Electrolux TC 15012 Technical information

COLD-CHAIN MAINTENANCE FEEDBACK
FEEDBACK ON REPAIR AND MAINTENANCE
FROM THE FIELD
AND
Important Technical Information
1
COLD-CHAIN MAINTENANCE FEEDBACK
Foreword……
The refreshers training courses on maintenance & repair of WIC electrical systems,
repair of Generator engine & refrigeration system provided the technician
participating in the courses to exchange views & experiences thus far. This booklet
'FEEDBACK…..' is a compilation of various experiences including valuable tips
which will serve on the one hand as a technical update & on the other hand as tool
for sharing & exchanging technical realities related to the repair & maintenance of
cold chain equipments of UIP in India.
It is felt that the technicians in the field will be benefited from the information
contained in this booklet & will receive guidance in attending to similar problems in
the equipments & their repair.
To the readers of this booklet,' FEEDBACK….' would be available to share various
interesting observations, repair actions, innovative ideas & also some
suggestions(tested/verified/confirmed only)based on their last few years of
maintenance experience. Please send them, in a similar format, to the address given
below. The valuable experiences which can help others in maintaining cold-chain
equipments efficiently & better will be included in the next issue of 'FEEDBACK…'
Project Officer(HEM)
UNICEF,
73,Lodi Estate
New Delhi-110 003
2
COLD-CHAIN MAINTENANCE FEEDBACK
COLD CHAIN MAINTENANCE- 'FEED-BACK'
COMPONENT
FAULT
LOCATION
OBSERVATION
/FINDING
'Foster' (WIC)
Cooling unit
1.'Gas' leak
1.Balasore
2.Bhagalpur
3.Bhopal (WIF)
1.WIC Temp.high
2.Suction pr.7.8
psi(Good unit – 20
psi)
3.Soap water
testing indicated
service valve on
suction side leak
from gland
packing.
4.Bubbles with
liquid in sight
glass.
1.Leak in
evaporator pipe.
2.No liquid in
sight-glass.
3.Compressor
stops on HP/LP
4.Ajmer
1.Compressor
trips after 1- 2 min
on HP/LP
2.Bubble in sight
glass
3.Leak at flare-nut
connection to
HP/LP1.
5.Bhuj
6.Kota
1.WIC temp.high
2.Bubble with
liquid in sight
glass.
3
ACTIONS/
SUGGESTIONS/
REMARKS
Screw on service valve
tightened. No leak.
Added required qty.of
R12 till suction pr.was
about 20 psi & no
bubbles in sight-glass.
Charged with R12 for
leak testing & leak
detected on evaporator
coil. Unit taken out &
leak repaired by gas
welding. Evacuated &
charged with
combination of R12 &
R22 in equal quantity.
Working OK.
Closed service valve on
compressor, removed
flare- nut from
HP/Pomade flare proper,
refitted applying Teflon
tape. Replaced
compr.mountingsmodifying available
grommet of
Airconditioners.Charged
R12 till full liquid in
sight-glass-OK(This
might be due to
vibration of the
compressor.
Leak detected at filter
flare joint, tightened
flare nut-OK.Added R12
till auction pr.was about
20 psi & no bubble in
sight glass.
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster' (WIC)
Cooling unit
2.Compressor
defective
1.Balasore
1.Noisy
2.Guntur
1.Unit not running
2.High
compressor
amps(20 amps)
3.No hum/noise
4.Relay &
capacitor tested in
the good
compressor-OK
5.Resistance:
R-C=0 ohms
S-R=2 ohms
Terminal
Body=Infinite
1.Compressor too
hot.
2.Trips at high
amps on
overload(after
about 2 min)
3.Compressor not
running, no
hum/noise
4.Tried with the
relay,OLP &
capacitor or
working unit-does
not run.
1.Unit trips –off
often on HP
3.Bhopal (WIF)
3.Condenser
fan-motor burnt
1.Amritsar
2.Parabhani
3.Bhopal (WIF)
4. Gorakhpur
5.Bhuj
6.Kota
7.Jabalpur
4
Transit damage. taken
out compressor opening
flare joint on suction &
discharge. Opened the
compressor by
cutting,found one of the
three mounting spring
broken.repaired,refitted
& changed drier.
Evacuated-heating
during evacuation.
Charged R12, OK.
Compressor defective,
to replace.
Compressor taken out &
winding repaired.
Replaced one defective
valve plate. Refitted &
charged with R12- Ok
Fan-motor
rewound/replaced OK
# Compressor may trip
off on OLP also.
# MOTORS CAN BE
REWOUND
LOCALLY(Rs.150/Gorakhpur)
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster' (WIC)
Cooling unit
4. Condenser
fan-motor
jammed.
1.Vadodara
2.Phulbani
3.Balasore
4.Parabhani
5.Gurgaon
6. Hyderabad
7.Nasik
8.Akola
9.Dibrugarh
10 Gandhi-nagar
11.Jabalpur
12.Tirunelve-lly
1.Bush /bearing
jammed
2.Running slow &
sometimes stops
3.Compressor
may trip off on HP
Bushing
removed,cleaned,oiled
& refitted- OK
Can be replaced from
spares.
# 3-in-1 oil can be used
for cleaning & oiling.
