
The customer reported that the ballroom fridge was freezing up and that the cool room was not reaching its temperature setpoint. Stored product was affected by icing while warm, humid air circulated across the product area. The unit had previously pulled down to -12°C on a +3°C setpoint, which indicated unstable control of cooling and defrost operation.
Diagnosis & technical assessment
Inspection of the cool room identified evaporator fans not dropping out during the defrost cycle, allowing air movement across stored product while defrost should have been isolating the evaporator. This condition contributed to product icing and the reported freezing issue. The Carel controller was suspected faulty after the unit previously drove to -12°C on a +3°C setpoint, which indicated the compressor was not being cycled correctly. The compressor relay was also found to be sticking and not releasing as required, which aligned with uncontrolled compressor operation. The door seal was inspected and found to require replacement, consistent with loss of enclosure integrity and humid air ingress affecting temperature stability.
This job record is derived from first-party technician notes and internal job management systems (SimPRO).
Solutions delivered
The site was attended and the fault findings were recorded from the inspection of the cool room system. Rectification requirements identified in the notes were evaporator fan drop-out wiring during defrost, replacement of the Carel controller, installation of an intermediate relay between the controller output and compressor contactor coil, replacement of the sticking compressor relay, and replacement of the cool room door seal. The intermediate relay was specified to separate the controller output from the inductive load, provide a clean switching signal, and reduce wear on the controller relay. The cool room was left operational at the customer's request.
Tools, parts & systems used
- Cool room
- Carel controller
- Compressor relay
- Intermediate relay
- Cool room door seal
Outcome & results
The cool room remained operational at the customer's request after inspection. The recorded findings support follow-up rectification for defrost control, compressor switching, and door sealing.
All work was carried out in accordance with relevant Australian Standards and manufacturer requirements.
This job record is derived from first-party technician notes and internal job management systems (SimPRO).
Repair vs replacement
When a refrigeration system shows unstable temperature control, the decision between repair and replacement depends on the fault source and the condition of the control components. A sticking relay, failed door seal, or defrost wiring fault can often be corrected directly, while a controller that is cycling the compressor incorrectly may justify replacement when it is driving the system outside the setpoint range. An intermediate relay is often used where controller outputs are switching inductive loads, as it protects the controller relay and makes future fault tracing clearer. The selected solution should match the observed fault pattern and the operating condition of the system.
If a heating, cooling or refrigeration system shows signs of a fault, such as burning smells, water leaks or tripping power, switch it off where safe and contact a licensed technician.