# BUSHING MAY BE
AVAILABLE
LOCALLY.SHAFT-IF
WORN OUT,CAN BE
REPAIRED THROUGH
LOCAL WORKSHOP.
13.parabhani(x2)
14.Thane (x3)
Temp of WIC
slightly high,
compr, trips
frequently,
Running &
Starting
capacitors
became defective
Bushings replaced with
bearings locally
available-OK.
15.Ganjam
Winding defect
Rectified – OK
5.Evaporator fan
defect
1.Purnea
2.Bhagalpur
3.Ganjam
4.Faizabad
5.Shimla
Motor jammed
(then heats up &
burned in some
cases).
More frost on
evaporator
Serviced# Bearings are cleaned
with K. oil and by petrol.
# Don't use Kerosene or
Mobil.
6. C1Contactor
defect
1.Gurgaon
2.Vadodara
Jammed/
mechanical
problem.
Compressor
coming on/off
erratically.
Replaced / Refitted.
Contactor coil
burnt in both the
units at the same
One replaced with
available spare and
other by equivalent
3.Gandhi-Nagar
4.Nasik
5
See Suggestion #1
Remove cleaned and
refitted - OK
COLD-CHAIN MAINTENANCE FEEDBACK
time(Voltage
problem-NK Low
voltage protector
also burnt)
Coil bobbin
partially deformed
due to overheat &
not allowing
contacts to make.
5.Bikaner
6.Merrut
7.Bhopal (WIF)
7.Defrost- timer
defect
8.Starting
capacitor
defect
9.Compressor
starting
trouble
10.Thermostat
defect
8.Almorah
9.Bhuj
10.Ajmer
11.Faizabad
12.Bhagalpur
13.Tirunelvelly
14.Jabalpur
1.Vadodara
2.Lucknow
3.Gunjam
Compressor not
working.
Burning smell
from contactor.
Contactor coil
burnt.
Simens contactor model
3TB4117-OA available
locally.
Replaced.
Replaced Coil.
# Can be replaced by
any other equivalent
230V contactor COIL.
Not
working/contacts
remained
open/Stops
intermittently
Compressor does
not start.
CBI trips off,
capacitor found
short/burnt.
Replaced
4.Jabalpur
Both start & run
capacitor of one
unit burst at the
same time.
# This may be due to
excessive high
voltage/spikes,
Replaced-OK
1.Purnea
High starting
current vibration
of compr.& heats
up.Trips on OLP.
Capacitor tested,
apparently OK.
1.Merrut
2.Almorah
3.Dibrugarh
1.Bikaner
WIC temp.falling
down to 10C.
2.Ajmer
WIC temp. falling
down to 10C
6
Replaced
# Check starting relay &
capacitor.
# Main scale adjustment
screw turned 1/2 turn to
increase setting
Stopped the unit.
Carbon observed on
thermostat contact
points. Cleaned-OK.
COLD-CHAIN MAINTENANCE FEEDBACK
11.HP/LP
pressostat
defect
1.Vadodara
Did not trip on low
pressure when
drier was choked
& pr.was 7
psi(i.e.0.5
BAR).While
pumping down
also it did not cut
off.
1.Both units were
running
2.Drier cold
3.Suction line
warm
4.Discharge line
less warm.
5.Current less,
about 4A.
(normally=7-8 A)
12.Filter drier
choked
1.Vadodara
'Foster'(WIC)
cooling unit
1.No defrosting
1. Chandigarh
'Foster' Coldroom Panel
1.New type
panel not
received/
fitted.
1.Amritsar
2.Hosiarpur
3.Parbhani
4.Gurgaon
5.Firozepur
6. Kurukhetra
7.Thirunelvelli
8.Kurnool
9.Almorah
10.Bikaner
11. Gorakhpur
7
Heavy ice
formation on
evaporator.
Defrost timer,
contactor &
heaters-OK.Heatlimit defective.
Only one unit
works from mains
power.
(In most of the
places the new
panel is not filled
as the mains
power cannot run
both units
together due to
poor line/voltage
condition, will be
fitted only on
improvement of
the power supply
condition)
# As main setting is 25
psi & also diff.setting is
25 psi,it should only cutoff just above 0
psi.During pumping
down, it should have
cut-off may be
defective.Check the
settings.
Opened flare nut at
expansion valve, very
little gas coming
out,doubt that filter is
choked.
Connected manifold
gauge on suction
service,valve,pr=7
psi(normal=20 – 25
psi).Closed suction line
valve ,kept
compr.running & closed
receiver valve on
pumping down.
Changed filterdrier,purged,opened
suction & receiver
valves –OK.
First defrosted the unit
by shorting the heat
limit terminals on the
terminals strip in unit
control panel.Changed
heat –limit-OK.
# One New-panel,one
cable,one aux.contact
for NK,T1 for 3-start
order(yellow,with 2
pots).
Dispatched to all WIC/F
in end 1986.
#Locate & connect them
in place of old-panel as
given in
*See suggestion #3
*Also see suggestion# 2
COLD-CHAIN MAINTENANCE FEEDBACK
2.MCB tripping
1.Gurgaon
2.Kota
3.Low voltage
protector,C2
relay defect
1.Nasik
2.Balasore
3.Thane
4.Calicut
5.Guntoor
6. Chattarpur
7.Gandhi nagar
MCB trips off after
about one hour &
becomes hot(oldpanel)
Replaced- OK
# If the system takes
heavy current,the MCB
will trip immediately. In
case MCB is faulty, it
will trip after sometime
of putting the load ON.
Confirm fault by
measuring the load
current. For
replacement,use MCB
with similar
rating(motor-load type)
MCB trips at
intervals even
when running
current is OK.
1.Relay not
functioning/
2.Base & Relay
pin burnt(Base &
Relay cannot
carry heavy
current)
Replaced-OK
Replaced- OK
# This relay contacts
can be replaced by a
contactor when
connected properly in
the circuit.
# For cleaning relay
contacts use finest
emery paper/needle file
4.Only one unit
works
1.Thirunelvelly
Only the selected
unit(1 or 2)works
even on mains
power.
# Contact burning is
caused by fluctuating
low voltage.
#Check-NK
aux.contact(33-34)in
generator panel.
-the cable connection to
the above contacts
points
-the cable connection
(other end)at 11 & 12 of
"new" cold room panel.
5.B3 Selector
switch defect
1.Thane
2.Gandhinagar
8
Units not getting
supply
# If NK(33-34)is
defective,use the free
NC contact pair of NK.
Replaced- OK
B3 points shorted. To
replace
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster'
generator
panel
# Try to find locally
available two-way
switch with off position.
One unit not
Shorted contacts
working Contactor temporarily.
burnt.
# WHEN SHOTTED LIKE
ABOVE,KEEP THE
SELECTOR IN THE
POSITION SELECTING
THE UNIT FOR WHICH
THE CONTACTOR IS
SHORTED.
6. Contactor
defect
1.Bhopal (WIF)
7.Alarm Circuit
1. Gorakhpur
Alarm 'on' when
WIC temp.OK.No
effect of pressing
reset.
Check T1 & its circuit &
wirings.
1.Mains power
not going to the
units.
1.Gurgaon
2. Berhampur
3.Kurnool
4.Guntur
5. Chattarpur
6.Jabalpur
7.Bhopal (WIF)
8.Bikaner
9.Jodhpur
10.Ajmer
11.Kurukhetra
12.Merrut
13.Gorakhpur
14.Purnea
15.Ganjam
16.Phulbani
17.Sambalpur
18.Balasore
19.Faizabad
20.Vadodara
1.NK contact not
making/
2.S6 fuse blown
off/
3.NK contactor
coil burnt.
# Replace defective
coil/contactor/fuse
1.Hyderabad
2.Gorakhpur
3.Bhopal (WIF)
4.Ganjam
T3 defective
2.Generator
power not
extended to
units
9
# Coil can be rewound
locally.
# Removed the contacts
which were not making,
cleaned carbon from
contact points &
refitted- OK
# Services of locally
available Tc-contactors
are found better, lasts
longer.
# THIS IS MAINLY DUE
TO LOW/FLUCTUATING
VOLTAGE PROBLEM.
Power not
available at coldroom panel
GK & T3 not
working.
# see suggestions #4
Replaced OK
# Check T1,T3 7 GK
circuits as per diagram
#3
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster'
Generator
Panel
3.Generator not
starting
T3 potentiometer turned
both ways slightly &
reset,it worked so also
GK- OK
Replaced switch-OK
1.Parbhani
Auto/manual
switch contacts
not making
2.Nasik
Auto/manual
switch
faulty,GK(5152)burnt.
# To replace
3.Vadodara
Works on
Auto,does not
work on manual
Auto/manual switch A15 & 6 not making. To
repair/replace.
4.Akola
5.Vadodara
Starter bendix &
flywheel ring gear
teeth damaged.
# To replace
6.Phulbani
Starter solenoid
connection
terminal lug
sulphated
Replaced –OK
7.Kurnool
Starter motor
winding
burnt,flywheel
teeth work out.
R1 relay defective,
not operating.
Motor rewoundOK,flywheel needs early
replacement.
9. Nasik(on
other occasion)
R1 not operating,'ve' line not getting
completed, wire
came out of 'C'
terminal of
charging relay.
10.Agra
Fuse,S1 blow off
Protection diode
defective
Wire connected-OK
# Wires of start 7 stop
solenoid circuits should
be more than 20 gauge
size.Diode replaced with
BY127,locally available.
# Note: R1 & R2 are
identical.
# Check the 3 protection
diodes
*See suggestion #8
8.Guntur
11.Jabalpur
Smoke from
charging relay on
engine
12.G'nagar
13.Ajmer
10
Replaced- OK
# Replace charging
relay. Check battery
condition & replace if
not good.
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster'
Generator
Panel
4.Generator
panel
Wiring/
component
burnt
5.Generator not
stopping
1.Amritsar
2.Vadodara
3.Akola
4.Ernakulam
5.Kurukhetra
6.Thane
7.Bikaner
Panel wiring &
stop solenoid
burnt
Panels required- OK.If
only a few
wires/components
burn,the panel can be
repaired easily.
8.Berhampur
Stop solenoid &
RH1 & RH2 burnt.
1.Amritsar
Stop solenoid not
drawing the
plunger in
Burnt wires & relays
replaced-OK
Rewound, worked for 3
months & burnt again.
Replaced-OK
See suggestion #5 #9
Solenoid fixing nut-bolts
loose due to vibration
resulting in defect in
alignment
Defect rectified –OK.
2.Gorakhpur
Fuse,S1 blows off
after genr. started.
Hence to be
stopped manually.
# Check fuse rating &
also if 'slow-blow' type.
Check the 3 protection
diodes in the back of the
panel.Also check RH2 &
wirings.
3.Bhopal
RH2 chatters.
Solenoid testedOK but not
operating.
# Check RH2 & wiring to
solenoid.
4.Nasik
RH2 operates
solenoid- OK but
does not operate.
5.Ajmer
Stops on 'Manual'
but not in
'Auto'.+ve wire to
Terminal #1
becomes hot,+ve
available upto L18
only but not at
stop-solenoid.
Wire from panel to stopsolenoid was of thin
aluminium.Changed to 4
mm2 copper cable- OK.
# Check connection &
connecting wires from
L18 to other multiple
points.
11
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster'
Generator
Panel
6.Nasik
6.Automatic
charging
rectifier,E1
'Foster
Generator
Engine' (DM188)
Stop solenoid coil
burnt
Resistors from E1
circuit came out.
1.Gurgaon
2.Vadodara
3.Bikaner
4.Bhopal
5.Ajmer
6.Gurgaon
7.Dibrugarh
8.Jabalpur
Battery charge very low.
Recharged externally &
reconnected- OK
9.Ajmer
Two resistor
burnt.
10 Gandhi-nagar
No charging, dry
solder on resistor
terminal
Units not
working,N1 & NK
not working.N1
contacts defect
Mains fuse
blowing
off.Terminals R &
O shorted by
sparking/ melting.
Foundation/
grouting loose
Wires come out of
terminals
Fitting local ones did
not help. Some more
problem may be there.
Need to change E1
Rectified soldering –OK
*See suggestion #10
1.Bhopal(WIF)
8.Terminal strip
1.Madras
1.Excessive
vibration
1.Bikaner
2.Gandhinagar
1.Ajmer
Burnt out
1.Madras
Self-starter
winding burnt
Fuel-pump assy.&
seat found broken
Sensor bulb
damaged in
transit /major
defect
Not working
2.Coimbatore
'Foster'
Tempera-ture
Recorder
Temperature
recorder not
working
Resoldered- OK
# While resoldering,tie
the resistor to the
eyelets with extra wire.
S2 fuse blown off
7.N1 defect
2.Charging relay
defect
3.Not Starting
Replaced- OK
1.Vadodara
2.Sambalpur
3.Berhampur
4.Gorakhpur
12
Recorder arm not
sitting properly.
Replaced N1
Replaced terminals- OK.
Corrected OK
# Check grouting &
mounting,coupling &
alignment of engine &
alternator shafts
Replaced –OK
Replaced-OK
Need replacement(Float
Genset connected)
Replaced
No details.To examine
before replacement.
# Repair/Adjust
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre'
Cooling Unit
1.F1 MCB trips
when unit
switched ON
2.Frost on
evaporator not
completely
melted during
defrosting
3.Thermostat
defect
5.Ajmer
6.Gandhinagar
Dirt & lubricant
formed
paste,gears
jammed.
Cleaned & oiled Ok
7.Akola
Chart speed slow
covers 2 hours
division in 3
hours.
Circuit breaker
trips off.Varistor
R7 defective,
shorted.
# Check your
mechanism,may be
defective/dirty.
1.Chandigarh
(Punjab)
2.Rajkot
3.Bhubaneswar
4.Trivendrum
5.Madurai
6.Muradabad
7.Surat
8.Gwalior
9.Visakhapattanam
1.Bhubaneswar
2.Muradabad
3.Bhopal
1.Chandigarh
2.Aurangabad
3.Rajkot
4.Condenser fan- 1.Lucknow
motor
2.Patna
burnt/defect
3.Madurai
4.Kolhapur
5.K1 contactor
defect
1.Bareilly
2.Lucknow
3.Pune
4.Chandigarh
5.Bhubaneswar
6.Trivandurum
7.Ratlam
8.Betul
9.Gwalior
10.Kolhapur
11.Surat
12.Visakhapattan
an
13
Replaced –OK.
Timer-OK,but time
set is 15 minute.
Increased time-setting
to 30 min- OK.
Not-cutting OFF
Replaced-OK.
Motor winding
burnt.
Unit trips off on
HP,winding burnt.
Replaced-OK.
Jammed, unit
trips on HP
Contactor coil
burnt.
Cleaned & lubricated –
OK.
Replaced-Ok
Replaced-OK.
# K1 contactor can be
replaced by any 3 phase
16 Amps contactor
having 220 volts coil.
Locally available 'Tc'
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre'
Cooling Unit
6.Condenser fancapacitor defect
7.Evaporator fan
motor
8.Condenser fan
motor
13.Moradabad
Mechanical jam
contactor similar to NK
of 'Foster' is suitable.
1.Bhubaneswar
2.pune
1.Betul
2.Patna
3.Tiruchirapalli
Capacitor Burnt
Replaced-OK.
Winding burnt
Bearing jammed
Replaced-OK.
Replaced bearing from
another burnt motor &
overhauled- OK.
4.Visakhapattan
am
Bearing jammed
Replaced with
'Crompton' 12" exhaust
fan-OK.
1.Tiruchirapalli
Jammed
2.Madurai
Burnt,Compr
tripping on HP.
Work for about 10
min.,gets
overheated &
stops
Bush replaced &
overhauled- OK.
Replaced OK.
3.Kolhapur
4.Visakhapattanam
9.Switch SI defect 1.Kolhapur
No making
contact.
10.Gas Leak
No cooling.
condenser fan not
working. Bubbles
in sightglass.Pressostat
for condenser-fan
not working.
Leak detected on
the capillary tube
connected to the
pressostat for
condr-fan.The
coiled portion
cracked minutely
due to rubbing on
vibration.
1.Madurai
14
Replaced OK.
# This may be due to
defect in winding
insulation.
Shifted connections
from defective contact
to free contact available
# There is one pair of
free contacts in SI
#Any other 10 Amps
ON-OFF switch can be
used.
Changed the defective
capillary tube.
Leak Test carried
out.Evacuated &
charged
refrigerant(about 11/2
kg.of R12)
-Not working-OK.
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre'
Cooling Unit
'Huurre'Tempe
rature
Recorder (old
type)
2.Rajkot
11.HP/LP
1.Udaypur
pressostat defect
Leak from nonreturn valve on
charging tube
Compressor stops
after running
about some time.
Thermostat, GasOK.
12.compressor
defect
13.Vibration
element for
discharge line
1.Tanzania
Compressor
winding defect.
Brust,due to
compressor
vibration.
2.Kunoor
Leak
14.HP switch for
condenser fan
motor
1.Kolhapur
Not operating
/contacts open
Temperature
recorder not
working
1.Chandigarh
2.Trivandrum
3.Bhubaneswar
Transformer FBI
winding burnt.
4.Rajkot
Relay contact
defective
3.4 V Battery low
1.Patna
5.Madurai
6.Gwalior
7.Rajot
8.Bhubaneswar
'Huurre' Alarm
unit
1.Alarm
sounder,A1
defect
Defect in circuit
# To check
electronic
circuit/replace
Valve not sitting
properly-rectified-OK.
See suggestions #6 & #7
Tested unit by shorting
Pressostat terminals
temporarily-OK.HP/LP
cuts off on LP.Increased
setting adjustment by
1/2 turn-OK.
Replaced-OK.
ReplacedOK.Compressor
vibration reduced by
changing grommet &
rectifying mountings.
Changed with locally
available copper pipe of
higher size.
One component of
contact operating
mechanism
dislocated.Repaired-OK.
Re-wound locally &
refitted-OK.
Repaired-OK
#Replace battery.Also
check for defect in the
external d.c.circuit(KAP4,FBI etc).
# To be replaced.
9.Jaipur
Chart cut-off by
holder
# Check chart rotation if
restricted anywhere.
1.Visakhapattanam
A1 does not
sound.
# Need
repair/replacement.
# Any 12 V DC electronic
sounder can be
connected in its place.
15
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre'
1.Mains power
Control
not extended to
panel(for petrol the units
engine)
2.Generator not
starting
1.Pune
K11 faulty,K1 coil
& contacts burnt,
voltage between N
& E observed
more than 30 volts
K11 & K1
replaced.Power line
checked & N-E voltage
corrected.
2.Trivandrum
K1 contacts fused
together,coil
burnt.
K1 replaced.
3.Bhubaneswar
4.Surat
5.Gwalior
6.Aurangabad
7.Madurai
8.Kolhapur
9.Gwalior
10. Visakhapattanam
11.Udaypur
12.Ratlam
K1 coil burnt
Replaced.
K11 defective
Replaced.
K11 not
working.Phase
sequence
changed by SEB.
Sequence corrected in
the main-switch-OK.
# K11 & K12 are
identical & can be
interchanged.
1.Trivandrum
DC fuse on
Replaced.
generator terminal
box blown off.
2.Rajkot
3.Pune
4.Lucknow
5.Gwalior
6.Kolhapur
KAP-3 defect
Replaced.
No manual/auto
start.No 12 V+ at
pin-3 of KAP-3
when start order
is given.
Replaced.
7.Bhubaneswar
K13 coil burnt.
Replaced.
#In this case the
generator will start &
run on 'auto' even if
mains power is
available.
16
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre'
Control
panel(for petrol
engine
'Foster'
V.M.Diesel
engine
3.generator starts 1.Lucknow
& stops on
'manual'but not
on 'auto'
Recent problem,
not yet analysed.
4.generator not
1.Rajkot
stopping on
2.Gwalior
manual but stops 3.Raipur
on Auto
This problem was
experienced
sometime back,
but later
disappeared(in all
the 3 cases)
5.FBI(2203.4V)transformer
defect
6.Phasesequence relay
defect
1.Pune
2.Bhopal
3.Bhubaneswar
1.Madurai
Winding
damaged/burnt
7.Generator
power not
extended to units
1.Diesel found
mixed with Mobil
oil
1.Surat
2.Visakhapattanam
1.Amritsar
2.Not stopping
1.Amritsar
even after
solenoid plunger
is fully pulled in
3.Oil Seal leak
1.Nasik
4.Engine noise,
knocking
1.Thane
No generator
power to
units.K21 not
working.
K2 coil burnt.
Replaced-OK.
1.Oil pressure
increased to
about 70 psi
2.Abnormal
rubbing sound.
3.About 2.5 lt.of
liquid(oil +
diesel)in sump.
Stop-lever is not
pulled fully by
solenoid as the
coupling nut-bolts
were loose(slips
on thread).
Profuse leakage
of mobil oil on
coupling side
Nozzle defect
Possibility-orifice
enlarged too much to
allow diesel to drop
down
Replaced nozzle,engine
running OK.
Excessive
vibration, nozzle
defect
17
# Suggestion for
testing:
1.Check Aut/Man Switch
contacts 1-2
2.Check connections to
terminal 3 & 6 of KAP-3
from Aut/Man switch.
# Probable reason:
1.loose connection at
terminals/connecting
points in stop-circuit;
2.Selector contacts not
making properly, at
times;
3.Stop switch contacts
dirty.
Replaced-OK.
Replaced-OK.
New nut- bolt fitted-OK.
Fitted new oil-seal –OK
# Replacement locally
available
# Check crank-case
ventilation
Cleaned nozzle,pressure
adjusted- OK
# Assistance from MICO
Pressure setting 200 –
210 kg per cm.sq.
COLD-CHAIN MAINTENANCE FEEDBACK
'Foster'
V.M.Diesel
engine
5.Oil pressure
decreases after
about 2 hours
running
1.Phulbani
2.Vadodara
6.Engine starts
1.Bhubanswar
but can not attain
full speed.
7.Excessive
1.Nasik
vibration
'Huurre'
(New)Control
Panel for
Diesel Engine
1.Generator not
stopping
1.Ratlam
2.Stop solenoid
defect
1.Moradabad
3.K2 contactor
defect
1. Moradabad
2.Betul
3.Tiruchirapalli
1.Ratlam
4.Generator not
starting
2.Tiruchirapalli
5.Trickle charger 1.Ratlam
defect
18
Improved after
change of oil. Oil
changed again
after 15 days &
more
improvement
observed.
Carbon on nozzle
orifice
Chassis cracked
& fuel tank strap
broken due to
vibration.Generat
or grouting OK
but no mounting
fitted.
Doubt on stopsolenoid & km2
relay.
No record of earlier oil
change.
#Oil must be changed
strictly as per schedule.
Cleaned orifice with thin
steel wire & finest emery
paper-OK.
#Examine grouting &
Engine-Alternator
alignment.They should
be properly aligned &
firmly mounted on
chassis.
To be checked & replace
if required.
Solenoid not
pulling fully due
to pull-wire out of
position.
K2 coil winding
burnt.
Put in proper position &
tightened connector-OK.
Km1,km2 operate
but contacts not
making properly
due to carbon
formation on the
points.
Opened relay & cleaned
contact points-OK.
K31 relay got
stuck.
Rectified the spring-OK.
Transformer
burnt,
transistor(TAG861
8)defective.
Parts not
available.Fabricated a
charger locally
providing a switch on
the AC input side &
connected working OK.
Replaced K2-OK.
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre' petrol
Engine (Honda
G-400)
1.Starting trouble 1.Trivandrum
Scaling observed
in the
carburetor(breaks
to powder),float
stuck
Cleaned carburetor
completely, working OK
2.Japiur &
several other
places
Sludge in fuel
tank & carburetor
Drained fuel tank &
cleaned carburetor &
fuel tank.Filled fresh
fuel-OK.
Probable reason:
1.Contaminated fuel,
2.Long storage without
use.
See suggestions #12
Replaced from local
market.
2.leakage from
1.Rajkot
carburetor(o-ring)
o-ring defective
3.Choke not
1.Rajkot
working
automatically has
to be operated
manually
4.Leakage from
1.Lucknow
carburetor
2.Madurai
(No more detail)
Slight leakage
from carburetor.
3.Dispur(B & S)
5.Engine not
taking load
1.Kolhapur
2.Pune
6.Engine
misfiring
1.Madurai
19
# Check chokesolenoid/choke-solenoid
arrangement to chokelever.
Cleaned the carburetor.
Minute leak still
persists.
# Check needle valve
Float valve
Replaced by float valve
defective
of 'Bajaj' scooter(length
had to be cut to bring to
proper size.)
Doubt in
Taken out the sparkcombustion
plug & measured
chamber.Alternato compression=75
r,CB point & valve psi.Some oil poured
etc.of engine
through the port of the
checked-OK
plug & measured
compression=80
psi.Generator is working
OK now.
Plug defective
Changed plug &
governor need
adjusted governor-OK.
adjustment.
Engine misfires
Adjusted carburetorOK.
COLD-CHAIN MAINTENANCE FEEDBACK
'Huurre' petrol
Engine (Honda
G-400)
'Huurre' Diesel
Engine (New)
ALTERNATORS
7.Speed low on
load
1.Visakhapattanam
1.Starting
problem
1.Tiruchirapalli
---do—
Battery charge
low.
2.Surat
Engine can be
started only after
giving +ve supply
to the solenoid
valve in fuel line
2.Engine not
stopping
1. Tiruchirapalli
3.Charging relay
defect
1.Tiruchirapalli
1.No output
1.Pune(HUU)
Mecc alte
2.Only 2 phases
available
1.Surat(HUU)
Mecc Alte
Not stopping in
either manual or
Auto mode. Stop
solenoid coil
burnt.
No +ve output on
running of
generator.
Rectifier Bridge in
regulator(18)diode shorted
No output in one
phase. Field
excitation voltage
in all the 3 phases
are OK.
3.Output Voltage 1.Surat(HUU)
low
Power Supply
(MAINS)
No load speedOK. Speed low
when loaded.
Air filter blocked.
4.Carbon Brush
worn out
1.Bikaner(Fos)
1.Voltage low/
fluctuations.
1.Nasik
20
After repair of the
missing phase as
advised
above,output
voltage found to
be low
Brushes worn out
to half due to
dislocation of
Brush-arm
Severe
fluctuations.
Voltage stabilizer
needed.
# Check engine &
governor.
Cleaned with
diesel/petrol & refitted –
OK.
Added distilled water &
recharged-OK
# It appears that the
solenoid valve is of 'NC'
type.
# Try changing
connection of relay
K26:Shifted to 4 & 7 to
5.If not successful put
connections to original .
Give feed-back.
To replace.
Replaced-OK.
Replaced by making a
bridge with BY 127
diode (Locally available)
#Isolate generator from
panel & check circuit
voltage(No-load)& find
out the missing phase;
#Check 'B' coil & its
connection.
#First,check the engine
speed & then the
regulating transformer
connections.
Rectified brush-arm-OK.
COLD-CHAIN MAINTENANCE FEEDBACK
Power Supply
(MAINS
2.Ernakulum
3.Kozikode
Fluctuations (150250 V) during 6-10
pm.
4.Gurgaon
Fluctuations (140200 V)
Maharashtra
,A.P.& U.P.
In Some places
voltage as low as
160 V
2.Voltage drop in Several
service
installations
connection
'Vestfrost'MK140/142 ILRs
-Aluminum
conductors used
-Lower size of
wire used.
2 units cannot run
together from
power most of the
time.CB of one
started later trips.
3.High Line
resistance
1.Jabalpur
4.Load shedding
Andhra Pradesh
1.Sub-zero
temperature at
minimum setting
of thermostat.
2.Thermostat tail
does not come
out for
replacement
3-4 hours power
cut(Scheduled &
notified).
# Probable defect.
-Tail of the
thermostat not in
proper position.
-Thermostat need
adjustment.
-Thermostat
defective.
Tail hard to pull
out. Rust in the
tube housing the
tail.
21
Locally purchased 5
KVA servo
stabilizer(120-280
V)fitted.'keltron'make,
with auto-cut.
Voltage stabilizer
(Voltas,relay type,5
KVA,no auto-cut)fitted.
NK burned due to low
voltage
# Need good servo
stabilizers 150-280 V
input & 220 V out-put.
# Replace wiring with
Copper wires or proper
size & make the joints
proper wih clamps.
Power circuit needs
check up/repair.
# Run generator when
the WIC temp.is +80C &
stop when reaches+40C.
# Rectify. If even after
rectification or
replacement problem
persists.
#Try adjustment of the
bellow screw.1turn anticlockwise will increase
temp.to about +20C.
(Orissa & Kerla
experience)
# Allow machine to
defrost completely &
then only try to pull out
the tail.
COLD-CHAIN MAINTENANCE FEEDBACK
'Vestfrost'MK140/142 ILRs
3.Filter /capillary
blocked in some
new units
Orissa
Bihar
Rajastan
4.Compressor
TFS 4 AT
Assam= 1 No
Orissa= 1 No
'Vestfrost' SB140/142
Freezers
1.Compressor
defect
1.Rajastan
'Electrolux'TC
W-1151 ILRs
1.Sub-zero
temperature
while running as
ILR
2.ILR/Freezer
selector switch
ILRs &
FREEZERs
Winding
resistance-OK,but
compressor
jammed in about
3-4.
This problem
occurred when
equipment was
changed from
freezer mode to
OLR mode.
1.Nasik(Naitale
PHC)
1.Leak in external 1.Shajapur(3)
parts
2.Bhopal(3)
3.Ropar(1)
4.Bikaner(1)
5.Kheda(1)
2.compressor
Jammed
This is mainly due
to storing/
transporting the
unit 'Upside
Down'.
Replaced with PW
3.5 compressors.
West Bangal
Rajastan
Assam
22
Works as freezer
but not as
ILR.Selector
switch defect.
Leak on charging
tube(Process
tube)near pinch
off or brazing of
the end.
Leak on
compressor body
near terminal(on
welding)oil found
leaked out &
compressor burnt
Compressor
observed to be
jammed,at site.
# Need to advise
MSD,State HQ & Dist.HQ
stores to take
appropriate care while
loading & transporting.
Running satisfactorily in
Assam for 3 months &
in Orissa for more than
year(as of May 92)
# Please observe
performance & send
feed-back.
Replaced
#These compressors
can be repaired.
#Electrolux,TCW-1151
machines should be
used only in one
mode,i.e.either as ILR or
as FREEZER only.No
changeover is
recommended.
Replaced selector-OK.
Repaired leak-OK.
Compressor replaced.
After transportation to
repair centre,the jam
found absent.This may
be due to
vibration/shock during
transportation, the
jammed rotor became
free.
COLD-CHAIN MAINTENANCE FEEDBACK
ILRs &
FREEZERs
# Try inserting a
capacitor(40-60
µF,220V)between No.11
& 13 of starting device.
Knock the compressor
body during starting
process with a handle of
a hammer,at different
places. These actions
may free the jam.
# CANNOT BE
REPAIRED.
#Test the unit as per
recommended test
procedure & complete
the Test-Certificate.
3.Internal leak in
condenser
evaporator
-Temp goes down
2-3 days.
-Formation of
more frost on
inner liner joint.
-Abnormal liquid
flow sound.
-Trace of oil inside # While requesting
-Smell of
replacement, give the
refrigerant.
following details:
1/State,2/Ditrict,3/PHC,4/
type(Model
No.),5/machine
Sl.No.,6/Date of
installation,7/Date from
which beyond repair.
SUGGESTIONS
SEE THE 'INFORMATION SECTION' FOR MISCELLANEOUS INFORMATION
SUGGESTIONS
SUGGESTION #1
The reason for burning of condenser fan motor or jamming of bushings is mostly due
to accumulation of dusts.
Minimum once a year the fan motor should be removed,services & bushings
lubricated.bearings can be cleaned by using Kerosene/petrol.After cleaning,apply
only 3-in-1 or any other machine oil-Do not use grease/Mobil. Using the spare
fan,the fans can be removed one by one for servicing.
SUGGESTION #2
With the 'new' cold-room panel, both the units will work when mains power is
available. The old T1(Fi)timer in generator panel to be replaced by the new
timer(yellow, with potentiometers)provided. With this timer, there will be three tries to
start the generator, with intervals. In case of power failures. Another modification to
be done is to put the aux.contact (provided)to the two points of this contact. The
'new' cold-room panel has 12 terminals points(in place of 10 in the 'old' one).The
23
COLD-CHAIN MAINTENANCE FEEDBACK
other end of the above cable is to be connected to the points 11 &12 of the 'new'
panel.
SUGGESTION #3
One'new' panel, one two-core cable, one Aux.contact & one T1 timer(yellow,with two
pot.on(ront)dispatched to all WIC/F locations in end 1986.
Please locate them & connect in place of 'old'panel,as detailed in suggestion #2
above.
SUGGESTION #4
Locally available replacement for NK/GK contactors:
Telemecanique & controls(Tc)
Model: LC1 D1733,A60 with 220 Volts coil
Auxiliary contacts (Add-on-blocks):
LA1-D22(2 NO 2 NC)
SUGGESTION #5
Defect in stop-solenoid alignment leads to major problem like burning of solenoid,
wiring in the panel & interconnections & also other components.
Check alignment of stop-solenoid frequency and adjust if necessary. If plunger does
not go in fully, it may take about 30 Amps or more current .In case the solenoid holds
& does not release, release it by switching the AUT/MAN selector to
'0'position.Sometimes,the plunger gets rusted & does not move freely. Remove the
plunger, clean & apply a very thin coat of oil on it. Also check stop timing on T2(20
sec.).This time can be reduced to 12-15 sec.safely,if the generator stops within
shorter time.
SUGGESTION #6
Observe the following difference in 'Huurre' &'Foster' units:
*'Huurre' cooling units have capillary tube in place of expansion valves(as in 'foster'0.
*There is one extra pressostat in 'Huurre'units to control condenser fan.
*'Foster' units have separate thermostst,'Huurre'thermostat & thermometer are
combined in a single unit.
*Thermostats in cooling units & alarm unit in 'Huurre'WIC are identical.
SUGGESTION #7
Accumulation of dust in the condenser fins & wire mesh at the bottom of the cooling
units in all the 'Huurre' & 'Foster' units cannot be removed completely with general
equipments.Air blower is required to be used.
24
COLD-CHAIN MAINTENANCE FEEDBACK
SUGGESTION #8
The reason of fuse S1 blowing off in 'Foster'generator panel is mostly due to any of
the 3 protections diodes shorted.they can be replaced by locally available diodes,viz:
BY 127/BY126/IN4007/BY100 etc.
SUGGESTION #9
RH1 7 RH2 in 'Foster'generator panel & km1 & km2 of 'Huurre'control panel (new)
for Diesel engine are similar. All can be interchanged.
SUGGESTION #10
The resistance of E1 charging circuit in 'Foster' generator panel falls out of its
position mainly due to melting of the solder connection due to overheat. While
refitting, tie the terminals in position with a piece of copper wire & then re-solder.
NOTE:No Load output voltage of E1=14.4 Volts ,DC
Check battery condition. If low, it will draw high current & over-heat/damage the
components of E1.Also fuse S2(8 A)may blow off. Disconnect battery & boost charge
externally & reconnect.
It is suggested to keep one extra battery as stand-by.
SUGGESTION #11
DM-188 engines can be started by pull ropes. Open the decompression lever,pull the
rope & close the decompression lever at maximum speed.(Ranchi,Nasik
experience).
NEVER OPERATE THE DE-COMPRESSION LEVER WHEN THE ENGINE IS
RUNNING.
SUGGESTION #12
If the engine is not is use for longer time & tank is kept filled with fuel, sludge forms
in the fuel tank & the carburetor.
For cleaning, drain the fuel tank & clean tank carburetor. If complete cleaning is not
possible with petrol,cleaning with CTC or thinner may be tried.DO NOT USE
CTC/THINNER ON PLASTIC/NYLON PARTS(e.g.Float).
SUGGESTION #13
In case the Electronic Leak detector is malfunctioning(sounds in air only, LED dims
during sound):change the filter & cell.
25